Railway Industry, Ensuring Expertise and Proficiency in Engineering Projects Such As Mechanics, Hydraulics, Pneumatics, Electronic and Automation Technology

Zona Ind.le ASI – Loc. Pascarola 80023 Caivano (NA) – ITALY tel/fax +39 0818349757 – www.promecsrl.eu [email protected]

Engineering & Manufacturing

Company Profile

PROMEC S.r.l. is an engineering and manufacturing company established in 1986 to design and produce mechanical, hydraulic, pneumatic and automatic equipment, dies and special machines. For 20 years PROMEC has been operating in the railway market for Italian and international customers as HITACHI (ANSALDOBREDA), ALSTOM, BOMBARDIER TRANSPORTATION, FIREMA TRASPORTI, TRENITALIA, ZF Friedrichshafen AG (Germany), and ALENIA - LEONARDO, AERITALIA for aerospace market. Nowadays, our focal production concerns the railway bogie market construction, maintenance, testing and assembling. PROMEC’s plant covers an area of 9,000 square meters, 5000 indoor, with workshop areas fully equipped to completely support railway bogies production and maintenance process: material cutting, welding, machining, shot-blasting, painting, dimensional inspection, non- destructive testing, spring coils testing and final inspection testing. PROMEC relies on a team of 60 highly qualified engineers, technicians and skilled professionals with consolidated experience in mechanical engineering and railway industry, ensuring expertise and proficiency in engineering projects such as mechanics, hydraulics, pneumatics, electronic and automation technology. PROMEC engineering undertakes customers design and production needs developing complete design and manufacturing process to be implemented in our plant.

Certifications PROMEC has its own Quality Manual and holds the following certifications:

Ø IRIS International Railway Industry Standard

Ø UNI EN ISO 9001- 2008 for Quality Control System

Ø EN 15085 CL1 for welding of elements and rail vehicles

Ø UNI EN ISO 3834-2:2006 for welding activities

Ø S.G.C. (ANSF-E.R.A. European Railway Agency) Proficiency management system, for maintenance activities on critical rolling stock component (bogies, wheelsets, body car, traction).

Ø UNI EN ISO 14001:2004 for environmental management system

I Company profile v 3.3 Engineering & Manufacturing

Qualifications PROMEC has achieved qualifications in railway and aeronautic industry and owns qualified supplier certification for rolling stock production of bogie frames and subassembly for:

- HITACHI - ANSALDOBREDA qualified constructor and supplier for rolling stock. - ALSTOM (Italy and France) qualified constructor and supplier for rolling stock. - BOMBARDIER TRANSPORTATION (Italy and Europe) qualified constructor supplier for rolling stock. - TRENITALIA’s qualified supplier and producer of rolling stock subassemblies and Frames. - TRENITALIA’s qualified supplier and producer of rolling stock and Bogie–Frames (fatigue test accomplished) and Structural Repairing of Bogie–Frame system. - CIRCUMVESUVIANA qualification as producer of bogies and rolling stock.

- “Type” certifications - Moreover, during its activity, PROMEC achieved many “type” certifications (i.e.: validation of manufacturing capability of specific type/model, verified through life-simulation tests on 1 sample), such as, for example, the two quoted following cases:

Program: V250 “Belgium-Nederland” train Part / subass’y: Welded steel body bolster Certificate: Fatigue test (10K cycles)

Program: Various Trenitalia trains Part / subass’y: F90 bogie frame Certificate: Fatigue test (10K cycles)

Program: Circumvesuviana (Italy) Part / subass’y: Bogie frame Certificate: Fatigue test

Program: Metro Fortaleza (Brasil) Part / subass’y: Bogie frame Certificate: Fatigue test

Program: Metro TAIPEI (Taiwan) Part / subass’y: Bogie frame Certificate: Fatigue test

Program: Metro Milano (Italy) Part / subass’y: Bogie frame Certificate: Fatigue test

Program: Metro Brescia (Italy) Part / subass’y: Bogie frame Certificate: Fatigue test II Company profile v 3.3 Engineering & Manufacturing

Railway Industry The main PROMEC production activity is related to railway bogie construction. Our expertise covers every single critical element of the bogies lifecycle. We completely execute and manage the end-to-end process of bogie production, relying on extensive expertise in welding, machining, assembling and testing. The bogie manufacturing process is accomplished entirely with workshop tools, fixtures and test presses designed by our engineering team and completely manufactured in our plant. Our production and organization can easily fulfill customers' every need.

PROMEC produces motor and trailer bogies for all track gauges, including: ê Passenger carriage bogies ê Freight wagon bogies ê Locomotive bogies ê Light and heavy metro bogies ê Tramway bogies For railway industry PROMEC designs and produces also railway bogie test presses, suspension spring test presses, rubber elements testing machines. Furthermore PROMEC designs and develops complete production lines for bogies manufacturing composed of mechanic and hydraulic metalwork fixtures, jigs and workshop equipment.

PROMEC provides the following companies:

ê ALSTOM ê HITACHI – (ANSALDOBREDA) Napoli, Pistoia, Reggio Calabria (Italy) ê BOMBARDIER TRANSPORTATION (Italy-France) ê NTV Nuovo Trasporto Viaggiatori S.p.A. (Italy) ê TRENITALIA S.p.A. (Italy). ê ZF Friedrichshafen AG (Germany). ê Others.

