Thus, according to the results of the analysis carried out in this work, we were convinced that the organization of working conditions in the workplace is a complex and multifaceted process. In modern enterprises, this issue is receiving more and more attention from managers.
The types, functions and essence of the organization of working conditions in the workplace were considered. We also reviewed and studied the methodology for analyzing working conditions in the workplace. In the first chapter of this work, we have shown the importance of a special assessment of working conditions.
We have studied and analyzed the main technical and economic indicators at the JSC "Solikamskbumprom". On the basis of which we made conclusions about the functioning of the enterprise.
To analyze the improvement of working conditions at the workplace of the studied enterprise, the following data were considered in the diploma work. Criteria for establishing the categories of severity and compliance with the scores of sanitary and hygienic factors of working conditions. We found that in general, the workplaces meet the requirements, but disadvantages such as poor illumination of the work surface are not excluded. Also, in the course of the analysis, we found out that most of the absenteeism for work is made up of absenteeism for health reasons.
Based on the performed analysis and calculations, taking into account all the findings about the shortcomings of the investigated enterprise, some measures were developed and economically justified, aimed at improving the activities of JSC "Solikamskbumprom". Thanks to a more rational and reasonable organization of working conditions at the workplace, a significant increase in the main technical and economic indicators is possible.
Based on the results of the study, the following conclusions were made. Parts and assemblies of the electric rolling stock are subject to wear and damage during operation. To maintain electric locomotives and electric trains in good working order, there is a system of scheduled preventive repairs and inspections.
The storage battery serves as a voltage source of 50 V for the coils of devices, lighting and signal lamps when the control generator is not working. The electric locomotive is equipped with alkaline (cadmium-nickel) storage batteries.
Typical battery damage is:
- a). Decrease in battery capacity is a basic and serious malfunction alkaline batteries.
- b). Accumulation of carbonates.
- v). High electrolyte temperature.
- G). Electrolyte contamination with harmful impurities.
- e). Short circuit.
- e). Mechanical damage.
- g). Short circuit inside the battery.
- h). Increased self-discharge.
- and). Electrolyte contamination: ingress of metal impurities, use of non-distilled water.
- To). Reduced capacity: carbonate build-up, improper charging, high temperature operation.
At present, all types of locomotive maintenance are performed at the depot. For this purpose, the corresponding workshops have been organized in the depot. Batteries are repaired and charged in the battery department of the blanking shop. For this, a special room is allocated, as a rule, on the first floor. The battery compartment includes: repair, painting, charging, regeneration and generator, production facilities.
In order to improve the organization of repairs, it is proposed to mount a production line in the battery compartment, on which batteries will be repaired.
One-time costs for the introduction of the production line are equal to 1139.640 thousand rubles.
The payback period of the project is less than one year. The integral economic effect (NPV) from the introduction of the production line will amount to 9134.04 thousand rubles.
Thus, the goal and tasks set in the diploma project are fully completed.
CONNECTION OF HARMFUL SUBSTANCES
15 LIGHTING
Natural lighting with top and top-side lighting
e = 4%, with side illumination
General artificial lighting E = 200 lux,
Combined illumination E = 500 lux.
Noise level J = 80 dB at 1000 Hz.
16 ACTIVITYON TB
Workers engaged in battery repair and maintenance are constantly in contact with harmful substances (lead vapors, sulfuric acid), which, under certain conditions or improper handling, can lead to injury or poisoning of the body. In addition, when charging the battery, a chemical reaction occurs, as a result of which the liberated free hydrogen is mixed with oxygen in any proportions and a volatile gas is formed, which explodes not only from fire, but also from compression. In this regard, the battery shop of the ATP should consist of three departments: "repair", "charging", "acid".
The “CHARGING” compartment must have direct access to the street or to a common repair box. The floor in the battery shop should be either asphalt or metlakh tiles. All workers must wear protective clothing and protective equipment. Batteries weighing more than 20 kg must be transported on a trolley, excluding falls. When carrying the battery, you need to use various devices (so as not to pour over electrolyte).
You need to prepare the electrolyte in special vessels, pouring distilled water first, and then acid. You can pour acid using special devices. Pouring acid manually and pouring water into it is FORBIDDEN!
When preparing electrolyte, the safety rules must be strictly observed. Bottles with acid or electrolyte should be moved in warehouses only with the help of special stretchers with bottle fixing. Solid rubber stoppers should fit snugly against the neck of the bottle. Do not store acid bottles in the battery workshop for a long time. Control over the charge progress only with chargers (load plugs, hydrometers, glass intake tubes). In this case, the battery operator must wear rubber gloves. Do not check the battery charge by short-circuit. It is forbidden to stay in the battery workshop of persons who are not working in the workshop (except for the personnel on duty - at night).
At the entrance to the battery shop, you should install a sink, a bedside table with a first aid kit, an electric towel, and a soda solution (5-10%) should be kept ready on the bedside table. A neutralizing solution (2-3%) is made to wash the eyes. If acid or electrolyte comes into contact with open areas of the body, immediately wash this area of the body: first with a neutralizing solution, and then with water and alkaline soap. Electrolyte spilled on a rack or table is removed with a cloth soaked in a neutralizing solution.
Do not eat or drink in the battery workshop. After finishing work, workers are advised to shower with alkaline soap and then regular toilet soap. All tools, carts, fixtures must be in good working order. Posters with visual campaigning on TB should be posted in prominent places in the department. At the entrance, you should post the general safety requirements. Workers must undergo safety instrumentation at least once a year. Particular attention should be paid to ventilation. It is done separately from the ventilation of the entire enterprise. Fume hoods are made for hoods from racks.
Ventilation - explosive suction at the top, supply at the bottom. Panels are installed "taking" charged air along the baths for electrolyte preparation. The amount of air to be removed is at least 2.5 times the volume per hour.
Local ventilation is installed at workplaces: for smelting lead and workbenches for assembling and disassembling batteries.
17 FIRE-FIGHTING MEASURES
In terms of fire hazard, the battery shop belongs to the “D” category, and the “charging” compartment belongs to the “A” category (especially fire hazardous). Therefore, in the department, it is necessary to strictly observe all fire safety rules for the indicated categories.
In the “charging” compartment, the doors should open outward and face the street. Ventilation in the "charging" compartment (due to the release of hydrogen during charging) should provide 6-8 times the exchange; in "repair" - 2-3 times. In the compartment, all lamps are in gas-permeable fittings. Open lighting wiring is performed with lead wire.
It is prohibited to install switches, sockets, electric heaters, rectifiers in the “charging” compartment. At each site, without fail, there must be a fire extinguisher, both foam and carbon dioxide type (OP and OU).
I envisage installing the chargers (rectifiers) in special sealed cabinets (with a hood) made of durable glass and place them in the battery reception and control compartment. In addition to the fire notification panel, I propose to install maximum action heat detectors (IP-104, IP-105) in the workshop room, install an automatic gas analyzer with alarm in the “charging” compartment, as well as “smoke” sensors connected to the central control panel of the ATC.
I propose to install primary fire extinguishing equipment in each department:
1. FOAM EXTINGUISHER OHP-10 - 2 pcs.
2. FOAM AIR FIRE EXTINGUISHER ORP-10 - 2 pcs.
3. CARBON EXTINGUISHER OU-2 - 2 pcs.
4. BOX WITH SAND - 0.5 cubic meters - 1 pc.
5. SHOVEL - 1 pc.
18 FIRE SAFETY
It is FORBIDDEN to connect the battery clamps with a wire “twist”!
Control over the charge leaving is carried out by special devices.
Checking the battery with a short circuit is FORBIDDEN !!!
It is FORBIDDEN to use different types of “tees” and connect more than one consumer to the outlet !!!
To inspect the battery, portable electric lamps are used, with an explosion-proof voltage of no more than 42 V.
FORBIDDEN:
Enter the battery shop with an open fire (matches, cigarettes, etc.);
Use electric heating devices in the battery shop;
Store acid bottles (they need to be stored in a special room);
Store and charge acid and alkaline batteries together;
Stay of strangers in the room.
19 EQUIPMENT
PURPOSE OF THE CONSTRUCTION
TILTING MACHINE - designed for overturning batteries when flushing or draining electrolyte. It greatly facilitates the work on the above operations.
TILT CONSTRUCTION
The rotator consists of a platform 3, on which two posts are attached 2. The platform has four wheels 5, two of which are welded by brackets 4 to the platform 3, and the other two 6 can rotate around the vertical axis 12, because the bracket is welded to the bearing unit, which ensures that when the rotator is transported along the compartment, it can be rotated, and not just straight.
On the upper part of the struts 2, bearing units are installed, in which the semi-axes 8 of the lodgement rotate. The base has a window for installing the battery. The battery is attached to the cradle with clamps. The base with the installed battery can be manually rotated to any angle. In this case, the flywheel 7 will be fixed at angles of rotation 90, 180, in order to release the flywheel lock, you must pull the flywheel towards you, when fixing, you must release it and it will return to its place under the action of the spring.
