Development of a stand for editing car bodies

Contents

Introduction

1 Process calculation

Calculation of the production program for maintenance and repair of cars

Adjustment of vehicle mileage rates

Calculation of the production program for maintenance and CP using the system of equations

1.2 Calculation of annual volumes of maintenance, maintenance and self-maintenance of enterprises

1.2.1 Identification of regulatory difficulties

1.2.2 Calculation of annual volumes for maintenance and maintenance in human hours

1.2.3 Annual scope of self-service of the enterprise

1.3 Distribution of labour intensity of maintenance, maintenance and self-service of the enterprise by production zones, workshops and site

1.4 Calculation of the number of production workers

1.5 Calculation of number of TC and TR posts and lines

1.5.1 Maintenance zones operation mode depends on rolling stock operation mode on the line

1.5.2 Calculation of number of universal service posts

1.5.3 Calculation of the number of maintenance posts

Calculation of Production Space

2 Layout of the production building

3 Process

3.1 Work performed in the body area

3.1.1 Process

3.1.2 Technology of deformation elimination

3.1.3 Types of repairs

3.2 Bench structures

3.3 Spotter Straightening Technology

3.4 Selection of process equipment

4 Design part

4.1 Design bench arrangement

4.2 Calculation of bench elements

5 Process Safety

5.1 Occupational Safety

5.2 Personnel selection

5.3 Hazard Analysis

Conclusion

List of sources used

Introduction

In our time, road transport is developing at a rapid pace. The automotive industry, continuously improving its products, provides the population with a variety of transportation means, which, in turn, constantly complicates the tasks facing the car service.

The decisive for the development of infrastructure is the fleet of cars and the trend of its growth.

The Russian passenger car market is one of the most dynamically developing sectors of the consumer market, demonstrating steady growth. Increasing incomes of the population provides an increase in demand for both imported and Russian cars. Currently, buyers have the opportunity, using the car loan system, to acquire better imported products, ignoring the domestic one, especially since the selling prices for domestic cars are likely to soon equal the prices for imported ones, and the quality of Russian cars improves slightly.

Thus, the growth of the fleet of cars presented increased requirements for traffic safety. The bulk of the work to maintain cars in working condition will be entrusted to such an industry group of household services as the services of car service enterprises.

Not least, the organization of the work of the STO plays a role, as well as the ways and forms of performing services that would combine several competitive characteristics and ensure high efficiency of the production process.

One of these forms, which has now been widely used in practice both abroad and in Russia, is branded service. According to experts, branded service ranks first among other forms of car service in terms of competitive characteristics.

Branded STOs sell and service cars of specific firms and work directly with manufacturers, performing dealership functions. Their activities are completely subordinate to the interests of automobile plants, in their work they use regulatory and instructional materials of car factories, spare parts, etc.

Automobile plants achieve the fulfillment by all dealers of uniform requirements for the layout and equipment of dealerships trade and service centers, the performance of production functions in order to ensure high quality of service and high reputation of the automobile company, and its dealership network.

Branded STOs have a high level of technological equipment, trained personnel with a sufficient level of customer service culture, original spare parts, a wide range of services for a specific car brand and a high reputation.

Thus, the highest level of competitive characteristics, including the level of technical, and the quality of maintenance and repair of cars, the culture of customer service, the provision of spare parts, etc., are achieved at branded stations.

The essence of branded service is that the car manufacturer takes responsibility for maintaining the operability of the product throughout its life. In conditions of competition, service becomes an important means for manufacturers of equipment to fight for potential buyers.

This is due to the relevance of the selected topic of the course project.

The purpose of this course project is to design a workshop with the development of a bus section for VAZ cars.

Layout of the production building

Planning is carried out at a scale of 1:100.

The homogeneous nature of some works determines the relationship of technological requirements to the production environment, and therefore to construction, fire and sanitary conditions. Therefore, a number of works are performed in one room, which eliminates the fragmentation of the building into small rooms.

In one room we combine the following works:

a) locksmith, electrical, fuel;

b) blacksmith repair, welding, copper;

c) tires, carpentry, wallpaper, reinforcement bodies;

d) busbars, vulcanization.

When planning the production building, we use a grid of columns 12 × 12 m, which is caused by the overall size of UAZ cars.

In service and repair areas with dead end posts, we use a circular arrangement of cars with an independent exit. A circular arrangement allows you to get around one external gate. In addition, the advantage of such a layout is the simpler maneuvering of cars at the entrance and exit, a higher degree of useful use of production space.

Cars enter the work posts by the front entrance. When the car leaves, maneuvering is allowed, but using no more than one reverse.

For storage and painting works we plan separate rooms, as well as for storage of lubricants, paint, tires and spare parts.

The relative location of the premises is determined by the production relations between them. The main ones in the planning of premises are service posts.

Above each post we provide an extract.

The rooms in which the most accurate works are performed (electrical, fuel, mechanical, etc.) require good lighting, therefore they are located along the outer perimeter of the building.

Directly outside we design in the premises for blacksmith, welding and vulcanization works. External gates are provided for painting and welding shops.