Railway Industry Production Remarkable works for railway industries are the complete bogie and frames, tilting bolster, for Fortaleza metro, Circumvesuviana of Napoli, bogie completely manufactured and set up. Also the body bolster for the bogies EMU V250 Belgium-Netherland completely manufactured by Promec, has been submitted to fatigue testing (10.000.000 cycles) with positive results. Trenitalia F90 frames have been manufactured, the first one has overcome at first time the fatigue test at MIP (Milano Inernational Politecnico) with 10.000.000 of cycles. Only thermal relieving, electroplating, laser cutting, and UT or RX non-destructive-test are carried out by controlled and specialized companies, allowing PROMEC to provide complete production result fully operating according to a Quality Assurance System applied to the end-to- end production process with all requested documentation (PFC, testing certificates, NDT certificates, material certificates). III Company profile v 3.3 Engineering & Manufacturing

Railway Serial Production Some examples of production:

ê Manufacturing of bogie frames F90 and 7195 for Trenitalia (Italy) ê Manufacturing of bogies for metro Fortaleza (Brazil) ê Manufacturing of bogie frames for Lille tram - Bombardier (France) ê Manufacturing of bogies transoms for Bombardier (Italy) ê Manufacturing of bogies for metro Atlanta (U.S.A.) M.A.R.T.A. ê Manufacturing of bogies for Tram Sirio (Italy) . ê Manufacturing of bogies for Locomotive E 402 C (Italy) . ê Manufacturing of bogies and electric train’s body bolsters for Circumvesuviana (Italy) ê Manufacturing of Wagon Locomotive ETR500 (in partnership with other companies). ê Manufacturing of Wagon Locomotive E 402 C (in partnership with other companies) . ê Manufacturing of Brake system support transom for Trenitalia. ê Belgium-Holland Train body bolster. ê Body bolsters for Tram Oslo. ê Tram axles for Tram Sirio. ê Hallow shafts for wheel hubs, for gearboxes ZF. ê Brake caliper supports. ê Subassemblies of bogies like, shock absorber, engine body bolster supports, underframes, etc. ê Push-complete sticks. ê Interface plates bogie-frame. ê Gearboxes reparation for E 402 B e ALE 724. ê Design, manufacturing and testing of Gearbox TAF Morocco (in ATI). ê Body bolster for locomotive wagon of CIRCUMETNEA. ê Centre plate retaining ring for locomotive of CIRCUMETNEA.

Railway workshop equipment (fixtures and jigs) Below some examples of design, construction, development and starting up of fixtures and jigs for the realization of complete bogies production lines:

ê Motor and trailer bogies ETR 500. ê Metro-Madrid bogie. ê Locomotive bogie E 402 C. ê Sirio Tram bogie.

ê Motor bogie TAF. ê Brake system support transom for ê Motor and non-powered bogies for Trenitalia Denmark trains. IV Company profile v 3.3 Engineering & Manufacturing

Railway inspection and test equipment PROMEC designs and produces advanced bogie test presses, spring test machines ( for bogie coil suspensions) and every critical workshop tool or equipment. All our products are designed, manufactured and assembled in or plant: ê springs and bogies test press ê railway workshops and depots facilities ê rail weighing and handling systems

Some examples of supplied equipment: ê Automatic bogie load test bench press (for Alstom AGV high speed train, ETR500, E402C, TAF, SIRIO, DANIMARCA, etc.) ê Hydraulic spring test machine (test load height, Natural axle, lateral stiffness) with automatic testing certification printing C.N.C. metal punching for metallic ribbon); ê Rail vehicle balance machine (test on every single wagon bogie at time, automatically print weighing report certificates); ê Hydraulic service bogies for wagon weight lifting: this system allows to move the wagon on the truck and to lift the wagon to desire weight; it still allows work in vertically position (the bogies are equipped with automatic fall-safety system) ê Automatic equipment for shrunk-on inclusion of spindles in the axels bolster of SIRIO Tram; this system is equipped of rim test system with automatic test load reader. ê Raining test system for TAF ê Equipment for deformation testing of wagon.

AERONAUTICAL INDUSTRY In the aeronautical industry mainly operates as a designer and as a construction company for special equipment, fixtures and jigs, die equipment, construction of nose and main gears (P68 aircraft model). For Aeronautical Industry Promec provides the following customers: ê ALENIA – LEONARDO S.p.A. Pomigliano d’Arco in Napoli (Italy); ê ALITALIA S.p.A.;

V Company profile v 3.3 Engineering & Manufacturing

PROMEC PLANT MACHINES AND EQUIPMENT

INFORMATION TECHNOLOGY SYSTEMS 1. CAD-CAM CATIA V5 software; 2.1 HYBRID DESIGN 2 2.2 ADVANCED MANUFACTURING 2 2.3 NC MANUFACTURING REVIEW 2 2. Postprocessor generator system SG for CNC machines. 3. Programming system SI-CAM for Plasma and Automatic oxygen cutting. 4. Plotter Canon BJ-W3000 with continuous modulus, length. max 18 m.

MEASUREMENT AND TESTING INSTRUMENTATION 5. Measurement machine BROWN & SHARP DEA – ALPHA 2500 × 5000 × 1500 (± 7µ +7 µ/m). 6. Measurement machine BROWN & SHARP DEA – MISTRAL 700 × 1000 × 700 (± 3µ +3 µ/m). 7. Bogie press stand for bogies final inspection with automatic load application system. 8. Automatic spring test press for suspension coil spring test, max load 20 t, max spring height 1000 mm, spring max Ø 500 mm. 9. Automatic Railway buffers and rubber elements test machine max load 100 t. 10.Johansson gauge blocks. 11.Diabase control plans, durometer, EC meter, instrumentation for mechanical inspections. 12.Cambridge gauge TWI and Fillet Weld Gauge G.A.L. GAGE CO. 13.Magnetic yoke (CA/CC – 220 – 110 – 48 V) CGM for MT inspection NDT. 14.Gaussmeter (±10Gauss) and Berthold Probe (orthogonal plate). 15.Instrumentation and equipment for liquid penetration NDT. 16. Weighing system cell, carrying up to 15t 17.Infrared thermometer (for temperature control in welding activities).