1. The rechargeable battery (accumulator battery) is placed in the positioner of the rotator on the left side in the direction of travel.
2. Before working on draining the electrolyte, it is necessary to exclude the spontaneous movement of the tilter; for this, it is stopped with screw jacks located on the platform to the right and left of the rack with the flywheel.
3. In order to turn the battery over and pour out the electrolyte or water, pull the flywheel towards you perpendicular to the vertical plane. The handwheel will disengage from the lock and can be turned clockwise to any angle.
4. To stop the turn of the battery at an angle of 90 and 180, it is enough to release the flywheel.
5. To return the battery to its original position, perform work according to point “3”, but turning the flywheel counterclockwise.
CALCULATION OF THE DESIGN OF THE MAIN UNITS
Initial data:
P = 10 kg - force acting on the spring.
D = 12 mm - spring diameter.
= 13 mm - spring tension.
[] = 150 kg / cm 2 - maximum shear stress.
1. Determine the diameter of the wire - d
2. Determine the number of turns of the spring - n, where:
G - modulus of elasticity of the second order
G = 0.4 * E = 0.4 * 2 * 10 6 = 8 * 10 5 kg / cm 2
E - modulus of elasticity of the first order (Young's modulus)
E = 2 * 10 6 kg / cm 2
TECHNICAL SPECIFICATIONS:
1. Type - mobile, with manual drive
2. dimensions, mm - 980 * 600 * 1020
3. Weight, kg - 60
4. Rotation - manually
1) = 8PD / Pd 3; d = 3 8PD / P [] =
3 8 * 10 * 12 / 3.14 * 150 = 2 mm.
2) = 8PD 3 * n / G * d 4; n = * Gd 4 / 8P * D 3 =
13 * 8 * 10 5 * 0.2 4/8 * 10 * 1.2 3 = 10 turns.
LIST OF USED LITERATURE
1. EPIFANOV LI "Methodological guide for course design
MOT of cars. ”Moscow 1987.
2. KOGAN E. I. KHAYKIN V. A. “Labor protection at enterprises road transport". Moscow" Transport "1984.
3. SUKHANOV BN BORZYKH IO BEDAREV YF "Maintenance and repair of automobiles". Moscow "Transport" 1985.
4. KRAMARENKO GV BARASHKOV IV "Maintenance of cars". Moscow "Transport" 1982.
5. RUMYANTSEV SI "Car repair". Moscow "Transport" 1988.
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Introduction
2.3 Selection and adjustment of standards for the labor intensity of technological maintenance and overhaul per 1000 km of run
3. Organizational section
3.3 Routing
4. Labor protection
Conclusion
Literature
Introduction
Increasing the productivity, efficiency of using the rolling stock of road transport largely depends on the level of development and the conditions for the functioning of the production and technical base of the road transport enterprise, the main task of which is to ensure the required level of technical readiness of the rolling stock.
The development and improvement of the production and technical base of road transport enterprises must meet the modern requirements of scientific and technological progress. In solving the problems of studying production and technical bases, bringing it into line with the requirements of a dynamically developing road transport, an important place is occupied by the issues of improving the design of an enterprise.
Road transport is quite convenient compared to other modes of transport. It has great maneuverability, good maneuverability and adaptability to various conditions. The production service plays a significant role in the implementation of many complex tasks. The automotive industry is systematically working to improve production technologies and improve the structures of rolling stock.
Considering that the growth of labor productivity depends on the level of mechanization and automation of production processes, therefore, one of the main tasks is to equip each workplace, post with a set of technological equipment, tools and devices as much as possible.
Of great importance for increasing labor productivity during maintenance and repair and ensuring their quality is the widespread introduction of the scientific organization of labor (NOT) in production. The latter includes a large range of measures, including improving the organization and maintenance of workplaces, improving the techniques, methods and regulation of labor, creating favorable sanitary, hygienic and aesthetic working conditions, etc.
The goal of my course project is to design a battery compartment.
The objectives of the project are to calculate the frequency of maintenance; determination: the number of services per year, the technical readiness coefficient, the daily program of cars; distribution of labor intensity for maintenance and repair of vehicles and self-service of the enterprise; distribution of work intensity; calculation of the number of workers; selection of technological equipment; department layout, etc.
1. Characteristics of the design object
The motor transport enterprise (ATP) is located in an area with a warm, humid climate and belongs to the third category of operation.
The list of vehicles is 400 KAMAZ 5415 vehicles, of which 60% have been overhauled and 320 KRAZ 256B1 vehicles, of which 80% have been overhauled.
Mode work of ATU five-day, the number of work shifts is 2, which provides an eight-hour working day. ATP specializes in the transportation of goods.
The design theme is the battery compartment. The accumulator department carries out repairs of accumulators according to the applications recorded in the control coupons, and according to the applications of all divisions of the auto service.
The battery compartment is equipped with equipment in accordance with the nature of the work performed on it. Specialization makes it possible to mechanize labor-intensive work as much as possible, reduce the need for equipment of the same type, improve working conditions, employ less skilled workers, and increase the quality and productivity of labor. We use the following equipment in the battery compartment: Waste bin, baths for parts washing and electrolyte preparation, racks, stands, rectifier, cabinets, etc.
2. Settlement and technological section
2.1 Selection and adjustment of frequency Maintenance
The frequency of maintenance depends on the number of rolling stock, category of operating conditions and climatic conditions.
The frequency of TO - 1, L 1 km is determined by the formula:
L 1 = L K 1 K 3, (1)
where L is the standard maintenance frequency - 1, km, selected according to table 2.1 L KaMaz 5415 = 4000 (km); L KRAZ 256 B1 = 2500 (km).
K 1 - coefficient taking into account operating conditions, K 1 = 0.9, table 2.7 K 3 - coefficient taking into account natural and climatic conditions, K 3 = 1, table 2.9
L 1 Kamaz 5415 = 4000 0.9 1 = 3600 (km);
L 1 KRAZ 256B1 = 2500 0.9 1 = 2500 (km).
The frequency of TO - 2, L 2 km is determined by the formula:
L 2 = L K 1 K 3, (2)
where L is the standard maintenance frequency - 2, km, selected according to table 2.1 L (km); L Kamaz 5415 = 12000 (km);
KRAZ 256 B1 = 12000 (km).
L 2 Kamaz 5415 = 12000 0.9 1 = 10800 (km);
L 2 KRAZ 256B1 = 12000 0.9 1 = 10800 (km).
2.2 Selection and correction of mileage before overhaul
It is also necessary to adjust the frequency of the run before overhaul. The service life (mileage before overhaul) depends on K 1, modifications of the rolling stock - K 2 and K 3.
The frequency is calculated using the formula:
L KP = L K 1 K 2 K 3, (3)
where L is the standard frequency before overhaul, km, which is determined according to table 2.2 L KaMaz = 300000 (km); L KRAZ 256 B1 = 160,000 (km).
K 2 - correction factor taking into account the modification of the rolling stock, km, which is selected according to table 2.8
K 2 Kamaz 5415 = 0.95; K 2 KRAZ 256B1 = 0.85;
K 3 - coefficient of adjustment of standards depending on natural and climatic conditions, which is selected according to table 2.9
L KR Kamaz 5415 = 300000 0.9 0.95 1.0 = 256000 (km);
L KR KRAZ 256 B1 = 600000 0.9 0.85 1.0 = 122400 (km).
If cars are operated after overhaul, then the overhaul mileage, L, km, is reduced by 20%
L Kamaz 5415 = 0.8 256500 = 205200 (km);
L KRAZ 256 B1 = 0.8 122400 = 97920 (km).
If new and overhauled cars are operated in the car park, then it is necessary to calculate the separate mileage of cars L КР СР, km, according to the formula:
where A u is the percentage of cars that have not undergone major repairs A u KaMaz 5415 = 40%; And u KRAZ 256 B1 = 65%;
A - the percentage of cars that have undergone major overhaul A KaMaz 5415 = 60%; A KRAZ 256 B1 = 35%;
After repair, taking into account the coefficients, it is necessary to correct the multiplicity factor b 1; b 2; b 3 maintenance and repairs.
For TO - 1, the multiplicity factor b 1 is determined by the formula:
where L CC is the average daily mileage, km: L CC KaMaz 5415 = 160 km;
L CC KRAZ 256 B1 = 100 km;
For TO - 2, the multiplicity factor b 2 is determined by the formula:
For KR, the multiplicity factor b 3 is determined by the formula:
The corrected and initial data are summarized in table 1.
Table 1. Correction of vehicle mileage
| car | Mileage, km | ||||
| Correct taking into account the coefficients | Correct taking into account the multiplicity | to the calculation |
|||
| Average day. | |||||
| Average day. | |||||
2.3 Selection and adjustment of standards for the labor intensity of technological maintenance and overhaul per 1000 km of run
Correction of the labor intensity of maintenance is carried out depending on K 2 and the number of units of technologically compatible rolling stock (K 5) daily maintenance, t EO, man hours determined by the formula:
t EO = t K 2, (9)
where t is the standard labor intensity for daily maintenance, man-hours, we choose according to table 2.1 t KaMaz 5415 = 0.67 (man-hour),
t KRAZ 256 B1 = 0.45 (man hours)
t EO Kamaz 5415 = 0.67 1.10 = 0.73 (man-hours);
t EO KRAZ 256 B1 = 0.45 1.15 = 0.51 (man hours).
