Kazan Helicopter Plant. Kazan Helicopter Plant Kvz Helicopter

We visited the Kazan Helicopter Plant, which is part of the Russian Helicopters holding company, as bloggers who had never been there before. We were shown the mechanical assembly shop, the final assembly shop, a little of the territory of the plant itself, and even a test flight of the Mi-8.
But first things first.

The history of the Kazan Helicopter Plant dates back to 1933, when a wood processing plant was founded on the banks of the Volga in Kazan. And the plant itself dates back to September 4, 1940, when the Leningrad Aviation Plant No. 387 was created by order of the People's Commissariat of the Aviation Industry, which was later evacuated to Kazan and merged with the Wagon Parts Plant No. 169. The aviation fate of the enterprise was determined in 1940, it is from this date that the history of the current Kazan Helicopter Plant JSC begins. In 1941, light biplanes became the first aircraft produced by the plant.

2. The number of Po-2s produced during the war years exceeded 10,000 (more precisely, 11,334) aircraft, which accounted for 10% of all aircraft produced in the Soviet Union during the war years.
In 1951, the serial production of the Mi-1 helicopter, designed by M.L. Mil, began. The Mi-1 was replaced by the Mi-4.

3. In 1956, the Kazan Helicopter Plant began supplying helicopters for export.
In 1965, the production of the Mi-8 helicopter began. This was a turning point in the history of the plant. The modern Mi-17 helicopter and its modifications are the result of vast experience gained during the production and operation of Mi-8 helicopters.
Kazan Helicopter Production Association in 1993 was transformed into a joint-stock company Kazan Helicopter Plant, and in 1996 it became open - OJSC Kazan Helicopter Plant

4. In the same year, a design bureau was created for lung development multipurpose Ansat.

Helicopter production:
2006 - 53
2007 - 38
2008 - 58
2009 - 67
2010 - 81
2011 - 94
2012 - 103
Growth of about 10% expected in 2013

6. To date, KVZ remains the world's largest manufacturer of medium-class helicopters.

7. Markets traditional for the Russian helicopter industry: Russia, CIS countries, states of Southeast Asia, Africa, Central and South America. Currently Kazan Helicopter Plant supplies equipment to about 90 countries of the world (the products of the Russian Helicopters holding are generally represented in more than 110 countries of the world).

8. This year it is planned to reach the level of more than 100 machines per year with almost no change in the composition of the working team - about 7 thousand people with an average age of 36 years (in mechanical production shops; at the plant, the average age today is 43.2 years). And this was achieved through the reorganization of production, which began in the early 2000s with the repair of workshops.

9. An equally important stage in the reorganization of the enterprise followed with the purchase of new equipment for the machining industry. We bought foreign-made machine tools, in connection with which the labor intensity fell, and labor productivity increased 4 times.

10. Frames are now processed on four three- and five-axis machines, which replaced 24 old ones (three lines of 8 machines each). Russia, unfortunately, does not yet produce machines of this level. In the photo - processed stamping before coating.

11. Finished frames go for further assembly.

12. A part for the swashplate for Ansat used to be made in 18 hours, and now it takes 12. Due to processing on several machines, the marriage was a large percentage. Now the entire turning part, milling, drilling are carried out within one cycle. And so it is with many details.
In the photo there is an annular frame that goes to the tail boom on a serial helicopter.

13. Vibration damper hub. Not every client orders it. It used to take 136 hours to make this hub, now it takes 18 - the time has been reduced by almost eight times!

14. The service of the chief technologist is located right there in the workshop behind a glass partition and there is no need to wait a long time, as before, for a specialist until he arrives from another building.

15. There are 2 lines of the Mazak company in the milling workshop. One (4 machines) processes light alloys (duralumin), the other (3 machines) only steel. Each machine has its own shop for 120 tools, and on the "steel" line there is also a shop center for 240 units. The replacement of the tool on the "steel" line is formed automatically - this is incorporated by the software.

16. Let's say the cutter has run out of resource, computer program signals the end of the assigned resource, the running carriage takes the cutter from the machine, exchanges it, and further processing of the part is in progress. And the operator takes his used cutter. The tool goes for regrinding, its characteristics change and it goes to another production. All tools with chips on which the life history of the part is recorded.

