A rationally organized technological process is understood as a certain sequence of works that ensure high quality of their performance at minimal cost.
Car maintenance and repair work is carried out at work stations of the main production facility. In addition, work on the maintenance and repair of power system devices, electrical, battery, tire fitting, plumbing and other work is partially carried out at specialized production sites after removing the relevant components and assemblies from the car.
The organization of the technological process is based on a single functional diagram / 5 /: cars arriving at the PAS for maintenance and repair, go through the cleaning and washing section and go further to the acceptance, diagnostics, maintenance and repair sections (Fig. 4.1).
For the purpose of rational organization of the technological process at the PAS, all posts (car seats) have certain indices, in which the first digit (up to a dot) indicates the position of this post to a certain area, and the second digit (after a dot) - the type of post:
O - car-waiting place; / - work post with stationary lifting and transport equipment; 2 - working floor post; 3- auxiliary post; 4- work station with a stand for testing the brakes; 5- work station with stationary equipment for checking and adjusting the wheel alignment angles; 6- work station with equipment for checking instruments
lighting and signaling, as well as the engine and its systems (installation of a power stand is possible).
The posts and production sites of the PAS (Fig. 4.2) are designated by the following indices:
/ - area of acceptance and delivery; 1.3- post of control, acceptance and delivery (auxiliary); 2- washing area; 2.1- washing post (worker); 2.3- drying post (auxiliary); 3 - diagnostics area; 3.4- work station with a stand for testing the brakes; 3.5- a work station with stationary equipment for checking and adjusting the wheel alignment angles; 3.6- working station for checking the engine, its systems and lighting and signaling devices (can be equipped with a power stand); 4 - maintenance area; 4.0- car-waiting place; 4.1- maintenance work post with stationary lifting equipment; 4.2- working floor maintenance post; 5 - TR section; 5.0- car-waiting place; 5.1- working post TR with stationary lifting equipment; 6- lubrication area; 6.0- car waiting area; 6.1.- work station with stationary lifting equipment; 7 - repair and charge area rechargeable batteries; 7.0- car waiting area; 8 - repair area for electrical equipment and devices; 8.0- car-waiting place; 9 - repair area for power system devices; 9.0- car-waiting place; 10- aggregate-mechanical section; 10.0- car waiting area; 11 - tire fitting area; 11.0- car waiting area;
12 - wallpaper-aggregate section; 12.0- car-waiting place; 13- body section; 13.0- car waiting area; 13.1- work station with stationary lifting equipment; 13.2- working floor post;
14 - painting area; 14.1- work post with stationary lifting
equipment; 14.2- working floor post; 14.3- auxiliary post.
For universal PAS of a different standard size or specialized PAS, the nomenclature of posts and production sites may be different from the above, but the principle of indexing is preserved.
Securing the car-waiting areas for specialized areas (7- 12} is conditional in nature, since the types of specialized work under consideration are to a greater extent outside the post and can be performed when the car is at any work post or car-waiting place. The basis of the conditional assignment of the car-waiting places for specialized sections 7- 12 the principle of their closest approach to these posts is laid.
Rice. 4.1. PAS functional diagram
Typical types of work performed at the PAS are conventionally designated by indices:
ПР - acceptance and performance of the inspected works; UM - cleaning and washing works; D - diagnostic work; TO - technical maintenance (including КР - fastening works;
RG - adjustment work; SP - work on the power supply system;
SE - works on the electrical equipment system; CM - lubrication work); TR-current repairs (including out-of-post work
specialized sections 7-12); QC - control of work performed; B - delivery of cars to owners.
Rice. 4.2. Layout of posts and sections of a typical PAS:
/ - production area; // - administrative area
Taking into account the right of the car owner to order the performance of any type of work or a selective set of works for the PAS, the most typical variants of the combination of types and complexes of work on maintenance and repair of cars and their rational organization have been drawn up (Fig.4.3):
Option 1- MOT in full. The car enters the maintenance area, where, in a certain sequence, according to the flow charts, work is performed (fastening, adjusting for the power system, for the electrical equipment system, lubrication), the provided volumes of TO-1 or TO-2.
Option 2- selective maintenance work. The car enters the maintenance area, where selective types or a set of works are performed, agreed with the customer.
Option 3- Maintenance in full and TR. The car arrives in the TR zone and on the car-seat of specialized production sites (7- 72), on the body (13} and paint (14} plots. From the TP zone, after the diagnosis, the car goes to the maintenance, which is carried out according to the flow charts.
Option 4- selective work of TO and TR. The car enters the TP zone, and then, after being diagnosed, it enters the maintenance zone to carry out selective work packages from the scope of maintenance ordered by the car owner.
Option 5- Maintenance in full and the work of the TR, the need for which was identified during the diagnosis. The car enters the diagnostics section, then to the TP zone, after which to the maintenance zone, where it is carried out in full.
Option 6- Selective maintenance work and TP work, the need for which was identified during diagnosis. The sequence of work is the same as in option 5, but only the declared work packages are performed at the maintenance posts.
Option 7- TR work at the request of the owner. The car arrives at the TR section, where, according to the technological maps
the works declared by the owner are being carried out.
Option 8- TR work, the need for which
identified during diagnosis. After diagnosing and clarifying the scope of work with the customer, the car enters the TR zone, where, according to the flow charts, the necessary types of work are performed.
During the maintenance process, it may turn out that
the post to which the car should be sent for the next impact is occupied. In this case, the car is parked on the car-waiting area and, as the posts are vacated, is sent to them according to the corresponding variant of the scheme.
When performing any type or complex of works, the car undergoes acceptance and inspection and cleaning and washing works (the sequence of these works depends on the planning scheme of the PAS), as well as diagnostic work to determine the technical condition of components, assemblies and systems of the car that affect traffic safety, and if necessary, and in-depth diagnostics. Then the car is sent to the appropriate posts or car-waiting places to carry out the work provided for this option.
After the production of the appropriate technical interventions for one of the listed options, the car undergoes control of the completeness of the volume and quality of work (most often at the diagnostic and acceptance and delivery stations of cars), and then it is issued to the owner or enters the waiting area.
Depending on the number of posts, between which the complex of operations of this type of service and their equipment is distributed, two methods of organizing work are distinguished: at universal or at specialized posts.
Method of organizing work at universal posts provides for the performance of all works of this type of maintenance by one team of workers of all specialties or by highly qualified universal workers. Universal posts can be dead-end and travel. At the sections of TO and TR, dead-end posts are mainly used, at the harvesting and washing area - travel posts.
The advantage of organizing work at universal posts is the ability to carry out various amounts of work on them, and the disadvantage is an increase in the total time for servicing the car and multiple duplication of the same equipment. In the presence of several universal parallel posts, work can be performed by specialized teams, which, after completing their work at one post, move to another. Thus, as a result of a more rational distribution of performers by posts, working time is used more efficiently, however, organizational difficulties arise due to the uneven arrival of cars and a different volume of work.
