Production building design - NPP

Contents

Introduction

1. Process calculation of STR

1.1 Initial data

1.2 Organization of the production process at the STR

1.3. Demand Program Calculation

1.3.1. Calculation of labour intensity of post works

1.3.2 Calculation of the number of serviced cars

1.3.3. Annual scope of work of the designed station

1.3.4. Distribution of the annual scope of work at the designed workshop

1.3.5 Calculation of the number of employees

1.3.6 Calculation of the number of posts and vehicles

1.4. Calculation of STR areas

1.4.1 Determination of areas of production zones

1.4.2 Determination of production areas

1.4.3.Define the area of auxiliary rooms

1.4.4 Selection and justification of planning solutions, building structures

1.4.5. Mechanization Level Definitions

2. Development of maintenance process and brake system repair technology

3. Development of repair technology

3.1. Analysis of brake design and service purpose

3.2 Determination of the annual repair programme

3.3 Removal Procedure

3.4 List of failures and methods of their elimination

3.5 Diagnostics of braking system technical condition

3.6 Requirements for conjugations of components

3.7 Development of part recovery process

3.7.1 Analysis of repaired part

3.7.2 Selection of process bases

3.7.3 Selection of the method of defects elimination

3.7.4 Development of route process of recovery

3.7.5 Development of operational technological processes

Calculation of applied layer thickness

3.7.6 Calculation of operation modes

3.7.7 Development of assembly process

3.7.7 Sequence of transitions and definition of time standards

3.7.8.Compute assembly operation modes

3.7.6.2.1 Assembly of connections with interference

3.7.8 Assembly of threaded connections

3.8 Unit test

3.8.1 Road tests

3.8.2 Bench tests

3.9 Development of accessory for operations

3.9.1 Description of the structure

3.9.2 Calculation of main parameters of the accessory

4. Structural part

4.1. Prototype Selection and Justification

4.2. Description of purpose and composition of brake bench STM - 15000U

4.3 Traffic light and information annunciator

4.4 Bench operation

4.5 Technical characteristics of STM - 15000U braking bench

4.6 Verification calculations

4.6.1.Define basic geometric parameters of roller bench

4.6.2.Compute functional qualities of the bench

4.6.3 Calculation of roller bench load-drive device

4.6.4 Calculation of foundation bolts

4.7 Maintenance and repair of brake bench

4.7.1 General Instructions

4.7.2 Daily Maintenance

4.7.3 Preventive work

4.7.4 Maintenance of the stand roller unit

4.7.5 Brake bench maintenance

5. Labor protection and environmental protection

5.1 Occupational and environmental protection in the diagnostic area

5.1.1 Characteristics of the diagnostic area room

5.1.2 Operating area microclimate parameters

5.1.3 Noise and Vibration

5.1.4 Lighting

Natural and artificial lighting is used on the site

5.1.5 Electrical and Fire Safety

5.1.6 Ergonomics and Technical Aesthetics

5.1.7 Earthing Calculation for Diagnostic Area

6.Protection of the environment at the STR

6.1 Protection of atmospheric air from pollution

6.2 Protection of water resources

6.3 Protection of the lithosphere

7. CIVIL PROTECTION

7.1 Introduction

7.2 Design Part

7.3 Conclusions. Measures to protect workers and employees of road transport enterprise

8. ECONOMIC DIVISION

8.1. Calculation of capital investments

8.1.1. Calculation of nominal and effective working time funds

8.1.2. Calculation of process equipment quantity

8.1.3. Calculation of process equipment cost

8.1.4. Calculation of additional investments for implementation of new equipment at the STR

8.2. Costing Calculation

8.2.1 Calculation of direct costs

8.2.2. Calculation of indirect costs

8.3. Evaluation of the effectiveness of the implementation of new technology

8.3.1. Determination of the integral economic effect

8.3.2 Determination of internal rate of profitability

Conclusions

List of references

Applications

Project Description

This thesis contains: graphic part - 7 sheets of A1 format and 6 sheets of A2 format; explanatory note - 143s., 10 drawings; 74 tables; 50 sources.

