Maintenance and current repairs of cars in the ATP is a rather complex technological process, consisting of separate, sequentially performed technical actions.

A diagram of the organization of the technological process of maintenance and repair of cars at a motor transport enterprise is shown in Fig. 6.1. Solid lines show the main route of vehicles from the moment of their arrival to release on the line.

Figure 6.1 - Scheme of organization of maintenance and repair of cars in the ATP

It can be seen from the diagram that cars arriving at the ATP undergo primary control at the control and technical point (KTP) and are sent to the daily service area (EO) or, if there is no need for EO, ​​to the waiting area, to the parking lot or to the D-1 section ...

The D-1 section is followed by vehicles subject to additional or selective control of mechanisms; to the waiting area - subject to TO-1, TO-2 or application repair; to the parking lot - everyone else.

The cars that entered the D-1 section are sorted into serviceable and faulty ones (requiring repair). Serviceable cars go to the parking lot, and the faulty ones go through the waiting area for repairs. The rest of the cars in the waiting area move through D-1 to TO-1, to the D-2 section and, if there is an obvious need, for repairs, to the TR section.

The control and technical (Fig. 6.2) point is designed to monitor the technical condition of vehicles when leaving the line and returning from it, checking and issuing documentation (waybill, etc.). It is located at the entrance gate of the ATP. The KTP should have a room for a duty mechanic, posts for inspecting cars, a horizontal platform where, if necessary, you can check the serviceability of a car on the move, communication with a production dispatcher, instruments for checking the technical condition of the steering and headlights, a decelerometer, a gas analyzer (opacimeter), a ruler to check the amount of fuel, etc. The duration of the vehicle inspection is 2 - 4 minutes.

Figure 6.2 - Scheme of the control and technical point

After inspecting the car at the KTP, the driver receives a waybill and goes to the line. When the cars are returned to the ATP, they are again inspected. In this case, the driver informs the mechanic about all changes in the technical condition of the car. The KTP mechanic, in the presence of the driver, establishes the completeness of the car, the need for MOT or TP, records the speedometer readings and the return time of the car. Simultaneously with the inspection of the car, the accounting documentation accepted at the ATP is drawn up. Inspection of cars is carried out according to a certain list of works, which is drawn up at the ATP, taking into account the design and operating conditions of the cars.

In the event of a malfunction, accounting sheets are written out, which are transferred to the production dispatcher and remain with him until the end of maintenance or repair of the corresponding car.

The main disadvantage in the organization of the KTP operation is the irregularity of the arrival of cars, which sometimes leads to a low quality of control of the technical condition of cars.

One of the main conditions for the high-quality performance of maintenance is its timely implementation. Premature performance of maintenance leads to waste of labor, funds and materials, and performance of maintenance through more mileage in comparison with the accepted frequency leads to the fact that maintenance loses its preventive value.

There are several methods of operational planning of vehicle maintenance: by calendar time, by actual mileage, etc. In the first method, a maintenance schedule is drawn up for a certain period of time. It allocates the day of maintenance for each car based on the accepted frequency and the average daily mileage, which can differ significantly from the planned one. This method is acceptable under the condition of stable mileage and vehicle utilization rate.

The technological process of repair is a part of the production process associated with the implementation of the main work on the repair of a car: disassembling it into units, assemblies, parts; repair of parts; assembly, testing and painting; delivery of the car to the customer. These works are performed in a certain sequence in accordance with the technological process.

The following parts are the elements of the technological process.

Operation is a part of the technological process of repair, performed continuously at one workplace, by a certain type of equipment, by workers of the same profession. The operation is usually referred to as the equipment with which the operation is performed. For example, an assembly operation is performed in an assembly shop using assembly equipment by an assembly fitter, etc.

Installation is a part of an operation performed on a product when its position changes relative to equipment, tools. For example, the assembly operation of a car consists of installing the engine, gearbox, etc.

A transition is a part of an operation, an installation, performed on one section of the product, with one tool, working in the same mode. For example, an engine installation consists of several transitions: engine slinging; lift, move, put the engine on the frame; fasten the engine to the frame.

A passage is one of several transitions following each other. For example, the transition - slinging of the engine consists of two passes - tying one sling on the engine on one side and fixing the other end on the crane hook; the same, but with the second line and on the other side of the engine.

A working technique is a part of a transition or a passage, which is a complete cycle of working movements. For example, securing one end of the sling to the engine on one side is one technique, securing the other end of the sling to the crane hook is another working technique.

Working movement - the smallest moment of the operation. For example, take a detail is a labor movement.

The development of a technological process consists in the fact that for each of its elements a description of the content of the work, the necessary equipment, fixtures and tools, the complexity of the work and the norms of labor costs are established. All these data are entered into technological maps. Depending on the volume of work performed, a different depth of development of the technical process is established. For small businesses with a small volume of work, the process is developed at the level of operations and installations using versatile equipment and tools. In the technological map, only the order of operations is indicated (route technological map). The work is carried out by highly qualified workers.

For a workshop with a sufficiently large volume of work, the development of the technological process is carried out at the level of transitions and aisles, indicating the content of work for each operation. The work is performed on special equipment (stands) using special devices and tools according to operational flow charts.

The development of the technical process is carried out separately for the maintenance of TO-1, TO-2 and for repair work on current and overhaul.

The largest volume of work performed takes place during the overhaul of cars, which is carried out at specialized auto repair plants.

Cars accepted for repairs undergo an external wash and go to the disassembly operation. All units are removed from the car frame, base parts, cleaned of dirt, oil, disassembled into units and parts. The removed parts are sorted into usable, unusable and in need of repair. Suitable parts are re-assembled, unusable parts are sent for scrap, parts requiring repair are restored and sent to assembly of units. The units are assembled into units, the units are re-installed on the vehicle frame. The assembled car is tested and handed over to the customer.

It is important to note that according to the same scheme, the technological process for carrying out current repairs is being developed with the peculiarity that in this case there is less quantity and they are performed in a smaller volume.

Repair flow chart

The technological process of repairing electrical equipment consists of next steps works.

1. External cleaning. Usually it is carried out with a dry or lightly moistened wiping material in kerosene. Batteries can be cleaned well with warm or hot soda ash solution or hot water.

2. External examination. At this stage, a preliminary assessment of the condition of the electrical equipment is given. Inspection of the generator, starter is carried out with the protective tape removed, which makes it possible to assess the condition of the collector and brushes.

Relay controllers, signal relays and other relays are inspected with the cover removed.

3. A preliminary check is carried out using control equipment and stands to identify electrical defects. Generators are checked for speed at rated voltage no load and full load, as well as in electric motor mode. Starters and electric motors are checked in the mode idle move, fixing the consumed amperage and the frequency of rotation of the armature shaft, distributors and ignition coils for uninterrupted sparking, etc. Taking into account the identified defects, they begin repairs, which can be carried out by partial or complete disassembly.

4. Dismantling into units and parts. To prevent damage to parts and reduce the time for disassembly, it is necessary to use tools and devices specially designed for these works (pullers, socket wrenches, press screwdrivers, etc.), and in the conditions of specialized production, mechanical disassembly tools (nutrunners, specialized disassembly stands and etc.). Parts are placed on a rack or in a special container.

It should be borne in mind that in the conditions of specialized production (workshops, auto repair enterprises), where the repair is carried out by an impersonal method, the works listed in paragraphs 1, 2, 3 are not performed, but immediately proceed to dismantle the electrical equipment units received for repair.

5. Cleaning and drying of parts. Rinsing is carried out with hair brushes in gasoline or kerosene in washing baths, placed under exhaust hoods with suction of fuel vapors. In the conditions of specialized production, it is advisable to use a machine wash with the use of washing solutions. It is advisable to dry parts in a stream of hot air at temperatures up to 110 ° C.

Felt and felt protective bearing seals and lubricating wicks are washed in clean gasoline and then wrung out.

Parts with windings are wiped with a cleaning material soaked in gasoline, followed by blowing with compressed air.

6. Control of the state of assemblies and parts is carried out by an external

inspection or special equipment and tools. Electric

the insulation strength of the windings is checked under a voltage of 220-

As a result of checks in accordance with technical conditions, parts and assemblies are sorted into those fit for further use without repair, requiring repair and unusable.

7. Repair of units and parts, including winding rewinding and insulation replacement.

8. The assembly of units and devices is carried out in accordance with the technical conditions with the subsequent running-in of bearings, brushes and other interfaces.

9. Control tests make it possible to determine the quality of repair and assembly, as well as to obtain data characterizing the reliable operation of the unit or electrical equipment in the future.

10. The adjustment is made in accordance with the specifications for a specific model of the unit or device.

11. Painting the outer surface of electrical units and devices is necessary to update the type of products released from repair.

Engine repair and maintenance

Checking the technical condition of the engine on the car

Checking the technical condition of the engine includes checking its power, efficiency, oil consumption (waste), compression in engine cylinders, noise of its operation and toxicity of exhaust gases.

The engine power is checked by changing the dynamic qualities of the car - by reducing the maximum speed, as well as the dynamics of acceleration. Maximum speed and acceleration dynamics are determined as a result of road tests with a fully functional chassis. The serviceability of the car's running gear is determined by the vehicle run-out, i.e., by the distance that the car travels in neutral gear from a speed of 50 km / h to a complete stop. The maximum speed and acceleration time are determined on a control section of the road 1 km long.

All road tests are carried out with a fully warmed up engine on a horizontal rectilinear section of road with an even asphalt or concrete surface with two people in the car, including the driver, in dry weather and in the absence of strong winds.

The vehicle run-out is determined by two races in mutually opposite directions as the average of two values, subject to the above conditions. The run-out of a passenger car is usually at least 400 m.

The maximum speed of the vehicle is determined with its preliminary acceleration to the maximum speed in the highest gear to the beginning of the measuring section (1 km) based on the results of passing the measuring section at maximum speed in two mutually opposite directions. In this case, the time t of passing a section of 1 km in seconds is measured, according to which the maximum speed v is determined by the formula v = 3600 / t. The arithmetic mean of the speeds obtained from the results of two races in mutually opposite directions is taken as the actual value of the maximum speed.

The dynamics of the car acceleration is determined by the acceleration time to 100 km / h or by the time it takes 1 km to travel from a standstill with intensive acceleration of the car with sequential and fast gear changes also in two races in mutually opposite directions.

The values ​​obtained as a result of road tests are compared with the passport data of the car. A decrease in the maximum speed by 10 ... 15%, as well as an increase in the acceleration time by 20 ... 25% indicate insufficient engine power and the need for a more detailed check of its condition in order to determine the causes that caused the decrease in power and their elimination.

Removal and engine installation

Removal of the engine from the car is carried out, as a rule, when it is necessary to replace or repair parts of the crank mechanism - the cylinder block, its liners, parts of the piston group (piston rings, pistons, piston pins), when repairing or grounding the crankshaft and its main liners and connecting rod bearings, except for the cylinder head, head cover, oil pan and their gaskets. The need to remove the engine from the car for repair is determined by the results of checking its technical condition.

Due to the fact that the engines of the cars under study are structurally combined with the gearbox and clutch into a single power unit, which is attached to the car body on shock-absorbing supports, if it is necessary to repair the engine, it is usually more convenient to remove the entire power unit from the car (except for the A3LK-2141 car with with a VAZ-2106 engine, from which the gearbox assembly with the clutch housing is first removed, and then the engine is removed directly).

To remove the power unit, the car is installed on a viewing ditch or a lift and, after disconnecting the engine from the body, the power unit is removed from the engine compartment upwards using a hoist or any other lifting device with a carrying capacity of at least 200 kgf.

On front wheel drive vehicles, it is possible to remove the engine from the engine compartment downward. In this case, one lift is used without a lifting device, and the engine, after disconnecting it from the body, is installed on a special trolley brought under the vehicle standing on the lift.

Depending on the layout and design features power units on the vehicles under study, the sequence and technology for performing individual work on their removal and installation may differ slightly, however general order performance of these works is approximately the same for all considered vehicles and is given below.

1. Remove the hood (the hood can be left on if the power unit is pulled down).

2. Drain the engine oil (see the "Repair and maintenance of the lubrication system" section).

3. Drain the coolant (see Repair and Maintenance of the Cooling System).

4. Disconnect the hoses of the engine cooling system going to the radiator and heater.

5. Disconnect the electric wires from the storage battery, generator, starter, ignition coil, carburetor EPHH, sensors and switches.

6. Disconnect the hose from the brake booster.

7. Disconnect the fuel supply hoses to the fuel pump and the fuel bypass hose from the carburetor.

8. Disconnect the air and throttle valves carburetor.

9. Disconnect the cable drive or clutch operating cylinder.

10. Disconnect the front muffler pipes.

11. Disconnect the front wheel drive (on front-wheel drive vehicles) or cardan transmission (on vehicles with a classic layout) and close the fork hole cardan joint in the gearbox with a plug.

12. Disconnect the gearbox from the gearshift lever and disconnect the flexible shaft of the speedometer drive from it.

13. Secure the engine to a lifting device.

14. Unscrew the engine-body mountings.

15. Remove the engine complete with clutch and gearbox.

The engine is installed on the vehicle in the reverse order of its removal.

Dismantling the engine

The engine is disassembled after its external cleaning and washing on a special stand, which allows the engine to be turned to ensure the convenience of disassembly and assembly work. In order to ensure the high quality of the subsequent assembly of the engine and not to disturb the balance of its parts, it is necessary to install suitable parts in the old, worn-in places. To do this, when disassembling, parts are marked without damage by punching, paint, tags or inscriptions. Such parts include liners, pistons, piston rings, pins and connecting rods with caps, crankshaft and flywheel, flywheel and clutch, cylinder block and main bearing caps and flywheel housing.

Disassembly of the engine has approximately the same sequence for all studied engines and is performed in the following order. If the power unit was removed from the car, then before disassembling the engine, you need to remove the starter, gearbox with clutch housing and clutch.

Remove the ignition system devices (ignition distributor or sensor-distributor, its drive, high voltage wires, spark plugs) and the generator.

Disconnect the hoses for the power supply and engine cooling systems, remove the fuel pump, carburetor, fan, fluid pump, thermostat.

Remove the oil level indicator and the tube into which it is inserted, remove the oil filter.

Remove the alternator drive pulley from the toe of the crankshaft, for which block the flywheel with the locking pin and unscrew the pulley securing bolt.

Unscrew the front cover and, having disconnected the tensioning mechanisms, remove toothed belt or a timing chain.

Remove intake and exhaust pipes, head cover and cylinder head with gaskets.

Turn the engine upside down and remove the oil sump with gasket, oil pump and oil receiver. Remove the connecting rod caps by unscrewing the nuts of the bolts of their fastening, and carefully, so as not to damage the mirror (working surface) of the cylinders, remove the connecting rods with pistons through the cylinders and mark the connecting rod caps with connecting rods for their subsequent correct assembly.

For engines with removable liners (UZAM-331, -412), pistons with connecting rods are pushed out of the block together with the liners, and then removed from the liners through the lower part of the liner, which makes it possible not to pull the connecting rod through the liner and avoid possible scratches on its surface. If it is not possible to remove the piston with the connecting rod together with the sleeve, then first remove the piston with the connecting rod through the sleeve, and then remove the sleeve using a puller. If it is not required to remove the sleeves, then they are fixed in the block using the sleeve-clips (Fig. 204), and the pistons with connecting rods are removed, as usual, through the cylinders. If the sleeves are not fixed, then when removing and installing the pistons, they can move from their place and in this case their seal in the block will inevitably be broken.