Maintenance method at specialized posts consists in dividing the scope of work of this type of maintenance and distributing it over several posts. The posts are equipped with specialized equipment, and the workers specialize in them, respectively, taking into account the homogeneity of work or their rational compatibility. On typical PAS, specialized posts for lubrication and diagnostics of vehicles are provided. Specialization of other types of work is also possible. Specialized posts can be organized according to the flow or operational post (dead-end posts) method.
With streaming method the organization of the work of each type of service is carried out at several sequentially located posts, for each of which specialized jobs are assigned to perform certain operations. The set of posts makes up the service flow line. The flow method is effective if the shift service program is sufficient for the full load of the production line, maintenance operations are clearly assigned to performers, the work is widely mechanized, there is a proper material and technical base and a reserve post or sliding performers to quickly adjust the line rhythm and synchronize the loading of posts ... In this case, labor productivity rises to 20%.
With one rational-post method car maintenance, the scope of work for each type of service is also distributed over several posts. After service at one post, the car is moved to another post. The residence time at each service point should be the same. The organization of work by the operational-post method allows you to specialize equipment, mechanize the technological process and thereby increase the quality of work and labor productivity. However, this is inevitable loss of time for multiple installations and exits of cars and posts and pollution of the atmosphere of the premises with exhaust gases.
Taking into account the uneven nature of the supply of individual vehicles to the PAS, as well as the possibility of selectively carrying out individual complexes of work, the operational-checkpoint service method is most widespread on standard PAS, along with service at universal and partially specialized posts.
Car repair at PAS is carried out by the aggregate or individual method.
Aggregate repair method is more progressive and consists in replacing faulty units, assemblies or parts with serviceable ones, taken from the revolving fund, or with new ones, which makes it possible to reduce the downtime of vehicles at the PAS. For the successful implementation of this method, it is necessary to have a sufficient fund of circulating units and assemblies.
Individual repair method provides for the installation of units after repair on the same vehicle. In the future, a combined method of repair is possible, in which the unit or unit is replaced with a new one or taken from the circulating fund, and then, upon re-entry, is replaced with a previously removed from the same car and repaired within the agreed period, i.e., the method of units rental in agreement with the owner of the car and for an appropriate fee.
The organization of maintenance and repair at the PAS includes the use of technical, technological and accounting documents, the use of technical conditions, technological maps, as well as the organization of workplaces and debugging work on them.
Flow charts reflect the order of operations, the use of certain equipment, devices and tools, the necessary materials, the performance of work by performers of the relevant profession and qualifications and serve as a means of synchronizing the loading of work posts. With their help, it is possible to adjust the technological process by redistributing groups of work by posts, taking into account their labor intensity and specialization, dividing some groups of work into separate operations and combining them with other operations. Cards can be operational and technological and sentry.
Operational and technological maps represent a list of operations compiled in a certain technological sequence for units, assemblies and systems of the vehicle. Guards are the same operational and technological maps, in which the list and sequence of operations have been adjusted in accordance with the arrangement of performers and the method of organizing production.
Three methods of organizing production are most widely used in the maintenance and repair of cars: the method of specialized teams, the method of complex teams and the aggregate-division method.
Specialized brigade method provides for the assignment of all maintenance and repair work of vehicles to certain teams of workers. The use of this progressive form of labor organization is possible only with a sufficiently intensive supply of cars to the PAS, which is necessary to ensure the full load of workers, and in the presence of specialized posts for carrying out maintenance and repair of cars. Specialized brigades are created at large PAS with maintenance production lines and a TR zone, in other cases - complex brigades.
Complex brigade method consists in the performance by each team of the entire range of maintenance and repair works of vehicles. The brigades are staffed with performers of various specialties necessary to carry out the work assigned to the brigade. The advantage of complex teams is their full responsibility for the quality of work. The presence in the team of workers of all specialties allows you to quickly adjust the performance of various jobs in time. The foreman can transfer workers employed for maintenance to car repairs and vice versa. However, a complex brigade requires a higher qualification of workers, and the labor productivity of workers in this brigade is, as a rule, lower than in a specialized one.
Aggregate method consists in the fact that all maintenance and repair work is distributed between specialized production sites, fully responsible for the quality and results of their work. These sites are the main production links. Each of the production sites performs work on all types of maintenance and repair of one or more units, assemblies, systems, mechanisms, devices. With this method of organization, clear responsibility for the quality of the work performed is established. High specialization allows you to effectively use high-performance equipment, mechanize and automate work and, on this basis, improve their quality. The disadvantage of this method is the difficulty of maneuvering the car at specialized posts, which leads to unnecessary waste of time and thereby limits its application in practice.
The method of organizing production is chosen depending on the level of concentration and specialization of the enterprise. At PAS, to service cars of the same brand and with high technical equipment, specialized teams are created for each type of service and repair of cars, but there can also be complex teams.
The organization of technological repair processes depends to a large extent on the quality of production preparation and the provision of modern equipment for the PAS.
The level of mechanization of production processes at PAS is determined by the degree of coverage of workers with mechanized labor and the share of mechanized labor in total labor costs. Indicators of the level of mechanization are determined separately for each division and for the enterprise as a whole.
COURSE WORK
by discipline: " Maintenance and car repair "
Project topic: "Organization of maintenance and repair of tractors with the development of a dismantling and washing area"
1. Initial data
4. Determination of the annual workshop load plan
5.1 Determination of labor intensity renovation works on the workshop site
5.4 Calculation of the area of the plot
5.7 Calculating the area heating
8. Environmental protection
Conclusion
Literature
1. INITIAL DATA
Table 1.1. - Number of tractors
The area under development for the repair shop: Tire.
Determine the cost of TO-2 tractor K-700
2. DEFINITION OF ROUTINE REPAIRS AND NUMBERED SERVICE TRACTORS
2.1 Determination of quantity scheduled repairs and numbered maintenance graphically for tractors
Table 2.1.- Operating time of tractors by quarters of the year
To determine scheduled repairs and numbered maintenance in a graphical way, additional clarifications are required on the condition of each tractor at the beginning of the planned year.
The schedule for determining the number of maintenance and repair of tractors is carried out on graph paper. The horizontal axis shows the months or quarters of the year. On the vertical axis - in a certain sequence numbered maintenance and overhaul of tractors, as well as the operating time in the standard unit for each brand of tractor.
The graph is built as follows:
1) On the vertical axis in the selected scale, the work of the tractor is postponed from the beginning of operation or the last overhaul(Table (2.2.). Further, at the end of the first quarter, the sum of the tractor operating time since the beginning of operation and the operating time in the first quarter is postponed. The obtained points are connected with a line. for all quarters until the end of the year.Connect the obtained points with a broken line.At the end of the line, indicate the brand of the tractor and the number.
