Introduction

Vertex has been supplying jigs and fixtures for rolling stock manufacturers since 2015, delivering customized, compliant solutions. Our expertise includes layout planning, custom jig design, cost optimization, assembly jigs, and automated lines, supported by ergonomic studies and pneumatic, electrical, and hydraulic planning, with on-site installation and commissioning.

Our Indian & Global Presence in Rolling Stock
Vertex has designed, manufactured, installed, and commissioned jigs and fixtures for welding and assembly of rolling stock components, including end walls, side walls, underframes, roofs, bogies, e-blocks, and power modules.
We have also developed power module assembly workstations with automated, software-based monitoring systems, successfully delivering solutions for railway and metro coach manufacturers.

Car body

  • Car body shell

  • Underframe

  • Floor

  • Windows

  • Insulation

  • Crash structure

  • Painting and Sound damping

  • Fixing / connecting elements

The client required a jig to clamp and tilt the car body side wall frame by approximately 2 degrees on the assembly line to enable accurate and high-quality welding. Vertex designed and developed a dedicated jig solution to meet the application, safety, and production requirements.

Car body fittings

  • Front/End car body fittings

  • Roof car body fittings

  • Underframe car body fittings

  • Lateral car body fittings

The client required an automated solution to assemble the ceiling into the metro train body. Vertex designed the concept and delivered an integrated system utilizing PLC control, hydraulic systems, and electrical drives to enable controlled lifting, tilting, and movement of the jig into the main assembly station.

Guidance (Bogies and running gear)

  • Motor bogie

  • Trailer bogie

The client required a jig to handle and support the complete axle set during assembly operations. Vertex developed the concept and detailed design using high-strength structural steel and lifting shackles to meet application, safety, and operational requirements.

Power System

  • Power supply

  • Power generation

  • Power conversion

  • Power dissipation

  • Power storage

The client required an assembly jig for electrical loom routing to reduce assembly time and errors. Vertex developed a digital loom board with six display frames showing clear routing schematics, enabling operators to perform loom assembly on the top working surface. The solution incorporates vertical lift using electrical linear actuators and manual frame rotation through a worm gearbox, improving ergonomics, accuracy, and productivity.

Propulsion

  • Traction Control Unit (TCU)

  • Mechanical transmission

  • Traction motor

  • Gear box

  • Power converter

The client required a jig to secure components on the assembly line. Vertex developed detailed and shared drawings using advanced machining processes to meet application requirements. The solution incorporates a 3000-bar hydraulic system to compress and hold components during assembly, with all hydraulic systems designed and processed to specified technical requirements.

Auxiliary systems

  • Air supply system

  • Hydraulic system

  • Auxiliary electric system

  • Battery equipment

  • Flange lubrication device

  • External supply system

  • Horn

  • Sanding equipment

  • Fire protection system

  • Main Auxiliary Converter equipment

  • Low Voltage Power Supply / Battery Charger equipment

  • Special Aux. Converter equipment

  • Cooling unit for power and drive systems

MHE is used for movement of Battery Set within depot or from depot to other facility.

Braking System

  • Brake control system

  • Friction brake equipment

  • Wheel Slip Protection (WSP) equipment

  • Magnetic track brake equipment

  • Emergency brake equipment

  • Eddy current brake equipment

The client required a jig to assemble and dismantle bogie wheel axle bearings. Vertex enhanced the concept shared by Alstom, completed the detailed design, and successfully installed and commissioned the solution to meet operational and safety requirements.

On board vehicle control

  • Fault data logger

  • Video surveillance

  • Electronic rear mirror

  • Voice recorder

  • System, capture unit

  • Electronic Train Control System (ETCS)

  • Train Control Management System (TCMS)

  • Heritage Automatic Train Protection (ATP) unit

  • Automatic Train Operation (ATO) unit

  • Heritage juridical recorder unit

A Train Collision Detection System (ACD) prevents collisions by continuously monitoring train positions and transmitting data to a central controller. ATP and ATS systems provide automatic safety intervention by enforcing signal compliance and speed limits, applying emergency braking when required to prevent accidents.

Passenger information System (PIS)

  • Safety Alarm Systems

  • Seat reservation

  • Public Address System

  • Billing System

  • Trackside equipment

  • Central Passenger information System (PIS) unit

  • Driver-Machine Interface (DMI) for train/travel information

The Passenger Information System (PIS) is a modular solution that can be customized by configuring individual components and sub-systems, with functionality programmed to meet specific project requirements.

Communication systems

  • Train to wayside communication system

  • Onboard communication system

The client required an assembly line workstation with software-based communication and feedback for sub-assembly components. Vertex designed and delivered the complete production line, comprising three assembly workstations, three ball transfer unit stations, and one test bench conveyor line, enabling efficient assembly, traceability, and controlled workflow.

Heating, Ventilating and Air Conditioning (HVAC)

  • Air conditioning system

  • Heating system

  • Air intake

  • Exhaust air unit

  • Pressure protection system

  • Air ventilation and distribution system

  • Heating, Ventilating and Air Conditioning (HVAC) control unit

Clients requirement is to develop a test bench to test HVAC unhot leaking purpose. Vertex designed and developed the test bench & installed with demonstration.

Interiors

  • Interior architecture

  • Interior equipment

  • Toilet system

  • Engine room

  • Catering system

The client required a jig to hold and lift the driver desk cabin for installation into the vehicle interior. Vertex developed the concept design using aluminum profile frames, cast nylon components, and a hydraulic lifting system to meet the application and safety requirements.

Cabling and Cabinets

  • Cabling

  • Cabinets

The client required a jig to assemble and dismantle bogie wheel axle bearings. Vertex enhanced the concept shared by Alstom and successfully completed the design, installation, and commissioning to meet operational and safety requirements.

Tilt System

  • Tilt Control Unit

  • Actuating System

  • Pantograph tilt system

  • Tilt monitoring and detection

The client required a test bench to evaluate pantograph strength under lifted conditions. Vertex designed and developed the test bench using linear guide rails and linear displacement sensors to accurately measure deflection, and successfully installed the system to meet testing and safety requirements.

Coupler

  • Front coupler

  • Intermediate coupler

  • Emergency coupler (Towing coupler)

A dedicated tool, used in combination with a pit table or forklift, is employed for the safe removal and installation of the front automatic coupler.

Door System

  • External doors

  • Internal doors

Design, manufacture, supply, installation, commissioning, and demonstration of a Door Operation Test Setup for the Lucknow project.

Our Indian & Global Presence in Rolling stock

Designed, manufactured, installed, and commissioned jigs and fixtures for welding and assembly of coach components, including end walls, side walls, underframes, roofs, bogies, e-blocks, and power modules. Also developed power module assembly workstations with automated software-based monitoring systems. Delivered for railway and metro coach manufacturing facilities in India and overseas.

Our Clients

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