Maintenance and repair of the car is on the LLC 'Otabeksupertrans' (LLC 'Zhizzahavtotransservis')
CONTENTS
INTRODUCTION. ORGANIZATIONAL PART
.1 Feasibility study
.2 Analysis of rolling stock LLC
"Otabeksupertrans» (LLC «Zhizzahavtotransservis")
.3 Organization of maintenance and repair of rolling
stock
.4 Feature routes LLC
"Jizzakhautotransservice" and technical and operational performance.
TECHNOLOGICAL PART
.1 Selection and justification of the initial data
.2 Calculation of the production program of
maintenance
.3 Determination of daily programs by type TO
.4 Rationale and choice of MOT and car diagnostics
.5 Calculation of annual volume of work of the
enterprise
.6 Calculation of the number of production workers
.7 Calculating the number of posts and lines
maintenance and repair
.8 Calculation of the area
.9 Settlement areas of warehouse
.10 Calculation of the storage area rolling stock
.11 Definition of areas of support facilities.
RESEARCH PART
.1 Optimal technology Body Repair
.2 Scheme selection process Body Repair
.3 Tooling bodywork section
.3 Flow chart for bus body repair ISUZU SAZ
NP-37ECONOMIC PART
.1 Calculation of capital cost
.2 Payment of current expenses
.3 Calculation of economic efficiency. HEALTH AND
SAFETY
.1 security master plan and production building in
body section
.2 Heating Safety in the workplace when the body work
.3 Analysis of harmful and dangerous production
factors in body section. PROTECTION OF THE ENVIRONMENT
.1 Reduction of toxic emissions car emissions by
rationing
.2 Environmental protection in the MOT and diagnostics.
CIVIL PROTECTION
.1 Fire safety
.2 Fire safety in the zone TO
any socio-economic system of transportation and communication
are essential. For independent Uzbekistan with its huge concentration of raw
materials and production resources, transport and communication complex creates
prerequisites for economic development.55% of the volume of domestic passenger
traffic in recent years, the country performs road transport. This mode of
transport is no adequate substitute for the carriage of passengers on short and
medium distances, the transport providing retail, manufacturing logistics,
construction industry, agro, as well as small businesses.basis for policy
maintenance and repair of rolling stock of road transport is scheduled
preventive maintenance system and method for aggregate maintenance.is intended
to maintain the car in good working condition and in a proper appearance,
reduce the intensity of wear parts, prevention of failures and faults, and to
identify them in order to timely removal.is prevention activities forcibly
routinely runs at specific time or work vehicles.with defective units, nodes,
links and details, which involve a threat to safety, should not continue to
work or transport to be released on the line. Other faults affecting traffic
safety and non-intensive wear or premature failure of parts can be removed
after the completion of the transport operation within a removable or daily
tasks.requirements of existing vehicles set Rules of technical operation of
rolling stock and road transport Traffic Regulations.includes monitoring
(diagnostic), fasteners, lubricants, filling, leveling, electrical and other
work to be performed, as a rule, without disassembling the units removed from
the vehicle and the individual nodes.periodicity, and the complexity of the
list of works Car maintenance is divided into the following types:maintenance
(DM);first maintenance (M-1);second maintenance (M-2);maintenance (SM).includes
oversight aimed at ensuring safety, as well as work to maintain proper
appearance, refueling, oil and coolant, and for some types of rolling stock -
sanitization body. DM is performed after the work on the motor company (MC)
rolling line.and M-2 include control (diagnostic), fixing, adjusting,
lubricating and other activities aimed at the prevention and detection of
faults, reducing the intensity of derating technical state of rolling stock,
fuel economy and other operating materials, reducing the negative impact of
cars on the environment.must ensure trouble-free operation units, components
and systems for cars within the prescribed periodicities on the effects
included in the mandatory list of operations.technical condition and durability
of the car depends on the rules of operation (running a new car, his driving
techniques, load and maintenance). The main reason for the deteriorating
condition of the car is the wear of individual parts, assemblies, mechanisms,
devices and assemblies. Depreciation can be divided into two groups: natural
and premature.wear appear even with all the rules of operation, regulated by
the manufacturer as a result of frictional forces (abrasion), exposure to high
temperatures, metal fatigue and chemical effects of various gases, acids and
alkalis.to comply with regulations governing causes premature wear of the main
reasons for which are: non-compliance running car, untimely and poor
maintenance, fast driving on bad roads, failure to comply and start the engine
warms up, the use of unsuitable varieties of oils and lubricants.influence on
the wear parts have driving mode, road and weather conditions, fuel quality,
lubrication, maintenance and driving skills.justifying the optimum mode the car
is a list of operations is determined by the coefficient of repeatability, the
frequency is set by statistical data path of a vehicle to an acceptable
parameter value node unit. Since the mileage limit to the node status is
random, the large scatter in the data, and therefore to reduce costs to the
receiving frequency is more than the minimum, taking into account the
confidence level of probability. At the same time a certain portion of vehicles
needed at the specified intervals before, and the overwhelming majority -
later. To reduce cost and increase reliability maintenance necessary to carry
out work, when the parameter reaches the allowable value. And this is only
possible with timely and accurate determination of the technical condition of
the car without disassembling. Technical control, which is mainly produced the
motor company visually insufficiently effective, evaluation of technical
condition depends on the skill of the controller. For objective monitoring
devices are necessary, that can be used to identify vehicles that pose a risk
at the same time avoiding removing serviceable unit. Instrumental determination
of the technical state of the node, without disassembling the unit called
diagnosing.condition of the car is characterized by structural parameters
(clearance, center-distance, deflection, displacement, linear dimensions,
surface state of mating parts, etc.). Interaction of car with the environment
and mechanical loading lead to a change of its technical condition. Changes in
structural parameters of aggregates car has certain regularities.these problems
peculiar and Jizzakh regionon the foregoing, the subject of my final qualifying
work find relevant and useful.aim of this work is the final qualifying
justification optimal mode the car is on the LLC "Otabeksupertrans"
(LLC "Zhizzahavtotransservis")increase the efficiency of activity of
"Otabeksupertrans» (LLC «Zhizzahavtotransservis") and successful
activities should be solved the following problems:
Development of the motor cjmpany production building sites
with the location of existing data and the number of cars;
Development and introduction of a 6-rack lift buses with
placing it in the Touring Car division;
Development of working drawings lift;
Describe the principle and the main characteristics of the
lift;
Description of possible faults lift and troubleshooting.
.
ORGANIZATIONAL PART
1.1 Feasibility study
Limited Liability Company "Otabeksupertrans" refers
to enterprises manufacturing areas. The main specialization - passenger
transport. Rolling Stock Company is a bus different brands and different
capacity.company was formed in 2007 as a private enterprise in place of private
enterprise "Navruztrans." In February 2009 it was reorganized as a
limited liability entity.March 28, 2014 Limited Liability Company "Otabeksupertrans"
reorganization and renamed as LLC "Zhizzahavtotransservis" in this
moment of production site, LLC "Zhizzahavtotransservis" is located in
the industrial zone of the city Jizzak. This company has 7 work stations, two
of which are intended for repair of buses of the middle class; third and fourth
positions are intended for repair of large buses; fourth post is repairing
suspension; fifth, sixth, seventh positions designed for body and paint work.
OOO "Zhizzahavtotransservis" works on the imputed tax system. Located
on the premises the following facilities: 1) an office building; 2) parking for
storage of rolling stock; 3) repair and servicing base; 4) industrial
warehouses; 5) checkpoint.Limited - a legal entity duly registered and engaged
in business activities of an entity.company works with organizations and
individuals, and performs the carriage of passengers in urban and suburban
routes.the territory LLC "Zhizzahavtotransservis" is administrative
buildings, maintenance facilities and ancillary facilities. Car storage is
carried out on an open parking lot, located on the motor company (MC). The
structure consists of MC production, warehouse, residential and office
premises.building with a control tower is on the motor company. Mode of
operation of LLC "Zhizzahavtotransservis" is 365 days a year.
1.2 Analysis of rolling stock LLC
"Otabeksupertrans» (LLC «Zhizzahavtotransservis")
maintenance repair rolling stock
This time on the balance sheet vehicle fleet has 61 buses,
«ISUZU» SAZ NP-37, «ISUZU» SAZ NP-21, DAMAS.its inception up to the present
time, the company changed its name several times.chairman of LLC
"Otabeksupertrans" in December 2009 he was appointed Adiljanov
Sherzod that after Jizzakh Polytechnic Institute 5 years working at the
enterprise "Jizzakhtrans" chief engineer.this moment the passenger
motor company LLC "Otabeksupertrans" reorganization renamed as LLC
"Zhizzahavtotransservis" - has 61 units of rolling stock, there are
32 people working. Core business is the transportation of passengers., production
and technical base of the enterprise does not meet modern requirements.big
drawback is the lack of specialized production building.inspection rolling
stock is carried out before leaving the line, while working on the line and
when returning cars in the MC.of cars on the line drawn as follows. 600 in the
MC come vans delivering drivers. Drivers spend half an hour to start and warm
up the engine, vehicle inspection, receipt logs, vehicle refuelling and other
petroleum products. In 630 starts automobiles inspection mechanics control
auditoria point. Primarily controlled technical condition of influencing
traffic safety: steering, brakes and others. Technically sound cars are
available on line.LLC "Zhizzahavtotransservis" consists of buses of
various brands and different capacity. The table shows the brand and the number
of buses.
1.1on the rolling stock, LLC
"Zhizzahavtotransservis"
Vehicle
|
Number of units
|
1
|
2
|
Buses
|
«ISUZU» SAZ
NP-37
|
32
|
«ISUZU» SAZ
NP-21
|
1
|
DAMAS
|
28
|
1.3 Organization of maintenance and repair of rolling
stock
Daily maintenance on the MC produced in-line method. The
first and second maintenance performed on dead-end positions.maintenance
includes such works as mechanized car washing, wiping or blowing air vehicles,
refuelling vehicles oil and water, control air pressure in the tires and
pumping air to normal.M-1 produced maintenance work on power systems, checking,
fixing and adjusting work, electrical work, tire, lubricants, gas and cleaning
work.on the M-2 produced fastening, adjusting work and service power system
maintenance work on the brake system, steering and suspension, as well as
lubricants, refueling and cleaning work. Returning to the line vehicles are
inspected duty mechanic. Serviceable cars are sent to the DM and storage area.