SPECIAL EQUIPEMENTS 18. Equipment designed by PROMEC for shrunk-on inclusion of spindles, and slippage testing and skidding from body bolster. 19. Hydraulic equipment for liquid leakage test of body bolsters.

MACHINES 20. Boring machine C.N. MECOF-PROMEC, CNC HEIDENHAIN 530, working strokes x=12.000 y=3.000 z=1.300, turntable 2.500 × 2.500.

VI Company profile v 3.3 Engineering & Manufacturing

21. Boring machine C.N. MECOF, CNC HEIDENHAIN 530, working strokes x=6.000 y=2.500 z=1.300, turntable 2.200 × 2.200. 22. Boring machine C.N. TOS WHQ 13.8 CNC, CNC HEIDENHAIN TNC 426, working strokes x=3.500 y=2.500 z=1.250, boring bar diam. 130 working strokes=900, turntable 2.200 × 1.800. 23. Boring machine S.ROCCO MEC 120, CNC HEIDENHAIN TNC 430, working strokes x = 5.000 y = 2.400 z=1.000, boring bar diam. 120 working strokes=700, turntable 1.800 × 1.800. 24. Boring machine with sliding upright S. ROCCO AL 110, CNC HEIDENHAIN TNC 430, working strokes 6.000 × 2.500. 25. Boring machine with fixed upright and with turntable S. ROCCO MEC120 B4, CNC OSAI -8600 FAST, working strokes 2.100 × 1.200 × 1.700 Long. 26. Boring machine C.N. ALESAMONTI MAF 45 TG, horizontal vertical CNC SELCA S3045, turntable, working strokes x=1500, y=1000, z=1000. 27. HORIZONTAL boring machine C.N. FOREST T.C. 3, turntable table, working strokes x= 800 y=500 z=400, CNC OSAI-8600 FAST. 28. CNC work center MANDELLI REGENT 1001, working strokes x=1450 y=900 z=900, with SELCA S3045 and Pallets gear. 29. CNC work center OLIVETTI MULTIAUCTOR M25, working strokes 1.500 × 700 × 650 h, turntable supplied with level of Ø 500. 30. CNC work center CINCINNATI SABRE 500, working strokes 500 × 380 × 500, and continuous turntable. 31. CNC lathe machine OSAI OCN-PPL VEGA - 8600 FAST, Ø max 840 x L= 560. 32. CNC lathe machine OCN- PPL VEGA. 33. AZETA 250 parallel lathe machine h=250 × L=2.000. 34. GRAZIANO SAG parallel lathe machine 14 h=180 × L=1.000. 35. Parallel lathe machine MISAL 817 h=180 × L=1.500. 36. Universal grinding machine GIORIA RU/P 1000 h=250 × L=1.000. 37. Universal grinding machine RASTELLI R7A h=180 × L=1.000. 38. Ring grinding machine RASTELLI RT1 strokes 600 × 300. 39. Grinding machine CHEVALIER FGC 610. 40. Universal milling machine FNK 25, displayed, working strokes 800 × 350 × 400. 41. Press KIMM 320, 40 t. 42. Press EUROPRESS ENERPAC, 70 t. 43. Radial drilling machine BRAUN, jib L=1.200 tip max Ø 70 mm. 44. Drilling machine FAMUP with square table, tip max Ø 25 mm.

WELDING MACHINE VII Company profile v 3.3 Engineering & Manufacturing

45. Continuous welding machine FRONIUS TRANS PULS SYNERGIC 4000. 46. Continuous welding machine FRONIUS VARIO SINERGIC 5000. 47. 6 continuous welding machine CASTOLIN CASTOMIG 500. 48. Continuous welding machine CASTOLIN TOTAL ARC 2 4/5000. 49. Continuous welding machine MILLER PULSTRONIC 400A for L.L. and steel. 50. Continuous welding machine DECAMIG 755. 51. Continuous TIG welding and electrode machine WELDTRONIC 500 AC/DC. 52. Welding machine TIG MILLER SINCROWAVE 300P for L.L. INOX steel. 53. Welding machine DECAMIG 350. 54. Welding machine MILLER INTEGRA 243. 55. Portable welding machine CASTOLIN with electrode 200 A. 56. Electrode welding machine 200 A. 57. Welding torch.

CUTTING SYSTEMS 59 Automatic oxygen cutting system – Plasma TECNI PANT with CNC, working strokes 6000x2400. 60 Electro-hydraulic sawing machine MEP SHARK 332 NC EVO with multi-microprocessor, band 3320x27x0,9, Ø 300 □ 260 ▄ 330x260. 61 Band saw OUPUS 400. 62 Band saw THOMAS mod. 310.

GENERIC SYSTEMS 63 Compressors, cutting-off machines, grinding machine, forklifts, complementary equipment, etc. 64 5 Cranes, 1 FOM 20t, 1 DATI 15 t, DATI 10 t, 1 FOM 10t, 1 DATI 3 t. 65 Spry-oven booth SAIMA (GAMMA SUPER model) for bogie-frame system. 66 Shot-blasting system CAMIT for bogies and frames, 4500x7500x h. 3800.

VIII Company profile v 3.3 Engineering & Manufacturing

PLANT LAYOUT

IX Company profile v 3.3

Table of Contents

PRODUCTION pag. 4

Production Lines pag. 27

Special Equipment pag. 33

Workshop Handling pag. 44

Maintenance Services pag. 48

ROLLING STOCK

PRODUCTION ENGINEERING & MANUFACTURING Precision Mechanical Manufacturing Production Engineering Special Equipment — Jigs and Fixtures Design Consulting

Object: Complete bogie for Metro Fortaleza Market: Railway (Brazil) electric train

Customer: AnsaldoBreda S.p.A. Size: 2220 × 2920 × 820 mm Purchaser: Metro Fortaleza (Brasil)

Material: Design: Firema S.p.A.

