Tractor engine repair site in JSC DEP No. 44

Contents

CONTENTS

Introduction

1 Organizational and economic characteristics of OJSC DEP No.

1.1 General characteristics of the enterprise

1.2 Structure of OJSC DEP No.

1.3 Analysis of technical and economic indicators of the enterprise

1.4 Analysis of the state of technology and organization of production

1.5 Characteristics of engines repair area

2 PROCESS PART

2.1 Process of engine repair

2.1.1 Repair of cylinder block and gile

2.1.2 Repair of cylinders and cylinder liners

2.1.3 Repair of connecting rods

2.1.4 Repair of pistons and pins

1.5Removing the crankshaft

2.1.6 Repair of flywheel with rim

2.1.7 Repairing the camshaft

2.1.8 Repair of pushers

2.1.9 Recovery of valves

2.1.10 Repair of rocker arm and rocker axle

2.1.11 Repair and assembly of cylinder head

2.2 Existing engine repair technology

2.3 Engine assembly

2.3.1 Assembly of cylinder blocks

2.3.2 Assembly and laying of crankshaft

2.3.3 Installation of connecting rod-piston group

2.3.4 Installation of camshaft

2.3.5 Installation of unit head and valve mechanism

2.3.6 Clutch installation

2.4 Calculation of annual workshop load

2.4.1 Calculation of labour intensity

2.4.2 Selection of site equipment

2.4.3 General characteristics of the site

2.4.4 Organization of work on the site

3 DESIGN PART

3.1 Analysis of existing benches for engine repair and running-in

3.2 Description of the designed bench

3.3 Strength calculations

3.3.1 Gearbox calculation

3.3.2 Calculation and selection of hydraulic cylinder

3.3.3 Calculation of welded joint

3.3.4 Calculation of bolted connection

4 LIFE SAFETY AND ENVIRONMENTAL FRIENDLINESS

PROJECT

4.1 Analysis of working conditions in the engine repair area

4.2 Categorization of the object

4.3 Development of integrated solutions

4.4 Environmental friendliness of the project

5 TECHNICAL AND ECONOMIC INDICATORS OF THE SITE

REPAIR OF ENGINES

5.1 Absolute technical and economic indicators

5.2 Determination of relative techno-economic indicators

CONCLUSIONS AND PROPOSALS

Literature

PRILOZHNIYE

Summary

This diploma project consists of a calculation explanatory note on 90 page and a graphic part on 9 flippers of A1 format.

The first section of the explanatory note gives the organizational and economic characteristics of OJSC DEP No. 44.

The second section provides analysis of cylinder block defects, considered methods of repair of cylinder block cracks and developed repair technology.

As a design development, the design of a universal bench for disassembling and assembling engines is proposed and strength calculations of critical units are made.

Proposed measures for labor protection and environmental safety. Design solutions are justified and confirmed by calculation of feasibility indicators of efficiency.

The diploma project includes an introduction, 5 sections, conclusions and proposals, a list of the literature used and annexes.

The graphic part includes:

1 sheet - Analysis of business activities of the enterprise;

1 sheet - Plan of engine repair area;

2 sheets - Job instructions;

1 sheet - General view of the bench;

1 sheet - Process diagram of engines repair;

2 sheets - Detail Detail Drawings;

1 sheet - Technical and economic indicators

Introduction

The effective operation of the agro-industrial complex is largely due to the level of reliability of the equipment supplied to the village, the improvement of its technical operation system. In recent years, the reliability of the supplied machines has decreased sharply. Thus, the average time between failures of tractors decreased by more than 2 times with a significant increase in their cost.

The level of technical equipment of the Republic of Belarus agriculture, although it remains one of the highest in the CIS, has significantly decreased in recent years, which is due to the continued disparity in industrial prices for industrial and agricultural products, the lack of working capital in collective farms, state farms and other agricultural producers to purchase the necessary equipment.

