Stepper Chain Conveyor Development Project

Contents

1 General part

1.1 Short description of KGMK. Structure

1.2 Product Range

1.3 Characteristics of continuous wire mill 250-3 of rolling mill No.

2 Special part

2.1 Purpose and scope of package machine

2.2 Technical characteristics of the package machine

2.3 Package Machine Design Description

2.4 Package Machine Flaw Analysis

2.5 Literature and Patent Overview of Package Machine Analogues

2.6 Upgrade Proposals

2.7 Description of proposed structure

2.8 Calculations for the reconstruction of the base machine

3 Installation

3.1 Development of foundation configuration

3.2 Geodetic justification of installation

3.3 Conveyor Delivery Method to Installation Site

3.4 Installation Flow Sheet

4 Operation of the machine

4.1 Operating conditions of the designed machine

4.2 Wear pattern of the most important parts of the designed machine during operation

4.3 Maintenance measures for the machine in order to maintain its operability

4.4 Proposals for improvement of organizational and technological character aimed at maintenance of machine serviceability

5 Repair

5.1 Selection of form and method of stepper chain conveyor repairs

5.2 Development of a prospective schedule of planned preventive repairs of machines for the year

5.3 Description of recovery methods most frequently

parts that wear in the machine

5.4 Lubrication of the machine

5.5 Selection of lubrication system for machine units

5.6 Calculation of main parameters of lubrication systems

6 Organizational part

6.1 Characteristics of KGMK repair facilities

6.2 Characteristics of repair facilities of SPC

6.3 Equipment Repair Planning

6.4. Organization of repair works

6.5. Calculation of the annual salary fund of repair workers of the area where the packaging machine works

7 Economic part

8 Occupational safety

8.1 Layout of production buildings of the workshop

8.2 Major hazards and hazards

8.3. Measures to reduce harmful and dangerous factors

8.4 Personal protective equipment

8.5 Fire Safety

9 Protection of the environment

Literature

Applications

Table A1 - The specification to the general view of interface of the step conveyor and a krivoshipny table

Table A2 - Drawing Specification for General View of Stepped Chain Conveyor

Table A3 - The specification to the assembly drawing of a wave of the leader

Project Description

Explanatory note to the diploma project: 100 pages, 21 Fig., 12 Table, 12 sources.

Development object-packaging machine PS2503 SPC No. 2.

The purpose of the development is to develop a conveyor, which will allow transporting rolled stock riots without damaging the rolled stock surface and violating the integrity of the riots.

Research method - kinematic - confirmation of the possibility of introducing the proposed design into the production line; analytical - determination of loads on the stepper chain conveyor, check of strength of the main parts.

A conveyor design has been developed that can be used in the existing PS2503 train. The required power of the hydraulic drive and operating modes are determined.

The organization of repair works at the enterprise, methods of installation and control during installation of parts and assemblies of conveyor mechanisms have been considered.

Proposed design of stepping chain conveyor will allow carrying out transportation of rolled stock riots without damage to rolled stock surface and integrity of riots, improve conditions of overload of riots on bridge crane, implement automated control systems.

The stepper chain conveyor is designed according to production conditions and is fully adapted for use on PS2503.

In order to achieve full economic benefit from the introduction of the stepper chain conveyor, a marketing analysis of the metal rolling market should be carried out in order to find a market for a better product at a higher cost. The expected economic effect of the introduction of automated control systems and energy savings due to the use of a hydraulic drive is 25071 UAH/year in 2005 prices.

Keywords: packaging machine, BUNT, KATANKA, damage, process line, introduction, stepping chain conveyor,

Special part

2.6 Upgrade Proposals

As a result of the literary and patent search and on the basis of the revealed technological and structural shortcomings of the packaging machine, the use of a stepping chain conveyor [3] is seen as the most appropriate. The considered conveyor will allow receiving riots from the crank table without damage resulting from pushing the previous one installed by the riot and friction of the internal surface of the riot against the load-carrying organ. As a result of checking the interface between the stepper chain conveyor and the crank table, the possibility of implementing the stepper conveyor in the process line of the SPC-2 workshop of PS2503 became justified. To fix the riots in the vertical position, it is proposed to provide the load-carrying member of the step chain conveyor with stops that allow holding the lower part of the riot during transportation. The drive and driven sprockets of the conveyor are proposed to make different diameters: the driven one of a smaller diameter - to eliminate the engagement with the crank table of the stops during the installation of riots on the stepper conveyor, and the leading one of a larger diameter - to reduce the drive power, in case of using a hydraulic drive. It is advisable to move the crank table up to remove the riot from the hook conveyor by the inside, this will allow the step conveyor to freely exit the interface. It is proposed to transfer the riot not in the extreme left position of the crank table, but during lowering to the extreme lower position, which will allow installation between stops with the least touches on them, to eliminate the possibility of accidental sliding of the riot against the inner side of the stops during vertical movement.

