Diesel Oil Pump Test Bench Upgrade Project

Contents

CONTENTS

Thesis Project Assignment

Introduction

1 Analytical section

2 Research section

3 Design section

3.1 Purpose and technical data

3.2 Operation of the bench

3.2.1 Operating Procedure

3.2.2 Oil Pump Test

3.2.3 Filter test

3.3 Maintenance

3.4 Pump run-in

3.5 Main faults and ways of their rectification

3.6 Calculation of electric drive

3.7 Calculation of belt gear

3.8 Shaft calculation

3.9 Calculation of bearings

3.10 Selection of electromagnetic pusher

4 Automation

5 Project safety and environmental friendliness

6 Oil pump drive pulley recovery process

6.1 Basic Concepts and Provisions

6.2 Pulley Material

6.3 Main Process Operations

6.3.1 Welding and surfacing operations

6.3.2 Turning

7 Project Feasibility Study

7.1 Selection of comparison base

7.2 Determining Capital Costs

7.3 Calculation of stand performance and running time

7.4 Determination of annual operating costs

7.5 Calculation of Economic Effect

Bibliographic list of used literature

Applications

A. Test bench for YaMZ-236 oil pumps and motor filters, YaMZ-240 (specification)

B. Frame (specification)

B. Clamp (specification)

Report

Dear members of the commission, the purpose of the diploma work is to modernize the test bench and run-in of diesel oil pumps with the possibility of automatic control over the running-in process.

Running-in is an important stage in the operation of machines. The correct and complete conduct of it affects the reliability of the machines and the resource of its work. The accepted technology of pumping and testing consists in stepwise step-by-step loading of pumps, and then measurement of their capacity and oil pressure developed by the pump. Existing run-in recommendations have a significant time discrepancy, which is between 20 and 40 minutes for different authors.

That is, approximate run-in time and load values do not guarantee completion of run-in of friction surfaces in each particular pump and do not guarantee completion of run-in of friction surfaces in pumps.

Therefore, the tasks of the thesis include:

Review of oil pump test procedures.

Selection of the method and method of optimal mode of oil pump running in order to increase the service life and improve the quality of its operation, which reduces the cost of running in and maintaining the operability of hydraulic drive units.

Calculation of bench drive parameters, bench parts for strength.

Development of automatic bench control scheme.

Development of measures for safe working conditions during operation of the test bench for filters and oil pumps.

Compile the process of restoring the most worn part of the bench.

Calculation of feasibility study for modernization of oil pump test and run-in bench.

The thesis consists of an explanatory note on... pages and on... A1 sheets.

The analytical section provides an overview of methods and methods of testing and running-in of oil pumps of diesel engines.

In the Research section, the rationale for the modernization of the stand is given. It was established that the oil heating in the pumps occurs due to the rapid adiabatic compression of it and additional heating from contact with the friction surfaces of the mating parts of the pump. With decrease of value of internal friction in parts of unit temperature drop in oil flow at pump inlet and outlet decreases. Therefore, it is proposed to use this property of pumps when determining the end of the run-in stage.

It is proposed to take the minimum temperature difference in the oil flow at the inlet and outlet of the pump as the criterion for completion of the run-in.

ITP thermometers - T4 temperatures measuring a difference on the basis of sensitive elements are entered into the electric circuit of the stand. The oil temperature is measured at the centre of the pump inlet and outlet flow and allows to measure the difference in 1 ± 0.5 ° С. When the normalized difference in oil temperatures is reached, a light bulb will go out on the bench control panel, showing that the run-in stage is completed.

To accelerate the run-in of the pumps, it is necessary to observe the optimal thermal mode of the oil (within the range of 70 ± 5 ° С), at the pump inlet a heating system is proposed in the oil tank with automatic switching on and off of electric heating tents.

The proposed modernization of the bench, at low cost, will guarantee the full run-in of pumps and ensure their failure-free operation.

Design section includes calculation of electric drive, belt transmission, drive shaft for bending and torsion, bearing for durability. In the modernized bench, the pneumatic cylinder of the clamp drive of the tested pump was replaced with an electromagnetic pusher, which is designed for the transmitted force. This will make it possible to refuse to connect the bench to the compressed air line. Thus, the costs of installing, dismantling the bench and repairing it are reduced.

In the section Automation, a diagram is proposed that provides control of the modernized bench.

In the section Safety and Environmental Friendliness of the project, measures have been developed for safe working conditions in the work area of the bench for testing filters and oil pumps.

In section 6, the technological process of restoring worn creeks and the key slot of the belt transmission pulley of the bench was developed by preliminary machining, and then surfacing and subsequent machining.

Section 7 contains the feasibility study for the introduction of the modernized stand. According to the main technical and economic indicators, such as: annual economic effect (4.9 thousand rubles), payback period (1.5 years), economic efficiency coefficient (0.6), it is clear that the new modification of the stand will be more effective when used in production than the basic one.

