Engine shop equipment. ATP design with the development of a motor section. Increase in cargo and passenger turnover in road transport
Page 1
Choice technological equipment.
The motor section is intended for the repair of mechanisms and separate parts engine. Typical works during the current repair of the engine are: replacement of piston rings, pistons, piston pins, replacement of connecting rod and piston bearing shells with bushings of operational dimensions, replacement of the head gasket, elimination of cracks and breakdowns (in the welding department), lapping and grinding valves.
After performing the current repair of the engine, it is imperative to carry out cold and hot running in order to ensure reliable grinding of components and parts after repair without load, which ensures their greater durability under operating conditions. The choice of technological equipment is determined by the types of work performed and technical specifications rolling stock. The list of technological equipment is given in table 15
Table 15
List of technological equipment
Name, designation, type, model of equipment, accessories |
Technical specifications | |||
Stand for testing engines MPB 32.7 |
200 kW, 3660´2200 | |||
Engine Repair Stand 2164 |
1300´846, mobile | |||
Universal device for straightening connecting rods mod.2211 |
Desktop | |||
Cylinder boring machine mod.2407 |
275´380, 1.5 kW | |||
2291A Cylinder Polishing Machine |
425´172, 1.5 kW | |||
2414A Valve Grinding Machine |
Desktop, 0.27 kW | |||
Universal valve seat grinder, 2215 |
Desktop, 0.6 kW | |||
Desktop drilling machine NS-12A | ||||
Pneumatic Valve Lapping Drill, 2213 | ||||
Compressometer, mod.179 | ||||
Mobile hydraulic crane, 423M |
750kg, 2400´1200 | |||
Cylindrical grinding machine | ||||
Washing installation, mod. OM-5359 GOSNITI | ||||
Hydraulic press OKS-167IM |
1500´640, 1.7 kW | |||
Device for disassembly and assembly of cylinder heads, mod. |
Desktop | |||
Locksmith workbench for one workplace, ORG-1468-01-060A | ||||
Locksmith workbench for two workplaces, ORG-1468-01-070A | ||||
Engine Storage Rack | ||||
Tool storage cabinet, ORG-1603 | ||||
Cabinet for storage of materials and measuring tools, ORG-1468-07/-040 | ||||
Rag chest | ||||
sand box | ||||
Fire extinguishers OHP-10 | ||||
Fire extinguishers OU-5 | ||||
Washbasin |
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Selection of technological equipment
Selection of technological equipment.
The motor section is intended for the repair of mechanisms and individual parts of the engine. Typical works during the current repair of the engine are: replacement of piston rings, pistons, piston pins, replacement of connecting rod and piston bearing shells with bushings of operational dimensions, replacement of the head gasket, elimination of cracks and breakdowns (in the welding department), lapping and grinding valves.
After performing the current repair of the engine, it is imperative to carry out cold and hot running in order to ensure reliable grinding of components and parts after repair without load, which ensures their greater durability under operating conditions. The choice of technological equipment is determined by the types of work performed and the technical characteristics of the rolling stock. The list of technological equipment is given in table 15
Table 15
List of technological equipment
Name, designation, type, model of equipment, accessories |
Technical specifications |
|||
Stand for testing engines MPB 32.7 |
200 kW, 36602200 |
|||
Engine Repair Stand 2164 |
1300846, mobile |
|||
Universal device for straightening connecting rods mod.2211 |
Desktop |
|||
Cylinder boring machine mod.2407 |
275380, 1.5 kW |
|||
2291A Cylinder Polishing Machine |
425172, 1.5 kW |
|||
2414A Valve Grinding Machine |
Desktop, 0.27 kW |
|||
Universal valve seat grinder, 2215 |
Desktop, 0.6 kW |
|||
Desktop drilling machine NS-12A |
||||
Pneumatic Valve Lapping Drill, 2213 |
||||
Compressometer, mod.179 |
||||
Mobile hydraulic crane, 423M |
750kg, 24001200 |
|||
Cylindrical grinding machine |
||||
Washing installation, mod. OM-5359 GOSNITI |
||||
Hydraulic press OKS-167IM |
1500640, 1.7 kW |
|||
Device for disassembly and assembly of cylinder heads, mod. |
Desktop |
|||
Locksmith workbench for one workplace, ORG-1468-01-060A |
||||
Locksmith workbench for two workplaces, ORG-1468-01-070A |
||||
Engine Storage Rack |
||||
Tool storage cabinet, ORG-1603 |
||||
Cabinet for storage of materials and measuring tools, ORG-1468-07/-040 |
||||
Rag chest |
||||
sand box |
||||
Fire extinguishers OHP-10 |
||||
Fire extinguishers OU-5 |
||||
Washbasin |
In total, the area occupied by the equipment is 30.81 sq. m.