In the diploma work, a design of a taxi ATP for 90 cars was developed with detailed development of the diagnostic section and the technology of maintenance and repair of the front brake mechanism of the VAZ-2109 car. The selection of process equipment is justified. Measures on labor protection and environmental protection at the diagnostic site are described. Also described are the actions of workers and employees of the diagnostic site who found themselves in the explosion zone. In the final part, the economic justification of the project was carried out.

Technological calculation of the diagnostic site, repair technology, design developments, labor and environmental protection, civil defense, economic justification of the project, conclusions.

Source Data

We accept the initial data for the design of the workshop:

-number of work posts Prp = 10

- station operation mode:

a) number of days per year Drg = 365 days;

b) number of working days per year Dfg = 305 days;

c) change duration Ssm =8chas;

d) number of shifts 1.5;

- Percentage of residents applying to STO - 20% K1 = 5;

- percentage of residents with cars - 30% K2 = 3.3;

- number of cars per 1000 inhabitants Ap = 140 pcs;

-the number of races of one car per year at STO d = 1.2.

Normative labour intensity:

- TR and TR per 1000 km of mileage for small class machines is ttr = 2.3 [hourly hours];

- standard average annual mileage of serviced cars Ln = 15 [thousand km].

Introduction

During the operation of the car, its reliability and other operational properties are gradually reduced due to wear of the parts, as well as corrosion and fatigue of the material from which they are made. Various faults appear in the car, which are eliminated during maintenance and repair.

The need and expediency of repairing cars is primarily due to the inequality of their parts and assemblies. It is known that it is impossible to create an equal-strength machine, all parts of which would wear evenly and have the same service life.

Therefore, it is necessary from the point of view of safety to keep the car in working condition, and it is feasible from an economic point of view. Therefore, in the course of operation, cars at the workshop are subjected to all types of maintenance and repair, which is carried out by replacing individual parts and units that have failed to work. This allows you to maintain cars in a technically serviceable state. In the case of long-term operation of cars, such a condition is achieved when the cost of funds and labor associated with maintaining them in working condition in a workshop becomes impractical. This technical condition of cars is considered to be the limit, and they are sent for repair.

The task of maintenance and maintenance of cars as a field of practical activity of the STO is to maintain and restore the operability of the car fleet.

All road transport enterprises can be divided into three groups for their purpose:

-operational, which include automobile plants, fleets and other motor transport enterprises;

- servicing, servicing the rolling stock of various enterprises, organizations and individual owners;

- repair, overhauling automotive units and assemblies.

Operating enterprises carry out transportation of goods and passengers, maintenance, repair and storage of their rolling stock.

Service enterprises include all maintenance stations, parking lots, hotels for car tourists, campsites and gas stations. All of them serve the vehicles of private owners. In the presented diploma project, technical re-equipment of the existing STO was carried out, belonging to the servicing group of the enterprises of STO "RealAuto."

The designed STO is engaged in the maintenance of cars of the brands: Mazda, Ford, Mitsubishi, Volvo, Hyundai, Audi, Volkswagen, including cars of the VAZ family, has 10 working posts. The layout and equipment of the diagnostic site was considered in more detail. On the territory of the STO there is a car dealership that sells a/m brands: VAZ, Shevrolet, Subaru, Honda.

Selection and justification of planning solutions, building structures

The shape of one-story production buildings should be the simplest, in the form of a rectangle (or square), since the cost of building a building of complex configuration increases significantly.

Production building consists of several parallel spans.

The designed production building consists of three spans, each of which is characterized by the main dimensions - the width of the span L and the pitch of the columns (the distance between the axes of the columns in the longitudinal direction) t, which form a grid of columns.

The width of the spans of the building depends on the size of the equipment and on the length of the overall car - Subaru Legacy (4730 mm). We accept = 6 m.

We take the pitch of the columns = 6 m.

Thus, the colon grid is taken 66 m.

The height of the span of the production building is determined based on the size of the equipment used, the maximum size of the car served, the size of the structures of the bridge cranes, as well as sanitary and hygienic requirements. The span height is accepted in accordance with the recommendations of the ONTP - 01-91. The height of the premises of the maintenance and maintenance posts equipped with lifting equipment to the bottom of the projecting building structures is 5.4 m.

