Automotive Engine Repair Site Project

Contents

Introduction

1 Design Object Selection

1.1 Volume of production activity of the enterprise

1.2 Justification of expected engine overhaul orders

1.3 Objectives and objectives of the diploma project

Conclusions

2 Analytical part

2.1 Process of engines overhaul

2.1.1 General signs of engines repair

2.1.2 Repair diagnostics of engines

2.1.3 Removal and installation of engine

2.1.4 Cleaning

2.1.5 Engine disassembly

2.1.6 Engine parts defect and repair

2.1.7 Assembly of engine parts and assemblies

2.1.8 Testing and adjustment

3 Rationale of thesis project topic

4 Design and processing part

4.1 Determination of annual labour intensity of capital works

repair of engines

4.2 Calculation of annual scope of repair works

4.3 Selection of process equipment of the section

4.4 Process Equipment Layout

4.5 Calculation of standard composition of workers

4.6 Calculation of number of posts in engine repair area

4.7 Calculation of area of the site

4.8 Calculation of Energy Needs

Conclusions

5 Design development

5.1 Engine repair bench

5.2 Calculation of structural elements

5.2.1 Calculation of attachment bolts for tension

5.2.2 Calculation of pin-retainer on the cut

5.2.3 Calculation of welded joint with angular seams for action

moment in the plane perpendicular to the weld location plane

5.3 Selection of gear motor

5.3.1 Determination of electric motor power demand

5.3.2 Selection of gear motor

5.4 Check calculation of retainer finger

6 Life Safety

6.1 Occupational Safety

6.1.1 Analysis of the state of labor protection at the enterprise

6.1.2 Fire Condition Analysis

6.1.3 Conclusions on the state of labor protection and proposals for improving the organization of the labor protection and fire condition service

6.2 Calculation of area lighting

6.3 Ventilation Calculation

6.4 Design Safety

6.5 Project Environmental Safety

6.6 Stability of Best Master LLC in emergency situations

7 Cost-effectiveness of the project

7.1 Technical and economic assessment of design development

7.2 Project Feasibility Study

Conclusions

Conclusion

List of literature

Introduction

The fleet of cars in Russia increases from year to year and amounts to about 27 million cars. According to traffic police statistics, 48% of the Russian fleet of cars are cars produced by the Volga Automobile Plant. Other Russian brands continue to surrender their positions, although their number is still quite large. GAZ accounts for 6% of the fleet, UAZ occupies 2.5%, Oka - 1.6%, Izh - 0.7%. In addition, 1.76 million are still registered in the Russian traffic police. Muscovites (6.6%) and 887.5 thousand. "Zaporozhtsev" and "Tavry" (3.3%). There is also an increase in the share of foreign-made cars. According to 2008 data, their share is 25% and among foreign cars the following brands are the most popular: Toyota, Volkskvagen, Audi and other manufacturers.

But, it is worth noting that the age of the Russian fleet leaves much to be desired. After all, the share of cars under 5 years old is 21%, from 510 years old is 32%, and the share of cars over 10 years old is 47% of the total fleet.

During the operation of the car, its working properties gradually deteriorate due to wear of parts. Failures and faults appear in the car, which are eliminated during maintenance and repair.

Repair is a set of operations to restore serviceability or operability of products and restore resources of products and their component parts.

The need and expediency of repairing cars is primarily due to the unequal strength of their component parts (assembly units and parts). It is known that it is impossible to create an equal-strength car, all parts of which would wear evenly and have the same service life. Therefore, during operation, cars undergo periodic maintenance and, if necessary, ongoing repairs at maintenance stations, which are carried out by replacing individual parts and units. This allows you to maintain cars in a technically serviceable state.

During long-term operation, cars reach a state where the life of the components is generated and primarily this applies to the engine. In this case, the engine needs major repairs.

Overhaul must ensure serviceability and full (or close to full) life of the unit by restoring and replacing any assembly units, including basic ones. The base part is the part with which the product begins to assemble, attaching assemblies and other parts to it. Engine base part is cylinder block.

The main source of economic efficiency of engine overhauls is the use of residual life of its parts. Most of the engine parts received for major repairs can be reused either without repair or after a slight repair effect.

Parts that have completely exhausted their resource and are subject to replacement make up 25... 30% all parts. These are pistons, piston rings, rolling bearings, rubber products, etc. The number of parts whose working surfaces wear is within acceptable limits, which allows them to be used without repair, reaches 30... 35%. The remaining engine parts (40... 45%) can be reused only after their restoration. These include the most complex, metal-intensive and expensive engine parts, in particular the cylinder block, crank and camshaft, cylinder head, etc. The cost of restoring these parts does not exceed 10... 50% the cost of their manufacture.

The cost of overhaul of the engine usually does not exceed 60... 70% the cost of the new engine.

1 Design Object Selection

The Base Master passenger car maintenance station is located in the Soviet district of Novosibirsk. It has been operating since 2003. During this time, the company has firmly strengthened its position in the car service market, becoming one of the leading enterprises in the region in the field of providing car maintenance and repair services.

Thanks to the competent management and efficient organization of production, the company constantly expands the list of services provided, striving to maximize the satisfaction of the client's interests. The company re-equips and refurbishes posts and sites with modern equipment and tools, thereby improving the quality of services provided and reducing the time for performing technological operations.