Rice. 204. Fastening of sleeves with sleeve-clips

Remove the main bearing caps together with the lower shells, remove the crankshaft, and then the upper main bearing shells and the thrust half rings of the crankshaft axial fixation.

Press out the bearing of the input shaft of the gearbox from the crankshaft using a special screw or impact puller (fig. 205).

Rice. 205. Puller for extrusion of the bearing from the crankshaft:

1 - capture; 2 - bearing; 3 - hairpin; 4 - striker; 5 - handle

Disassemble the parts of the connecting rod-piston group: remove the piston rings using a special tool (Fig. 206), the antennae of which must be inserted into the gap of the lock of the ring being removed and, squeezing the puller handle, open the ring and remove it from the piston.

Rice. 206. Removing the piston rings from the piston with a puller

Remove the retaining rings from the grooves of the piston bosses and press out the piston pin using a press with a mandrel or a special screw puller (Fig. 207) or knock out the piston pin with hammer blows through a brass mandrel with the piston preheated in water to 60 ... 85 ° C (except VAZ engines, on which the pistons are not heated). If the parts of the connecting rod-piston group are slightly worn out and can be reused, they must be marked and installed during subsequent assembly in their original places.

Rice. 207. Pressing the piston pin out of the piston with a puller:

1 - piston; 2 - piston pin; 3 - mandrel; 4 - bolt

Conclusion

The purpose of the test is to plan the rational use of resources using the example of a service station. The solution to this problem is feasible under the condition of many factors, the main of which are the economic situation and the competitive environment. A clear understanding of the purpose, location, capacities, as well as its compliance with modern requirements for the operation of road transport, will lead to an increase in the efficiency of capital investments.

List of used literature

1. Bashkatova A.V. Formatting a text document: Methodical development... - ATEMK2. MP0703. 001 - SPb .: 2008 - 28s. / Administration of St. Petersburg. Committee for Science and Higher Education. Automotive and Electromechanical College.

2.Epifanov L.I., Epifanova E.A. Maintenance and repair of road transport - M .: Infra-M, 2007.

3. Regulations on the maintenance and repair of the rolling stock of road transport - Moscow: Transport, 2007.

4.Rumyantsev S.I., Car repair - M .: Transport, 2009.

5.Kramorenko N.A., Car maintenance: Textbook for motor transport technical schools. - M .: Transport, 2007.

The organization of works on the maintenance of passenger cars is carried out in accordance with the technological maps for a passenger car. Technological maps are developed by the manufacturer, which include a list of mandatory works. Organization of work on maintenance maybe carried out by two methods, individual and aggregate. At aggregate method faulty units, devices, units are replaced with new or previously repaired ones taken from the working fund. In this car repair shop, repairs are carried out by an individual method, in which faulty units, units are removed from the car, repaired and installed on the same car. In the case of claims on the quality of the work performed by the customer, if they incur material costs, then they are carried out by the auto mechanic himself, who made this inaccuracy, if his fault is obvious.

Technological processes imply two types of work, restoration and maintenance of the vehicle's performance.

The technological process of restoring operability provides for a set of works in order to eliminate a specific failure, the speedometer, stove motor, brakes, etc. are out of order. The driver arrives and himself says a malfunction that arose during the operation of the car.

The technological process of maintaining operability provides for a set of works that ensure the normal functioning of technically sound systems in the given aisles, restoration of engine idling, ignition adjustment, equalization of tire pressure, wheel alignment, etc. The driver, as a rule, says that something is wrong with the car, increased fuel consumption, car drifting away from straight-line traffic, whistling from the engine side, the mechanic, as a rule, already presents what list of work needs to be done to find out and eliminate this malfunction. When it is found, the mechanic tells the driver the type of malfunction and sends it to the store for a new part, if required.

When the car arrives at the auto repair shop, the driver of the car must go to the chief mechanic or to any free mechanic to describe the list of work that he wanted to carry out, the malfunctions, what is their nature, in what time frame it is necessary to complete the repair. The driver should leave a contact phone number in due time, since during the repair process, parts may be identified, units to be replaced in the absence of the driver in the auto repair shop, he is informed by phone about the need to replace this part.

The complexity of work on the maintenance of a car, as a rule, is small and 2 mechanics are assigned to it in two inspection pits in the room, but also car repairs can be carried out on the adjacent territory up to two cars. The workshop has it all necessary tools for independent work of all four mechanics: a set of tools for a car locksmith, a compressor hose 10 meters long and can be used both indoors and outdoors, a pneumatic wrench for unscrewing wheel nuts, an electric cordless wrench for unscrewing nuts on the engine and others.

The maintenance flow chart includes:

• 1. Complete car wash.
• 2. Determination of the technical condition of the vehicle systems, which includes:
  • - the technical condition of the power unit: checking the nodes - the crank mechanism, gas distribution, cooling system, power supply and clutch systems.
  • - power supply systems.
  • - ignition systems.
  • - the condition of the gearbox, driveline and differential.
  • - steering.
  • - carrier system.
  • - power supply and alarm and control devices.
• 3. Elimination of identified defects and adjustment work.
• 4. Assembling the car.
• 5. Delivery finished car to the customer.

List of works when performing maintenance:

Power unit: calibrated tightening of the nuts securing the head, pallet, neck supports, eliminating knocking in the engine, adjusting and restoring valve tightness, checking the tension of the alternator-fan belt, checking the tightness and filling level of the cooling system, technical condition of the pump, flushing and adjusting the carburetor, checking the work of the gas pump. Checking the fuel level in the carburetor, checking the ignition system - the condition of the high-voltage wires, the condition of the distributor, the condition of the spark plugs, the clutch operation - the reliability of operation, the condition of the clutch parts, the oil is changed at a certain mileage.

Braking system: the tightness of the system, the use of pads and discs, the level of the brake fluid.

Gearbox: check the level and quality of the oil, change the oil at a certain mileage, check for extraneous noise, smoothness of switching on speeds, reliability of fixing speeds, condition of bearings, condition of differential - condition of gears, satellites, bearings, condition of cardan transmission: determination of technical condition by backlash in the connection, the external state of the node.

Carrying system: checking the operation of shock absorbers, springs, rods, the condition of the ball joints and dampers, checking the camber and toe-in of the wheels, checking the wheel wear, the condition of the wheel bearings, balancing the wheels.

Control system: checking the steering wheel backlash, wheel backlash, changing the oil in the gearbox.

Power supply system: checking the condition of the generator, the condition of the collector, brushes, rectifier, the condition of the contacts, the output voltage and current, change the bearing grease, the condition of the starter, the condition of the brushes and the collector. The developed moment, the state of the contacts, checking the state of the battery, the level and density of the electrolyte, the state of the terminals, checking and correctness of the readings of the control and measuring instruments, checking the lighting and alarm systems.

Body: lubricate the hinge assemblies, reliability of operation and fixing of locks, the condition of the body, re-preserve the body.

Lubricate in accordance with the lubrication chart of the units.

Periodic maintenance and routine repairs ensure the maintenance of trouble-free and reliable operation of vehicles. Maintenance is divided into three periods:

daily, TO-1, TO-2. Maintenance allows you to maintain the performance of vehicle mechanisms between repairs. Maintenance is part of the maintenance. It is designed to restore the unit's performance.

To perform maintenance and current repairs, a set of devices and instrumentation is used. This kit is in stock.

When a car arrives at a car workshop to perform maintenance or current repairs, a list of mandatory works must be completed:

• 1. Carry out a car wash from operational pollution.
• 2. Check the technical condition of the components and assemblies of the vehicle.
• 3. Issue a technical condition card indicating defective components and assemblies.

The reliability and durability of the components and assemblies depends on the quality of the lubricants and the adherence to the terms of their replacement, determined by the manufacturer of the vehicle and component assemblies.

Maintenance (TO-1) TO-1 is performed after 15,000 km or after a year of vehicle operation. For each vehicle, this parameter is determined by the vehicle manufacturer.

With TO-1, they check the reliability of the fastening of the units and assemblies, the absence of fluid leakage.

They clean electrical wiring and units from operational pollution. They check the reliability of the electrical contact, check the integrity of the insulation. Accumulator battery cleaned of operational pollution, clean the ventilation holes, clean the terminals from oxides, check the level and density of the electrolyte. The amount of deflection of the fan belt is checked. The free movement of the throttle and air valve control rods, the effectiveness of the brakes are checked, and the steering wheel play is measured. The oil is being changed in the engine, gearbox, axle. Check the operation of the alarm system, locks, lighting.

Lubricate the units in accordance with the lubrication chart.

Defective units and assemblies must be repaired.

Maintenance (TO-2) TO-2 is performed after 30,000 km or after two years of vehicle operation.

TO-2 consists of works performed at TO-1 and a set of specific works.

Serviceability of door opening and closing mechanisms;

Tightness of the engine cooling system;

• - checking the fastening and condition of the radiator;
• - fastening of the cover of the distribution gears, the fan pulley, the water pump, the radial clearance in the bearings;
• - tightness of the engine lubrication system;
• - stretch the nuts of the inlet and outlet pipes and exhaust pipes of the muffler;
• - check the condition of the engine mountings cushions;
• - check the condition of the power supply system devices;
• - remove and wash the filter element and glass fine cleaning fuel;
• - check the operation of the drive and free run clutch pedals;
• - backlash in the hinges and splined joint of the cardan transmission;
• - check the condition and tightness of the rear axle;
• - backlash of the steering mechanism;
• - check the fastening and splitting of the nuts of the pins of the hinges and the levers of the steering knuckles;
• - the condition of the front axle beam;
• - take off brake drums and clear brakes from dirt;
• - check the condition of the main brake cylinder, amplifiers, pipelines;
• - checking the drive and the parking brake system;
• - check of fastening: front ladders and rear springs, shock absorbers, their mounting brackets;
• - check of wheel attachment, condition of rims and disks, condition and wear of tires;
• - clean the battery from dirt and dust, check the electrolyte level in all battery banks;
• - check the condition of the spark plugs;
• - after servicing, check the operation of units, mechanisms and devices with a test run;
• - check and, if necessary, adjust the clearances between the valves and rocker arms;
• - remove the hubs, wash the hub bearings and oil seals in kerosene, check the condition of the bearings, put fresh grease in the wheel hubs, adjust the hub bearings.

Diagnostics of D-1 and D-2. One of the elements of the technical process of maintenance and repair is diagnostics, which serves to determine the technical condition of vehicles, their units and assemblies without disassembly. A specific feature that distinguishes diagnostics from the usual determination of a technical condition is not an increase in the accuracy of its assessment, but the identification of hidden faults without disassembling the car. Currently, there are two options for performing diagnostic work: together with maintenance and repair or at specialized posts and diagnostic lines.

Diagnostics D-1 is used to check components and mechanisms that ensure traffic safety. This type of diagnosis is performed before TO-1. It is justified to carry out control and diagnostic work before TO-2 in the zone or at the diagnostic post in order to regulate the technological process and isolate from the mass of cars supplied to TO-2, those that have a significant volume of TR of high labor intensity. This type of diagnostics is called in-depth diagnostics D-2, performed at the post using a stand for testing the traction qualities of vehicles. Such diagnostics are not performed in the workshop due to the lack of equipment. Most often, according to the customer, a list of technical impact on the car is immediately identified, or during the inspection, problematic units and assemblies of the car are revealed.

industrial technological auto repair shop

Ministry of Education and Science of the Russian Federation State Autonomous Educational Institution of Higher Professional Education "NORTH-EAST FEDERAL UNIVERSITY named after M.K. AMMOSOV" automotive industry» COURSE WORK By discipline: Technological processes of maintenance, repair and diagnostics of automobiles Completed art. V year group АиАХ-08-2 Krylov Pavel Alexandrovich Checked by: Gao Gennady Innokentievich Yakutsk 2011

Content of the course work Introduction. 1. Theoretical part: 1.1. Types and frequency of maintenance; 1.2. Organization of maintenance of rolling stock; 1.3. Diagnostics of technical condition of cars; 1.4. Equipment for maintenance of cars. 2. Technological part: 2.1. Calculation of the annual production work program for maintenance and repairs. 2.1.1 Selection of initial data for planning. 2.1.2 Correction of the frequency and labor intensity of maintenance and repairs. 2.1.3 Determination of the number of maintenance for the planned period. 2.1.4 Definition of the daily program for vehicle maintenance. 2.1.5 Calculation of the annual labor intensity of work on maintenance and repair. 2.1.6 Determining the number of maintenance personnel. 2.1.7 Choosing a method for organizing maintenance of vehicles. 2.2. Development of a technological process for vehicle maintenance. 2.2.1 General characteristics and design features of rolling stock. 2.2.2 Calculation of the labor intensity of certain types of work on vehicle maintenance. 2.2.3 Development of an operational flow chart for vehicle maintenance. 2.3. Organization of work of the TO production line. 2.3.1 Determination of the number of posts of the production line. 2.3.2 Distribution of the scope of work by posts. 2.3.3 Selection of equipment for posts. General conclusions. List of used literature.

INTRODUCTION Significant growth vehicle fleet our country is causing an increase in the volume of work on the maintenance and repair of cars. Performing these works requires high labor costs and the involvement of a large number of skilled workers. In this regard, it is necessary to significantly increase labor productivity in all types of maintenance and repair of cars. Newly trained personnel for work in auto enterprises should thoroughly study the processes of maintenance and repair of cars using modern equipment. At enterprises for the maintenance of cars, methods are increasingly used. diagnostics of the technical condition of vehicle units using electronic equipment. Diagnostics allows you to timely identify malfunctions of units and systems of cars, which makes it possible to eliminate these malfunctions before they lead to serious disruptions in the operation of the car. - transport accidents. Mechanisms of work on maintenance and repair of cars with the use of more advanced equipment facilitates and accelerates many technological processes, but at the same time, the maintenance personnel are required to master certain techniques and skills, knowledge of the car design and the ability to use modern devices, tools and control - measuring instruments. Good technical condition means full compliance of the rolling stock with the standards determined by the rules of technical operation, and characterizes its performance. The performance of a car is assessed by a set of operational and technical qualities - dynamism, stability, efficiency, reliability, controllability, etc. - which are expressed for each car by specific indicators. In order for the performance of the car to be at the required level, the value of these indicators for a long time should change little compared to their initial values. However, the technical condition of the car, like any other machine, does not remain unchanged during long-term operation. It deteriorates due to wear of parts and mechanisms, breakdowns and other malfunctions, which leads to a deterioration in the operational and technical qualities of the car.