2) To determine the CR and TO of tractors, conditionally draw horizontal lines from the types, TO on the vertical axis and find the intersection points of this line with the tractor loading graph. In place of the intersection, a conventional sign is placed that corresponds to this type of maintenance.
Based on the results of the construction, table 2.3 is compiled.
Table 2.3.- Annual maintenance plan for tractors
3. DETERMINATION OF THE EFFICIENCY OF MAINTENANCE AND REPAIRS
3.1 Determination of the labor intensity of maintenance and tractors
The total labor intensity is determined using the standard specific labor intensity of tractors. For tractors, the labor intensity of the TR consists of the labor intensity of current repairs and the labor intensity of eliminating failures.
The approximate annual labor intensity of eliminating failures of all tractors of the same brand is determined by the formula:
Tuo = tuo * ntr, person h. (1)
where, tу is the average annual labor intensity of eliminating failures of tractors of a particular brand, people;
ntr - the number of tractors of this brand, pcs.
The total annual labor intensity of current repairs of tractors is determined by the formula:
Ttr = 0.001 * Bp * ttr x ntr, person hours (2)
ttr - the standard of the specific labor intensity of the TR of tractors, per 1000 conventional unit hectares
Table 3.1.- Regulatory data on TR tractors
For tractors T-150 K:
Tuo = 19.1 * 2 = 38.2 person hours.
Tr = 0.001 * 1500 * 76 * 2 = 228 person hours.
For tractors DT-75 MV:
Tuo = 19.4 * 11 = 213.4 person hours.
Tr = 0.001 * 1400 * 110 * 11 = 1694 person hours.
For tractors MTZ-80:
Tuo = 17.4 * 7 = 121.8 person hours.
Tr = 0.001 * 800 * 97 * 7 = 543.2 person hours.
4. DEFINITION OF ANNUAL WORKSHOP LOADING PLAN
When drawing up an annual plan for repair and maintenance work, it is necessary to take into account the fact that maintenance of tractors is planned on a round-year schedule throughout the year as it is used. The timing of setting up for repairs should be chosen so that the tractors at this time were the least loaded.
For tractors T-150 K, DT-75 MV, MTZ-80, the number of numbered maintenance by quarters of the year is distributed in proportion to the load of these machines (see Table 2.3)
Seasonal maintenance is planned for one for each tractor in the second and fourth quarters.
The annual maintenance plan is presented in table 4.1.
Table 4.1.- Annual maintenance plan
|
Name and brand of cars, type of work |
MOT for a year |
Labor intensity of maintenance, man-h |
Distribution of work by quarters |
|||||||||
|
Tractors |
||||||||||||
|
Total maintenance tractors |
Table 4.2.- Plan of loading of the central repair shop of the economy
|
Name and brand of machines, type of work |
Type of work or maintenance |
Labor intensity |
|||||
|
Tractors: |
|||||||
|
Total for tractors |
|||||||
|
Maintenance of MTP |
|||||||
|
Total major works on MTP |
|||||||
|
Total additional work |
|||||||
|
Total for CRM |
In addition to the main work of the central repair shop, additional work is also carried out. The labor intensity of additional work is determined as a percentage of the total labor intensity of the main work in the workshop. These percentages are as follows:
1. Repair of equipment in the workshop from 5% to 8%, we accept 8%;
2. Repair and manufacture of devices and tools from 0.5% to 1%, we accept 1%;
3. Manufacturing and repair of parts for the spare parts fund from 3% to 5%, we accept 5%;
4. Other unscheduled work from 10% to 12%, we accept 12%.
Then Tob = 0.08 * 3637.7 = 291pers.h
Type = 0.01 * 3637.7 = 36.38pers.h
Tz = 0.05 * 3637.7 = 181.9 people.h
Tpr = 0.12 * 3637.7 = 436.5 man.h
5. CALCULATION OF THE TIRE SECTION
The development of the production site of the workshop includes several stages and directions. This includes: determination of the number of posts, equipment, required area, calculation of lighting, ventilation, heating. One of the first steps is determining the number of workers. This is necessary for the subsequent selection of equipment, because, without knowing the number of workers, it is impossible to say how many workbenches, assembly tables, machine tools, etc. are needed.
5.1. Determination of the labor intensity of repair work at the workshop site
The labor intensity of repair work on the site is determined as a percentage of the total labor intensity of the work. The complexity of this type of work on the site is determined by the form:
Clouds = Ttot * x, man hours (4)
where, Ttotch is the total labor intensity of the repair work of the workshop performed for this type of work, people.
x is the percentage coefficient of the labor intensity of work on the workshop site.
Clouds = 4583.48 * 0.08 = 366.7
5.2 Calculation of the number of workers on the site
The number of workers employed in production is determined by the labor intensity of the repair work performed on the site.
where, Tuch is the labor intensity of repair work on the site, people. h
Fdr is the actual font of the worker's time, h.
With a six-day work week with a shortened pre-holiday and pre-holiday day, the valid time font will be:
Fdr = (dk - dv - dp - do) * f * z - (dpv + dpp), h, (6)
where, dк, dв, dп, do, dп - the number of calendar, weekends, holiday holidays, pre-holiday, pre-holiday days, respectively, days,
f - The duration of the work shift, h.
z is the coefficient of the use of working time.
Fdr = (365 - 52 - 15 - 24) * 7 * 0.95 - (53 + 3) = 1767.1 h
We accept P = 1 person.
5.3 Calculation and selection of equipment
The main Technical equipment is determined by the complexity of the repair work performed on the site:
where, Fob is a valid time base.
The actual fund of equipment time is determined by the formula:
Fob = (dk - dv - dp) * f * zob - (dpv + dp), (8)
where, zob - equipment utilization factor, zob = 0.96
Fob = (365 - 52 - 15) * 7 * 0.95 - (53 + 3) = 1947.5 h
We accept N = 1 pc.
The rest of the auxiliary equipment is selected from the list of the main equipment of the repair shops according to the standard design.
We enter all data in table 5.2.
Table 5.2.- List of the main equipment of the dismantling and washing area
|
equipment identification |
Brand, type, GOST |
Quantity |
Overall dimensions, mm * mm |
Occupied area, m2 |
|
5.4 Calculation of the area of the plot
The area of the site is calculated using the coefficient of the working area, taking into account the convenience of work and aisles in the workplace. The area of the plot is calculated by the formula:
Fuch = Freq * k, m2, (9)
where, Fob - the area occupied by the equipment, m2
k - coefficient of the working area,
Fuch = 35.76 * 3.5 = 125.16 m2
We accept 125 m2
5.5 Calculation of ventilation in the area
repair service tractor site
In all production premises repair shop accept natural, and in some shops and departments artificial ventilation. Calculation of natural ventilation is reduced to determining the area of transoms or vents, we take 2 - 4% of the floor area.
Table 5.3
5.6 Calculation of lighting on the site
Determine the required number of windows and lamps in the room.