Calculation of the production area of the motor section
The area of the motor section is determined by the formula:
where is the density coefficient of the equipment arrangement, we accept = 4 for the motor section; (table 16)
Equipment density factors
Table 16
The total area of equipment in the plan, from Table 15
Based on the SNiPs, we accept the width of the premise of the site B = 9 m, then the length of the premise of the site will be: 108: 9 = 12 m.
The height of the building is 3 meters. External walls are made 60 cm thick.
We choose a cement floor on a concrete base.
In total, the area occupied by the equipment is 30.81 sq. m.
2.6 Calculation of the production area of the motor section
The area of the motor section is determined by the formula:
where is the density coefficient of the equipment arrangement, we accept = 4 for the motor section; (table 16)
Equipment density factors
Table 16
The total area of equipment in the plan, from Table 15
Based on the SNiPs, we accept the width of the premise of the site B = 9 m, then the length of the premise of the site will be: 108: 9 = 12 m.
The height of the building is 3 meters. External walls are made 60 cm thick.
We choose a cement floor on a concrete base.
3. Technological map
The crankshafts of ZMZ-53 engines are cast from alloyed cast iron. The shaft consists of main and connecting rod journals connected by cheeks, the continuation of which are counterweights that reduce the effect of inertia. The ZMZ-53 engine has a five-bearing crankshaft, i.e. has five main bearings. Cast iron bearing caps are attached to the block with two bolts and cotter pins. The tightening torque of the main bearing bolts must be PO-110-120 n m (11 - 12 kgf m).
Replacing the crankshaft bearings.
The liners are replaced when the bearings knock and the oil pressure drops below 0.05 MPa (0.5 kg / cm2) at idle speed with the oil pump and pressure reducing valves working properly. The need to replace the liners is also determined by the amount of wear of the liners in terms of thickness and diametrical gaps in the interface. If the wear and thickness exceed 0.05 mm, and the diametral clearance is more than 0.20 mm, the liners are replaced with new ones. The nominal diametral clearance between the bearings and the main journal should be 0.026 - 0.071 mm. It is necessary that there are no burrs or scratches on the surface of the crankshaft journals. The ovality, taper and wear of the crankshaft journals must not exceed 0.05 mm. In the presence of scoring, scratches, wear of the surface of the necks more than acceptable, it is not advisable to replace the liners. In this case, the engine should be sent for overhaul.
The cylinder block, crankshaft must be delivered to the assembly post after washing, drying and purging. The liners are selected according to the size of the crankshaft journals. For repair, the industry produces liners of the following size groups - standard; 0.05; 0.25; 0.5; one; 1.25; 1.5.
After checking, new liners of the required size are washed, wiped and installed in the bed of the main bearings and the lower heads of the connecting rod, after lubricating the surface of the liner and neck with engine oil. The liners must be installed in the bed of the connecting rod and main bearings in such a way that the locking protrusions located at one of the joints of each liner go into the grooves intended for them in the beds. The fixing protrusions at the joints of the liners should freely enter the grooves on the covers and in the bed of the block or connecting rod under the action of the force of the hand.
After replacing the liners, the axial play of the crankshaft is controlled (0.075-0.175) and, if its value is outside the allowable limits (0.25), it is necessary to replace the thrust washer. The assembly quality of the liners and the crankshaft is controlled by turning it with a torque wrench. For the ZMZ-53 engine, the scrolling torque should not exceed 60 Nm (6.0 kgf-m) after tightening the main bearing shells.
4. Safety
4.1 Safety requirements for tools, fixtures and main process equipment
To ensure labor safety, it is necessary to ensure the safety of production equipment and technological processes. To do this, the available tool, technological equipment must comply with the requirements of the labor safety system standards (SSBT), norms and rules for labor protection and sanitary standards. In order to ensure electrical safety, all process equipment with an electric drive must be reliably grounded. Grounding resistance should be no more than 4 ohms. Checking the grounding and insulation resistance is carried out once a year.
When working on an asphalt concrete floor at a workbench, a wooden grate is placed near the workbench to prevent colds and protect against electric shock. Distances between workbenches are taken depending on the overall dimensions and layout in accordance with ONT-01-86. It is possible to install workbenches close to the walls only if heating radiators, pipelines and other equipment are not placed there. Chairs should be with height-adjustable seats and preferably with adjustable backs. Workbenches for disassembly and assembly work, in order to make it convenient to work, are adjusted according to the height of the worker using stands under the workbench or footrests. The working surface of the workbench is covered with sheet metal or linoleum, depending on the types of work performed. On the site, when using multi-seat workbenches or placing them against each other, a mesh metal separating partition is installed to prevent injury to those working nearby by flying pieces of the material being processed. The height of the partition should be at least 750 mm, and the size of the cells should not exceed 3 mm.