Thanks for the attention, the report is over.

Introduction

At the present stage of the development of our society, improving the efficiency of production and quality of products, is an important task in creating the material and technical base and increasing the living standards of the Russian people.

Improving the quality of prevention and repair of machines has a direct impact on the efficiency of their use by: reducing the flow of failures, production costs for their elimination and increasing efficiency in operation.

The increase of vehicles in operation is accompanied by the organization of production complexes with a large volume of the maintained fleet. According to this, improving the quality of maintenance and repair of rolling stock is of increasing interest to scientists and manufacturers. Many road transport enterprises and associations have introduced or are putting into production a comprehensive quality management system for maintenance and repair of cars.

In this diploma project, the test bench for filters and oil pumps of diesel internal combustion engines of cars and tractors is being modernized.

The deterioration of the mechanical condition of machines, as they are operated, is a natural and natural phenomenon. Over time, any design periodically loses its initial quality properties, reduces reliability, economy and completeness, and increases inoperable condition.

The repair shops use this bench to run in, adjust and adjust oil pumps and filters. Thus, partial restoration of lost properties of aggregates takes place. Moreover, the completeness of their restoration is determined by the state of this production, its organization and the presence of modern tools.

But regardless of this, the pumps run-in is 100% by the optimal mode for each particular pump. This process, the modernized stand controls automatically, which differs from the existing ones.

Research Section

During overhaul of construction and road machines, running and testing of pumps for hydraulic drives and internal combustion engines are carried out on special stands. Running-in is an important stage in the operation of machines. The correct and complete conduct of it affects the reliability of the machines and the resource of its work. The accepted technology of pumping and testing consists in step-by-step loading of pumps, and then measurement of their capacity and oil pressure developed by the pump. Existing roundup recommendations [2.3.8] have a significant discrepancy in time, which is from 20 to 40 minutes for different authors. This indicates that there is no theoretical justification for the recommended modes as they are assigned based on statistical data, that is, approximate run-in time and load values, do not guarantee the completion of run-in of friction surfaces in each particular pump and do not guarantee the completion of run-in of friction surfaces in pumps. The capacity of the pumps and the oil pressure developed by them characterize only the technical condition of the pump, but not the completion of its run-in.

Knowledge of physical processes allows to obtain analytical regularity of change of technical condition parameter during operation of the unit, and if there are accurate and reliable results of diagnostics - to predict, which means maximum use of the unit resource.

When the friction surfaces are run-in, a friction force occurs between them, which heats the surface. The lubricant primarily affects the coefficient of friction, which can be taken as an indirect indicator of the wear intensity during friction. Of the many oil properties, only viscosity affects the coefficient of friction. And the viscosity, in turn, changes only under the influence of temperature. Therefore, the criterion of the wear value is the oil temperature on the friction surface and accordingly in the oil line.

It is known that oil heating in pumps occurs due to its rapid adiabatic compression and additional heating from contact with the friction surfaces of the mating parts of the pump. With decrease of value of internal friction in parts of unit temperature drop in oil flow at pump inlet and outlet decreases. It is proposed to use this property of pumps when determining the end of the run-in phase.

With the correct and optimal running mode of the unit, it is possible to increase the resource and improve the quality of its operation. Thus, it is possible to reduce the cost of running in and maintaining the operability of the hydraulic drive units to a minimum value.

In practice, it is necessary to have a simple, easy to use, accurate and reliable criterion for the optimal mode of operation of conjugations.

Minimum temperature difference in the oil flow at the inlet and outlet of the pump is taken as the criterion for completion of the run-in.

At the department of SDM VISTeh, a project was carried out to modernize existing stands for rolling and testing pumps (KI stands - 4815, KI - 27526, KI - 3134, etc.) with the task of automatic control over the stage of completion of the run-in.

ITP thermometers - T4 temperatures measuring a difference on the basis of the TSM GOST 6651 sensitive elements - 78 are entered into the electric circuit of the stand. The oil temperature is measured in the center of the flow at the inlet and outlet of the pump and allows you to measure the difference in 1 ± 0.50 С. When the normalized difference in oil temperatures is reached, a light bulb will go out on the bench control panel, showing that the run-in stage is completed.

In order to accelerate the run-in of the pumps, it is necessary to observe the optimal thermal mode of the oil in the bench system. Avdonkin F.N. studies [6] found that the optimal operating mode of the pump is the oil temperature of 70 ° C. To maintain the oil temperature within the range of 70 ± 5 ° С at the pump inlet, a heating system is provided in the oil tank with automatic switching on and off of electric heating tents.

The proposed modernization of the stands, at low cost, will guarantee the full run-in of the pumps and ensure their failure-free operation.