17. During the restructuring, this shop has increased its capacity by more than three times. If earlier they did 6,000 standard hours, now the plan is approaching 21,000, and from January 2014 there will be even more.

18. Previously, a loaded dump truck of duralumin shavings left here every day, now there is 4 times more waste, but the shavings turn into briquettes convenient for transportation, which, after being melted down, go to other types of industry.
Every 28 seconds, a dural briquette falls out of the press. Every 32 seconds - steel. The cost of briquettes on the market is 4-5 times more than just shavings. The compactor cannot make twisted chips into briquettes, so it gets into the “meat grinder” and after grinding it also takes up less space.

19. Environmental protection. There are no rats or mice in the plant. Reportage Alexey look at his page.

20. Cleanliness is the key to economic growth in production.

21. We move to the assembly shop.
From the start of assembly to the first flight, the helicopter stays here for an average of one month, including painting production.

22. OJSC Kazan Helicopter Plant, which is part of the Russian Helicopters holding, produces the Mi-8/17 family of helicopters, which are operated in more than 100 countries around the world.

23.

24. A wide range of modifications of these helicopters is produced: transport, passenger, rescue, airborne transport and many others.

25. Since 1997, JSC "KVZ" has a certificate of developer of helicopter equipment: today, a light twin-engine helicopter "Ansat" is in mass production.

26. Russian Helicopters Holding is one of the world leaders in the helicopter industry, the only developer and manufacturer of helicopters in Russia, one of the few companies in the world that has the ability to design, manufacture, test and Maintenance modern civil and military helicopters.

27. As of 2013, Russian Helicopters enterprises produced 35% of the world fleet of combat helicopters, 17% of the world fleet of super-heavy helicopters with a maximum take-off weight of more than 20 tons, as well as 56% of the world fleet of medium-heavy helicopters with a maximum take-off weight of 8 to 15 tons .

28. Modifications of Mi-8/17 helicopters produced in Kazan are a new generation of equipment.

29. Unique flight performance, state-of-the-art avionics and special equipment manufactured by Russian and Western companies allow you to fly at high altitudes, in adverse weather conditions, at any time of the day, in automatic mode.

30. A multi-purpose helicopter is capable of performing a wide range of tasks: transportation of goods, passengers, fire fighting, search and rescue, evacuation of the wounded.

31. In a short period of time, the Mi-8/17 can be converted from transport to firefighting, search and rescue or ambulance. Options "salon", "flying hospital" and others are possible.

32. The high level of safety, reliability, simplicity and low cost of operation and maintenance make the Mi-8/17 one of the best-selling helicopters in its class.

33. There are two types of blades - metal and composite. Composite has a higher resource and less weight, but at the same time it requires more expensive maintenance when replacing or repairing.

34. Black box in the tail boom.

35.

36. Medium transport and passenger helicopter Mi-38.
This new generation helicopter is able to provide a new level of comfort and safety when performing passenger traffic and special works in category A (FAR-29). In the basic configuration, the Mi-38 can carry 30 passengers.

37. Today the Mi-38 project has entered a new stage.
Third flying prototype is undergoing tests at the flight test base of OJSC "Moscow Helicopter Plant named after M.L. Mil" (part of the "Helicopters of Russia"). This prototype is equipped with two TV7-117V turboshaft engines developed by OAO Klimov.

38. The first Mi-38 OP-1 prototype made its first flight (hovering) on ​​December 22, 2003, and the second Mi-38 OP-2 prototype on December 24, 2010. Both of these helicopters were powered by a single set of Pratt & Whitney Canada PW127/5 turboshaft engines. The first Mi-38 OP-1 helicopter, after the PW127/5 engines were removed from it, was converted in 2011 into a prototype of the Mi-38-2 variant with the installation of TV7-117V engines.

39. OJSC "KVZ" started assembling the fourth flight prototype. The OP-4 standard design helicopter will differ from the OP-3 prototype in a shock-resistant fuel system manufactured by "Aerazur" and enlarged portholes.
In addition to the production of flight prototypes in 2013, as part of the development work on the Mi-38 helicopter, the process of manufacturing the fuselage and a set of individual units for fatigue testing, as well as units and assemblies for bench tests, is underway. OP-4 is the last prototype of the helicopter before the start of serial production, scheduled for 2015.