The change in the specified qualities of the car as the mileage increases can also occur as a result of non-observance of the rules of technical operation or maintenance of the car. service. Maintenance is understood as a set of operations (cleaning, fastening, adjusting, lubricating, etc.), the purpose of which is to prevent the occurrence of malfunctions (increase reliability) and reduce wear of parts (increase durability), and consistently, for a long time, maintain the car in a state of constant technical serviceability and readiness for work. Even if all measures are followed, wear of car parts can lead to malfunctions and the need to restore its operability or repair. Consequently, repair is understood as a set of technical actions aimed at restoring the technical condition of a car (its units and mechanisms) that has lost maintenance and repair of cars. The main document according to which maintenance and repairs are carried out at auto enterprises are provisions on maintenance and repair of road transport. According to this document, maintenance is carried out on a planned and preventive basis after a certain mileage. Recently, the production of cars, both high and low carrying capacity, has significantly increased. Recently created trucks of new models are designed for operation in various climatic and road conditions. Their design uses the latest achievements of modern technology, which significantly improve performance. New cars have a lower dead weight per ton of carrying capacity, a higher liter engine power and a higher travel speed. The role of road transport in the development of the eastern and non-black earth regions of our country is also important. In the absence of a developed network railways and the limited possibilities of using rivers only with the help of cars in these areas, large-scale construction is possible, provided for by five-year plans. It is proposed to increase the efficiency and durability of cars, dieselization of the car fleet has also been widely used, and the improvement of the organizational structure of road transport will provide a reduction in the cost of road transport. road transport are concerned with the issues of saving fuel and lubricants and protecting environment... More attention is paid to expanding the network of bus transportation in rural areas, organizing intercity and interdistrict transportation, improving the general culture of serving the population with passenger transportation. Cars, depending on the purpose and work performed, are divided into freight, passenger and special. The cargo passenger train includes vehicles for the carriage of goods, vehicles - tractors, trailers and semi-trailers. Trucks can

have a platform and be used as a universal transport carrying various goods, and can have specialized devices for the transportation of certain goods. determines the success of all parts of the road transport system. 1. THEORETICAL PART.1.1. Types and frequency of maintenance. Maintenance in our country is carried out according to the so-called scheduled preventive system. The peculiarity of this system lies in the fact that all cars undergo scheduled maintenance without fail. The main purpose of maintenance is to prevent failures and malfunctions, to prevent premature wear of parts, and to eliminate damage in a timely manner. Thus, maintenance is a preventive measure. Failure is a malfunction of the vehicle, leading to a temporary interruption of its normal operation. All other deviations of the technical condition of the rolling stock and its units from the established standards are malfunctions. Maintenance includes cleaning and washing, control and diagnostic, lubrication, filling, adjusting and other work performed, as a rule, without disassembling the units and removing individual units from the car. .According to the current regulation, maintenance by frequency, volume and labor intensity of the work performed is divided into the following types: first maintenance (TO-1); second maintenance (TO-2); Seasonal Maintenance (CO) - Daily maintenance includes cleaning and washing, inspections, fuel, coolant and oil refueling. EO work is performed after the vehicle has finished working on the line and before leaving the line. The first maintenance includes all work performed during daily maintenance. In addition, it includes additional fastening, lubrication and control and adjustment work performed without removing the units and devices from the vehicle and disassembling them. with partial disassembly of the units. Individual appliances removed from

car and are checked on special stands and control and measuring installations. Seasonal maintenance is carried out twice a year and provides for the performance of work related to one season to another, while trying to combine it with the next TO-2. Typical works for CO are: flushing the system cooling, changing the oil in the engine and lubrication in the crankcases of other units according to the coming season, checking the fuel supply system and flushing the fuel tank. Before the start of the autumn-winter operation, check the operation of the starting heater and the heating system in the car cab. 1.2. Organization of maintenance of rolling stock. To carry out maintenance in a motor transport company, schedules are drawn up, covering all the rolling stock available in it. The schedule is drawn up for a month, based on its frequency corresponding to the basics of operating the rolling stock of a given motor transport company, and the average daily mileage. Cars are sent to perform one or another maintenance, depending on the mileage traveled, which is taken into account daily for each car. organization of maintenance provides for the creation of teams for performing TO-1, TO-2 and current repairs. These teams perform work on all vehicle units within this type of repair or maintenance. In the aggregate-sectional form of maintenance, separate production areas are created, designed to perform all maintenance and repair work, but only those units that are assigned to these areas. All car maintenance work is carried out according to flow charts developed for each operation for checking, adjusting and lubricating this unit. The flow chart indicates the method of performing the corresponding operation, the tools and devices used, the materials used. The maintenance record is kept according to garage leaflets issued for each car arriving for inspection for TO-1 or TO-2. A record of the work performed is kept by the foreman of this production site, and the column mechanic who accepts the car after service in the technical department of the trucking company confirms the implementation of the schedule of maintenance work on the basis of the records in these sheets.

In small motor transport enterprises, work on several types of units can be performed on one site, but all these units must be assigned to this site. 1.3. Diagnostics of the technical condition of cars. In motor transport enterprises, methods are being introduced for diagnosing the technical condition of a car. Diagnostics is a system for checking the technical condition of cars without disassembling its components and assemblies, using special equipment that allows an objective assessment of the suitability of the car for further operation. Diagnostics can be general or item-by-item. During general diagnostics, the technical condition of the units and assemblies of the car is determined, ensuring the safety of movement. Elementary diagnostics allows you to determine the technical condition of the units and units of the car, to identify the causes of certain malfunctions and to clarify the scope of work on the maintenance and repair of the car. The organization of diagnostics of the technical condition of the car depends on on the capacity of the given motor transport enterprise and its provision with the appropriate equipment. In this case, one of two diagrams of the organization of the diagnostic process is used. According to the first diagram, the general diagnostics of the car and the main adjustments are carried out in a separate specialized section, it is a line with two posts. All diagnostics and basic adjustments are performed before the vehicle enters the TO line. 1. After diagnostics for vehicles entering the TO-1 line, they mainly perform fastening and lubrication work... This arrangement requires a larger area for the entire technical equipment area. 1.4. Car maintenance equipment.The car maintenance work is very time consuming, therefore modern technology maintenance provides for the mechanization of these works using various equipment. First of all, the most time-consuming work is mechanized, including external care operations. External care operations include washing and cleaning work. Installations of various types are used for washing cars. Installations with rotating brushes made of nylon threads are used for washing cars and buses.

At the end of the wash, the car is blown with warm compressed air supplied from the compressor unit, or the cab and plumage are wiped dry with soft flannel or suede. possible damage, using for this inspection ditches, overpasses or lifts. Inspection ditches are divided into dead-end and direct-flow. A dead-end ditch is a narrow rectangle in terms of the length not less than the length of the serviced vehicle. The walls of the ditch are laid out with bricks, tiles or concreted, and then tiled. Being the simplest in design, an insulated ditch provides the least convenience for vehicle maintenance and is mainly used in trucking companies that have only heavy vehicles that cannot be serviced by lifts. Dead-end and straight-flow ditches can be connected by a transverse trench. In such a trench there are dead-end ditches with their ends, located parallel to each other. The trench connecting them is made wider (up to 2 m) and in it workbenches and equipment necessary for servicing the car from below are located. All ditches are framed by flanges to guide the wheels of the vehicle. Outside, the connecting ditch is fenced with handrails and equipped with ladders. Dead-end ditches on the side of the vehicle entrance have a so-called rebound, which helps to align the wheels of the car when entering the ditch. As a rule, the length of each dead-end ditch should be 1 m greater than the base of the car plus its front overhang, and its depth is 1.2-1 , 5 m. The floor of the dead-end ditches has a slight slope (1-2%) in the direction of the trench for the drainage of gasoline, oil and water. Wooden grates are placed on the floor of the ditch. The trestle is a rugged bridge with a height that provides convenient maintenance of the car from below. Inclined ramps are used to enter and exit the overpass. Overpasses can be dead-end and straight-through. Overpasses are simple in design, but occupy a large area, since in addition to the overpass itself, a significant place has to be allocated for the ramp. Therefore, overpasses are used mainly in open areas. In premises for the purpose of installing a car at a height convenient for work, electromechanical or two-plunger lifts are used. Electromechanical lifts can be two or four-post. The hoist is driven by an electric motor with gearboxes connected by cardan shafts.

A four-column electromechanical lift designed for servicing trucks with a carrying capacity of up to 80 kN (8 tf), has a lifting height of 1000 mm. In the struts there are screws, which are suspended by their upper flanges on rubber cushions to the flange of the struts. The frame beams supporting the car are supported on the gearbox housings. An electric motor is installed on one of the longitudinal beams, connected to cardan shafts with gear reducers. supporting frame lifting the car. The frame can be rotated about 360 ° about the axis of the lift cylinder. The working pressure in the cylinder is generated by a gear-type hydraulic pump driven by an electric motor. The plunger is lifted by increasing the pressure of the oil supplied to the cylinder by a hydraulic pump, and lowering by pumping the oil from the cylinder into the tank. The single-plunger hydraulic lift is used for lifting cars and light-duty trucks. The double-plunger hydraulic lift consists of two single-plunger lifts paired with each other. It can have a common frame or separate forks on each plunger. Mobile garage jacks are used to raise the front or rear of the vehicle to a low height. The mobile jack is designed for a load of 60 kN and a lift height of up to 600 mm. Engines and other units are removed and installed using a mobile power crane. A jib hydraulic crane is widely used, consisting of a U-shaped welded frame, moving on four rollers. Mounted on the frame, vertical struts with struts carry the load boom. The pressure of the oil supplied to the power cylinder is generated by a hand-operated hydraulic pump. The crane is designed for maximum load 10 kN. Equipment for lubricating cars and refueling them with water, air and oil. Manual and mechanized equipment is used to lubricate car units with grease oils. The number of mechanized lubrication equipment includes mobile solid blowers with pneumatic and electromechanical drives, as well as hydraulic punches for cleaning clogged oil In mechanized servicing of cars on production lines, complex installations are used for centralized lubrication of a car. Automotive enterprises use a complex installation designed for lubrication of vehicle units and assemblies with greases and liquid oils, mechanized filling with water and air.

The units of the installation are made separately and can be placed in different places in accordance with the location of the posts for maintenance. 2. TECHNOLOGICAL PART. 2.1.Calculation of the annual production work program for maintenance and repair. 2.1.1.Selection of initial data for planning. The initial data when planning maintenance of cars are: - the list of vehicles in the ATP by brands and models; - vehicle mileage since the beginning of operation; - average daily mileage of vehicles; - indicators characterizing the conditions of their operation; - normative data regulating maintenance and repair of vehicles. the composition given in the initial data of the course work are presented in Appendix. 3. The initial data characterizing the list number of cars at the ATP, the indicators of the use of the rolling stock of the ATP and the characteristics of the operating conditions are taken from Table. 1-3 by finding a three-digit number using the formula: Cho = 500 - NZK where NZK - the digits of the grade book number or cipher without the year of admission or the sum of their numbers. Cho= 500 - (0 + 8 + 2 + 2 + 2 + 2) = 484 According to Table 1. variant number = 4; According to Table 2. variant number = 8; According to Table 3. variant number = 4. Table 1 - Rolling stock structure ATP.

Cipher markstudent)carType ofcarOption number (first digit of the Cipher brandstudent)4 PAZ-3206Bus23ZIL-432720 (Bychok) Onboard42KAMAZ-55111Dump truck38Table 2 - Indicators of the use of rolling stock of ATP. ParameterOption number (second digit of the cipherstudent) car model 8 ZIL-432720 (Bychok) Vehicle type Onboard Mileage since the beginning of operation, thousand km 200 Average daily mileage, km 60 Number of days of operation per year 253 Table 3 - Operating conditions of rolling stock. ParameterOption number (third digit of the cipherstudent)4 Road surface D1 Terrain P1 Traffic conditions Small town Natural climatic zone Moderate Regulatory frequency and labor intensity of maintenance and repair of cars is determined on the basis of the Regulations on maintenance and repair of rolling stock

road transport, manuals for the maintenance and repair of cars of certain models and are presented in app. 4. Given in the appendix. 4 normative data without correction can be used in calculations only for the following operating conditions: - 1st category of operating conditions (road - asphalt and concrete pavement, relief - flat, slightly hilly and hilly terrain, traffic conditions - outside the city); - application of basic car models; - use of transport in a temperate climatic region; - mileage from the beginning of operation 50-75% of the mileage to the first overhaul; - the work of transport as part of a motor transport enterprise, which has 200-300 vehicles of three technologically compatible groups, for which the same posts, equipment and personnel qualifications are applicable when carrying out maintenance and repair. When planning maintenance and repair of vehicles, it should be borne in mind that: 1) the labor intensity standards of TO-1 and TO-2 do not include the labor intensity of the UTO; 2) the labor intensity of additional work on seasonal maintenance is to the labor intensity of TO-2: for the regions of the Far North - 50%, for a cold climate zone - 30% and for other conditions - 20 %; 3) the standards do not take into account labor costs for auxiliary work (self-service work) in the garage, which are set at 25-30% of the total labor intensity of TO and TR. The auxiliary work includes maintenance and repair of equipment and tools; transport and handling operations related to the maintenance and repair of rolling stock; driving cars inside the garage; storage, acceptance and delivery of material values; cleaning of industrial and service premises. 2.1.2. Correction of the frequency and complexity of maintenance and repair. Cars operating in more severe conditions than the reference ones will require large labor and material resources to ensure the operability, and the costs of maintenance and repair of cars and the cost of transportation will be objectively higher. Taking into account the actual operating conditions, the frequency of maintenance, mileage to CD, labor intensity is adjusted. TO and TR. Correction of regulatory data is made using coefficients that take into account the operating conditions ( TO 1), type and modification of vehicles ( TO 2), natural and climatic conditions ( TO 3), vehicle mileage since the beginning of operation ( TO 4) and the size of trucking companies ( TO 5). PAZ-3206 When determining the maintenance frequency, the correction factor: Cr 1 = TO 1· TO 3 Cr 1 = 0.1 0.1 = 0,01

When determining the mileage to KR, the correction factor: Cr 2 = TO 1· TO 2 TO 3 CrCr 3 = TO 2 TO 5 CrCr 4 = TO 1· TO 2 TO 3 TO 4· TO 5 Cr 4 = 0.1 0.1 0.1 0.5 0.8 = 0.0004ZIL-432720 (Goby) When determining the maintenance frequency, the correction factor: Cr 1 = TO 1· TO 3 Cr 1 = 0.1 0.1 = Cr 2 = TO 1· TO 2 TO 3 Cr 2 = 0.1 0.1 1.0 = 0.001 When determining the labor intensity of TO, the correction factor: Cr 3 = TO 2 TO 5 Cr 3 = 0.1 0.8 = 0.08 When determining the labor intensity of the TR, the correction factor: Cr 4 = TO 1· TO 2 TO 3 TO 4· TO 5 Cr 4 = 0.1 0.1 0.1 1.9 0.1 = 0.00019 KAMAZ-55111 When determining the maintenance frequency, the correction factor: Cr 1 = TO 1· TO 3 Cr 1 = 0.1 0.1 = 0.01 When determining the mileage to KR, the correction factor:

Cr 2 = TO 1· TO 2 TO 3 Cr 2 = 0.1 0.1 1.0 = 0.001 When determining the labor intensity of TO, the correction factor: Cr 3 = TO 2 TO 5 Cr 3 = 0.1 0.8 = 0.08 When determining the labor intensity of the TR, the correction factor: Cr 4 = TO 1· TO 2 TO 3 TO 4· TO 5 Cr 4 = 0.1 · 0.1 · 0.1 · 0.4 · 0.9 = 0.00036 The value of the coefficient K1 is determined depending on the category of operating conditions and the type of adjusted standard from table. 4. Table 4 - Correction factor TO 1 standards depending on the category of operating conditions. Condition categoryexploitationStandard typeperiodicityTHENspecificlabor intensity of TRresource up to KR I1.01.01.0 II0.91.10.9 III0.81.20.8 IV0.71.40.7 V0.61.50.6 Category of operating conditions characterized by the road surface D, terrain R and traffic conditions Have, is determined by the table. 5. Table 5 - Classification of operating conditions. Condition categoryexploitationDriving conditionsHave 1 Have 2 Have 3

