ZIL-130 Steering Project

Contents

Contents

Task

Introduction

1 General part

2 Organizational and technological part

2.1 Calculation of annual scope of work

2.2 Calculation of the number of production workers

2.3 Selection of required process equipment

2.4 Design of repair area

2.5 Drawing Up Part Recovery Route

3 Process Technical Rationing

3.1 Surfacing operation in CO medium

3.2 Thermal operation, annealing

3.3 Milling Operation

3.4 Finishing grinding

3.5 Thermal operation. Training

4 Design part

Conclusion

Attachments A

List of sources used

Graphic part of the project:

1 Sheet (A2) - Assembly Drawing

2 Sheet (A3) - Part Working Drawing

3 Sheet (A3) - Part Inspection-Sorting Specification

4 Sheet (A3) - Sketch Map

5 Sheet (A3) - Operating Card

6 Leaf (A2) - Adaptation

Introduction

The production process of repairing machines is a set of actions of people and tools of production performed in a certain sequence and ensuring the return of operability to worn-out mechanisms, parts, machines lost during operation.

The production process at the repair enterprise covers all stages of repair of machines, units or parts: organizational, procurement, technological and others. They also refer to business units, workshop, department or site. They distinguish between the production process, for example, the dismantling and washing section, mechanical, assembly and others.

The repair process is used to reduce labor and money costs for the manufacture of new parts or to replace not the entire unit, but its failed part or unit.

During operation, machines inevitably fail due to wear and other damage to parts. The cost of repair and maintenance of tractors and vehicles for the period of operation is several times higher than their cost. The production capacity of enterprises engaged in the repair of tractors is almost four times more than the capacity of enterprises for their manufacture. The labor intensity of repair and maintenance of tractors and cars during the period of work before write-off is many times higher than the labor intensity of manufacturing new ones.

Part Repair Process

2.5.1 Organization of unit parts recovery

Depending on the purpose, complexity and scope of work performed, repairs are divided into current and overhaul.

Capital is a type of repair in which all units and braces, including basic ones, are restored. During overhaul, the unit to be repaired is completely dismantled and assembled, all worn-out parts requiring repair are replaced with restored or new ones, and basic parts are restored, since they are more complex to manufacture and expensive. Overhaul should ensure the service life of the machine or mechanism not less than the planned overhaul period, which is 80% of the resource of the new machine.

The current is a type of repair in which certain types of work are carried out to eliminate minor malfunctions that arise during the operation of the machines and replace individual units or parts that require major repairs. In the current repair, the base parts are not replaced or restored.

The main methods of repair are: modular, agregatnouzlovy, periodic replacement of sets.

The repair site has an aggregate repair method. Repaired units are handed over to the finished product warehouse, and the units coming for repair are handed over to the pending repair warehouse, after which the parts requiring repair are sent to the repair site.

In the repair area, a map of sketches is compiled taking into account standard time standards. Before drawing up the sketch map, a punch list is filled in, which indicates all possible defects of the part to be restored; nominal dimensions, dimensions permissible for operation of the part without repair and limit dimensions, after which the part must be repaired. The operating map specifies the part action, current modes, and part machining modes. The roadmap shows the recovery sequence of the part indicating the equipment, instruments, working and auxiliary tools used.

A picking list and a tooling list are necessarily attached to the process documentation. The pick list indicates the name and number of parts required to assemble this assembly, the catalog part number, and the standard product number and year of implementation. Used main and auxiliary equipment and process equipment selected for the site are included in the tooling list.

The part to be restored, together with the required documentation, is moved through the repair areas depending on the operations performed in the required sequence. The units are moved on mobile trolleys, which are two on the section, and loading and unloading operations are carried out by a suspension crane, which allows increasing labor productivity and mechanizing operations.

After the last operation, the quality control of the work is performed. Parts that have passed this control together with the accompanying documentation are sent to the finished product warehouse.

Design Part

For disassembly, assembly and repair of parts with defects, various devices, stands, instruments and tools are used. This excludes heavy human labor, sometimes unassuming, because the units and parts of heavy vehicles are very bulky and heavy.

Disassembly of the steering hydraulic booster ZIL130 is carried out on a special bench. The proposed stand for disassembling the steering of the ZIL130 is stationary, since it has a large own weight of 110 kg and overall dimensions of 1175. 1240.

The structure includes a stationary stand (mast), which is installed on the iron floor without any attachment to it. Working equipment is installed on the yard, on the working plate. In the left part of the table there is an accessory for pressing out the ball nut from the piston-rack. Wrench and accessory for disassembly of control valve, screw and piston-rack are installed in middle part. A container for storing parts is attached to the right edge of the table. Hydraulic unit installed inside table is used as drive for wrench and accessories.

Conclusion

Parts of machines during operation wear out, therefore, during repair these parts must be replaced with new or restored ones.

Based on the data obtained from the calculations of the course project on the topic "Organization of the technological process of repairing the hydraulic booster of the ZIL130 car with the development of a map for shaft restoration," he received the following data.

To repair the hydraulic booster of the ZIL 130 car, a repair section of dimensions 16 is required. 12 with required process. The number of employees in the repair site is 25 people, including ITR and MOS. Since the average discharge of workers was 4.6, it should be assumed that such works as surfacing, galvanic, turning, milling, etc., can be carried out with high quality and high productivity.

When repairing the steering shaft, the following operations are used: surfacing, complete annealing, milling, finishing grinding and hardening, allowing you to restore the part without replacing it with a new one.

The technical normalization described in paragraph 3 makes it possible to ensure that the recovery of the fleece on the shaft is advisable to restore by a surfacing operation with further machining.

Compared to vibration surfacing, surfacing in a carbon dioxide environment is more acceptable, since in a CO2 environment the metal is practically not sprayed, that is, it is saved. Vibration surfacing is cheaper and simpler. But the advantage of surfacing in CO2 is the ability to supply wire at different speeds, current and at different angles to the surfaced surface, when this is impossible when surfacing under flux or during vibration surfacing.