Reconstruction of the engine section in the conditions of LLC TN - RemService Transport

Contents

Contents

Introduction

1 Process layout

1.1 Summary of the existing situation in the enterprise

in general (date of formation, subordination, location,

works to be performed)

1.1.1 List of fleet by types and models and data on vehicle mileage and operating time of road construction machines

1.1.2 Operating conditions of motor vehicles and road construction machines

1.1.3 Rolling stock operation mode (number of working days per year, production and return procedure of cars and road construction machines)

1.1.4 Main performance indicators of the enterprise operation service

1.1.5 Company Technical Service Key Indicators

1.1.6 Methods of maintenance and maintenance management

vehicles, road construction machines, units and units

1.1.7 Power, steam, water supply options

1.2 Description of the existing situation of the reconstructed production division

1.2.1 Purpose and nomenclature of production unit works

1.2.2 List and summary of available equipment, accessories and tools, process layout of the site, organization of work on the site

1.2.3 Composition of production and auxiliary workers,

their tariff rates, safety condition

1.2.4 Deficiencies in the operation of the production division

and proposals for process improvement

and organization of work of the unit

1.3 Initial Data and Demand Calculation

1.4 Calculation of number of jobs (posts)

1.5 Calculation and selection of required equipment of the site

1.6 Area calculation

1.7 Proposed Production Organization

divisions

1.8 Designed security measures

environment

1.9 Designed safety measures and

fire-fighting equipment, industrial sanitation,

and technical aesthetics

1.10 Economic part

1.10.1 Calculation of the number of production workers

1.10.2 Calculation of cost estimates

1.10.3 Costing of Production Works

divisions

1.10.4 Cost effectiveness of project proposals

Reconstruction of the Production Unit

2 Job Instruction for Replacement of Engine Pistons D-

2.1 Characteristics of the unit (unit according to the task)

2.2 Sequence of operations with indication of equipment and

workplace

2.3 Calculation of the time norm for this type of maintenance or

process

2.4 Calculation of cost of maintenance or process

3 Construction

3.1 Rationale for development and implementation

designs

3.2 Purpose, device and operation of the structure

3.3 Calculation of the working force required for the drive

designs

3.4 Calculation for strength of basic, decisive parts

designs

3.5 Adjustment, Adjustment and Safety Instructions

designed structure

3.6 Economic efficiency of the design

3.7 Advantages of implementation of designed design

4 Conclusion

Literature

Introduction

During the operation of cars, road construction machines, their working properties are gradually deteriorated due to wear of parts, as well as corrosion and fatigue of the materials from which they are made.

Failures and faults appear in the car, which are eliminated during maintenance and repair.

Repair is a set of operations to restore malfunction or operability of parts.

The need and expediency of repairing cars is primarily due to the unequal strength of their components. Therefore, during operation, cars undergo periodic maintenance and, if necessary, ongoing repair (TR) on ATP, which is carried out by replacing individual units. This allows you to maintain cars in a technically serviceable state.

With long-term operation, cars reach a state where their repair in ATP conditions becomes technically impossible or economically unsuitable. In this case, they are sent to a centralized maintenance or overhaul (CR) to a car repair enterprise (ATM).

The current repair should ensure the guaranteed operability of the car during the mileage to the next scheduled repair, and this mileage should be at least the mileage to the next TO-2. in case of failures, an unscheduled TR is performed, in which parts and assembly units are replaced or restored in the volume determined by the technical condition of the car.

Overhaul should ensure serviceability and full (or close to complete) life of the car or unit by restoring and replacing any assembly units and parts, including basic ones. The base part is the part with which the product begins to assemble, attaching assemblies and other parts to it. In cars, the base part is a frame, in units - a body part, for example, an engine cylinder block, a gearbox crankcase.

The main source of economic efficiency of RC cars is the use of the residual resource of their parts. About 70... 75% parts of the car delivered to the CD can be reused either without repair or after a minor repair.

Parts that have completely exhausted their resource and are to be replaced constitute 25... 30% all parts. These are pistons, rings, rolling bearings, rubber products, etc. the number of parts, the wear of the working surfaces of which is within the permissible limits, which allows them to be used without repair reaches 30... 35%. The remaining parts of the car 40... 45% can be used again only after their restoration, these include most of the more complex, metal-intensive parts of the car, in particular the cylinder block, crankshaft, cylinder head, rear axle gear crankcase, etc. The cost of restoring these parts does not exceed 10... 50% the cost of their manufacture.

The cost of a car KR does not exceed 60... 70% the cost of new ones. The high efficiency of centralized repairs has led to the development of car repair production, which has always occupied a significant place in the industrial potential of our country.