ID1 - P1, P2, P3 - IID1 - P4D2 - P1, P2, P3, P4D3 - P1, P2, P3D1 - P1, P2, P3, P4D2 - P1-IIID1 - P5D2 - P5D3 - P4, R5D4 - P1, P2 , P3, P4, P5D1 - P5D2 - P2, P3, P4, P5D3 - P1, P2, P3, P4, P5D4 - P1, P2, P3, P4, P5D1 - P1, P2, P3, P4, P5D2 - P1, P2 , P3, P4D3 - P1, P2, P3D4 - P1IVD5 - P1, P2, P3, P4, P5D5 - P1, P2, P3, P4, P5D2 - P5D3 - P4, P5D4 - P2, P3, P4, P5D5 - P1, P2 , P3, P4, P5V-D6 - P1, P2, P3, P4, P5-Coefficient values TO 2 take from table. 6 Table 6 - Correction Factor TO 2 standards depending on the modification of the rolling stock and the organization of its work. Rolling stockLabor intensityTO and TRResourceto KR Basic vehicle 1.00 1.00 Tractor unit 1.100.95 Vehicle with one trailer 1.150.90 Vehicle with two trailers 1.200.85 Dump truck with over 5 km shoulders 1.150.85 Dump truck with one trailer or up to 5 shoulders km 1,200,80 Dump truck with two trailers 1,250,75 Specialized rolling stock 1,10-1,20-

Coefficient values TO 3, taking into account the natural and climatic conditions of operation, are taken according to table. 7 depending on the climatic region. Characteristics of the territory of Russia in terms of natural and climatic conditions are presented in Appendix. 5.Values ​​of the correction factor TO 4 are taken from table. 8 depending on the mileage of a car of this brand from the beginning of operation (see table. 2). Table 7 - Correction factor K3 standards depending on natural and climatic conditions. DistrictPeriodicityTHENUd. labor intensityTRResource up toKR Moderate 1.01.01.0 Moderately warm, moderately warm moist, warm humid 1.00.91.1 Hot dry, very hot, dry 0.91.10.9 Moderately cold 0.91.10.9 Cold 0.91.20.8 Very cold 0.81 , 10.7 Table 8 - Correction factor for the norms of the specific labor intensity of the current repair TO 4 depending on the mileage from the beginning of operation. Run from the startexploitation in sharesstandard mileageto KRAutomobilepassengerbuscargo Up to 0.250.40.50.4 Over 0.25 to 0.500.70.80.7 Over 0.50 to 0.751.01.01.0 Over 0.75 to 1.001.41.31.2 Over 1.00 to 1.251.51.41 , 3 Over 1.25 to 1.501.61.51.4 Over 1.50 to 1.752.01.81.6

Over 1.75 to 2.002.22.11.9 Over 2.002.52.52.1 Correction factor value TO 5 varies from 0.8 to 1.3 depending on the number of cars. Calculated values ​​of the correction factors Cr 1, Cr 2, Cr 3 and Cr 4 by car brands are entered in table. 9. Table 9 - Calculated values ​​of the correction factors. Coefficientcar modelPAZ-3206ZIL-432720(Goby)KAMAZ-55111Кр10,010,010,01 Кр20,0010,0010,001 Кр30,080,080,08 Кр40,00040,000190,00036 Taking into account the correction coefficients, the recalculation of the standard maintenance frequency, the mileage rate to КР, as well as the labor intensity standards of TO and TP according to the expressions: PAZ-3206 - maintenance frequency: Lto-2 = Kr1 Lnto-2Lto-1 = Kr1 Lnto-1 Lto-2 = 0.01 20000 = 200 Lto-1 = 0.01 5000 = 50 where Lto-1, Lto-2 - respectively, the standard mileage to TO-1 and TO-2 after correction; Lto-1, Lto-2 - accordingly mileage to TO-1 and TO-2 before correction (see Appendix 4); - mileage to CD: Lcr = Kr2 Lncr- labor intensity of maintenance: Ztto-2 = Kr3 Zt.nto-2Ztto-1 = Kr3 Zt.nto-1Zteto = Kr3 · Zt.no

Ztto-2 = 0.08 18.0 = 1.44 Ztto-1 = 0.08 5.5 = 0.44 Zto = 0.08 0.7 = 0.056 where Ztto-2, Ztto-1, Zto - respectively, the labor intensity of one TO-2, TO-1 and ETO after correction; Zt.nto-2, Zt.nto-1, Zt.no - respectively, the labor intensity of one TO-2, TO-1 and ETO before correction (taken from App. 4); - labor intensity of TR: Ztr = Kr4 · Zt.ntr Zttr = 0.0004 · 5.4 = 0.00216 where Ztr, Zt.ntr - respectively, the normative labor intensity of the TR (per 1000 km of run) after and before the correction. Zt.intr values ​​are taken from app. 4.ZIL-432720 (Goby) - maintenance frequency: Lto-2 = Kr1 Lnto-2Lto-1 = Kr1 Lnto-1 Lto-2 = 0.01 16000 = 160 Lto-1 = 0.01 4000 = 40 where Lto-1, Lto-2 - respectively the standard mileage to TO-1 and TO-2 after correction; Lto-1, Lto-2 - accordingly mileage to TO-1 and TO-2 before correction (see Appendix 4); - mileage to CD: Lcr = Kr2 Lncr Lcr = 0.001 · 450 = 0.45, where Lncr is the standard vehicle mileage to KR before correction; - labor intensity of maintenance: Ztto-2 = Kr3 Zt.nto-2Ztto-1 = Kr3 Zt.nto-1Zteto = Kr3 · Zt.no Ztto-2 = 0.08 10.0 = 0.8 Ztto-1 = 0.08 2.6 = 0.208 Zto = 0.08 0.42 = 0.0336 respectively, the labor intensity of one TO-2, TO-1 and ETO after correction; Zt.nto-2, Zt.nto-1, Zt.no - respectively, the labor intensity of one TO-2, TO-1 and ETO before correction (taken from App. 4); - labor intensity of TR: Ztr = Kr4 · Zt.ntr

Zttr = 0.00019 3.8 = 0.000722 where Zttr, Zt.ntr - respectively, the normative labor intensity of the TR (per 1000 km of run) after and before the correction. Zt.intr values ​​are taken from app. 4. The results of the calculations for the adjustment should be summarized in table. 10.KAMAZ-55111 - maintenance frequency: Lto-2 = Kr1 Lnto-2Lto-1 = Kr1 Lnto-1 Lto-2 = 0.01 16500 = 165 Lto-1 = 0.01 5500 = 55 where Lto-1, Lto-2 - respectively, the standard mileage to TO-1 and TO-2 after correction; Lto-1, Lto-2 - accordingly mileage to TO-1 and TO-2 before correction (see Appendix 4); - mileage to CD: Lcr = Kr2 Lncr Lcr = 0.001 * 300 = 0.3, where Lncr is the standard vehicle mileage to the CD before correction; - labor intensity of maintenance: Ztto-2 = Kr3 Zt.nto-2Ztto-1 = Kr3 Zt.nto-1Zteto = Kr3 · Zt.no Ztto-2 = 0.08 16.5 = 1.32 Ztto-1 = 0.08 3.8 = 0.304 respectively, the labor intensity of one TO-2, TO-1 and ETO after correction; Zt.nto-2, Zt.nto-1, Zt.no - respectively, the labor intensity of one TO-2, TO-1 and ETO before correction (taken from App. 4); - labor intensity of TR: Ztr = Kr4 · Zt.ntr Zttr = 0.00036 · 6.0 = 0.00216 where Zttr, Zt.ntr - respectively, the normative labor intensity of the TR (per 1000 km of run) after and before the correction. Zt.intr values ​​are taken from app. 4. The results of the calculations for the adjustment should be summarized in table. ten. 2.1.3 Determination of the number of maintenance for the planned period

In accordance with the initial data (see Tables 1-3), determine the planned mileage by cars of this brand: L∑ i = Ki (Lg i T) where L∑i is the planned mileage of cars of this brand, km; Ki is the listed number of cars of this brand (see table. 1); Lg i is the average mileage of a car of this brand in the planned period km (see Table 2). T - Number of work days per year (see Table 2). L∑ PAZ-3206 = 23 · (90 · 305) = 631 350 km L∑ ZIL-432720 (Bychok) = 42 · (60 · 253) = 637 560 km L∑ KAMAZ-55111 = 38 (70 305) = 811 300 km Taking into account the adjusted values ​​of the frequency and labor intensity of maintenance and repair, determine the number of services of each type in the planned period for the fleet of cars of this brand: nij =L∑ iL¿ ij - L∑ iL¿( j+ 1)i where n is the number of services; j is the index of the type of service (for example, TO-1, TO-2); i - car brand index (for example, KAMAZ-4308), i.e. n2i =L∑ iLTHEN−2 i - L∑ iLkpin1i =L∑ iLTHEN−1 i - L∑ iLTHEN−2 i n2 PAZ-3206 = L∑ GROOVE−3206LTHEN−2 GROOVE−3206 - L∑ GROOVE−3206LkpPAZ−3206 = 631350200 - 631350449.55 = 3156.7 - 1404.4 = 1752.3n1 PAZ-3206 = L∑ GROOVE−3206LTHEN−1 GROOVE−3206 - L∑ GROOVE−3206LTHEN−2 GROOVE−3206 = 63135050 - 631350200 = 12627 - 3156.7 = 9470.3n2 ZIL-432720 (Bull) = L∑ ZIL−432720(Goby)LTHEN−2 ZIL−432720 (Goby) - L∑ ZIL−432720(Goby)LkpZIL−432720(Goby) = 637560160 - 637560449,55 =

3984.7 - 1418.2 = 2566.5n1 ZIL-432720 (Goby) = L∑ ZIL−432720(Goby)LTHEN−1 ZIL−432720 (Goby) - L∑ ZIL− 432720(Goby)LTHEN−2 ZIL−432720 (Goby) = 63756040 - 637560160 == 15939 - 3984.7 = 11954.3n2 KAMAZ-55111 = L∑ KAMAZ−55111LTHEN−2 KAMAZ−55111 - L∑ KAMAZ−55111LkpKAMAZ−55111 = 811300165 - 811300299.7 = = 4916.9 - 2707.04 = 2209.8n1 KAMAZ-55111 = L∑ KAMAZ−55111LTHEN−1 KAMAZ−55111 - L∑ KAMAZ−55111LTHEN−2 KAMAZ−55111 = 81130055 - 811300165 = = 14750.9 - 4916.9 = 9834 Table 10 - Adjusted values ​​of the original data. Indicatorscar modelPAZ-3206ZIL-432720(Goby)KAMAZ-55111 Mileage to TO-1: before correction500040005500 after correction495039605445 Mileage to TO-2: before correction200001600016500 after correction198001584016335 Mileage to KR: before correction450450300 after correction449.55449.55299.7 Labor intensity ETO: before correction0.53

Labor intensity of TO-1: before correction 5.52.63.8 after correction 5.062.3923.496 Labor intensity of TO-2: before correction 18.010.016.5 after correction 16.569.215.18 Labor intensity of TR (per 1000 km run): before correction 5.43.86, 0 after correction 5.397843.7992785.99784 The number of daily services is determined by the value of the average daily mileage: netoi =L∑ ilcci where lcci Is the average daily mileage of a car of this brand, km (see Table 2). NetoPAZ-3206 = L∑ GROOVE−3206lcc PAZ−3206 = 63135090 = 7015netoZIL-432720 (Goby) = L∑ ZIL−432720(Goby)lcc ZIL−432720(Goby) = 63756060 = 10626netoKAMAZ-55111 = L∑ KAMAZ−55111lcc KAMAZ−55111 = 81130070 = 11590 Number of seasonal maintenance nSTOi = 2Ki where 2 is the number of seasonal services per year; Кi - the number of cars of this brand.nSTO PAZ-3206 = 2 23 = 46 nSTO ZIL-432720 (Bull) = 2 42 = 84

nSTO KAMAZ-55111 = 2 38 = 76 The daily vehicle maintenance program is determined separately for each type of service for each car brand: mTOij =njiD where mTOij is the daily number of services j-th kind i-th brand of cars in the planned period; D - the number of working days per year of the site or service area performing this type of service. For calculations, accept. D = 253 days. That is mЕТОi =nit's iDmTO-1i =n 1i DmTO-2i =n 2i D METO PAZ-3206 = nUTB PAZ−3206D¿7015253 ¿27.7m TO-1 PAZ-3206 = n 1 GROOVE−3206D¿9470.3253 ¿37.4m TO-2 PAZ-3206 = n 2 GROOVE−3206D= 1752.3253 ¿6.9metO ZIL-432720 (Goby) = netoZIL−432720(Goby)D¿10626253 ¿42mTO-1 ZIL-432720 (Goby) = n 1 ZIL−432720 (Goby)D¿11954.3253 ¿47.2mTO-2 ZIL-432720 (Goby) = n 2 ZIL−432720 (Goby)D= 2566.5253 ¿10.1 METO KAMAZ-55111 = nUTB KAMAZ−55111D¿11590253 ¿45.8

mТО-1 KAMAZ-55111 = n 1 KAMAZ−55111D¿9834253 ¿38.8m TO-2 KAMAZ-55111 = n 2 KAMAZ−55111D= 2209.8253 ¿8.7 The calculation results for the annual and daily number of technical services are summarized in Table. 11. Table 11 - Estimated number of maintenance by type of service and car brands. Indicatorscar modelPAZ-3206ZIL-432720(Goby)KAMAZ-55111 Number of vehicles ∑ ЗTGTHEN−i = ZTTO−i· nji where ∑ ЗTGTHEN−i- the annual labor intensity of work on the i-th maintenance for cars of the same brand, man-hours. When determining the labor intensity of seasonal maintenance, it is necessary to take into account that the labor intensity of the service station is determined as a percentage of the labor intensity of TO-2, taking into account the climatic region (see above). ∑ ЗTGETO groove−3206 = ZTHETOPAZ−3206 n ETO PAZ-3206 = 0.644 7015 = 4517.6 man-hours

