Diploma on modernization of transport workshop

Contents

1.1. General characteristics of Maltsovsky Portlandze-ment CJSC

1.1.2. Main production areas

1.1.1. Analysis of the technical performance of the road transport company

1.2. Structure of the rolling stock fleet

1.3. Management structure of Maltsovskiy CJSC motor transport shop

Portlandze-ment "

1.4. Characteristics of production and technical services

1.5. Project Feasibility Study

1.6. Project Objective and Objectives

1.7. Conclusion on Research Frequency

2.1. Calculation of the annual production program

2.1.1. Select Source Data

2.1.2. Establishment and adjustment of standards

2.1.3. Calculation of technical readiness factor

2.1.4. Determination of the number of technical impacts on the car,

group of cars and the entire fleet for

2.1.5. Determination of number of diagnostic effects by models

and for the entire park per year

2.1.6. Definition of daily maintenance and diagnostic program

2.2. Calculation of annual scope of work

2.2.1. Establishment and adjustment of standards

2.2.2. Annual scope of seasonal services

2.2.3. Redistribution of scope of work for maintenance and maintenance areas

2.2.4. Distribution of RW, MT and TR by work types

and production zones and sites

2.2.5. Determination of scope of work for D1 and D diagnostics

2.3. Calculation of the number of workers, ITR and employees

2.3.1. Calculation of the number of production workers

2.3.2. Calculation of the number of auxiliary workers

2.3.3. Calculation of the number of ITR, employees

2.4. Process calculation of production areas, areas and warehouses

2.4.1. Calculation of number of maintenance, TR and diagnostics posts

2.4.2. Calculation of the number of support items

2.4.3. Calculation of the number of waiting posts

2.5. Space Area Calculation

2.5.1. Calculation of areas of maintenance and maintenance zones

2.5.2. Calculation of Production Areas

2.5.3. Storage area calculation

2.5.4. Calculation of storage areas

2.5.5. Calculation of the area of ​ ​ administrative and domestic corporation

2.6. Identify the most significant optimization directions

activities of the enterprise within the organization of maintenance and maintenance

2.6.1. Proposed layout of the busbar and

vulcanization section

2.6.2. Description of the process produced on

design version of busbar section

2.7. Conclusions on Process Frequency

3.1. Navigator 03-58 GIGA Bus Installation Bench Brief

3.2. Technical specifications of busbars

3.3. Requirements for lighting

3.4. Tire mounting wall attachment system

3.5. Bus bench control mechanism

3.6. General Safety Rules

3.7. Operation of the aggregate

3.7.1. Preparation for work

3.7.2. Preparation of the school

3.7.3. Kole sa clamp

3.7.4. Removal of seam

3.7.4.1. Removal of tractor wheels

3.7.4.2. Dismantling of single and tubeless co-forest

3.7.4.3. Removal of wheels with compound housing

3.7.5. Installation of seams

3.7.5.1. Installation of tractor pod-forest

3.7.5.2. Installation of single and tubeless co-forest

3.7.5.3. Installation of wheels with compound housing

3.8. Equipment certification

3.9. Patent search

3.10. Proposed option for improvement of tyre-mounting walls

3.11. Output by Design Time

4.1. Process Safety

4.1.1. Occupational safety at the busbar

4.1.2. Danger of electric shock and measures

electrical safety

4.1.3. Production noises and vibrations, their impact on

organism, rationing and protective measures

4.1.4. Production lighting

4.1.5. Normalization of microclimate parameters

production premises

4.2. Project development in emergency situations

4.2.1. Analysis of emergency man-made and natural situations

4.2.2. Engineering and technical measures for building protection,

facilities, equipment in emergency situations

4.2.3. Fire safety

4.3. Ecology of production

4.3.1. Harmful factors of production

4.3.2. Environmental protection activities

4.4. Safety Requirements for Bus Assembly Area

during operation with thermal equipment

4.5. Assessment of production resistance to RBMS

4.6. Output on Organizational Part

5.1. Short characteristic of the busbar section

5.2. Calculation of depreciation asset values and

capital investments

5.3. Calculation of the required number of workers

5.4. Calculation of the required wage fund of repair workers

5.5. Calculation of repair cost

5.6. Calculation of economic effect from implementation of measures

5.7. Technical and economic indicators

5.8. Conclusion on the economic part

1.6. Project Objective and Objectives

Project Objective:

- modernization of the production and technical base of the transport workshop of Maltsovsky Portland Cement CJSC with the development of a tire installation site.