Labor intensity of TO - 1, t TO-1, person hour. determined by the formula:
t T O -1 = t K 2 K 5, (10)
where t is the standard labor intensity for maintenance - 1, is selected according to table 2.1, t Kamaz 5415 = 2.29 (man-hours), t KRAZ 256 B1 = 3.7 (man-hours)
t T O -1 Kamaz 5415 = 2.29 1.10 0.80 = 2.01 (man hours);
t T O -1 KRAZ 256 B1 = 3.7 1.15 0.80 = 3.4 (man hours).
Labor intensity of TO - 2, t TO-2, man hour. determined by the formula:
t Т O -2 = t K 2 K 3, (11)
where t is the standard labor intensity for maintenance - 2, is selected according to table 2.1, t Kamaz 5415 = 9.98 (man-hour), t KRAZ 256 B1 = 14.7 (man-hour)
t T O -2 Kamaz 5415 = 9.98 1.10 0.80 = 8.78 (man hours);
t T O -2 KrAZ-260V = 14.7 1.15 0.80 = 13.5 (man hours).
The complexity of current repairs per 1000 km of run depends on the type of cars, operating conditions, modification, natural conditions, vehicle mileage and the size of the vehicle, t TR, person hour. and determined by the formula:
t TP = t K 1 K 2 K 3 K 4 K 5, (12)
where t is the standard labor intensity for current repairs, we choose according to table 2.1, t Kamaz 5415 = 6.7 (man-hours), t KRAZ 256 B1 = 6.4 (man-hours)
К 1 - coefficient of standard correction depending on operating conditions, К 1 = 0.9
K 2 - the correction factor taking into account the modification of the rolling stock, km, which is selected according to table 2.8 K 2 KaMaz5415 = 0.95; K 2 KRAZ 256 B1 = 0.95
K 3 - coefficient of adjustment of standards depending on natural and climatic conditions, K 3 = 1.0
K 4 - the coefficient of correction of the norms of the specific labor intensity of the current repair (km) and the duration of the downtime of maintenance and current repair (K), depending on the mileage from the beginning of operation, K 4 KaMaz 5415 = 1.4; K 4 KRAZ 256 B1 = 1.4
К 5 - coefficient of adjustment of standards of maintenance and current repair, depending on the number of serviced and repaired vehicles at the ATP and the number of technologically compatible groups of rolling stock К 5 = 0.80.
t TR Kamaz 5415 = 6.7 0.9 1.10 1.0 1.4 0.80 = 7.42 (person hour);
t TR KRAZ 256 B1 = 6.4 0.9 1.15 1.0 1.4 0.80 = 7.41 (person hours).
2.4 Determination of the technical readiness of the park
The coefficient of technical readiness of the park, α Т, is calculated by the formula:
where D TO TR is the duration of the rolling stock downtime in maintenance and current repairs, determined according to table 4.5, D TO TR GAZ-53A = 0.5; D TO TR MAZ-53363 = 0.6; D TO TR MAZ-64226 = 0.8, D KR - the duration of the rolling stock downtime in overhaul, determined according to table 4.5, D KR KaMaz 5415 = 22; D KR KRAZ 256 B1 = 22
2.5 Determination of vehicle utilization rate and annual fleet mileage
Since the park is constantly being equipped with new technology, more productive equipment, the level of labor, the reliability of cars, etc. will increase. The utilization rate of the fleet, α u is determined by the formula:
where D RG is the number of working days, D RG = 257
D KG - the number of calendar days, D KG = 365
Knowing the utilization rate of the fleet, it is possible to calculate the annual mileage of the fleet, L PG, km, using the formula:
L PG = D RG α u L CC A u, (15)
L PG KaMAz5415 = 257 0.6 160 400 = 9868800 (km);
L PG KRAZ 256 B1 = 257 0.6 100 320 = 4934400 (km).
2.6 Determine the number of services per year
The number of overhauls, N, is determined by the formula:
The amount of daily maintenance, N, is determined by the formula:
The amount of TO - 2, N, is determined by the formula:
The amount of TO - 1, N, is determined by the formula:
2.7 Determination of the annual scope of maintenance and repair work
Annual volume of work on daily maintenance, T person hour. determined by the formula:
Т = t ЕО N, (20)
T Kamaz5415 = 0.73 61680 = 45026.4 (man-hour);
T KRAZ256B1 = 0.51 49344 = 25165.44 (person hour).
The annual scope of maintenance work - 1, T, man-hour, is determined by the formula:
T = t TO-1 N, (21)
T Kamaz5415 = 2.01 1728 = 3533.58 (man hours);
T KRAZ256B1 = 3.4 748 = 2543.2 (person hour).
The annual scope of maintenance work - 2, T, man-hour, is determined by the formula:
T = t TO-2 N, (22)
T Kamaz5415 = 8.78 864 = 7585.92 (person hour);
T KRAZ256B1 = 13.5 374 = 5049 (person hour).
The annual volume of work on current repair, T, man-hour, is determined by the formula:
T Kamaz5415 = (person hour);
T KRAZ256B1 = (person hour).
If there are vehicles in the park different types, then it is necessary to determine the total labor input for maintenance and overhaul. The total labor intensity of daily maintenance, Σ T EO, is determined by the formula:
Σ T EO = T Kamaz5415 + T KRAZ256B1, (24)
Σ T EO = 45026.4 + 25165.44 = 70191.84 (person hour)
The total labor intensity of TO - 1, Σ T TO - 1, is determined by the formula:
Σ T TO - 1 = T Kamaz5415 + T KRAZ256B1, (25)
Σ T TO - 1 = 3533.58 + 2543.2 = 6076.78 (person hour)
The total labor intensity of TO - 2, Σ T TO - 2, is determined by the formula:
Σ T TO - 2 = T Kamaz5415 + T KRAZ256B1, (26)
Σ T TO - 2 = 7585.92 + 5049 = 12634.92 (person hour)
The total labor intensity of the current repair, Σ Т ТР, is determined by the formula:
Σ T TR = T Kamaz5415 + T KRAZ256B1, (27)
Σ T TR = 73127.808 + 36563.904 = 109691.71 (person hour)
In addition to maintenance and current repairs, the vehicle fleet carries out self-service work of the enterprise, that is:
a) Maintenance and repair of machine tools, energy and power equipment;
b) Manufacturing, maintenance and repair of technological equipment;
c) Repair of buildings, structures, water pipes, sewerage systems, etc.
Therefore, it is necessary to enter the self-service work scope in the annual scope of work. The scope of work for self-service of the enterprise, T CAM, man hours, is determined by the formula:
where K CAM is the coefficient taking into account the amount of work on self-service of the enterprise in%. The coefficient depends on the number of cars at the ATP.
2.8 Calculation of the number of production workers
Productive workers include work areas and sections directly performing maintenance and repair work on rolling stock.
When calculating the number of workers, there is a distinction between the turnout (technically necessary) - Р Я and the staff (payroll) - Р Ш number of workers.
The number of technologically necessary workers corresponds to the number of jobs. In this case, a workplace is understood as a section of the area on which work is performed by one worker. One or several workers can work at a work station at the same time.
The number of technologically necessary workers is determined by the formula:
where T OTD is the annual volume of work of the department T OTD = 2786 man-hours.
F RM - annual fund working time
where H N is the duration of the worker's work during the week, H H = 40
D N - the number of working days per week, D N = 5
D K - number of calendar days, D K = 365
D B - the number of days off, D B = 103
Д П - number holidays, D P = 5
Determine the number of full-time workers using the formula:
where Ф ПР - the annual fund of time for regular workers is determined by the formula:
where Ф T is the annual fund of time of one worker
D O - the number of days of vacation of the worker
D U.P - the number of days of absence from work for a good reason
5 - the number of working days
2.9 Calculation of the number of posts for a branch
where T POST is the labor intensity of the post, T POST = 1229 man-hours.
P - number of posts
K N - reservation ratio, K N - 1.35
С - number of shifts, С - 1
D RG - the number of working days per year, D RG - 302
T CM - shift duration in hours, T CM - 8 hours
Р СР - the number of workers simultaneously working at the post, Р СР = 2
η P is the coefficient of using the working time of the post, η P - 0.98
3. Organizational section
3.1 Selection of technological equipment and tooling at the site
overhaul car battery
The technological equipment includes stationary, mobile and portable stands, machine tools, all kinds of devices and devices that occupy an independent area on the layout, necessary to perform work on TR.
Organizational equipment includes production equipment (workbenches, racks, cabinets, tables) that occupy an independent area on the layout. Technological equipment includes all kinds of tools, fixtures, devices necessary for performing work on TR, which do not occupy an independent area.
When choosing technological equipment, it is necessary to take into account that the number of many types of stands, installations and devices does not depend on the number of workers in the workshop, while workbenches, work tables are taken based on the number of workers.
