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INTRODUCTION
The topic of my thesis project is “Organization of a battery shop of a motor transport enterprise at 370 ZIL-5301”. The battery shop occupies an important place in the general technological process of the DRA.
As a legacy from the former USSR, Russia inherited a relatively powerful infrastructure of road transport with an extensive planning system for organizing transportation and an operation service with a sufficiently modern technological base for maintenance and repair of substations AT. However, a significant increase in the efficiency of the transportation process while simultaneously reducing the cost of transportation was not enough - a search for new optimal solutions is required, especially in the context of the transition of the entire economy to market relations. The privatization and corporatization of the former ATP with full or partial transfer to private ownership, including the substation, required significant changes both in the organization of the transportation process and in the organization of the repair service. The very structure of AT management has undergone significant changes, both quantitatively and qualitatively. For example, the former Ministry of AT and Highways of the Russian Federation became part of the joint Ministry of Transport, whose work is aimed at uniting the efforts of previously isolated modes of transport and creating a unified transport system that meets the modern requirements of a market economy.
However, it should be noted that the previously developed and debugged basic provisions for the operation, maintenance and repair of the Substation AT remained virtually unchanged, not counting certain "cosmetic" innovations. As before, a powerful lever for increasing the efficiency of the vehicle as a whole is the mechanization and automation of the production processes of the repair service in the ATP with the introduction of the latest technologies, garage equipment (including foreign firms) into production. To accomplish the tasks set, the domestic industry, despite the difficult economic situation, continues to expand the range of manufactured garage equipment for almost all types of work and, first of all, for performing labor-intensive operations. A significant role in increasing the labor productivity of repair workers, and therefore in reducing the cost of work on maintenance of the in-line method, and in the areas of the TR of specialized posts (in addition to universal ones), the introduction of the aggregate method of repair into production, when instead of faulty components and assemblies on the car immediately put in advance repaired from the revolving fund - this allows you to drastically reduce the downtime of the car for repair. In auxiliary shops, a significant effect is provided by the use of route technology, which makes it possible to reduce the waste of work time.
Even more importance will be given to the corresponding types of diagnostics, since in addition to quickly and accurately identifying various failures and malfunctions, it allows you to predict the possible service life of a vehicle without repair, which in general makes it easier to plan in advance the optimal amount of maintenance and repair work, and this, in turn, allows you to improve the clarity of the organization of work of all links ATP repair service, including supply issues. The experience of using diagnostics in ATP indicates a significant decrease in emergency situations on the line for technical reasons and a significant saving of production resources - up to 10-15%. The implementation of the tasks set for the repair service of the ATP will allow, in addition to the indicated positive aspects, to increase the general culture of production, to create optimal sanitary and hygienic conditions for workers. Another direction in increasing the efficient operation of vehicles is the production by manufacturers and the introduction into the transportation process of a fundamentally new type of PS - from powerful tractor trucks for intercity transportation to various types of mini-trucks with increased maneuverability for cities (for example, Gazelles, Bychki ).
The implementation of the planned activities will undoubtedly allow more efficiently and to a greater extent to carry out transport process when serving the population and various parts of the industry of the Russian Federation, while reducing the cost transport services, which will make the transport of the Russian Federation cost-effective, meeting modern requirements.
1 ORGANIZATION OF THE TECHNOLOGICAL PROCESS IN THE BATTERY WORKSHOP of a motor transport company
The battery compartment carries out repairs, charging and recharging the battery. In many large car fleets, the specialists of this department also produce battery maintenance at TO-1 and TO-2. In accordance with the technology of maintenance and repair of batteries and modern requirements for production in a workshop in especially large motor vehicles, the department premises are divided into reception, storage and repair departments (acid and charging).
The acid compartment is intended for storing sulfuric acid and distilled water in glass bottles, as well as for preparing and storing electrolyte, for which a bath of lead or faience is used. It is installed on a wooden table lined with lead. For safety reasons in the event of acid spills, the bottles are installed in special devices.
Defective batteries arrive at the reception room. Here, control is carried out from the technical condition and the content of maintenance and repair work is determined. Further, depending on the condition, they are sent for repair or recharging.
Battery repair is usually done using off-the-shelf parts (plates, separators, tanks). After the repair, the battery is filled with electrolyte and enters the room to charge the batteries. The charged battery is returned to the vehicle from which it was removed or goes to the revolving fund.
Batteries are usually assigned to vehicles. For this, a garage number is placed on the battery jumpers. In medium or small car fleets, the battery compartment is usually located in two rooms. In one, batteries are received and repaired, while the other is charged with electrolyte and batteries are charged.
2 CALCULATION OF THE PRODUCTION PROGRAM
Initial data for design
| Initial data | Legend | Data accepted for calculation | Units |
| 1. Car make | __ | ZIL 5301PO | __ |
| 2. List of vehicles | A C | 370 | pCS. |
| 3. Average daily car mileage | 1 SS | 90 | km. |
| 4. The number of days of work in a year ATP | D RGP | 305 | days |
| 5. The number of days of operation of the battery workshop | D DTD | 305 | days |
| 6. Category of operation | __ | III | __ |
| 7. Duration of release and return to the park | __ | 3 | hour. |
NOTES:
1. The number of days of operation of the battery shop for planning purposes according to the technique of the technical school is taken equal to 305 days.
3 ADJUSTMENT OF SERVICE PERIOD AND MILEAGE TO MAJOR REPAIR
We adjust the mileage standards based on the following factors:
2. Coefficient K 2, taking into account the modification of the rolling stock, we take according to table. No. 3 "Appendix" equal to - K 2 \u003d 1.0;
3. Coefficient K 3, taking into account natural and climatic conditions, for our central zone according to table. No. 3 of the "Appendix" we accept - K 3 \u003d 1.0.
The resulting correction coefficients are taken as follows:
1) for the periodicity of TO - K TO \u003d K 1 * K 3 \u003d 0.8 * 1.0 \u003d 0.8
2) for the run to the cap. repair - K KR \u003d K 1 * K 2 * K 3 \u003d 0.8 * 1.0 * 1.0 \u003d 0.8
The standards for the frequency of maintenance (for new car models, for category I of operation) are taken from Table. No. 1 "Appendix", and the standards for the overhaul mileage to KR from table. # 2.
1. We adjust the mileage to TO-1:
L 1 \u003d K TO * H 1 \u003d 0.8 * 3000 \u003d 2400 km
2. Correct the mileage to TO-2:
L 2 \u003d K TO * H 2 \u003d 0.8 * 12000 \u003d 9600 km
3. Correct the mileage to KR (cycle):
L C \u003d K KR * N KR \u003d 0.8 * 300000 \u003d 240,000 km
4 DEFINITION OF THE PRODUCTION PROGRAM BY TO AND KR PER CYCLE
For the cycle we take the mileage to KR
NOTE:
Since all planning in the ATP is carried out for a year, it is necessary to transfer the indicators of the production program for the cycle to the annual program for the entire rolling stock of the ATP; for this purpose, we preliminarily determine the coefficients of technical readiness (a TG), the use of the car park (a И) and the transition from cycle to year (¦ Г).
5 DETERMINATION OF THE TECHNICAL AVAILABILITY RATIO
The coefficient of technical readiness is determined taking into account the operation of the car per cycle (DEC) and the idle time of the car in maintenance and repairs per cycle of operation (D RC).
| Name of indicators, formulas | Payment | Calculation indicators |
| Technical readiness factor: a TG \u003d D EC / D EC + D RC, | 2667/2667+68 | a TG \u003d 0.97 |
| where D RC - downtime per cycle in maintenance and repair: D RC \u003d D K + L C / 1000 * D OR * SR, | 8 + 240000/1000 * 0,25 | D RC \u003d 68 days. |
| DK - simple in the KR at the ARZ, according to the table. No. 4 "Supplements" we accept - D K \u003d 16 days., | Due to the centralized delivery of cars from ARZ, for planning purposes. reduce downtime by 50% | DK \u003d 8 days. |
| D OR * SR - specific downtime in TO and TR per 1000 km of run, according to table. No. 4 "Supplements" we accept - D OR * SR \u003d 0.5 days, | Due to the partial maintenance and repair work in between shifts, it can also be reduced by 50% | D OR * SR \u003d 0.25 days. |
| D EC - the number of days of operation of the car per cycle: D EC \u003d N EOC \u003d L C / l SS | 240000/90 | D EC \u003d 2667 days. |
6 DETERMINING THE PARK USE RATE
This coefficient is determined taking into account the number of days of operation of the park in a year - D RGP (on assignment) according to the formula:
a \u003d a TG * D RGP / 365 \u003d 0.97 * 305/365 \u003d 0.81
7 DETERMINING THE AMOUNT OF THAT AND TO R
As mentioned above, this coefficient is determined in order to transfer the cycle production program to the annual one:
n Г \u003d a И * 365 / D EC \u003d 0.81 * 365/2667 \u003d 0.11.
DETERMINING THE AMOUNT OF THAT AND TO R FOR THE WHOLE PARK IN A YEAR
Note.
Calculation indicators - N KRG, N 2g, N 1g, N EOG - are rounded to whole numbers.
DETERMINING THE AMOUNT OF TOPS BY THE PARK PER DAY
Note.
1. Indicators of calculation - N 2 days, N 1 days, N EO SUT - round to whole numbers.
2. Since the TO-1 and TO-2 zones in most ATP do not function on Saturdays and Sundays and on holidays, and the EO zones operate as long as the entire park operates, i.e. D RG ZONES EO \u003d D RGP park (on assignment).
We accept:
D WG ZONE TO-2 \u003d 305 days.
D WG ZONE TO-1 \u003d 305 days.
D WG ZONES EO \u003d 305 days.
8 DETERMINATION OF THE ANNUAL EMPLOYMENT OF THE WORKSHOP
The annual labor intensity of work for the shops and departments of the ATP is taken as a share of the total labor intensity of work on the TR for the entire fleet, and that, in turn, is determined by the formula:
Т ТР \u003d L ГП * t ТР, where:
L ГП - the total annual mileage of all rolling stock of the ATP (in thousands of km);
t ТР - specific labor input according to ТР, given for every 1000 km of run of cars and trailers of parks;
L GP - determined by the formula:
L GP \u003d 365 * a I * l SS * A C \u003d 365 * 0.81 * 90 * 370 \u003d 9845145 km.
t TP - we take from the table. No. 5 "Appendices" and we accept -
t TR \u003d 4.8 man-hours.
Because the specified standards are given for the main basic models of new cars, for the I category of operation - it is necessary to adjust t TP taking into account the correction factors - K 1, K 2, K 3, etc., and we take their values \u200b\u200bfrom the Appendix tables to correct “Labor intensity”, not “runs” as before.
K 1 - coefficient taking into account the category of operating conditions.
K 2 - coefficient taking into account the modification of the rolling stock.
К 3 - coefficient taking into account natural and climatic conditions.