Project Tasks:

- study of the operation of the automotive repair plant, its condition

production and technical base, consideration of the structure of the PS fleet and the activities of the enterprise itself;

- development of the project feasibility study;

- calculation of the production program; development of design works

busbar section with arrangement of required process equipment;

- development of life safety measures and

occupational safety for the tire section;

- calculation of economic feasibility of tyre modernization

of the site.

1.7. Conclusion on the research part

After analyzing the activities of the enterprise, the following conclusions can be drawn:

- a significant part of the rolling stock is in satisfactory condition;

- the enterprise as a whole is not equipped with process equipment;

- to increase the efficiency of the PTB operation, it is necessary to introduce modern technological equipment, improve the skills and working conditions of personnel, and increase the rate of renewal of road transport.

Having critically assessed the work of the bus assembly section, it is possible to draw conclusions about the need for its reconstruction due to the lack of process equipment, which leads to:

- to process disturbance and as a consequence to the occurrence of accidents at work, failure of repair works, etc.

- to increase labour intensity of repair works;

- reduced quality of repair works, which reduces service life of the rolling stock fleet.

High-quality repair work on the tire area, as well as at the entire enterprise, provides for the maximum use of related process equipment and equipment, which in this case will be possible only after modernization

2.5. Space Area Calculation

ATP areas in their functional purpose are divided into three main groups: production storage, for storage of rolling stock and auxiliary.

The production and storage facilities include maintenance and maintenance zones, TR production areas, warehouses, as well as technical rooms of power and sanitary services and devices (compressor, transformer, pump, ventilation, etc.). For small ATPs with a small production program, some areas with a homogeneous nature of work, as well as individual warehouses, can be combined.

The areas of storage (parking) of rolling stock include areas of parking lots (open or closed) taking into account the area occupied by equipment for heating cars (for open parking lots), ramps and additional floor passes (for closed multi-storey parking lots).

In accordance with SNiP 2.09.0487 "Administrative and household buildings" the company's administrative and household premises include: sanitary and household premises, public catering, health care (medical points), cultural services, management, premises for training sessions and public organizations.

2.6.2. Description of the process to be performed on the design version of the bus assembly section

After the wheel has been removed from the vehicle and delivered to the pinching section, it is necessarily subjected to a washing process in the bath 7 if subsequent work with the tire (vulcanization) or with the wheel as a whole (balancing) is required. If it is not necessary to perform these operations and visually the wheel has no pronounced contaminants, the washing process may be omitted.

The wheel then enters the tire bench 9, where it is disassembled and, depending on the needs, a part of the wheel is repaired on certain equipment. In particular, if it is desired to rebuild the wheel chamber, the electric vulcanizer 10 is used, if it is desired to rebuild the tire after puncture, the stand 4 and 5 are used depending on the type of co-scaffold. Locksmith 2 can be used for preparatory works.

After the wheel component has been repaired or replaced, the wheel is assembled, pumped by the compressor 3, balanced (in the case of a passenger car wheel) on the balance bench 11 and mounted back on the car.

The pumping of oversized wheels should be mentioned separately, since this process is specific and the main difference between this process and the process of pumping tires of freight or passenger vehicles is that it is produced in the safety cell 1 in order to avoid possible injuries among workers. The process of pumping a large wheel itself consists of two stages. At the beginning, the wheel is pumped to a pressure of 0.5 atm, after which the employee checks the reliability of the locking ring attachment and only after that "pumping" to the standard pressure.

2.7. Conclusions on process part

As a result of execution of the process part there were:

- initial data is selected;

- technical readiness factors, annual scope of work, scope of maintenance works by types of work and TR by production zones and areas, number of workers, area of premises are calculated;

- Performance of Maltsovsky Portland Cement CJSC Motor Transport Shop was evaluated using technical and economic indicators;

- process equipment and accessories are selected.

By analyzing the data presented in the research part and the flow of the process part, the following conclusions can be drawn:

- at the enterprise the area of production areas, maintenance and maintenance areas is less than the design value

- number of production workers is less than estimated

This makes it possible to conclude that part of the maintenance and repair of the IR is either partially or not performed at all.

3.7. Unit operation

Before operation of the unit, the operator must ensure that there are no strangers or objects in the work area, the location of the control panel allows you to have a full view of the work area.

3.7.1. Preparation for operation

The purpose and design of the separation device allows the operator to work with wheels of large diameters (up to 2700 mm) and large weight (up to 2500 kg).

When carrying out work, it is recommended to be careful and use the help of other qualified operators with appropriate working clothes.

3.7.2. Wheel preparation

Remove balancing weights from both sides of the wheel .

Remove the central part of the tire valve and completely release the air from it.

