Rear Axle Gearbox Repair Site Design - Diploma

Contents

INTRODUCTION

1. LITERATURE REVIEW

2. ANALYSIS OF PRODUCTION ACTIVITIES

COLLECTIVE FARM "PEACE" DEBYOSSKY DISTRICT

RATIONALE FOR THE PROJECT THEME

2.1 _ General characteristics of the farm

2.2 _ Organization of machinery repair

2.3 _ Technical and economic indicators of repair work

workshop

2.4 _ Justification of the project theme

3. ORGANIZATIONAL AND DESIGN DEVELOPMENT

ORGANIZATION OF REPAIR OF MACHINES

ON THE COLLECTIVE FARM "MIR"

3.1 _ Justification of the program, its structure and scope of work

3.2 _ Distribution of labor intensity by sections. Calculation

number of workers, equipment and areas

3.3 _ Site Layout, Equipment Layout

4. SOWING PROCESS

4.1 _ Analysis of existing processes

4.2 _ Description of the process to be developed

3.2.1 _ Determination of time standards for running-in operations and

adjusting seeders

4.3 _ Preparation of process documentation

5. DESIGN DEVELOPMENT. STAND FOR

SEEDLOCKS RUN-IN AFTER REPAIR

5.1 _ Justification of feasibility and necessity

performing accepted design development

5.2 _ Analysis of existing similar structures

5.3 _ Description of the designed structure and its

features

5.4 _ Kinematic calculation and calculation of main parts

designs

5.4.1 _ Determination of required electric motor power

5.4.2 _ Electric motor selection

5.4.3 _ Gear ratio calculation

5.4.4 _ Calculation of chain transmission

5.4.5 _ Belt transmission check

5.4.6 _ Calculation of shafts

5.4.7 _ Calculation of bearings for shafts

5.4.8 _ Weld Calculation

5.4.9 _ Calculation of dimension chain

5.5 _ Techno-economic evaluation of designed

designs

6. SAFETY OF LIFE AT THE

PRODUCTION

6.1 _ Organization of work to create healthy and

safe working conditions

6.2 _ Analysis of working conditions, occupational injuries

6.2.1 _ Measures to improve the state of labor protection

6.3 _ Operating Safety Instruction

stand for sowing and adjustment

6.3.1 _ General Safety Requirements

6.3.2 _ Occupational Safety Requirements Before Commencement of Work

6.3.3 _ Occupational safety requirements during operation

6.3.4 _ Work safety requirements upon its completion

6.4 _ Fire Safety

7. NATURE CONSERVATION

8. ECONOMIC EVALUATION OF THE PROJECT

CONCLUSION

Literature

Project Description

The diploma project was developed on the topic: A project to improve the organization of machine repair at the experimental station of the UGNIISKh of the village of Pervomaisky, Zavyalovsky district, Udmurt Republic .

The explanatory note is made on pages, it presents diagrams, tables, specification sheets and attachment sheets.

The graphic part is made on 9 sheets of A1 format. 25 sources of literature were used.

List of keywords: activity, economy, analysis, labor intensity, repair, maintenance, cost, profitability, efficiency, productivity, restoration, fixture, design.

The project provides an assessment of the economic activity of the economy for the period from 2000. to 2002 and it was concluded that the au pair should pay attention to the development of the repair and maintenance base. In this regard, a theoretically justified project of a central repair workshop is proposed. The proposed design development is simple to manufacture and requires small material costs, which makes it possible to introduce development into production .

The diploma project was developed for the implementation of the village of Pervomaisky in the Zavyalovsky district of the Udmurt Republic in the UGNIISH State University.

Introduction

The country's agriculture has a developed system of repair and maintenance enterprises and factories, central repair shops and machine maintenance points. But the availability of farms with central repair shops and maintenance points in our time is only slightly more than 60%. And even the existing workshops do not meet the requirements for high-quality repairs and maintenance.

One of these reasons is the lack of a material base and the low equipment of the CMM with modern qualified engineering personnel and equipment.

Solving the problems of timely and high-quality repair becomes more important, the more agriculture is equipped with energy-saturated equipment. All this complicates the solution of technical problems during repair and increases the responsibility of the repair service of the economy for technical readiness and reliability of machines. Despite the fact that a significant amount of complex types of repairs and technical services are carried out at repair enterprises, most (75% or more) of the work is carried out in the repair and maintenance base of the farm, including also types of repairs, such as routine repairs and seasonal types of technical services.

