Pipe bending machine

Contents

INTRODUCTION

1 ORGANIZATIONAL AND TECHNICAL SECTION

1.1 Description of the route to be repaired

1.1.1 General characteristics of the pipeline

1.2 Use of pipe bending machines in routing conditions

1.2.1 Design Overview of Pipe Bending Machines

1.3 Control of the machine when working with the mandrel

2 TECHNICAL SERVICE

2.1 Quality control of bending process

2.2 Improvement of pipe bending quality using mandrel

2.3 Diagnostic Methods

2.4 Machine maintenance under route conditions

2.4.1 Daily Maintenance

2.4.2 Periodic Maintenance

2.4.3 Monthly Maintenance

2.4.4 Seasonal Maintenance

2.4.5 Hydraulic system maintenance

2.4.6 Maintenance of electrical elements

2.5 Types and periodicity of dorn maintenance

2.5.1 Daily maintenance of the don

2.5.2 Monthly maintenance of dorn

2.5.3 Seasonal maintenance of dorn

3 DESIGN SECTION

3.1 Selection and calculation of basic parameters of pipe bending machine .35 3.1.1 Calculation of bending moment for bending of thin-walled pipes

3.1.2 Calculation of hydraulic cylinders of cradle and its dimensions

3.1.3 Determination of hydraulic cylinder rod stroke length

3.1.4 Determination of finger diameters

3.2 Strength calculation of bending cradle

3.3 Calculation of winch

3.4 Pump calculation

4 LIFE SAFETY

4.1 Analysis of hazardous and harmful factors

4.2 Production microclimate

4.3 Electrical Safety

4.4 Fire safety

4.5 Effect of sound waves

4.6 Environmental Safety

4.7 Effects of electromagnetic radiation

4.8 Calculation of illumination

5 ECONOMIC SECTION

5.1 Determination of annual operating capacity

5.2 Determination of costs for delivery of finished taps

5.3 Determination of annual current consumer costs

5.3.1 Depreciation deductions for renovation

5.3.2 Costs of ongoing, unscheduled repairs and maintenance

5.3.3 Overhaul Costs

5.3.4 Salary of the machine manager

5.3.5 Energy Costs for Electric Motor

5.3.6 Hydraulic Fluid Costs

5.3.7 Relocation costs for heavy duty trailer vehicles

5.4 Determining Economic Impact

CONCLUSION

LIST OF SOURCES USED

1 organizational and technical section

Transport is the most important area of ​ ​ social production. The development of the economy of any country, the normal production activities of all its participants depend on the clear work of transport for the timely delivery of raw materials and finished products. To meet this and other diverse needs, a highly developed, state-of-the-art system of all modern modes of transport must be in place.

2 technical services

The uninterrupted operation of the pipe-bending machine and the duration of its service largely depend on the skillful and correct care of it. Most outages, breakdowns, and accidents are mainly due to the fact that basic maintenance rules are not observed when working on pipe bending machines. One of the areas of technical service is considered in the diploma design - this is the maintenance of the machine and elements that ensure a high-quality pipe bending process.

2.4 Machine maintenance under route conditions

Maintenance of the pipe-bending machine consists in daily and periodic inspection of the technical condition, cleaning, lubrication and adjustment of its assembly units (units) and units. Safety precautions shall be observed during maintenance of the pipe bending machine.

2.4.1 Daily Maintenance

Daily technical service is performed before each shift, but at least after 10 hours of operation of the machine. Daily technical service includes: cleaning the machine from snow, checking the correctness of the machine on site, the presence and state of the machine, checking the state of electrical equipment (state of drives, cables, state of protective and control equipment), checking the state of hydraulic equipment (level of operating fluid in the hydraulic system tank, state of high-pressure hoses and hydraulic system connections, serviceability of spools and interlocks, state of pressure gauge.). Check of winch condition (hydraulic motor, reduction gear box, drum, cable).

2.4.2 Periodic Maintenance

For the machine, a daily and periodic technical service is installed. Periodic maintenance is carried out monthly. In addition, during the transition to the autumn - winter or spring - summer periods of operation, seasonal technical service is carried out. The specified periodicity of technical service is provided for a serviceable machine. During the technical service of the machine, in addition to the measures described above, it is also necessary to maintain: an electric motor, a pump, a hydraulic motor, a reduction gear box, safety valves and a magnetic filter.