Production: Promec S.r.l.

Description Complete powered and non powered bogies, entirely manufactured and set up by Promec.

5 ENGINEERING & MANUFACTURING Precision Mechanical Manufacturing Production Engineering Special Equipment — Jigs and Fixtures Design Consulting

Object: Bogie equipping area Market: Railway

Customer: Metro Fortaleza (Brazil) Size: 2220 × 2920 × 820 mm electric train

Material: Design: Firema S.p.A.

Production: Promec S.r.l.

Description Complete powered and non powered bogies, entirely manufactured and set up by Promec.

6 ENGINEERING & MANUFACTURING Precision Mechanical Manufacturing Production Engineering Special Equipment — Jigs and Fixtures Design Consulting

Object: Iron casting for petrol pump Market: Petrolchemical

Customer: Peroni Pompe Size: 2200 mm lengtht: 710 mm height

Material: iron Design: Peroni S.p.A.

Production:

Description Dimensional inspection in DEA, afther machining, of an iron casting baty for of a petrolchemical block pump.

7 ENGINEERING & MANUFACTURING Precision Mechanical Manufacturing Production Engineering Special Equipment — Jigs and Fixtures Design Consulting

Object: Metro Expò—Leonardo Market: Railway

Customer: AnsaldoBreda Size: 2200 lenght: 3800 height 700 [mm]

Material: steel Design: AnsaldoBreda

Production: Promec

Description Machining of two frames with high speed boring machine designed and manufactured by Promec.

8 ENGINEERING & MANUFACTURING Precision Mechanical Manufacturing Production Engineering Special Equipment — Jigs and Fixtures Design Consulting

Object: Metro Taipei Market: Railway

Customer: AnsaldoBreda Size: 2100 lenght: 3600 height 650 [mm]

Material: steel Design: AnsaldoBreda

Production: Promec

Description Machining of frames with high speed boring machine.

9 ENGINEERING & MANUFACTURING Precision Mechanical Manufacturing Production Engineering Special Equipment — Jigs and Fixtures Design Consulting

Object: Hembot motor bogie for Market: Railway locomotive E 402 C Costumer: Firema and AnsaldoBreda Size: 2250 × 3310 × 670 mm S.p.A.

Material: Steel Design: AnsaldoBreda S.p.A.

Production: Promec

Description Hembot powered bogie before machining. For this bogie Promec has produced all the subassemblies, executed the two machining phases of the whole frame, and performer the final dimensional inspection in DEA. Note: Promec has designed, manufactured and tested the complete production line of fixtures ang jigs for the frame.

10 ENGINEERING & MANUFACTURING Precision Mechanical Manufacturing Production Engineering Special Equipment — Jigs and Fixtures Design Consulting

Object: “Meneghino” Body bolster train Market: Railway

Customer: AnsaldoBreda S.p.A. Size: 2620 × 1800 × 80 mm

Material: Light alloy 6082 T6 Design: AnsaldoBreda S.p.A.

Production: Promec S.r.l.

Description Two bolsters for each vehicle. The bolsters accept the center plates for the connection between the supporting bogies bolsters and the frame of the wagon.

11 ENGINEERING & MANUFACTURING Precision Mechanical Manufacturing Production Engineering Special Equipment — Jigs and Fixtures Design Consulting

Object: M.A.R.T.A. Underground bogie frame Market: Railway

Customer: AnsaldoBreda S.p.A. Size: 2220 × 2600 × 610 mm Purchaser: Atlanta metro — U.S.A. metro

Material: Steel Design: AnsaldoBreda S.p.A.

Production: Promec S.r.l.

Description Dimensional and geometric inspection in Promec DEA.

12 ENGINEERING & MANUFACTURING Precision Mechanical Manufacturing Production Engineering Special Equipment — Jigs and Fixtures Design Consulting

Object: TSR bogie frame machining Market: Railway

Customer: Keller S.p.A. Size: 2250 × 3310 × 670 mm Purchaser: Railways Nord Milano

Material: Steel Design: AnsaldoBreda S.p.A.

Production: Promec S.r.l.

Description First machining stage with vertical set-up of the frame on a CNC boring machine. Working strokes of the boring machine: 6000 X 2500.

13 ENGINEERING & MANUFACTURING Precision Mechanical Manufacturing Production Engineering Special Equipment — Jigs and Fixtures Design Consulting

Object: TSR trailer bogie Market: Railway

Customer: Keller S.p.A. Size: 2250 × 3310 × 670 mm Purchaser: Railways Nord Milano

Material: Steel Design: AnsaldoBreda S.p.A.

Production: Promec S.r.l.

Description Second phase: horizontally working on CNC boring machine.

14 ENGINEERING & MANUFACTURING Precision Mechanical Manufacturing Production Engineering Special Equipment — Jigs and Fixtures Design Consulting

Object: TSR Non trailer bogie Market: Railway

Customer: Keller S.p.A. Size: 2250 × 3310 × 670 mm Purchaser: Nord Railways Milano

Material: Steel Design: AnsaldoBreda S.p.A.

Production: Promec S.r.l.

Description Bogies shipping, after machining and dimensional inspection in DEA.

15 ENGINEERING & MANUFACTURING Precision Mechanical Manufacturing Production Engineering Special Equipment — Jigs and Fixtures Design Consulting

Object: Metro Expò bogie frame Market: Railway

Customer: AnsaldoBreda S.p.A. Size: 2300 × 3500 × 700 Purchaser: A.T.M. (Milano)

Material: Steel Design: Ansaldo S.p.A.

Production: AnsaldoBreda S.p.A.

Description Painted bogie frames.