For timely and high-quality repair works, the farm must be equipped with modern equipment of the repair shop with a sufficient productive area.

Currently, the repair service is not established at the UGNIISH due to the lack of a good repair workshop, which negatively affects the technical readiness of the machines.

Therefore, the purpose of the diploma project is :

Selection of repair shop according to standard design for "UGNIISH" MNU on the basis of labor intensity by types of maintenance and repair of machines.

Selection of necessary equipment for maintenance and maintenance.

Distribution of works by CMM sites based on calculation of equipment and areas.

Calculation of the number of maintenance personnel and development of machinery repair technology.

This project also provides for a project for the introduction of a galvanic site into the workshop, addresses issues of safety of life at work, environmental protection.

Analysis of the production activities of Mr. "ugniish" of the village of Pervomaisky Zavyalovsky district

2.1 General characteristics of the farm

The Izhevskoye pilot production farm was organized on the basis of order of the Ministry of Agriculture of the RSFSR No. 333 of November 9, 1961, is a state agricultural enterprise of the Russian Agricultural Academy of Sciences. December 29, 1997 renamed the GNU "UGNIISH" of the village of Pervomaisky, Zavyalovsky district.

The central farm of the GNU "UGNIISH" is located in the eastern part of the Zavyalovsky district, 12 km from the city of Izhevsk.

The IzhevskVotkinsk railway crosses the territory of the farm from west to east, in the eastern part the access road to the Bummash plant approaches.

The distance from the center of the estate to the district center is 12 km, to the capital of Udmurtia, Izhevska12km, to the motorway 5km. To the railway station Izhevsk-1-20km.

Communication with the city of Izhevsky and the district center - the village of Zavyalovo is carried out on roads with asphalt pavement.

Land use of GNU "UGNIISH" consists of one compact array. Its length from west to east is 7 km; from south to north 7.5 km. The central estate of the farm - the village of Pervomaisky - with the presence of residential, cultural, domestic and industrial premises.

The experimental economy uses the land allotted to it for indefinite, free use and state property fixed in operational management on the basis of economic management to ensure experimental work and carry out production and economic activities in accordance with the program of the research institution.

In its activities, GNU "UGNIISH" is guided by legislative acts of the Russian Federation, orders, instructions of the Russian Agricultural Academy, as well as the charter of the economy, which contains the following sections:

- general provisions;

- tasks and functions of experimental economy;

- Production and economic activities;

- Management of the economy;

- Reorganization and liquidation of the economy.

GNU "UGNIISH" multi-industry elite seed farming with developed breeding dairy and meat direction.

It is the main distributor of elite seed material in the economy of the republic. The entire number of cattle and pigs is located on the central estate. Livestock and warehouse buildings with complete mechanization and in good condition.

The economic conditions for the development of the enterprise's economic activity are influenced by the provision of land, basic means of production, labor resources, as well as the historical experience of agricultural production.

2.1.1 Climatic conditions

GNU "UGNIISH" like the entire Udmurt Republic, is located in a temperate continental climate with long cold snowy winters and short warm summers. The average annual air temperature is + 2 C. The frost-free period is 125 days. The average annual rainfall is 400500 mm. The dominant winds are the south and south-west winds. The average wind speed is 3-4 meters per second. The soil freezes to 6590 cm, and in low snow areas - up to 1 meter. On the territory of the experimental farm, turf-podzolic, gray forest landowned, turf-carbonate soils. Climatic conditions favor the growth of winter, early spring, potatoes and rapeseed.

2.4 Justification of the project theme

The transition to new forms of management requires a reasonable approach to the values ​ ​ available, and therefore to ways to maintain technology in high efficiency. To do this, the farm must have a workshop equipped with progressive technological equipment, areas for the restoration of worn out parts, where qualified workers must work. At this stage, when the farm is trying to carry out all complex repairs on its own, areas will be required whose equipment would meet all the requirements of restoration work. It is also necessary to prepare workers for work in these areas. In order to solve these and a number of other problems related to the organization of repair of the machine and tractor fleet in the GNU "UGNIISH" it is necessary:

develop a schedule for the maintenance and repair of machines;

design a new CMM building, since the existing workshop does not allow you to carry out the entire volume of maintenance and repair of machines, due to insufficient production space;

equip the designed workshop with modern equipment, select qualified personnel and in the future organize work on economic calculation;

design a galvanic area for restoring bearing landing sockets in gearbox housings.

In this regard, the topic of the diploma project being developed is of current importance.