The overall dimensions of the columns are assumed to be 400x400 mm.

The outer walls are accepted with a thickness of 400 mm, the remaining partitions between the rooms are accepted with a thickness of 250 mm.

Unit test

3.8.1 Road tests

The test conditions are as follows: the road section shall be hard-coated, straight, horizontal, dry, free of loose materials or oil on the surface. The tyres of the car must be clean, dry and meet the requirements. At least two measurements of determined parameters are carried out during tests. Braking is carried out by sharp (without impact) impact on the drive pedal, while the car must maintain rectilinear movement. The force on the pedal must be not more than 687 N, which is recorded by the sensor.

Test 1. Check braking performance. Performance indicators of the service braking system are values ​ ​ of braking path or steady-state deceleration. Install deselerometer in the cockpit. Outline the landmark from which the braking distance measurements will begin (this landmark can be a chalk mark on the roadway, the installation of any object). Before the landmark, the car accelerates to a speed of 83... 85 km/h to approach it at a speed of 80 km/h. Then engine is disconnected from transmission and full braking is performed. Deceleration is determined by readings of deselerometer, and braking distance is measured by roulette. Races for measurement of braking parameters shall be performed in case of road and wind slopes in both directions, in each at least two races. For analysis, take the arithmetic mean. Compare the obtained data with the bench test data.

Test 2. Check the performance of the parking brake. An indicator of the parking braking system is its ability to keep the full-weight car stationary on a rise with a slope of at least 16%. It is necessary to brake the car at a slope of at least 16% (artificially created from building material of the ramp type or from an earthen embankment) and ensure the reliability of the lever locking device.

3.8.2 Bench tests

Bench tests of the braking system are carried out on specialized posts or lines using fast-acting platform stands of inertial or power type. The principle of the inertial platform bench is based on the measurement of inertia forces from the translational and rotationally moving masses of the car arising during its braking and applied at the points of contact of the wheels with dynamometer platforms. The car when diagnosed at a speed of 6:.. 12 km/h runs into the movable platforms of the stand with wheels and stops during sharp braking. The resulting inertia forces correspond to the braking forces. Acting on the movable platforms of the bench, they are perceived by mechanical, liquid or electronic sensors and are fixed by measuring instruments. Significant disadvantages of a platform stand of the inertial type are: the need for a significant area for its placement (taking into account the need to accelerate the car); instability of tyre adhesion coefficient depending on their contamination, humidity.

The principle of operation of the power type platform bench is based on the fact that the braking forces arising during braking at the points of contact of the wheels with the dynamometer platforms are formed due to the forced movement of the car through the platforms using a traction conveyor.

During element-by-element diagnostics, inertial stands with running drums and power stands with rollers are used. Inertial stands with running drums can be driven by wheels of car, rotation of which is provided by automobile engine, or driven by electric motors of stand. The former, due to the high metal consumption and complexity, were not widely used in the practice of motor vehicles. The principle of the inertial stand with running drums is as follows. Having installed the car on the stand, with the help of electric motors, the circumferential speed of the car wheels is brought to 50... 70 km/h and they are slowed down sharply, while at the same time breaking all the carriages of the stand by turning off the electromagnetic couplings. At the same time, inertia forces occur in places of contact of wheels with drums, which counteract braking forces. After stopping the rotation of the stand drums and the wheels of the car, the paths travelled by each wheel or the angular deceleration of the drums are determined, which will be equivalent to the brake tracks of the wheels and the braking forces. The path travelled by the wheel during braking can be determined by the total number of revolutions of the bench drums, which is fixed by the counter, or by the duration of rotation of the drums, measured by a stopwatch. The deceleration of the rotation of the drums is determined using an angular deselerometer. In addition, on the inertial bench, it is possible to directly measure the braking torque from the reactive torque generated on its shaft.

Power stands allow you to set braking forces during the rotation of the car wheel at a frequency corresponding to the speed of movement from 2 to 10 km/h. Braking force of each wheel is measured by braking them during rotation performed from bench electric motor. The braking force is determined by the torque generated on the stand rollers during wheel braking.

