Scraper MOAZ-60148 - drawings

Contents

INTRODUCTION

1 Process Part

1.1 Types of process diagrams of work execution by fastener

1.2 Selection of process diagram of works execution by fastener

2 Special part

2.1 Overview of the Scraper

2.1.1 Purpose, classification, scope

2.1.2 Scraper Arrangement

2.1.3 Description of the working process of the fastener

2.2 General calculation of the scraper

2.2.1 Initial data for calculation

2.2.2 Calculation of soil resistance forces to cutting and digging according to the method of N. G. Dombrovsky

2.2.3 Determination of forces of resistance to cutting of soil by method of Yu. A. Vetrov

2.3 Traction calculation of the scraper

2.4 Static calculation of the scraper

2.5 Scheduled warning system for maintenance and repair of fasteners

2.5.1 Calculation of annual production program for repair and maintenance of scrapers

2.5.2 Choice of maintenance and repair organization

2.5.3 Determination of the valid working time fund

2.5.4 Calculation of number and nomenclature of machines and workers

2.6 Design of MDF mechanization base

2.6.1 Development of the enterprise master plan

2.6.2 Calculation of production areas and warehouses

2.6.3 Calculation of the number of mobile workshops

2.7 Storage of machines, installation, removal

3 Operation and repair of scrapers

3.1 Acceptance of scraper and its commissioning

3.2 Technical diagnostics of the stapler

3.3 Lubrication and filling of fasteners

3.3.1 Selection of lubricants

3.3.2 Development of fastener lubrication map

3.3.3 Fuel and lubricant economy measures

3.3.4 Oil regeneration

3.4 Development of stand for shaft surfacing

3.5 Development of Job Instruction for Hydraulic Cylinder Rod Repair

4 Development of part manufacturing process

4.1 Part Purpose and Design

4.2 Part Constructability Analysis

4.3 Definition of production type

4.4 Selection of workpiece

4.5 Development of route process

5 Life Safety

5.1 Legislative and regulatory acts on labor protection

5.2 Organization of occupational safety service at the enterprise

5.3 Supervision and supervision of compliance with occupational safety legislation

5.4 Analysis of working conditions at workplaces

5.5 Electrical Safety

5.6 Fire Safety

5.7 Measures to protect workers from hazardous and harmful industrial factors

5.7.1 Protection against production noise and vibration

5.8 Calculation of grounding device

6 Economic part

6.1 Description of the activity

6.2 Product Description

6.3 Production Plan

6.4 Distribution of OPF and preparation of a consolidated labor plan

6.5 Calculation of expenses for maintenance of equipment, workshop and plant-wide expenses

6.6 Calculation of costs for spare parts and basic materials

6.7 Calculation of Cost, Production Cost Estimate, Sales Plan and Profit Distribution

CONCLUSION

LIST OF SOURCES USED

APPLICATIONS

Introduction

The development of the road network, ensuring the increasing volume of construction of new and the maintenance of existing transport highways is associated with the renewal and maintenance of the fleet of road construction vehicles.

During the operation of the fastener, the reliability inherent in it during design and production is reduced due to wear of parts, corrosion, fatigue and aging of the material and other harmful processes. These processes cause various faults and defects, the elimination of which becomes necessary to keep the machine in working condition. This creates an objective need for maintenance and repair of the stapler.

Repair is an integral part of maintenance, carried out during operation to ensure the serviceability of the scraper. The amount of maintenance (MT) has a decisive effect on the trouble-free operation of the machines, as well as on the volume of repair work, the duration of their idle state, the consumption of spare parts and operational materials.

2.7 Storage of machines, installation, removal

Scrapers are placed on interschange (up to 10 days), short-term (from 10 days to 2 months) and long-term (more than 2 months) storage. They can be stored indoors or under a canopy. It is also allowed to store them on open sites during preservation, sealing and removal of electrical equipment for storage. Mechanization facilities shall be provided in storage areas.

During long-term storage, nozzles, accumulators, headlights, lamps, generators are removed, marked from which scraper are removed, and stored indoors. Wooden plugs are inserted into nozzle sockets. Engine bonnets are closed and sealed. Once a month, the stored machine is inspected. Note here that engine crankshaft is turned to update anticorrosive lubricant.

In the rooms under the canopy, staplers are placed in rows with a distance between rows of at least 1 m and between staplers of at least 0.7 m.