K 4 is a coefficient characterizing the mileage of vehicles in the fleet since the beginning of operation (from Table No. 3 “Appendices”), and conditionally we assume equal to 1.
K 5 is a coefficient characterizing the size of the ATP and, therefore, its technical equipment, we take from table. No. 3 "Appendices".
Now we determine the resulting coefficient for the correction of labor intensity - CTE, according to the formula:
K TP \u003d K 1 * K 2 * K 3 * K 4 * K 5 \u003d 1.2 * 1 * 1 * 1 * 0.8 \u003d 1.02.
We adjust the specific standard labor input t TR:
t ¢ TR \u003d t TR * K TR \u003d 4.8 * 1.02 \u003d 4.9 man-hours.
Determine the annual labor input for the TR according to the above formula:
T TR \u003d L GP / 1000 * t ¢ TR \u003d 9845145/1000 * 4.9 \u003d 48241 man-hours.
Determine the share of work from T TR that comes to the battery shop according to table. No. 8 "Appendices".
Share of dep. \u003d 0.03.
We determine the annual labor intensity of the workshop for the battery workshop of the ATP according to the formula:
T G OTD \u003d T TR * Share of dep. \u003d 48241 * 0.03 \u003d 1447 man-hours.
All indicators of annual labor intensity are rounded to whole numbers.
Since the organization of work in the department is planned by me taking into account the latest recommendations of NIIAT, with the introduction of the main provisions of the NOT, with the use of new models of garage equipment, labor productivity in the department will increase by at least 10%, and the coefficient of increase in labor productivity will be:
Then the projected annual labor intensity of work in the shop will be:
T ¢ G DTD. \u003d T G DTD. * K PP \u003d 1447 * 0.9 \u003d 1303 man-hours.
The released annual labor intensity due to the planned increase in labor productivity (in comparison with the generally accepted existing norms) will be:
T G HIGH \u003d T G DTD. - T ¢ G DTD. \u003d 1447 - 1303 \u003d 144 man-hours.
9 DETERMINING THE NUMBER OF WORKERS IN THE BATTERY SHOP
We determine the number of technologically necessary workers (number of jobs) by the formula:
P T \u003d T ¢ G DTD. / F M \u003d 1303/2070 \u003d 0.6 people.
Accept: Р Т \u003d 1 person,
where F M is the actual fund of the workplace (taking into account the number of days of work in the year of the department and the duration of the shift), according to table. No. 10 “Appendices” of the methodological manual are accepted:
F M \u003d 2070 man-hours.
Determine the staff (payroll) number of workers:
R W \u003d T ¢ G DTD. / F R \u003d 1303/1820 \u003d 0.7 people,
where FR is the actual fund of working time, taking into account holidays, illnesses, etc., we take according to table. No. 10 "Appendices" -
F R \u003d 1820 man-hours.
Thus, I finally accept the number of employees in the department: P W \u003d 2 people.
Note: Based on the technological necessity and work experience, I accept P W \u003d 2 people.
10 DETERMINATION OF THE PRODUCTION AREA OF THE WORKSHOP
We determine the total area occupied in terms of equipment and organizational equipment, according to the formula:
F SUM \u003d F ¢ SUM + F ¢¢ SUM \u003d 1.697 + 14.345 \u003d 16.042.
The estimated area of \u200b\u200bthe workshop is determined by the formula:
F SHOP \u003d F SUM * K PL \u003d 16.042 * 3.5 \u003d 56.147,
К ПЛ - equipment density coefficient for a given workshop, taking into account the specifics and safety of work;
We take the PL from the table. No. 11 “Appendices” equal to 3.5.
Considering that new buildings and premises are usually built with a grid multiple of 3 m, and the most common dimensions of workshops are: 6 * 6, 6 * 9, 6 * 12, 9 * 9, 9 * 12, 9 * 24, etc. ... - I take the size of the workshop equal - 6 * 9 m.
Then the workshop area will be 54 m 2.
MANUAL FOR SELECTION OF TECHNOLOGICAL EQUIPMENT OF THE SHOP
| P / p No. | Name | amount | Dimension. dimensions (mm) | Plan area (total) m 2 | Energy intensity (total) kw | Make or model |
| 1 | Transformer | 1 | 400´200 | 0,080 | 20 | purchased |
| welding | ||||||
| 2 | Electric towel | 1 | 200´150 | 0,030 | 0,6 | purchased |
| 3 | Rectifier | 2 | 500´400 | 0,400 | 2,13 | VAGZ 120-60 |
| 4 | Force shield | 1 | 300´150 | 0,045 | ____ | purchased |
| 5 | Electric distiller | 1 | 150´150 | 0,022 | 3 | DE-6 |
| 6 | Installation for cooking | 1 | 1400´800 | 1,120 | ____ | development |
| electrolyte | SKB AMT | |||||
| 7 | Electric drill for | 1 | 500´200 | 0,100 | 2 | development |
| drilling pins | SKB AMT | |||||
| 8 | Sub-assembly clamps | 2 | 150´150 | 0,045 | ____ | purchased |
| plates | ||||||
| 9 | Electric crucible for | 1 | 200´200 | 0,040 | 20 | purchased |
| lead | ||||||
| 10 | Installation for distribution | 1 | 900´900 | 0,810 | ____ | development |
| electrolyte | SKB AMT |
MANUAL FOR SELECTION OF ORGANIZATIONAL EQUIPMENT OF THE SHOP
| P / p No. | Name | Amount | Dimension. dimensions (mm) | Plan area (total) m 2 | Type, model |
| 1 | Shelving unit with hood | 2 | 1500´800 | 2,4 | OG-04-OOO |
| for battery charging | |||||
| 2 | Rack for special charging | 1 | 1000´800 | 0,8 | own. |
| batteries | manufactured | ||||
| 3 | Sectional cabinet for | 1 | 600´300 | 0,18 | own. |
| impregnation of batteries with a hood | manufactured | ||||
| 4 | Electrolyte drain bath | 1 | 1000´1000 | 1,00 | PA-03-OOO |
| 5 | Battery disassembly workbench | 1 | 1200´300 | 0,36 | E-403 |
| 6 | Portable Chest for Lead | 1 | 150´300 | 0,045 | own made |
| 7 | Combined bath-workbench | 1 | 1500´300 | 0,45 | development of SKB AMT |
| 8 | Plate subassembly workbench | 1 | 1000´300 | 0,3 | own made |
| 9 | Battery Assembly Workbench | 1 | 1200´300 | 0,36 | own made |
| 10 | Sectional cabinet | 1 | 600´300 | 0,18 | own made |
| 11 | Shelving trolley for | 1 | 1350´600 | 0,81 | development |
| spare parts and materials | SKB AMT | ||||
| 12 | Lead waste bin | 1 | 600´600 | 0,36 | development |
| sealed | SKB AMT | ||||
| 13 | Battery rack | 2 | 1200´400 | 0,96 | E-405 |
| 14 | Trash bin | 2 | 400´200 | 0,16 | purchased |
| 15 | Table for instruments | 1 | 600´600 | 0,36 | purchased |
| 16 | Stationery table | 1 | 1200´500 | 0,6 | purchased |
| 17 | Battery control table | 1 | 1200´600 | 0,72 | own made |
| 18 | Rectifier cabinet | 1 | 1200´600 | 0,72 | own made |
| 19 | Transport trolley | 2 | 700´400 | 0,56 | own made |
| batteries | |||||
| 20 | Household bedside table | 1 | 700'700 | 0,49 | purchased |
| 21 | Transport trolley | 1 | 1150´756 | 0,87 | P-206 |
| acids in bottles | |||||
| 22 | Installation table for | 1 | 1000´700 | 0,7 | own made |
| electrolyte dispensing | |||||
| 23 | Acid bottle | 2 | 600´600 | 0,72 | purchased |
| 24 | Sink | 1 | 400´600 | 0,24 | purchased |
MANUAL FOR SELECTION OF TECHNOLOGICAL EQUIPMENT OF THE SHOP
11 PROPOSED TECHNOLOGICAL PROCESS ORGANIZATION
The battery shop in my project has overall dimensions - 6 * 9 and, accordingly, an area of \u200b\u200b54 m 2. Since the workshop has zones with specific working conditions, I propose to divide the workshop into four sections:
1. Department of "RECEPTION and CONTROL"
3.3 * 2.9 9.57 m 2
2. "REPAIR DEPARTMENT"
6.1 * 3.7 22.57 m 2
3. "CHARGING COMPARTMENT"
4.8 * 2.7 12.96 m 2
4. "ACID COMPARTMENT"
2.2 * 4.1 9.02 m 2
I propose to carry out separate workshops using highly efficient ventilating transparent partitions (developed by SKB MAK). The floor in all offices should be tiled with metlakh tiles, the walls should be dull. I propose to lay out the lower part of the walls with tiles at a height of 1.5 m.
In the vicinity of the battery shop, there should be a TO-2 zone, an electrical and carburetor shops, as the most gravitating in the technological process used in the ATP.
The “acid” department should have an independent exit to the street. Defective batteries are delivered from the TO-2 zone along a roller table connecting the TO-2 zones and the battery shop to the battery reception and control post, where battery faults are clarified. The batteries are then transported on a trolley, either to the “charging” compartment for recharging, or to the “repair” compartment for necessary work by TP of batteries.
In the "repair" department, all equipment is located in the order of the progress of work on the repair of batteries, i.e. a directional route technology is being introduced (developed by SKB IAC). To reduce unnecessary crossings and to increase labor productivity, a roller conveyor is installed throughout the battery repair line.
Waste received during repairs is stored in hermetically sealed waste containers (developed by SKB MAK). All app. parts and materials are transported on a special trolley - a rack (developed by SKB AMT). The repaired batteries are also delivered through a through roller table to the battery charging and refueling workshop (section). Charging and impregnation is carried out using a special installation for electrolyte dispensing (electrolyte production is carried out in the “acid” section, where a special installation for electrolyte preparation is also used). Ready-to-use batteries are stored on a battery storage rack, from where they are returned to the TO-2 area for installation on a vehicle.
Batteries not being repaired are removed from the workshop.
12 MAIN TASKS FOR THE IMPLEMENTATION OF ENERGY-SAVING TECHNOLOGIES AND ECONOMIC MEASURES IN ATP
The protection of the environment from the harmful effects of AT is carried out in many directions, some of which should become the field of activity of graduates of motor transport educational institutions and which I have outlined for implementation in my project.
At the moment, more than 30 standards for environmental protection have been developed and are being implemented everywhere. In particular, it is not allowed to put into operation the ATP (and other industrial facilities) until the end of their construction and testing of treatment and dust and gas collection facilities and devices. The harmful effect of AT on the environment occurs in two directions:
1) direct negative impact of the car on the environment associated with the emission of a huge amount of harmful toxic substances into the atmosphere and with increased noise from the car on the line;
2) the indirect influence comes from the organization and functioning of the ATP for the maintenance and repair of cars, parking garages, fuel filling stations, etc., occupying a large and annually increasing area necessary for human life and, first of all, in the boundaries of large cities-megalopolises.