Window area, m2
Fо = Fн * d, (10)
where, Fн - floor area of the room, m2
d - coefficient of natural light, even 0.25 - 0.35
Fо = 125 * 0.3 = 37.5 m2
Window height in meters:
hо = h - (h1 + h2), (11)
where, h - room height, m
h1 - height from floor to window sill,
h2 - distance from the table to the ceiling, h2 = 0.5 m
ho = 7 - (1.2 + 0.5) = 5.3 m
Reduced width of windows, m
Knowing from the norms of building design the width of the window in meters, the number of the window is found, B = 4.05 m.
Accept 1 window
The calculation of artificial lighting is reduced to determining the required number of lamps.
where, Fsp is the luminous flux required to illuminate the area, ln
Fl - luminous flux of one electric lamp, ln
Luminous flux in the area:
where, Fп - floor area of the site, m2
E - Norm of artificial lighting, ybp, E = 75 - 100 ybp.
Kz - the factor of the stock of illumination, for incandescent lamps - 1.3;
Kp is the utilization factor of the luminous flux, depending on the type of luminaire, the size of the room, the color of the walls and ceiling,
(Kp = 0.4 - 0.5)
Accepts 12 lamps of 200 W
5.7 Calculating the area heating
Number of heating devices on the site:
where, Vн - the volume of the building by external measurement, m3
qо and qв - specific heat consumption for heating and ventilation with a difference between internal and external temperatures of 1 0С,
qо = 1.88 - 2.3, qw = 0.62-1.04
tв - internal room temperature, 18 0С
tн - minimum outside temperature during the heating period, tн = -30 0С
F1- heating surface area of one heating device, m2 (for finned tubes 4m2)
Kн - heat transfer coefficient,
tср - the average design temperature of the water in the device, equal to - 80 0С
We accept 8 heating devices.
6. CALCULATION OF THE PLANNED COST OF THE UNIT OF REPAIR AND MAINTENANCE IMPACT
The cost price of TO-2 K-700 made in the workshop is determined by the formula:
С = Зо + Зд + Нсф + Мр + Рт + Зч + Зст + Нрц + Нрз + Ннв, rub, (17)
where, Зо - basic wages of workers, rubles
Zd - additional wages, rub
Nsf - charges to social funds, rubles
MR - the cost of repair materials, rubles
Рт - costs for technical fuel, rub
Зч - costs for spare parts, rub
Zst - costs incurred on the side, rub
Нрц - overhead general production costs, rub
Nrz - overhead general operating expenses, rub
Нвн - overhead non-production costs, rubles
For jobs with difficult and harmful working conditions, tariff rates are increased by 12%.
Consider bonus rates at 40% of the basic salary as mandatory when working without violating labor discipline, high quality work and performing shift tasks.
Additional salary from the main one is 15%.
Contributions to social funds from basic and additional salaries are:
Pension fund - 28%
Social insurance - 5.4%
Medical insurance - 3.6%
Employment Fund - 1.5%
General production overhead costs from wages with accruals are approximately 11%, general business - 36%, non-production - 0%, planned savings from the total cost of 16%. The coefficient of conversion of prices for spare parts and repair materials from 1990 prices increases 20 times.
We make the determination of the cost of one repair and maintenance impact of TO-3 T-150 K. The basic wages of production workers are determined by the formula:
Зо = tto * Wed, rub (18)
where, tto is the labor intensity of maintenance of TO-2 K-700;
Wed - hourly wage rate of a worker, rub / h
tto = 11.6 person h
Zo = 11.6 * 30 = 348 rubles
Additional salary:
Zd = Zo * 0.15 = 341 * 0.15 = 52.2 rubles (19)
Accruals to social funds:
Nsf = (Zo + Zd) * (0.28 + 0.054 + 0.036 + 0.015) = (348 + 52.2) * 0.385 = 154.1 rubles (20)
Repair costs:
Мр = 20 * Срм = 20 * 23.3 = 466 rubles (21)
where, Срм - the cost of spare parts and repair materials in 1990 prices for TO-2 K-700, rubles
Overhead general production costs
Nrts = (Zo + Zd + Nsf) * 0.11 = (348 + 52.2 +154.1) * 0.11 = 60.9 rubles
Overhead general expenses
Hrz = (Zo + Zd + Hsf) * 0.36 = (348 + 52.2 + 154.1) * 0.36 = 188.5 rubles
Full cost price:
С = 348 + 52.2 + 154.1 + 466 + 60.9 + 188.5 = 1269.7 rubles
The selling price includes planned savings if the tractor of an outside customer:
C = 1.16 * C = 1.16 * 1269.7 = 1472.9 rubles (22)
In addition, there is a VAT tax which is 18%:
CTO2 = 1.18 * C = 1.18 * 1472.9 = RUB 1738 (23)
7. HEALTH AND SAFETY
1. Workers entering the tire repair shops of repair enterprises must receive instructions on general rules safety precautions, instruction at the workplace, as well as master the practical skills of safe work performance and undergo a test of the acquired knowledge and skills.
In addition, service vulcanizers and other pressure equipment should be familiar with the Pressure Vessel Service Personnel Rules.
The results of the knowledge test should be recorded in a special journal.
2. The worker must perform only those operations that are entrusted to him by the foreman or the head of the shop.
3. Before starting work, the worker must put on the overalls, safety shoes, headwear and, if necessary, protective devices established for this type of work. Clothes must be buttoned up.
4. The worker, starting to work, must check the presence and serviceability of protective fences, devices, as well as the reliability of fastening the grounding conductors.
5. Loads weighing more than 20 kg may only be lifted with lifting mechanisms using special grapples. The load must be lifted vertically.
6. The worker is prohibited from:
A) touch the wiring and casings of running electric motors;
B) stand under the load and in the path of its movement;
C) smoke in workshops at workplaces and other places where flammable materials and gases are used and stored. Smoking is allowed only in designated areas.
7. When transferring to another work site using new equipment, the worker must familiarize himself with its design, methods of safe work on it and must undergo additional safety training.
8. The worker is obliged to keep the workplace clean and tidy, not to clutter up the aisles and driveways, to lay workpieces and products in the designated places, to inform the foreman about all equipment faults noticed.
9. All workers are required to know the rules and techniques of first aid and, in case of an accident, provide it to the victim.
Immediately report an accident to the foreman or shop manager.
8. ENVIRONMENTAL PROTECTION
A system of measures aimed at ensuring favorable and safe conditions for the environment and human activity. The most important environmental factors are atmospheric air, home air, water, soil. O. about. with. provides for the preservation and restoration of natural resources in order to prevent direct and indirect negative impact of the results of human activities on nature and human health.