The list of necessary technological equipment and accessories is given in the table.
Table 2 Technological equipment
| № | Name | Brand | Dimensions (edit) | ||
| 1-repair department | |||||
| 1 | Waste bin | 2 | 0.6x0.8 | 0,48 | |
| 2 | Parts rinsing bath | 2257 | 1 | 0.9x0.5 | 0,45 |
| 3 | Workbench | 1019 | 1 | 1.0x0.8 | 0,8 |
| 4 | Electrolyte drain bath | E - 204 | 1 | 0.58x0.21 | 1,22 |
| 5 | Rack | 2242 | 1 | 1.0x0.4 | 0,4 |
| 6 | Stand | 1 | 0.7x0.6 | 0,42 | |
| 7 | Rectifier | BCA-5A (BCA-111B) | 1 | 0.41x0.31 | 1,28 |
| 8 | Melting workbench | 1 | 1.0x0.8 | 0,8 | |
| 9 | Material cabinet | 551 | 1 | 0.5x0.6 | 0,30 |
| 2- charging compartment | |||||
| 1 | Shelving rack | E-409 OG | 4 | 1.10x1.10 | 1,21 |
| 3-pantry | |||||
| 1 | Rack for parts | 3 | 0.6 x0.5 | 0,30 | |
| 2 | Rack for bottles | 1 | 1.0x0.6 | 0,6 | |
| 3 | Battery rack | E-405A | 1 | 0.5x0.6 | 0,30 |
| 4-acid department | |||||
| 1 | Electrolyte bath | E-204 | 1 | 0.58x0.21 | 1,22 |
| 2 | Acid dispenser | P-206 | 1 | 0.4x0.4 | 0,16 |
| 3 | Electric distiller | 737MRTU / 2 | 1 | 0.5x0.5 | 0,25 |
| TOTAL: | 10,19 | ||||
3.2 Calculation production area
The area of the site is determined by the formula:
3.3 Technological map
The charging of the battery is checked by measuring the density of the electrolyte. By changing the initial density of the electrolyte poured into the battery (which must correspond to the data in Table 2.4), you can determine the degree of its discharge. A decrease in the density of the electrolyte, reduced to a temperature of +25 ° C, by 0.01 g / cm3 indicates that the battery is discharged by about 6%. that is, when the density drops by 0.04 g / cm3, the battery discharge is 25%, 0.08 g / cm3 - 50%, and when the density drops by 0.16 g / cm3, the battery is completely discharged. With a different decrease in the density of the electrolyte in individual batteries, the total discharge value of the storage battery can be roughly determined as the average discharge value of its batteries. The measurement of the density of the electrolyte in the batteries is carried out in the same manner as in the preparation of the electrolyte. For accuracy, check the electrolyte level before measuring the density of the electrolyte. After charging the storage battery or long-term operation of the engine, before measuring, it is necessary to hold it for about 30-40 minutes until gas evolution stops. After adding distilled water to the battery, the electrolyte density can be measured only after 10-15 minutes so that the water mixes with the electrolyte, and the electrolyte density becomes equal. A battery discharged in summer by more than 50% (with an average decrease in electrolyte density by 0.08 g / cm3), and in winter by more than 25% (with a decrease in electrolyte density by 0.04 g / cm3) should be removed from the car and charge. A storage battery put into storage should be recharged when discharged by 25-30%, which corresponds to a decrease in the density of electrolyte in batteries by 0.04-0.05 g / cm3.
4. Labor protection
Individuals who are at least 18 years old, have the appropriate qualifications, who have received introductory instruction and initial instruction at the workplace, trained in safe working methods and having the appropriate certificate, are allowed to independent work on the repair and maintenance of batteries.
A battery operator who has not undergone a timely re-training on labor protection (at least once every 3 months) and an annual examination of knowledge on labor safety should not start work.
The battery operator is obliged to comply with the internal labor regulations established at the enterprise.
The duration of the battery operator's working time should not exceed 40 hours per week. The duration of daily work (shift) is determined by the internal labor regulations or the shift schedule approved by the administration in agreement with the trade union committee. The battery operator must know that hazardous and harmful production factors that can act on him in the process of performing work are:
electricity;
sulphuric acid;
caustic potassium;
lead and its compounds;
Sulfuric acid, if it gets on parts of the body, damages the skin, and dermatitis and burns are formed.
Potassium hydroxide works in a similar way to sulfuric acid.
Lead and its compounds lead to poisoning of the working organism, as well as to the disorder of the peripheral and central nervous systems, damage to the locomotor system, lead paralysis.
Hydrogen is released during battery charging, mixing with atmospheric oxygen to form an explosive oxyhydrogen gas.
It is forbidden to use tools, fixtures, equipment, handling of which the battery operator has not been trained and instructed.
The battery operator must work in special clothing and special shoes, and, if necessary, use other personal protective equipment.
In accordance with the Standard Industry Standards for the Issuance of Special Clothing, Special Shoes and Other Personal Protective Equipment, the battery operator is issued:
cotton suit with acid-proof impregnation;
rubber ankle boots;
rubber gloves;
rubber apron;
protective glasses.
The battery operator must follow the rules of personal hygiene:
before using the toilet, eating, smoking, you should wash your hands with soap and water;
do not store or consume in battery food and drinking water, in order to avoid the ingress of harmful substances from the air into them;
for drinking it is necessary to use water from specially designed devices (saturators, drinking tanks, fountains, etc.);
to protect the skin of the hands, apply specially designed protective ointments.
It is prohibited.
in the room for charging batteries, in order to avoid an explosion, light a fire, smoke, use electric heating devices (electric stoves with an open spiral, etc.) and allow sparking of electrical equipment;
allow unauthorized persons to enter the charging and acid rooms;
connect the battery terminals with a wire;
check the battery with a short circuit;
pour molten lead into wet molds and put wet pieces of lead in the molten mass;
pour water into acid, as this causes "boiling" and possible splashing out of the electrolyte from the vessel;
store in the repair and charging compartments battery vessels with sulfuric acid and alkali in an amount exceeding the daily requirement, as well as empty vessels, which should be stored in a separate room;
jointly store and charge acid and alkaline batteries in the same room;
take in battery food and store drinking water there in order to avoid the ingress of harmful substances from the air;
use glass promises for electrolyte preparation.
END OF WORK SAFETY REQUIREMENTS
At the end of the work, the battery operator must:
Turn off ventilation and electrical equipment.
Tidy up the workplace. Remove electrolyte, devices and tools in the place provided for them.
Used personal protective equipment (gloves, apron, ankle boots), rinse in water and put away in a designated place.
Take off personal protective equipment, special clothing and shoes and put them in their designated place. Timely hand over them and other personal protective equipment for dry cleaning (washing) and repair.
Wash your hands with soap and water and take a shower.
Conclusion
In this course project developed:
- organization of the battery section
- the method of organizing the production of the TOD complex and the site has been selected and justified;
- calculated the annual labor intensity of work in the Asia-Pacific region and the site;
- the equipment of the site is selected;
- the number of production works is calculated
- requirements for safety and fire safety were developed;
- a planning drawing of the accumulator section has been completed.
Literature
1. Regulations on the maintenance and repair of the rolling stock of road transport / Ministry of Transport and Communications of the Republic of Belarus - Minsk: Transtekhnika 1998 - 59s.
3. Design of motor transport enterprises and service stations. Educational / M.M. Bolbas, N.M. Kapustin and E.I. Petukhov, V.I. Pokhabov - Mn. Universitetskoe, 1997 - 24bc.
4. Maintenance and repair of cars. A guide to coursework and diploma design. M .: Transport, 1985 - 224s.
5. Maintenance and repair of cars. Graduation design manual / B.N. Sukhanov et al. - M .: Transport, 1991 - 159p.
8. Maintenance of cars. G.V. Kramarenko, I. V. Barashkov M .: Transport, 1982 - 368s.
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Introduction
1. Justification of the project
1.1 Brief description of JSC "Solikamskbumprom"
1.2 Analysis of technical and economic indicators
1.3 Workplace of the accumulator
1.4 Safety requirements for battery operation
1.5 Analysis of protective measures to prevent the manifestation of hazardous and harmful factors
2. Calculation and design part
2.1 Characteristics of the production line at the battery station
2.2 Maintenance on a production line
2.3 Calculation of the production line of continuous daily technical equipment (EO)
3. Operational and technological part
4. Safety and environmental friendliness
4.1 Environmental protection
4.2 Objectives in the field of quality and environmental protection of JSC "Solikamskbumprom" for 2012 -2013
4.3 Expertise of industrial safety
4.4 Sanitation rules and first aid to victims
5. The economic part
5.1 Specifications battery repair production line
5.2 Calculation of energy consumption and labor resources for battery repair
5.3 Calculation of the cost of repairing batteries
Conclusion
List of literature and normative and technical documentation
Introduction
In a civilized society, great importance is attached to working conditions and their improvement. Working conditions are determined by the state of the production environment (environment), which includes socio-economic, material, production and natural elements. An enlarged classification of factors affecting the formation of working conditions.