2.4.3 Monthly Maintenance

Monthly technical service includes: performance of electrical equipment maintenance (with a megometer of 500 V is checked

insulation resistance of the power circuits of the machine and the lead-in cable, it must be at least 0.5 Mom), technical work on the service of the hydraulic system (check of the quality of liquid and oil in the reduction gear box, check of the magnetic filter, check of the mesh filter of the hydraulic system, check of the condition of cuffs and mud collectors for hydraulic cylinders, if necessary, their replacement).

2.4.4 Seasonal Maintenance

The seasonal technical service includes work on electrical equipment (checking the state of magnetic starters, circuit breaker, checking the insulation state of the outlet ends), on the hydraulic system: washing the entire hydraulic system, replacing the working fluid depending on the season, checking for corrosion of the entire machine, if there are traces of corrosion - grinding the site, with further painting.

Hydrosystem care includes:

- control of working fluid quality and quantity;

- monitoring of system tightness;

- quality adjustment of pressure spools and safety valve.

2.4.5 Hydraulic system maintenance

The durability of the hydraulic system largely depends on the purity of the filters. Therefore, it is necessary to clean the strainer.

regular: for the first time 100 hours of operation of new or overhauled machines - every 50 hours of operation in the subsequent period - at least once a month, as well as during the change of working fluid or in case of contamination. It is necessary to check the condition of the hydraulic system pipelines daily. Prevent leakage at the points of pipe connections. For that, tighten threaded connections periodically and replace sealing rings and gaskets in a timely manner. If mechanical damages are detected on the pipeline, their repair is required. Before installation on the machine, the internal surfaces of the pipelines must be thoroughly cleaned of rust, with the obligatory use of degreasing, etching, neutralization, treatment in an inhibited aqueous solution and inhibited oil. If hoses with mechanical damages are detected, the latter are replaced with new ones.

Keep the hydraulic panel clean, prevent corrosion of parts, replace worn-out seals and gaskets in a timely manner. All bolting connections shall be fully tightened and locked. The service of the winch reduction gear consists in observing the absence of oil leakage through the covers, in timely replacement and addition of oil to the crankcase.

2.4.6 Maintenance of electrical elements

Motor service is performed by inspection, depending on production conditions, but at least once a year. During each inspection, clean the motor from dust and dirt, wash the bearings and replace the lubricant. Lubrication condition of bearings is checked every 500 hours of operation. During the check examine the chamber of external bearing cover and bearing, paying attention to the lubricant color, filling degree in the chamber and presence of lubricant layer inside the bearing, Co.

lubricant located in the cover chamber, remove the surface layer not more than 2 mm thick, which was in contact with bearing parts during operation, check for clogging of lubricant with metal and other foreign impurities, as well as how much its structure has changed compared to fresh lubricant of the same grade.

The care of the winch consists in monitoring the absence of a leak, a power unit, the condition of the gears, timely additional filling, washing the oil bath, according to the lubrication map. A systematic check of the reliability of the ropes in the drum. The rope should not have loops, inflections, rubbing.

The care of steel structures consists in systematic observation of the condition of the joints and the base metal. In case of detection of cracks and explosions of metal and seams, operation is stopped until troubleshooting.

Lubrication of mechanisms is an essential component of the machine care operation. With correct and timely lubrication of the friction surfaces of the machine parts, their wear is significantly reduced and the long and reliable operation of all mechanisms and the machine as a whole is ensured.

Conclusion

In this diploma project, on the basis of a review of the technical literature and analysis of the existing machine for the manufacture of curved pipe sections during the laying of a pipe with a diameter of 530mm, a machine for cold bending of pipes of large diameter GT532 was selected.

A number of engineering calculations were also carried out in this diploma project: the operating parameters and overall dimensions of the machine were determined, the cradle was calculated for strength, as a result of which it was shown that stresses arising during bending of the pipe do not exceed permissible values.

An analysis of harmful factors during the operation of the GT532 machine was carried out. The issues of labor protection and environmental protection are considered. Illumination calculation for machine operator has been performed.

As a result of calculation of costs for operation of this machine in manufacturing of bent pipes on construction site and costs for purchase and transportation of finished bent pipes, the greatest effect was obtained when using the GT532 cold pipe bending machine.