Operation of the machine

4.1 Operating conditions of the designed machine

The conveyor operation mode is heavy with FP - 40... 60%, loading during the year - 349 days, during the day - 19... 20 hours, stopping at commissioning - 2 times a month, inspection of the conveyor is carried out every day.

The hydraulic drive operates in variable mode, the movement is reverse. Conveyor load-carrying chain experiences high specific loads.

Ambient temperature:

• summer - + 25... + 30 ° С;

• winter- − 5... + 10 ° С.

Relative humidity is 50... 70%.

The amount of dust content is not significant, mainly consists of iron scale.

4.2 Wear pattern of the most important parts of the designed machine during operation

The most worn parts of the stepper chain conveyor include: bearings of supports, bearings of rollers of the load-carrying chain, surfaces of teeth of traction sprockets, rollers of the drive disk.

In bearings, due to high specific loads and low speed of movement, rolling surfaces wear (pitting) occurs. The surfaces of the teeth of the driven and driving sprockets experience wear by setting the first kind. Similarly, the rollers of the drive disk wear. The reasons for wear are low relative sliding speeds at high specific loads.

4.3 Maintenance measures for the machine in order to maintain its operability

Strict adherence to inspection schedules and current conveyor repairs helps to keep the equipment in working condition and timely detection of defects.

To maintain the serviceable condition of the conveyor, it is necessary to carry out planned preventive inspections by the employees of the mechanical service of this section, from the locksmith on duty to the chief mechanic of the workshop, but the volume, content and periodicity of inspections for these workers are different.

The mechanic inspects the equipment of the subordinate site. Locksmiths on duty inspect the equipment during maintenance, performing regulated work and eliminating detected faults. The results of the inspection are recorded in the replaceable log.

ITR of all ranks inspect the equipment less often, but to a greater extent, and the main purpose of their inspections is to determine the technical condition of the equipment and control the maintenance of subordinate personnel. In general, the purpose of scheduled preventive inspections, identification of minor malfunctions, obtaining objective information serves to plan repairs. For inspections of mechanical equipment, a realistic periodicity is assigned: the master mechanic of the site should inspect all equipment once every 2 weeks, the workshop mechanic once every 2 months, and the assistant to the shop manager once every 4 months. The deputy chief mechanic is obliged to inspect the equipment of the workshops entrusted to him once every 6 months, the chief mechanic - all equipment of the enterprise once a year. The time of these inspections is combined with the time of determining the technical condition of the main process units and machines included in the design of the overhaul schedule for the next calendar year.

If necessary, during inspection, the machine is partially disassembled, the unit or part is separated, cleaned and washed, and the degree of wear is determined. When disassembling, they use installation drawings or machine diagrams. Homogeneous parts are labeled to ensure proper assembly. The wear value is determined by measuring tools (micrometers, indicators, profilometers), as well as by the method of wells or hairlines.

Timely ordering of spare parts significantly reduces equipment downtime. For overhauls 6 months before the start of the repair, and when ordering to the side for 12 18 months.

It is also necessary to monitor:

involvement of pre-trained maintenance workers to perform repairs and fixation of all equipment to repair personnel;

Major repairs in accordance with the approved standard repair regulations and network schedules.

To reduce downtime of the conveyor during repairs, it is necessary to record all spare units and parts in the central warehouse with the allocation of only quick-wearing parts to the shop pantries, the nomenclature of which is established by the department of chief mechanics.

Pipeline maintenance is carried out during the interchange period. The maintenance personnel at the beginning and at the end of the shift shall check: the quality of tension of the load-carrying chains, the presence of foundation bolts and fastening equipment, the correspondence of the position of the receiving section of the conveyor with respect to the crank table, the presence of lubricant in the friction units.