In the context of scientific and technological progress and the intensification of industrial production, the problems of o.o. with. have become one of the most important national tasks, the solution of which is inextricably linked with the protection of human health. For many years, the processes of environmental degradation were reversible. affected only limited areas, individual areas and were not of a global nature, therefore, effective measures to protect the human environment were practically not taken. In the last 20-30 years, irreversible changes in the natural environment or dangerous phenomena began to appear in various regions of the Earth. In connection with the massive pollution of the environment, the issues of its protection from regional, intrastate have grown into an international, planetary problem. All developed countries have defined the O. about. with. one of the most important aspects of humanity's struggle for survival.
They are as follows: determination and assessment of the main chemical, physical and biological factors that negatively affect the health and performance of the population, in order to develop the necessary strategy to reduce the negative role of these factors; assessment of the potential impact of toxic substances polluting the environment to establish the necessary risk criteria for public health; development of effective programs for the prevention of possible industrial accidents and measures to reduce the harmful effects of accidental emissions on the environment.
CONCLUSION
In the course project, a plan was drawn up for repairs and numbered maintenance of tractors. The labor intensity of maintenance and repair of tractors has been determined, and the annual workshop load plan has been calculated. The plan of the welding and surfacing section has been drawn up. Calculations were made for the selection of equipment, site area, ventilation, artificial lighting and heating.
Issues of labor protection and safety, and environmental protection were considered.
LITERATURE
1. Kurchatkin V.V., Taratorkin V.M., Batishchev A.N. and others. Maintenance and repair of machines in agriculture. - M .: Academy, 2008
2. Puchin E.A., Kushnarev L.I., Petrishchev L.N. and others. Maintenance and repair of tractors. - M .: Academy, 2008
3. Gladkov G.I., Petrenko A.M. Tractors: Device and maintenance. - M .: Academy, 2008
4. Designing of technical service enterprises. Ed. Puchina E.A. - M .: KolosS, 2010
5. Economics of technical service in enterprises. Ed. Konkina Yu.A. - M .: KolosS, 2010
6. Zangiev A.A., Shpilko A.V., Levshin A.G. Operation of the machine and tractor park. - M .: KolosS, 2010
7. Shkrabak V.S., Lukovnikov A.V., Turgiev A.K. Life safety in agricultural production. - M .: KolosS, 2007
8. Technology of car repair. Ed. E.A. Deepskin. - M .: KolosS, 2007
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Introduction
1. Technological part
1.3 Determination of the annual labor intensity of work
1.4 Determination of the number of production workers
1.5 Determining the number of site posts
1.7 Definition production areas plot
1.8 Planning solutions buildings
2. Organizational part
3.1 Compliance with safety requirements when performing work in the area
4. Energy saving in the area
4.2 Measures to save heat energy
Conclusion
Literature
Introduction
Automobile passenger transport is the main mode of transport for short and medium-distance travel. Automobile transport is one of the largest sectors of the national economy with a complex and diverse equipment and technology, as well as a specific organization and management system.
For the normal operation of road transport and its further development, it is necessary to systematically update the car park and maintain it in good technical condition. The provision of the required number of the rolling stock fleet can be carried out in two directions:
purchase of new cars;
accumulation of the park due to the repair of cars.
Car repair is an objective necessity, which is due to technical and economic reasons.
Firstly, the need of the national economy for automobiles is partially satisfied by operating the repaired automobiles.
Secondly, the repair ensures the further use of those parts of the cars that are not completely worn out. As a result, a significant amount of the previous labor expended in the manufacture of these parts is saved.
Thirdly, the repair helps to save materials used for the manufacture of new cars.
The technical perfection of cars from the point of view of their durability and laboriousness of repair should be assessed not from the standpoint of the possibility of correcting and restoring worn parts in the conditions of repair enterprises, but from the standpoint of the need to create cars that require only low-laborious disassembly and assembly works during repair, associated with the change of interchangeable quickly wearing out parts. parts and assemblies.
An important element of the optimal organization of repair is the creation of the necessary technical base, which predetermines the introduction of progressive forms of labor organization, an increase in the level of mechanization of work, equipment productivity, and a reduction in labor costs and funds.
The purpose of the course project is the design of the electrical department, the determination of the labor intensity of work, the number of workers, the selection of equipment, the development of a technological map.
1. Technological part
1.1 Selection of initial data for design
The initial data for the technological calculation are selected from the design assignment and from the regulatory literature.
Initial data from the design assignment:
The number of the population in the served area - P = 9000 people;
Number of cars per 1000 inhabitants - Aud. = 225 units;
Average annual mileage of a car - LГ = 14000 km.;
Standard specific labor intensity of TO and TR per 1000 km of run - tn TO and TR = 2.43 man-h / 1000 km;
Coefficient taking into account the number of customers using the services of car service organization - kkp = 0.81
The climate is moderately warm.
Initial data from the regulatory literature:
Days of downtime of vehicles for maintenance and repair, dTO and TR, days / 1000 km;
Labor intensity standard diagnostic work, person-h;
Maintenance frequency standard, km;
Overhaul mileage, km;
The number of days of downtime of cars in major repairs, recreation center, days
1.2 Determining the number of vehicles serviced in a given area
The annual number of cars serviced in a given area is determined by the formula
car maintenance equipment
where P is the number of residents in the serviced area;
Aud. - the number of cars per 1000 inhabitants, taken according to the traffic police data;
Ккп - coefficient, taking into account the number of customers using PAS services, which is taken equal to 0.75-0.90;
1.3 Determination of the annual labor intensity of work
The annual volume of work on maintenance and repair for urban PAS is determined by the formula
Where LГ is the annual mileage of the vehicle;
Asto is the number of serviced cars;
tTO, TR is the specific labor intensity of TO and TR per 100 km of run, person hours / 1000;
the specific labor intensity of TO and TR per 100 km of run, person hours / 1000 is determined by the formula
Where tНТО, ТР - standard specific labor intensity of TO and ТР per 1000 km of run, person-hours;
К1 - coefficient taking into account the number of work stations (up to 5-1.05, from 6 to 10-1.0, from 16 to 26-0.9, from 26 to 35-0.85, over 35-08);
K3 - coefficient taking into account the climatic zone
tTO, TR = 2.4310.9 = 2.19 man-h
At the post, 50% of the work is carried out, the repair of components, systems and assemblies is 14.9%
ТТО, ТР = 502820,50,147 = 2891 people-hours.
1.4 Calculation of the number of production workers
For the zone of maintenance and repair, in which work is carried out directly on the car, the technologically required number of workers of the Republic of Tatarstan, people. determined by the formula
where FM - annual fund workplace time, hours (from the production calendar);
kn - coefficient of uneven loading of posts,
The coefficient of using the working time of the post, (Table 9).
we accept 2 people.
