Siemens Innovates Vectron Locomotive Production: Laser Welding Systems and AI Support

Siemens has significantly expanded the production capacity of Vectron locomotives at its Munich - Allach site. With a €250 million expansion of the production base, it now has the capacity to produce up to 385 locomotives and 180 Vectouro carriages annually. Production is highly automated, relying on modern technologies such as laser welding systems and AI - supported quality inspections.

Laser - assisted assembly is one of the highly automated production steps, which needs to adapt to diverse customer needs—control current channels are almost never duplicated, and semi - automated solutions ensure the production of highly complex locomotives in high - cost locations. In the production of car body steel structures, after parts are cut, stainless steel bodies are welded together. The site is home to two of Europe's four laser welding systems, specializing in manufacturing long beams. Compared with traditional processes, they cause less deformation, increase speed by 500%, and significantly reduce rework rates. Siemens implements a "zero - defect policy" with AI - supported quality inspections: photoelectric sensors detect missing components or deviations under low tolerances, while collecting data for digital twins to aid subsequent maintenance and repairs. However, human labor remains indispensable—boxes and locomotive frames use traditional welding. Bodies are processed in the paint shop and colored as per customer requirements. Meanwhile, many components are assembled in pre - assembly, which is also highly automated.