According to data from environmental organizations in Moscow, about 90% of all emissions of harmful toxic substances come from AT.
In connection with the increasing shortage of energy resources, a whole complex of introducing energy-saving technologies into production has been developed, incl. for ATP.
In connection with the above, I propose the creation of a modern production that meets environmental requirements with a device modern system supply and exhaust ventilation with the introduction of a system of dust collectors, gas filters, etc. In the ATP, in general, modern diagnostics using high-precision electronic devices, etc. should be introduced. for the timely detection of vehicles with a faulty power supply system, ignition, etc., the operating parameters of which do not meet environmental requirements, as well as the creation of appropriate workshops, posts and workplaces to eliminate malfunctions in these systems (by making the necessary adjustments, replacing faulty nodes and parts, etc.).
In order to save electricity for daytime lighting at maintenance and repair posts and at workplaces in auxiliary shops, I propose to make the most of natural light by creating modern large-format window openings, and in the upper part of production buildings - daylight lamps of a large area. Accordingly, the arrangement of equipment in the shops (so as not to obstruct the light flux) and the location of posts with a / m should be carried out. I propose to develop an optimal technological mode of work for each post and workplace in order to minimize the time spent on operations and thereby reduce the consumption of electricity and materials. All energy consumers, from artificial lighting fixtures to electric drives power plants, stands and devices must be equipped with automatic elements to disconnect them from the network at the end of work.
To preserve heat in repair areas (and, therefore, in workshops), they should be equipped with doors with a mechanized opening and a thermal curtain with a bottom location (folding type doors with a vertical lift are recognized as one of the best types of doors). In the EO ATP zone with posts for car washing, I propose to place a system for repeated (multiple) use of water, with the introduction of the latest treatment facilities such as "CRYSTAL", etc.
Mechanized installations in the zone must be equipped at the entrance and exit from the post with flexible controllers with sensors for automatic switching on and off of the installations, which will also give great savings.
This is just a part of the environmental and energy saving measures that I propose to implement in my project.
13 CONTEMPORARY WORKSHOP PRODUCTION REQUIREMENTS
To improve the quality of repairs and increase the productivity of workers, I propose the following activities in my project:
1. Widespread introduction of appropriate types of diagnostics; this allows you to dramatically reduce the time for servicing specific faults and to identify possible service life without repair.
2. Introduction of advanced methods of organizing the production of progressive technology.
3.In order to increase labor productivity, the quality of work and the general culture of production in the shop, to introduce the directional routing technology developed by SKB AMT (at the same time, irrational transitions of workers are reduced to a minimum, the technological process takes into account the most modern requirements).
4. I suggest periodically, by the efforts of the VET staff, to conduct timekeeping at workplaces in order to compare the time spent with generally accepted norms to identify unaccounted reserves and the reasons for increasing these norms.
5. In order to improve the working conditions of workers, I propose to carry out a number of sanitary and hygienic measures (cleanliness of premises, good ventilation, good lighting, installation of soundproof partitions, maintenance of an artificial climate).
14 PASSPORT CARD TO THE WORKPLACE
Room area S \u003d 54 m 2
Equipment filling factor n \u003d 3.5
The number of workers per shift P \u003d 2 people.
Air temperature t \u003d 18 - 20 ° C
Relative humidity 40 - 60%
Air speed 0.3 - 0.4 m / s
Work in the battery shop is classified as medium-duty work.
Energy 232 - 294
CONNECTION OF HARMFUL SUBSTANCES
15 LIGHTING
Natural lighting with top and top-side lighting
e \u003d 4%, with side illumination
General artificial lighting E \u003d 200 lux,
Combined illumination E \u003d 500 lux.
Noise level J \u003d 80 dB at 1000 Hz.
16 EVENTS TB software
Workers engaged in battery repair and maintenance are constantly in contact with harmful substances (lead vapors, sulfuric acid), which, under certain conditions or improper handling, can lead to injury or poisoning of the body. In addition, when charging the battery, a chemical reaction occurs, as a result of which the released free hydrogen is mixed with oxygen in any proportions and a volatile gas is formed that explodes not only from fire, but also from compression. In this regard, the battery shop of the ATP should consist of three sections: "repair", "charging", "acid".
The “CHARGING” compartment must have direct access to the street or to a common repair box. The floor in the battery workshop should be either asphalt or metlakh tiles. All workers must wear protective clothing and protective equipment. Battery weighing more than 20 kg must be transported on a trolley, excluding falls. When carrying the battery, you need to use various devices (so as not to pour over electrolyte).
It is necessary to prepare electrolyte in special vessels, pouring distilled water first, and then acid. Acid can be poured using special devices. Pouring acid by hand and pouring water into it is FORBIDDEN!
When preparing electrolyte, you must strictly follow the safety rules. Bottles with acid or electrolyte should be moved in warehouses only with the help of special stretchers with bottle fixation. Solid rubber stoppers should fit snugly against the neck of the bottle. Do not store acid bottles for a long time in the battery shop. Control over the charge progress only with chargers (load plugs, hydrometers, glass intake tubes). The battery operator must wear rubber gloves. Do not check the battery charge by short circuit. It is forbidden to stay in the battery shop for persons not working in the shop (except for the personnel on duty - at night).
At the entrance to the battery shop, you should install a sink, a bedside table with a first aid kit, an electric towel, and a soda solution (5-10%) should be kept ready on the bedside table. A neutralizing solution (2-3%) is made to wash the eyes. If acid or electrolyte comes into contact with open areas of the body, immediately wash this area of \u200b\u200bthe body: first with a neutralizing solution and then with water and alkaline soap. Electrolyte spilled on a rack or table is removed with a cloth soaked in a neutralizing solution.
Do not eat or drink in the battery shop. After completing the work, workers are advised to shower with alkaline soap and then regular toilet soap. All tools, carts, devices must be in good working order. Posters with visual TB campaigning should be posted in prominent places in the department. At the entrance, you should post the general safety requirements. Workers must undergo safety instrumentation at least once a year. Particular attention should be paid to ventilation. It is done separately from the ventilation of the entire enterprise. Fume hoods are made for hoods from racks.
Ventilation - explosive suction at the top, supply at the bottom. Panels are installed "taking" charged air along the baths for electrolyte preparation. The amount of air to be removed is not less than 2.5 volumes per hour.
Local ventilation is installed at workplaces: for lead smelting and workbenches for assembling and disassembling batteries.
17 FIRE-FIGHTING MEASURES
In terms of fire hazard, the battery shop belongs to the “D” category, and the “charging” compartment belongs to the “A” category (especially fire hazardous). Therefore, the department must strictly observe all fire safety rules for the indicated categories.
In the “charging” compartment, the doors should open outward and go out into the street. Ventilation in the "charging" compartment (due to the release of hydrogen during charging) should provide 6-8 times the exchange; in "repair" - 2-3 times. In the compartment, all lamps are in gas-permeable fittings. Open lighting wiring is made with lead wire.
It is prohibited to install switches, plug sockets, electric heaters, rectifiers in the “charging” compartment. At each site, without fail, there must be a fire extinguisher, both foam and carbon dioxide type (OP and OU).
I envisage installing the chargers (rectifiers) in special sealed cabinets (with an exhaust hood) made of durable glass and place them in the battery reception and control section. In addition to the fire notification panel, I propose to install maximum action heat detectors (IP-104, IP-105) in the workshop room, install an automatic gas analyzer with an alarm in the “charging” compartment, as well as “smoke” sensors connected to the central control panel of the ATP.
I propose to install primary fire extinguishing equipment in each department:
1. FOAM EXTINGUISHER OHP-10 - 2 pcs.
2. AIR-FOAM EXTINGUISHER ORP-10 - 2 pcs.
3. CARBON EXTINGUISHER OU-2 - 2 pcs.
4. BOX WITH SAND - 0.5 cubic meters - 1 pc.
5. SHOVEL - 1 pc.
18 FIRE SAFETY
It is FORBIDDEN to connect the battery clamps with a wire “twist”!
Control over the charge departure is carried out by special devices.
Checking the battery with a short circuit - FORBIDDEN !!!
It is FORBIDDEN to use different types of “tees” and connect more than one consumer to the outlet !!!
To inspect the battery, portable electric lamps are used, with an explosion-proof voltage of no more than 42 V.
FORBIDDEN:
Enter the battery shop with an open fire (matches, cigarettes, etc.);
Use electric heating devices in the battery shop;
Store acid bottles (they need to be stored in a special room);
Store and charge acid and alkaline batteries together;
Stay of strangers in the room.
19 EQUIPMENT
PURPOSE OF THE CONSTRUCTION
TURNER - designed for overturning batteries when flushing or draining electrolyte. It greatly facilitates the work on the above operations.
TILT CONSTRUCTION
The rotator consists of a platform 3, on which two posts are attached 2. The platform has four wheels 5, two of which are welded by brackets 4 to the platform 3, and the other two 6 can rotate around the vertical axis 12, because the bracket is welded to the bearing unit, which ensures that the rotator is transported along the separation, and not just straight motion.
On the upper part of the struts 2, bearing units are installed, in which the semiaxes 8 of the lodgement rotate. The base has a window for installing the battery. The battery is attached to the cradle with clamps. The base with the installed battery can be manually rotated to any angle. In this case, the flywheel 7 will be fixed at angles of rotation 90, 180, in order to release the flywheel lock, you must pull the flywheel towards you, when fixing, you must release it and it will return to its place under the action of the spring.
1. The storage battery (accumulator battery) is placed in the positioner of the tilter on the left side in the direction of travel.
2. Before working on draining the electrolyte, it is necessary to exclude the spontaneous movement of the tilter; for this, it is stopped with screw jacks located on the platform to the right and left of the rack with the flywheel.
3. In order to turn the battery over and pour out the electrolyte or water, pull the flywheel towards you perpendicular to the vertical plane. The handwheel will disengage from the lock and can be turned clockwise to any angle.
4. To stop turning the battery at an angle of 90 and 180, it is enough to release the flywheel.
5. To return the battery to its original position, perform work according to point “3”, but turning the flywheel counterclockwise.
CALCULATION OF THE CONSTRUCTION OF MAIN UNITS
Initial data:
P \u003d 10 kg - force acting on the spring.
D \u003d 12 mm - spring diameter.
l \u003d 13 mm - spring tension.
[t] \u003d 150 kg / cm 2 - maximum shear stress.
1. Determine the diameter of the wire - d
2. Determine the number of turns of the spring - n, where:
G - modulus of elasticity of the second order
G \u003d 0.4 * E \u003d 0.4 * 2 * 10 6 \u003d 8 * 10 5 kg / cm 2
Е - elastic modulus of the first order (Young's modulus)
E \u003d 2 * 10 6 kg / cm 2
TECHNICAL SPECIFICATIONS:
1. Type - mobile, with manual drive
2. dimensions, mm - 980 * 600 * 1020
3. Weight, kg - 60
4. Rotation - manually
1) t \u003d 8PD / Pd 3; d \u003d 3 Ö8PD / P [t] \u003d
3 Ö8 * 10 * 12 / 3.14 * 150 \u003d 2 mm.