1.5 Calculation of the number of posts in the TO-2 zone
The number of posts n is determined by the formula
where TN is the annual volume of post work, man-hours,
The coefficient of uneven arrival of cars at the post, (= 1.15),
Рср - the average number of workers at one post, (tab. 8),
Фп - the annual fund of working time of the post, person-hours,
The utilization rate of the working time of the post (= 0.94-0.95)
accept 1
1.6 Selection of technological equipment, technological and organizational equipment
Table 11 - Technological equipment, technological and organizational equipment
|
Name |
Dimensions in plan, mm |
Footprint, |
Notes (edit) |
||||
|
Air Impact Wrench for Wheel Nuts |
|||||||
|
Hydraulic lift |
|||||||
|
Engine remover |
|||||||
|
Gearbox remover |
|||||||
|
Installation for removing oil and filling from the engine system |
|||||||
|
Installation for filling and removing coolant |
|||||||
|
Installation for removing the springs of the front suspension |
|||||||
|
Unit transport trolley |
|||||||
|
Tool trolley |
Unior Europlus_920Plus1 |
||||||
|
Locksmith workbench |
|||||||
|
A set of keys |
|||||||
|
Exhaust gas removal device |
Vega 3515/100 UEH |
||||||
|
Installation for removing the rear axle gearbox |
|||||||
|
Wash basin |
|||||||
|
Sectional rack |
|||||||
|
Installation for replacement of steering mechanisms |
|||||||
|
Container for draining oil (polyethylene) |
1.7 Calculation of the production area of the TR site
The area of the site is determined by the formula
F3 = fа хз кпл,
Where kpl is the coefficient of the density of the arrangement of equipment and the placement of posts, [p. 54.14],
хз - coefficient,
fa - the area occupied by the car in terms of m2.
F3 = 9.6 6.52 = 124.8 m2
2. Organizational part
Technological map of removing the checkpoint from a passenger car
|
Name |
Time rate |
Tools |
Specifications and penalties |
||
|
Remove intercooler and engine cover |
|||||
|
Remove the battery |
|||||
|
Disconnect the mass air flow sensor connector |
|||||
|
Remove the air filter hose and loosen the clamp bolt |
|||||
|
Remove the clip and then the top cover of the air filter |
|||||
|
Unscrew for mounting the bolt and then remove air filter assembled |
|||||
|
Remove the four bolts and then remove the battery shelf |
|||||
|
Remove negative terminal from transmission |
|||||
|
Disconnect the vehicle speed sensor connector and turn off the reversing light |
|||||
|
Remove the control cable assembly by removing the locking pins and clamps |
|||||
|
Remove the tube of the coaxial slave cylinder |
|||||
|
Remove the four top gearbox mounting bolts. |
|||||
|
Support the engine and transmission |
With the help of special equipment |
||||
|
Unscrew the bolts and then remove the transmission insulation mount |
|||||
|
Remove the front wheels |
|||||
|
Lift vehicle |
|||||
|
Unscrew the steering column connecting bolt |
|||||
|
Remove the underbody protection of the vehicle |
|||||
|
Drain the power steering system fluid through the return pipe |
|||||
|
Disconnect the power steering injection hose from the pump. |
|||||
|
Drain transmission oil gearbox through drain hole |
|||||
|
Disconnect the lower arm, track rod end ball, stabilizer link lateral stability from the front steering knuckle |
|||||
|
Unscrew the roller support mounting bolt. |
|||||
|
Unscrew the mounting bolts from the subframe, support the subframe |
Using a jack |
||||
|
Disconnect drive shafts from transmission |
|||||
|
Disconnect the connector from the starter and remove the starter |
|||||
|
Remove the transmission cover |
For four-wheel drive car remove the transmission housing assembly |
||||
|
Unscrew the mounting bolts of the lower part of the gearbox and the left side cover and remove the gearbox assembly while supporting it |
Using a jack |
3. Labor and environmental protection
3.1 Compliance with safety requirements when performing work in the department
General safety requirements include checking the technical readiness of the machine, starting it up, inspection after completion of work and troubleshooting. The workplace should be comfortable and provide a good view of the front of work, equipped with fences, protective and safety devices and devices.
An increase in the degree of safety is achieved by the use of safety devices.
Before being allowed to work, mechanics and their assistants receive instructions on receipt, containing also safety requirements. Every year, the persons who service the machines are tested in the amount of production instructions... The results of the knowledge test are drawn up and entered into the attestation and knowledge test log. A warning sound must be given before starting work. Do not start work in low light conditions.
Work must be stopped if the safety devices are damaged and if emergencies... At the end of the work, all combustible and lubricants must be handed over to the warehouse. Switch in front of the main power cable power plant with an electric drive must be turned off and locked. In case of an accident or accident, it is necessary to stop the power plant before the arrival of a representative of the administration. Failure to follow the safety instructions can lead to work-related injuries.
Modern machines and equipment are equipped with means of protecting workers from vibration, shock, industrial noise, dust.
To prevent electric shock in the lighting or control network, if possible, use an electric current with a voltage of up to 36 V; insulate and shield electrical equipment and live wires; install protective equipment that turns off electrical equipment at hazardous loads in the electrical circuit; ground electrical equipment.
3.2 Compliance with industrial hygiene requirements
Industrial sanitation is a system of organizational measures and technical means that prevent or reduce the impact on working harmful production factors. The main hazardous and harmful production factors are: increased dust and gas content of the air in the working area; high or low air temperature in the working area; high or low humidity and air mobility in the working area; increased noise level; increased vibration level; increased level of various electromagnetic radiation; lack or lack of natural light; insufficient illumination of the working area and others.
Dangerous and harmful production factors:
Physical;
Chemical;
Biological;
Psychophysiological.
The boundaries of industrial sanitation:
Improvement of the air environment and normalization of microclimate parameters in the working area;
Protection of workers from noise, vibration, electromagnetic radiation, etc.;
Ensuring the required standards of natural and artificial lighting;
Maintaining in accordance with the sanitary requirements of the territory of the organization, the main production and auxiliary premises.
The industrial microclimate is one of the main factors affecting the working capacity and human health. Meteorological factors strongly affect life, well-being and human health. An unfavorable combination of factors leads to a violation of thermoregulation.
In accordance with GOST 12.0.003-74 “SSBT. Dangerous and harmful production factors. Classification "increased dust and gas content of the air in the working area refers to physically hazardous and harmful production factors.
Many substances entering the body lead to acute and chronic poisoning. The ability of a substance to cause harmful effects on the vital activity of the body is called toxicity.
3.3 Ensuring environmental protection
Road transport is one of the most powerful sources of environmental pollution. The direct negative impact of cars on the environment is associated with emissions of harmful substances into the atmosphere. The indirect impact of road transport on the environment is due to the fact that car roads, parking lots, service enterprises occupy an ever-increasing and daily increasing area necessary for human life.