16 ENGINEERING & MANUFACTURING Precision Mechanical Manufacturing Production Engineering Special Equipment — Jigs and Fixtures Design Consulting

Object: F90 bogie frame Market: Railway

Customer: Bombardier Transportation Size: 2300 × 3500 × 700 Purchaser: Trenitalia

Material: Steel Design: FIAT Ferroviaria

Production: Bombardier Transportation

Description Painting facility for bogie frames.

17 ENGINEERING & MANUFACTURING Precision Mechanical Manufacturing Production Engineering Special Equipment — Jigs and Fixtures Design Consulting

Object: “Oslo” tram body bolster Market: Railway

Customer: Firema S.p.A. Size: 1840 × 1600 mm Purchaser: Tramway Company - Oslo

Material: Steel Design: Firema S.p.A.

Production: Promec S.r.l.

Description Full implementation, including welding, machining thermal relieving, NDT, and dimensional inspection in DEA.

18 ENGINEERING & MANUFACTURING Precision Mechanical Manufacturing Production Engineering Special Equipment — Jigs and Fixtures Design Consulting

Object: Brake system support transom Market: Railway

Customer: Bombardier Transportation Size: 2030 X 740 X 470 mm Purchaser: Trenitalia S.p.A.

Material: Steel Design: FIAT Ferroviaria

Production: Promec S.r.l.

Description Complete Welding, machining, painting and testing of the brake system support transom.

19 ENGINEERING & MANUFACTURING Precision Mechanical Manufacturing Production Engineering Special Equipment — Jigs and Fixtures Design Consulting

Object: Body bolster for V250 “Belgium- Market: Railway Nederland” train

Customer: AnsaldoBreda S.p.A. Size: 2850 × 800 × 630 mm

M a t e r i a l : - s t e e l b o l s t e r s t r u c t u r e Design: AnsaldoBreda S.p.A. - Pin drop in 30 NI CR MO 12

Production: Promec S.r.l.

Description Body bolster (bogie/wagon interface) with center pivot pin. The welding process and its WPS (Welding Procedure Specification) for the center pivot pin on the body bolster, have been defined by Promec together with customer AnsaldoBreda. The inside of the bolster is split into two distinct airtigh sectors; theese sectors act as tanks for additional air to the secondary suspensions. The bolster is subjected, in addition to NDT, to a pneumatic leakage test, to an hydraulic leakage test (15 bar), and to the impregnation of the inner surfaces of the two additional tanks.

Two PROMEC bolsters were submitted to fatigue tested, with positive results.

20 ENGINEERING & MANUFACTURING Precision Mechanical Manufacturing Production Engineering Special Equipment — Jigs and Fixtures Design Consulting

Object: Torsion bar subassembly Market: Railway

Customer: Firema S.p.A. Size: 1021 × 491 mm

Material: Steel Design: Firema S.p.A.

Production: Promec S.r.l.

Description Complete realization of the torsion bar subassembly. Bar-bar levers coupling achieved by splined grafts (allowance H 7 - M 6).

21 ENGINEERING & MANUFACTURING Precision Mechanical Manufacturing Production Engineering Special Equipment — Jigs and Fixtures Design Consulting

Object: TAF Marocco Gearbox case Market: Railway

Customer: AnsaldoBreda S.p.A. Size: 890 × 1240 × 300 mm Purchaser: Marocco Railways

Material: Cast iron Design: Darimec

Production: Promec S.r.l.

Description The gearbox case, along with all other mechanical components, such as oil labyrinths, shafts, flanges, crankcase, are produced by Promec.

22 ENGINEERING & MANUFACTURING Precision Mechanical Manufacturing Production Engineering Special Equipment — Jigs and Fixtures Design Consulting

Object: POSTRAIN Gearbox Market: Railway

Customer: R&D program Size: 1100 × 540 × 368 mm

Production: Promec S.r.l. Design: Promec S.r.l.

Main characteristics:

 Double stage speed reducer  Total reduction ratio: 3.838/1  Max dynamic impact torque: 38.092 N*m  Max input speed: 4.325 rpm  Total mass: 520 kg  Case material: cast spheroidal iron  Max load on the axle: 190.000 N  Max / min wheel dia: 820 / 760 mm

23 ENGINEERING & MANUFACTURING Precision Mechanical Manufacturing Production Engineering Special Equipment — Jigs and Fixtures Design Consulting

Object: Tram transom Market: Railway

Customer: AnsaldoBreda S.p.A. Size: 2020 × 610 × 330 mm Purchaser: Atene - Tramway Company

Material: - Steel structure - Spindle (30 NI CR Design: AnsaldoBreda S.p.A. MO 12) - steel hardened

Production: Promec S.r.l.

Description Tram Sirio axle for powered and non-powered bogies submitted to dimensional inspection in DEA. Welded steel frame, stress relieved, and submitted to NDT. Spindles (30 Ni Cr Mo 12) steel hardened, shrunked on housing in the structure by an hydraulic automatic equipement (designed by PROMEC), the same tool is also used for shrinking-on test.

24 ENGINEERING & MANUFACTURING Precision Mechanical Manufacturing Production Engineering Special Equipment — Jigs and Fixtures Design Consulting

Object: Tram Spindle. Market: Railway

Dimensioni: Ø sup. : 75 mm Ø inf: 130 mm Customer: AnsaldoBreda S.p.A. Lenght : 450 mm

Material: 30 NI CR MO 12 steel hardened Design: AnsaldoBreda S.p.A.

Production: Promec S.r.l.

Description

Athens SIRIO tram spindle submitted to dimensional inspection in DEA - Mistral machine.