The first group includes: normative and legislative state regulation of socio-economic and industrial working conditions (working hours, work and rest regimes, sanitary standards and requirements, a system of state, public control over compliance with applicable laws, norms, requirements and rules in the field of conditions labor, etc.); socio-psychological factors characterizing the attitude of workers to work and to the conditions in which it takes place, the psychological climate in production teams, the effectiveness of the benefits and compensation for work, which are inevitably associated with adverse influences.
The second group includes means of labor (industrial buildings and structures, including various sanitary and technical and sanitary devices, technological equipment, tools, devices, including means ensuring the technical safety of labor, etc.); objects of labor and its product (raw materials, materials, blanks, semi-finished products, finished products); technological processes (physical, mechanical, chemical and biological effects on the processed objects of labor, methods of their transportation and storage, etc.); organizational forms of production, labor and management (level of specialization of production, its scale and mass character, shift work of the enterprise, discontinuity and continuity of production, forms of division and cooperation of labor, its methods and methods, applied modes of work and rest in relation to the work shift, week, year, organization of workplace maintenance, the structure of the enterprise and its divisions, the ratio of functional and linear production management, etc.). rechargeable technical repair battery
The third group includes natural factors that are of particular importance in the formation of working conditions in agricultural production, mining, transport and construction.
This group includes the following factors: geographic (climatic zones, altitude, weather conditions); geological (the nature of the occurrence of minerals, the method of their extraction); biological (features of flora and fauna, human life in accordance with biological rhythms).
In the literature, the elements that form the working conditions are often called factors. If we proceed from the generally accepted understanding of the term "factor", then such an application will not be entirely accurate, because we are talking about the constituents of the working conditions, and not about the reasons for their formation. At the same time, if we consider the elements that make up the working conditions, from the point of view of their influence on a person, a favorable or unfavorable effect on his performance, health, mood and, in general, on the development of personality, then these elements act as factors. That is why in the literature and many official documents the elements of working conditions are interpreted as factors, since the elements of working conditions are expressed by quantitative or qualitative characteristics, then in what follows we will call them "indicators" (elements) of working conditions.
Working conditions are a set of elements of the working environment that affect the health and performance of a person in the labor process.
Such working conditions should be considered favorable when the quantitative and qualitative totality of their constituent elements exerts an influence on a person, contributing to the spiritual and physical development of the individual, the formation of a creative attitude towards work in workers, and a sense of satisfaction with it.
The unfavorable working conditions are those when their impact can cause deep fatigue in a person, which, accumulating, can lead to a painful condition or cause an occupational pathology; due to the negative influence of working conditions, workers may form a negative opinion about the work (unattractive, unpopular, little prestigious, etc.).
In the classification developed by the Research Institute of Labor, all elements of working conditions are divided into four groups. With all the conventionality of the division, it is important both for the study of working conditions and for the development of practical measures to improve them and monitor their condition, compliance with sanitary and hygienic, psychophysiological and aesthetic standards, requirements and rules.
The requirements for working conditions in production are determined by the need to ensure such working conditions at the workplace, in the shop, at the enterprise, in which an adverse effect on the working capacity and health of workers is excluded and optimal boundaries of division and cooperation of labor can be ensured, and ultimately improving the efficiency and quality of labor.
Enterprises must strictly adhere to sanitary norms and rules, maximum permissible concentrations (MPC) of harmful substances and maximum permissible levels (MPL). The development of sanitary standards and requirements is especially important in the design of new equipment, technology and production facilities.
Measures to eliminate the adverse health effects of working elements of the working environment - sanitary and hygienic, psychological, aesthetic and other factors - are considered in the literature on labor protection, industrial sanitation and safety.
The purpose of the diploma project is to improve the organization of the battery repair shop.
In accordance with the goal, the tasks are set:
1. To study the purpose, device and principle of operation of storage batteries;
2. To study the organization of work of the workshop for the repair of batteries;
3. Develop a project for the introduction of a production line to the battery repair site;
The object of the diploma project is the Auto-timber workshop (post for the repair of batteries), the subject is the improvement of the organization of repair in the workshop for the repair of batteries.
1. Justification of the project
In solving the problem of improving working conditions, the planned implementation of measures plays an important role. The main document that determines the essence and sequence of measures in the field of improving working conditions is an action plan to improve and improve working conditions in the organization.
The plan is drawn up on the basis of the results of a special assessment of working conditions by the certification commission, taking into account the proposals received from the departments of the organization or individual employees. The plan should provide for measures to improve equipment and technology, the use of personal and collective protective equipment, health improvement measures, as well as measures for the protection and organization of labor.
Labor protection is a system for ensuring the safety of life and health of workers in the process of work, including legal, socio-economic, organizational, technical, psychophysiological, sanitary and hygienic, treatment and prophylactic, rehabilitation and other measures and means.
Labor protection identifies and examines possible reasons industrial accidents, occupational diseases, accidents, explosions, fires and develops a system of measures and requirements in order to eliminate these causes and create safe and human-friendly working conditions.
Working conditions are a combination of factors of the working environment and the labor process that affect the performance and health of an employee (Article 209 of the Labor Code of the Russian Federation).
Working conditions at an enterprise as the living conditions of workers in the process of their activities are both an element of the production system and an object of organization, planning and management. Therefore, changing working conditions is impossible without interfering with the production process. That is, it is necessary to combine, on the one hand, working conditions, and on the other, the technology of production processes.
Workplace is an organizationally indivisible (in given specific conditions) link of the production process, serviced by one or more workers, designed to perform one or more production or service operations, equipped with appropriate equipment and technological equipment. In a broader sense, it is an elementary structural part of the production space, in which the subject of labor is interconnected with the allocated means and the object of labor for the implementation of unit labor processes in accordance with the target function of obtaining the results of labor.
1.1 Brief description of the enterprise JSC "Solikamskbumprom"
JSC "Solikamskbumprom" is located in the city of Solikamsk, Perm Territory. The enterprise is largest manufacturer newsprint price Russia |
The structure of OJSC "Solikamskbumprom" on the principles of equality, economic independence and common strategic interests in the production of competitive end products - newsprint - integrated 9 Russian logging enterprises located in the northern regions of the Perm Territory and supplying raw materials (wood) for newsprint production.
Own logging accounts for 45% of the total timber consumed by the enterprise.
The joint-stock company also includes LLC “Solikamskaya CHPP”, which is located on the territory of the enterprise and provides production units with process steam and part of the electricity. Part of the CHPP's energy is directed to the needs of the residential and social complex in the northern part of Solikamsk.
The enterprise consists of the following productions:
Timber production for the reception and processing of wood in the amount of 1.5 million m3, supplied by road, rail and water transport;
Cellulose production;
Wood mass production;
Thermomechanical pulp (TMM) production;
Boom production # 2 (production of large XXL paper rolls up to 2.4 meters wide, up to 1.5 meters in diameter, weighing up to three tons; launched a new packaging line for large rolls);
Boom production # 3;
Workshop "Waste treatment facilities";
Wood waste processing area;
The sale of finished products of JSC "Solikamskbumprom" produces:
High-quality newsprint (GOST 6445-74) weighing 40, 42, 45, 48.8 g / m2, possessing high optical, mechanical and structural characteristics, allowing for both black-and-white and multicolor printing on any high-speed printing units;
Wrapping paper (GOST 8273-75) used as a packaging material for wrapping medicines and industrial goods and products, as well as for making paper bags.
Technical lignosulfatones (LST) (TU 54-028-00279580-97) are used in the production of carbon black, chipboard, fiberboard, plywood, cement, foundry, oil industry, road construction;
Consumer goods (notebooks, folders, notebooks, notebooks, writing paper);
Social complex (kindergartens, a polyclinic, a sanatorium-preventorium, the Bumazhnik House of Culture and a stadium) (Table 1.1.).
Table 1.1. Assortment list of products manufactured by JSC "Solikamskbumprom"
|
№ p / p |
Name, appointment |
GOST, TU |
Type of packaging |
Transportation conditions |
|
|
Newsprint paper |
GOST 6445-74 |
In rolls |
Railway carriage-40 tons |
||
|
Lignosulfonate technical liquid |
TU 54-028-00279580-2004 |
In tanks |
Railway tank 60-ton |
||
|
Powdered lignosulfonate |
Paper bags |
Railway carriage - 30 tons Container up to 3 tons |
|||
|
Wrapping paper, gray |
GOST 8273-75 |
In rolls |
Railway carriage-35 tn |
||
|
Rapid Rotary Printing Paper |
TU 5431-013-00279580-2008 |
In rolls |
Railway carriage-40 tons |
||
|
Thin newsprint paper for offset printing |
TU 5431-025-00279580-99 |
In rolls |
Railway carriage-40 tons |
JSC "Solikamskbumprom" constantly makes significant investments in the reconstruction and modernization of the existing equipment.
The comprehensive program for the technical improvement and renovation of production includes successful cooperation with industry research and design institutes, machine-building enterprises in Russia and leading foreign firms.