Environmental protection work at each accident site should include the following main activities:
Training of AP personnel and drivers in the basics of environmental safety;
Improvement of the technical condition of the rolling stock produced on the line, fuel economy, reduction of empty vehicle mileage, rational organization of traffic;
Organization of warm parking lots, electric heating of cars and other measures to improve the state of the environment;
Ensuring the serviceability of cars, correct adjustment of the engine operation;
Elimination of leakage of fuel, oil, antifreeze in the parking lot;
Cleaning the resulting smudges of operating materials, backfilling with sand or sawdust;
Collection of waste oils, other liquids and their delivery to collection points;
Periodic smoke check and prohibition of the release of cars on the line with high smoke levels;
Organization and provision effective cleaning sewage of household, industrial and storm water with the help of treatment facilities, the introduction of recycling water supply at the AP;
Systematic monitoring of the condition of vehicle components and assemblies in order to reduce noise;
If there is an existing boiler house on the territory of the AP, it is necessary to envisage measures to reduce atmospheric pollution with harmful emissions (smoke, soot, gases), in the future - the liquidation of the boiler house on the territory of the ATO and the transition to central heating.
The territory, production, auxiliary, sanitary facilities and storage areas for cars must comply with the current sanitary norms and rules. Garbage, industrial waste, etc. must be removed in a timely manner to specially designated places. The territories of enterprises should be equipped with drainage systems. Where acids, alkalis and petroleum products are used, the floors must be resistant to these substances and not absorb them.
Premises for storage and maintenance of vehicles, where a rapid increase in the concentration of toxic substances in the air is possible, should be equipped with an automatic control system for the state of the air environment in the working area and alarms.
The organization must be equipped with drinking and industrial water supply, as well as industrial sewerage in accordance with the standards.
4. Energy saving in the electromechanical area
4.1 Energy saving measures
The main ways to reduce electricity losses in industry are:
Rational construction of the power supply system;
Laying of networks in polyurethane foam insulation;
Wipe dust off a light bulb;
Do not leave electrical appliances in standby mode;
Painting walls and ceilings white;
Maximizing natural light;
The use of solar panels;
Replacement of incandescent lamps with energy-saving lamps;
Transferring loads from the maximum hours of the power system to other hours;
Application of 2 tariff meters;
Reducing the growth of tariffs for energy resources;
Development of a methodology for determining the specific norms of energy consumption.
4.2 Measures to save heat energy
The successful application of energy-saving technology largely predetermines the norms of technological and construction design of buildings and, in particular, the requirements for the parameters of internal air, specific heat, moisture, steam, and gas release.
Significant reserves of fuel economy are contained in the rational architectural design of new public buildings. Savings can be achieved:
Appropriate choice of the shape and orientation of buildings; - volumetric planning solutions; - the choice of heat-shielding qualities of external fences; - the choice of walls and window sizes differentiated by the cardinal points.
Careful installation of systems, thermal insulation, timely adjustment, adherence to the terms and scope of work on the maintenance and repair of systems and individual elements are important reserves for saving fuel and energy.
To radically change the state of affairs with the use of heat for heating and hot water supply of buildings, we need to carry out a whole range of legislative measures that determine the procedure for the design, construction and operation of structures for various purposes.
Requirements for design solutions of buildings that provide reduced energy consumption should be clearly formulated; the methods of regulation of the use of energy resources have been revised. The tasks of saving heat for heat supply of buildings should also be reflected in the corresponding plans for the social and economic development of the republic.
Equipping heat consumers with means of control and regulation of consumption allows to reduce the cost of energy resources by at least 10-14%. And when taking into account the change in wind speed - up to 20%. In addition, the use of systems for frontal regulation of heat supply for heating makes it possible to reduce heat consumption by 5-7%. By automatically regulating the operation of central and individual heating points and reducing or eliminating network water losses, savings of up to 10% are achieved.
With the help of regulators and means of operational temperature control in heated rooms, you can stably maintain a comfortable mode while simultaneously reducing the temperature by 1-2C. This makes it possible to reduce up to 10% of the fuel consumed for heating. Due to the intensification of heat transfer from heating devices with the help of fans, a reduction in heat energy consumption by up to 20% is achieved.
Thermal insulation of the ceiling with fiberglass mats reduces heat loss by 69%. The recoupment of the cost of an additional thermal insulation device is less than 3 years. During the heating season, savings were achieved in comparison with regulatory solutions - in the range of 14-71%.
The use of low-density concrete with fillers such as perlite or other light materials for the manufacture of building envelopes makes it possible to increase the thermal resistance of organizations by 4-8 times.
The main areas of work to save thermal energy in heat supply systems of buildings are:
Development and application in planning and in production of technically and economically justified progressive rates of heat energy consumption for the implementation of the economy mode and their most efficient use;
Organization of efficient accounting of heat supply and consumption;
Optimization of operating modes of heating networks with the development and implementation of commissioning measures;
Development and implementation of organizational and technical measures to eliminate unproductive heat losses and leaks in networks.
Conclusion
In this course project, the following tasks were solved:
Initial data are selected;
The number of cars serviced in a given area is determined;
The annual labor intensity of the work has been determined;
The number of production workers has been determined
The number of posts of the site has been determined;
The selection of technological equipment, technological and organizational equipment was made;
The production area of the projected diagnostic site has been determined;
The layout of the TO site has been made
List of sources used
Standards
1 GOST 2.105-95. ESKD. General requirements for text documents.
2 GOST 21.204-93 Conventional graphic symbols and images of elements of master plans and transport structures.
3 TCP 248-2010 (02190). Maintenance and repair of automobile Vehicle... Norms and rules of conduct.
Literature
Main literature
Internet sources.
5 Kovalenko N.A. Technical operation of cars: textbook / N.A. Kovalenko, V.P. Lobakh, N.V. Veprintsev. - Mn., 2008.
6 Kovalenko N.A. Technical maintenance of cars. Course and diploma design: textbook / N.A. Kovalenko, ed. ON. Kovalenko - Mn., 2011.
7 Lokhnitskiy I.A. Energy saving / I.A. lohnitsky. - Mn., 2004.
9 Guidelines for course design for technical operation cars.
10 Design of road transport enterprises: textbook / M.M. Bolbas; ed. MM. Bolbas. - Mn., 2004.
11 Sokol T.S. Labor protection: textbook / TS. Falcon; under the general ed. N.V. Ovchinnikova. - Mn., 2005.
12 Sukhanov B.N. Maintenance and repair of cars: a guide to diploma design / B.N. Sukhanov, I.O. Borzykh, Yu.F. Bedarev. - M., 1991.
additional literature
13 Turevsky I.S. Labor protection at road transport: tutorial / I.S. Turevsky. - M., 2009.
14 Novochikhina L.I. Technical drawing reference / L.I. Novichikhin. - Mn., 2004.
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In recent years, a new form of organization of production and labor has become widespread in motor transport - the aggregate-division method of organizing maintenance and current repair of cars.