2) l \u003d 8PD 3 * n / G * d 4; n \u003d l * Gd 4 / 8P * D 3 \u003d
13 * 8 * 10 5 * 0.2 4/8 * 10 * 1.2 3 \u003d 10 turns.
LIST OF USED LITERATURE
1. EPIFANOV L.I. “Methodological manual for course design
MOT of cars. ”Moscow 1987.
2. KOGAN EI KHAIKIN VA "Labor protection at the enterprises of road transport". Moscow "Transport" 1984.
3. SUKHANOV BN BORZYKH IO BEDAREV YF "Maintenance and repair of automobiles". Moscow "Transport" 1985.
4. KRAMARENKO GV BARASHKOV IV "Maintenance of automobiles". Moscow "Transport" 1982.
5. RUMYANTSEV SI "Car repair". Moscow "Transport" 1988.
6. RODIN YU.A. SABUROV LM "Handbook of a car repairman". Moscow "Transport" 1987 year.
Introduction
2.3 Selecting and adjusting the standards for the labor intensity of technological maintenance and overhaul per 1000 km of run
3. Organizational section
3.3 Technological map
4. Labor protection
Conclusion
Literature
Introduction
Increasing the productivity, efficiency of using the rolling stock of road transport largely depends on the level of development and conditions of functioning of the production and technical base of the road transport enterprise, the main task of which is to ensure the required level of technical readiness of the rolling stock.
The development, improvement of the production and technical base of road transport enterprises must meet the modern requirements of scientific and technological progress. In solving the problems of studying production and technical bases, bringing it in line with the requirements of a dynamically developing road transport, an important place is occupied by the issues of improving the design of an enterprise.
Road transport is quite convenient compared to other modes of transport. It has great maneuverability, good maneuverability and adaptability to various conditions. The production service plays a significant role in the implementation of many complex tasks. The automotive industry is systematically working to improve production technologies and improve the design of rolling stock.
Considering that the growth of labor productivity depends on the level of mechanization and automation of production processes, therefore, one of the main tasks is the maximum equipping of each workplace, post with a set of technological equipment, tools and devices.
Of great importance for increasing labor productivity during maintenance and repair and ensuring their quality is the widespread introduction of the scientific organization of labor (NOT) in production. The latter includes a large range of measures, including improving the organization and maintenance of workplaces, improving the techniques, methods and rationing of labor, creating favorable sanitary, hygienic and aesthetic working conditions, etc.
The goal of my course project is to design a battery compartment.
The objectives of the project are to calculate the frequency of maintenance; determination: the number of services per year, the technical readiness coefficient, the daily program of cars; distribution of labor intensity for maintenance and repair of vehicles and self-service of the enterprise; distribution of work intensity; calculation of the number of workers; selection of technological equipment; department layout, etc.
1. Characteristics of the design object
The motor transport enterprise (ATP) is located in an area with a warm, humid climate and belongs to the third category of operation.
The list of vehicles is 400 KAMAZ 5415 vehicles, of which 60% have been overhauled and 320 KRAZ 256B1 vehicles, of which 80% have been overhauled.
The ATP has a five-day mode of operation, the number of work shifts is 2, which provides an eight-hour working day. ATP specializes in the transportation of goods.
The design theme is the battery compartment. The battery department carries out repairs of batteries according to the applications recorded in the control coupons, and according to the applications of all divisions of the auto service.
The battery compartment is equipped with equipment in accordance with the nature of the work performed on it. Specialization makes it possible to mechanize labor-intensive work as much as possible, reduce the need for equipment of the same type, improve working conditions, employ less skilled workers, and improve labor quality and productivity. We use the following equipment in the battery compartment: Waste bin, baths for parts washing and electrolyte preparation, racks, stands, rectifier, cabinets, etc.
2. Settlement and technological section
2.1 Selection and adjustment of maintenance intervals
The frequency of maintenance depends on the number of rolling stock, category of operating conditions and climatic conditions.
The frequency of TO - 1, L 1 km is determined by the formula:
L 1 \u003d L K 1 K 3, (1)
where L is the standard maintenance frequency - 1, km, selected according to table 2.1 L KaMaz 5415 \u003d 4000 (km); L KRAZ 256 B1 \u003d 2500 (km).
K 1 - coefficient taking into account operating conditions, K 1 \u003d 0.9, table 2.7 K 3 - coefficient taking into account natural and climatic conditions, K 3 \u003d 1, table 2.9
L 1 Kamaz 5415 \u003d 4000 0.9 1 \u003d 3600 (km);
L 1 KRAZ 256B1 \u003d 2500 0.9 1 \u003d 2500 (km).
The frequency of TO - 2, L 2 km is determined by the formula:
L 2 \u003d L K 1 K 3, (2)
where L is the standard maintenance frequency - 2, km, selected according to table 2.1 L (km); L Kamaz 5415 \u003d 12000 (km);
KRAZ 256 B1 \u003d 12000 (km).
L 2 Kamaz 5415 \u003d 12000 0.9 1 \u003d 10800 (km);
L 2 KRAZ 256B1 \u003d 12000 0.9 1 \u003d 10800 (km).
2.2 Selection and adjustment of mileage before overhaul
It is also necessary to adjust the frequency of the run before overhaul. The service life (mileage before overhaul) depends on K 1, modifications of the rolling stock - K 2 and K 3.
The frequency is calculated using the formula:
L KP \u003d L K 1 K 2 K 3, (3)
where L is the standard frequency before overhaul, km, which is determined according to table 2.2 L KaMaz \u003d 300000 (km); L KRAZ 256 B1 \u003d 160,000 (km).
K 2 - correction factor taking into account the modification of the rolling stock, km, which is selected according to Table 2.8
K 2 Kamaz 5415 \u003d 0.95; K 2 KRAZ 256B1 \u003d 0.85;
K 3 - coefficient of adjustment of standards depending on natural and climatic conditions, which is selected according to table 2.9
L KR Kamaz 5415 \u003d 300000 0.9 0.95 1.0 \u003d 256000 (km);
L KR KRAZ 256 B1 \u003d 600000 0.9 0.85 1.0 \u003d 122400 (km).
If cars are operated after overhaul, then the overhaul mileage, L, km, decreases by 20%
L Kamaz 5415 \u003d 0.8 256500 \u003d 205200 (km);
L KRAZ 256 B1 \u003d 0.8 122400 \u003d 97920 (km).
If new and overhauled cars are used in the car park, then it is necessary to calculate the separate mileage of cars L КР СР, km, according to the formula:
where A u is the percentage of cars that have not undergone major repairs A u KaMaz 5415 \u003d 40%; And u KRAZ 256 B1 \u003d 65%;
A - percentage of cars that have undergone major overhaul A KaMaz 5415 \u003d 60%; A KRAZ 256 B1 \u003d 35%;
After the repair, taking into account the factors, it is necessary to correct the multiplicity factor b 1; b 2; b 3 maintenance and repairs.
For TO - 1, the multiplicity factor b 1 is determined by the formula:
where L CC is the average daily mileage, km: L CC KaMaz 5415 \u003d 160 km;
L CC KRAZ 256 B1 \u003d 100 km;
For TO - 2, the multiplicity factor b 2 is determined by the formula:
For KR, the multiplicity factor b 3 is determined by the formula:
The corrected and original data are summarized in table 1.
Table 1. Correction of vehicle mileage
| car | Mileage, km | ||||
| Correct. taking into account the coefficients | Correct. taking into account the multiplicity | to the calculation |
|||
| Average day. | |||||
| Average day. | |||||
2.3 Selection and adjustment of the standards for the labor intensity of technological maintenance and overhaul per 1000 km of run
Correction of the labor intensity of maintenance is carried out depending on K 2 and the number of units of technologically compatible rolling stock (K 5) Labor intensity of daily maintenance, t EO, man hour. determined by the formula:
t EO \u003d t K 2, (9)
where t is the standard labor intensity for daily maintenance, man-hours, we choose according to table 2.1 t KaMaz 5415 \u003d 0.67 (man-hour),
t KRAZ 256 B1 \u003d 0.45 (man hours)
t EO Kamaz 5415 \u003d 0.67 1.10 \u003d 0.73 (man-hour);
t EO KRAZ 256 B1 \u003d 0.45 1.15 \u003d 0.51 (man hours).
Labor intensity of TO - 1, t TO-1, person hour. determined by the formula:
t T O -1 \u003d t K 2 K 5, (10)
where t is the standard labor intensity for maintenance - 1, is selected according to table 2.1, t KAMAZ 5415 \u003d 2.29 (man-hour), t KRAZ 256 B1 \u003d 3.7 (man-hour)
t T O -1 Kamaz 5415 \u003d 2.29 1.10 0.80 \u003d 2.01 (man-hour);
t T O -1 KRAZ 256 B1 \u003d 3.7 1.15 0.80 \u003d 3.4 (man hours).
Labor intensity of TO - 2, t TO-2, person hour. determined by the formula:
t T O -2 \u003d t K 2 K 3, (11)
where t is the standard labor intensity for maintenance - 2, is selected according to table 2.1, t KAMAZ 5415 \u003d 9.98 (man-hours), t KRAZ 256 B1 \u003d 14.7 (man-hours)
t T O -2 Kamaz 5415 \u003d 9.98 1.10 0.80 \u003d 8.78 (man hours);
t T O -2 KrAZ-260V \u003d 14.7 1.15 0.80 \u003d 13.5 (man hours).
The complexity of current repairs per 1000 km of run depends on the type of cars, operating conditions, modification, natural conditions, vehicle mileage and size of the vehicle, t TR, person hour. and determined by the formula:
t TP \u003d t K 1 K 2 K 3 K 4 K 5, (12)
where t is the standard labor intensity for current repairs, we choose according to table 2.1, t Kamaz 5415 \u003d 6.7 (man-hours), t KRAZ 256 B1 \u003d 6.4 (man-hours)
К 1 - coefficient of standard correction depending on operating conditions, К 1 \u003d 0.9
K 2 - the correction factor taking into account the modification of the rolling stock, km, which is selected according to table 2.8 K 2 KaMaz5415 \u003d 0.95; K 2 KRAZ 256 B1 \u003d 0.95
K 3 - coefficient of adjustment of standards depending on natural and climatic conditions, K 3 \u003d 1.0
К 4 - coefficient of correction of norms of specific labor intensity of current repair (km) and duration of downtime of maintenance and current repair (К), depending on mileage from the beginning of operation, К 4 KaMaz 5415 \u003d 1.4; K 4 KRAZ 256 B1 \u003d 1.4
К 5 - coefficient of adjustment of standards of maintenance and current repair, depending on the number of serviced and repaired vehicles at the ATP and the number of technologically compatible groups of rolling stock К 5 \u003d 0.80.
t TR Kamaz 5415 \u003d 6.7 0.9 1.10 1.0 1.4 0.80 \u003d 7.42 (person hour);
t TR KRAZ 256 B1 \u003d 6.4 0.9 1.15 1.0 1.4 0.80 \u003d 7.41 (person hour).