One of the main reasons for the increase in net profit from production is the increase in the average price of newsprint, compared to the same period last year.
Particular attention is paid to the issues of minimizing the impact of production activities on the environment and labor protection.
1.2 Analysis of technical and economic indicators
Technical and economic indicators are a set of indicators that characterize the activities of an enterprise from the point of view of its material and production base and the complex use of resources.
The calculation of these indicators is carried out when planning and analyzing the activities of the enterprise regarding the organization of production itself and labor, machinery, equipment, the quality of products, labor resources.
The technical and economic analysis of the enterprise includes:
Analysis of the volume, assortment and sales of products;
Analysis of labor indicators;
Analysis of the cost of production;
Profit analysis;
Comprehensive assessment of the actual production intersification against the planned level and a summary analysis of the production and economic activities of the enterprise.
The number of personnel of JSC "Solikamskbumprom" as of 01.01.2010 was 3112 people. The enterprise works in three shifts. The number of people working in one shift on paper machine No. 2 is 61, of which 24 are women, 37 are men. And as of 01.01.2013, the number of personnel was 4144 people.
1.3 Battery operator's workplace
The accumulator is a specialist whose duties include servicing accumulators and rechargeable batteries of different types and capacities.
In a broader sense, the accumulator assembles, disassembles batteries, maintains equipment that is part of the charging stations, mounts and dismantles battery cells with fixing the connecting parts.
The truck shop of JSC "Solikamskbumprom" is equipped with the necessary modern equipment, fixtures and measuring devices that allow you to quickly and accurately check, regulate and repair cars, apparatus and devices for electrical equipment of cars.
Accumulator batteries in the Timber Shop are classified as especially dangerous premises with hazardous working conditions.
Batteries are repaired and charged in the battery department of the blanking shop. For this, a special room is allocated, as a rule, on the first floor.
The battery compartment includes: repair, painting, charging, regeneration and generator, production facilities.
The battery compartment must have a general independent supply and exhaust ventilation and local suction for drying cabinets, washing devices and other equipment. The capacity of the ventilation units and their placement are determined by local conditions.
The battery removed from the car is delivered to the charging room to discharge it to a voltage of 1V on each cell.
After discharging, the battery on the trolley is transported to the repair room, where the rubber covers are removed from the batteries, then the batteries are sent to the installation for repair - flushing.
Figure 1. Plan of the battery compartment for repairing alkaline batteries: I - Repair: 1 - crane with a lifting capacity of 1 ton; 2 - installation for washing alkaline batteries; 3 - rack for accumulator batteries of electric cars; 4 - a rack for alkali-resistant varnishes; 5 - bath for painting cans with alkali-resistant varnish; 6 - tank for drying battery cans; 7 - rack for storage batteries; 8 - cabinet for charging storage batteries; 9 - selenium rectifier; 10 - tanks for a solution of acetic and boric acids; 11 - adjuster cabinet; 12 - cabinet for heating the filling mastic; 13 - exhaust cabinet; 14 - workbench; 15 - electric soldering iron; 16 - writing desk; II - Charger: 17 - charging shield; 18 - dispenser valve for filling electrolyte into the battery; III -Electrolyte: 19 - electric distiller; 20 - distilled water bath; 21 - tank for adjusting the electrolyte after regeneration; 22 - bath for electrolyte dilution; 23 - reservoir for the finished electrolyte; 24 - water tank; 25 - installation for dissolving barium oxide; 26 - installation for electrolyte regeneration; 27 - tanks for a solution of acetic and boric acids; 28 - control cabinet for regeneration units; 29 - writing table; 30 - electric hoist with a lifting capacity of 0.5 t.
The elements inside are washed with warm water at a temperature of 40-50C automatically according to a predetermined program.
For washing batteries outside and washing rubber covers it is advisable to use warm water.
To dry the rubber covers, air heated to a temperature of 40-50C can be supplied to the unit through the shower system.
After washing, individual elements that need to be repaired are transferred to the workbench, after which the batteries are transported on a trolley to the paint room, where they are cleaned of old paint and rust, washed, degreased, painted and dried in special baths and cabinets.
The transfer of elements from position to position is carried out by a crane with a pneumatic hoist and a special suspension, on which four accumulators are fixed.
The repaired storage battery on a trolley is delivered to the charging room for filling it with electrolyte and subsequent charging. For these purposes, the charging room is equipped with a tap for electrolyte spillage and shields for connecting wires to the battery being charged. After charging, the battery is issued for installation on the vehicle.
Equipment used for battery repair:
Charging and discharge installation.
Installation for washing batteries and rubber covers.
Pneumatic lift.
Installation for the regeneration of electrolyte.
Electrolyte filling valve.
Installation for dissolving barium oxide.
Electrolyte storage tank.
A trolley used to transport a battery.
Regeneration units control cabinet.
A device for monitoring the voltage on the banks of the storage battery, tanks for boric acid solution, for water, for filling the storage battery.
Table 1. Instrumentation and accessories
1.4 Safety requirements when performing workaccumulator
In the battery room, it is allowed to carry out work related to the repair and charging of batteries.
Batteries received for repair or charging should be installed on serviceable racks. It is prohibited to move the racks with batteries.
When using a portable luminaire, in order to avoid sparking, first insert the plug into the socket and then turn on the breaker, when turning it off, vice versa: first turn off the breaker and then remove the plug.
Follow smooth operation ventilation during charging and soldering.
When carrying batteries, use tools (grabs, stretchers, trolleys) and observe safety precautions.
When transporting battery acid and preparing electrolyte, in order to avoid burns to the skin and eyes, observe the following rules:
Store bottles with battery acid or electrolyte with closed ground stoppers and only in special crates;
Drain the battery acid from the bottles together with the help of devices, avoiding spilling it on the floor; cover spilled acid with sawdust, moisten with a solution of soda or cover with soda, after wearing rubber gloves;
Wear protective goggles and rubber gloves before preparing electrolyte;
Prepare electrolyte in ebonite, earthenware or ceramic dishes (do not use glassware). In this case, first pour cold water into the dishes, and then pour the acid in a thin stream, periodically stirring the solution with a glass or ebonite stick.
When charging batteries, be sure to meet the following requirements:
The filler plugs must be turned out;
Connect the battery terminals before charging and disconnect them after charging with the charger equipment turned off;
Connect the batteries only with tight-fitting (springs) leaded terminals, which ensure tight contact and exclude sparking;
Do not touch two terminals at the same time metal objects to avoid short circuit and sparking;
Battery charging control is carried out only with the help of instruments (thermometer, voltmeter, hydrometer, etc.);
Do not lean close to batteries to avoid burns from acid splashes from the filler openings.
When charging batteries, it is not allowed:
Use faulty chargers and tools;
Work without exhaust ventilation;
Connect batteries to an ungrounded charger;
Measure the voltage at the battery terminals with a load plug due to possible arcing and explosion of gases, and also touch the plug to the resistance in order to avoid burns;
Overload Charger current higher than nominal;
Disconnect the ground wire and touch it to open current-carrying terminals;
Produce any renovation work when the charger is on.
If acid gets on the skin, you should quickly and carefully blot it with a cotton swab or dry cloth, rinse the affected area with water or 2% baking soda solution, lubricate with petroleum jelly, tie with a bandage, and then contact the health center.
If acid gets into eyes, rinse them thoroughly with water, then with 2% baking soda solution and immediately contact a health center.
In case of contact with acid on clothes, rinse the latter with a stream of water, neutralize with soda, chalk or lime, rinse again with water and dry.
Work using a blowtorch should be performed in a specially designated area on a steel-lined workbench under an exhaust hood.
When performing these works, the following requirements must be observed:
Workbenches and racks should be installed horizontally and not come into contact with heating devices and risers of water supply, heating and sewerage;
The place for lighting the blowtorch should be fenced from the sides and in front with a metal or brick screen;
To prevent the blowtorch from exploding, fill the lamp with only the flammable liquid for which it is intended to operate;
Before lighting the lamp, check its serviceability.
When working with a blowtorch, it is not allowed:
Fill the lamp reservoir with a flammable liquid to more than 3/4 of its volume;
Tighten the filler plug with less than 4 threads;
Excessively pumping air;
Clean the clogged nozzle hole by increasing the pressure;
Operate a lamp that does not have a stop on the shut-off valve;
Add fuel to a burning lamp;
Release the compressed air through the filler hole of the burning lamp. The flame must be extinguished with a shut-off valve.
If any faults are found, stop working immediately and have the lamp repaired.
After finishing work with a blowtorch, it is necessary to extinguish it, allow it to cool to ambient temperature and drain the fuel into a canister. Do not store a refueled lamp in the workplace.
When melting lead, do not allow water to enter the vessel with molten lead to avoid burns caused by superheated steam and lead splashes.
During heating, the soldering iron must be fixed and lie on a special stand.
Avoid splashing solder to avoid burns. Store solder in metal box and in the process of soldering, carefully remove the excess from the soldering iron into the box, it is not allowed to shake off the solder.
Do not drink water or eat in the battery workshop.