All workplaces must be kept clean, not cluttered with parts, equipment, tools, fixtures, materials. Parts and assemblies removed from the engine during repair must be carefully placed on special racks or on the floor.
Hand tools must be in good condition, clean and dry. Its culling, as well as the culling of fixtures, must be carried out at least once a month. The tool must be firmly seated on the handle and wedged with sharpened mild steel wedges. The axis of the handle must be perpendicular to the longitudinal axis of the tool. The length of the handle is chosen depending on the mass of the tool: for a hammer 300 - 400 mm; for a sledgehammer 450 - 500 mm. The handles of hacksaws, files, screwdrivers, scrapers must be tightened with bandage rings.
4.2 Safety requirements when performing basic work on the site
When washing engines and parts, the concentration of alkaline solutions should not exceed 5%. Engine parts running on leaded gasoline are washed after tetraethyl lead deposits have been neutralized with kerosene. After washing parts and assemblies with an alkaline solution, they must be washed with hot water. It is strictly forbidden to use flammable liquids for washing. When using synthetic detergent surfactants, they are pre-dissolved in special containers or directly in the containers of the washing machine. In this case, the water temperature should not exceed the temperature of the parts by more than 18 - 20 ° C. To protect hands and prevent splashing of the solution on the mucous membrane of the eyes, workers must use goggles, rubber gloves and dermatological agents (Silicone cream, IER-2 paste).
When working on grinding machines, special attention should be paid to the abrasive wheel. It must be inspected, checked for the absence of cracks (when tapped in a suspended state with a wooden hammer weighing 200 - 300 g, it makes a clear sound), tested for strength, balanced.
Only workers who have been instructed in safety precautions and trained in the correct methods of performing work are allowed to perform work on the motor section.
When performing boring work of cylinders, block-cylinders must be securely fixed on the machine bed with the help of conductors, it is forbidden to hold the workpieces with hands.
When performing disassembly and assembly work, wrenches must be matched to the size of nuts and bolts. The size of the gap of the keys should not exceed the dimensions of the heads of the bolts and the faces of the nuts by more than 0.3 mm. Wrenches should not have cracks, nicks, burrs, non-parallelism of the jaws and the development of a pharynx. It is forbidden to unscrew the nuts with large wrenches with metal plates between the faces of the bolts and nuts and the jaws of the wrench.
For yews, the sponges should have an unfinished surface - a notch. The screws holding the jaws must be in good condition and tightened. The clamping screw must be free of cracks and chips.
4.3 Safety requirements for the premises
The production area of the motor section must be kept clean. It should regularly be wet cleaning, cleaning the floors from traces of oils, dirt and water. Oil spilled on the floor must be immediately cleaned up using absorbent materials such as sawdust, sand. The room must be equipped with supply and exhaust ventilation.
In order to protect workers from noise, the test bench room must be isolated from the rest of the room by a partition. The test room must be equipped with a local exhaust gas exhaust.
5. Conclusion
In the process of course design, tasks were solved in the following sections:
Settlement and technological section
selection, adjustment of maintenance and repair standards
determination of the design values of the coefficient of technical readiness and the coefficient of use of vehicles
determination of the annual mileage of the car at the ATP
determination of the annual and shift program for car maintenance
determination of the total annual labor intensity of maintenance and repair of rolling stock at ATP
determination of the total annual labor intensity of work on the design object
Organization section
choice of the method of organizing the production of maintenance and repair at the ATP
flow diagram at the design object
selection of the operating mode of production units
calculation of the number of TR posts
selection of technological equipment
determination of the production area of the engine shop.
6. References
1. Tutorial IN AND. Karagodin, N.N. Mitrokhin "Repair of cars and engines" 5th edition. Moscow. 2008
2. Regulations on the maintenance and repair of rolling stock of road transport / Minavtotrans RSFSR. - M.: Transport, 1986.
4. Manual for the operation of the car GAZ-53A. Edition 29. Gorky 1980.
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Short description
The efficiency of the use of motor vehicles depends on the perfection of the organization of the transport process and the properties of vehicles to maintain within certain limits the values of parameters characterizing their ability to perform the required functions. During the operation of the car, its functional properties gradually deteriorate due to wear, corrosion, damage to parts, fatigue of the material from which they are made, etc. Various malfunctions appear in the car, which reduce the efficiency of its use. To prevent the appearance of defects and timely eliminate them, the car is subjected to maintenance (TO) and repair.