25 ENGINEERING & MANUFACTURING Precision Mechanical Manufacturing Production Engineering Special Equipment — Jigs and Fixtures Design Consulting

Object: Shock absorbers for tram Market: Railway

Customer: Firema S.p.A. Size: Ø 150 mm lenght: 710 mm

Material: Steel Design: Firema S.p.A.

Production: Promec S.r.l.

Description Shock absorbers designed and manufactured entirely by Promec.

Rolling Stock — Aeronautical Production Engineering

Production Lines JIGS and FIXTURES ENGINEERING & MANUFACTURING Precision Mechanical Manufacturing Production Engineering Special Equipment — Jigs and Fixtures Design Consulting

Object: Hydraulic rotating fixture for sill frame Market: Railway assembling for the Denmark train.

Customer: AnsaldoBreda S.p.A. Size: 6000 × 1500 × 2000 h mm

Production: Promec S.r.l. Design: Promec S.r.l.

Description Nota: Promec designs, realizes, tests and customizes the implementation of complete production lines of fixtures and jigs for the construction of railway bogies. Shown fixture is a typical realization for sills frame assembling. The locking of the various parts composing the sill is obtained by brackets and operated by a suitable number of hydraulic cylinders, which keep the sill constantly tied to the gear, preven- ting any deformation. The rotation of the workholder allows the welding in plane of all internal parts.

28 ENGINEERING & MANUFACTURING Precision Mechanical Manufacturing Production Engineering Special Equipment — Jigs and Fixtures Design Consulting

Object: Hydraulic rotating fixture for sill frame assembling for the Taipey Metro bo- Market: Railway gies.

Customer: AnsaldoBreda S.p.A. Size: 6000 × 1500 × 2000 h mm

Production: Promec S.r.l. Design: Promec S.r.l.

29 ENGINEERING & MANUFACTURING Precision Mechanical Manufacturing Production Engineering Special Equipment — Jigs and Fixtures Design Consulting

Object: Fixtures Market: Railway

Customer: Size: 2500 × 5000 mm

Production: Steel Design: Promec S.r.l.

Realizzazione: Promec S.r.l.

Description Fixtures examples

30 ENGINEERING & MANUFACTURING Precision Mechanical Manufacturing Production Engineering Special Equipment — Jigs and Fixtures Design Consulting

Object: Fixture for assembling and Market: Railway supporting of bogie-frame

Customer: AnsaldoBreda S.p.A. Size: 2500 × 5000 mm

Material: Steel Design: Promec S.r.l.

Production: Promec S.r.l.

Description

Fixture production submitted to a dimensional inspection in DEA.

31 ENGINEERING & MANUFACTURING Precision Mechanical Manufacturing Production Engineering Special Equipment — Jigs and Fixtures Design Consulting

Object: Complete fixtures production line Market: Railway

Customer: AnsaldoBreda S.p.A. Size:

Material: Steel Design: Promec S.r.l.

Production: Promec S.r.l.

Description Welding workshop unit equipped by complete fixtures and jigs production line.

Rolling Stock — Aeronautical Workshops and Depots Equipment Design

TESTING and Special EQUIPMENT ENGINEERING & MANUFACTURING Precision Mechanical Manufacturing Production Engineering Special Equipment — Jigs and Fixtures Design Consulting object: Bogie load testing bench Settore: Railway

Customer: NTV S.p.A. Dimensions: 4500 × 4600 mm

Materiale: Steel Design: Promec S.r.l.

Production: Promec S.r.l.

Description: Bogie test press is designed to carry out the homologation test for railway bogies after construction and maintenance activities. The press reproduces the wagon body load to correctly set up the bogie, to adjust suspensions and check compliance with bogie design specifications. Adjustable height beam press - adjustable load cylinders position - 2 or 3 cylinders models (for center plate load simulation) - Wheels and axels load distribution calculation - Shim plates thickness automatically calculated - Air suspension leakage test - Suspension air pressure calculation - Brake system leakage test - bogie centering system. Computer controlled operations: load driven (height is read as result) and height driven (load is read as result) - Automatic data collection, inspection and report certification printing. Wi-Fi gauge for automatic dimensional data acquisition. PC Panel touch screen control unit with test results database and bogie models archive. Designed to operate in workshop environments, the equipment has been solidly built as a sturdy steel framework, well dimensioned to operate with high frequency of tests per day. High quality components for electronic and hydraulic, have been used to guarantee high precision results and reliable test accuracy.

34 ENGINEERING & MANUFACTURING Precision Mechanical Manufacturing Production Engineering Special Equipment — Jigs and Fixtures Design Consulting object: Bogie load testing bench Settore: Railway

Customer: Taiwan Railway Administration Dimensions: 4500 × 4600 mm

Materiale: Steel Design: Promec S.r.l.

Production: Promec S.r.l.

35 ENGINEERING & MANUFACTURING Precision Mechanical Manufacturing Production Engineering Special Equipment — Jigs and Fixtures Design Consulting

Object: Bogie load testing bench Market: Railway

Customer: AnsaldoBreda S.p.A. Size: 4500 × 4600 mm

Material: Steel Design: Promec S.r.l.

Production: Promec S.r.l.

Description: Assembling of a bogie press with automatic application of the load. The press will be set on a stell structure blocked in a concrete basement where an operator pit is provided for under bogie test and assembling activities. FEATURES: Adjustable height beam press and thrust cylinders position - 2 or 3 cylinders press (for center plate load simulation) - Shim plates thickness automatically calculated - Air suspension leakage test - Suspension air pressure calculation - Computer controlled operation: load driven (height is read as result) and height driven (load is read as result) - Automatic data collection, inspection and report certification printing.

36 ENGINEERING & MANUFACTURING Precision Mechanical Manufacturing Production Engineering Special Equipment — Jigs and Fixtures Design Consulting

Object: Spring test press Market: Railway

Customer: Cima riparazioni S.r.l. Size: 1900 × 950 × 2670 mm

Material: Steel Design: Promec S.r.l.