2.4 Determination of the technical readiness of the park
The technical readiness factor of the fleet, α Т, is calculated by the formula:
where D TO TR is the duration of the rolling stock downtime in maintenance and current repair, determined according to Table 4.5, D TO TR GAZ-53A \u003d 0.5; D TO TR MAZ-53363 \u003d 0.6; D TO TR MAZ-64226 \u003d 0.8, D KR - the duration of the rolling stock downtime in overhaul, determined according to table 4.5, D KR KaMaz 5415 \u003d 22; D KR KRAZ 256 B1 \u003d 22
2.5 Determination of vehicle utilization rate and annual fleet mileage
Since the park is constantly being equipped with new technology, more productive equipment, the level of labor, the reliability of cars, etc. will increase. The utilization factor of the fleet, α u is determined by the formula:
where D RG is the number of working days, D RG \u003d 257
D KG - the number of calendar days, D KG \u003d 365
Knowing the utilization rate of the park, you can calculate the annual mileage of the park, L PG, km, using the formula:
L PG \u003d D RG α u L CC A u, (15)
L PG KaMAz5415 \u003d 257 0.6 160 400 \u003d 9868800 (km);
L PG KRAZ 256 B1 \u003d 257 0.6 100 320 \u003d 4934400 (km).
2.6 Determine the number of services per year
The number of overhauls, N, is determined by the formula:
The amount of daily maintenance, N, is determined by the formula:
The amount of TO - 2, N, is determined by the formula:
The amount of TO - 1, N, is determined by the formula:
2.7 Determination of the annual scope of maintenance and repair work
Annual volume of work on daily maintenance, T person hour. determined by the formula:
Т \u003d t ЕО N, (20)
T Kamaz5415 \u003d 0.73 61680 \u003d 45026.4 (man-hour);
T KRAZ256B1 \u003d 0.51 49344 \u003d 25165.44 (person hour).
The annual scope of maintenance work - 1, T, man-hour, is determined by the formula:
T \u003d t TO-1 N, (21)
T Kamaz5415 \u003d 2.01 1728 \u003d 3533.58 (person hour);
T KRAZ256B1 \u003d 3.4 748 \u003d 2543.2 (person hour).
The annual scope of maintenance work - 2, T, man-hour, is determined by the formula:
T \u003d t TO-2 N, (22)
T Kamaz5415 \u003d 8.78 864 \u003d 7585.92 (person hour);
T KRAZ256B1 \u003d 13.5 374 \u003d 5049 (person hour).
The annual volume of work on current repair, T, man-hour, is determined by the formula:
T Kamaz5415 \u003d (person hour);
T KRAZ256B1 \u003d (person hour).
If vehicles of various types are operated in the park, then it is necessary to determine the total labor input for maintenance and overhaul. The total labor intensity of daily maintenance, Σ T EO, is determined by the formula:
Σ T EO \u003d T Kamaz5415 + T KRAZ256B1, (24)
Σ T EO \u003d 45026.4 + 25165.44 \u003d 70191.84 (person hour)
The total labor intensity of TO - 1, Σ T TO - 1, is determined by the formula:
Σ T TO - 1 \u003d T Kamaz5415 + T KRAZ256B1, (25)
Σ T TO - 1 \u003d 3533.58 + 2543.2 \u003d 6076.78 (person hour)
The total labor intensity of TO - 2, Σ T TO - 2, is determined by the formula:
Σ T TO - 2 \u003d T Kamaz5415 + T KRAZ256B1, (26)
Σ T TO - 2 \u003d 7585.92 + 5049 \u003d 12634.92 (person hour)
The total labor intensity of the current repair, Σ Т ТР, is determined by the formula:
Σ T TR \u003d T Kamaz5415 + T KRAZ256B1, (27)
Σ T TR \u003d 73127.808 + 36563.904 \u003d 109691.71 (person hour)
In addition to maintenance and current repairs in the fleet, self-service works are performed at the enterprise, that is:
a) Maintenance and repair of machine tools, power and power equipment;
b) Manufacturing, maintenance and repair of technological equipment;
c) Repair of buildings, structures, water pipes, sewerage, etc.
Therefore, it is necessary to enter the self-service work scope in the annual work scope. The scope of work for self-service of the enterprise, T CAM, man hours, is determined by the formula:
where K CAM is the coefficient taking into account the amount of work on self-service of the enterprise in%. The coefficient depends on the number of cars at the ATP.
2.8 Calculation of the number of production workers
The productive workers include work areas and sections directly performing maintenance and repair work of rolling stock.
When calculating the number of workers, there is a distinction between the turnout (technically necessary) - Р Я and the staff (payroll) - Р Ш number of workers.
The number of technologically necessary workers corresponds to the number of jobs. In this case, a workplace is understood as a section of the area on which work is performed by one worker. One or several workers can work at a work station at the same time.
The number of technologically necessary workers is determined by the formula:
where T OTD is the annual volume of work of the department T OTD \u003d 2786 man hours.
Ф РМ - annual working time fund
where H H is the duration of the worker's work during the week, H H \u003d 40
D N - the number of working days per week, D N \u003d 5
D K - number of calendar days, D K \u003d 365
D B - number of days off, D B \u003d 103
D P - the number of holidays, D P \u003d 5
Determine the number of full-time workers using the formula:
where Ф ПР - the annual fund of time for regular workers is determined by the formula:
where Ф T is the annual fund of time of one worker
D O - the number of days of vacation of the worker
D U.P - the number of days of absence from work for a good reason
5 - the number of working days
2.9 Calculation of the number of posts for a branch
where T POST is the labor intensity of the post, T POST \u003d 1229 man-hours.
P - number of posts
K N - reservation ratio, K N - 1.35
С - number of shifts, С - 1
D RG - the number of working days per year, D RG - 302
T CM - shift duration in hours, T CM - 8 hours
Р СР - the number of workers simultaneously working at the post, Р СР \u003d 2
η P is the coefficient of using the working time of the post, η P - 0.98
3. Organizational section
3.1 Selection of technological equipment and tooling at the site
overhaul car battery
The technological equipment includes stationary, mobile and portable stands, machine tools, all kinds of devices and devices that occupy an independent area on the layout, necessary to perform work on TR.
The organizational equipment includes production equipment (workbenches, racks, cabinets, tables) that occupy an independent area on the layout. The technological equipment includes all kinds of tools, devices, devices necessary for performing work on the TR, which do not occupy an independent area.
When choosing technological equipment, it is necessary to take into account that the number of many types of stands, installations and devices does not depend on the number of workers in the workshop, while workbenches, work tables are taken based on the number of workers.
The list of necessary technological equipment and accessories is given in the table.
Table 2 Technological equipment
| № | Name | Brand | Overall dimensions | ||
| 1-repair department | |||||
| 1 | Waste bin | 2 | 0.6x0.8 | 0,48 | |
| 2 | Parts rinsing bath | 2257 | 1 | 0.9x0.5 | 0,45 |
| 3 | Workbench | 1019 | 1 | 1.0x0.8 | 0,8 |
| 4 | Electrolyte drain bath | E - 204 | 1 | 0.58x0.21 | 1,22 |
| 5 | Rack | 2242 | 1 | 1.0x0.4 | 0,4 |
| 6 | Stand | 1 | 0.7x0.6 | 0,42 | |
| 7 | Rectifier | BCA-5A (BCA-111B) | 1 | 0.41x0.31 | 1,28 |
| 8 | Melting workbench | 1 | 1.0x0.8 | 0,8 | |
| 9 | Material cabinet | 551 | 1 | 0.5x0.6 | 0,30 |
| 2- charging compartment | |||||
| 1 | Shelving rack | E-409 OG | 4 | 1.10x1.10 | 1,21 |
| 3-pantry | |||||
| 1 | Rack for parts | 3 | 0.6 x0.5 | 0,30 | |
| 2 | Rack for bottles | 1 | 1.0x0.6 | 0,6 | |
| 3 | Battery rack | E-405A | 1 | 0.5x0.6 | 0,30 |
| 4-acid department | |||||
| 1 | Electrolyte bath | E-204 | 1 | 0.58x0.21 | 1,22 |
| 2 | Acid dispenser | P-206 | 1 | 0.4x0.4 | 0,16 |
| 3 | Electric distiller | 737MRTU / 2 | 1 | 0.5x0.5 | 0,25 |
| TOTAL: | 10,19 | ||||
3.2 Calculation of the production area
The area of \u200b\u200bthe site is determined by the formula:
3.3 Technological map
The charging of the battery is checked by measuring the density of the electrolyte. By changing the initial density of the electrolyte poured into the storage battery (which must correspond to the data in Table 2.4), you can determine the degree of its discharge. A decrease in the density of the electrolyte, reduced to a temperature of +25 ° C, by 0.01 g / cm3 indicates that the battery is discharged by about 6%. that is, when the density drops by 0.04 g / cm3, the battery discharge is 25%, 0.08 g / cm3 - 50%, and when the density drops by 0.16 g / cm3, the battery is completely discharged. With a different decrease in the density of the electrolyte in individual batteries, the total discharge value of the storage battery can be roughly determined as the average discharge value of its batteries. The measurement of the density of the electrolyte in the batteries is carried out in the same manner as when preparing the electrolyte. For accuracy, check the electrolyte level before measuring the density of the electrolyte. After charging the storage battery or long-term operation of the engine, before measuring, it is necessary to hold it for about 30-40 minutes until gas evolution stops. After adding distilled water to the battery, the electrolyte density can be measured only after 10-15 minutes so that the water mixes with the electrolyte and the electrolyte density becomes equalized. A battery discharged in summer by more than 50% (with an average decrease in electrolyte density by 0.08 g / cm3), and in winter by more than 25% (with a decrease in electrolyte density by 0.04 g / cm3) should be removed from the car and charge. The storage battery placed in storage should be recharged when discharged by 25-30%, which corresponds to a decrease in the electrolyte density in batteries by 0.04-0.05 g / cm3.
4. Labor protection
Individuals who are at least 18 years of age, have the appropriate qualifications, who have received introductory instruction and initial instruction at the workplace, trained in safe working methods and having the appropriate certificate, are allowed to independently work on the repair and maintenance of batteries.
A battery operator who has not undergone a timely re-training on labor protection (at least 1 time in 3 months) and an annual examination of knowledge on labor safety should not start work.
The battery operator is obliged to comply with the internal labor regulations established at the enterprise.
The duration of the battery operator's working hours should not exceed 40 hours per week. The duration of daily work (shift) is determined by the internal labor regulations or the shift schedule approved by the administration in agreement with the trade union committee. The battery operator must know that hazardous and harmful production factors that can act on him in the process of performing work are:
electricity;
sulfuric acid;
caustic potassium;
lead and its compounds;
Sulfuric acid, when it gets on parts of the body, damages the skin, and dermatitis and burns are formed.