∑ ЗTGTHEN−1 GROOVE−3206 = ZTTO−1GROOVE−3206 n TO-1 PAZ-3206 = 5.06 * 9470.3 = 47919.7 man-hours ∑ ЗTGTHEN−2 GROOVE−3206 = ZTTO−2GROOVE−3206 n TO-2 PAZ-3206 = 16.56 1752.3 = 29018.08 man-hours ∑ ЗTGSTO PAZ−3206 = ∑ ZTGTO−2GROOVE−3206 30% = 29018.08 0.3 = 8705.4 man-hours ∑ ЗTGETO ZIL−432720(Goby) = ZTETOZIL−432720(Goby) N ETO ZIL-432720 (Goby) = 0.3864 10626 = 4105.8 man-hours. ∑ ЗTGTHEN−1 ZIL−432720 (Goby) = ZTTHEN−1ZIL−432720(Goby) N TO-1 ZIL-432720 (Goby) = 2.392 11954.3 = 28594.6 man-hours. ∑ ЗTGTHEN−2 ZIL−432720 (Goby) = ZTTHEN−2ZIL−432720(Goby) N TO-2 ZIL-432720 (Goby) = 9.2 2566.5 = 23611.8 man-hours ∑ ЗTGSTO ZIL− 432720(Goby) = ∑ ЗTGTHEN−2 ZIL−432720 (Goby) 30% = 23611.8 0.3 = 7083.54 people-hours ∑ ЗTGETO KAMAZ−55111 = ZTETOKAMAZ−55111 n UTS KAMAZ-55111 = 0.5336 11590 = 6184.4 man-hours ∑ ЗTGTHEN−1 KAMAZ−55111 = ZTTO−1KAMAZ−55111 n TO-1 KAMAZ-55111 = 3.496 9834 = 34379.6 man-hours ∑ ЗTGTHEN−2 KAMAZ−55111 = ZTTO−2KAMAZ−55111 n TO-2 KAMAZ-55111 = 15.18 2209.8 = 33544.7 man-hours ∑ ЗTGSTO KAMAZ−55111 = ∑ ZTGTO−2KAMAZ−55111 30% = 33544.7 0.3 = 10063.4 man-hours Labor intensity of work on TR for cars of one brand is determined by the expression ∑ ЗTTR = Lg· ZTTR· K 1 /1000 where ∑ ЗTTR- annual labor intensity of work on TR for cars of the same make, man-hours PAZ-3206 ∑ ЗTTR = Lg· ZTTR· K 1/1000 = 27450 5.39784 0.1 / 1000 = 14.8 man-hours ZIL-432720 ∑ ЗTTR = Lg· ZTTR· K 1/1000 = 15180 3.799278 0.1 / 1000 = 5.7 man-hours KAMAZ-55111 ∑ ЗTTR = Lg· ZTTR· K 1/1000 = 21350 5.99784 0.1 / 1000 = 12.8 man-hours The labor intensity of self-service work is taken in the amount of 25-30% of the total labor intensity of TO and TR ( ZTSMO=0,25−0,3 (∑ ZTTO+∑ ZTTR)) (see above) PAZ-3206 ZTCMO=0,3(∑ ЗТTHEN+∑ ЗТTR) = 0,3(90160,78+14,8) = 27052.6 man-hours ZIL-432720 ZTCMO=0,3(∑ ЗТTHEN+∑ ЗТTR) = 0,3(63395,74+5,7) = 19020.4 man-hours KAMAZ-55111 ZTCMO=0,3(∑ ЗТTHEN+∑ ЗТTR) = 0,3(84172,1+12,8) = 25255.4 person-hours

The results of calculating the labor intensity of work on maintenance and repair should be summarized in table. 12. Table 12 - Labor intensity of works on maintenance and repair of cars, man-hours. Labor intensity indicatorsto the car parkcar modelPAZ-3206ZIL-432720(Goby)KAMAZ-55111 Labor intensity ETO4517.64105.86184.4 Labor intensity TO-147919.728594.634379.6 Labor intensity TO-229018.0823611.833544.7 Labor intensity STO8705.47083.5410063.4 Total labor intensity of TO work by car make 90160.7863395.7484172.1 Total labor intensity car park ( ∑ ЗTTHEN) 237728.62 Labor intensity of TR by brand 14.85.7 12.8 Total labor intensity of TR work ( ∑ ЗTTR) 33.3 Labor intensity of self-service garage works ( ZTCMO) 27052.619020.425255.4 The total annual labor intensity of work on the garage 309090.32 The number of workers required to perform maintenance and repair work is determined by the expression mр = (∑ ЗTTHEN+ ∑ ЗTTR + ZTCMO) / F where ∑ ЗTTHEN,∑ ЗTTR, ZTCMO- respectively, the total labor intensity (throughout the park) of maintenance, repair and self-service works in the garage; Ф - fund of the performer's working time (taken equal to 1860-1950 hours) .mр = ( ∑ ЗTTHEN+∑ ЗTTR + ZTCMO) / Ф = (237728.62 + 33.3 + 71328.4) / 1950 = 158.5. The number of workers required to perform certain types of maintenance and repair is determined in a similar way. When determining the number of repair workers, the following should be considered.

1. The labor intensity standards of the ETO include both cleaning and washing work, usually performed by the working areas of maintenance, and control and refueling, performed by the driver. The volume of cleaning and washing operations is 50-60% of the total labor intensity of the UTS. The standard labor intensity of the ETO should be taken into account in the event that the driver does not take part in the performance of work on the ETO. When the driver performs only control and refueling work, the standard labor intensity is taken with a coefficient of 0.5-0.6. In addition, ETO standards should be reduced by another 50-70% if mechanized washing is used. The use of a mechanized car wash is mandatory for garages with more than 100 cars. ETO = 14807.8 · 0.7 / 1950 = 10365.46 / 1950 = 5.3. = 5.3 · 0.6 = 3.12.It is not recommended to involve drivers to perform maintenance-1 work. To carry out work on TO-2, service station and TR, it is proposed to involve drivers (50% of the scope of work). TO-1 without drivers. = 110893.9 / 1950 = 56.8 TO-2 = 86174.58 0.5 / 1950 = 22.09 TO-2 without driver = 86174.58 / 1950 = 44.18 STO = 25852.34 0.5 / 1950 = 6.6 STO without driver = 25852.34 / 1950 = 13.2TR = 33.3 0.5 / 1950 = 0.008TR without driver = 33.3 / 1950 = 0.0163. To perform TO-1 and TO-2 on the stream, it is recommended to reduce the labor intensity by 15-25%. In the course work, it is necessary to consider 2 options for organizing work on TO and TR - with and without the participation of drivers. The results of determining the required number of workers are summarized in table. 13. Table 13 - The results of determining the required number of garage workers. Service or repairEstimated number of workers, peopletaking into account workdriversexcluding workdrivers ETO5,33,1ТО-1-56,8ТО-222,0944,1STO6,613,2TR0,0080,016 Self-service work 36,5736,57 Requires total workers 70,5153,7 To determine the method of organization of maintenance, the recommendations of NIIAT are used, according to which:

- TO-1 of trucks on dead-end flows is carried out according to the program of up to 10 services per day; with a greater number of services for cars of the same name per day, TO-1 is carried out on the production line; - TO-2 trucks at dead-end posts are carried out according to the program up to 1-2 services per day; with a daily program of 2-5 cars, service is carried out at dead-end posts with a separate lubrication post; with a daily program, more than 6 vehicles TO-2 are carried out on the production line. The results are entered in table. 14. Table 14 - Methods of organizing maintenance work. BrandcarDaily programmaintenance workSelected optionorganization of work onmaintenance TO-1TO-2TO-1TO-2PAZ-320625.94.8265ZIL-432720 (Goby) 32.77.03337KAMAZ-5511126.96.052762.2. Development of the technological process of vehicle maintenance2.2.1 General characteristics and design features of rolling stock The development of the technical maintenance process is influenced by many factors that characterize, first of all, the design of the car. Therefore, for a given brand of car, it is necessary to briefly describe the design features in the following order: 1. Design features of the engine (engine type, displacement, engine location, number of cylinders, camshaft arrangement, type of timing mechanism drive, lubrication system volume, etc.) 2. Design features of the transmission (type of transmission, number of driving wheels, availability of a transfer case, number of gears of the gearbox, volume of the gearbox housing and main gear, etc.) 3. Design features of the chassis and steering (type of suspension, size of tires and disks, availability of power steering, type of steering, etc.). 4. Design features of the brake system (type of brake system, brake design, number of circuits, etc.). Technical characteristics of the rolling stock: PAZ-3206 bus: 1.MarkPAZ-32062. Wheel formula 4х43. Number of seats25

4. Engine brand ZMZ 52345. Engine power 88.3 kW 6. Base 3600 mm 7. Front and rear wheel track 1800 mm and 1690 mm 8. Ground clearance 264 mm 9. Fuel consumption per 100 km 25 liters 10. Overall dimensions 6925x2480x3105 mm 11. ManufacturerPAZ Onboard truck ZIL-432720: 1.MarkAZIL-4327202. Wheel formula 4х23. Weight of transported cargo 6,000 kg 4. Engine brand ZIL-6455. Engine power 136 kW 6. Base 3340 mm 7. Front and rear wheel track 1820 mm 8. Ground clearance 330 mm 9. Fuel consumption per 100 km 19 liters 10. Overall dimensions 7645x2500x2656 mm 11. ManufacturerZIL. Dump truck KAMAZ-55111: 1. Brand KAMAZ-551112. Wheel formula 6x43. Weight of transported cargo 13000 kg 4. Engine brand KAMAZ 740.51-240 (Euro-2) 5. Engine power 176 kW 6. Body volume 6.6 m 37. Direction of unloading back 8. Base 2840 + 1320 mm

9.Front and rear wheel track 2043 mm and 1890 mm 10. Ground clearance 290 mm 11. Fuel consumption per 100 km 28 l 12. Overall dimensions 6700x2500x2850 mm 13. ManufacturerKAMAZ 2.2.2. Calculation of the labor intensity of certain types of work on vehicle maintenance. Regardless of the type of maintenance, it contains the following main work: - control and diagnostic; - adjusting; - fastening, - lubricating and filling; - electrical; - tire. The distribution of time spent on performing maintenance work as a percentage of the total volume is presented in table. 15. Taking into account the design features of a given brand of car, it is necessary to determine the types of maintenance work and their labor intensity. The complexity of certain types of work is determined on the basis of the data in the table. 15. The value of the total labor intensity of maintenance is taken from Part 2. The results of calculations of the labor intensity of certain types of maintenance work are summarized in Table. 16. Table 15 - Distribution of labor costs for TO-1 and TO-2 cars by type of work,% Type of workPassenger carscarsBusesFreightcarsTO-1TO-2TO-1TO-2TO-1TO-2 Control and diagnostic 12-1610-125-95-78-106-10 Adjustable 9-119-118-107-910-1217-19 Fasteners 40-4836-4044-5246-5232-3833-37 Lubricants 17-219-1119-219-1116- 2614-18 Electrical 4-66-84-66-810-138-12 Maintenance of the power supply system 2.5-3.52-32.5-3.52-33-67-14 Busbars 4-61-23.5-4.57-97 -99-3

Body18-2215-17Total 100100100100100100 Table 16. Distribution of labor intensity of TO No. 1 of PAZ-3206 by type of work. Type of workLabor intensity, man-h Control and diagnostic5-9Adjusting8-10Fasteners44-52Lubricating19-21 Distribution of labor intensity of TO No. 2 of PAZ-3206 by type of work Type of workLabor intensity, man-h Control and diagnostic5-7Adjusting7-9Fasteners46-52Lubricating and filling9-11Electrical6-8Service for the power supply system2-3Tyres7-9Body15-17Total100Table 16.2. Distribution of labor intensity of TO No. 1 of the car ZIL-432720 (Bychok) by type of work.

Type of workLabor intensity, man-h Control and diagnostic8-10Adjusting10-12Fasteners32-38Lubricating and filling16-26Electrical10-13Power system maintenance3-6Tyres7-9BodyTotal100Table 16.3. Distribution of labor intensity of TO No. 2 of the car ZIL-432720 (Bychok) by type of work. Type of workLabor intensity, man-h Control and diagnostic6-10Adjusting17-19Fasteners33-37Lubricating14-18 Distribution of labor intensity of TO No. 1 of the KAMAZ-55111 vehicle by type of work. Type of workLabor intensity, man-h Control and diagnostic 8-10 Adjustment 10-12 Fasteners 32-38

Lubrication and filling stations16-26Electrotechnical10-13Maintenance of the power supply system3-6Tyres7-9BodyTotal100Table 16.5. Distribution of labor intensity of TO No. 2 of the KAMAZ-55111 vehicle by type of work. Type of workLabor intensity, man-h Control and diagnostic6-10Adjustment17-19Fasteners33-37Lubricating14-18 2.2.3. Operational flow chart of vehicle maintenance. The full scope of work includes all operations related to the preparatory and final work of the technological process (entering the post, lowering the car, etc.). The list of works during maintenance of a given brand of car is determined on the basis of a typical technology of maintenance and repair of cars or independently, taking into account the recommendations of the regulations on maintenance and repair of rolling stock of automobile transport (Appendix 6). individual works carry out on the basis of the data in the table. 15.

The results of calculations of the labor intensity of certain types of maintenance work are summarized in table. 17. Table 17. Distribution of annual labor intensity for TO-1 and TO-2 in%. Type of work PAZ-3206 TO-1TO-2 Control and diagnostic 73354,379102901,808Adjustments104791,97113191,9888Fasteners5224918,2443911317.0512Lubrication and filling Distribution of annual labor intensity for TO-1 and TO-2 in%. Type of work ZIL-432720 (Goby) TO-1TO-2 Control and diagnostic82287.568102361.18Adjusting123431.352174014.006Fasteners3810865.948337791.894Lubricating and filling174861.082184250,124

Table 17.2. Distribution of annual labor intensity for TO-1 and TO-2 in%. Type of work KAMAZ-55111 TO-1TO-2 Control and diagnostic82750,368103354,47Adjustment124125,552175702,599Fasteners3813064,2483311069,751Lubrication and filling175844,532186038,046Electrical134469,348124025,364Service of the power system31031,38872348,129 Organization of operation of the TO production line. A progressive method of organizing maintenance is to perform it on production lines, which makes it possible to increase labor productivity, reduce the cost of maintenance and repair, and reduce vehicle downtime in maintenance and repair. However, for the organization of production by the flow method, certain conditions are necessary, the main of which is a sufficient shift production program of serviced vehicles. Such lines are mainly used to perform TO-1 and TO-2. The minimum shift program, in which it is advisable to use the flow method, is 11-13 for TO-1 and 5-6 for TO-2. The initial data are: - car brand; - daily maintenance work program; - step-by-step flow chart of maintenance (part 2). Required: - calculate the required number of technological workers; - determine the duration of the work shift; - determine the number of posts for the production line.