If one of the above points is not fulfilled, it is necessary to immediately notify the repair personnel and monitor the implementation of repair measures.

4.4 Proposals for improvement of organizational and technological character aimed at maintenance of machine serviceability

Maintenance personnel must carefully study the design of the machine and the rules for its technical operation. During inspection, inspection and repair of the conveyor by the team of fitters, the worker who serves it must personally participate in these operations.

Repair

5.1 Selection of form and method of stepper chain conveyor repairs

The process of repair of the conveyor must be organized in such a way as to ensure the execution of the production plan with high quality, on time and with minimum labor and material costs.

The main type of repair in rolling production is planned - preventive repair, using knot and unit replacement. Overhaul requiring long-term shutdown and disrupting flow and operation shall be carried out as often as possible and with minimal time.

To repair the equipment of PS2503 mill, a mixed form of repair is used, in which specialized workshops are involved in the repair work, along with the repair bases of the SPC 2 workshop. Production of spare parts and preparation of units, for replacement of existing ones is carried out by repair and mechanical workshops - RMC .

The repair method is aggregate, in which to reduce the repair time, replacement of worn or failed mechanisms is carried out by units (assemblies) as a whole (for example, the drive shaft assembly).

Repaired units, which are in reserve, are installed in place of removed units.

Preventive, maintenance and inter-repair maintenance is carried out by the shop repair service, namely the equipment repair team of PS2503 mill of SPTS2 workshop.

5.3 Description of methods for restoring the most frequently worn parts in the machine

The most worn parts of the stepper chain conveyor include:

rolling bearings of load-carrying chains and shaft supports;

surfaces of sprocket teeth;

driven and driving shafts;

part of frame, which is support guide for chains.

Worn-out rolling bearings of load-carrying chains and shaft supports are replaced, since they are not subject to repair.

Part of frame, which is support guide for chains, is repaired by installation of additional parts (straps)

Repair of drive and driven shafts is carried out by method of restoration of original dimensions, in case of extreme wear of surfaces.

5.4 Lubrication of the machine

Given the heavy operating conditions of metallurgical equipment, the required reliability and continuity of operation, and the need for large amounts of lubricant, the following main requirements are imposed on lubricants:

reliable antifriction and anti-wear properties;

required viscosity and ability to well wet rubbing surfaces (anti-galling properties);

the ability to withstand high pressure and resist displacement from the gap between the friction surfaces;

stability, i.e. stability with respect to temperature, oxidation, decomposition, etc.;

chemical neutrality;

economic benefits of application.

5.5 Selection of lubrication system for machine units

The most suitable type of grease for a stepper chain conveyor is a thick grease. It reduces the coefficient of friction and partially prevents rubbing surfaces from corrosion.

It is used for units, the heat of which is completely removed into the surrounding space, and for heavy-loaded bearings, if the shaft rotates at a low angular speed (p < 50 rpm) or makes only part of the revolution. Consequently, the operating mode of the conveyor does not contradict the process parameters of the thick lubricant.

Organizational Part

6.1 Characteristics of KGMK repair facilities

The task of improving production efficiency largely depends on the fullest use of fixed assets. This requires, first and foremost, their smooth functioning through systematic care, supervision and repair. Such duties are assigned to the repair farm of the KGMK.

The mission of the mill maintenance is to ensure uninterrupted, reliable and high-performance operation of the equipment at minimum cost.

The plant's repair facilities include workshops for the repair of equipment (metallurgical, rolling, agglomeration) for the manufacture of repair and production metal and spare parts (foundry, blacksmith, metal structures, mechanical, etc.), a warehouse of spare parts, a warehouse of semi-finished products.

In addition to the above-mentioned workshops, subordinate to the department of the chief mechanic, the plant has repair shops of the power industry, a repair shop of metallurgical furnaces, a repair building, and a roll-and-roll shop. They are also part of the repair farm of the plant.

At the head of the repair farm is the chief mechanic, who reports to the chief engineer of the plant (technical director). Direct management of repair facilities is carried out in large workshops with a large amount of equipment by the assistant to the head of the workshop for equipment, in the rest - by the workshop mechanic.