Cars to be the next maintenance and faulty after washing directed to the
appropriate positions diagnosis, maintenance and repair, or to the waiting
area.and osmotrovye work performed mechanic control technical points and the
driver. Washing and cleaning work - a specialized team, which includes
cleaners, washers and obtirschiki. Gas works - the driver. Acceptance of work
performed by the driver or Drover. Selective control - quality department
employees.M-1 cars are common diagnosis D-1 to detect faults and determine the
status of units and systems to ensure safety. In case of troubleshooting before
they are eliminated M-1 in the complex corrective maintenance (CM). M-1 is
performed by a specialized team. Quality control is carried foreman M-1 and a
representative of the quality department.one or two days before the M-2 cars
head on in-depth diagnosis of D-2 for troubleshooting purposes, the elimination
of which requires a lot of maintenance. These problems can be solved until the
M-2complex in the CM. All the work of M-2 (routine maintenance and related
repairs) done by specialized teams on the production line or the dead-end
positions depending on the program. Quality control is carried foreman M-2 and
a representative of the quality department.the beginning of the shift driver
inspects the car, make sure it is operating normally and performs operations on
DM.
1.4 Feature routes LLC
"Jizzakhautotransservice" and technical and operational performance
On Table 1.2 presents the structure and composition of the
workers LLC "Zhizzahavtotransservis."
1.2workers LLC "Zhizzahavtotransservis"
Workers
|
Number of man
|
Engineering
staff
|
4
|
Drivers
|
61
|
Maintenance
workers
|
32
|
OOO "Zhizzahavtotransservis" provides passenger
transportation in urban and suburban routes of varying lengths. The main city
routes, organized LLC "Zhizzahavtotransservis" this number routes 9
and 35. Moreover, the carriage of passengers carried on the routes for
organizations and enterprises of the city, called duty routes.number of flights
per year buses represented in Figure 1.1.
1.3number of flights operated buses for the year
Years
|
Number of hauls
|
2009
|
262338,9
|
2010
|
266855,2
|
2011
|
273408,3
|
2012
|
283425,8
|
2013
|
280429,2
|
1.1 - Total number of hauls
total mileage of buses is presented in Table 1.4.
1.4total mileage of buses
Yaers
|
The total
mileage of buses, km
|
2009
|
7215918,114
|
2010
|
7383172,571
|
2011
|
7537830,428
|
2012
|
7767527,217
|
2013
|
7795796,249
|
1.2-Total distance buses
fuel consumption of the rolling stock, LLC
"Zhizzahavtotransservis" is presented in Table 1.5.
1.5consumption
Years
|
Consumption of
diesel fuel, litr
|
2009
|
1476314
|
2010
|
1703431
|
2011
|
1950608
|
2012
|
2583982
|
2013
|
2740057
|
the graph (Figure 1.3) shows that the fuel consumption diesel
cars increases. This is due to changes in the structure of the bus fleet.
Conducted by LLC "Zhizzahavtotransservis" policy on replacement of
the bus fleet, gasoline powered buses with diesel engine has a number of
advantages. First, the reduced fuel costs. Second, use the buses with diesel
engine economically advantageous due to the low fuel consumption car. Thirdly,
a diesel engine compared to a carburettor, has less adverse environmental
impact.
1.3 Total fuel consumption
total mileage of buses with passengers is presented in Table
7.
1.6total mileage of buses with passengers
Years
|
The total
mileage of passengers, km
|
2009
|
6490983,374
|
2010
|
6634533,011
|
2011
|
6781510,828
|
2012
|
6990709,487
|
2013
|
7016890,379
|
1.4 Total distance passengers
.
TECHNOLOGICAL PART
2.1 Selection and justification of
the initial data
maintenance repair rolling stock
1. Initial data for calculation of accept a feasibility
study. In the long term management of the enterprise provides fleet renewal and
planned to purchase 60 buses ISUZU. Proceeding from the above calculations
supremely proizvozhu for bus fleet of 121 buses:
. The design City - Jizzakh.
. Balance number of cars - 121 buses.
. Average daily mileage - 260 km
. Mileage since new - 1,6 thousand km
. Buses:
«ISUZU» SAZ
NP-37
|
88
|
«ISUZU» SAZ
NP-21
|
25
|
«ISUZU» SAZ
NP-26
|
8
|
. Projected land-body section.number of days the rolling
stock on the line adopted by 365 days. The number of buses on the line shifts
receive one shift. Working hours 10:00 accept. Category for operation in hilly
cities more than 100 thousand inhabitants accept III.
2.2 Calculation of the production
program of maintenance
program MC maintenance is characterized by a number of
technical services, planned for a certain period of time (year, day).method of
calculating production program involves selection and adjustment of frequency
M-1, M-2 and run to capital repair rolling stock designed for MC, payment
number and capital repair for 1 car per cycle, that is to run the CD ratio
calculation conversion from cycle to year and, based on counting the number of
values obtained and capital repair per cycle for 1 car park for the whole
year.MC plan on the basic parameters set for the calendar year, and production
program for each type then rely on year. The program serves as a basis for
determining the annual volume of work required MC and state workers.
Adjustments to regulatory periodicity maintenance and mileage
to the capital repair. Mileage to the i-th species is then determined by the
formula:
(1)
-
standard mileage to the i-th type of maintenance;
coefficient taking into account the category of
vehicle operating;
coefficient taking into account the climatic
conditions;
К1 = 0,8; К2 =0,9
to
the average daily mileage proizvozhu follows:
where
- average mileage, km;
the
number of the capital repair, for one car per cycle. Specifies the number of
overhauls and maintenance for one car per cycle using the following formulas:
Determining the number of maintenance for one car and the
entire park for the year. Define technical readiness coefficient applied to the
repair cycle by the formula:
dТОиТР - days of downtime in the maintenance and capital
repair, day/1000 km to accept payments dТоиТР=0,30;- number of days of
inactivity car capital repair accept DK = 18 days.
Based on the
calculated values of αT define possible annual vehicle mileage formula:
of work days per year =365
days.
The transition rate from cycle to year determined by the
formula:
Number maintenance on one car per year determined by the
formula:
Number maintenance the entire park for the year determined by
the formula:
-
balance number of vehicles.
Determination of the number of diagnostic effects of D-1 and
D-2 for the entire park for the year. Number of diagnostic effects of D-1 and
D-2 for the entire park for the year determined by the formula:
2.3 Determination of daily programs by type
maintenance
The daily program of fleet determined by the formula:
.4 Rationale and choice of
maintenance and car diagnostics
The criterion for selecting the method of maintenance is a
daily production program for each type of service similar cars. Diagnosing D-1
is organized on separate posts (selected diagnostics D-1). With a daily program
of more than 100 cars DM provides service on the line. M-1 and M-2 is produced
on the lines.
M-1 - line- line- line
2.5 Calculation of annual volume of
work of the enterprise
to regulatory complexity. Adjustments to regulatory
complexity was producing in the following order:
Define the complexity of the formula DM:
Км - coefficient mechanization factor considering
reducing labor by mechanization DM;
К4 - coefficient taking into account the size of the
MC.- regulatory complexity M-1 and M-2.
КМ=0,6; К4=1,2; tDMH=0,80
frequency determined by the formula M-1and M-2:
regulatory
complexity adjusted current repairs:
-
factor considering mileage vehicles since the beginning of operation.
complexity
of diagnosing D-1 is determined by the following formula:
complexity
of diagnosing D-1 is determined by the following formula:
complexity
of seasonal maintenance is determined by the formula:
δ=30%.
where δ - share work with, from the complexity of M-2, %.
of
annual volumes of activities of maintenance, diagnosis and CR. The annual
volume of production activities of maintenance, diagnosis and repair of current
determined by the formula:
Годовой
объём производственных работ определяю по формуле:
of
auxiliary labor costs for the enterprise. Annual volume of auxiliary labor
costs, which include ongoing care for buildings and facilities, equipment
repair, equipment, the enterprise is determined by the formula:
2.1 shows the distribution of self-service works by
type of activity.
2.1of self-service works by type of activity
types of jobs
|
labor content, %
|
labor content,
person-hour
|
mechanical
|
10,0
|
2991,259968
|
Hand
|
16,0
|
4786,015949
|
Forging
|
2,0
|
598,2519936
|
welding
|
4,0
|
1196,503987
|
tinsmith
|
4,0
|
1196,503987
|
coppersmith
|
1,0
|
299,1259968
|
Electrical
|
25,0
|
7478,14992
|
Piping
(locksmith)
|
22,0
|
6580,77193
|
Repair and
construction and woodworking
|
16,0
|
4786,015949
|
TOTAL
|
100,0
|
29912,59968
|
complexity of the general production work for a large share
of service jobs, as workers have to provide daily production of all
necessary.composition and the approximate distribution of overhead work mix in
Table 2.2.
2.2composition and the approximate distribution of overhead
work
types of jobs
|
labor content, %
|
labor content,
person-hour
|
black gang
|
12,0
|
5383,067942
|
cleaners
|
12,0
|
5383,067942
|
Storekeepers
|
14,0
|
6280,245933
|
Drivers
peregonschiki
|
30,0
|
13457,66986
|
general workers
|
32,0
|
14354,84785
|
TOTAL
|
100,0
|
44858,89952
|
distribution of annual volumes of works on and capital repair
(CR) works on industrial zones and areasand CR distributed at his place of
execution by technological and organizational characteristics. And TS performed
on fasting and production sites. To include guards work and TS performed
directly on the car. Checking and repair units, mechanisms, assemblies removed
from the vehicle, performing on.distribution of annual volume of work is
presented in Table 2.3.