Restrictions: - minimum movement of technological workers; - the same amount of work for each performer; - similarity of work performed by one performer. 2.3.1. Determination of the number of production line posts. Determining the number of TO-1 posts begins with determining the tact of posts τp:τп = (60 t 1Pn) + T nc, min where t 1 - the complexity of one maintenance (part 1), man-h; Rp- the number of workers simultaneously working at the post (for cars 2-3, for trucks 2-4 people); Tps- the time spent on setting and leaving the car from the post ( Tps= 1-3 min) .PAZ-3206 τп =(60 t 1Pn) + Tnc= (60∗5,064) + 3 = 75.9 minutes ZIL-432720 (Goby) τп =(60 t 1Pn) + Tnc= (60∗2,3924) + 3 = 38.88 minutes KAMAZ-55111 τп =(60 t 1Pn) + Tnc= (60∗3,4964) + 3 = 55.44 minutes Then the rhythm of production is determined: Rn = 60 Tcm ncmmTO−ij, min where Tcm- operating hours of the maintenance area per day; ncm- the number of shifts per day (take ncm= 1);mTO-ij- daily maintenance program (part 1); PAZ-3206 Rn = 60 Tcm n cmmTO−1GROOVE−3206 = 60 * 8 * 137.4 = 12.8 minutes ZIL-432720 (Goby)

Rn = Goby¿ THEN−1 ZIL−432720 ¿ m¿60 Tcm ncm¿= 60 ∗ 8 ∗ 147.2 = 10.1 minutes KAMAZ-55111 Rn = 60 Tcm ncmmTO−1KAMAZ−55111 = 60 * 8 * 138.8 = 12.3 minutes The number of maintenance posts is determined in relation to the ratio of the cycle of posts to the rhythm of production: Xmo−i = τ nRn PAZ-3206 Xmo−i = τ nRn= 75.912.8 = 5.9ZIL-432720 (Goby) Xmo−i = τ nRn= 38.8810.1 = 3.8KAMAZ-55111 Xmo−i = τ nRn= 55.4412.3 = 4.5 The shift time for the maintenance work area should be applied in the range from 6 to 8 hours so that the number of posts is an integer. 18 Table 18 - Performance indicators of the production line TO.PAZ-3206 IndicatorsThe values Cycle of work of posts, min 75.9 Rhythm of production, min 12.8 Duration of changing the maintenance zone, h 8 Number of posts, pcs 5.9 Number of performers at the post, people 4 Table 18.1 - Performance indicators of the production line TO.ZIL-432720 (Bychok)

IndicatorsThe values Cycle of work of posts, min 38.88 Rhythm of production, min 10.1 Duration of changing the maintenance zone, h 8 Number of posts, pcs 3.8 Number of performers at the post, people 4 Table 18.2 - Performance indicators of the TO.KAMAZ-55111 production line IndicatorsThe values Cycle of work of posts, min 55.44 Rhythm of production, min 12.3 Duration of changing the maintenance zone, h 8 Number of posts, pcs 4.5 Number of performers at the post, people 4 2.3.2. Distribution of the scope of work by posts. Having determined the number of posts at each post, you can proceed to the distribution of the entire scope of maintenance work. The entire list of work on this maintenance (Appendix 6) must be combined into several general groups: 1.- control and diagnostic; 2.- lubrication and filling ; 3.- maintenance work on the transmission; 4.- maintenance work on the steering and chassis; 5.- electrical work; 6.- maintenance work on the brake system; 7.- work on the engine maintenance, etc. according to the group of works to be entered in the table. 19. The distribution of work groups by posts should be entered in table. 20. Table 19 - List of types of work.

№ p / pWork groupfor maintenancenumber of operations according totechnologies 1 Control and diagnostic 1, 22 Lubrication and filling stations 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93, 943 Transmission maintenance works 14, 15, 16, 17, 18, 19, 20, 21, 224 Works on steering and chassis maintenance 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 365 Electrical work 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 796 Maintenance work on the brake system 37, 38, 39, 40, 41, 42, 43, 44, 45, 467 Maintenance work on the engine 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13 , 55, 56, 57, 58, 59, 60, 61, 62, 63, 64, 65, 66, 67 Table 20 - Distribution of types of work by posts. Post numberMaintenance work groups I1, 3, 4, 6 II2, 5, 7 2.3.3. Selection of equipment for posts. The list is compiled on the basis of the data of the main operations of vehicle maintenance (Appendix 6). The choice of equipment is carried out by deciding rational use, i.e. whether to use it or not.

Bibliography. 1. Kuznetsov E.S. Technical operation of cars: textbook. for universities / E.S. Kuznetsov, V.M. Boldin, V.M. Vlasov et al. - 4th ed., Revised. and add. - M .: Nauka, 2004 .-- 535 p. 2. Technical operation of cars: textbook. for universities / ed. G.V. Kramarenko. - 2nd ed., Rev. and add. - M .: Transport, 1983 .-- 488 p. 3. E.S. Kuznetsov Car maintenance management. - M .: Transport, 1982 .-- 224 p. 4. Regulations on the maintenance and repair of the rolling stock of road transport / Minavtotrans RSFSR. - M .: Transport, 1983 .-- 86 p. 5. Kolesnik P.A. Maintenance and repair of cars: textbook. for universities / P.A. Kolesnik, V.A. Sheinin. - 2nd ed., Rev. and add. - M .: Transport, 1985 .-- 325 p. 6. Regulatory (second) parts of the Regulations on the maintenance and repair of rolling stock of road transport for specific models cars: family of cars GAZ, ZIL, KAMAZ, PAZ buses, etc. 7. Handbook of mechanical engineer of agricultural production: textbook. allowance. - M .: Rosinforagrotech, 2003. - Ch1. - 340 p. 8. Operation manual, device, MOT and TR of KAMAZ vehicles. - Naberezhnye Chelny, 2007 .-- 310 p. 9. Anikin S.A. Technology of performing technical maintenance of KAMAZ-4308 vehicles / S.А. Anikin, V.A. Bashkirov, V.I. Bruskov and others - Naberezhnye Chelny: OJSC KAMAZ, 2005. –80 p. 10. E.S. Kuznetsov Technical exploitation of cars in the USA. –M .: Transport, 1992. –352 p. 11. Zavyalov S.N. Car wash. –M .: Transport, 1984. –184 p. 12. Kramarenko G.B. Garage-free car storage at low temperatures/ G.B. Kramarenko, V.A. Nikolaev, A.I. Shatalov. –M .: Transport, 1984. –136 p. 13. E.S. Kuznetsov Industrial base of road transport: state and prospects / E.S. Kuznetsov, I.P. Kurnikov. –M .: Transport, 1988. –154 p.

Technological process of car maintenance and repair

Introduction

1. Technological process of car maintenance and repair

1.1 General

1.1.1 Characteristics of the trucking company

1.1.2 Characteristics of the projected area

1.2 Design part

1.2.1 Selection of technological equipment

1.2.2 Technological maps

1.3 Organizational part

1.3.1 Organization of the technological process of maintenance and repair

1.3.2 Production control scheme using MCC

1.3.3 Quality management

1.4 Safety and industrial hygiene

1.4.1 General Provisions on labor protection

1.4.2 Industrial sanitation and environmental protection

1.4.3 Safety and fire protection measures

2. Settlement and technological part

2.1 Initial data for design

2.2 Reduction of the park to the main model

2.3 Selection and correction of maintenance and repair standards

2.4 Definition annual mileage parka

2.5 Calculation of the annual production program for maintenance and repair

2.6 Determination of the annual scope of work of the projected site

2.7 Determining the number of manufacturing jobs

2.8 Calculation of the area of ​​the projected site (zone)

3. The economic part

3.1 Payroll

3.2 Payroll taxes and contributions

3.3 Calculation of the cost of performing work in the department

Conclusion

Literature

Application

Introduction

The role of road transport is quite large in the national economy and in Armed Forces. The car is used to quickly move goods and passengers around different types roads and terrain. Road transport plays a vital role in all aspects of the country's life. It is impossible to imagine the work of any industrial enterprise without a car, state institution, a construction organization, a commercial company, an agricultural enterprise, a military unit. A significant amount of freight and passenger traffic falls on this transport. The passenger car has widely entered the life of the working people of our country, has become a means of transportation, recreation, tourism and work.

To ensure the operability of the car during the entire period of operation, it is necessary to periodically maintain its technical condition with a complex of technical actions, which, depending on the purpose and nature, can be divided into two groups: actions aimed at maintaining the units, mechanisms and components of the car in working condition during the greatest period of operation; impacts aimed at restoring the lost performance of units, mechanisms and components of the car.

In our country, a planned preventive system for the maintenance and repair of automobiles has been adopted. The essence of this system lies in the fact that maintenance is a preventive measure, it is carried out compulsorily, according to a plan, and repairs - as needed, i.e. after discovery of a defect or malfunction.

The regulation provides for two types of repairs of cars and its units: current repairs (TR), performed in motor transport enterprises, and capital repairs (CR), performed at specialized enterprises.

Rolling stock with faulty constituent parts, the condition of which does not meet the established safety requirements or causes increased wear of parts, should not continue transport work or be released onto the line.

The operative condition of the rolling stock is ensured by the production and technical service, which is responsible for the timely and high-quality performance of maintenance and repairs in compliance with the established standards, the effective organization of work of the repair and maintenance personnel, compliance with the normative and technical documentation for maintenance and repair.

The nomenclature of professions of personnel, ensuring the good condition of the rolling stock, includes workers of various specialties, technicians and engineers.

Technicians monitor the technical condition of the rolling stock, guide and control the work of production sites, carry out current production and technical accounting, analysis and planning of maintenance and repair work, introduce progressive forms and methods of organization, technology and mechanization of production, and also monitor compliance with technology security.

Significant for solving the problem of managing the technical condition of a car is a scheduled preventive system for maintenance and repair of cars, which is based on the "Regulations on the maintenance and repair of rolling stock of road transport" and regulates modes and other standards for maintaining a car in good condition.

Important elements of solving the problems of managing the technical condition of vehicles are the improvement of technological processes for the production of maintenance and repair of vehicles, including technological methods, equipment of posts and workplaces and the scientific organization of labor (NOT), as well as the widespread use of mechanization and automation.

The most important task of the technical operation of vehicles is to improve the design methods of the technical base: vehicle transport, garages and service stations, which ensure the fulfillment of all the above requirements for the maintenance of the vehicle fleet. Thus, in order to ensure the high technical readiness of the rolling stock of the ATP, it becomes necessary to design the production lines of maintenance and repair in order to modernize them, by adjusting the initial data of maintenance and repair standards, calculating the annual and shift programs for maintenance, determining the labor intensity and calculating the number of workers at the facility. design, the choice of the method of organizing production and the method of organizing the technological process.

In our time, modern motor transport enterprises need a thorough mechanization of repair zones, lines, sections. The state of the organization of maintenance and repair in modern conditions is at a low level of mechanization. This leads to a decrease in labor productivity and an increase in the labor intensity of the work carried out. At the same time, the role and importance of road transport in transport system is continuously increasing. The main requirement is to ensure a high technical level and high economic efficiency of the projected enterprise, buildings and structures by using the latest achievements of science and technology, so that the projected and reconstructed enterprises by the time of their commissioning are technically advanced and have high performance indicators and working conditions, the level of mechanization in production activities, the cost price, the quality of production, as well as the efficiency of the use of capital investments.

The construction of new road transport enterprises is carried out, as a rule, according to standard projects intended for repeated use in similar conditions, i.e. typical for this class of enterprises. Such projects are based on the use in construction of standard standard parts, structures and materials, produced in large quantities by enterprises in the construction industry. Typical design also has a certain value in terms of the operation of enterprises, provided that the most progressive production methods, technological processes were laid down in the project, the composition and dimensions of production premises were substantiated, latest designs technological equipment, etc.

The goals and objectives of the diploma project are to summarize the disciplines passed during the training, in this educational institution; show your knowledge and skills in calculations for the design of motor transport enterprises and independent solution of production and technical issues; at the cost of maintenance and repair work received during training and consolidation of knowledge on the use of normative and reference literature.

maintenance repair car

1. Technological process of car maintenance and repair

1.1 General

1.1.1 Characteristics of the trucking company

Automobile transport enterprise STO "Spets" diagnostics of the technical condition of the vehicle is intended for cargo transportation and other services to the population of Angarsk and nearby settlements. Legal address: Angarsk st. Karl Marx 87. Also, a motor transport company carries out storage, maintenance and repair of cars. This company is also engaged in replenishing the fleet with new cars, technological equipment, spare parts and materials. The structure of the enterprise is based on three production subsystems: main, auxiliary, service. The main production performs work on SW; TO-1; TO-2; TR.

The rolling stock of the motor transport enterprise STO "Spets" is operated on roads of 1, 2 and partially 3 categories.

Roads of the 1st and 2nd category have a solid foundation and an improved surface (asphalt or cement concrete), which ensure the movement of wheeled vehicles on them. Vehicle with axial load. Not exceeding 10 tons.

Roads of the 3rd category have a lightweight improved surface (tar concrete, bitumen-mineral mixtures), which is also designed for the movement of vehicles on them with an axle load not exceeding 10 tons, but with a lower intensity.

The rolling stock of road transport is 48 units, including:

Table 1.

Vehicle fleet status

Indicator brand auth.	dimensions		own. weight	number of cars		not used equal
	11400x3500x3000
	5200x2500x2000
	6395x2280x2190

The age composition of the car park is distributed as follows:

Table 2.

The structure of the car park by the service life of cars

Indicators

Under the operating conditions of the "Spets" service station, there are regions of cold and moderately cold climates with temperatures from -40 0 to +35 0 Celsius, humidity up to 95%.

Table 3.

The dependence of the frequency of maintenance on operating conditions

1.1.2 Characteristics of the projected area

The department (workshop) for maintenance and repair of engines is intended for the operations of washing instruments and units of mechanisms and engine systems, disassembly, defect detection of parts with subsequent dispatch for disposal, repair or assembly, assembly of units, their assembly, adjustment and running-in. The technological cycle for the repair of lubrication system devices consists of: external cleaning from dirt, disassembly, washing, control and sorting of parts, replacement of rejected parts with new or rebuilt parts after mechanical processing, assembly of the assembly and unit, adjustment and verification for compliance with the requirements of technical specifications for repair. The repaired device or unit is installed on the engine.

At present, some of the equipment of the department (workshop) has exhausted its established resource and is out of order, which creates inconvenience and time-consuming repairs. The workshop does not have sufficient natural light, and artificial lighting does not provide normal illumination of the workplace. The area of ​​the premises meets the requirements, however, the placement of equipment is not rational and does not fully provide the technical conditions for the performance of work for different models cars.

1.2 Design part

1.2.1 Selection of technological equipment

The main technological equipment is selected according to the tables of technological equipment, reference books and catalogs, as well as according to the catalog of non-standard equipment.

The engine compartment is equipped with the following equipment:

Table 11.

Name	Type or model	Quantity	Overall dimensions, mm)	Total area m 2
1. Installation for grinding valves			560x440; 34 kWt
2. Break-in stand			750x800; 21 kWt
3. Trolley
4. Fire shield
5. Workbench 2-column
6. Workbench 1-column
7. Washing installation			1140x690; 3.1 kW
8. Cart with a set of tools
9. Stand for disassembly and assembly of internal combustion engines
10. Parts storage rack
11. Grinding machine			513x670; 2.1 kW
12. Drilling machine			500x280; 0.6 kW
			Mechanical, 10t
15. Suspended crane			450x260; 1t, 3.6 kW

1.2.2 Technological maps

For the most rational organization of work on maintenance, repair and diagnostics of cars, its units and systems, various flow charts are drawn up. Based on these flow charts, the scope of work for technical impacts is determined, and the distribution of work (operations) between the performers is also made.

Any technological map is a guideline for each contractor and, in addition, serves as a document for the technical control of the performance of maintenance or repair.

Technological maps for the performance of work in the engine compartment:

Table 12.

Technological map of assembly and disassembly of the LiAZ-5256 centrifugal oil filter

	The name of the operation	Executor	Place of work	Equipment and tools	Time rate
	Unscrew the nut securing the casing on the axle.	Auto-locksmith	Engine compartment	Spanner 13 mm
				Spanner 13 mm		Secure the rotor with the locking pins.
	Clamp the filter housing in a vice
	Unscrew the cap securing nut			Spanner 22 mm
	Remove the hood, strainer and insert					Clean hood and strainer
	Unscrew the nut securing the rotor on the axle			Spanner 22 mm
	Remove the thrust washer, guide sleeve and rotor assembly
	Remove the relief valve plug from the centrifuge housing.			Spanner 27 mm
	Remove the spring and valve					Defective parts, clean rotor
	Install the valve into the body					Combine the risk on the base of the rotor with the protruding mark on the outer part of the cap to ensure the balancing of the rotor (the mismatch of the marks is not more than 5 mm is allowed)
	Tighten the valve plugs			Spanner 27 mm
	Install the rotor with support bearings and flat washer
	Install the cap
	Tighten the rotor cover retaining nut			Spanner 22 mm		Tightening torque of rotor cap and outer cap nuts not more than 30 Nm
	Install the cover			Spanner 13 mm		Before installing the outer cap, check the correct assembly of the centrifuge by the ease of rotation of the rotor, for which squeeze the plate of the rotor stopper and turn the rotor on the axis, it should rotate easily, without jamming

Table 13.