Potassium hydroxide works in a similar way to sulfuric acid.
Lead and its compounds lead to poisoning of the working organism, as well as to the disorder of the peripheral and central nervous system, damage to the locomotor system, lead paralysis.
Hydrogen is released during battery charging, mixing with atmospheric oxygen to form an explosive oxyhydrogen gas.
It is forbidden to use tools, fixtures, equipment, handling of which the battery operator has not been trained and instructed.
The battery operator must work in special clothing and special shoes, and, if necessary, use other personal protective equipment.
In accordance with the Standard Industry Regulations for the Issuance of Special Clothing, Special Shoes and Other Personal Protective Equipment, the battery operator is issued:
cotton suit with acid-proof impregnation;
rubber ankle boots;
rubber gloves;
rubber apron;
goggles.
The battery must follow the rules of personal hygiene:
before using the toilet, eating, smoking, you should wash your hands with soap and water;
do not store or consume in battery food and drinking water, in order to avoid the ingress of harmful substances from the air;
for drinking it is necessary to use water from devices specially designed for this purpose (saturators, drinking tanks, fountains, etc.);
use specially designed protective ointments to protect the skin of the hands.
It is prohibited.
in the room for charging batteries, in order to avoid an explosion, light a fire, smoke, use electric heating devices (electric stoves with an open spiral, etc.) and allow sparking of electrical equipment;
allow unauthorized persons to enter the charging and acid rooms;
connect the battery terminals with a wire;
check the battery with a short circuit;
pour molten lead into wet molds and put wet pieces of lead into the molten mass;
pour water into acid, as this causes "boiling" and possible splashing of the electrolyte from the vessel;
store in the repair and charging compartments battery vessels with sulfuric acid and alkali in an amount exceeding the daily requirement, as well as empty vessels, which should be stored in a separate room;
jointly store and charge acid and alkaline batteries in the same room;
take in battery food and store drinking water there in order to avoid the ingress of harmful substances from the air;
use glass promises to prepare electrolyte.
END OF WORK SAFETY REQUIREMENTS
At the end of the work, the battery operator must:
Turn off ventilation and electrical equipment.
Tidy up the workplace. Remove electrolyte, devices and tools in the place provided for them.
Used personal protective equipment (gloves, an apron, ankle boots), rinse in water and put away in a designated place.
Take off personal protective equipment, special clothing and shoes and put them in their designated place. Timely hand over them and other personal protective equipment for dry cleaning (washing) and repair.
Wash your hands with soap and water and take a shower.
Conclusion
In this course project developed:
- organization of the battery section
- the method of organizing the production of the TOD complex and the site was selected and substantiated;
- calculated the annual labor intensity of work in the Asia-Pacific region and the site;
- selected equipment of the site;
- the number of production works is calculated
- requirements for safety and fire safety were developed;
- the planning drawing of the accumulator section was made.
Literature
1. Regulations on the maintenance and repair of the rolling stock of road transport / Ministry of Transport and Communications of the Republic of Bashkortostan - Mn .: Transtekhnika 1998 - 59p.
3. Design of motor transport enterprises and service stations. Training / M.M. Bolbas, N.M. Kapustin and E.I. Petukhov, V.I. Pokhabov - Mn. University, 1997 - 24bc.
4. Maintenance and repair of cars. A manual for course and diploma design. M .: Transport, 1985 - 224s.
5. Maintenance and repair of cars. Graduation design manual / B.N. Sukhanov et al. - M .: Transport, 1991 - 159p.
8. Car maintenance. G.V. Kramarenko, I. V. Barashkov M .: Transport, 1982 - 368s.
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Introduction
1. Justification of the project
1.1 Brief description of JSC "Solikamskbumprom"
1.2 Analysis of technical and economic indicators
1.3 Battery operator's workplace
1.4 Safety requirements for battery operation
1.5 Analysis of protective measures to prevent the manifestation of hazardous and harmful factors
2. Calculation and design part
2.1 Characteristics of the production line at the battery station
2.2 Maintenance on a production line
2.3 Calculation of the production line of continuous daily technical equipment (EO)
3. Operational and technological part
4. Safety and environmental friendliness
4.1 Environmental protection
4.2 Objectives in the field of quality and environmental protection of JSC "Solikamskbumprom" for 2012 -2013
4.3 Expert examination of industrial safety
4.4 Sanitation rules and first aid to victims
5. Economic part
5.1 Technical characteristics of the battery repair production line
5.2 Calculation of energy consumption and labor resources for battery repair
5.3 Calculation of the cost of repairing batteries
Conclusion
List of literature and normative and technical documentation
Introduction
In a civilized society, great importance is attached to working conditions and their improvement. Working conditions are determined by the state of the production environment (environment), which includes socio-economic, material, production and natural elements. An enlarged classification of factors affecting the formation of working conditions.
The first group includes: normative and legislative state regulation of socio-economic and industrial working conditions (working hours, work and rest regimes, sanitary standards and requirements, a system of state, public control over compliance with applicable laws, norms, requirements and rules in the field of conditions labor, etc.); socio-psychological factors characterizing the attitude of workers to work and to the conditions in which it takes place, the psychological climate in production teams, the effectiveness of the benefits and compensation for work, which are inevitably associated with adverse influences.
The second group includes means of labor (industrial buildings and structures, including various sanitary and technical and sanitary devices, technological equipment, tools, devices, including means ensuring the technical safety of labor, etc.); objects of labor and its product (raw materials, materials, blanks, semi-finished products, finished products); technological processes (physical, mechanical, chemical and biological effects on the processed objects of labor, methods of their transportation and storage, etc.); organizational forms of production, labor and management (the level of specialization of production, its scale and mass character, shift work of the enterprise, discontinuity and continuity of production, forms of division and cooperation of labor, its methods and methods, applied modes of work and rest in relation to the work shift, week, year, organization of workplace maintenance, the structure of the enterprise and its divisions, the ratio of functional and linear production management, etc.). rechargeable technical repair battery
The third group includes natural factors that are of particular importance in the formation of working conditions in agricultural production, mining, transport and construction.
This group includes the following factors: geographic (climatic zones, height above sea level, weather conditions); geological (the nature of the occurrence of minerals, the method of their extraction); biological (features of flora and fauna, human life in accordance with biological rhythms).
In the literature, the elements that form the working conditions are often called factors. If we proceed from the generally accepted understanding of the term "factor", then such an application will not be entirely accurate, because we are talking about the components of the working conditions, and not about the reasons for their formation. At the same time, if we consider the elements that make up the working conditions, from the point of view of their influence on a person, a favorable or unfavorable effect on his performance, health, mood and, in general, on personality development, then these elements act as factors. That is why in the literature and many official documents the elements of working conditions are interpreted as factors, since the elements of working conditions are expressed in quantitative or qualitative characteristics, then in what follows we will call them "indicators" (elements) of working conditions.
Working conditions are a set of elements of the working environment that affect human health and performance in the labor process.
Such working conditions should be considered favorable when the quantitative and qualitative totality of their constituent elements exerts an influence on a person, contributing to the spiritual and physical development of the individual, the formation of a creative attitude towards work in workers, a sense of satisfaction with it.
Adverse working conditions are those when their impact can cause a person deep fatigue, which, accumulating, can lead to a painful condition or cause occupational pathology; due to the negative impact of working conditions, workers may form a negative opinion about work (unattractive, unpopular, unpopular, etc.).
In the classification developed by the Research Institute of Labor, all elements of working conditions are divided into four groups. With all the conventionality of the division, it is important both for the study of working conditions and for the development of practical measures to improve them and monitor their condition, compliance with sanitary and hygienic, psychophysiological and aesthetic norms, requirements and rules.
The requirements for working conditions in production are determined by the need to ensure such working conditions at the workplace, in the shop, at the enterprise, in which an adverse effect on the working capacity and health of workers is excluded and optimal boundaries of division and cooperation of labor can be ensured, and ultimately improving the efficiency and quality of labor.
Enterprises must strictly adhere to sanitary norms and rules, maximum permissible concentrations (MPC) of harmful substances and maximum permissible levels (MPL). The development of sanitary standards and requirements is especially important in the design of new equipment, technology and production facilities.
Measures to eliminate adverse health effects of working elements of the working environment - sanitary and hygienic, psychological, aesthetic and other factors - are considered in the literature on labor protection, industrial sanitation and safety.
The purpose of the diploma project is to improve the organization of the battery repair shop.
In accordance with the goal, the tasks are set:
1. To study the purpose, device and principle of operation of storage batteries;
2. To study the organization of the workshop for the repair of batteries;
3. Develop a project for the introduction of a production line to the battery repair site;
The object of the diploma project is the Auto-timber workshop (post for the repair of batteries), the subject is the improvement of the organization of repair in the workshop for the repair of batteries.
1. Justification of the project
In solving the problem of improving working conditions, the planned implementation of measures plays an important role. The main document defining the essence and sequence of measures in the field of improving working conditions is an action plan to improve and improve working conditions in the organization.
The plan is drawn up on the basis of the results of a special assessment of working conditions by the attestation commission, taking into account proposals received from the organization's divisions or individual employees. The plan should include measures to improve equipment and technology, the use of personal and collective protective equipment, recreational activities, as well as measures for the protection and organization of labor.
Labor protection is a system for ensuring the safety of life and health of workers in the process of work, including legal, socio-economic, organizational, technical, psychophysiological, sanitary and hygienic, treatment and prophylactic, rehabilitation and other measures and means.
Labor protection identifies and studies the possible causes of industrial accidents, occupational diseases, accidents, explosions, fires and develops a system of measures and requirements in order to eliminate these causes and create safe and human-friendly working conditions.
Working conditions are a combination of factors of the working environment and the labor process that affect the performance and health of an employee (Article 209 of the Labor Code of the Russian Federation).
Working conditions at the enterprise as the living conditions of workers in the process of their activities are both an element of the production system and an object of organization, planning and management. Therefore, changing working conditions is impossible without interfering with the production process. That is, it is necessary to combine, on the one hand, working conditions, and on the other, the technology of production processes.
Workplace is an organizationally indivisible (in given specific conditions) link of the production process, serviced by one or more workers, designed to perform one or more production or service operations, equipped with appropriate equipment and technological equipment. In a broader sense, it is an elementary structural part of the production space, in which the subject of labor is interconnected with the allocated means and the subject of labor to carry out unit labor processes in accordance with the target function of obtaining labor results.
1.1 Brief description of the enterprise JSC "Solikamskbumprom"
JSC "Solikamskbumprom" is located in the city of Solikamsk, Perm Territory. The enterprise is the largest producer of newsprint in Russia.
The structure of OJSC "Solikamskbumprom" on the principles of equality, economic independence and common strategic interests in the production of competitive end products - newsprint - integrated 9 Russian logging enterprises located in the northern regions of the Perm Territory and supplying raw materials (wood) for newsprint production.
Own logging accounts for 45% of the total timber consumed by the enterprise.
