PROSES PRODUKSI KERETA API
Madiun, 27 September 2021
Ir.AGUNG SEDAJU M.T.
DIAN RAHMAT FAUZI ST.
WAHYU ADE SAPUTRA ST.
YUDHA K.WIJAYA ST.
POLITEKNIK NEGERI MADIUN
JURUSAN PERKERETAAPIAN
Perusahaan Manufaktur Kereta Api
Pengenalan Diagram Alur Kereta
KERETA Carbody Shell
(General Arrangement)
Installation
Carbody Set
Exterior & Interior
Bogie
Pengenalan Diagram Alur Kereta
Underframe
Front Part
Bolster
Midle Part
CARBODY SHELL Floor Construction
Supporting Frame
Sidewall Welded Duct
To Carbody Set Welded Bracket
Frame work & Ext. Sheating
Welded Duct
Welded Bracket
Body End
ell Frame work & Ext. Sheating
y Sh
b od
Car Gangway
Welded Duct
Welded Bracket
Roof Frame work & Ext. Sheating
Frame Work Of Ceiling
Welded Duct
Welded Bracket
Partition
Frame Work
Welded Duct
Welded Bracket
Pengenalan Diagram Alur Kereta
To Generall BOGIE Bogie Frame Bogie Frame
Arrangement
Welded Bracket
Wheel Set Assy Axle 8607.19.00.00
Wheel 8607.19.00.00
Axle Box Axle Box
BOGIE
Bearing 8607.19.00.00
Primary
Spring 7320.20.90.00
Suspension
Spring Seat
Scondary
Spring 7320.20.90.00
Suspension
Dumper 8607.19.00.00
Brake
Equipment
TB398
Painting & Painting
Marking Marking
Carbody
Centre Pivot
Conection
Side Bearer
Assembly DN
Optional (bisa LN/DN)
Lokal/Dalam Negeri
Import
Raw Material Carbody
CARBODY MILD STEEL CARBODY STAINLESS STEEL CARBODY ALUMINIUM
• Raw material (SS 400, SPAC, SPAH) • Raw material (SUS 301, SUS 304) • Raw material (6061, 6065)
lokal Import Import
• Manufacturing process : • Manufacturing process (Import): • Manufacturing process (Import):
• Melting • Melting • Melting
• Casting • Casting • Extrusion
• Hot rolling • Hot rolling
• Cold working • Cold working
Raw Material Bogie
BOGIE FRAME WHEEL SET ASSY AXLE BOX
• Raw material • Raw material • Raw material (casting steel)
(mild steel, casting steel) (casting steel, forging steel) • Axle box
• Casting • Axle Import PT BARATA (?) PT BARATA
PT BARATA • Wheel Import PT BARATA (?) • Bearing
Import
• Construction
PT INKA
PRI. & SEC. SUSPENSION BRAKE EQ. CARBODY CONNECTION
• Raw material (steel, rubber) Raw material • Raw material (mild steel,
• Rubber bonded Local/Import • Mild steel casting steel, forging steel,
• Spring Local PT KRAKATAU STEEL composite)
• Spring seat Local • Casting steel • Side bearer PT INKA
• Dumper Local PT PINDAD • Center pivot PT INKA
• Air spring Import
Proses Fabrikasi
Proses fabrikasi : suatu proses produksi yang meliputi antara lain : pemotongan,
pembentukan, penyambungan, perakitan atau pengerjaan akhir
PENYAMBUNGAN
PEMOTONGAN
PERAKITAN
PEMBENTUKAN
RAW MATERIAL
Flow Proses Fabrikasi
Raw Material Fabrikasi
Steel Work-Pemotongan Material Type Gap Shear
Max thickness of worksheet 9 mm
Max cutting length 4000 mm
Operating system CNC/manual
Shear Mechanism
MESIN GAP SHEAR
Steel Work-Pemotongan Type Laser Cutting CNC
Max thickness of worksheet 20 mm
Material Cutting sheet range 5000 mm x 2500 mm
Laser type Mix Gas (CO2 : N2 : He)
Material type Mild steel, stainless steel,
Aluminium
Hasil laser cutting
Laser Cutting Mechanism
MESIN LASER CUTTING
Steel Work-Pemotongan Material
Type Gas Cutting CNC
Max thickness of worksheet 120 mm
Cutting sheet range 4000 mm x 2000 mm
Number of tourches Max 10 set
Material type Mild steel
MESIN GAS CUTTING
Steel Work-Pemotongan Material
Type Mesin Sawing
Max thickness 350 mm
Material type Profile steel
Underframe
MESIN SAWING
Channal steel
Steel Work-Pembentukan Type Press Bending
Material Max thickness 25 mm
Control system Manual/CNC
Bending length 4000 mm
Produk mesin bending
Press Bending Mechanism
MESIN PRESS BRAKE
Steel Work-Pembentukan Material
Type Stretch forming
Jaw bore 152,4 mm
Max/min. distance between jaws 6000/500 mm
Stretch forming mechanism
Roof framing
MESIN STRECTH FORMING
Steel Work-Pembentukan Material
Type Roll Forming
Material Thickness (Up to) 1.2 mm
Roller Material High Grade 45# Tool Steel,
Coated With Chrome
MESIN ROLL FORMING
Roll forming mechanism
Steel Work-Pembentukan Material
Type Stretch forming
Size of baseplate (L x W x H) 2710 x 1180 x 240 mm
Diamater (max) 75mm
MESIN DRILLING
Steel Work-Pembentukan Material
CNC Milling Lathe machine
Bogie Frame
CNC Planno miller Annealing furnace
Penyambungan-Perakitan
MESIN WELDING
Produk Welding
Penyambungan-Perakitan
Type Indirect Spot welding (sidewall)
Control System CNC
Number of control axis 4 axis (x, y, z, w)
Number of Electrode 2 main electrode, 2 assist electrode
Spot welding mechanism
MESIN INDIRECT SPOT WELDING
Penyambungan-Perakitan
Type Indirect Spot welding (Roof)
Control System CNC
Number of control axis 5 axis (x, y, z, a, w)
Number of Electrode 2 main electrode, 2 assist electrode
MESIN INDIRECT SPOT WELDING
Penyambungan-Perakitan
Type Seam Welding
Max Speed 3m/min
Cooling Water 40 lt/min
Supply Volt 400 V
MESIN SEAM WELDING
Underframe + keystone
Seam welding mechanism
Penyambungan-Perakitan
Type Portable Spot Welding
Voltage 600 V
Weight 49 kg
MESIN PORTABLE SPOT WELDING
Flow Assy Carbody
Tugas :
- Desain lah sebuah produk minimum menggunakan 5 alat produksi seperti contoh diatas.
mulai dari proses Raw material hingga menjadi produk jadi.
- Sebutkan alat produksi apa yang dibutuhkan oleh PT. INKA dalam proses manufaktur
kereta api.
- Selasa depan 5 Oktober 2021 masing - masing kelompok mempersentasikan desain
produk tersebut.
TERIMA KASIH