Technological map of assembly and disassembly of the oil pump of the LiAZ-5256 engine

The name of the operation

Executor

Place of work

Equipment and tools

Time rate

Specifications and Notes

Remove the oil pump drive gear retaining nut

Car mechanic

Engine compartment

Spanner 27 mm

Unscrew the plug in the housing and secure the rotor against turning

Foot puller

The keyway must not be damaged.

Remove the bolts securing the radiator section housing

Spanner 13 mm

Remove the case

Remove the driven gear with the axle from the housing

Unscrew the driven gear with the axle from the housing

Spanner 24 mm

Remove valves with springs and washers

Valve springs must not be damaged

Unscrew the plug from the delivery section.

Spanner 24 mm

Remove the section relief valve

Remove the roller assembly with drive gears, steel spacer and driven gear

Unscrew the oil plugs of the delivery section

Defect parts. Clean oil channels

Tighten the oil channel plugs

Special hex key

Install a driven gear, a steel spacer, a roller with drive gears into the housing of the delivery section

Section gears must not be damaged.

Install a pressure relief valve

Close the valve plug

Spanner 24 mm

Install the safety valve and the valve of the lubrication system with springs in the housing of the radiator section

Tighten the valve plugs

Spanner 24 mm

Install the driven gear with the axle into the housing

Install the radiator section housing

Tighten the securing bolts of the section

Socket wrench 13 mm

1.3 Organizational part

1.3.1 Organization of the technological process of maintenance and repair

The choice of the method for organizing the technological process of maintenance and repair is made on the basis of calculating the shift program of the corresponding type of action. According to the NIIAT organization, it is advisable to organize maintenance by the flow method, if the shift program for maintenance is more than 5-6 services, and otherwise the method of universal or specialized posts is adopted.

The organization of the technological process of maintenance and current repair of cars is carried out according to the scheme: when returning from the line, the car passes through the control and technical point (KTP), where the duty mechanic conducts a visual inspection of the car (road train) and, if necessary, makes an application for TR in the established form. Then the car undergoes daily maintenance (EO) and, depending on the schedule of preventive work, arrives at the posts of general or element-by-item diagnostics (D-1 or D-2) through the waiting area for maintenance and current repairs or the car storage area.

TO (TR) begins with control and diagnostic work, which allows you to determine the technical condition of the car and a list of necessary adjustments. Evaluation parameters: engine power and fuel consumption, efficiency of transmission units and chassis, vehicle braking distance and noise level in mechanisms.

Mandatory work includes fastening work. When assessing the state of the fastener, its restoration and determination of the frequency of maintenance, the purpose and operating conditions are taken into account.

Repair and adjustment work is carried out as necessary in specialized areas or in the process of diagnostics.

Electrical work (about 11% of the total work) is carried out in order to eliminate malfunctions of the ignition system and current sources (battery, generator and relay-regulator).

Lubrication work during maintenance of vehicles reaches 30% of labor costs for maintenance. The main technological document is the lubrication chart.

Table 14.

1.3.2 Production control scheme using MCC

At present, at most ATP, operational management of production is carried out from one center, by one official. The production management department in the MCC system is headed by the production manager, to whom two groups are subordinate, as well as foremen, chiefs, and foremen of production sites. The main task of the information processing and analysis group is the systematization, processing, analysis and storage of information about the activities of all divisions of the technical service.

The chief engineer of the ATP manages production not only through the head of production, but also through the heads directly subordinate to him (head of the garage, supply department, technical department, department of OGM).

Operational management of the production of work at the posts of maintenance and repair of cars is carried out by the dispatcher. The dispatcher is responsible for organizing the execution of work at the posts in the shortest possible time, preparing the car for release, and efficiently using the production base. The dispatcher is subordinate to all those working at the posts, and in the absence of a production manager, the entire team is subordinate to him.The primary document for reporting and information support of the processes of current repair of rolling stock in the ATP is Repair sheet... In the event of a road failure (when the car fails on the line and is unable to return to the ATP on its own, as a result of which a call for technical assistance is required to tow it), a linear failure, when the transport process is interrupted and the car returns to the ATP on its own, or in the case of when, in the process of work on the line, the driver detects the onset of a pre-failure state of any unit or system, the car is finalized until the end of the shift and returns to the ATP, where the mechanic of the KTP with the driver's participation is drawn up Repair sheet to fulfill the TR. It contains: the car's garage number, model and body type codes, mileage since the beginning of operation, the date and time of registration are stamped and the external manifestations of malfunctions are described. Then the driver drives the car into the zone

UMR, where it takes part in a thorough washing of the chassis and transmission units of the car from below, after which it delivers the car to the waiting area for repair (ZOR). The ZOR on duty inspects the car, checks the quality of the car wash, the completeness (presence of mirrors, sidelights, etc.) and puts the ZOR stamp in a special column in the Repair sheet - "The car is washed, complete, accepted", his code and signature. After that, the car is considered accepted and the ITS ATP is responsible for its safety, and the transfer to the TP zone and from site to site is carried out by the drivers of the pre-production complex. The driver transfers the Repair Sheet with the ZOR stamp to the MCC, where the operator-technician checks the correctness of its execution and hands it over to the production dispatcher for making a decision.

The dispatcher examines the information contained in the Service Sheet and makes one of the following alternative solutions. If the external manifestations of malfunctions described in the Service Sheet are unambiguous, i.e. each of them corresponds to one possible malfunction and a certain repair and adjustment operation (PPO), the dispatcher of the TOC MCC:

· Gives instructions on the technical preparation of production;

· Plans the passage of the vehicle through specialized posts and sections of the TP complex in the Operational Shift Plan of the MCC;

· Instructs the driver to deliver the car to the work post;

Communicates through the means of communication to the performers from the specialized TP brigade the task of performing the necessary repair and adjustment operations

Operational and production management is carried out - TO and TP

vehicles by the personnel of the operational management department of the MCC ATP.

According to the established algorithm, the MCC operator-technician takes the completed Repair Sheet from the driver with the external manifestations of malfunctions entered into it, checks the correctness of the entry and encryption of the initial data on the vehicle and, if necessary, makes additions and corrections.

Table 8.

Block diagram of the algorithm for the formation of the control room and technological characteristics of the requirement.

Production control scheme using MCC

1.3.3 Quality management

Assembled units and devices of mechanisms and systems of the engine are run-in and tested at stands. During the running-in process, the running-in of the mating surfaces of the parts assembled with a gap occurs. The duration and test modes are established by the technical conditions for the maintenance, TR and KR of the car. Some assemblies and parts are subjected to dynamic and statistical balancing before assembly. Special attention during assembly, the mutual arrangement of parts is paid, which is controlled by appropriate tools, devices and fixtures. Jamming, knocking, increased noise and heating, oil leakage are not allowed in the mechanisms and systems of the engine.

For an objective assessment of the quality of the repair of units, devices are used with the help of which the power losses for friction, vibration, noise, heating, the total angular clearance of gears and other parameters are determined. The total angular clearance on the output shafts is set by an indicator or a hydraulic device. The change in the total angular clearance is used to judge the quality of the unit repair and the residual resource. Tests allow to establish the quality of repair and assembly of units, compliance of parameters with technical conditions, as well as readiness to work under operating conditions.

The normative quality indicators are established, and the actually obtained ones are identified and compared with the normative ones.

Timely documented recording of the facts and causes of malfunctioning and serviceability of vehicles, as well as performing repair and maintenance operations, includes: fixing the name of operations, the contractor, the name of the unit or vehicle unit being repaired, the type of service or repair; systematic accumulation of these data in special maps of the technical condition of the car. This allows for each repair operation to identify a specific culprit in the appearance of a failure (malfunction).

Scheme of quality management of TO and TR at ATP

1.4 Safety and industrial hygiene

1.4.1 General provisions on labor protection

Occupational Safety and Health. At a motor transport enterprise, measures must be taken that meet the requirements for labor protection, industrial sanitation, safety and environmental protection, adopted on vehicles, that meet the requirements of GOST.

Labor protection is understood as a system of legislative acts and the corresponding measures aimed at maintaining the health and working capacity of workers. The system of organizational technical measures and means of preventing industrial injuries is called safety precautions.

All employees, regardless of their work experience and qualifications, upon admission to work, must undergo initial briefing, then briefing at the workplace, and also once every 6 months undergo a second briefing, and persons performing work of increased danger (vulcanizer workers, welders, etc.) - 1 every 3 months. When re-instructing, the violations are analyzed in detail. Each briefing is recorded in a journal.

Initial briefing at the workplace is carried out before the start of independent work: with all newly recruited employees into the organization, including employees who perform work under the terms of an employment contract concluded for up to two months or for the period of seasonal work, in their free time from the main job (part-time ), as well as at home (homeworkers) using materials, tools and mechanisms provided by the employer or acquired by them at their own expense; with employees of the organization, transferred in accordance with the established procedure from another structural unit, or employees who are entrusted with the implementation of new work for them; with posted workers of third-party organizations, students of educational institutions of the corresponding levels, undergoing industrial practice (practical training), and other persons participating in the production activities of the organization.

Initial briefing at the workplace is carried out by the direct supervisor of work on programs developed and approved in accordance with the established procedure in accordance with the requirements of legislative and other regulatory legal acts on labor protection, local regulations of the organization, instructions on labor protection, technical and operational documentation.

All employees of the organization are re-instructed, regardless of their qualifications, work experience and education, with the exception of persons exempted from the initial briefing.

Briefing is carried out at least once every six months according to programs developed for initial training in the workplace.

Unscheduled instruction is carried out:

when new or amended legislative and other regulatory legal acts containing labor protection requirements, as well as instructions on labor protection;

when changing technological processes, replacing or modernizing equipment, fixtures, tools and other factors affecting labor safety;

in case of violation by employees of labor protection requirements, if these violations have created a real threat of the onset of grave consequences (industrial accident, accident, etc.);

at the request of officials of state supervision and control bodies;

during a break in work (for work with harmful and (or) dangerous conditions - more than 30 calendar days, and for other work - more than two months);

by the decision of the employer (or his authorized person).

Targeted briefing is carried out when performing one-time work, during the elimination of the consequences of accidents, natural disasters and work for which an admission work permit, permit or other special documents are issued, as well as during mass events in the organization.

All types of briefings, except for the introductory one, are conducted by the immediate supervisor (manufacturer) of the work (foreman, foreman, teacher, and so on), who has undergone training in labor protection in accordance with the established procedure and tested knowledge of labor protection requirements.

Conducting briefings on labor protection includes familiarizing employees with the existing hazardous and harmful production factors, studying the labor protection requirements contained in the organization's local regulations, labor protection instructions, technical, operational documentation, as well as the use of safe methods and techniques for performing work.

The briefing on labor protection is completed by verbal verification of the knowledge and skills acquired by the employee in safe working practices by the person who instructed.

1.4.2 Industrial sanitation and environmental protection

All workshops, sections, subdivisions at the ATP are equipped with supply and exhaust ventilation with heating (SN and P.2.04.05-86). Ventilation systems must always be in good condition and located in rooms separately from other rooms.

Optimal meteorological conditions for the working area of ​​the premises (the space to the place, above the floor level or the platform where the places of permanent residence of workers are located), taking into account the heat surplus, the severity of the work and the periods of the year, should be in accordance with SN 245-71 and GOST 12.1.005-76.

Lighting. Industrial lighting, depending on the light source used, are divided into 3 types, and according to their functional purpose, into 5 types. Depending on the light source: artificial, natural, and combined. Depending on the purpose: working; emergency; evacuation; security and duty.

The standards provide for the use of gas-discharge light sources. Use incandescent lamps only in cases of impossibility or technical and economic inexpediency of using gas-discharge light sources.

Industrial noise, ultrasound and vibration. Sources of noise at ATP: engines of various types, machine tools, compressors, ventilation systems, and so on. Ultrasound is emitted by installations for cleaning and washing parts, mechanical processing of fragile and hard materials. All these sources have a negative effect on the body and health of workers to combat noise, ultrasound and vibration, various solutions are used:

planning buildings in a special way, using anti-acoustic materials;

rationally place workers in their places and the movement of road transport at the ATP, and so on.

Measures to protect the environment, reduce the harmful effects of vehicles on the environment. Road transport, in addition to playing a huge role in modern world causes

many negative processes, consequences. Tons of exhaust gases are emitted into the atmosphere harmful substances that negatively affect human health, soil pollution, poisoning the flora and fauna.

Waste water, oils and industrial waste must be sorted and further processed. To do this, the ATP is used: mud ponds, oil-petrol catchers, as well as various treatment facilities.

To reduce the harmful effect of rolling stock on the environment, it is proposed to introduce the following measures in the garage of the projected enterprise:

timely and high-quality adjustment of the power supply system of engines and exhaust gases through the introduction of additional diagnostic equipment;

drain waste liquids, oils, acids into special containers for their subsequent disposal at special factories.

development of treatment facilities at the car wash post, providing a high degree of water purification, which will allow it to be sent back to the car wash;

landscaping the territory of the enterprise.

1.4.3 Safety and fire protection measures

Requirements for technological processes and equipment. Equipment, tools and fixtures must, throughout the entire service life, comply with the safety requirements and the correctness of measurement control in accordance with GOST 12.2.003-74 and GOST 12.2.027-80.

The equipment is installed on foundations and bolted. Dangerous places are fenced off. All control panels are grounded and neutralized. Start-up of new equipment is carried out only after its acceptance by a commission with the participation of workers of the labor protection service.

Organization of a car repair mechanic's workplace. A specific section of the production area, designed to perform a specific job and equipped with the appropriate tools, equipment, fixtures and materials is the workplace of a car repair mechanic.

A locksmith's workbench is the main type of equipment for a locksmith's workplace for performing manual work. The workbench must be stable and sturdy. The workbench should contain only the items needed to complete this task. The items that the worker uses most often are placed closer, and less often further. All items that have to be taken with both hands are placed directly in front of you.

If possible, avoid placing objects that require turns during work, and especially bending the body, as well as shifting objects from one hand to another.

Fixtures, materials and finished parts are located in special boxes located in the places designated for them. Measuring instruments are stored in special cases. Cutting tools (files, taps, drills, etc.) are stored on wooden supports (tablets).

After finishing work, the tools and devices used are cleaned of dirt, oil and wiped. The surface of the workbench is cleaned with a brush from shavings and debris.

All work required for maintenance or repairs of the car is allowed to be performed only at specially equipped posts, while the car must be reliably braked, the engine must be turned off and a sign "Do not start the engine - people work" is posted. A worker performing vehicle maintenance at a maintenance station must strictly comply with safety requirements:

Lifting and transporting equipment must be in good condition and used only for its intended purpose. Only trained and instructed persons are allowed to operate this equipment. When lifting and transporting large, heavy units and parts, do not stand under them. It is forbidden to remove, install and transport units and large parts with a rope or rope without special grips. Do not assemble and disassemble units and assemblies suspended on lifting mechanisms. Disassembly and assembly stands should be comfortable.