40. "Ansat" in the Tatar language means "comfortable", "light".
In 1993, a design bureau was created at Kazan Helicopter Plant, the purpose of which was to develop a helicopter with a maximum take-off weight of 3.3 tons, which must meet the aviation requirements of FAR-29.

41. In February 1997, KVZ receives a certificate from the IAC aviation register, which allows the development of these helicopters. The first flight of the Ansat light multi-purpose helicopter was carried out in 1999 by test pilot V.M.Rusetsky.

Flight performance

Maximum speed 275 km/h
Cruise speed 220 km/h
Max. flight range with main tanks 520 km
Practical ceiling 5500 m
Static ceiling outside the zone of influence of the earth 3300 m

Mass characteristics
Max. takeoff weight 3 300 kg
Max. payload 1,184 kg
GT engines (2хPW207K, Pratt&Whitney)
Takeoff power 630 hp
Power in emergency mode 710 hp

Cabin dimensions
Length 5700 mm
Width 1770 mm
Height 1370 mm
Volume 8.0 m3

Capacity
Flight crew 1-2
Passengers 7+1

43. Ansat is the only Russian helicopter equipped with a digital electrical system remote control(KSU-A). The presence of a digital engine control system allows you to simulate the engine shutdown mode without stopping it.

The transport and passenger modification of the helicopter is designed to perform a wide range of tasks:
- transportation of goods and passengers to remote and hard-to-reach settlements;
- use as an air taxi in the city and between settlements;
- delivery of shifts of workers to offshore drilling rigs;
- the use of a helicopter for corporate transportation and general aviation.

45. Lifetime tests of Ansat have been carried out at Kazan Helicopter Plant since 1999.

46. ​​The training modification of the Ansat-U helicopter is intended for training piloting of the helicopter by cadets of flight schools and civilians, as well as for retraining pilots and improving their skills. Equipping the helicopter with two gas turbine engines, combined with duplication of the main most important units and systems, ensures a high level of flight safety in the specific conditions of flight training.

47. We were not allowed to photograph the entire territory, only individual helicopters. Because nobody canceled the secrets.

48. We were lucky - we caught the test flight of the Mi-17V-5. The machine flew away for half an hour, then returned.

49. Such beauty is produced by Kazan Helicopters - one of the leading enterprises of the Russian Helicopters holding, which has crossed the 70-year mark. The company does not cease to increase the pace of production from year to year. Workhorses made in Kazan have flown more than 50 million flight hours worldwide, performing a variety of missions in the service of man. The main thing is that people choose peaceful tasks more and more often - and helicopters will not let you down!

Thanks for the detailed tour to Valery Alexandrovich Pashko, Director of Marketing and Sales of the Kazan Helicopter Plant, Igor Nikolaevich, Head of Machining Production, Kalyupa, Galina and Vlada from the press service.

The Kazan Helicopter Plant is a manufacturer of Mi-8/17 helicopters, which is part of the Russian helicopter-building concern Russian Helicopters. Helicopters made in Kazan Russian production, flew in total around the world. more than 50 million flight hours During the existence of the Kazan Helicopter Plant, more than 12 thousand helicopters, Mi-14, Mi-4, Ansat, Mi-17 and their variations have been delivered to one hundred countries of the world.

Story

The plant began its history on 09/04/1940, when, by order of the People's Commissariat of Aviation Industry, the Leningrad Aviation Plant No. 387 was built, which was then evacuated to Kazan during the war and merged with the Kazan Wagon Parts Plant No. share of the enterprise, it is from this date that the history of the current Kazan Helicopter Plant begins. During the war years, the enterprise produced about eleven thousand Po-2 biplanes for the front - for this, in 1945, the plant staff was awarded the Order of the Red Labor Banner. At the plant, by 1945, the production of military aircraft increased from one hundred to three and fifty copies per month (3.5 times). Every tenth military aircraft produced by the aviation industry of the Union of Soviet Socialist Republics during the Second World War was created here. Being actively involved in the post-war renewal of the national economy, and in 1947-1951, the plant produced over 9 thousand of the first C-4 for the country (self-propelled combines).