2.3volume of work on MC
|
DM
|
M-1
|
M-2
|
CR
|
Тсам
|
ΣТ
|
guards Cleaning
washers wiping diagnostic Fixing Thrust Lubricants, refueling, cleaning
Electrical By the system power bus Body Razborochno-assembly
|
10255,77
7976,71 4558,12 - - - - - - - - -
|
- - - 1212,71
7276,2624 1364,2992 3031,776 909,5328 454,7664 909,5328 - -
|
- - - 1149,984
10119,86 1609,98 2069,97 1379,98 689,9904 3219,955 - -
|
- - - 3238,24 -
3238,24 - - - - - 40478
|
- - - - - - -
- - - - -
|
10255,77
7976,71 4558,12 5600,9344 17396,12 6212,5192 5101,746 2289,5128 1144,7568
4129,4878 - 40478
|
TOTAL
|
22790,6
|
15158,88
|
20239,72
|
46954,48
|
-
|
105143,68
|
precinct
aggregate Mechanical fitter Electrical Cordless By the system power Tire
Changers vulcanization Forging and for springs coppersmith welding tinsmith
reinforcement Joinery Painting Upholstery
|
- - - - - - - -
- - - - - - -
|
- - - - - - - -
- - - - - - -
|
- - 689,9904
689,9904 689,9904 689,9904 - - - - - - - - -
|
25905,92
12952,96 12952,96 1619,12 4857,36 4857,36 3238,24 4857,36 3238,24 8095,6
8095,6 8095,6 - 12952,96 3238,24
|
- 7777,3 - - -
- - 598,252 299,126 1196,5 1196,5 - - - -
|
25905,92
20730,26 13642,95 2309,1104 5547,3504 5547,3504 3238,24 5455,612 3537,366
9292,1 9292,1 8095.6 - 12952.96 3238.24
|
TOTAL
|
-
|
-
|
2759,96
|
114957,52
|
11067,68
|
128785,16
|
Lots of
self-care: electro technical Pipeline Repair and construction
|
- - -
|
- - -
|
- - -
|
- - -
|
7478,15 6580,77
4786
|
7478.15 6580.77
4786
|
TOTAL
|
-
|
-
|
-
|
-
|
18844,92
|
TOTAL
|
22790,6
|
15158,88
|
22999,68
|
161912
|
29912,6
|
252773,76
|
2.6 Calculation of the number of production
workers
For production workers include working areas and areas
directly performing work and CR rolling stock. Foundation depends on the
duration and the number of shifts working days a year. Annual Fund-time
"regular" worker determines the actual time spent executing directly
in the workplace.
2.4of the number of workers
Name areas and
shops
|
Annual volume of
work on the zone or area
|
РТ
|
accepted number
РТ
|
ФР
|
Number of
full-time employees
|
|
|
|
Total
|
reassignment
|
|
rated
|
adopted
|
Zone M and CR: -
DM Zone - Zone M-1 - Zone D-2 - ZonaD-1 - Area M-2 - CR zone (posts)
|
22790,6
15158,88 2508,48 23902,032 20239,72 46954,48
|
11 7 1 12 12 23
|
11 7 1 12 12 23
|
6 4 1 6 6 12
|
1780 1780 1780
1780 1780 1730
|
13 9 2 14 14 27
|
13 9 2 14 14 27
|
TOTAL
|
|
66
|
66
|
35
|
|
79
|
79
|
Industrial
areas: - aggregate - Electrical Engineering - battery - By the system power -
tire - vulcanising - coppersmith - welding - Forging and mechanical
suspension - Mechanical fitter - carpenter - Reinforce-body - wallpaper -
painter - sheet metal
|
25905,92
13642,95 6264,9 2309,1104 5547,3504 3238,24 3537,366 9292,1 5455,612 20730,26
- 8095.6 3238.24 12952.96 9292,1
|
12 7 3 1 3 2 2
4 3 10 - 4 2 6 4
|
12 7 3 1 3 2 2
4 3 10 - 4 2 6 4
|
6 3 1 1 1 1 1
2 2 5 2 1 3 2
|
1780 1780 1730
1730 1780 1730 1730 1730 1730 1780 1780 1780 1780 1760 1780
|
15 8 4 1 3 2 2
5 3 12 5 2 7 5
|
15 8 4 1 3 2 2
5 3 12 5 2 7 5
|
TOTAL
|
|
62
|
62
|
31
|
|
73
|
73
|
- repair and
construction - steam piping - Electrical Engineering
|
4786 6580,77
7478,15
|
2 3 4
|
2 3 4
|
|
1840 1840 1840
|
3 4 4
|
3 4 4
|
TOTAL
|
|
9
|
9
|
|
|
11
|
11
|
TOTAL
|
|
137
|
137
|
|
|
144
|
144
|
of workers needed technologically determined by the formula:
of workers needed technologically determined by the formula:
Фм - annual fund temporary jobs or technologically necessary
working in one shift, hour.
Annual Fund-time job or technologically necessary working
hours for a six-day working week is:
Фм=(Дкг-Дв-Дм)•7-Дпп•1, час
Фм=(365-52-7)•7-56•1=2086 ч
According to calculations, the annual fund-time one
workstation will be Фм = 2086 hour.of the number of workers on the MC mix in
the table 2.4.
2.7 Calculating the number of posts and lines
maintenance and capital repair
Mode of operation zones maintenance and repair. Mode of
operation zones maintenance depends on the mode rolling stock on the line.DM
and M-1, operated in time between replacement duration defined service areas of
intragarage release schedule and return vehicles. Duration time between
replacement for uniform release vehicles can be determined:
where ТН - duration of the cars on the line, hour;
То - Lunchtime driver, hour;
ТВ - duration producing cars on line, hour.
zones
assigned to one shift. To assign a M-2 in 1 shift. Daily posts of this mode
assign repair in 1 shift. Production shops operate in one shift.production:
where Тоб - duration of the zone for this type of M
within days, ;
С - the number of shifts;
batch
production lines used for M-1and M-2. Tact line is then determined by the
formula:
where Рл - the total number of technologically
necessary working on the line M, person.number of workers on the line defined
by the formula:
Рл=Хл • РсрХл - number of posts on the line,
adjustable for technological reasons, in accordance with the distribution of
works of this kind of service; Рср - the average number of workers in the post.
Рл1=4 • 2=8 man
Рл2=4 •2=8 manline is equal to:
number
of lines is determined by the relation service:
length
of the production line defined by the formula:
zone
calculation. Tact DM line defined by the formula:
where Nу - washing plant performance, the
bus/hour;у=40 bus/hour. - for buses.
of
posts on the line DM 2 posts.of lines:
of
the number of posts D-1 and D-2. Number of specialized posts diagnosing the D-1
and D-2 defined by the formula:
where Тд - annual diagnostic work, person-hour;
Драб. г. - number of working days in the area of
diagnosis;
Тсм - duration of change, hour;
С - number of change;
Рд - the number of workers in the post, man;
ηд =0,85…0,90 - utilization of working time
post diagnosis.
the
number of posts the current repair
φ - coefficient of irregularity of cars on the positions
CM,
φ=1,2…1,5. accept φ=1,5;
ТТРп - annual guards work CR, person-hour;
Драб. г. - number of days of work per year zone CR;
Тсм - duration of change, hour;
С - number of change (2…3);
Рп - the number of workers in the post, man;
ηп =0,85…0,90 - utilization of working time
post.
CR
specialize by type of work performed:
Universal posts - 2 post;
Posts transmission repair, brakes, steering and
suspension - 6 posts;
Post control and brake adjustment - 1 post;
Post adjustment and control wheel alignment 1 - Lent;
Engine repair stations and systems - 1 positions.of
posts expectations. Posts expectations - it posts that cars requiring some form
or another and CR, waiting queue to go to the appropriate post or production
line. These posts provide stable operation and CR zones, eliminating to some
extent on the uneven cars and CR.number of posts is as follows:
Before the line DM - starting from 15 ... 20% of the
time line capacity of DM;
Before the M-1- based on 10 ... 15% of the replacement
program;
Before the M-2 starting from 30 ... 40% of the
replacement program;
CR before proceeding from 20 ... 30% of the number of
posts CR.
Since the company has covered parking for storage of
buses, the posts waiting in front lines do not provide M.the number of storage
locations (parking) cars. Car-seat storage can be assigned to specific vehicles
or impersonal.of car-storage locations when attaching them for the scheduling
of matches car park. At MC take possession rolling stock without securing
parking places.
Choice of a rational number at post M and CR. The
number of simultanDMusly working on Harvesting washing zone positions DM take 6
people. Positions on M-1and M-2 concurrent set depending on the method of
organization M: on the production lines 4 people. For specialized positions
diagnosing D-1 and D-2 the number of workers in the post 2 people. The number
of simultaneously running for CR taken depending on the type of rolling stock:
for buses 2 people.
2.8 Calculation of the area
To premises. Square MC functional purpose are divided into
three main groups: production, storage, storage rolling stock and support.and
storage - area M and CR, production sites CR, warehouses, as well as technical
areas of energy and sanitation services, and devices (compressor, transformer,
etc.).rolling stock - parking area, the surface area occupied by equipment for
heating, frames and other passages of floor.- sanitary and domestic, catering
facilities, public health, cultural services and communication, training sessions
and public organizations.of the area zones M and CR. Area zones M and CR is
given by:
where fа - the area occupied by the vehicle in terms
of, m2;
Х - number of posts;
КП - density ratio placement positions, for
calculations accept Кп=4,5.fooCMrint of the car in terms defined by the
formula:
where Ш - car width, to accept payments over the width
of the bus ISUZU SAZ NP-37, Ш =2,5 m;- length of the car, to accept payments
over the length of the bus ISUZU SAZ NP-37, L =7,0 м.
Number of posts to accept zones without waiting positions, as
the company has covered parking for car storage:
area
M-1:
area
M-2
CR zone area:
DM zone area:
Area D-1 zone:
D-2
zone:
of
the area of industrial sites. Area of industrial sites by counting the specific
area per production worker of the number of simultanDMusly working on a plot by
the formula:
where fp1 - specific area per worker, m2;- specific area in
subsequent work stations, m2;
РТ - technological concurrent to the greatest change.fitter
mechanical part:
Forge-size portion of spring:
Land area coppersmith:
Area of sheet metal section:
Area welding area:
Size of wallpaper section:
reinforcing
portion:
area
of electrical:
paint
area:
Lot size tire changer:
Area vulcanization area:
size
battery:
Land area repair the power supply system:
aggregate
area:
Area bodywork section:
2.9 Settlement areas of warehouse
Calculation of storage space on specific standards for
mileage. Settlement areas of warehouse made on a specific area of 1 million
kilometers rolling stock is determined by the formula:
where Lг - annual mileage cars, km;
Аи - Balance number of vehicles;уд - the specific area of the
warehouse to 1 million kilometres, m2;
КПС- coefficient taking into account the type of rolling
stock;
Кр - coefficient taking into account the number of vehicles;
Краз - factor considering rolling stock miscellaneous
branded.
2.10 Calculation of the storage area rolling stock
Vehicles, storage space is determined by the formula:
where Аст - Balance number of vehicles;
КП - density ratio arrangement cars, accept for
payment КП=2,5.