The organization of car repair in our country has been constantly paid great attention. In the early years of Soviet power, the automobile fleet in our country consisted of only a few thousand cars, mainly foreign-made. To organize the production of cars in the young Soviet republic, there was neither material base, nor experience, nor trained personnel, so the development of automobile production historically determined the development of the domestic automotive industry.

Process Layout

1.1 Summary of the existing situation in the enterprise as a whole

The motor transport enterprise OOO TATNEFT - RemService Transport was established on January 1, 2008. The enterprise is structural unit of JSC TatneftRemServisTransport. ATP is located on the street. Tukhvatullina 19. It has a completed balance sheet and a settlement account with Almetyevsk Devon Credit Bank.

As of January 1, 2013, the company has 208 units of equipment.

As part of OOO TATNEFT - RemService Transport, it has 3 convoys, a repair and mechanical workshop and a garage service. Certification of maintenance and repair of vehicles at the production base has been carried out.

The company carries out work on servicing suburban oil and gas producing facilities, as well as third-party car services for their purpose.

Standards for maintenance and repair of automotive equipment have been developed. Repair and reconstruction of repair and mechanical workshops was carried out, which made it possible to carry out maintenance and maintenance in an economic way .

The company has two services responsible for the efficiency of the machine fleet:

- The Technical Service is responsible for the technical condition of the rolling stock;

- Operation services - for timeliness and quality of transportation.

1.1.2 Operating conditions of motor vehicles and road construction machines

Proceeding from a payroll of the park and the location of LLC TatneftRemServisTransport near the city of Almetyevsk, the equipment will be operated generally on roads with an asphalt concrete covering, only a part of machines, generally TsA320 units, will work at dirt roads, on the access roads which do not have a hard coating on the flat, slabokholmisty area.

Relief conditions belong to weakly alleyed up to 200 meters above sea level. Climatic conditions are moderate. In general, the operating conditions for performing calculations are equal to the third category of operating conditions. [3, Table 2.7]

1.1.3 Rolling stock operation mode

The mode of operation of the rolling stock is characterized by the number of working days per year, the duration and number of working shifts, the start and end times of the working shift, as well as the procedure for the production and return of cars.

Cars of OOO TATNEFT - RemService Transport operate on schedule with two days off falling on the schedule of 250 working days a year, beginning of 1 shift at 7, ending at 19 hours, beginning of 2 shift 19, ending at 7. The average time spent in an outfit is 11 hours. On weekends, departures are strictly by order.

Before departure the driver, the driver checks technical condition of the car for the line, takes waybills in dispatching office (previously the permit is noted in the computer), has daily medical examination and drives by the car to the checkpoint located at exit gate. The on-duty mechanic checks the technical condition of the machine and notes in the travel list the departure time, meter readings, checks the remaining fuel, after which he signs and allows the exit to the line.

When returning from the line, the car again undergoes the same inspection, the speedometer readings and the time of returning the car are recorded.

If there are faults, a maintenance and repair sheet is written out and the machine is sent to the washing area then to the repair waiting station, and serviceable machines to the storage area. Cars, tractors requiring technological maintenance, after washing are sent to the appropriate service waiting posts.

1.1.6 Methods of organization of maintenance and maintenance of vehicles, road construction machines, units and units

For ensuring operational reliability in LLC TatneftRemServisTransport it is accepted the scheduled preventive system of maintenance and repair of the rolling stock. This system provides for the mandatory performance of a permanent set of maintenance works through the established mileage regardless of its technical condition, the current repair is carried out according to demand.

TO-1 works on flow lines, TO-2 and repair are performed at universal posts, of which they are equipped with inspection ditches of narrow type. Maintenance is mainly carried out by the aggregate method, partially by the individual method.

Each type of maintenance (maintenance) includes a strictly established list (nomenclature) of works (operations) to be performed. These operations are divided into two components control and executive.

The control part of maintenance operations is mandatory, and the executive part is carried out according to demand. This significantly reduces material and labor costs in the maintenance of rolling stock.

Diagnostics are part of process maintenance and maintenance, providing initial information about the technical condition of the equipment. Diagnostics of machines is characterized by the purpose and place in the process of maintenance and repair.

Daily maintenance (EO) is carried out daily after the machine returns from the line between shift times and includes: monitoring inspection work on mechanisms and systems that ensure traffic safety, as well as the body, cockpit, lighting devices; cleaning and drying-wiping operations, as well as refuelling with fuel, oil, compressed air and cooling liquid. Car washing is carried out according to the need depending on the weather, climatic conditions and sanitary requirements, as well as on the requirements for the appearance of the car. The first maintenance (TO-1) consists in external technical inspection of the entire car and in performing control diagnostics, fastening, adjustment, lubrication, electrical and filling operations in the established volume with checking the operation of the engine, steering, brakes and other mechanisms.