The joint-stock company also includes LLC “Solikamskaya CHPP”, which is located on the territory of the enterprise and provides production units with process steam and part of the electricity. Part of the CHPP's energy is directed to the needs of the residential and social complex in the northern part of Solikamsk.
The enterprise consists of the following productions:
Timber production for the reception and processing of wood in the amount of 1.5 million m3, supplied by road, rail and water transport;
Cellulose production;
Wood mass production;
Thermomechanical pulp (TMM) production;
Boom production # 2 (production of large size XXL paper rolls up to 2.4 meters wide, up to 1.5 meters in diameter, weighing up to three tons; launched a new packaging line for large rolls);
Boom production # 3;
Workshop "Waste treatment facilities";
Wood waste processing area;
The sale of finished products of JSC "Solikamskbumprom" produces:
High-quality newsprint (GOST 6445-74) weighing 40, 42, 45, 48.8 g / m2, possessing high optical, mechanical and structural characteristics, allowing both black-and-white and multicolor printing on any high-speed printing units;
Wrapping paper (GOST 8273-75) used as a packaging material for wrapping medicines and industrial goods and products, as well as for making paper bags.
Technical lignosulfatones (LST) (TU 54-028-00279580-97) are used in the production of carbon black, chipboard, fiberboard, plywood, cement, foundry, oil industry, road construction;
Consumer goods (notepads, folders, notebooks, notebooks, writing paper);
Social complex (kindergartens, polyclinic, sanatorium-preventorium, House of Culture "Bumazhnik" and stadium) (Table 1.1.).
Table 1.1. Assortment list of products manufactured by JSC "Solikamskbumprom"
|
№ p / p |
Name, appointment |
GOST, TU |
Type of packaging |
Transportation conditions |
|
|
Newsprint |
GOST 6445-74 |
In rolls |
Railway carriage-40 tons |
||
|
Lignosulfonate technical liquid |
TU 54-028-00279580-2004 |
In tanks |
Railway tank 60-ton |
||
|
Powdered lignosulfonate |
Paper bags |
Railway carriage-30 tons Container up to 3 tons |
|||
|
Wrapping paper, gray |
GOST 8273-75 |
In rolls |
Railway carriage-35 tons |
||
|
Rapid Rotary Printing Paper |
TU 5431-013-00279580-2008 |
In rolls |
Railway carriage-40 tons |
||
|
Thin newsprint paper for offset printing |
TU 5431-025-00279580-99 |
In rolls |
Railway carriage-40 tons |
JSC "Solikamskbumprom" constantly makes significant investments in the reconstruction and modernization of existing equipment.
The comprehensive program for the technical improvement and renovation of production includes successful cooperation with industry research and design institutes, machine-building enterprises of Russia and leading foreign firms.
One of the main reasons for the increase in net profit from production is the increase in the average price of newsprint, compared to the same period last year.
Particular attention is paid to the issues of minimizing the impact of production activities on the environment and labor protection.
1.2 Analysis of technical and economic indicators
Technical and economic indicators are a set of indicators that characterize the activities of an enterprise from the point of view of its material and production base and the complex use of resources.
The calculation of these indicators is carried out when planning and analyzing the activities of the enterprise regarding the organization of production itself and labor, machinery, equipment, quality of products, labor resources.
The technical and economic analysis of the enterprise includes:
Analysis of the volume, assortment and sales of products;
Analysis of labor indicators;
Analysis of the cost of production;
Profit analysis;
Comprehensive assessment of the actual production intersification against the planned level and a summary analysis of the production and economic activities of the enterprise.
The number of personnel of JSC "Solikamskbumprom" as of 01.01.2010 amounted to 3112 people. The enterprise works in three shifts. The number of people working in one shift on paper machine No. 2 is 61, of which 24 are women, 37 are men. And as of 01.01.2013, the number of personnel was 4144 people.
1.3 Battery operator's workplace
The accumulator is a specialist whose duties include servicing accumulators and rechargeable batteries of different types and capacities.
In a broader sense, the accumulator assembles, disassembles batteries, maintains equipment that is part of the charging stations, mounts and dismantles battery cells with fixing the connecting parts.
The auto-forestry shop of OJSC "Solikamskbumprom" is equipped with the necessary modern equipment, fixtures and measuring instruments, which make it possible to quickly and accurately check, regulate and repair cars, apparatus and electrical equipment of cars.
Accumulator batteries in the Timber Shop are classified as especially dangerous premises with harmful working conditions.
Repair and charging of batteries is carried out in the battery department of the blanking shop. For this, a special room is allocated, as a rule, on the first floor.
The battery compartment includes: repair, painting, charging, regeneration and generator, production facilities.
The battery compartment must have general independent supply and exhaust ventilation and local suction for drying cabinets, washing devices and other equipment. The capacity of the ventilation units and their placement are determined by local conditions.
The battery removed from the car is delivered to the charging room to discharge it to a voltage of 1V at each cell.
After discharging, the battery on the trolley is transported to the repair room, where the rubber covers are removed from the batteries, then the batteries are sent to the installation for repair - washing.
Figure 1. Plan of the battery department for repairing alkaline batteries: I - Repair: 1 - crane with a lifting capacity of 1 ton; 2 - installation for washing alkaline batteries; 3 - storage rack for electric cars; 4 - a rack for alkali-resistant varnishes; 5 - bath for painting cans with alkali-resistant varnish; 6 - tank for drying battery cans; 7 - storage battery rack; 8 - cabinet for charging storage batteries; 9 - selenium rectifier; 10 - tanks for a solution of acetic and boric acids; 11 - adjuster cabinet; 12 - cabinet for heating the filling mastic; 13 - exhaust cabinet; 14 - workbench; 15 - electric soldering iron; 16 - writing table; II - Charger: 17 - charging shield; 18 - dispenser-tap for filling electrolyte into the battery; III -Electrolyte: 19 - electric distiller; 20 - distilled water bath; 21 - tank for electrolyte adjustment after regeneration; 22 - bath for electrolyte dilution; 23 - tank for the finished electrolyte; 24 - water tank; 25 - installation for dissolving barium oxide; 26 - installation for electrolyte regeneration; 27 - tanks for a solution of acetic and boric acids; 28 - control cabinet for regeneration units; 29 - writing table; 30 - electric hoist with a lifting capacity of 0.5 t.
The elements inside are washed with warm water at a temperature of 40-50C automatically according to a predetermined program.
It is advisable to use warm water for washing the batteries outside and washing rubber covers.
To dry the rubber covers, air heated to a temperature of 40-50C can be fed into the unit through the shower system.
After washing, individual elements that need to be repaired are transferred to the workbench, after which the batteries are transported on a trolley to the paint room, where they are cleaned of old paint and rust, washed, degreased, painted and dried in special baths and cabinets.
The transfer of elements from position to position is carried out by a crane with an air lift and a special suspension on which four accumulators are fixed.
The repaired storage battery on a trolley is delivered to the charging room for filling it with electrolyte and subsequent charging. For these purposes, the charging room is equipped with a tap for electrolyte spillage and shields for connecting wires to the battery being charged. After charging, the battery is issued for installation on the vehicle.
Equipment used for battery repair:
Charging and discharge installation.
Installation for washing batteries and rubber covers.
Pneumatic lift.
Installation for the regeneration of electrolyte.
Electrolyte filling valve.
Installation for dissolving barium oxide.
Electrolyte storage tank.
A trolley used to transport a battery.
Regeneration units control cabinet.
A device for monitoring the voltage on the battery banks, tanks for boric acid solution, for water, for filling the battery.
Table 1. Instrumentation and accessories
1.4 Safety requirements when performing work accumulator
In the battery room, it is allowed to carry out work related to the repair and charging of batteries.
Batteries received for repair or charging should be installed on serviceable racks. It is prohibited to move the racks with batteries.
When using a portable luminaire, in order to avoid sparking, first insert the plug into the socket and then turn on the breaker, when turning it off, vice versa: first turn off the breaker and then remove the plug.
Observe the smooth operation of ventilation during charging and soldering.
When carrying batteries, use tools (grabs, stretchers, carts) and take precautions.
When transporting battery acid and preparing electrolyte, to avoid burns to the skin and eyes, observe the following rules:
Store bottles with battery acid or electrolyte with closed ground stoppers and only in special crates;
Drain the battery acid from the bottles together with the help of devices, avoiding spilling it on the floor; cover spilled acid with sawdust, moisten with soda solution or cover with soda, after putting on rubber gloves;
Before preparing electrolyte, wear protective goggles and rubber gloves;
Prepare electrolyte in ebonite, earthenware or ceramic dishes (use of glassware is prohibited). In this case, first pour cold water into the dishes, and then pour acid in a thin stream, periodically stirring the solution with a glass or ebonite stick.
When charging batteries, be sure to meet the following requirements:
The filler plugs must be turned out;
Connect the battery terminals before charging and disconnect them after charging with the charger equipment turned off;
Connect the batteries only with tight-fitting (springs) leaded terminals, which provide tight contact and eliminate sparking;
Do not touch two terminals at the same time with metal objects to avoid short circuit and sparking;
Battery charging control is carried out only with the help of instruments (thermometer, voltmeter, hydrometer, etc.);
Do not lean close to batteries to avoid burns from acid splashes from the filler openings.
When charging batteries, it is not allowed:
Use faulty chargers and tools;
Work without exhaust ventilation;
Connect batteries to an ungrounded charger;
Measure the voltage at the battery terminals with a load plug due to possible arcing and explosion of gases, and also touch the plug to the resistance to avoid burns;
Overload the charger with a current higher than the rated one;
Disconnect the ground wire and touch it to open current-carrying terminals;
Produce any renovation work when the charger is on.
If acid gets on the skin, you should quickly and carefully blot it with a cotton swab or dry cloth, rinse the affected area with water or 2% baking soda solution, lubricate with petroleum jelly, tie with a bandage, and then contact the health center.
If acid gets into eyes, rinse them well with water, then with 2% baking soda solution and immediately contact a health center.
In case of contact with acid on clothes, rinse the latter with a stream of water, neutralize with soda, chalk or lime, rinse again with water and dry.
Work using a blowtorch should be carried out in a specially designated place on a workbench sheathed with steel under an exhaust hood.
When performing these works, the following requirements must be observed:
Workbenches and racks should be installed horizontally and not come into contact with heating devices and risers of water supply, heating and sewerage;
The place for lighting the blowtorch should be fenced from the sides and in front with a metal or brick screen;
To avoid blowing the blowtorch, fill the lamp with only the flammable liquid for which it is intended to operate;
Before lighting the lamp, check its serviceability.
When working with a blowtorch, it is not allowed:
Fill the lamp reservoir with a flammable liquid to more than 3/4 of its volume;
Tighten the filler plug with less than 4 threads;
Excessively pumping air;
Clear the clogged nozzle hole by increasing the pressure;
Operate a lamp that does not have a stop on the stopcock;
Add fuel to a burning lamp;
Release the compressed air through the filler hole of the burning lamp. The flame must be extinguished with a shut-off valve.