Production: Promec S.r.l.

Description Spring test press - Industrial patent. The PROMEC spring test press is an flexible and accurate testing device of bogie suspension coils. The machine carries out automatic testing of the spring, or nested springs, and generates an inspection report, showing the height under load, the value of the Natural axle deviation under load, and the transversal stiffness. A special metal marker produces a metal ribbon, marked with spring test data, to be applied to the tested spring. The dedicated hydraulic crane allows easy loading and unloading of the springs into the press, wi- thout requiring any other lifting tools.

37 ENGINEERING & MANUFACTURING Precision Mechanical Manufacturing Production Engineering Special Equipment — Jigs and Fixtures Design Consulting

Object: Railway Buffer Test Press Market: Railway

Customer: Promec S.r.l. Size: 1900 × 950 × 2670 mm

Material: Steel Design: Promec S.r.l.

Production: Promec S.r.l.

Description Railway buffer test press 900 kN. The PROMEC Buffer test press is an accurate testing device for rubber and hydraulic buffers. The press performs the test also of single rubber element or group of elements like the kit present in traction hooks. The machine carries out automatic test cicles that can be programmed specifing load to be applied or stroke of the load cylinder. The sliding plate for the load and unload of the items to be tested allows a very easy handling of the objects tested.

38 ENGINEERING & MANUFACTURING Precision Mechanical Manufacturing Production Engineering Special Equipment — Jigs and Fixtures Design Consulting

Object: Axle bearing fitting — pulling press Market: Railway

Customer: N.T.V S.p.a. Size:

Production: Promec S.r.l. Design: Promec S.r.l.

Description Hydraulic press for removal and fitting of wheelset axle bearings. Floor lifting and turnable system. Fitting force monitoring and recording.

39 ENGINEERING & MANUFACTURING Precision Mechanical Manufacturing Production Engineering Special Equipment — Jigs and Fixtures Design Consulting

Object: Landing gear load test bench for Market: Aeronautical aircraft at 320 and similar.

Customer: Alitalia S.p.A. Size: 2000 × 1500 × 6000 h mm

Production: Promec S.r.l. Design: Promec S.r.l.

Description Load bench press for testing of the landing gear for A 320 Industrial patenta. The press tests the load/ height trend of the - shock absorber placed inside the landing gear. The test output consists in an automatically generate graphical an numeric report of load and heigh. The test results are plotted graphically and compared to the ideal ra- te diagrams. Steering torque force and re- turn torque are automatically tested for the front landing gear. In order to perform a leakage test, the press is equipped with an hydraulic bench for the adduction of a mixture of nitrogen and oil in the shock absorber.

40 ENGINEERING & MANUFACTURING Precision Mechanical Manufacturing Production Engineering Special Equipment — Jigs and Fixtures Design Consulting

Object: Hydraulic bench Market: Aeronautical

Customer: Alitalia S.p.A. Size: 1500 × 2200 × 1500 h mm

Material: Steel Design: Promec S.r.l.

Production: Promec S.r.l.

Descripction A 320 landing bogies testing Hydraulic bench designed to perform a leakage test, for the correct adduction of a mixture of nitrogen and oil in the shock absorber.

41 ENGINEERING & MANUFACTURING Precision Mechanical Manufacturing Production Engineering Special Equipment — Jigs and Fixtures Design Consulting

Object: Hydraulic bench Market: Aeronautical

Customer: EMA S.p.A. (Rolls Royce group) Size: 1500 × 2500 × 2200 h mm

Material: Steel Design: Promec S.r.l.

Production: Promec S.r.l.

Descripction Wax injection press of 10000 kN for lost wax casting production. Double sliding table. Controlled Heating of the table. Injection of 5 liters of wax per casting..

42 ENGINEERING & MANUFACTURING Precision Mechanical Manufacturing Production Engineering Special Equipment — Jigs and Fixtures Design Consulting

Object: Rail vehicles automatic weighing sy- Market: Railway stem.

Customer: AnsaldoBreda, Keller Size: 2500 × 5000 mm

Production: Promec S.r.l. Design: Promec S.r.l.

Description Rail vehicles automatic weighing balance. The system performs the weighing of the wagon in two steps, by performing the load test on every sigle wagon bogie at time. The system detectes the load for each wheel, for axle, for trailer and for whole car or locomotive/ wagon. The system automatically prints weighing report certificate.

Rolling Stock — Aeronautical Workshops and Depots

Workshop HANDLING EQUIPMENT ENGINEERING & MANUFACTURING Precision Mechanical Manufacturing Production Engineering Special Equipment — Jigs and Fixtures Design Consulting

Object: Motorized platform for work activity on Market: Railway wagon body side and on the roof

Customer: Trenitalia S.p.A. Size: 6000 × 1500 × 4500/7000 h mm

Material: Steel Design: Promec S.r.l.

Production: Promec S.r.l.

Description Motorized equipment for working activities on wagon body side and on the roof. The equipment is a travelling lift that moves along the wagon car body. The equipment can rise the central platform to a desired height and the platform slides closely to the wagon side allowing a correct and safe operator position for works on body side. There are also 2 lateral platforms that can be raised, turned in an horizontal position. The two lateral platforms can extend their floor to overcome the train roof granting a comfortable and safe access for the operators.

45 ENGINEERING & MANUFACTURING Precision Mechanical Manufacturing Production Engineering Special Equipment — Jigs and Fixtures Design Consulting

Object: Frontal platform for work activity on Market: Railway wagon head.

Customer: NTV S.p.A. Size: 6000 × 1500 × 4500/7000 h mm

Material: LiSteel Design: Promec S.r.l.

Production: Promec S.r.l.