In-depth diagnosis of D-2 is carried out 1-2 days before TO-2 in order to provide information about the TO-2 zone about the upcoming scope of work, and if a large amount of current repair is detected, forward the car to the current repair zone in advance. The second maintenance (TO-2) includes the performance of fixing, adjustment, lubrication and other works in the established scope, as well as the check of units, mechanisms and devices during operation. Maintenance is carried out - 2 with removal of the car for 1-2 days from operation.

1.1.7 Power, steam, water supply options

Power supply is provided from the electric grid through transformer substations (2 ktp 6/0.4 kV 250 kVA; F34 OB, A 3418). The ferry for production needs and heating of premises of LLC TatneftRemServisTransport is supplied centrally from Almetyevsk with CHPP LLC TeploEnergoservis. Water for the needs of the enterprise is received from the water supply.

1.2 Description of the existing situation of the reconstructed production division

1.2.1 Purpose and nomenclature of production unit works

The engine section repairs the engines and its components of the car and road construction machines, and mainly by replacing faulty parts. The repair process includes: washing the unit; for disassembly in accordance with the scope of repair; washing of removed parts and their defect; layout of parts after repair; assembly and running-in of the unit.

1.2.3 Composition of production and auxiliary workers, their tariff rates, safety condition

Currently, there are five car fitters on the site, four fifth categories with an hour rate of 72.5 rubles, one sixth category with an hour rate of 78.8 rubles in one first shift from 7:00 hours to 16:00 with a break for lunch from 11:00 to 12:00 hours, there are no auxiliary workers. In order to ensure the safe performance of the fitter's work, safety instructions are given, and the room is regularly cleaned on schedule. The condition of the equipment is satisfactory, for the current period there were no cases of injuries. On the sockets, switches and switches there are inscriptions indicating the voltage supplied to them. The site has a fire cabinet with inventory.

1.2.4 Deficiencies in the work of the production division and proposals for improving the technological process and organization of the work of the division

In the engine section, there is not enough one stand for disassembling the engine assembly, there are no stands for controlling crankshafts and camshafts, there is no device for straightening connecting rods, there is no test plate.

To improve the performance of the engine section, I propose to purchase and install one universal stand for disassembling and assembling engines, purchase two devices for checking and editing connecting rods, three stands for controlling crankshafts and distribution shafts and one locksmith, create an identical work place for each car fitter, place equipment on the sections in accordance with the technological process, provide each work station with technological documentation.

1.8 Designed environmental protection measures

The issue of environmental protection and the rational use of natural resources is one of the most pressing among the global problems of mankind.

Transport enterprises, especially the cars they operate, contribute to environmental pollution. Road transport in our country accounts for about 13% of the total emissions of pollutants into the atmosphere, and in some cities up to 60%. The exhaust gases of cars include harmful substances such as carbon monoxide, nitrogen oxides, various hydrocarbons, sulphur dioxide, lead compounds, carbon black. Only one truck emits up to 8 tons of carbon monoxide into the atmosphere in one year of operation, and when a car malfunctions, the amount of emissions increases significantly.

Used wiping materials should be collected in metal urns and removed daily to specially installed places where they will be centrally disposed of. Around the enterprise there should be a sanitary zone at least 50 m wide. This zone should be landscaped and landscaped. Green spaces enrich the air with oxygen, absorb carbon dioxide, noise, clean the air from dust and regulate microclimate. In order to maintain the purity of the atmospheric air within the limits of the standards for ATP, it is necessary to provide for the preliminary purification of ventilation emissions with their subsequent dispersion in the atmosphere.

Characteristics of the unit (unit according to the task)

The D245 diesel engine is a 4-stroke piston four-cylinder internal combustion engine with an in-line vertical arrangement of cylinders with a capacity of 108.8 hp, direct injection of diesel fuel and compression ignition, a compression ratio of 15.1. Engine weight 473 kg, displacement 4.75l. piston stroke 125 mm.

Pistons are made of aluminum alloy. Combustion chamber is located in piston bottom. Pistons by outer diameter of skirt are sorted into three dimension groups (B, C, M). The group marking is applied on the piston bottom. When installed on the engine, the sleeves and pistons must be of the same size group. The difference in mass of pistons of one type should not exceed 10 g, and the difference in connecting rods assembled with pistons should not exceed 30 g.