Find the side of the tyre (with mounting recess) from which its dismantling will begin.

Check rim clamp point.

3.7.3. Wheel clamp

When working with wheels weighing more than 500 kg, use a lifting device or forklift.

All wheels shall be fixed on the inside. If it is not possible to fix the rim in the central hole of the disk, the wheel should be clamped using the bottom of the rim near the disk.

To fix the wheel, perform the following actions:

- Place the wheel on the unit table in vertical position;

- Adjust the clamping device according to the wheel type using the "open" function - I, L (Fig. 3.6.);

- Use the buttons - B, C, F and D (Figure 3.6.) to align the spindle and wheel axes so that the clamps touch the rim edge slightly. Use the - I button (Fig. 3.6.) to lock the wheel completely.

Check that the rim is properly fixed and aligned and that the wheel rises above the table surface to avoid slipping out during subsequent operations.

3.7.4. Removal of tyre

After fixing the wheel, remove the tyre according to the instructions given below and depending on the type of wheel.

3.7.5.2. Installation of single and tubeless wheels

Fix the clamps on the front edge of rim 3 (Fig. 3.10. b) and place both sides of the tyre behind them.

Insert the hook 2 cm beyond the front edge of the rim and turn the wheel clockwise until the tire is fully shrunk. In this case, it is necessary to monitor the correct shrinkage of the sides into the mounting depressions .

For separate shrinkage of the sides, perform the actions described in the section "Installation of tractor wheels and wheels for other agricultural machinery ."

3.7.5.3 Installation of wheels with composite rim

Install the tire on the rim, aligning the position of both sides as much as possible. If the wheel has a camera, insert it before installing the tire, carefully and correctly spreading it inside.

Using the separation tool 1 (Fig. 3.9. a) sit down the second side.

Insert the rim components and lock them with a locking ring. When working with tubeless tyres, insert an annular seal between the rim and the components.

3.8. Equipment Certification

Bus installation bench Navigator 0358 GIGA has a certificate of conformity (Certification system GOST R Gosstandard of Russia).

3.11. Output by Design Part

During the design part, the device of the Navigator 0358 GIGA bus bench was described, its technical characteristics were given, the requirements for lighting and the fastening system were described, the tire bench control mechanism and general safety rules for working on it, the stages of the operational process when working with wheels of various designs were described in detail. A comparative analysis of the introduced stand was carried out with stands that differ in design and algorithm. Well, at the end of the design part, an option was proposed to improve this tire installation bench.

4.1. Process Safety

Problems of industrial safety at the present stage are moving from the social sphere to the sphere of social and economic, which actively affects the results of the enterprise's economic activity. Therefore, and now and in the future, there will be a great need for highly qualified specialists in the safety of technological processes and industries.

4.1.1. Occupational safety at the tire assembly area

Occupational safety and safety is a set of measures and appropriate techniques for performing work that ensures the preservation of workers' health at work.

The basis of safety procedures for car repair and maintenance is reflected in the State Standard of the Russian Federation in the section "Intersectoral rules for labor protection in auto-mobile transport" (POTRM02703)

Responsibility for labor protection, as well as for carrying out measures to reduce and prevent industrial injuries and occupational diseases in the whole enterprise is assigned to the head of the enterprise, and for individual areas to the appropriate managers. To prevent industrial injuries, appropriate safety regulations are developed and communicated to employees.

The management of enterprises is obliged to ensure timely and high-quality training and training of workers in safe techniques and working methods, preliminary and periodic medical

inspections, issue personal protective equipment.

The proper organization of the workplace is of great importance for the prevention of industrial injuries during the production of current repairs of cars. The workplace shall be equipped with means of mechanization of main and auxiliary works, necessary documentation, place for tools, specialized packaging.

The busbar shall have strong non-combustible walls. The floors on the site should be even. They must be systematically cleaned of grease and dirt. You should paint the ceilings and walls with light tones.

Used wiping material is folded into metal boxes with cover.

For safety and ease of work in the area, distances between individual units of process equipment are adopted in accordance with ONTP 0191.

Wooden portable floorings are installed at workplaces to prevent overcooling of the legs of working personnel.

The low level of industrial injuries largely depends on the quality and serviceability of the equipment and tool used, the type and size of the tool should be indicated in the process charts posted at workplaces. Tools used by production workers (hammers, wrenches, screwdrivers, etc.) must always be smooth, without cracks and wrenches, wrenches must be serviceable and strictly correspond to the size of nuts and bolts.

The condition of the tool shall be monitored by the production site craftsmen and, if necessary, the unsafe tool shall be replaced with a new one.