The area of the TO-1 and overhaul section is determined depending on the number and dimensions of the equipment, the area occupied by the car, the standard distance between the equipment and building structure elements.

If there are posts in the premises of production sites, then it is necessary to add the area occupied by the posts to the estimated area.

Process

3.1 Works performed in the body area.

3.1.1 Process of car body repair.

Body section is designed to eliminate defects and faults of bodies that occurred during operation. On the body section, the original shape and strength of the repaired body is restored, as well as work is carried out to maintain the body and its mechanisms in a technically serviceable state. In this area, welding and reinforcement work is carried out, which includes disassembly, assembly, editing and welding of damaged panels, body parts and its mechanisms. Usually the car is delivered to the body section on wheels, and emergency bodies on special trolleys.

Tin works are such works that provide for the repair (elimination of dents, cracks, breaks) of wings, splashes, hoods, doors and other parts of the body. Progressive is the panel repair method, which provides for the complete replacement of the damaged body element.

Disassembly and assembly work - includes the removal and installation of doors, individual panels or body parts, mechanisms, glasses and other removable parts. Partial disassembly of the body for repair of its parts is carried out in the volume necessary for qualitative performance of all repair operations. To assemble bodies after repair, including the installation of units and parts on the car body (doors, wings, panels), various sets of devices and tools are used, as well as a set of templates.

Straightening work, depending on the nature of the damage, consists in eliminating irregularities on deformed surfaces, as well as in correcting distortions of the geometric dimensions of the body (skews).

Welding works are an integral part of body work.

Almost all repair operations require the use of welding, in one volume or another. The body section uses gas, arc and spot welding. Welding is used when removing a damaged section, installing parts or new sections of the body and additional parts (reinforcement boxes, linings, inserts, etc.), as well as when brewing cracks, breaks and holes with and without patches depending on the area and state of the damaged surface.

Reinforcement works - include repair of all body mechanisms (locks, door hinges, windows, etc.), as well as repair of windows and replacement of windows. The repaired and assembled mechanism is installed in place with subsequent adjustment. When replacing glasses, devices for assembling glasses, wooden and rubber brushes, mandrels should be used.

Depending on the technical condition of the body, the following repair methods are used:

- straightening by mechanical action (straightening, drawing) in cold state or using local heating;

- repair by cutting out the destroyed part of the part with manufacture of a repair insert and its adjustment in place;

- repair using used parts, or blocks of such parts, or part of the part to replace the damaged area from the rejected emergency bodies;

- repair of the body by replacing the damaged part with repair inserts made from the range of spare parts of the manufacturer (partial replacement);

- repair by replacement of damaged part or part block with spare parts from manufacturer's nomenclature;

- welding of body elements depending on the structure of the assembly, which is performed butt-wise, overlapping or using an intermediate insert. In butt welding, the gap between the edges shall not exceed 1.5 times the diameter of the welding wire. Overlapping welding is carried out with a point, intermittent or continuous seam with overlapping edges of 10-20 mm. Welding of intermediate welding is carried out in accordance with the method of its connection used (butt or overlapping);

- welds on the front surfaces of the body panels are cleaned to the level of the base metal. Welds are allowed on closed surfaces that do not interfere with the installation of parts;

- before installation of parts forming hidden (inaccessible) cavities, it is necessary to remove corrosion and perform anti-corrosion treatment in the specified places.

3.1.2 Technology of deformation elimination.

The technology for eliminating body deformations depends on the type of skew and the nature of the deformations of the parts. Dents in body and plumage panels, in which the metal is not stretched after impact, are most often leveled by extruding or pulling out the concave section until it gives the correct curvature and, if necessary, subsequent straightening of the extruded surface. Those formed in the panel with a large stretch of metal are bulged and cannot be straightened by straightening, since during its execution the vertex of bulging can lose stability and move to the other side of the sheet. Therefore, another technological process for repairing a car is the replacement of a damaged element.

The main technological operations that ensure the restoration of the operability of passenger car bodies by replacing the damaged area include the following types of work:

- marking and section of damaged part of the part;

- machining of deformed edges of connected parts and manufacturing or fitting of repair part taking into account 10 mm allowance for connection;

- forming the edge at the joint of the restored part;

- piercing or drilling holes with a diameter of 5 mm on the edge of the attached part in steps similar to factory welding points;

- cleaning on both sides of the edge of the connected parts, fitting in place and welding along the holes of the repair part;

- preparation of the restored section of the body for painting, which provides for grinding of welds flush with the base metal, covering and grinding of the surface.

The method of restoring car bodies by replacing their components is based on the use of only semi-automata for electric welding in the medium of carbon dioxide and ticks for point electric contact welding.

Conclusion

As a result of technological calculation, the production program for TR and maintenance of cars was determined; Best practices for organizing production have been identified; number of posts and lines for maintenance and maintenance are determined.

Maintenance station master plan developed.

The optimal choice of technological equipment of the body section allows reducing labor costs for performing technological operations and reducing industrial injuries.

The development of the safety section of the production process of the designed STOA allows you to systematize the harmful and dangerous factors of the bus assembly site and propose a plan of main measures to ensure labor and environmental protection, as well as consider the safety of the service for the client.