The Kazan Helicopter Plant in 1951 began manufacturing Mi-1 helicopters - it became the first serial production of rotary-wing equipment in the Union of Soviet Socialist Republics. The Mi-4 helicopter, which has been manufactured at the plant since 1954, became the first Soviet helicopter to be exported abroad. In 1965, the enterprise began serial production of the Mi-8, the most popular and massive among all Mi-class helicopters.

Plant No. 387 was renamed the Kazan Helicopter Plant in 1966. In 1973, the enterprise mastered the production technology of the Mi-14, an amphibious helicopter widely used in naval aviation. The successes achieved labor collective were awarded in 1980 the International Prize "Golden Mercury", and in 1970 the Order of the October Revolution.

Despite the fact that in the 90s there were objective problems in the development of the Russian aviation industry, the plant received the right to participate in the international market, was converted into an open joint-stock company, which made it possible to re-equip production, introduce modern technologies assembling devices of complex geometry and processing materials.

In 1993, the enterprise began developing the Ansat, the only helicopter designed and built in Russia, in the post-Soviet period. In 1997, the Kazan Helicopter Plant received an official certificate from the Aviation Register of the IAC, which makes it possible to develop helicopters, and the first Ansat prototype equipped with an electrical remote control system appeared. It made its first flight in 1999. Ansat in currently, along with the Mi-17 helicopter, the main product of the plant, is included in the updated model range of the plant.

Kazan Helicopter Plant in 2007 became part of the Russian Helicopters concern.

Products

Today, the enterprise owns the infrastructure typical for machine-building multi-series production, has a modernized technological and production base that allows for the production and repair of helicopters: Kazan Helicopter Plant produces the entire cycle of helicopter construction from design and serial production to its warranty support.

Mi-17 - multipurpose medium helicopter, which is an improved version of the Mi-8 helicopter. At the moment, more than eleven thousand helicopters of this type have been produced. Currently, the Kazan Helicopter Plant is mass-producing three main variations:

Mi-172 - passenger variation, intended for the carriage of passengers. Special VIP variations are also produced;

Mi-17-V5 is a transport variation, designed to transport cargo on an external sling and inside the cabin. Actively used in rescue operations;

Mi-17-1V is a multi-purpose variation, on the basis of which helicopters for various purposes are produced, including a hospital on departure.

Ansat is a multi-purpose light helicopter developed directly by the Kazan Helicopter Plant. The Ansat helicopter series is actively developing in two directions: civil and military. The Ansat-U training helicopter is purchased by the Russian Ministry of Defense for military training centers and flight schools and is supplied in series. With the help of quick-detachable units, the Ansat multi-purpose helicopter is able to quickly re-equip for a wide range of tasks: passenger transportation, cargo delivery, patrolling, search and rescue operations, emergency health care, fire extinguishing.

According to the program of the Russian Helicopters Concern for the creation of a multi-purpose medium-sized Mi-38 helicopter, the enterprise is responsible for the construction of prototypes of the helicopter and the adjustment of its mass production.

In order to ensure the competitiveness of their products, improvements are made throughout the life of the service helicopter. To service the machines currently in operation, the Kazan Helicopter Plant has a modernized repair base that provides a high degree of repair and restoration of helicopters.

Production

According to the tasks of the technical re-equipment of the plant, it continues to be equipped with high-performance state-of-the-art equipment, unified procedures and processes are being introduced. The development of the industrial base is aimed at reducing costs and, thus, at reducing the cost of production, increasing the volume of products that are produced. At the same time, the task was set to increase the reliability and quality of manufactured helicopters, to increase the range of helicopters in terms of standard sizes and available capabilities.

Experimental design bureau and research work of the enterprise

The enterprise, as a developer, plans to build target variations and upgraded versions of the Ansat helicopter; performance of work on ultralight helicopters weighing up to one and a half tons, up to two and a half tons. Together with open joint stock company"Moscow Helicopter Plant named after Mil M.L. » Modernization of mass-produced Mi-8/17 helicopters and preliminary preparations for mass production of the Mi-38 helicopter are being carried out. Research and scientific activity of the enterprise is focused on increasing economic effect production and technical level of the plant to obtain product developments that will be competitive. Every year, up to two hundred people participate in inventive and rationalization activities. Of the three hundred proposals submitted by them, about thirty patents for industrial designs, inventions, utility models and about two hundred and fifty rationalization proposals are being implemented.