2.11 Definition of areas of support facilities
facilities - administrative, household, community - are the
subject of architectural design and construction must comply with design
standards and regulations.approximate composition of ancillary facilities
provided for by the MC as follows:offices:
For senior staff (director, chief engineer, chief operation);
Departments (technical, planning, operational, accounting,
etc.);
Dispatch, elegant, chauffeur, shop offices, facilities
director of the colony, and pass protection watchdog;
Non-governmental organizations - trade unions, as well as
classrooms, meeting and recreation.administrative offices is calculated from
the state administrative apparatus to the following standards:
Departments working rooms - 4 m2 per worker in the room;
Rooms - from 10 to 15% of working rooms depending on the
number of employees.space for drivers to determine the rate of the simultanDMus
presence of 30% of drivers working in the most populous change per 1 m2 per
person, but not less than 18 m2 total area.of the premises to rescue drivers
determined the rate of 3 m2 per attendant.the territory MC detached two-storey
administrative building.: cloakroom, showers, washrooms, toilets, smoking,
eating establishments, clinics.of public spaces at rates calculated based on
the number of employees.stored in closed closets all kinds of clothes number of
individual cabinets is taken to be working on all shifts. Dimensions for closed
stationary locker for storing clothes following: depth - 0.5 m, width - 0,33 m,
floor area dressing one locker - 0.25 mbuildings designed MC envisage dressing
with the number of lockers for workers - 50, -100 for drivers. Then make a
dressing room area: 177.2 sqmof shower screens and taps in washrooms is
determined by the number of employees in most large change depending on the
group of the production process of calculation from 3 to 15 people per shower
and from 7 to 20 people per tap. Floor space on one shower with dressing room
is taken equal to 2 m2, one sink - 0.8 m2 at their sole location.of shower
rooms for workers to accept MC design 12 showers. Number of shower rooms for
drivers take to design 12. Overall shower area will be: (12 +12) • 2 = 62
sq.m.space is taken equal to 2.0 WC x3, 0 per cabin. The bathrooms, number of
cabins with toilets at work in the most populous accept change rate of one
stall for 5 women and 1 in 10 men at the cabin, the number of booths for
drivers - at the rate of drivers traveling in the period of maximum production
of the vehicles. Cabin size 1,2 x0, 9 m distance from the most remote
workstation must be no more than 75 min the MC: (125 +192 +110) / 30 = 14, 14
for design accept. Area toilets: 14 • 2 • 3 = 84 sq.m.area is determined based
on an employee in most big change: 0.03 m2 - for men and 0.01 m2 - for women,
but not less than 9 m2. Distance from jobs to smoking should not exceed 75
mrooms on MC: 0,03 • 121 = 3.63 meters, design accept 4 sq.m.support facilities
should be considered as the area of technical facilities, which are calculated
in each case on the relevant standards, depending on the system adopted for
heating, water and ventilation.accept the compressor room area of 15 m2, for
pumping - 10 m2, ventiljatornaja - 20 m2, transformer - 15 m2. Boiler house and
coal storage is not provided as heating in the building MC centralized.the
total area of MC by the formula:
(57)
.
RESEARCH PART
3.1 Optimal technology Body Repair
Body repair technology provides a set of measures aimed at
the implementation of quality car repairs. Body repair technology determined by
the degree and extent of damage, as well as cooperates depending on the goals
and objectives. So the optimal body repair technology with significant damage
is to replace metal parts. For minor injuries chips, scratches, abrasions, the
technology of the local body repair, where exposures are directly affected
area, but not the entire piece in its entirety. When this body repair
technology also provides a local painting eliminating defects. In addition, the
technology provides for the restoration of body repair parts by embossing the
surface aligned as possible options to avoid having to applying a thick layer
of putty.repair technology with complex lesions of the body, accompanied by his
skewed or breach geometry, provides pre-reduction options, followed by
replacement parts. Reverse body repair technology is not provided. Compliance
with recommended elements in the body repair work regardless of its complexity
is a guarantee of quality work.section is intended to correct defects and
malfunctions body that occur during operation. On site kuzovnom restore their
original shape and strength of repaired body, and also perform work to maintain
the body and its mechanisms in good technical condition.this area is carried
out sheet metal and welding Fittings and body works, which include operations
for disassembly, assembly, welding and straightening damaged panels, body parts
and mechanisms can be carried out repairs of radiators, fuel tanks, as well as
springs and wheel rims. There also needed to produce replacement body parts:
panel inserts, patches, etc.repair sheet metal work (removal of dents, cracks,
tears) mudguards, front hood, radiator facings, doors and other parts of the
body, as well as partial manufacture simple parts to repair replace
dilapidated. Panel is a progressive method of repair, providing a complete
replacement of the damaged item or part of the body.assembly operations include
removal and installation of doors, panels or individual body parts, tools,
glass and other removable parts. Partial disassembly of the body to repair its
parts is carried out to the extent necessary to ensure quality execution of all
maintenance operations. For body assembly after repair, including the
installation of parts and components to the body (doors, fenders, panels), use
different sets of equipment, tools and a set of templates.operation depending
on the nature of the damage is to eliminate irregularities in the deformed
surfaces, as well as in correcting distortion gDMmetric dimensions of the body
(distortions).operations are an integral part of the sheet metal-body work.
Almost all repair operations require the use of welding in a given volume. body
use on site gas, arc and spot welding. For repair welding is used for removing
the damaged area, straightening work, installing new parts or areas of the body
and additional details (amplifier boxes, pads, liners, etc.), as well as welding
cracks, gaps and holes with or without the imposition of patching depending on
the size and condition of the damaged surface.works include repairs of all the
mechanisms of the body (locks, door hinges, windows, etc.), as well as repairs
of windows and glass replacement. Renovated and assembled mechanism put in
place followed by adjustment. When replacing the glass used tools for assembly
of glass, wood and rubber mallet, mandrel.section provide the necessary
documentation, including technical cards on main activities and associated
equipment.main elements of the manufacturing process body repair are:
Preparation of the body to repair (washing, dismantling,
removing coatings, determination of repairs);
Renovation of the old and new parts manufacturing, as well as
the creation of an adequate supply of components and parts for repair and
procurement departments for uninterruptible power supply repair and assembly
areas of the body;
Implementation of body repairs on the principle of
interchange ability of parts and components removed from the body.basic
elements of the manufacturing process are carried out on the basis of mutual
coordination and procurement of all major sites. The manufacturing process also
includes training of repair facilities; organization service jobs; receiving
and storing repair fund materials, semi-spare parts; all stages of repair and
body assembly and its components, transportation of parts and assemblies.the
design of the body have different requirements, some of which are common to all
types of bodies, and some depend on the purpose of the body.general
requirements include the provision of: good visibility for the driver and
passengers, the tightness of the body that does not allow penetration into the
body moisture and IPT; Body strength housing elements and their compounds,
allowing to perceive acting on the body load and voltage with minimal
deformation of the structure and form; disassembly and repair capabilities
hidden under the body of the car mechanisms and free access to them;
technological hull design, convenient for assembly, finishing, maintenance and
repair, and parts there of shall be simple to manufacture; beautiful appearance
of the car.design of the body is not allowed pockets of moisture. Not allowed
as rattling and creaking body. Of great importance is the body performance, the
ability of the body to be repaired with a minimum expenditure of time.main
objectives of overhaul of the car body are full checks of the construction and
equipment of the body; Troubleshooting and recovery of strength properties of
the body and its reliability; repair or replacement of damaged structural
elements of the car body and its equipment.process overhaul body is determined
by its design features. Repair starts with the inspection body for acceptance
it repaired to identify feasibility body repair, verify its completeness and
detection of visible without dismantling the body damage. After washing the
body is pre-inspection, the purpose of which ascertain the status and
feasibility of repair of parts and components subject to mandatory removal from
the body (glass, interior upholstery, etc.). After preliminary Troubleshooting
perform general dismantling of the body. With a total disassembly disconnect
and remove all installed on the body shell assemblies, components and parts.
Unparsed remains only body shell. When cleaning the exterior of the body to its
disassembly not washed surface, closed interior panels, body floor, assemblies
and parts mounted on the body.and cleaned the body and tail of the car is sent
to the site of old paint removal; units and components to be repaired in other
shops, is sent to the warehouse storage units awaiting repair.; fittings,
upholstery and other parts and body parts that need repair - in the specialized
department of the body shop. On a plot of collation also receives refurbished
and new parts installed on the body instead of discarded when it is
built.removing the old paint is subjected to detailed monitoring body at which
indicate the nature of damage to a body when it is operating. Then the body
acts on the site of repair. Renovated box is pre-assembled, with the body hung
on the door panel set, feathers and other parts to be painted with the body.
Then the body paint and final assembly.
3.2 Scheme selection process Body
Repair
Preparing the body for the repair is carried out in
accordance with the scheme of the process of repairing and includes
disassembly, removal of coatings, damage detection and repair work. Dismantling
body runs for two consecutive times:
. Removal from the bodies of all units and components
installed on his body from the inside and the outside.
. Dismantling body to repair after removal of paint and to
identify any damages in the case.of the body to repair its parts is carried out
to the extent necessary to ensure quality execution of all maintenance
operations. Metal welded body shell does not understand. Unfit panel cut out
and replaced with new repair parts. Technological processes in body repair are
usually designed in accordance with the specifications that contain
requirements of major assemblies and parts of the body, the permissible methods
of recovery and the data required to monitor them after repair.of the car when
the old paint is recommended to remove it from the body to repair, as often
hidden under the paint damage (dents, cracks and other defects). Removing the
old paint is also one of the first steps of surface preparation for the
application of the new body paint.removing the old paint body undergoes careful
monitoring in order to identify areas needing repair, and determine the amount
of repair work directly on the body, the so-called flaw.of the technical state
of (testing) Body usually carried out in accordance with the technical
specifications for its repair. The accepted method of fault detection and
thoroughness of its performance depends heavily on the quality of repair. Flaw
detection of a body and its parts are organized in the areas of the provisional
body disassembly and Divisions repair.the detection of cracks and determine
stocking density articulated parts used parts tapping method, which is based on
the definition of tone sound when a hammer rapping parts. By changing the pitch
of the sound can identify cracks and loose connections. In some places, the bearing
members of the body due to the accumulation of fatigue and a significant
hardening of the metal due to work hardening, which appeared in the process of
re-repair panels, there are hairline cracks that can be detected with a
magnifying glass with a four-or six-fold increase, and the best with a dye
penetrant. Surface to be checked previously degreased by wiping with a clean
cloth dipped in gasoline; then covered with red paint; wipe dry with a painted
surface and cover with the help of white paint spray gun. Using dye penetrant
can check the state of the metal in the most critical areas of the body. If
there is a crack on the surface, the red paint lingers in it, visible through
the white paint, revealing the contour of the crack.on the nature of the metal
body repair damage done:
The elimination of irregularities in the panels and
distortion geometric dimensions of the body;
Elimination of damage to cells bearing the body frame;
Replacement of the destroyed body parts with new parts;
Welding cracks and breaks.irregularities in the body panels
and plumage are currently engaged in three main ways: mechanical impact on
metal (pressure treatment); thermal influence on the metal panels; hardens
quickly plastics. The main requirements for car bodies are as follows: line
formed by two or more surfaces of the body panels should be smooth; faceplates
subjected to repair Align carefully, all traces of straightening and welding,
and places that can not be straightening filled plastic mass to complete their
alignment. Doors, fenders, hood and other body parts should be strengthened
reliably and without distortions. Mismatch of the mating surfaces must not
exceed the tolerance. Not allowed creaks noise jamming rotating parts and
assemblies, backlash in the loops, self opening doors while driving and other
deviations from the normal state assemblies and parts of the body, agreed
specifications. Glass should not have defects that distort the profile path,
yellowing and cracking.3.1 is a flow diagram of the execution body work.