Improving the design and technical and economic performance of engines is accompanied by increasing their complexity, increasing requirements for material quality, accuracy of manufacturing parts, assembly accuracy, adjustment and testing of individual units and engines as a whole.

The level of organization and repair technology must correspond to the technical level of modern engines, meet the requirements of modern agricultural equipment, which are required for the reliability of machines, for the stability of their technical and economic indicators during the overhaul period.

The modern level of technical equipment and the organization of motor repair production does not provide high quality repairs, and primarily engines of energy-saturated tractors. Engines are repaired at enterprises with small production programs that do not have the necessary

machine and process equipment, equipment and controls. As a result, the post-repair resource and reliability of parts amount to 40... 60% to repair values ​ ​ of the same indicators, which negatively affects the agricultural economy.

Improvement of quality of repair works for engines can be achieved due to modernization of obsolete repair and technological equipment and improvement of repair technologies at large enterprises on the one hand, and on the other hand - due to increase of level of concentration of repair of multi-mark units and machines having similar defects and structural and technological properties (use of principles of node and technological specialization), and deepening of professional specialization.

Organizational and economic characteristics

OJSC dep No. 44

1.1 GENERAL CHARACTERISTICS OF THE ENTERPRISE

OJSC DEP No. 44 specializes in the construction and repair of motor roads. The total length of the served Federal highways is 603.46 linkm (874.37 priv.km). The company is located in the city of Roslavl, Smolensk Region at the address: st. Bol. Smolenskaya, 28. It was formed in 1943. The work of the enterprise is aimed at solving one of the tasks of transport - meeting the needs of the population of the city and the region for high-quality repair of the roadway.

OJSC DEP No. 44 carries out all types of activities provided for in the profile: transportation, storage, maintenance and repair of rolling stock. The company employs 158 people, of which 30 are engineering and technical workers, 128 are production personnel.

The company has two production bases. The production base located in the city of Roslavl has: repair and mechanical workshops with the ability to simultaneously repair 12 units of road construction equipment. The repair workshop includes a lathe, locksmith, welding, assembly, battery shop; warm parking boxes for 12 cars, open parking with a paved area of ​ ​ 0.3ha; warehouses, dispatch service, main energy service. The production base located in the village of Oster, Smolensk Region, has: repair and mechanical workshops that provide simultaneous repair of 6 units of vehicles; warm boxes for parking 6 cars, open parking

Yankee with a hard coating, area of ​ ​ 0.3 hectares, gas stations - a gas station for the reception, storage of gasoline, diesel fuel, oils and refueling of its own fleet of cars and road construction equipment. Also in the village of Oster, there is a complex for the preparation and production of asphalt concrete mixture, with a capacity of 25 n/h., a crushing and sorting plant for the preparation of crushed stone for production, a/concrete, a capacity of 33 m3/h., a bitumen storage and tar storage each with a capacity of 500 tons, a building laboratory. The ABZ complex of OJSC DEP No. 44 includes a hardcoated site with an area of ​ ​ 500m2 for storing bulk materials, as well as an energy saving complex. On the territory of the production base of Oster there are auxiliary rooms (household, shower, warehouse).

Design Part

3.1 ANALYSIS OF EXISTING BENCHES FOR REPAIR AND RUNNING OF ENGINES

3.1.1. A test bench for internal combustion engines is known, comprising a base with a frame for fixing the engine and a system for providing diagnostics.

The main disadvantage of such a stand is the limited functional capabilities due to the immobility of the base.

There is also known a station for diagnosing and testing internal combustion engines, which includes a suspension conveyor with a cargo trolley on which the engine is fixed, which allows you to perform several diagnostic or repair operations without reinstalling the engine.

However, this solution is cumbersome and difficult to operate.

The closest is a bench for repair and running-in of an internal combustion engine comprising a movable platform with a spatial frame structure equipped with engine fixing devices, which are removable shifting units with fastening elements, and a system providing engine operation and diagnostics.

The disadvantages of this stand include the fact that the spatial structure is fixed, which limits the functionality of the stand.