If any faults are found, stop work immediately and have the lamp repaired.
After finishing work with a blowtorch, it is necessary to extinguish it, allow it to cool to ambient temperature and drain the fuel into a canister. Do not store a filled lamp in the workplace.
When melting lead, do not allow water to enter the vessel with molten lead to avoid burns caused by superheated steam and lead splashes.
During heating, the soldering iron must be fixed and lie on a special stand.
To avoid burns, avoid splashing solder. Store the solder in a metal box and carefully remove it from the soldering iron into the box during the soldering process; it is not allowed to shake off the solder.
Do not drink water or eat in the battery workshop.
1.5 Analysis of protective measures to prevent the manifestation of hazardous and harmful factors
To reduce the negative impact of harmful substances on human health, the following methods of prevention and protection are used:
1. Elimination of contact of a harmful substance with a working person. This can be achieved by mechanizing production processes, sealing equipment, etc.
2. The use of personal protective equipment (PPE), such as overalls, respiratory protection, special ointments to protect the skin, etc.
3. Compliance with hygiene standards in the production area, timely ventilation.
Harmful vapors and gaseous emissions from the removed air are extracted by the following methods: absorption by solid porous materials (absorption), chemical transformation of harmful substances into less harmful ones, neutralization in chemical neutralizers.
Dust chambers, "cyclones", and electric filters are used to clean the air emitted into the atmosphere from dust.
Basic general requirements:
Production equipment must be safe during installation, operation and repair, both separately and as part of complexes and technological systems, as well as during transportation and storage. It must be explosion and fire safe during the entire service life;
An indispensable condition is to ensure reliability, as well as the elimination of danger during operation in full accordance with the technical documentation. Violation of reliability can occur as a result of exposure to moisture, solar radiation, mechanical vibrations, pressure and temperature differences, wind loads, icing, etc .;
Materials used for the manufacture of parts, assemblies and assemblies of production equipment should not be hazardous and harmful. New materials must be tested for hygiene and explosion and fire safety;
Safety requirements for production equipment are provided by the choice of the principles of operation of structural schemes, safe structural elements, etc., the use of protective equipment in the design, and the fulfillment of ergonomic requirements; inclusion of safety requirements in technical documentation for installation, operation, repair, transportation and storage;
Dangerous moving parts must be guarded;
The equipment should not be a source of significant noise, ultrasound, vibration, and harmful radiation;
Structural elements with which a person can come into contact should not have sharp edges, hot and overcooled surfaces;
Workplaces built into the structure of the equipment must ensure the convenience and safety of the worker;
The equipment should have means of signaling a dangerous malfunction and means of automatic stop and shutdown;
Allocation and absorption of heat by equipment, as well as the release of moisture by it in production areas should not exceed the maximum permissible concentrations in the working area;
The design of production equipment must provide for protection against electric shock, including cases of erroneous actions of maintenance personnel, and also exclude the possibility of accumulation of static electricity charges in dangerous quantities.
Emergency stop devices should be red, marked to make them easy to find and easily accessible. Reducing the level of exposure to harmful substances or its complete elimination is achieved by carrying out technological, sanitary-technical, therapeutic and prophylactic measures and the use of personal protective equipment.
Measures to combat industrial dust are the rationalization of production processes, the use of general and local ventilation, the replacement of toxic substances with non-toxic ones, the mechanization and automation of processes, the wet cleaning of premises, etc. clothing or dust-proof fabric.
To control the gas content of the air during technological processes, the method of sampling in the breathing zone using chromatographers and gas analyzers is often used. The actual values \u200b\u200bof harmful substances are compared with the norms of the maximum permissible concentration.
In the event that the content of harmful substances in the air of the working area exceeds the maximum permissible concentration, it is necessary to take special measures to prevent poisoning.
These include limiting the use of toxic substances in production processes, sealing equipment and communications, automatic control of the air environment, the use of artificial and natural ventilation, special protective clothing and footwear, neutralizing ointments and other personal protective equipment.
2. Calculated-design section
Maintenance production lines are divided into continuous and batch lines. The nature of the production line is determined by the type of service. On a continuous line, all operations can be performed on a moving vehicle, while cleaning, washing and wiping operations can be organized.
TO-1 and TO-2 are best carried out on a batch production line, since the performance of individual operations requires the vehicle to be stationary.
The streaming method is effective if:
Daily or shift service programs sufficient for full loading of the production line;
The schedule for submitting vehicles for maintenance is strictly observed;
Maintenance operations are clearly distributed among performers;
The work is widely mechanized and, if possible, automated;
There is a proper material base;
There is a backup post or sliding performers.
The streaming method is more progressive than the service method at universal posts.
A relatively small amount of equipment, which is better used, provides a more complete mechanization of work.
As a result of the specialization of work performed at each post by workers with a narrower specialization of work performed at each post by workers of narrower qualifications, labor productivity is increased by 20%.
Technical diagnostics of cars to a large extent contributes to the introduction of the flow method, since cars with more stable labor intensity come to service.
With the operational-post method of servicing vehicles, the scope of work for each type of maintenance is also distributed over several specialized posts, and a certain group of works and units is assigned to each of them. For example, the first station serves the engine and clutch, the second station serves the rear axle and the braking system, etc. however, the positions are inconsistent. After servicing at one post, the car has to leave the premises and again call in at another post. The length of stay at each of the service posts should also be the same. The organization of work in the operational-post method contributes to the specialization of equipment, which allows mechanizing the technological process and thereby increasing the quality of work and labor productivity. This method makes it possible to perform some TO-2 operations during TO-1. With this method, it is also possible to service the car between shifts without removing it from the stick, which increases the vehicle utilization rate.
2.1 Characteristics of the production line at the accumulator station
The production line is a complex of technological, control and transport equipment, which is located during assembly or disassembly and is specialized in performing one or more operations.
The most technically advanced are production lines with a distribution conveyor, if objects are automatically distributed to workstations that have receiving and dispatching devices with timers, flexibly connected to the moving conveyor. This frees workers from removing and placing the objects to be processed on the conveyor. However, the use of such devices requires careful economic justification due to their high cost.
Figure 2.1. Scheme of planning a production line with a distribution conveyor: 1 - belt conveyor; 2- storage places; 3 - driving and tensioning stations; 4 - rack
The working conveyor (Figure 2.2) is equipped with a mechanical conveyor that moves the processed object along the line, regulates the rhythm of work and serves as a place for performing operations. Since the objects are not removed from the conveyor, lines with a working conveyor are used mainly for assembly, welding of products, casting into molds (in foundries), painting units and assemblies in special painting and drying chambers.
Figure 2.2. Scheme of planning a production line with a working conveyor: 1 - belt conveyor; 2 - storage areas; 3 - drive and tension station
In order to improve the organization of repairs, it is proposed to mount a production line in the battery compartment, on which batteries will be repaired.
The production line is equipped with four charging stations, allowing the charge-discharge-charge cycle to be carried out simultaneously with four batteries.
All battery cells (for an alkaline battery of the NK-125 type, 42 cells) are assembled into a cassette, which is installed on the conveyor transport device and moves through positions. The production line is closed. In the case at each position there are hatches for access to the cassette mechanisms. The control panel sets the rhythm, the necessary cycle parameters, and also controls the technological operations at each of the 10 positions. The electric control circuit is single-wire, voltage 50 V. The air pressure in the line is 0.6 MPa.
Figure 2.3. The project to change the organization of the workshop
1 Position. In the first position, the battery cells are installed in the cassette.
2. Position. On the second, the electrolyte is drained into a special container for subsequent registration, then the elements are washed with hot water (t \u003d 60 degrees Celsius) under a pressure of 0.3 - 0.45 MPa. The washing hydraulic system is powered by a centrifugal pump. Contaminated water enters the sump.
3. Position. On the third, cassettes with elements are dried with hot air.
4. Position. On the fourth, the cells are filled with electrolyte using a dispenser, which allows all the elements to be filled simultaneously to the required level. The electrolyte filling is monitored using special sensors.
5,6,7,8. Positions. The fifth, sixth, seventh and eighth positions are charging posts. The panel - the diagram at the charging stations is made of fiberglass, and after stopping the cassette is automatically superimposed on the battery, the drive is pneumatic. Voltage monitoring on individual elements battery operated by a stepping finder.
Position. At the ninth position, the electrolyte level is adjusted by adding distilled water, after which the plugs of the elements are wrapped.
10. Position. On the tenth, the cassette is moved to the shelves of finished products in anticipation of being put on the locomotive.
Battery covers are repaired and checked at a special stand.
9 cases are installed in the stand bath, into which water is poured. In turn, a probe is lowered into each case and a voltage of 500 V is applied. A milliammeter installed on a control panel outside the stand shows the value of the leakage current. If the leakage current exceeds 20 mA, the cover is rejected
The A960.06 (2-ЗРУ-75-100) charging and discharging unit is designed for charging and discharging storage batteries from a three-phase current network with a frequency of 50 Hz, voltage of 380 V, has two posts for charging (discharging) batteries.
The unit can charge or discharge rechargeable batteries in the following modes: charging with a stabilized current during charging time; two-stage charge with control at the first stage by voltage, and the entire charge by time; two-stage charge with voltage control at the first stage, cycle time is not set; discharge with stabilized current with control of the minimum voltage of the batteries and the return of electricity to the network.
To convert AC mains to DC when charging batteries and to convert direct current of discharged batteries into a variable, returned to the network as the main power elements, thyristors are used, which in both modes are controlled by special control units included in the installation.
Thyristor control is based on the principle, the essence of which is the formation of the thyristor control phase by comparing the sawtooth voltage, synchronized with the network, with the control voltage, which is either set by the operator (with manual control), or is automatically maintained at a level that provides the set value of the charge current (with automatic current stabilization mode).
Tyrimstor - a semiconductor device made on the basis of a semiconductor single crystal with three or more pn junctions and having two stable states: a closed state, that is, a low conductivity state, and an open state, that is a high conductivity state.
When designing posts on the production line and dead-end posts of TO and TR, the normalized distances between vehicles, as well as between vehicles and building structures, are taken into account (Table 2.1).
The arrangement of dead-end posts in the TO and TR zone can be one-sided (Fig. 2.4, {!LANG-2687819f223d8d926e999943a1314835!}{!LANG-ba40b31c5c488cf5acf5a27624b0997c!} {!LANG-7d9132b64b6531edca5473afcad3fcb4!}{!LANG-b90438763e65c76f0840763cbaa2ab6d!} {!LANG-858c9587e00d2880faf2afd17157a582!}{!LANG-9f452fa2e2b0621facef42f4305ec8f0!} {!LANG-af433969d1a59fc4fd2654f1c6c4eaa7!}{!LANG-cb047dd3210251c9b9ed6b764830deec!} {!LANG-d93ded6aaec402a1a267423817c176d5!} {!LANG-cd5b50d00a02fd1c4bc2b1f16238c4bd!}
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