3.1
- Technological diagram of the execution body work.
body should be taut; backwardness, sagging, wrinkles
and creases are not allowed. Screws securing the trim and cladding parts should
be wrapped without distortions, and their heads should not have burrs.
Upholstery color should be in harmony with the color of decorative paint
finishes. Not allowed warping cab interior upholstery.finishes must be
monochromatic, without spots, with a smooth sheen without streaks of paint,
rowan, cracks, scratches from the grinding tool and the like. Chipped paint on
the edges are not permitted.
3.3 Tooling bodywork section
to main body shop equipment include:
Lifts;
Jacks;
Grinder;
Welding equipment;
Stands for dismantling, body assembly;
Stands for the repair and straightening of car bodies;
Installations for the anticorrosive coating;
machine work piece, bending, flanging, grooving and cutting
sheet material;
Racks for tools;
Shelving for parts and assemblies;
Welding table for work;
Table for gas welding works;
Bench for body and sheet metal work with a set of tools;
Trolley to move the body.of necessary equipment and tooling
designed bodywork section is given in Table 3.1.
3.1equipment bodywork section
Name of
equipment
|
Type, brand
|
Number
|
Tripper
electromechanical
|
П-129
|
1
|
Hydraulic jack
garage
|
П-130
|
1
|
Grinding machine
reversible dust collectors
|
33Б or ЗИЛ-900
|
1
|
inverter welding
|
ПСО-300Д
|
1
|
Welding
transformer odnopostovoj
|
СТШ-300
|
1
|
Stand for repair
and straightening of car bodies
|
Р-612М или Р-620
|
1
|
Table for
electric welding
|
ОКС-7523
(Russia)
|
1
|
Table for gas
welding works
|
7547 (Russia)
|
1
|
Trolley for
moving body
|
ИЭ-70 (Russia)
|
1
|
Workbench for
body and sheet metal work (with kit)
|
«Клесто-1»
(Czech Republic)
|
1
|
Stand for
fitting glass doors Car
|
|
1
|
The materials used for the bodywork:
Sandpaper;
Putty;
Corrosion mastics;
Protective, mastics;
Compressed air;
Metal work piece;
Glue, etc.used in the process of bodywork:
Hammers;
Support;
Hydraulic pump;
Hydraulic wedges;
Rack;
Wrenches;
Brackets;
Straightening hammer;
adaptation to insert locks, glass, rubber;
Cylindrical clamp.
3.3
Flow chart for bus body repair ISUZU SAZ NP-37
3.2 shows a flow chart on the bus body repair ISUZU» SAZ
NP-37.
Table 3.2chart for bus body repair
№
|
Name and content
of work
|
place of performance
|
Seats impact
|
Labour capacity
(person-minutes)
|
Appliances, tools, devices
|
Technical requirements
|
Disassembly body
|
1
|
Removing upholstery
|
inside the body
|
1
|
0,8
|
manually
|
|
2
|
Removing the fuel tank
|
from above
|
2
|
0,6
|
manually
|
|
3
|
Washing and drying body
|
From above, from
below, inside
|
1
|
1,2
|
Elevator
|
body should be
washed with shampoo and blow dry. Residual moisture around the bumpers and
door mirrors dry warm air from the vacuum cleaner.
|
4
|
Disassembly of
the car body
|
From above, from below
|
1
|
0,9
|
load-carrying conveyor
|
On a conveyor
belt from the body remove the door boot lid, grille, electric buffer,
glazing, fittings and other components and spare parts. To remove the units
chassis with a body mounted on a car lift
|
5
|
Removing the
door from the body
|
laterally
|
2
|
0,5
|
manually
|
To remove the
door, open it to the maximum possible angle and lock into position suitable
fence or slings lifting mechanism. Disconnect lever limited door at the front
of the bracket body and pull axis. Remove
the door.
|
6
|
Removing glass lifting
nickname
|
from above
|
2
|
12х13, key, wedge,
screwdriver
|
Loosen the
screws securing the top scenes; disconnect the rocker from the glass; raise
your glass up; inhibit it in this position by means of a click timber
interposed between the glass and the inner door panel flange; remove the two
screws that secure; Unscrew the fixing screws and remove the window from the
door windows.
|
7
|
Removing the
sliding window on the door zadays
|
from above
|
1
|
0,3
|
manually
|
lower glass
(broken glass at lower glass holder); Remove door trim; unscrew the screws
that secure the cage to the wings; remove the upper guide groove detach the
stand sliding window from above and from below; remove the rack on the door;
remove dull glass with gasket; picking up the glass, remove it
|
8
|
Removal and
dismantling door hinges
|
laterally
|
2
|
0,5
|
manually
|
In the event of
a large backlash in the hinge loop to remove the door from the body, then
disconnect from the door hinges and dismantle them.
|
9
|
Removing the front fender
|
from above
|
1
|
0,2
|
12х13, key, screwdriver
|
unscrew the
screws on the right and left; unscrew the two nuts; forwards to remove buffer
|
10
|
Removing the
hood and hood lock
|
from above
|
2
|
0,2
|
key 12х13
|
open the hood;
unscrew the four bolts fastening the hood to the hinges; remove hood
|
11
|
Removing the front wing
|
from above
|
1
|
0,3
|
|
remove the front
buffer; lift the hood; Unscrew and remove the 5 screws along the top flange
of the wing; unscrew one nut in the bottom of the rear wing; remove the
grommet nut and washer; doors open at unscrew one bolt in the wing bolt and
remove the gasket remote; Unscrew and remove the three bolts in the front,
connecting flanges of the wings; remove the wing
|
12
|
Removing the grille
mudguards
|
from above
|
2
|
0,3
|
key 12х13
|
remove the front
buffer; Unscrew the two screws and mudguard part to the sub-spars to unscrew
the three screws securing the left and right front fenders with mudguard;
open the hood and remove the two screws on the top panel mudguard to mudguard
remove radiator grille
|
13
|
Removal and
adjustment of the boot lid and the torsion bars
|
from above
|
1
|
0,4
|
Adjustable wrench assembly
shovel
|
Dismantling
torsion perform when fortified in the open position the trunk lid (this can
be done with wooden slats, struts) remove the torsion bars on the support;
mounting a shovel (or use a wrench) gently bring the movable end of the
torsion bar out of engagement with the movable member and the loop is
gradually moving blade, enable to take torsion free position; also release
the second torsion bar. After this operation, if necessary, remove the lid of
the trunk. Check condition of plugs torsion (by visual inspection) and the
presence in them abundant lubrication. If necessary, a sleeve or is replaced
by a new refill or grease.
|
14
|
Removing the instrument
panel
|
from above
|
1
|
0,2
|
wrench
|
To remove the
instrument panel must first dismantle the parts and components: 1. Strip
inclined racks wind window by removing 3 screws. 2. Facing blowing wind
window right and left, held spring holders, remove from the slots dashboard.
3. Remove the bottom casing, taxiing column by removing the screws. 4. Remove
the 2 screws on the steering column and disconnect the steering column from
the instrument panel. 5. Remove the 2 screws on the instrument panel in the
area of the steering column from the steering column bracket.
6. Remove trim gear lever on the dashboard console. 7. Remove the 4 screws
from the front ashtray and remove it. 8. Remove the 2 nuts to the dashboard
console. 9. Unscrew 4 screws pos. 10 panel mounting in the top of the zone facing
blowing wind window. 10. Unscrew 2 screws pos. 13, a bottom panel fastening
the right and left corners of the side uprights. 11. 2 Remove the heater
control knob, unscrew the two screws securing the trim panel and remove it.
12. Remove the lower left side of the front rack by removing 3 screws. 13.
Remove bolt bracket relay block and remove the unit from the frets. 14.
Unscrew all the screws that secure the wire bundle to the units and devices,
disconnect all the connectors in the engine compartment. 15. Loosen sleeve
fixing the wiring harness from the engine compartment. 16. Detach the
instrument panel of the bulkhead, and disconnect hoses corrugated two lateral
and one central nozzle blowing. 17. Remove the instrument panel along with a
bundle of wires from the car.
|
15
|
Dismantling of
the dashboard console
|
from above
|
1
|
0,2
|
wrench, key 9х12
|
1. Remove trim
gear lever. 2. Unscrew 4 screws front ashtray and remove it. 3. Unscrew
Peridium bolt to the floor console. 4. Remove the 2 nuts to the dashboard
console under the ashtray. 5. Open the armrest and remove the cassette holder
together with a rug. 6. Remove the 2 screws that secure the rear of the
console to the floor inside the compartment armrest. 7. 2 Remove the pipe
blowing the rear of the console. 8. Raise the parking brake lever to the top
position. 9. Raise the rear of the console to remove the console from the
studs instrument panel in the front. 10.