Description Sliding platform for working activities on wagon body head. The equipment can be moved both on workflow wheels and on rail wheels. A special lock keys safety system allow the platform access on the maintenance rail only when electric power has been interrupted.

46 ENGINEERING & MANUFACTURING Precision Mechanical Manufacturing Production Engineering Special Equipment — Jigs and Fixtures Design Consulting

Object: Bogie frames rotating and lifting tools Market: Railway

Customer: Trenitalia S.p.A. Size: 6000 × 1500 × 3200 h mm

Material: Steel Design: Promec S.r.l.

Production: Promec S.r.l.

Description Motorized tools for bogie frames rotation and lifting, one mobile upright and one fixed upright. Load up to 8 Tons. Continuous rotation. Max bogie length (according to customer require- ment). Synchronous vertical movement.

ROLLING STOCK

SERVICES MAINTENANCE AND REPAIR ENGINEERING & MANUFACTURING Precision Mechanical Manufacturing Production Engineering Special Equipment — Jigs and Fixtures Design Consulting

Object: ITALO Train Market: Railway Bogie Frames Refurbishment

Customer: ALSTOM Material: Welded steel

Operation: substitution of motor supports

Description On each frame, it was necessary:  to remove the old supports  to weld the new ones with implemented characteristics  to execute the HI-FIT treatment (local hardening through pneumatic hammer gun)  to rework locally with NC machine tools in way to restore the correct mounting dimensions  to repaint the reworked areas in way to restore the protection against corrosion The area of intervention can be recognized trough the lighter color of the painting

49 ENGINEERING & MANUFACTURING Precision Mechanical Manufacturing Production Engineering Special Equipment — Jigs and Fixtures Design Consulting

Object: 402B bogies Market: Railway

Customer: TRENITALIA S.p.A. Size:

Material: Design: AnsaldoBreda S.p.A.

Production: Promec S.r.l.

Description Bogies maintenance.

50 ENGINEERING & MANUFACTURING Precision Mechanical Manufacturing Production Engineering Special Equipment — Jigs and Fixtures Design Consulting

Object: Sirio Bogie Market: Railway

Customer: AnsaldoBreda S.p.A. Size: 2200 × 2900 × 550 mm

Material: Steel Design: AnsaldoBreda S.p.A.

Production: Promec S.r.l.

Description SIRIO bogies maintenance.

51 ENGINEERING & MANUFACTURING Precision Mechanical Manufacturing Production Engineering Special Equipment — Jigs and Fixtures Design Consulting

Object: F85 frame dimensional test after Market: Railway reparation and NDT

Customer: Trenitalia S.p.A. Size: 2200 × 2900 × 550 mm

Material: Steel Design:

Production:

Description F85 frame reparation and testing.

52 ENGINEERING & MANUFACTURING Precision Mechanical Manufacturing Production Engineering Special Equipment — Jigs and Fixtures Design Consulting

Object: Non-powered bogie Market: Railway

Customer: Trenitalia S.p.A. Size: 2250 × 3310 × 670 mm

Material: Steel Design: Trenitalia S.p.A.

Production: Promec S.r.l.

Description Bogies frame repairing — the deteriorated flame plate is repaired by sectors replacement.

53 ENGINEERING & MANUFACTURING Precision Mechanical Manufacturing Production Engineering Special Equipment — Jigs and Fixtures Design Consulting

Object: TSR non-powered bogie Market: Railway

Customer: Trenitalia S.p.A. Size: 2250 × 3310 × 670 mm

Material: Steel Design: Trenitalia S.p.A.

Production: Promec S.r.l.

Description

Bogie frames repairing - the flat arch is replaced by new material and NDT (UT) are executed.

54 ENGINEERING & MANUFACTURING Precision Mechanical Manufacturing Production Engineering Special Equipment — Jigs and Fixtures Design Consulting

Object: Lille Tram trailer Bolster Market: Railway

Customer: Bombardier Transportation Size: 750 × 1310 × 670 mm

Material: Steel Design: AnsaldoBreda S.p.A.

Production: Bombardier Transportation

Description

Bogie frames repairing - Local Heat treatment of the welded joints of new parts on an old machi- ned casting.

55 ENGINEERING & MANUFACTURING Precision Mechanical Manufacturing Production Engineering Special Equipment — Jigs and Fixtures Design Consulting

Object: E 402 B Locomotor gearbox Market: Railway

Customer: Trenitalia S.p.A. Size: 1650 × 990 × 260 mm

Material: Steel Design: Trenitalia S.p.A.

Production: Promec S.r.l.

Description Bearing housing repairing, by housing restoring, housing boring and dimensional inspection in DEA.

56 ENGINEERING & MANUFACTURING Precision Mechanical Manufacturing Production Engineering Special Equipment — Jigs and Fixtures Design Consulting

Object: Napoli (Italy) SIRIO tram bogies Market: Railway

Customer: AnsaldoBreda S.p.A. Size: 2200 × 2900 × 550 mm

Material: Steel Design: AnsaldoBreda S.p.A.

Production: Promec S.r.l.

Description SIRIO bogies maintenance.

57 ENGINEERING & MANUFACTURING Precision Mechanical Manufacturing Production Engineering Special Equipment — Jigs and Fixtures Design Consulting

Object: ALE 724 Locomotor gearbox Market: Railway

Customer: Trenitalia S.p.A. Size: 950 × 770 × 260 mm

Material: Cast-iron Design: Trenitalia S.p.A.

Production: Promec S.r.l.

Descritpion Bearing housing repairing, by housing restoring, housing boring and dimensional inspection in DEA.

58 Promec srl Zona Industriale ASI Località Pascarola 80023 Caivano / Napoli Italy Tel. fax +39 081 8349757 pbx www.promecsrl.eu [email protected]