We went to see the Kazan Helicopter Plant. In the format of a quick tour, it is difficult to cover the entire work of the enterprise. Usually it takes me at least a whole day to shoot such a shoot. But here's what I managed to see, I'll show you.

Kazan Helicopter Plant is a manufacturer of Mi-8/17 family helicopters, which is part of the Russian Helicopter Holding Russian Helicopters of the Rostec State Corporation. Russian-made helicopters manufactured in Kazan have accumulated more than 50 million flight hours worldwide. Over the entire history of KHP, more than 12,000 Mi-4, Mi-8, Mi-14, Mi-17, Ansat helicopters and their modifications have been delivered to 100 countries of the world.

The history of the plant dates back to September 4, 1940, when the Leningrad Aviation Plant No. 387 was created by order of the People's Commissariat of the Aviation Industry, which was later evacuated to Kazan and merged with the Kazan Wagon Parts Plant No. 169. Since the aviation fate of the enterprise was determined in 1940, it was from this date the history of the current KHP begins. During the war years, the enterprise produced about 11,000 Po-2 biplanes for the front. By 1945, the production of combat aircraft at the plant had grown 3.5 times: from 100 to 350 per month. Every tenth combat aircraft produced by the aviation industry of the USSR during the Great Patriotic War was assembled here.

In 1951 Kazan Helicopter Plant started the production of Mi-1 helicopters - this was the first serial production of rotary-wing aircraft in the USSR. The Mi-4 helicopter, which has been produced at the plant since 1954, became the first domestic helicopter to be exported. In 1965, the enterprise began manufacturing the Mi-8, the most massive and popular of all the Mi family helicopters.

In 1993, the enterprise began developing the Ansat, the only helicopter designed and built in Russia in the post-Soviet period. In 1997 KVZ received an official certificate from the Aviation Register of the IAC, allowing the development of helicopters, and the first Ansat prototype with an electric remote control system was also created. In 1999 he made his first flight. At the moment, Ansat, along with the main products of the plant, the Mi-17 helicopter, includes the current model range of the enterprise.

1. Let's look at the assembly production of the Mi-17 (and its families), Ansat and Mi-38 helicopters.

2. Today, the enterprise has an infrastructure typical for mass production of a machine-building profile, has a modern production and technological base certified for the production and repair of helicopters: Kazan Helicopter Plant carries out a full cycle of creating helicopters from development and serial production to its after-sales support.

3. In the case of a slipway assembly, the product is usually assembled in one place in an assembly fixture (slave), which facilitates fixing in the desired position and crimping the assembled product. The photo shows Ansat fuselage fittings.

4. Part of the bottom of the Mi-17.

5. Almost finished Mi-17 fuselage.

6. A machine for drilling holes in the frame to which the tail boom is attached.

7. Ansat fuselages in varying degrees of readiness. At the factory

8. The Mi-8 family of helicopters has been produced since 1965 and now more than 12,000 units have been produced in total. More than 7,500 helicopters have been produced at the Kazan Helicopter Plant.

9. The fuselage of the Mi-17V-5.

10. Mi-8/17 are even operated in the USA. And for their company in Afghanistan, they turned out to be indispensable due to their survivability and suitability for repair in the field.

11. The plant now produces three main modifications of the helicopter: Mi-172 is a passenger modification designed to carry passengers. There are also special VIP modifications. Mi-17V-5 is a transport modification designed to transport cargo inside the cabin and on an external sling. Can be used to transport rescuers. Mi-17-1V is a multi-purpose modification, on the basis of which helicopters for various purposes are produced, including a flying hospital.

12. In total, several dozen modifications were released. The helicopter is operated in dozens of countries.

13. But on the right is the Mi-38 cabin.

14. The beginning of the design of the Mi-38 - 1981 Presentation of the model in Le Bourget - 1989 Model - August 1991 Presentation of the full-scale model - Mosaeroshow - 1992 Start of production of two prototypes - 1993 Presentation of the modified model - MAKS - 95. The Mi-38 multi-purpose helicopter can be used to transport cargo and passengers, including VIPs, as a search and rescue helicopter and a flying ambulance, for flights over land and water areas. The Mi-38 has many progressive features (in particular: a "glass cockpit" for two pilots and the widespread use of composite materials, including in the main and tail rotors). After a long journey, the first mass-produced cars are now being assembled at the plant.