During the storage period, the condition of the supports and liners under the fastener, its completeness, tyre pressure, the state of tightness of the holes, anti-corrosion and protective coatings are checked, the battery is recharged.

When removed from storage, the scraper is removed from the liners and supports, restored and depressurized, previously removed electrical equipment is installed, adjusted and checked in operation.

In case of short-term and interchange storage, it is allowed only to turn off the batteries. They are removed from cars only at low temperatures.

3.2 Technical diagnostics of the stapler

Before maintenance and repair of the scraper, the actual technical condition of its systems and mechanisms is established by means of their technical diagnostics. It is carried out sequentially in two ways: first visually, during external inspection and listening to mechanisms, and then using special diagnostic devices that give an accurate picture of the technical state of the mechanisms. Tools for diagnosing machines are very diverse and are grouped into a number of stationary portable and mobile complexes, based on dozens of devices. For example, the stationary complex KI5308A, designed for diagnostics during maintenance and after repair of the machine, contains 40 diagnostic devices and devices; portable complex KI13901F, used for diagnostics at TO-1 and TO2, contains 20 devices and devices, and mobile complexes KI4270A and KI13905 based on UAZ452 and UAZ451 vehicles used in maintenance, contains 35... 40 devices and devices.

3.3.4 Oil regeneration

Oil regeneration is an economically profitable branch of the national economy. With the correct organization of the process, the cost of restored oils is 4070% lower than the cost of fresh oils with almost the same quality.

Regeneration of oil oils is carried out either by continuous cleaning of oil oils during operation in circulation systems of industrial equipment and engines using filtered devices and centrifuges, or by restoration of spent oils drained from various equipment units at oil recovery plants, as a rule, in stationary conditions (special oil recovery stations, workshops, plants).

Continuous oil cleaning directly on operating equipment and in engines is the most rational form of regeneration, giving the maximum technical and economic effect. This method increases the service life of oils, accordingly reduces its consumption, as well as increases the durability of mechanisms and equipment. The latter is no less important than the problem of oil saving. So, the wear of the main engine parts in the case of using fine oil filters decreases by an average of 3538%.

The quality of recycled regenerated oils in our country is constantly increasing.

Regenerated motor oil for slow-moving diesel engines, as well as other diesel oils without additives, is recommended to be used as intended with fresh oil in a ratio of 1:3.

Diesel oil with an additive after regeneration can be used for its intended purpose as a mixture with fresh oil (1:4) of the same grade and containing the same additive.

4.5 Development of route process

On recommendations [11], p. 131, sequencing should be guided by the following considerations:

1) First of all, surfaces are processed, which are bases for further processing.

2) The surfaces from which the thickest layer of metal is removed are then processed, since it is easier to detect internal defects of the workpiece.

3) Each subsequent operation must be more accurate than the previous one.

Using these recommendations, we draw up a technological route for processing the shaft-gear.

In the first operation, the workpiece ends must be processed and alignment holes obtained, since they are later used as process bases. The cylindrical surfaces of the support necks and the cylindrical surface of the splined end of the shaft must be treated at the first preliminary and final turning operations. Processing is carried out in centers in two installations. Also, in the first operations, the chamfers and the cylindrical surface of the gear rim should be treated as the least accurate. Next, the worm milling operations should be performed by rolling. The workpiece is based on center holes, which must already be processed with sufficient accuracy in previous operations. Also, before heat treatment, the operation of treating the groove for the locking ring is followed.

Next, heat treatment should be performed. After the heat treatment operation, it is necessary to perform the operation to restore the process bases, namely, to grind the center holes. The required accuracy of the surface for bearings and the surfaces of the end faces of the gear rim is achieved by double and single grinding, respectively, which should be carried out after the restoration of the center holes. The teeth and splines should then be finished.

5.5 Electrical Safety

Electricity in the stapler service shop is the main type of energy, so electrical safety is given a lot of attention.

The risk of electric shock is assessed in accordance with GOST 12.0.38-82 "SSBT. Electrical safety. Maximum allowable levels of contact voltage and currents. "

All electrical equipment shall be performed in accordance with the "Rules for operation of electrical installations of consumers." The prevention of electric trams is an important function of labor protection, which is implemented at work in the form of a system of measures that ensure the protection of people from electric shock.

These activities include:

1) serviceability check of operating equipment wiring;

2) grounding of operating equipment;

3) insulation of live parts of equipment;

4) fencing of hazardous areas in accordance with PUE.

Room class as per PUE - BIa.