Remove the console of the car.
|
16
|
Removing the motor heater
|
from above
|
1
|
0,5
|
wrench
|
Remove the lower
right instrument extensions; disconnect the connector from the motor; unscrew
the three screws; remove the motor rotor downwards; loosen the locking screw
fastening the rotor and remove it from the motor shaft; loosen the two nuts
and remove the drive motor and gasket
|
17
|
Removing heater
|
from above
|
1
|
0,6
|
Manually, wrench
|
move to the far
right lever mixer heater and drain the engine cooling system and heat
exchanger; Unscrew the locking clamps and disconnect the inlet and outlet
hoses from the heat exchanger tubes; remove the rubber seals tubes; loosen
the bolt fixing flexible rod holders on tap; remove draft from the tap;
Remove the handle and lever actuator; Remove the two screws and remove the
trim actuator; Remove the instrument panel; loosen the two nuts heater;
disconnect the wires from the motor; and resistance heater and remove heater
|
Repair bodyshell
|
18
|
Removal from the
repaired place layers of paint
|
from above
|
1
|
0,9
|
scraper
|
Remove from the
repaired space-gluing layers of upholstery, sound insulation and corrosion
protection with a scraper or knife
|
19
|
Deformed metal
removal with the damaged area
|
from above
|
1
|
0,6
|
Scissors, chisel, hacksaw
|
Observe safety
|
20
|
Scraping metal edges
|
from above
|
1
|
1,2
|
file, emery wheel, skin
|
Cleaned to
bright metal edges on the perimeter of the metal scraps
|
21
|
Pattern patch
|
from above
|
1
|
0,8
|
scissors cutter
|
Patch and carve
out a place fit for a fully replaceable parts.
|
22
|
welding
|
from above
|
1
|
1,5
|
Gas-electric or
gas burner with a fine filler
|
To reduce war
page weld metal place near the weld should smear raw asbestos.
|
Assembling the body
|
23
|
heater installation
|
from above
|
1
|
0,6
|
Manually
|
Heater
installation done in reverse order. After installing the heater and connect
all hoses, refill the cooling system and heater.
|
24
|
Mounting console dashboard
|
from above
|
1
|
0,8
|
manually
|
The mounting
bracket to make in reverse order.
|
25
|
Installing the instrument
panel
|
from above
|
1
|
0,5
|
manually
|
Installation of
the instrument panel in the reverse order to implement
|
26
|
Replacing the headliner
|
From below, laterally
|
1
|
1,2
|
Glue, scissors, cutter
|
remove cover
lighting, three handrail above openings and right rear doors, decorative
edgings doorways, wall-pillars, brackets inside rear-view mirror and sun
visors with visors, windshield and rear window, along with seals, tailgate
trim shelves; Slightly moisten the edge of the roof lining gasoline in places
gluing and 10-15 min gently separate them from the body; remove headliner
together with arcs, bringing the ends of the arcs of holes side rails of the
cover. Installation headliner start back. Please install back arc, and then
pull the upholstery, consistently setting the rear arc, pulling upholstery,
consistently setting the following arc. Before
gluing upholstery remove the old glue.
|
27
|
Replacing
windshield and rear window
|
Laterally, from above
|
2
|
1,4
|
Blade assembly, glue,
mastic.
|
release the seal
from the adjacent nodes; to rear disconnect connectors glass. The rest of the
order of operations for the windscreen and rear window is the same: to remove
the debris of shattered glass seal; carefully wooden click, separate petals
seal (around the perimeter of both sides) from the opening of the body and
remove the seal; clean and seal the body opening of the old mastic; fill with
fresh mastic 51-G-7 slot under glass in the seal; put the seal on the new
glass and tuck into a groove seal decorative border; lay in a free slot seal
around the perimeter of overlapping mounting cord (solid twisted rope
diameter of 4-5mm), leaving the top of the loose ends about 400 mm long;
Apply a continuous layer of sealing mastic 3-5 mm vertical opening window
ledge; insert glass window opening so that the free ends of the mounting cord
were inside the body. Perform this operation together: one person should
press on the outside glass consistently in those places, where the skins
pulled out, the other pulls the cord inside. Check the tightness of the
windscreen, showering glass on the outside and seal water jet. If necessary, additional fluff found gaps with
putty.
|
28
|
Installing windows
|
from above
|
2
|
0,5
|
Wedge, key 12х13, grease
|
Carefully place
the glass with a holder assembly through the window opening in the door;
install guide sliding window and simultaneously make them in glass; raise
your glass hands in the uppermost position and hinder it in this position by
a wooden wedge; make the door windows and fix it at five points screws;
install guide (only for front doors) and fasten bolts top and bottom; fix the
rocker bottom screws to the door, whilst ensuring that the slope of the
scenes in the vertical plane of the trajectory matched glass; fasten upper
connecting link to the glass cage screws; attach the holder to the cage with
glass stones. Friction surfaces of both wings and the guide should be
lubricated with grease.
|
29
|
adjustment window
|
from above
|
2
|
0,4
|
Key 12х13
|
loosen the upper
bolts holder, press the glass to the rear chute and fasten bolts; if this is
not enough, loosen lower bolts guide 6i move forward until skew glass;
Tighten bolts and check the operation window; if necessary, repeat the adjustment.
Rotating the control window must be lowered and raised smoothly without
jerking and jamming and securely held in any intermediate position.
|
30
|
Replacement and
adjustment of the trunk lock
|
from above
|
1
|
0,3
|
manually
|
Release
cravings, get it out of engagement with the drive socket, unscrew the bolt
lock and remove the locking rod. Use a screwdriver to disconnect the rod with
a tip and then snap it on the replacement lock. Lock installation in the
reverse order to check operation of the lock from the drive with the trunk
lid open. Why Use a screwdriver to move the cam lock in position
"closed", and click the drive. If the lock is open, the control rod
is correct, if not, then it is necessary to release cravings, unscrew the tip
2 turns, fix and check again. After checking the boot lid can be closed by
checking pre-engagement (contact) snap lock. To replace the drive also must
be disconnected from the drive rod, to take her to the side, and by removing
the 2 screws, remove the actuator. Make install drive in reverse order.
Functional test drive conducted in the following order: put the cam lock to
"lock off" the dog must securely hold the cam in engagement; put
the drive in the "open".
|
31
|
Installing
torsion bars and covers
|
from above
|
2
|
0,5
|
Adjustable wrench assembly
shovel
|
Upon
cancellation of the drive on the "open" turn key clockwise by 45
degrees, and by pressing the drive, open the lock.
|
32
|
Mudguard assembly and
installation
|
from above
|
2
|
0,8
|
Key 12х13
|
Mudguard grille
assembly and install it in the reverse order
|
33
|
Installing the wing
|
from above
|
2
|
0,3
|
manually
|
Torsions and
covers installation and perform the reverse sequence.
|
34
|
Mounting the
hood and hood lock
|
from above
|
1
|
0,8
|
manually
|
Mudguard grille
assembly and install it in the reverse order
|
35
|
Setting buffer
|
from above
|
1
|
0,3
|
manually
|
Installation in
the reverse order
|
36
|
Adjusting door locks
|
from above
|
2
|
0,6
|
Pencil, key 12х13
|
lead castle in
working order; note marker pencil clamp position; secure doors and inspected
externally; note ceasing or protrusion of the door; its vertical movements;
based on the previous decision on the magnitude and direction of displacement
of the lock; unscrew 2-3 turns lock bolts and move it in the right direction;
if necessary, repeat the above steps.
|
37
|
|
Laterally
|
2
|
1,2
|
Manually, scissors, cutter.
|
After the
necessary repair and adjustment work on the doors and door gaskets
installation sites and upholstery in the reverse order verifying the
integrity and accuracy of the pre-installation of the seal and sliding
window.
|
38
|
Installing door trim
|
From above, laterally
|
2
|
0,5
|
Allen key, screwdriver
|
Destroyed when
removing trim caps replace conditionally, pens with raised glass windows
should be installed vertically downwards.
|
39
|
Installation of
hinges on the pillar
|
laterally
|
2
|
0,8
|
Allen key
|
Repaired and
greased hinges inserted into slit-like openings in the pillar, combine the
previously mentioned risks and tighten bolts and screws.
|
40
|
installation of locks
|
from above
|
2
|
0,6
|
screwdriver
|
free links loops
into the position corresponding to the maximum opening angle of the door;
push the door on the links and loops through the mounting socket hatches
tighten bolts. Adjusting the door in the doorway: on the one hand if both
doors were removed, then the adjustment is recommended to start with door;
lock door lock in the "open" or remove a clamp; loosen 2-3 turns
bolts top and bottom hinge to the door; the door is in the open position;
adjustment is desirable to conduct reviews; at the bottom of the door opening
to put two wooden lining 40x70 mm and 7 mm thick (nominal); gently close the
door and adjust its position in the doorway.
|
.
ECONOMIC PART
4.1 Calculation of capital cost
Inlet qualification work provides design lift for body area.
Main technical characteristics of the projected lift following:load, kN
.................................... 160lifting height not less, mm 1600, m / s
.................................................... 0,006capacity of the
drive, no more .......................... 12 kWdimensions, mm:
one rack ................................................
1220x1200x2760Coach ................................... 1010x910x1410, kg:
Support for buses ..................................................
80.................................................................. 3313of the
proposed lift buses will improve the quality of work in the body section,
improve the usability of the work, to reduce the volume of work and mechanize
the process of car repairs.investments for the manufacture of lift includes the
cost of materials required for the manufacture of the lift installation, and
workers' wages, conducting manufacturing; energy costs, etc.above types of
costs are summarized in Table 4.1.
Table 4.1expenditures for the manufacture of lift
name
|
Price per unit,
sum
|
Number
|
Amount, sum
|
racks
|
125100
|
6 pcs
|
750600
|
shock absorber
|
100080
|
6 pcs
|
600480
|
mounting racks
|
25020
|
6 pcs
|
150120
|
cylinder racks
|
120375
|
6 pcs
|
722250
|
grounds racks
|
72225
|
6 pcs
|
433350
|
Boot rack
|
72225
|
6 pcs
|
433350
|
platform rack
|
38520
|
6 pcs
|
231120
|
electric wire
|
19260
|
20 пог.м.
|
385200
|
electric motor
|
433350
|
1 pcs
|
433350
|
rubber seal
|
28890
|
24 pcs
|
693360
|
lift lever
|
36112,5
|
1 pcs
|
36112,5
|
buttons stand
|
2407,5
|
5 pcs
|
12037,5
|
catch
|
19260
|
12 pcs
|
231120
|
electronic
screen
|
108337,5
|
1 pcs
|
108337,5
|
control lever
|
28890
|
1 pcs
|
28890
|
panel stand
|
144450
|
1 pcs
|
144450
|
cotton waste
|
9630
|
0,5 кг
|
4815
|
housing
|
48150
|
1 pcs
|
48150
|
Energy costs
|
|
|
114789,6
|
Salary
installation work
|
|
|
1869287,726
|
Costs of
verification
|
|
|
361125
|
TOTAL
|
|
|
7792294,826
|
of workers in the manufacture and installation will be:
where Тизгот - complexity of
manufacturing the lift; τchas - hourly wage rate; Nр- the number of workers involved in the
manufacture of lift.
tax
is calculated by the formula:
СН=7%•(ЗП-ПФ)=0,07•(1700898,75 - 170089,875)=
107156,62125 sum
where ПФ - pension fund, 10% of the wages;
ПФ=0,1•ЗП=0,1•1700898,75=170089,875 sumcontributions
account:
СО=4%•(ЗП-ПФ)=0,04•(1700898,75 - 170089,875)=
61232,355 sum
Total costs ACM wages in manufacturing lift:
ЗП=1700898,75+107156,62125+61232,355 = 1869287,72625
sumcosts in the manufacture of lift:
where Руст - total installed capacity of the equipment
(welding equipment, power tools, air compressor), kWt;
Рэф - Fund effective operating time of equipment,
hour;
К3 - equipment load factor for change;
Ксм - shift factor;
τ - tariff for e / energy, sum / kWt h;
η- efficiency of the service (η=0,7
÷ 0,9).
making
the lift, according to the safety requirements necessary to check the new
equipment. Fees for inspection, according to the current pricelist is 361125
sum.