1.5 Analysis of protective measures to prevent the manifestation of hazardous and harmful factors
To reduce the negative impact of harmful substances on human health, the following methods of prevention and protection are used:
1. Elimination of contact of a harmful substance with a working person. This can be achieved by mechanizing production processes, sealing equipment, etc.
2. The use of personal protective equipment (PPE), such as overalls, respiratory protection, special ointments to protect the skin, etc.
3. Compliance with hygiene standards in the production area, timely ventilation.
Harmful vapors and gaseous emissions from the removed air are extracted by the following methods: absorption by solid porous materials (absorption), chemical transformation of harmful substances into less harmful ones, neutralization in chemical neutralizers.
Dust chambers, cyclones, and electric filters are used to clean the air emitted into the atmosphere from dust.
Basic general requirements:
Production equipment must be safe during installation, operation and repair, both separately and as part of complexes and technological systems, as well as during transportation and storage. It must be explosion and fire safe during the entire service life;
An indispensable condition is to ensure reliability, as well as the elimination of danger during operation in full compliance with the technical documentation. Violation of reliability can occur as a result of exposure to humidity, solar radiation, mechanical vibrations, pressure and temperature differences, wind loads, icing, etc .;
Materials used for the manufacture of parts, assemblies and assemblies of production equipment should not be hazardous and harmful. New materials must be tested for hygiene and explosion and fire safety;
Safety requirements for production equipment are provided by the choice of the principles of operation of structural schemes, safe elements structures, etc., the use of protective equipment in the design, the fulfillment of ergonomic requirements; inclusion of safety requirements in technical documentation for installation, operation, repair, transportation and storage;
Dangerous moving parts must be guarded;
The equipment should not be a source of significant noise, ultrasound, vibration, and harmful radiation;
Structural elements with which a person can come into contact should not have sharp edges, hot and overcooled surfaces;
Workplaces built into the structure of the equipment must ensure the convenience and safety of the worker;
The equipment must have means of signaling a dangerous malfunction and means of automatic stop and shutdown;
The release and absorption of heat by equipment, as well as the release of moisture by it in industrial premises should not exceed the maximum permissible concentration in the working area;
The design of production equipment must provide for protection against electric shock, including cases of erroneous actions of the operating personnel, and also exclude the possibility of accumulation of static electricity charges in dangerous quantities.
Emergency stop devices should be red, marked and easily accessible. A decrease in the level of exposure to hazardous substances or its complete elimination is achieved by carrying out technological, sanitary-technical, treatment-and-prophylactic measures and the use of personal protective equipment.
Measures to combat industrial dust are the rationalization of production processes, the use of general and local ventilation, the replacement of toxic substances with non-toxic ones, the mechanization and automation of processes, wet cleaning of premises, etc. clothing or dust-proof fabric.
To control the gas content of the air during technological processes, the method of sampling in the breathing zone using chromatographers and gas analyzers is often used. The actual values of harmful substances are compared with the norms of the maximum permissible concentration.
In the event that the content of harmful substances in the air of the working area exceeds the maximum permissible concentration, it is necessary to take special measures to prevent poisoning.
These include limiting the use of toxic substances in production processes, sealing equipment and communications, automatic control of the air environment, the use of artificial and natural ventilation, special protective clothing and footwear, neutralizing ointments and other personal protective equipment.
2. Settlement-design section
Maintenance production lines are divided into continuous and batch lines. The nature of the production line is determined by the type of service. On a continuous line, all operations can be performed on a moving vehicle, while cleaning, washing and wiping operations can be organized.
TO-1 and TO-2 are best carried out on a batch production line, since the performance of individual operations requires the vehicle to be stationary.
The streaming method is effective if:
A daily or shift service program sufficient for the full load of the production line;
The schedule for the supply of vehicles for maintenance is strictly observed;
Maintenance operations are clearly distributed among performers;
The work is widely mechanized and, if possible, automated;
There is a proper material base;
There is a standby post or sliding performers.
The streaming method is more progressive in comparison with the service method at universal posts.
A relatively small amount of equipment, which is better used, provides a more complete mechanization of work.
As a result of the specialization of work performed at each post by workers with a narrower specialization of work performed at each post by workers of a narrower qualification, labor productivity is increased by 20%.
Technical diagnostics of cars to a large extent contributes to the introduction of the flow method, since cars with more stable labor intensity come to service.
With the operational-post method of servicing vehicles, the scope of work for each type of maintenance is also distributed over several specialized posts, and a certain group of works and units is assigned to each of them. For example, the first station serves the engine and clutch, the second station serves the rear axle and brake system etc. however, the positions are inconsistent. After servicing at one post, the car has to leave the premises and enter again at another post. The length of stay at each of the service posts should also be the same. The organization of work in the operational-post method contributes to the specialization of equipment, which allows mechanizing the technological process and thereby increasing the quality of work and labor productivity. This method makes it possible to perform some TO-2 operations during TO-1. With this method, it is also possible to service the car between shifts without removing it from the stick, which increases the vehicle utilization rate.
2.1 Characteristics of the production line at the accumulator station
A production line is a complex of technological, control and transport equipment, which is located during assembly or disassembly and is specialized in performing one or several operations.
The most technically advanced are production lines with a distribution conveyor, if objects are automatically distributed to workstations that have receiving and dispatching devices with timers, flexibly connected to the moving conveyor. This frees workers from removing and placing the objects to be processed on the conveyor. However, the use of such devices requires careful economic justification due to their high cost.
Figure 2.1. Scheme of planning a production line with a distribution conveyor: 1 - belt conveyor; 2- storage places; 3 - driving and tensioning stations; 4 - rack
The working conveyor (Figure 2.2) is equipped with a mechanical conveyor that moves the processed object along the line, regulates the rhythm of work and serves as a place for performing operations. Since the objects are not removed from the conveyor, lines with a working conveyor are used mainly for assembly, welding of products, pouring into molds (in foundries), painting units and assemblies in special painting and drying chambers.
Figure 2.2. Scheme of planning a production line with a working conveyor: 1 - belt conveyor; 2 - storage areas; 3 - drive and tension station
In order to improve the organization of repairs, it is proposed to mount a production line in the battery compartment, on which batteries will be repaired.
The production line is equipped with four charging stations, which allow the charge-discharge-charge cycle to be carried out simultaneously with four batteries.
All battery cells (for an alkaline battery of the NK-125 type, 42 cells) are assembled into a cassette, which is installed on the conveyor transport device and moves through the positions. The production line is closed. In the case at each position there are hatches for access to the cassette mechanisms. The control panel sets the rhythm, the necessary cycle parameters, and also controls the technological operations at each of the 10 positions. The electric control circuit is single-wire, voltage 50 V. The air pressure in the line is 0.6 MPa.
Figure 2.3. The project to change the organization of the workshop
1 Position. In the first position, the battery cells are installed in the cassette.
2. Position. On the second, the electrolyte is poured into a special container for subsequent registration, then the elements are washed with hot water (t = 60 degrees Celsius) under a pressure of 0.3 - 0.45 MPa. The washing hydraulic system is powered by a centrifugal pump. Contaminated water flows into the sump.
3. Position. On the third, cassettes with elements are dried with hot air.
4. Position. On the fourth, the elements are filled with electrolyte using a dispenser, which allows filling all the elements at the same time to the required level. The electrolyte filling is monitored using special sensors.
5,6,7,8. Positions. The fifth, sixth, seventh and eighth positions are charging posts. The panel - the diagram at the charging stations is made of fiberglass, and after stopping the cassette is automatically superimposed on the battery, the drive is pneumatic. Voltage control on individual battery cells is carried out using a stepping finder.
Position. At the ninth position, the electrolyte level is adjusted by adding distilled water, after which the plugs of the elements are wrapped.
10. Position. On the tenth, the cassette moves to the shelves of finished products in anticipation of being put on the locomotive.
Battery covers are repaired and checked at a special stand.
9 cases are installed into the bath of the stand, into which water is poured. In turn, a probe is lowered into each case and a voltage of 500 V is applied. A milliammeter installed on the control panel outside the stand shows the value of the leakage current. If the leakage current exceeds 20 mA, the cover is rejected.
The A960.06 (2-ЗРУ-75-100) charging and discharging unit is designed for charging and discharging storage batteries from a three-phase current network with a frequency of 50 Hz, a voltage of 380 V, and has two posts for charging (discharging) batteries.
The unit can charge or discharge rechargeable batteries in the following modes: charging with a stabilized current during charging time; two-stage charge with control at the first stage by voltage, and the whole charge by time; two-stage charge with voltage control at the first stage, cycle time is not set; discharge with a stabilized current with control of the minimum voltage of the batteries and the return of electricity to the network.
To convert alternating current network to constant when charging batteries and for converting direct current of discharged batteries into a variable, returned to the network as the main power elements, thyristors are used, which are controlled in both modes by special control units included in the installation.
Thyristor control is based on the principle, the essence of which is the formation of the thyristor control phase by comparing the sawtooth voltage synchronized with the network with the control voltage, which is either set by the operator (with manual control), or is automatically maintained at a level that provides the set value of the charge current (with automatic current stabilization mode).