Table of contents
Introduction
Characteristics of the ATP and the design object
1. Settlement and technological section
1.1 Selection, adjustment of maintenance and repair standards
1.2 Determination of the design values of the coefficient of technical readiness and the coefficient of use of vehicles
1.3 Determination of the annual mileage of the vehicle at the ATP
1.4 Determination of the annual and shift program for vehicle maintenance
1.5 Determination of the total annual labor intensity of maintenance and repair of rolling stock at the ATP
1.6. Determination of the total annual labor intensity of work on the design object
1.7 Determination of the number of repair workers at the ATP and the design object
2. Organizational section
2.1 Choice of production organization method Maintenance and current repairs at ATP
2.2 Scheme technological process at the design object
2.3 Selecting the mode of operation of production units
2.4 Calculation of the number of posts in TR zones
2.5 Selection of technological equipment
2.6 Calculation of the production area of the motor section
3. Technological map
4. Safety
4.1 Safety requirements for tools, fixtures and main process equipment
4.2 Safety requirements when performing basic work on the site
4.3 Safety requirements for the premises
5. Conclusion
6. References
The selection of technological equipment, organizational and technological equipment for the motor section will be made taking into account the recommendations of standard projects of workplaces in the ATP, as well as the sheet of garage technological equipment.
AT modern conditions you need to use modern high-performance equipment. To this end, we will install modern equipment on the site.
Stand R23.74M for grinding valves of cylinder heads of KAMAZ, YaMZ, GAZ, ZIL engines. Stand with electromechanical drive, stationary. Electric motor power 2.2 kW, weight 145 kg.
Designed and manufactured using the latest patented innovative technologies of KOPIS LLC, universal break-in stands of the KS276 series for internal combustion engines are high-quality modern energy-saving equipment that reduces User costs by more than 10 times compared to technically and morally obsolete stands of the Soviet period
Universal break-in benches of the KS276 series provide running-in of various brands of diesel and gasoline internal combustion engines for trucks, light-duty and cars, construction and special equipment, buses, tractors, special machines and other equipment.
Mass-produced models of stands of the KS276 series have the capabilities that most fully meet the tasks of high-quality post-repair running-in and testing of different brands of internal combustion engines.
The automated control system (ACS) of stands of the KS276 series is a software and hardware complex based on microcontrollers.
The stand of the KS276 series uses the principle of dynamic loading and innovative technical solutions, which provide the following advantages: versatility, energy saving, reduction of production areas, maximum automation, ease of installation and maintenance, ease of use.
Tabletop press with pressure gauge Trommelberg 10t SD100802 is indispensable at service stations. It is used for pressing bearings, bending and straightening of metal elements, as well as for fine stamping and calibration of parts. The press is driven by a manual hydraulic drive, develops a force of 10 tons. The plant has a solid metal structure and is characterized by a simple control mechanism.
The stand universal for repair of engines KAMAZ, YaMZ236, 238 (manual) M401. The stand is designed for assembly and disassembly operations of the KAMAZ and YaMZ engines. The stand consists of a welded frame, two posts, one of which is fixed in two positions. The first position of the movable rack is set to the maximum size for the YaMZ (MAZ, KRAZ) engine, the second position for the KAMAZ engine. A worm gear with a leading traverse is installed on a fixed rack, and a driven traverse is mounted on the other. The traverses have pins that are inserted into the holes of the block of the serviced engine.
To repair the engine, the movable rack is installed in the required position and fixed. The engine is lowered onto the hooks, fixed with four screws, which are screwed all the way into the holes in the engine block. Turning the engine to the desired position is done with the handle
Technological equipment
Name |
Dimensions in plan, mm |
Area, m2 |
||
Locksmith workbench |
||||
Tool cabinet |
||||
Cylinder head valve grinding stand |
||||
Engine disassembly stand |
||||
Stand for testing and running engines |
||||
Installation for mechanized washing of parts |
||||
The stand universal for repair of engines |
||||
Stand for disassembly and assembly of cylinder heads |
||||
Workwear cabinet |
||||
waste bin |
ORG146807080A |
|||
Fire shield and sand box |
Own production |
|||
Hydraulic Press |
Trommelberg SD100802 |
|||
Transport trolley |
Own production |
|||
Tool rack |
||||
Hanging crane beam |
||||
Technological equipment
Name |
Model, GOST |
Quantity |
Yew locksmith |
||
Bench grinder |
||
Tool kit auto mechanic |
||
Calibration plate |
||
Lever micrometer |
||
Micrometer smooth |
||
Micrometer smooth |
||
Micrometer smooth |
||
Micrometer depth gauge |
||
Nutrometer |
||
Calipers |
||
Calipers |
||
Height gauge |
||
Probe set No. 2; |
||
Indicator |
||
Angle backlash meter |
||
Bearing puller |
||
Valve spring removal and installation tool |
||
Piston ring installer |
When calculating the production area of the engine section, we take into account the fact that the engines arrive at the site after dismantling and washing, so the area of the car in the plan is not taken into account in the calculations.