Process for updating bearing seat sockets in gearbox housings

4.1 Analysis of existing technological processes

Restore parts by spraying. This process, in which the metal (most often in the form of a wire) is melted by an electric arc and then applied by a jet of compressed air to the surface of the restored part. Electrode wires are fed by two pairs of rollers isolated from each other, contact, leaving brass tips. The latter are energized, which leads to the emergence of an electric arc in which the wire melts.

Restoration of parts by galvanic coating. Bathroom method: Parts are placed in electrolyte, located in any container (in stationary baths, bells, bell and drum baths).

Wetless method: When restoring body and other large parts, the area of ​ ​ enlarged surfaces is small compared to the entire area. Therefore, they are increased in harmless ways: flowing, jet, electric contact. In the flow method, the electrolyte is pumped by a pump at a certain speed through the space between the surface to be covered and the anode. The highest rate of metal deposition is achieved at electrolyte flow rate more than 1 m/s, which creates turbulent flow mode. The current density can be increased by 5... 10 times (during ironing - up to 200... 300 A/dm or more). In jet method electrolyte is supplied by jets into interelectrode space through nozzle holes. The latter simultaneously serves as an anode and a local bath. To obtain a uniform coating, the part rotates with a frequency of up to 20 minutes.

Restore parts with nozzles and replace worn part. The method of recovery with nozzles allows you to restore the surface of the part to a nominal size by rigidly connecting it with an additional manufactured (repair) part that provides compensation for wear of the main part.

Reduction by application of epoxy composition. The essence of the method consists in application of a layer of epoxy composition on the worn-out surface, which is then formed under the nominal size by drawing a steel polished mandrel.

4.2 Description of the process to be developed

In this project, a technological process is being developed to restore the landing sockets of bearings in the gearbox housings in an unwanted manner. Prior to restoration of bearing seat sockets in gearbox housings, the following operations are carried out in an unwanted manner:

washing and cleaning the part of contaminants and oils;

cleaning the surfaces of the nests with sandpaper;

degreasing them, for which purpose calcium carbide is diluted with water to a porridge-like state and rubbed with a brush;

rinsing with running water.

4.3 Preparation of process documentation

Technological processes are designed in relation to the CMM or machine yard in accordance with the requirements of the ESKD and AETD standards, as well as taking into account additions, explanations set out in the technical guidance materials and industry standards. For restoration of bearing seat sockets in gearbox housings, the following documentation is developed in an unwanted manner:

title sheet (T.L.) of PMDP sheet;

sketch map (K.E.) of the PMDP sheet;

operating card (O.K.) of the PMDP sheet.

Process documentation is executed on A1 sheet.

Design development.

5.1 Justification of feasibility and necessity

performing accepted design development

In connection with the fact that the repair and maintenance base of agricultural enterprises needs repair equipment, the diploma project is considering the creation of a site for the restoration of landing sockets of variable transmission bearings in a wanton way.

Wear of landing sockets for bearings in gearbox housings causes significant downtime of tractors, cars, combines and other equipment.

Studies have been carried out in farms, 68 boxes, in which the wear of bearing sockets is unequal and amounts to 0.1... 0.5 mm. This causes the bearing rings to scroll, which intensifies the wear process, leads to misalignment of the shafts and jamming of the gears.

The micrometric area of landing nests showed that at 44% of cases their wear of 0,1...0,2 mm, 22 - 0,2...0,3, 15 - 0,3...0,5, 12 - 0,5...0,9, 7% - 1...1.5 mm.

Since most of the hulls have significant wear (0.1... 0.5 mm) of landing nests, it is advisable to use an extravagant galvanic method to restore them .

This method does not have such drawbacks as electroplating in a bath (complexity and insufficient reliability of the technological process, leading to a decrease in labor productivity and unstable results in the adhesion of coatings to parts; low performance; coating quality does not always meet the requirements).

With the in-line and jet method, due to a decrease in the depletion of the cathode layer of the electrolyte, conditions are created that allow to 2... 3 times increase the productivity of the process. These methods provide higher coating quality and better uniformity.

5.2 _ Analysis of existing similar structures

There are several wetless ways to restore parts: flowing, jet, electric contact, local deposition.

In the flow method, the electrolyte is pumped by a pump at a certain speed through the space between the surface to be covered and the anode. The highest rate of metal deposition is achieved at electrolyte flow rate more than 1 m/s, which creates turbulent flow mode. The current density can be increased by 5... 10 times compared to the bathroom methods (during ironing - up to 200... 300 A/dm or more).