In practice, power stands became most widespread, which is due to their adaptability to element-by-element diagnostics when combining diagnostic work with adjustment, small dimensions, relatively low cost and power consumption.

Diagnostics of brakes can also be carried out with the help of static power stands, which are roller or platform devices that allow turning, "tearing" the braked wheel and measuring the force applied. However, these stands do not reproduce actual braking conditions and reliable results.

Compared to road tests, the diagnosis of the braking system on stands has a number of advantages, which should include: high accuracy of the diagnosis results; The possibility of simulating any road conditions; possibility to standardize test conditions, which ensures repeatability of results and comparability of data obtained on different stands; safety of tests at different speed and load modes.

Development of an instrument for performing operations

3.9.1 Description of the structure

The designed accessory is designed to press bearings into the hub holes.

Accessory consists of manual press with handle and mandrel for bearing pressing. Attached to a table or verstak.

Design Part

4.1. Prototype Selection and Justification

In the diploma project, the modular universal brake stand STM-15000U was chosen for the prototype of the designed stand. This bench determines the following braking performance parameters:

- mass of the axis to be diagnosed;

- force on the control;

- specific braking force;

- relative difference of braking forces of one axle;

- brake system actuation time;

- ovality of the wheels of the diagnosed axle.

To control cars that do not have a differential between the driving axles, the stand provides rotation of the left and right wheels in different directions.

The stand is designed for operation in the designated territories of motor transport enterprises and maintenance stations, the electric networks of which are not connected to the networks of residential buildings.

The type of climatic design is U2 as per GOST 1515069.For resistance to mechanical impacts - the version of the bench is ordinary as per GOST 1299784. The bench meets all requirements ensuring consumer safety according to GOST 26104, GOST 12.2.007.0.

4.2. Description of purpose and composition of brake bench STM - 15000U

stand relates to power-type roller stands based on the principle of measurement of braking force transmitted from car wheels through support rollers to balance motor and perceived by strain gauge sensor, with further processing of results on personal computer and their output to monitor screen and printing device.

Stand consists of two modules of roller installation for LH and RH wheels, control post containing PC and power electric elements (power panel), traffic light or information annunciator and force sensor.

Roller unit measures mass of diagnosed axle and drives wheels of this axle to measure braking force.

The roller unit includes:

- motor - reduction gear box;

- two support rollers;

- servo roller;

- four weight sensors;

- brake force sensor;

- vehicle presence sensor;

- slip sensor;

- sensor controller (for LH roller unit only).

All roller units can be mounted on a welded rectangular frame with ramps for independent entry and exit of a car to a roller unit or on a frame - a framework of a foundation mounted on the basis of a viewing pit. Roller installations for both the right and left wheels are installed in the frame on supports - weight sensors and are kept from displacement by two retainers.

Weight sensors are designed to convert the mass of the diagnosed axis into an electrical signal. The gear motor drives the support rollers on which the car drives. During braking, reactive moments from the reduction motor are transmitted to the sensors of braking forces that generate electrical signals proportional to the braking forces of the right and left wheels.

Between each pair of support rollers there are tracking rollers, to which there are connected sensors of car presence and slippage sensors, intended for control of speed of wheels rotation and determination of moment of beginning of wheels slippage of diagnosed axle, relative to support rollers, as well as for determination of car presence on support rollers of roller installation.

The sensor controller is designed to convert and amplify sensor signals, convert analog sensor signals into digital code and transmit their values ​ ​ to a personal computer at its request.

Power panel is intended for arrangement of elements of power electric automation. It consists of:

- disconnector;

-automatic differential switch with protective shutdown device;

- phase circuit breaker;

- set of connectors for connection to:

a) force sensor;

b) to the traffic light;

c) to roller installation;

d) to the switch;

e) to control buttons;

f) to the HAS adapter;

g) PC grounding terminal;

h) combined unit.

The electrical equipment of the bench is connected to the network by a magnetic starter. When the "START" button is pressed, the starter starts, self-locks and connects the power cabinet electrical equipment with its main contacts to the network.

The actuation of the reduction motor is controlled by a brake stand adapter, which is connected to the personal computer port.

To protect against switching interference, RCchains are used, which are connected in parallel to the starter coils (included in the combined unit).