5.6 Fire Safety

The concept of fire safety means the condition of an object (workshop, site, workplace) in which the possibility of fire is excluded, and in the event of its occurrence, the exposure of people to dangerous fire factors is prevented and material assets are protected.

When assessing fire safety, they are guided by the documents: GOST 12.1.004-91, SNiP 21-01-97, SNiP 31-03-2001, NPB 105-03, etc.

The fire resistance of the building is determined by the fire resistance of its individual structures (structural elements of the building, external walls, floors, etc.). SNiP 21-01-97 regulates the classification of buildings according to the degree of fire resistance, structural and functional fire hazard.

The explosion and fire hazard room belongs to category B1. The structure of the workshop building refers to the III degree of fire resistance - the main parts of the building are non-combustible.

Categories of premises and buildings are used to establish regulatory requirements for ensuring explosion and fire safety of buildings and structures in relation to planning and development, storeys, areas, placement of premises, structural solutions, engineering equipment, etc.

The main causes of fire in repair shops should be identified:

1) short circuit, which is caused, as a rule, by malfunctions of electrical and electronic systems;

2) spontaneous burning of rags caused by the lack of proper control over the state of workplaces.

For each section of the territory of the enterprise, a scheme of escape routes is being developed, access routes for the fire brigade should be provided.

It is not allowed to clutter passages, exits, corridors, stairs with various objects and equipment. All escape exit doors shall open freely in the direction of exit from the building.

Smoking at work is allowed only in specially designated places by agreement with the fire department of the enterprise. Smoking areas are equipped with cigarette butt urns and water containers.

To extinguish fires in the initial stage, internal fire water pipelines are provided inside the buildings. Internal water supply system consists of inlets, water metering units, risers, dilution network, water collecting and control equipment.

Internal fire cranes are installed in niches or lockers at the entrances at the sites of heated staircases, in corridors and other accessible places at a height of 1.35 m from the floor level. Hoses with trunks are attached to fire cranes.

The internal fire water supply system is designed to ensure uninterrupted and convenient supply of water from fire barrels until more powerful fire protection or fire fighting means arrive.

Fire cranes are equipped with fire barrels with a nozzle diameter of 16 mm. Fire cranes are arranged so that compact jets supplied from barrels connected to two neighboring cranes touch at the highest and most distant point at the boundary of their interaction.

5.7.1 Protection against production noise and vibration

The source of noise in the workshop is machines, mechanisms, units and other equipment of the workshop. The degree of influence of noise depends on its intensity and duration of exposure, the state of the central nervous system and, most importantly, on the individual sensitivity of the body to acoustic stimulus.

Hygienic noise standards are defined in GOST 12.1.00383, CH2.2.4/2.1.8.56296 and SNiP 23032003 "Noise protection." The permissible sound level and the equivalent sound level at permanent workplaces and in working areas in production premises and on the territory of enterprises is 75... 80 dB.

To reduce noise in the production premises, various methods are used:

1) reduction of noise level in the source of its occurrence;

2) sound absorption and sound insulation;

3) installation of noise silencers;

4) rational placement of equipment;

5) use of personal protective equipment (inserts, headphones, helmets).

Hygienic rationing of vibrations is performed as per GOST 12.1.01290 and SN 2.2.4/2.1.8.56696.

Prolonged exposure to vibration leads to the development of occupational vibration disease. Vibration, acting on the machine component of the FM system (man-machine), reduces the performance of technical installations (with the exception of special cases) and the accuracy of the readings of devices, causes alternating vibrations, leading to fatigue damage and stresses in the structure.

The main methods of combating vibrations of machines and equipment are:

1) reduced vibration activity of machines;

2) vibration damping;

3) vibration insulation;

4) use of individual protective equipment (for hands - vibration insulating sleeves, gloves, inserts and gaskets; for feet vibration-insulating shoes, insects, sweeps).

Vibration levels at workplaces are determined at the unit for accuracy testing. The vibration level is checked when each new equipment sample is tested.

Preventive measures should be taken to prevent occupational diseases and reduce the harmful effects of noise and vibration. First of all, they should be taken into account in the design, construction and organization of the technological process. The noisy equipment with intense vibration is located in isolated rooms. To reduce the background of reflected noise of the wall, the ceilings need to be lined with sound absorbing materials. Rotating, moving parts of process equipment are sources of noise and vibrations, so they must be carefully adjusted, balanced, lubricated.