Currently, the car service provides a range of car maintenance and repair services, namely, performs the following types of work:

- scheduled operations (by types of maintenance);

- replacement of units, units and parts;

- repair of engines;

- repair of checkpoints and driving bridges;

- repair of front suspension and steering;

- repair of the braking system ;

- repair of electrical equipment;

- control and diagnostic works;

- lubrication and filling operations;

- adjustment of headlamps;

- adjustment of controlled wheels installation angles;

- adjustment of petrol engines fuel equipment;

- electrical works;

- installation and filling of air conditioners;

- car washing.

The structure of the enterprise is represented by the presence of the following divisions and sections:

- electrical work area (one post);

- vehicle maintenance and repair section (two posts);

- engines repair area (one post);

- car washing area (one post);

- store-warehouse. Sells consumables and spare parts, as well as goods for car tuning (alarms, audio systems and related goods);

- Accounting.

The company is managed by the general director, who performs the duties and technical director. The production process is controlled by the workshop master, who reports to all sites and production workers. Work with the client and acceptance of cars for maintenance or repair is carried out by a service consultant. Accounting and store-warehouse are subordinate to the CEO. Transport and expeditionary work is carried out by a forwarding driver.

1.1 Volume of production activity of the enterprise

In 2008, the Best Master car maintenance station provided about 3.5 thousand car repair and maintenance services. At the same time, the distribution by types of services provided turned out to be as follows:

- repair and replacement of running gear units - 20%;

- maintenance (maintenance) - 20%;

- tuning (alarms, music, tinting) - 10%;

- car washing - 15%;

- repair of engines - 25%;

- repair of electrical equipment - 5%;

- miscellaneous 5%.

Considering the type of service provided in the diploma project - overhaul of engines, we note that in the activities of the engine repair site over the past 3 years, a certain dynamics of increasing demand for this service has been noticeable. So in 2006, 25 major repairs were carried out, and in 2007 and 2008, respectively, 60 and 95.

An analysis of the distribution of cars served by STO by countries of production shows that the predominance of Japanese cars (Toyota, Mitsubishi, Nissan) is noticeable - about 50% of all cars, cars of domestic production (VAZ, GAZ) are 30% and 10% European and other cars. A large share of Japanese cars at the STO is due to the prevalence of these cars in the city, due to the geographical location of Novosibirsk and the difficulty of servicing outside specialized enterprises.

1.2 Justification of expected engine overhaul orders

The most important element of the organization of the section for the overhaul of passenger car engines in the conditions of the Best Master STO is the determination of the expected volume of orders per year, that is, the annual program of the section. The choice of technological equipment and equipment, the area of ​ ​ the site, the number of people working on the site and other organizational parameters depend on this. So, in case of overstatement of the annual production program, we will not receive a full load of the site with the ensuing consequences - simple equipment and workers. And if the program is underestimated by more than 15% of the actual volume of orders, we will encounter the problem of oversaturation of the volume of work and lack of working time, since overload of workers is allowed only within 15%. But, in turn, the last version of the development of events stimulates further expansion of production.

Predicting the volume of orders for major engine repairs, we are not able to accurately determine the fleet of serviced cars, since the workshop works on the principle of attracting customers, and not servicing a specific fleet of cars of any organization. Based on this, we will determine the factors that in one way or another can affect the increase in the number of attracted customers for this service:

1. Location of STO "Best Master" - Sovetsky district

Novosibirsk, in the central part of the district, near the main roads;

2. Station fame - STO has been operating since 2003, constantly advertising in print media of the Soviet region;

3. Number of custom orders issued for performance of various works

from the range of services provided by STO in 2008 - about 3.5 thousand, of

among them, the number of major engine repairs performed was 95, and the number of orders for major engine repairs was 180, in the conditions of the engine repair section.

Considering all the above, we accept the annual program of the section for the overhaul of passenger car engines - 180 engines.

Planned ratio of engines:

VAZ 2106 - 72 pieces;

Toyota 4A - 70 pieces;

Nissan RB20 - 38 pieces.

This choice is made based on the proportions of engine models overhauled in 2008. at STO "Best Master." The focus of the overhaul area on VAZ and Toyota engines is associated with the greatest prevalence of these models, which allows you to significantly increase the performance of repairs, since personnel quickly acquire certain skills (sequence of operations, etc.), reducing the time of the technological process.

1.3 Objectives and objectives of the diploma project

The purpose of the work is to develop a production area for repairing passenger car engines for a particular enterprise.

Objectives:

1. Analyze the production activities of the enterprise.

2. Develop the organization and technology of car engine repair.

3. Perform calculation of process parameters for design of engine repair area under conditions of STO "Best Master."

4. Offer design development that reduces the labor input of repair work.

5. Develop life safety measures for maintenance personnel.

6. To give a technical and economic assessment on the implementation of design development and the project as a whole.

Conclusions

The production activity of STO "Best Master" is aimed at providing services in the automotive service sector. The company is dynamically developing and has a stable market position. Attracting more and more customers requires further development of the production process of maintenance and repair of cars by introducing modern equipment and creating additional jobs.

The dynamics of the increase in demand for major engine repairs require the enterprise to take measures to meet all the needs for this service. The solution to this issue is the allocation of overhaul of engines from the engine repair section to a separate section, ensuring that all repair needs are met.