When "STOP" button is pressed, the starter is switched off.

Electrical equipment of the power panel is disconnected from the network.

Protection against overloads and short circuits in the supply circuits of the motor-reducers is carried out by a thermal relay.

The power panel is located on the middle shelf of the control rack behind the printer.

The bench includes a force sensor.

Force sensor is designed to measure force on controls of working and parking braking systems. It consists of a housing, an upper plate, a lower plate, a button, a protective membrane, a sensor cable with a connector. Belt with lock is attached to lower plate. Tensoresistor bridge is arranged inside housing.

Before checking the braking system of the car, the sensor is fixed using a belt on the brake pedal of the car. The sensor connector is connected to the mating part located on the power cabinet.

4.4 Bench operation

The condition of the braking system of the car is checked by two operators. The driver operator is located in the driver's place of the car being checked. The PC operator supervises the actions of the driver operator. Commands to the driver operator are displayed on the monitor screen, and are also duplicated on the traffic light or information board. The stand makes it possible to measure the complete set of parameters of the braking system of the car by sequentially moving all axes of the car to the roller installations of the stand and measuring all parameters of each axis to be diagnosed in accordance with the instructions of the working program and instructions of the PC operator. Braking forces are measured on the wheels surface and counted in kilonyutons (kN).

The principle of operation of the bench consists in forced rotation of the wheels of the diagnosed axle of the car from the support rollers and measurement of forces arising on the surface of the support rollers during braking. After the diagnosed axle enters the roller units and when the left and right vehicle presence sensors operate, the axle is weighed with the help of weight sensors.

Then support rollers of roller units are rotated. Rotation occurs at a given speed from the geared motor. Reactive moments arising during braking are transmitted to sensors that generate electric signals proportional to braking forces on each pair of rollers. The rotation of the car wheels is transmitted to the tracking rollers, which are pressed to the wheels of the diagnosed axle. The speed of rotation of the tracking rollers is controlled by slip sensors. The moment of start of action on the brake pedal is fixed by a button located on the force sensor, which is also designed to determine the force on the brake pedal.

The signals of all sensors are transmitted to the sensor controller located on the left roller unit. Sensor signals are amplified to the required value by precision amplifiers, converted into digital code by analog-to-digital converter and supplied to microprocessor, which preprocesses incoming information. Upon request from the personal computer, the microprocessor transmits complete information on the status of the brake bench sensors.

Communication of the personal computer with the sensor controller is carried out by an № adapter connected to the system unit of the personal computer. The USB adapter also controls the operation of the gear motor and traffic light. Devices are installed on the USB adapter, which perform galvanic isolation through the control lines of the traffic light and gear motors, as well as through communication lines with the sensor controller.

The personal computer controls the operation of the traffic light and information annunciator, which display the PC operator's commands to the driver.

In the power cabinet there are elements of power automation that implement the operating algorithm of the bench. Signals of motor-reduction gear actuation control are transmitted to transistor current switches, in collector circuits of which electromagnetic relays are connected, which control magnetic starters of motor-reduction gear .

Traffic light switching control signals are also transmitted to transistor current switches, in collector circuits of which electromagnetic relays are connected, which control switching on of traffic light lamps.

4.5 Technical characteristics of STM - 15000U braking bench

- initial braking speed simulated on the bench, km/h 2 ± 0.1

- range of brake force measurement on each wheel of the axle to be checked, kN:

a) STM15000U 0 - 40

b) STM15000U.01 0 - 30

- limit of permissible reduced error,% ± 3

-the measurement range of the force generated on the organ

- brake system control, N 0-1000

- limit of permissible reduced error,% ± 5

-axial mass measurement range, kg 0-15000

- limit of permissible reduced error,% ± 3

- range of brake system actuation time measurement, sec 0-1.5

- parameters of four-wire three-phase power supply network with permissible

deviations:

a) voltage, V, 380 + 10% -15%

b) frequency, Hz 50 + 1

-powered power, max., kV⋅A 16.0

- size dimensions, not more than, mm:

a) roller unit module 2010x810x415

b) control rack 650 x 1200 x 680

c) traffic light 70 x 200 x 200

-mass, maximum, kg:

a) roller unit module 650

b) control rack 50

c) traffic light 5

- vehicle gauge, mm from 900 to 3100

- operating mode setting time, min, not more than 15

- stand continuous operation time, h, not less than 8

- average service life of the stand, at least , 8 years

- operating range of temperatures, °C - 30÷+50

4.7 Maintenance and repair of brake bench

4.7.1 General Instructions

Maintenance of the stand is divided into daily (once per shift) and periodic.