Sequence of operations with indication of equipment and workplace

Remove the mounted equipment from the diesel engine installed on the engine disassembly bench with a tray down using the head wrench and screwdriver.

Remove the cover from the cylinder head, 17 mm head, wrench.

Remove the axle struts assembled with the rocker axle and the rockers themselves and remove the rods from the cylinder block, head by 17 mm, wrench .

Remove cylinder head and gasket, 19 mm head, wrench.

Turn the diesel engine 90 ° and remove the oil crankcase and connecting rod covers with inserts; to take out from cylinders connecting rods assembled with pistons by means of a mandrel of I806.01.200, to vypressovat piston fingers by means of screw adaptation.

After disassembly, all diesel parts must be washed in the Typhoon washer and blown with air.

Install compression and oil removal rings on pistons.

Install piston pins and locking rings with the help of a stand for pressing of piston pins and thin teeth.

For installation of shatunnoporshnevy group in a sleeve of the block it is necessary to use mandrels of I806.01.200 and I804.01.200. Tightening torque of connecting rod bolts nuts shall be within the limits of 180... 200 Nm. Lubricate the cylinder liner mirror, pistons with rings, connecting rod journals and connecting rod neck inserts with motor oil.

Wear an oil crankcase. Pre-install seals. Turn the diesel 90 ° tray down.

A head gasket is placed on the cylinder block, lubricated on both sides with graphite paste .

Install the cylinder head and tighten the bolts. Tightening torque - 190... 210 Nm.

Install push rods in holes of cylinder heads, install axle struts assembled with rocker axle and rockers. Install the valve mechanism. Spheres of adjusting screws must be aligned with rod tips. Nuts of studs and bolts of valve mechanism attachment must be tightened till failure. Adjust the valve mechanism clearance using a set of probes and install hinged equipment.

Design

3.1 Rationale for design development and implementation

In all cases, it is necessary to strictly and unconditionally perform the technological process. Strict execution of the process is one of the elements characterizing a high production culture. When developing disassembly processes, it is necessary to strive for the most complete and economically justified mechanization of work, worldwide cost reduction and facilitation of manual labor.

The engine section in terms of the volume of dismantling and assembly operations is the most labor-intensive, therefore, to facilitate work, simplify operations, it is necessary to use as many various devices as possible.

The primary shaft bearing of the gearbox is installed in the crankshaft with the greatest tension and therefore a certain force must be applied to remove it. In order to reduce the labor input for engine repair, it is proposed to introduce a bearing extractor of the gearbox primary shaft.

3.2 Purpose, device and operation of the structure

Bearing extractor is used to remove bearings of gearbox primary shafts. Extractor consists of power screw, collet, wrench and wrench.

The principle of the design is not complicated: we clamp the collet and insert it into the bearing hole, expand the collet and cling the collets to the inner bearing race, put a wrench on the collet and screw in the power screw. Smoothly rotate the power screw, the screw rests on the crankshaft and displaces the collet together with the bearing. Key is held from rotation of collet .

3.5 Instructions for adjustment, adjustment and safety of works of designed structure

As mentioned in the description of the construction device, the device does not require special adjustment and adjustment. The accessory must be stored in a dry place, the thread must be lubricated with a thin layer of grease. Use of the design is safe.

3.7 Advantages of implementation of designed design

The introduction of a extractor to remove the bearing of the primary shaft of the gearbox facilitates the work of the worker during disassembly, increases ease of operation, increases the safety of parts during disassembly, and also increases the culture of production .

Conclusion

This diploma project was developed on the topic "Reconstruction of the engine site in the conditions of LLC TN - RemService Transport."

The section "Technological Layout" describes LLC "TN - RemService Transport" as a whole, as well as the engine section. Shortcomings in the work of the site were identified, measures to improve work were outlined. You have calculated the production program and defined the scope of work of the engine section.

The set of measures on safety and environmental protection is presented. Heating, lighting and ventilation of the site have been calculated. Operating costs, investments for the reconstruction of the site were calculated, the economic effect was determined - 291899.76 rubles. and the payback period - 0.30 rubles..

In the section "Job Instruction" the technological process was developed to replace the pistons of the D245 engine, a plan of technological operations was drawn up. The time standards have been calculated and the cost of the process has been determined - 912.92rub.

The section "Design" describes the purpose of the device and the action of the extractor to remove the bearing of the primary shaft of the gearbox, the cost of manufacturing the accessory was calculated. Capital investments for the manufacture of the structure are 531.69 rubles.

Payback period 0.6 years.

This diploma project can be used as a recommended material for the reconstruction of the engine section in LLC TN - RemService Transport.