6.2 Characteristics of repair facilities of SPC 2

The following repair teams are available in the SPC 2 workshop, which are assigned to certain areas of equipment; fixation is carried out based on the same type, complexity of metallurgical equipment and its territorial location:

floor equipment repair team;

crane repair team;

PS2503 equipment repair team;

automotive and hydraulics equipment repair team;

air conditioner and pump ventilation unit repair team;

air lines and sewerage repair team;

team for repair and assembly of bearing supports;

repair team of finished goods warehouse equipment.

Repair facilities of the workshop provide operation, maintenance, repair of equipment. The repair farm of the workshop is also entrusted with the task of modernizing the equipment and participating in its repairs. In connection with the round-the-clock work of the workshop, the repair service is divided into duty and day repair personnel. Daily personnel are engaged in the manufacture of spare parts, parts and assemblies, as well as participate in preventive repairs of equipment. On-duty shift personnel provide supervision and maintenance of equipment during the day and eliminate all breakdowns and faults. The duty personnel shall be distributed in such a way that a certain amount of equipment is assigned to the duty mechanic, for the serviceable condition of which he is personally responsible during the shift. All work in the shift is planned and carried out under the guidance of the foreman of replacement locksmiths. The general management of the mechanical service is carried out by the assistant to the head of the workshop for mechanical equipment and the mechanic of the workshop. During major repairs, workshop repair personnel are assigned to the foremen of specialized workshops and organizations, which allows strict control over the repair and quickly solve problems arising during the repair.

6.3 Equipment Repair Planning

The SPC 2 workshop adopted a system of scheduled preventive repairs. The essence of this repair system lies in regular inspections and inspections of equipment, on the basis of which the volumes of repairs are determined. The results of inspections and audits are recorded in aggregate journals and in shift acceptance and delivery journals. The nature and scope of repair works are established on the basis of lists of defects.

Lists of defects are: for current repairs based on the analysis of entries in aggregate journals and in acceptance and replacement journals; for major repairs, in addition, on the basis of an act of the commission on the state of equipment.

Current repairs are carried out on the days of planned equipment stops, in accordance with the annual schedule, or combined with interruptions in equipment operation.

To perform the current repairs on the basis of the inspection and revision data, the equipment defect lists are drawn up, which indicate the planned date of the unit shutdown for repair, the list of locksmith and installation works, the name of the parts to be replaced, the scope of work, the required number of parts, workers and the terms of repair.

Ongoing repairs are carried out by workshop repair teams under the guidance of the workshop mechanic with the involvement of duty personnel, and in large workshops - by the forces of the cluster or repair and installation workshop. Parts are made by mechanical repair shop, cluster and workshop repair shops.

The equipment after the current repair is accepted by a commission consisting of an assistant to the head of the equipment workshop and representatives of the chief mechanic and the chief power engineer. The units are accepted after their external inspection and testing in operation during the shift.

Equipment stops for major repairs are regulated by annual schedules.

Major repairs are performed on the basis of survey data, inspections and current repairs of equipment and lists of equipment defects compiled 6 months before the units shutdown for repair. The survey of the main production units is carried out by a commission chaired by the chief engineer of the enterprise. Two months before the start of the repair, the repair contractor draws up an operational schedule, which lists the types of work, terms and the required number of workers. For the general management of the repair, the head of the repair is appointed.

Major repairs, as well as reconstruction and modernization are carried out by the repair, mechanical and repair and installation workshops of the plant, cluster workshops and, if necessary, repair teams of specialized repair trusts.

After major repairs, the equipment is accepted by the factory commission and issued with an acceptance certificate. The units are put into operation after their external inspection and testing in operation within 24 h. The acceptance certificates shall indicate the warranty period of equipment operation after repair.

The workshop shall have an annual schedule of scheduled preventive repairs and a monthly schedule. The annual schedule is linked to the work plan for the modernization of equipment and the mechanization and automation of production processes, as well as to the plan dictated by the technological and organizational conditions of production.

The monthly schedule shows all equipment in the shop to be repaired. Annual plans for major and ongoing repairs of the main process equipment are approved by the chief mechanic and chief engineer of the mill. To compile the current repair schedule, the scope of work in the repair lists is determined, and an operational schedule is also drawn up for the repair of large units. The repair list is signed by the shop manager and assistant to the shop manager for mechanical equipment. The workshop plans to carry out scheduled preventive repairs per month for 8 hours.