Daily maintenance of the stand is performed during its operation. Periodic maintenance includes preventive work and maintenance of individual bench units:

- annually before periodic verification;

- after installation of the bench;

- after repair of the bench;

- after adjustment works;

- after long interruptions in operation.

If the relevant conditions are met during storage and transportation of the bench, maintenance is not carried out.

Daily maintenance of the stand is carried out by the stand operators.

Personnel who have studied the technical documentation and have a safety qualification group not lower than the third are allowed to perform periodic maintenance and preventive work.

4.7.2 Daily Maintenance

The bench shall be kept clean during operation.

Before starting operation, check the attachment of controls, reliability of connectors connection.

4.7.3 Preventive work

Preventive work is carried out during the annual inspection of the technical condition, at the same time the condition of paint and varnish, galvanic coatings, attachment of parts and assembly units, locking of fastening joints, reliability of packs and contact joints, absence of chips and cracks on parts made of insulating material are visually checked.

Places subjected to corrosion should be cleaned and covered with enamel (lacquer) and grease (if necessary). During visual inspection, it is recommended to check the completeness of the bench and the condition of the accessories .

Accumulation of dust inside the power cabinet and dirt on the surface of moving mechanical parts of the roller unit can cause overheating and damage to the elements. Dust removal shall be performed by dry air blowing. Outside, dust and dirt are removed with a soft rag and brush. The surfaces of the keyboard and monitor should be cleaned with a tampon wetted with 40% ethyl alcohol solution. The contaminated surface of the structural elements of the bench can be cleaned with a soft cloth moistened with water with synthetic washing powder dissolved in it.

When removing fat stains and dust, it is forbidden to use organic solvents, acetone, potent acids and bases that damage the integrity of the bench protective coatings.

Economic section

In this section of the diploma project, it is necessary to carry out an economic justification for the creation of a diagnostic site at the workshop. This service is in demand in the city, so the creation of such a site will bring profit, due to which the capital investments necessary to create this site will pay off. It is necessary to evaluate the profitability of the proposed design solution using indicators of economic efficiency, widely used in world practice, namely: integral economic effect, internal rate of profitability, period of return on capital investments. To do this, you must first calculate the capital investments necessary to create a diagnostic site, the current costs arising from the provision of diagnostic services, as well as the amount of profit that the enterprise will receive for these services.

8.1. Calculation of capital investments

At the first stage, it is necessary to calculate the cost of additional capital investments that will be needed to implement the proposed solution - the creation of a diagnostic site at the workshop. We will calculate additional capital investments in the following sequence.

Conclusion

In the diploma project, the task was set for the design of the STO.

The introduction justified the need to design a workshop in connection with the constant growth of personal road transport.

In the technological part of the diploma project, in the section "Technological calculation of the STO," the designed object was calculated and the diagnostic area (D) was developed in detail, and equipment was selected. In accordance with the calculations made, a master plan, layout of the production building, and the diagnostic area were developed.

In the technological part, the front brake mechanism of the VAZ-2109 car was chosen for the development of maintenance technology and repair technology. The process of disassembly and adjustment of the brake mechanism was considered. During the development of the repair technology, disassembly, assembly processes were considered and a maintenance and maintenance routing was compiled based on the results. For the selected part, a defect analysis was carried out and a defect map was compiled, a repair drawing and technological adjustments for mechanical processing were developed.

In the design part, the design of the STM-15000U brake bench was carried out.

In the section "Labor Protection and Environmental Protection," an analysis of harmful production factors was made, protection measures were developed, earthing was calculated at the diagnostic site, the pollution released by the STO during operation was analyzed, and environmental protection measures were developed.

In the economic part, the economic justification for the creation of a diagnostic site at the STO is considered.