Tyrimside- a semiconductor device made on the basis of a semiconductor single crystal with three or more pn junctions and having two stable states: a closed state, that is, a state of low conductivity, and an open state, that is, a state of high conductivity.
When designing posts on the production line and dead-end posts of TO and TR, the normalized distances between vehicles, as well as between vehicles and building structures, are taken into account (Table 2.1).
The arrangement of dead-end posts in the TO and TR zone can be one-sided (Fig. 2.4, a, in), two-sided (Fig. 2.4, b, d), rectangular (Fig. 2.4, a, b), oblique (Fig. 2.4, v) and combined (Fig. 2.4, G). At dead-end posts, car seats are located only in one row.
a b
v G
Figure 2.4. Arrangement of dead-end posts in the areas of maintenance and repair of cars: a and v - one-sided; b and G - double-sided; a and b - rectangular, v - oblique, G - combined
When choosing a method of placing dead-end posts in the zone of maintenance and repair, it should be borne in mind that when they are obliquely placed, the width of the passage, which is necessary for the installation of vehicles at the posts, decreases, but the area of the post, taking into account the width of the passage, increases. Oblique placement of posts is usually advisable if there is any restriction on the width of the zone, for example, when reconstructing the zone for larger rolling stock.
Table 2.1. Standardized distances in the premises of the maintenance and repair of vehicles
|
Elements between which the distance in the premises of TO and TR is normalized |
Distance, m for car category |
|||
|
IIandIII |
||||
|
Longitudinal side of the car and wall: |
||||
|
Longitudinal sides of cars: Maintenance and repair without removing tires, brake drums and gas cylinders Maintenance and repair with the removal of tires, brake drums and gas cylinders |
||||
|
Longitudinal side of the vehicle and stationary technological equipment |
||||
|
Car and Column |
||||
|
Front side of the car and wall |
||||
|
Front sides of the car |
||||
|
End face and stationary technological equipment |
Note: 1. The distance between cars, as well as cars and the wall at the posts of mechanized car wash and diagnostics is taken depending on the type and dimensions of these posts. 2. If it is necessary to regularly pass between the wall and the posts of maintenance and repair of cars, the distance between the longitudinal side of the car and the wall is increased by 0.6 meters.
2.2 Maintenance on a production line
With the flow method, all work is performed at several specialized posts located in the technological sequence, forming a flow line. Each post is specialized and designed to perform part of the operations of the service complex. A necessary condition for the application of this method is the same duration of the car's stay at each of the posts, which is achieved by a constant volume of work performed at the posts, and a constant number of workers at them. According to the purpose, each post is equipped with specialized equipment and tools.
Cars that undergo technical inspection on a production line are most often moved by means of a conveyor.
Cars move from checkpoint to checkpoint at a speed of 2.7 m / s. Conveyor length 47.4 m, pull chain length 97.2. The width of the inspection ditches is 600 mm.
The conveyor is driven by a drive station with a 22 kW electric motor and a gearbox. There are two drive stations, one of them is backup. The conveyor frame is mounted on a concrete base. The pulling device is a lamellar sleeve-roller chain, to which ten support brackets (grips) for the rear and front axles of the vehicle are welded. Chain link pitch 135 mm, breaking force 50,000 daN (kgf).
There can be five cars on the production line at the same time.
The conveyor is controlled by the dispatcher - the master on duty at the central post. Near each of the five posts, there is also a command post associated with the central post.
The master on duty informs about the beginning of work on the production line by sound signaling. Then the senior for each post gives a signal to the master, who controls the operation of the line, while a light board on the central console lights up, indicating the readiness of one or another post. Upon reaching the readiness of all five posts, the foreman turns on the sound alarm, warning of the start of the conveyor movement, after which the mechanized gates for the entry of cars are remotely opened. After installing a vehicle that has entered the first post, the conveyor is turned off and a sound signal is given.
The opening and closing of the gate in the dispensary is also accompanied by an audible signal.
Each post in the inspection ditch has a control panel for emergency stop of the conveyor.
In the conveyor control system, an automatic blocking is used, which is triggered in the event of foreign objects falling under the chain.
Before entering the production line, the car is subjected to outdoor sink and external examination.
One vehicle arrives at the production line every two hours. The cycle of the line posts is 2 hours.
When the car arrives at the first post, the light signaling at the post comes on.
At the first post of the line, waste oils are drained (by grade for transfer to regeneration). The post is equipped with retractable oil collecting funnels that allow oil to be drained from all vehicle units. From the funnels, the oil flows into the tanks of the oil pumping station, located under the floor to the right of the conveyor. From there the oil is pumped to the storage tanks.
Removal and replacement of wheels is carried out if necessary; spare tires are stored on a rack near the post. To remove tires, use an electric car with a carrying capacity of 2 tons, equipped with a wheel stripper.
Refueling a car with oils and water, pumping tires, lubricating with greases is carried out centrally at the post of the production line. The same post is equipped with a rectifier for electric start car engines, from an external current source.
After the production of the technical inspection, the car is taken over by the OTD master on duty.
Drivers are not involved in the maintenance of vehicles, their participation is limited to work on the removal and installation of units.
The production line is serviced by a team of locksmiths. During one work shift, the team performs maintenance of four vehicles, that is, 12 vehicles are serviced on the line per day.
In the immediate vicinity of the production line, there are auxiliary production departments serving the production line: defect-completing, electrical repair, battery, fuel equipment, spare parts warehouse.
The dispensary room is equipped with the necessary lifting and transport vehicles.
On the production line, there is a mobile pumping station for driving various hydraulic devices (for example, devices for pressing out pins steering knuckles), Posts No. 1 and 5 are equipped with pneumatic impact wrenches for removing and setting car wheels.
At post No. 2, a mobile device is used for removing and setting the front and rear suspension cars.
Post No. 3 is equipped with a mobile hydraulic device for removing and installing a jet suspension fork rear axle... To remove and install the front and rear wheel hubs at posts No. 3 and 4, a battery loader with a special device is used. For lifting and transport operations, a beam crane with a lifting capacity of 3 tons, as well as electric loaders EP-201 with a lifting capacity of 2 tons, are used. For work on fastening wheels, carrier, wheel, gearboxes and other screw connections, pneumatic wrenches IP-3106 are used with a tightening torque of 80 to 150 daN-m (decanewton-meter). The IP-3103 pneumatic impact wrenches are used to loosen and tighten the bolts for securing the oil pan of the hydromechanical transmission and other connections with a tightening torque of up to 20 daN-m.
On this production line, the so-called "combined" maintenance No. 1 and 2 is carried out, in which the full scope of work on TO-2 is divided into five parts and is carried out during five races of the car on TO-1, but no more than during the period of the run car 7.5 --- 10 thousand km; At the same time, both TO-1 and TO-2 are produced only between shifts.
In accordance with the number of scheduled arrivals at TO-2, several zones (in this case there are five of them) are organized in car fleets, specialized in aggregate and vehicle systems. Labor-intensive work is evenly distributed over all posts in each zone. The number of brigades corresponds to the number of specialized zones, workers are specialized in groups of units and vehicle systems.
Under these conditions, the aggregate-nodal repair method is used: the car is repaired by replacing worn out components and assemblies with serviceable ones, coming from the working capital. Thanks to this method, the car is under repair only for the time that is necessary for the dismantling and installation of the units and their adjustment on the car. This reduces downtime, allows for the specialization of repair workers, improves the utilization of production space, and improves the quality of repairs.
The most important condition for the repair by the aggregate-nodal method is the creation and preservation of a revolving fund of units and assemblies, which is completed from new and restored units. The economic efficiency of this method of vehicle maintenance is to increase the technical readiness of vehicles through better use of the shift time. The introduction of this method at OJSC "Solikamskbumprom" in the Truck Shop, instead of maintenance at universal posts, doubled the capacity of the preventorium, reduced the participation of drivers in maintenance and repairs to a minimum, and significantly increased the operating time of vehicles on the line. In addition, due to the specialization of the work performers and the introduction of mechanization means, labor productivity has increased and the quality of maintenance and repair of cars has improved.
So, the use of the in-line method of car maintenance ensures: rhythm of the technological process, mechanization and automation of work, maximum use of equipment, specialization of workers by type of work and high quality work performed, high labor productivity, improving production standards, reducing the need for equipment and production areas.
The flow method is most suitable for servicing cars of the same brand or type, for servicing EO or TO-1, with a sufficient number of serviced cars to fully load the production line.
The method of combined maintenance is advisable to be used in large motor vehicle fleets with 100 or more BelAZ vehicles.
In small farms with an insufficient staff of repair workers, which does not allow organizing the work of all zones in 2 - 3 shifts, maintenance and Maintenance It is advisable to carry out vehicles at universal or specialized posts. The car must be thoroughly washed and cleaned beforehand. Maintenance should be carried out in conditions that exclude the ingress of dust and dirt into the components and assemblies.
2.3 Production line calculationdaily maintenance (EO) continuous action
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