The duration of major repairs for each year is planned 10... 15 days depending on the volume of modernization work. Preparation for the WP begins in advance with the determination of the scope of work, i.e. with the identification of the required number of units and parts, mechanisms, etc. to be replaced and repaired. Data are used for this purpose:

- daily inspections of equipment by the foreman;

- entries in the magazines of reception and delivery of shifts by replacement teams of locksmiths;

- entries in aggregate logs, which are made by the site mechanic every decade;

- personal survey of the site mechanic as large a number of all maintenance personnel as possible;

- based on the obtained data, the site mechanic shall draw up a list of the proposed equipment repair on the site.

The repair list is discussed with all the repair personnel of the site, then the site mechanic together with the workshop mechanic decide how best to use the time allocated for repair and make high-quality repairs.

The frequency of equipment stops for repairs, both current and capital, is determined by the stability of the units and parts, and the duration of stops is the time required to perform the most labor-intensive of the work planned for a given repair.

6.4. Organization of repair works

After determining the content and scope of repair, the technological process of its implementation is developed. The process of complex and often repeated repairs is drawn up in the form of a post-operation schedule, the purpose of which is as follows:

- determination of the specific content and sequence of all repair operations for this scope;

- establishment of standard duration of each repair operation, number and qualification of workers performing the operation;

- development of a schedule of all repair operations with the aim of speedy and high-quality execution of all repairs.

The most important condition for reducing the duration of repairs is the parallel execution of repair operations. The operation schedules list the tool and fixtures without which these operations cannot be performed. The post-operation schedules for the repair of units and assemblies are compiled by the workshop mechanic together with the labor organization bureau. The schedule should include only those operations that really need to be carried out during the repair itself. All preparatory works that can be performed before the start of repair are not included in the schedule. The number of workers required to perform individual operations is set taking into account the weight and size of the parts, as well as the convenience of performing operations.

Time standards for certain operations are established on the basis of analysis of timing observations, according to standards, or by experiment. As part of the operational schedule, care should be taken to carry out operations as concurrently as possible, ensuring a drastic reduction in the duration of repairs. When scheduling, the workload of individual workers is checked, significant downtime is unacceptable. Based on the developed schedule, the workload of individual workers is determined, significant downtime is not allowed. Based on the developed schedule, the total duration of repair and its labor intensity are determined. Networks are used to perform complex and labor-intensive repairs.

Conclusion

Existing operational and structural disadvantages of the package machine:

Design disadvantages:

large occupied area;

due to the small capacity, the crane delays are not compensated;

high metal capacity due to the console loads perceived by the pins.

Technological disadvantages:

deformation of the riot during loading and unloading of the package machine;

high labor intensity when removing a riot from the pin of the packing machine with a bridge crane;

As a result of the literary and patent search and on the basis of the identified technological and structural shortcomings of the packaging machine, the use of a stepping chain conveyor is seen as the most appropriate. The proposed conveyor will allow receiving riots from the crank table without damage resulting from pushing the previous one installed by the riot and friction of the internal surface of the riot against the load-carrying organ. As a result of checking the interface between the stepper chain conveyor and the crank table, the possibility of implementing the stepper conveyor in the process line of SPC-2 of mill PS2503 became justified. To fix the riots in the vertical position, it is proposed to provide the load-carrying member of the step chain conveyor with stops that allow holding the lower part of the riot during transportation. The drive and driven sprockets of the conveyor are proposed to make different diameters: the driven one of a smaller diameter - to eliminate the engagement with the crank table of the stops during the installation of riots on the stepper conveyor, and the leading one of a larger diameter - to reduce the drive power, in case of using a hydraulic drive. It is advisable to move the crank table up to remove the riot from the hook conveyor by the inside, this will allow the step conveyor to freely exit the interface. It is proposed to transfer the riot not in the extreme left position of the crank table, but during lowering to the extreme lower position, which will allow installation between stops with the least touches on them, to eliminate the possibility of accidental sliding of the riot against the inner side of the stops during vertical movement.

In order to achieve full economic benefit from the introduction of the stepper chain conveyor, it is necessary to carry out a marketing analysis of the metal rolling market in order to find a market for a better product at a higher cost. The expected economic effect of the introduction of automated control systems and energy savings due to the use of the hydraulic drive will be 25071 UAH/year in 2005 prices.