4.2 Payment of current expenses
Wages repair workers. Repair workers work on time-bonus pay
system, but hourly rate earners. From the current practices of companies works
for middle grade M and CR is - 3.5 digit. Hourly
wage rate τchas = 8426,25-12037,5 sum, accept τchas = 8426,25 sum.The
basic wage maintenance workers when working with the lift in the Touring Car
division was:
τчас - hourly wage rate, sum/hour;basic wage
workers to lift introduction:
wages
- 10%:
СН=0,07•(68215549,5 - 6821554,95)= 4297579,6185 sum
СО=0,04•(68215549,5 - 6821554,95)= 2455759,782 summaintenance
workers with charges:
where К1- rate premiums, К1 = 1,3;
connection
with the introduction of new equipment in the body section - rack lift,
increased level of mechanization on average by 20% and, therefore, decreases
the volume of work in a body section 8095.6 person-hour to 6746.3
person-hour.basic wage of workers after the introduction of the lift:
wages
- 10%:
СН=7%•(ЗП-ПФ)=0,07•(56846010,375-5684601,0375)=
3581298,65 sum
СО=4%•(ЗП-ПФ)=0,04•(56846010,375-5684601,0375)=
2046456,37 sum
Payroll maintenance workers with charges:
the
cost of electricity. Drive hoist - electric, so the cost of electricity per
year calculated by the formula:
charges
following the introduction of the lift. Depreciation charges are determined:
where СОБ - the cost of equipment, sum;
ТСЛ - service life, year.the cost of equipment M and
CR. Bandwidth costs and TS equipment shall be equal to:
costs of materials. Costs of materials make:
Current costs. Current costs when working with lift
amount:
Table 4.2of current expenses before and after the
introduction of the lift in Body section
Name
|
Unit
|
Value
|
|
|
Before the introduction
of
|
After the
introduction of
|
+/-
|
labor content
|
person-hour
|
8095,6
|
6746,3
|
1349,3
|
The number of
workers on the shop floor
|
person
|
4
|
3
|
1
|
The basic wage
|
sum
|
68215549,5
|
56846010,375
|
11369539,125
|
Additional wages
|
sum
|
6821554,95
|
5684601
|
1136953,9
|
Wage bill
|
sum
|
104301575,2
|
86917549,8
|
17384025,4
|
Average monthly
wage
|
sum
|
2172949,48
|
2414376,38
|
-241426,9
|
Energy costs
|
sum
|
0
|
114789,6
|
-114789,6
|
depreciation
deductions
|
sum
|
0
|
519486,32
|
-519486,32
|
Costs and TS
|
sum
|
0
|
194807,37
|
-194807,37
|
Costs of
materials
|
sum
|
0
|
77922,95
|
-77922,95
|
current expenses
|
sum
|
104301575,2
|
87824556,04
|
16477019,16
|
4.3 Calculation of economic
efficiency
Calculate the annual saving running costs of the event due to
MC:
С1 - amount of costs to implementation activities,
sum;
С2 - amount of costs after the introduction of
measures, sum.
Э =104301575,2-87824556,04= 16477019,16 sumperiod is
calculated as the lift:
where КВ - capital investments (КВ = 7792294,826 sum -
according to table 4.1);
Э - total savings, sum.period lift for buses:
coefficient
of effectiveness of capital investments
,
the introduction of rack lift for buses to reduce the volume of work by 20%
(from 8095.6 man-hour to 6746.3 man-hour) and free one working. By reducing the
complexity of work, an additional profit from the difference of current costs
to implementation and post-implementation lift in 16477019,16 sum.
.
HEALTH AND SAFETY
5.1 security master plan and
production building in body section
LLC "Zhizzahavtotransservis" in accordance with the
sanitary and epidemiological rules and norms have a smooth surface. For
stormwater it is equipped with drainage, guttering and drains. Groundwater
level below the depth ditches.LLC "Zhizzahavtotransservis" has two
entrance gates. Entrance to the production building is possible with one hand.
The area around the production building has concrete cover is kept clean, oiled
cotton waste and industrial waste collected in specially designated areas and
at the end of work shifts are removed.as an escape gate with gate and swing
gates with manual opening and having a gate.and power supply of the bus fleet
is carried out from the main lines of urban communications by retracting energy
on a separate terminal with centralized.territory covered sources of artificial
light at night.LLC "Zhizzahavtotransservis" located within an
industrial zone outside the city.territory of the bus fleet landscaped. Green
spaces reduce dust and fumes in the environment and reduce the noise level.,
walkways for people in the territory are paved. Walkways and driveways are
watered in summer and winter are cleared of snow.and well-being fitter during
repair defined conditions, which are characterized by the parameters of the
microclimate in the workroom, state industrial lighting, noise and vibration in
the workplace, the presence in the working area of dust and toxic
impuritiesconditions are largely determined by the organization of the
workplace, working posture, physical and neuropsychological loads (monotony of
labor, mental and emotional stress, etc.), psychological climate in the team,
the degree of aesthetic production.Maintenance and repair of vehicles are
performed only in designated, equipped, fenced and marked places (positions).
Jobs and positions in the rooms provide a safe working environment for employees
and appropriately protected. Per worker is given not less than 4.5 m2 area and
the amount of space not less than 15 m3. Gates open outside working rooms have
locks, curtains and vestibules. Entrances to the production facilities run with
a slope of not more than 5%. They do not have thresholds, stairs, ledges.
Floors in rooms steady and level, are coated with a smooth, non-slip surface,
easy to clean.revive the ambient air space for car repairs and general exchange
organized by local supply and exhaust ventilation. Exhaust system for vehicles
using local pumps.repair shops use of natural, artificial and combined
lighting. The lighting in the repair shops satisfies requirements and meets the
specifics of the work.sound pressure levels at the workplace locksmiths repair
vehicles comply with the requirements, to reduce noise and vibration using
various devices (fencing, hanging sound absorbers, silencers, soundproof booths
and screens, etc.).for car repairs are very dangerous to fire on, so they are
isolated from the parking lot. The premises are provided fire stands. On the
stands are the main means of fire (fire extinguishers and tools). Placed boxes
with sand or soil.Body section to ensure safe and harmless working maintenance
workers, reducing the complexity, improve the quality of implementation of the
bodywork of buses conducted in specially equipped positions equipped with
electro-mechanical lifts that after lifting the vehicle mounted with special
stoppers, various devices, devices, instruments and equipment. Car on the lift
to be installed at an angle.prevent electric shock defeat working lifts
grounded. Maintenance workers to work "from below" used car
individual lighting 220, which are equipped with the necessary safety features.
Removing units and parts associated with significant physical stresses
inconveniences produced using pullers. Units filled with liquids, previously
freed from them, and only after that is removed from the vehicle. Lightweight
parts and aggregates are transferred manually, heavy machines weighing more
than 20 kg removed from devices and transported on mobile carts., fuel pump,
remove the exhaust pipe when the engine is cold. Maintenance workers should
enjoy a serviceable tool and equipment, as cars drive the positions of body work
its course, body section is provided with a mechanical exhaust ventilation.jobs
in body site kept clean, not cluttered with items, equipment, fixtures. In the
workplace, car repair mechanic has the necessary equipment, fixtures and tools.
All equipment and tools, spare parts and tools are located in close proximity
within the reach.
5.2 Heating Safety in the workplace
when the body work
Creating a safe and healthy working conditions at each
workplace is the main task administration enterprises. Administration is
obliged to comply with labor laws, standards, rules and regulations on labor
protection, to carry out activities on safety and occupational health.car must
possess safe methods to perform basic plumbing operations, rational selection
of the necessary tools and appropriate equipment, to be able to use mechanisms,
strictly follow the rules and safety requirements, correct use protection when
performing certain operations.repair work allowed a person not less than 16
years, and to perform work related to the use of leaded gasoline and repairs
batteries, be at least 18 years that have passed a medical examination, shall
be adequately trained and trained in safe methods and techniques work directly
on the location. When performing manufacturing operations work required to
apply safe work practices, train students in these methods, to monitor the
implementation of the requirements of labor safety instructions.operation must
be careful not to get distracted and not distract others, to prevent the
workplace parties unrelated to work. If faulty equipment or tool, you can not
work. About noticed shortcomings and faults in the workplace must immediately
inform the master and to eliminate them to work not to proceed.in the shop, the
worker must:
When driving on the shop floor use only established passages
and transitions;
Pay attention to the signal sent from lifting cranes and a
moving vehicle;
Do not enter without permission for fencing dangerous places;
Not to cling to a moving vehicle;
Do not touch moving parts and their parts, do not touch the
electrical parts, electrical wires (even isolated), cables, bus bars,
terminals, lighting patrons, not to step on the floor lying on portable
electric wire.
5.3 Analysis of harmful and
dangerous production factors in body section
Working conditions at the MC - a collection of industrial
environmental factors affecting health and human performance in the labor
process. These factors are different in nature, forms, manifestations, nature
effects on humans. Among them are a special group of dangerous and harmful
production factors. Their knowledge helps to prevent occupational injuries and
diseases, to create more favourable conditions of work, thus ensuring his
safety.of the causes of occupational injuries puts the task to establish the
laws that caused the causes of accidents and to identify specific actions to
address them.of occupational injuries can be:
. Organizational reasons. Absence or poor quality briefing
and training process violation, poor jobs, violation of work and rest, lower
manufacturing discipline clutter walkways and driveways, lack of personal
protective equipment, failure or discrepancy overalls working conditions.
. Technical reasons. Imperfection process, equipment
malfunction and fixtures, inadequate or improper installation Conveyor, missing
or defective fences, imperfection or failure of the service tool, the lack of
the correct distances between the machines, benches and plants, hand movement
or transport of loads without the use of facilitating devices.