15. After assembly and leak testing, the board is painted.

17. Cabin Mi-17V-5

18. Ansats. Experienced specimens.

19. As they said at the factory, they specifically did not begin to make a composite fuselage at Ansat. First, it is the development and implementation new technology and secondly, security. The metal bent during a rough landing - this place is visible. A piece was cut out, patched up and again into the sky. But with a composite fuselage, this will not work. And just the place of the fracture will not be visible - only instrumental control.

20. Marketing and Sales Director of the Kazan Helicopter Plant Valery Pashko and experienced Ansat. Sensors of barometric instruments are placed on the bar so that the case and the propeller do not interfere with them during tests.

21. Mi-17V-5.

21. Small demonstration flights were arranged specially for us.

23. The Mi-17 helicopter costs an average of $15 million.

24. Yellow boxes - vibration dampers. With them, it is halved. I flew on board without them - the vibration stand is still the same.

25. Cabin. You can even buy this board. He is assembled, covered. All defects were shaken out of it. Miracle, not a machine.

26. VIP lounge.

27. And the test pilot, having landed the Mi-17, moved to Ansat.

28. The first prototype of the helicopter was assembled in May 1997. The first flight was made in 1999. In 2011, the process of certification of the civilian version of the helicopter began. In August 2013, a type certificate was received from the Aviation Register of the Interstate Aviation Committee. At the moment, more than 20 units have been delivered to customers.

31. You can buy from 5 million dollars, which is three times cheaper than the Mi-17.

32. Ansat cabin.

33. "Ground computer".

34. VIP lounge.

35. The crew of test pilots: Victor Rusetsky and Gennady Goncharov.

36. Of course, the simulator.

37. Behind the handle

In total, more than 50 million flight hours have been flown worldwide. We are going on an excursion to the Kazan Helicopter Plant, which is part of the Russian Helicopters holding.

JSC "Kazan Helicopter Plant" is a manufacturer of helicopters of the Mi-8/17 family. The plant carries out a full cycle of helicopter technology development from development and serial production to after-sales support, personnel training and repairs. Over the entire history of the enterprise, more than 12,000 Mi-4, Mi-8, Mi-14, Mi-17, Ansat helicopters and their modifications have been delivered to 100 countries of the world.

Blade production. The Kazan Helicopter Plant is the only enterprise in Russia and in the world that produces blades using three fundamentally different technologies: the manufacture of metal blades, composite blades by winding and laying out.

This is how metal blades are assembled. The rigidity is based on a frame in the form of honeycombs:

These elements are called ribs and are designed to shape the blades:

Blade assembly:

Assembly shop. Helicopters are assembled here:

Bonnet assembly area power plant on the fuselage:

Rivet seams on the surface of the "tail" of the helicopter:

There is a lot of manual labor in the factory. Here is the assembly of the parts of the end beam, on which the tail rotor is located:

The now obsolete name "helicopter" was borrowed from French already at the end of the 19th century. The authorship of the word "helicopter" (from "spins" and "flies") belongs to N. I. Kamov.

Assembly shop. On the picture: Mi-17V-5 helicopter:

Engine:

The main advantage of helicopters is the ability to take off and land vertically - a helicopter can land (and take off) anywhere where there is a flat area one and a half rotor diameters in size.

Installation in the cockpit:

The main disadvantages inherent in all rotary-wing technology compared to aircraft are a lower maximum flight speed and increased fuel consumption.

Also, the disadvantages of helicopters include the complexity of control compared to aircraft.

Installation of harnesses under the floor of the Mi-38 loader:

The production of helicopters reached more than 900 helicopters per year

Dashboard mounting:

As mentioned at the beginning, Russian-made helicopters made in Kazan have accumulated more than 50 million flight hours worldwide. Up to 8,500 domestic helicopters are operated in the world. For example, this Mi-17V-5 will fly to Azerbaijan...