With this method, production areas are organized in the motor vehicle fleet, which are responsible for all the maintenance and repair of the rolling stock. At the same time, each production site performs work on one or several units and mechanisms of a car in all types of exposure (TO-1, TO-2 and TP). So, for example, the workers of the production site, performing work on the engine, perform them at the maintenance posts (TO-1 and TO-2), at the maintenance posts and in the engine repair department of the aggregate shop.
Production sites specializing in the maintenance and repair of certain units, mechanisms and systems of a car are considered basic, and those specializing in types of work (tin, welding, copper, blacksmith, plumbing, mechanical, etc.), serving the main sites, are auxiliary.
For large and medium-sized auto enterprises, eight production sites are organized with a corresponding distribution of work between them.
| Production area no. | Name and types of work |
| 1 | Maintenance and repair of engines |
| 2 | Maintenance and repair of clutches, gearboxes, hand brake, cardan transmission, reducer, tipper mechanism |
| 3 | Maintenance and repair front axle, steering, rear axle, brake system, car suspension |
| 4 | Maintenance and repair of electrical equipment and power supply systems |
| 5 | Maintenance and repair of the frame, body, cab, empennage and cladding. Copper, tin, welding, blacksmith, thermal and body works |
| 6 | Maintenance and repair of tires |
| 7 | Locksmith and mechanical work |
| 8 | Washing and cleaning works |
With an insignificant average daily mileage and a small number of cars in the vehicle fleet, which determine a small amount of work at production sites and underutilization of workers on them, the number of production sites can be reduced to four by combining them.
In this case, sections I and II, III and VI and V and VII are combined. Washing and cleaning work is not allocated to an independent production site. This type of service is performed by drivers.
The work assigned to the main production sites is carried out at the posts of technical maintenance and repair of cars.
When performing maintenance on production lines, it is organized into an independent section (for example, EO and TO-1) or specialized line posts or workplaces are assigned to the corresponding production sections, if their full load is possible.
With this organization of maintenance and repair production, the responsibility of the performers increases, and therefore the quality of work and the reliability of vehicles.
Rice. Production management scheme for the aggregate-division method of maintenance and repair
The management of the production of maintenance and current repairs of cars in motor vehicles with the aggregate-division method is carried out according to the scheme.
In accordance with this scheme, the chief engineer carries out general production management. The production manager organizes production and its efficient accounting. It is responsible for measures aimed at improving the quality of maintenance and repair of rolling stock, reducing vehicle downtime in current repairs, reducing the cost of maintenance and repair, etc.
The production manager carries out the operational management of all work at the posts of maintenance and repair of cars and is responsible for the timely preparation of the car for release.
Checkpoint mechanic controls technical condition cars both upon returning from the line, and upon release after maintenance or repair. The head of the department of the chief mechanic (foreman, foreman) ensures the repair of equipment, buildings and structures.
The production site is headed and supervised by a foreman, foreman or chief (depending on the purpose and scope of work of the site). The manager organizes the work of the site, secures workers by types of maintenance and repair, moves workers from one type of work to another, provides them with an irreducible stock of spare parts, materials and assemblies, and takes measures to improve the quality of maintenance and repair.
At the ATP, maintenance and repair are carried out. For these purposes, specialized sections are created at the ATP. They are housed in separate isolated rooms.
Maintenance technological processes are carried out in the evening and daytime, cars, MAZ and KamAZ undergo maintenance on two production lines of three control lines (TO-2 is carried out in the first shift, and TO-1 in the second and third shift).
At the same time, repair of KAMAZ engines and current car repairs have alternative solutions.
They are developed taking into account the production area, the availability of appropriate technological equipment and instruments, the car park, as well as the qualifications of technical personnel.
Every day, in one shift, 7 performers provide repair of engines of vehicles of modification - KamAZ and MAZ.
The engine repair shop is divided into posts. The repair is carried out by a dead-end method. Two performers work at each post, and the foreman-locksmith of the fourth category participates in the work of all posts.
Each work post or workplace is provided with post technological maps.
Guards technological maps make up of operational and technological maps, which include groups of technologically indivisible operations.
In the posts of the KAMAZ engine repair shop, they are equipped with a dynamometer, an electronic tachometer, a fuel flow meter, stands for checking and adjusting fuel equipment devices.
In this section, control and adjustment work is carried out on the elements and systems of the fuel equipment, affecting the power and economic qualities, smoke and exhaust gas toxicity.
The repair is carried out in accordance with the technological process developed for them at stationary repair plants.
The technological process of overhaul of engines includes the following technological operations: removal attachments, washing complete engines without attachments, disassembling engines into units and parts, washing parts, detecting and restoring parts, assembling assemblies, general assembly of engines, running in engines (running in and testing), painting and presenting a repaired OTK engine.
The scheme of the route technological process of the overhaul of KamAZ engines is shown in the figure
The technological process of overhaul of KamAZ engines differs from in-depth current repairs by a wider range of remanufactured, manufactured and replaced parts.
The motors are loaded into the cradles of the rotating crosspiece of the machine. The cradles are periodically immersed in a bath with an aqueous solution.
An aqueous solution of synthetic detergents (CMC) fills the inner cavity of the engine oil pan through the holes in the walls of the cradles and, when the cradles are lifted, pours out of the crankcase, and thus, not only the outside of the engine, but also the inside of it is washed.
Washing is carried out with hot (90 ... 95 ° С) CMC with continuous cleaning of the solution from oily and solid contaminants. Periodic immersion of engines in a solution and their vibration at a frequency of 46 Hz allows cleaning from contaminants not only from the outside, but also washing out contaminants inside the engine with a solution flowing through the oil drain hole in the lower part of the engine crankcase.
The detergent "Labomid-203" with a concentration of 30 g of powder per 1 liter of water is used as a washing solution.
After washing, the engines are disassembled into units and parts, which are washed in a second washing machine of the same model. The washed parts go to the parts inspection post.
Basic parts to be restored are sent to the engine repair shop at separate posts.
Suitable parts (not requiring restoration) for major and in-depth current repairs of the engine, as a rule, include the fan impeller, flywheel housing, valve springs, fuel lines, oil system pipes, cooling system connecting pipes.
After flaw detection, these parts are sent to the assembly and assembly of engines.
Scheme of the route technological process of repairing KamAZ engines
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Diagnostic stand and testing (running-in) devices for engines |
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Washing machine for blocks and parts |
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Stand for disassembly-assembly of V-engines |
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Rack for storage of components det. |
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benchtop radial drilling machine |
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vertical drilling machine |
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cabinet for instruments and tools |
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stand for disassembly, assembly, defect detection of KAMAZ engine system instruments |
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hydraulic press 10 t |
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engine break-in stand |
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mobile washing bath |
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Place of repair of pumps of high-pressure fuel pump |
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Place of defect detection of internal combustion engine shafts |
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Stand for disassembling fuel devices |
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Devices (stand) for testing high-pressure fuel pumps |
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Fuel injection pump assembly site |
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tool rack |
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ICE mechanisms picking table |
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