. Sanitation reasons. Abnormal weather conditions
(temperature, humidity, wind speed and air pressure, and thermal radiation),
air pollution production facilities, poor lighting jobs, passages and
territories, noise and vibration, lack of space and poor maintenance of
industrial and domestic premises, lack of ventilation, failure to comply with
the rules of personal hygiene.hazards and harmful production factors are
divided into: moving machinery; moving parts production equipment and technical
equipment; moving products, parts, components and materials; increased dust and
gas workplace air; hot or cold surfaces of equipment and materials; hot or cold
air in the working area; increased noise level in the workplace; elevated
levels of vibration; elevated levels of ultrasound and infrasound vibrations;
high or low barometric pressure in the working area and an abrupt change;
increased or reduced humidity, ionization of the air in the work area; absence
or lack of natural light; insufficient illumination of the working area;
reduced contrast; increased brightness of light; sharp edges, burrs and
roughness on the surfaces of work pieces, tools and all equipment.dangerous and
harmful production factors are classified by nature to human exposure to toxic,
irritant, sensitizing, carcinogenic, mutagenic, affecting reproductive
function, and on pathways in the human body - by penetrating through the
respiratory, gastrointestinal tract, skin and mucous membranes.dangerous and
harmful production factors vkeyayut following biological objects: pathogens
bacteria, viruses, fungi, spirochetes, rickettsiae) and their metabolic
products; organisms (plants and animals).dangerous and harmful production
factors in character actions are divided into physical and neuro-psychological
overload per person. Physical overload divided into static and dynamic, and
neuropsychiatric - on mental strain, over-analysers, the monotony of labor,
emotional overload.maintenance and current repairs of cars there, dangerous and
harmful production factors: moving cars, moving vulnerable elements of the
production equipment, increased space gassed by exhaust gases of cars, the danger
of electric shock when working with power tools, etc.
.
PROTECTION OF THE ENVIRONMENT
.1 Reduction of toxic emissions car
emissions by rationing
The share of road transport in air pollution of major cities
in recent years has grown considerably and is 40-80%, and the content of toxic
substances in the atmosphere of many of them exceed the maximum allowable
concentrations are safe for human health. Automotive internal combustion
engines pollute the atmosphere with harmful substances, releasing exhaust gases
blow-by gases, fuel evaporative emissions 95-99% falls on the exhaust gases is
an aerosol of complex composition, depending on the engine speed. Only the
products of incomplete combustion contained in the exhaust gases, discovered
about 280 components. Group of toxic substances comprise carbon monoxide (CO),
nitrogen oxide (NOx), a large group of hydrocarbons (SnHm) paraffin’s, olefins,
and other aroma tiny. Followed aldehydes.the combustion of sulfur fuels
produced inorganic gases, sulfur dioxide SO2 and hydrogen sulphide H2S. A
special group of carcinogenic polycyclic aromatic hydrocarbons, including benzo
most active. In the case of leaded petrol, moreover, produces toxic lead
compounds. The main toxic components of gasoline engines are CO, SnHm, NOn and
lead compounds; Diesel engines of NOx and soot.and SnHm in the exhaust gases of
vehicles with petrol engines in operation must not exceed the values given in
Table 6.1.
6.1content of the exhaust gases SnHm gasoline engines
Engine behaviour
|
Maximum permissible
CO content, the volume fraction%
|
Prohibitive
amount CnHm, the volume fraction of the number of engine cylinders
|
|
|
up to 4
|
more than 4
|
nхх min nхх пов
|
1,5 2,0
|
1200 600
|
3000 1000
|
Notes to Table 6.1:хх min - minimum speed of the crankshaft
of the engine idling ;хх пов - increased engine speed to idle.and industry
standards establishing limits of harmful substances in the exhaust gases of
vehicles can be divided into two groups.first group - these are the standards
used during acceptance testing before directing vehicles in production.second
group - the standards applied in mass production, renovated and in operation.of
diesel cars should not exceed the limits specified in Table 6.2.
Table 6.2smoke in diesel engines
Mode measurement
of opacity
|
Opacity,% not
more
|
Free
acceleration for cars with diesel engines: unsupercharged supercharged
Maximum speed
|
40 50 15
|
and controlled components of the exhaust gas vehicles are the
first group of standards CO, CnHm, NOn for gasoline and diesel engines, smoke
only for diesels. For the second group of standards CO, CnHm c 01.01.1988 for
gasoline engines, the only smoke for diesel engines.
6.2 Environmental protection in the
M and diagnostics
problem of environmental protection and rational use of
natural resources is one of the major global problems, since its decisions
depend on the life on earth, the health and welfare of mankind.year, the world
economy throws only in an atmosphere of 350 million tons of carbon monoxide,
more than 50 million tons of various hydrocarbons, 120 million tons of ash, 150
million tons of sulphur dioxide. In an atmosphere of carbon dioxide gas is
accumulated and at the same time decreases the amount of oxygen. Rapidly
growing shortage of fresh water. There has also biological and acoustic (noise)
pollution.share of pollution and make MC, especially exploited their cars. The
composition includes a vehicle exhaust gas substances such as carbon monoxide,
nitrogen oxides, various hydrocarbons, sulphur dioxide, a lead compound, carbon
black. Only one defective truck with carburettor engine within a year emits
10.8 tons of carbon monoxide. Vehicles are exposed to high noise and
electromagnetic radiation.need to protect nature in the constitution of the
Republic of Uzbekistan. To reduce the harmful effects of MC on the environment
in its design, construction and operation must be carried out environment protection
activities.the enterprise should be sanitary protection zone with a minimum
width of 50 m This area greened and beautify. Green spaces enrich the air with
oxygen, absorb carbon dioxide, noise, dust filtration and regulate climate.of
harmful emissions as possible focus in the branches on the outskirts of the
city.permissible emission of harmful substances into the atmosphere is
determined in accordance with GOST 17.2.3.02-78. In this case go from the
condition that the concentration of harmful substances in the atmospheric
surface layer should not exceed the maximum permissible concentration
(MPC).order to maintain the purity of weathering within the rules on the MC
provide ventilation and pre-cleaning process emissions and their subsequent
dispersion in the atmosphere.emissions engine cars can be achieved maintaining
good technical condition of the car. At MC engines should be regulated on the
toxicity of smoke and exhaust gases to levels specified by GOST 21393-75 and
GOST 17.2.2.03-87*.MC control the operation of vehicles on the CO content and
must be carried out at CnHm M-2, after the repair of units, systems and
components,the content of CO and CnHm, as well as on demand drivers.of harmful
substances into the atmosphere is achieved through fuel savings. The less burnt
with fuel, the exhaust gas is less, and thus the toxic components.gas opacity
to motor vehicles under free acceleration with naturally aspirated diesel
engines should not exceed 40%, with a supercharged 50%.air pollution
contributes to transfer vehicles with gasoline (carburetor) diesel engine, the
exhaust gases which contains much less carbon monoxide and hydrocarbons.
.
CIVIL PROTECTION
7.1 Fire safety
in the enterprise does great harm to agriculture and is often
accompanied by accidents with people.fire hazard considered repair shops, so
they should be placed in isolated areas of the parking lot.interference
immediate evacuation of people, property and maintenance of a fire-fighting are
strictly prohibited:
Block undeveloped territory Enterprise defective parts and
other items for free access to fire hydrants running water to places of fire
equipment and equipment for emergency gate;
Serve a number of vehicles that exceed the design capacity of
the diagnostic station.areas for maintenance and diagnostics of vehicles is
prohibited:
Smoking;
Use open fire;
To repair vehicles with tanks filled with fuel;
Store fuel and kerosene in quantities exceeding the
replacement demand;
Store the empties out of fuel and lubricants.addition, these
areas must be carefully cleaning after work each shift, oil spills and clean
fuel with sand, collect used cleaning materials, store them in metal boxes with
lids and after the change to take them in a timely and safe to fire on place to
organize storage of spent oils and grease in underground tanks or in
basements.effective fire fighting equipment any fire seen in a timely manner
and not widely spread, can be quickly eliminated. Therefore, for body area and
need to take to install two fire shield, two boxes with dry sifted sand
capacity of 0.5 m3. In each room to repair and body plot has extinguishers. In
each room for repair and M in the area include carbon dioxide extinguishers OU5
(VVK3, 5), portable container for up to 5 litters (3.5 kilograms). Total number
of fire extinguishers in Engineering building MC 23 pieces, in an office
building - 18 pieces.
7.2 Fire safety in the zone M
our country, fire safety is a national priority. For its
implementation are responsible leaders of the Soviet and economic agencies.
Provided that the provision of fire protection of cities and other human
settlements, economic facilities is essential.of the state fire supervision in
our country are assigned to the Department of Fire Protection Ministry of Internal
Affairs of Uzbekistan and its peripheral organs. In accordance with the
Regulation on state fire supervision supervisors: develop and publish rules,
regulations and technical standards for fire safety, and systematically monitor
their implementation; monitor the implementation of the fire safety
requirements of all enterprises and institutions as well as individuals;
monitor and check the combat readiness of fire units and the condition of fire
alarm and fire in all departments, institutions organizations.fire caused great
material damage and is often accompanied by accidents with people. Major causes
of fires in the MC are careless with fire, violation of fire safety in welding
and other hot work, improper use of electrical fault heaters and heat treatment
furnaces, violation of operating the device for heating the car, violation of
fire safety and battery painting works etc.operating the rolling stock the most
common causes of fires are faulty electrical car, not the tightness of supply
Leakage of gas equipment for natural gas vehicles, the accumulation of dirt on
the engines, etc.of fires - one of the most important conditions for fire
safety at MC. Fire safety MC must meet the requirements of GOST 12.1.004-85
building codes and regulations, fire safety standard for industrial fire safety
rules for road transport enterprises public Uzbekistan.territory must be kept
clean and cleared out of industrial waste. Oiled cotton waste and industrial
waste should be collected in designated places, and at the end of work to
remove.fuel and lubricants should immediately remove. Driveway entrances,
driveways to buildings and fire water sources, fire breaks between the
buildings, structures and approaches to fighting equipment and equipment must
be kept clear.prevent fire near the parking places and storage of flammable
materials are not allowed to smoke or use an open flame. To prevent fire in the
premises installed ventilation system with fans and regulators sparking. The
room must be equipped with fire extinguishers, sand and fire shield.
increase the efficiency of activity of LLS
"Jizzakhavtotransservis" and success in the future, it was suggested
the introduction of the following measures:of MC production building sites with
the location of existing data and the number of cars;and introduction of a
6-rack lift buses with placing it in touring car section.drawings were offered
lifts, describes the principle of the lift, the main characteristics of the
lift, the lift describes possible faults and remedies.calculations can be said
that these measures are effective in improving MC production activities and
reduce production costs.particular event to introduce the lift will reduce the
complexity of work performed by 20% and reduce the production costs of the
bodywork on sum 16,477,019.16 per year.
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