In jet method electrolyte is supplied by jets into interelectrode space through nozzle holes. The latter simultaneously serves as an anode and a local bath. To obtain a uniform coating, the part rotates with a frequency of up to 20 minutes. This can be achieved with a fixed part, if the holes in the anode through which the electrolyte enters are made at an angle of 30... 40 ° to the radial direction.

Local deposition with a stationary electrolyte is also used in repair production. Hole is sealed from below, electrolyte is poured into it, anode is installed and connected to current source. The opening itself serves as a bath. This method is often used to restore bearing fits in housing parts.

The essence of the electrocontact method (electro-saturation) lies in the fact that electrodeposition of the metal occurs when direct current passes through a small bath. The latter is formed in the contact zone of the coated part with the anode wrapped with adsorbing, electrolyte-impregnated material. The part and the anode move relative to each other (the part rotates when the anode is stationary, or vice versa), i.e., friction of the anode on the part occurs.

5.3 _ Description of the designed structure and its features

The installation includes a body (container) of the main bath for containing a larger volume of electrolyte, a chamber for receiving electrolyte from the main bath and supplying it to the openings of the gearbox of the body. The electrolyte is supplied by the pump through the pipeline and fills the recoverable holes of the part and partially the cell capacity, and the excess electrolyte flows through the holes into the filtration chamber and returns to the bath.

The automatic supply of electrolyte to the cell zone is controlled by the electrical circuit according to the time set by the operator. The solution in the cell can be replaced after 20. 40, 60, 80, 100 min. The following is the composition of the electrolyte of high corrosion resistance and the mode:

FeCl· 4HO, g/l................................................................................................................................................................. 250

HCl, g/l............................................................................................................. 1

Temperature, ° С............................................................................................................................. 60 - 70

Current density, A/dm............................................................. 10 – 30

From this electrolyte, iron can be deposited - steel coatings with a microhardness of 3000-9000 MPa, and at a current density of 50-60 A/dm - 12000 - 14000 MPa.

The results of studies show that at a constant current at a density of 10-70 A/dm from an electrolyte with a volume of 100-300 liters at a temperature of 30, 60, 80, 90 ° C, coatings with a microhardness of 1500-6500 MPa can be deposited. With a small electrolyte volume, a high-density current cannot be used. For volumes of 5-10 liters, 5-10 A/dm is enough. It is desirable to deposit galvanic coatings on an asymmetric alternating current with a coefficient β = 5... 10 from a small volume of electrolyte. On an asymmetric current at a temperature of 30 ° C and a current density of 10-40 A/dm, coatings with a microhardness of 1500-3500 MPa can be deposited.

When restoring body parts and the "sleeve" type, periodic replacement of a small volume of electrolyte or constant provision of electrolyte flow at a rate of 20-25 l/h through the restored surface of the part is of great importance. The proposed design of the plant allows you to automate the replacement of electrolyte in the electrolysis cell using a pump.

5.4 _ Kinematic calculation and calculation of main plant parts

5.4.1 _ Pump selection

Since we have an aggressive medium (the pump works in the electrolyte), we need to take a corrosion-resistant pump. The pump is selected by two values: capacity and head.

The electrolyte flow through the recoverable surface of the part will be 20 - 25 l/h [].

Then the pump supply is selected as 25 l/h. By installation, the head is 288 mm.

According to these data, we choose a pump.

5.4.3 _ Electric motor selection

When selecting an electric motor, the calculated power is taken into account.

The power of the motor selected for the drive must be at least calculated.

In the range of non-standard electric motor capacities above the design power, an electric motor with a power of P = 5.5kW with a synchronous speed nn = 750 min-1 is suitable.

At high speeds of rotation, it is difficult to realize the gear ratio. CHA132M8UZ engine with speed, taking into account slips, nc = 720 min-1.

Conclusion

An analysis of production activities in the UGNIISH State University of Zavyalovsky District shows that the organization of technology and quality of repair do not meet the requirements of modern repair, which is one of the main reasons for the high cost of repair and maintenance work.

In this project, a central repair shop was designed, equipped with the latest equipment and equipment, which in many respects gives a good result. The repair workshop has become profitable, the cost of repair has decreased, labor productivity has increased.

The developed installation allows you to restore sockets for bearings in the gearbox housing. This can be used for any box of any material.

In the section "Safety of life at work," an analysis of accidents that occurred over the past three years is made, measures are planned to improve the state of labor protection and reduce injuries.

5. Environmental protection measures are envisaged.