During operation, do not leave tools at the edge of the inspection ditch, on the steps, on the fenders or on the hood of the vehicle. During assembly work, it is forbidden to check the coincidence of the holes in the parts to be connected with your finger: for this, you must use special crowbars, barbs or mounting hooks.

During disassembly and assembly of units and assemblies, special pullers and keys should be used. When tightening the fastening nuts, you must use a serviceable tool. It is forbidden to unscrew and tighten nuts using large wrenches and placing metal plates between the edges of the nut and the wrench, lengthening the wrench handle by attaching another wrench or pipe.

Car braking systems must be tested on a test bench or on a special site outside, ensuring the safety of people and vehicles in the event of a brake failure.

Removal and installation of springs, shock absorbers, springs should be carried out after unloading them from the mass of the car after installing the tragus. Repair or replacement of the lifting mechanism cargo platform dump truck must be carried out after installing an additional stop under the platform. Pressing out bushings, bearings, removing other parts that require significant efforts should be done using presses or special pullers.

The danger of electric shock arises when using faulty hand-held electrified tools, in contact with electrical wiring or accidentally energized metal structures. You can work with any electrified tool with an operating voltage of over 42V only with rubber gloves and galoshes, or standing on an insulated surface, and you can only work with tools that have protective grounding. Do not hold an electrified tool with one hand on the wire. In rooms without increased danger, you can use portable lamps with a voltage of up to 42 V, and in especially dangerous rooms (damp, with conductive floors) no more than 12 V.

In all industrial premises the following firefighting measures:

smoke only in specially designated places; do not use open fire; store fuel and kerosene in quantities not exceeding the replacement requirement;

do not store empty containers from fuel and lubricants;

carry out a thorough cleaning at the end of each shift;

clean up spilled fuel and oil with sand;

used cleaning materials must be put into metal boxes with lids and taken out to a specially designated place at the end of the shift.

Fire extinguishers must be extinguished with foam or carbon dioxide fire extinguishers or sprayed water. If it is impossible to extinguish with water, the burning surface is covered with sand, or covered with special asbestos blankets.

2. Settlement and technological part

2.1 Initial data for design

For the convenience of performing calculations in this part of the diploma project, it is necessary to draw up a table "Technical characteristics of the car"

Table 4.

Mileage of cars.

Car model	The number of cars with mileage from the start of operation to overhaul in%				Total cars	Including				D r рп. days
	Up to 0.25 L KR	O.25.0.5 L KR	0.05-0.75 L KR			Not passed CD	Past CD
LiAZ-5256 KamAZ-5320 Gas-5312 Total:

Mileage standards to KR for LiAZ vehicles = 380,000 km

Average daily mileage of one car = 300 km.

Average annual mileage of one car = 75 300 km.

The company operates from 8:00 to 17:00, 5 days a week.

Number of days of work per year = 251

Working hours for drivers = 8.5 hours

2.2 Reduction of the park to the main model

For the convenience of calculations, we bring the park to the main model, for example, LiAZ-5256.

Reduction is performed by type of impact (EO, TO-1, TO-2 or TP - depending on the project topic) using the reduction factor. The essence of bringing a group of cars to the main model is to determine the coefficient of bringing a given car model to the main one, taken for calculation, i.e.

K pr =tNSL/ (t LNS),

where t pr, t are the estimated labor intensity of a TO unit (TO-1, TO-2), respectively, of the reduced and basic model, man-h; L, L pr - the calculated periodicity of this type of TO, respectively, for the main and reduced models, km.

The estimated labor intensity and frequency of maintenance is determined using the correction factors.

Number of cars shown,

A PR = A and. K pr

where A and - listed number of cars shown .

Then K pr EO for KAMAZ vehicles = tNSL/ (t LNS)

= 0.64x300 / 1.76x300 = 0.36, and for GAZ = 0.5x300 / 1.76x300 = 0.28;

K pr TO-1 for KAMAZ vehicles = tNSL/ (t 1 LNS) = 1.9x4000 / 7.5x3000 = 0.34, and for GAZ = 2.0x4000 / 7.5x3000 = 0.8;

K pr TO-2 for KAMAZ vehicles = tNSL/ (t 2 LNS) = 9.08x16000 / 31.5x12000

= 0,39, and for GAZ cars = 12.0x16000 / 31.5x12000 = 0.51.

When performing current repair projects (TP zone, repair departments, etc.), the reduction factor is calculated using the formula:

K pr = t TPpr / t TP,

where t ТРпр, t ТР is the estimated labor intensity of the ТР per 1000 km, respectively, for the main and reduced models, man-h,

then K pr TR for KAMAZ vehicles = 4,2/6,8=0,62, but for cars GAS = 3,5/6,8=0,51.

2.3 Selection and correction of maintenance and repair standards

For the convenience of scheduling maintenance and repairs and subsequent calculations, the mileage values ​​between individual types of maintenance and repairs should be adjusted with the average daily mileage. The frequency of the EO (L EO) is usually equal to the average daily mileage (L cc). The frequency of TO-1 (L 1) and TO-2 (L 2) is set for the 1st KUE, therefore, when operating the rolling stock in the II KUE, in cold and moderately cold climates, it is necessary to adjust the frequency of TO-1 and TO- 2 for these conditions. The adjustment consists in the selection of numerical values ​​of the frequency of mileage in kilometers for each type of maintenance and repair, multiples of each other and the average daily mileage and close in magnitude to the established standards.

The adjusted frequencies can be as follows:

L EO = L cc = 300 km;

L 1 = 4000 x K 1 x K 3 = 4000 x 0.8 x 0.9 = 2880 km;

L 2 = 16000 x K 3 x K 4 = 16000 x 0.8 x 1 = 12800 km;

Since at a given frequency and average daily mileage, these periodicities are not multiples of each other, it is necessary to correct them for the average daily mileage. For TO-1 it will be 2880/300 = 9.6 = 10 then the adjusted periodicities of TO-1 and TO-2 will be:

L 1 = 3000 km;

L 2 = 12900 km.

For example, the overhaul mileage of a LiAZ car operated in category I of operating conditions, taking into account the increased durability of the car, is 380,000 km. The mileage standard for the II category is reduced by 20% and will be 304,000 km.

Table 5.

Estimated intervals of maintenance and repair

Car model	Type of TO, KR	Periodicity
		Estimated	Adopted

Selection and correction of the normative labor intensity of TO. The labor intensity of one cleaning and washing action is equal to:

t EO = t norms EO K 2 K 5 K m man-hour

where t EO norms is the standard labor intensity of one harvesting effect, man-h (1.76);

K 2 - coefficient of standard correction depending on the modification of the rolling stock and the organization of its work (1,2)

K 5 - coefficient of correction of labor intensity of maintenance depending on the number of technologically compatible groups of rolling stock. (1)

K m man-hour - the coefficient of mechanization, which reduces the labor intensity EO =

- (C M + C O) / 100,

where C M -% labor intensity due to the use of a washing installation, taken as 50%;

C O -% reduction in labor intensity by replacing cleaning work with air blowing, taken 15%;

K m person-hour = 100 - (50 + 15): 100 = 0.35;

t EO = 1.76.1.2.1 .0.35 = 0.74 man-hours.

The complexity of TO-1 is equal to:

t TO-1 = t norms TO-1 K 2 K 5, where t norms TO-1 - one-time standard labor intensity of one TO, man-h (7.5);

K 2 - coefficient of standard adjustment depending on the modification of the rolling stock and the organization of its work (1,2);

t TO-1 = 7.5 .1, 2.1 = 9 man-hours.

The complexity of TO-2 is equal to:

t TO-2 = t norms TO-2 K 2 K 5, where t norms TO-2 is a one-time standard labor intensity of one TO, man-h (15);

K 2 - the coefficient of standard correction depending on the modification of the rolling stock and the organization of its work (1,2);

K 5 - coefficient of correction of the labor intensity of maintenance, depending on the number of technologically compatible groups of rolling stock (1);

t TO-2 = 31.5.1.2.1 = 37.8 man-hours.

Labor intensity of СО:

t CO = t TO-2. P N / 100,

where P N is the percentage of CO, depending on climatic conditions (for areas with a cold climate, 30% is taken).

t CO = 37.8.30: 100 = 37.8.0.3 = 11.34 man-hours.

Labor intensity of general and element-by-element diagnostics: the corrected labor intensity of TO-1 and TO-2 is multiplied by the corresponding share of work on D-1 and D-2, t D-1 = t TO-1.

S D - 1/100 people. - h,

where C D-1 -% of diagnostic work performed during TO-1 (10%);

t D-1 = 9.0.1 = 0.9 pers. - h.

t D-2 = t TO-2. With D - 1/100 people. - h,

where C D-2 -% of diagnostic work performed during TO-2 (10%);

t D-2 = 37.8 .0, 1 = 3.78 people. - h.

Table 6.

Estimated labor intensity of maintenance

Car model		Labor intensity
		Estimated	Adjusted

Selection and adjustment of the standard labor intensity of the current repair. Specific normative adjusted labor intensity of current repair is determined by the formula:

t TP = t norm tr K 1 K 2 K 3 K 4av K 5

where t norms tr is the standard specific labor intensity of the TR, people. - h / 1000 km. (6.8);

K 4ср - coefficient of correction of norms of specific labor intensity ТР = 0.7;

t TP = 6.8.0.8.1.2.0.8.0.7.1 = 3.66;

Table 7.

Estimated labor input of TR

Car model						Labor intensity
						Regulatory	Estimated

2.4 Determination of the annual mileage of the fleet

The fleet's annual mileage is calculated using the formula:

Lr =AandaTIss drg,

LG = Aand.aT . Iss. Drg. K e = 48 .0, 89.300 .3 05.0.96. = 37 52,524.8 km

where Aand - number of serviced cars, PCS;

aT - park technical readiness coefficient;

Iss - average daily mileage of one car, km;

Drg - the number of days of car operation per year , days;

To e - coefficient taking into account the idle time of the rolling stock

operational reasons, K = 0.95.0.97;

We determine the coefficient of technical readiness for the "cycle", ie. time

work of cars before the Kyrgyz Republic:

aT1= D ets / D ets + D rem. c, = 0,89

where D ets - the number of days of car operation for a "cycle", days;

D rem. c, - the number of days of vehicle downtime in TR and KR for a "cycle" days

The number of days of car downtime for repairs for a "cycle":

D rem. q = D cr +dTO and TRLKR/ 1000 K 4 = 12 + 0.3 .3 04000 / 1000.0.7 = 130.3 days.

where D KR - the number of days of car downtime in the Kyrgyz Republic, day (12).

dTO and TR, - the number of days the vehicle is idle in MOT and TR, days / 1000 km (0.3);

K 4 - downtime factor for maintenance and repair, taking into account mileage

car from the beginning of operation (0.7);

Lcr - mileage of the car to the Kyrgyz Republic , km (304000).

The number of days of car operation for a "cycle":

D ets= Lcr: Iss = 304000/300 = 1013.33 days = 1013 days

2.5 Calculation of the annual production program for maintenance and repair

Annual production program for maintenance and repair in numerical terms... For the calculation, you need to know what planned technical impacts are organized at the enterprise (KR, EO, TO-1, TO-2, SO auto

beats). To calculate the annual program, you need to know the annual mileage and the frequency of planned technical interventions. Frequencies are accepted for 1 category of operating conditions and are adjusted taking into account the specified operating conditions.

KR number: N cr = L G / L c p cr

L c p cr - the weighted average value of the run to the KR;

L c p cr = L cr (1 - 0.2. A KR / Ass),

where L cr is the corrected value of the mileage to KR (304000);

And ss is the list of cars at the ATP (48);

A cr - the number of cars that have passed the KR, taken 15% of A cc, = 3.2 = 3;

Ncr = LG / L cRcr= 37 52524,8 /296250 = 12,67 = 13

Annual production program for TO-2, TO-1, EO, CO:

N GTO-2 = LG: L nTO-2= 37 52524,8/12900=290,89=291

N GTO-1 = LG: L nTO-1= 37 52524,8 /3000= 1250,84=1551

N GEO = LG: L nEO= 37 52524,8 /300=12508,42=12508

N GCO= 2 A u = 2.48 = 96;

Taking into account the separation into an independent type of work D-2.1, the annual program for D-2.1 will be:

N GD 2= 1,2. NTO-2= 1,2.79 =94,8=95;

N GD-1= 1,1. NTO-1= 1,1.1251 =1376,1 =1376.

For calculating the annual volume of work, you need to know the annual program and specific labor intensity. Specific labor intensity is taken according to the 1st category and is adjusted taking into account the specified operating conditions.

EO labor intensity: T G EO= N GEO. t n EO = 12508 .1 ,76 =22014,08 people h;

Labor intensity TO-1: T G TO-1= t n TO-1 . N GTO-1+ T ref (1) = 7.5.1251 + 1688.85 = 11071.35 people. h;

T ref (1) - labor intensity of accompanying repairs during TO-1;

T ref (1) = C tr. T TO-1. N GTO-1= 0,15 .9 .1251 = 1688.85 people h

Labor intensity TO-2: T G TO-2= t n TO-2N GTO-2+ T ref (2) = 31.5.2910 + 21999.6 = 113.664.6 people. h;

where tn TO-2 - standard specific labor intensity TO-2, people h;

T ref (2) - labor intensity of accompanying repairs during TO-2;

T ref (2) = C tr. tTO-2. N GTO-2= 0,2.3 7,8 .2 910 = 21999.6 people h

Labor intensity of seasonal service (CO):

T CO = t CON GCO= 11.34 .9 6 = 1088.64 people h

The complexity of the general diagnosis D-1:

T D-1 =t D-1N GD-1= 0.9.1376 = 1238, people h;

Labor intensity of D-2 in-depth diagnostics:

T D-2 =t D 2N GD 2= 3.78.95 = 359.1 people h

Annual labor intensity of all types of maintenance:

∑Т TO= T g EO + T g TO-1 + T g TO-2 + T g CO + T D-1 + T D-2 = 22014,08 +11071,35+ 113664,6 + 1088,64+ 1238+ 359,1 = 149435.77 people. h.

Annual production program for TR . The annual volume of work on current repair is determined by the formula:

T TR= LG/1000. t TR= 37 52524,8/1000.3 ,66 = 1025.28 people h;

where t TR - specific labor intensity of TR, people / 1000 km

Table 8.

Annual production program for maintenance and repair

Indicators	Symbols	Numerical values
Number of EO
Number TO-1
Number TO-2
CO quantity
Number of CDs
Number of diagnostic Impacts D-1
Number of diagnostic Impacts D-2
Annual volume of work on SW, people h.
Annual volume of work on TO-1, people h.
Annual volume of work on TO-2, people h.
Annual volume of work on CRM, people h.
Annual volume of work on D-1, people h.
Annual volume of work on D-2, people h.
Annual volume of work on TR, people h.

In addition to maintenance and repair work, the enterprise must be organized

self-service work, which according to the "Regulations on maintenance and repair of rolling stock" make up 20 - 30% of the total volume of work on maintenance and repair of vehicles.

Depending on the capacity of the enterprise, the share of work is accepted To sun at the enterprise, the total amount of work will be:

T ATP = ∑T TO + T TR. K 4 = 149435.77 + 1025.28 .1 = 150461.05 people h.

The scope of self-service work at the enterprise will be:

T pop=T ATP K vsp= 150461.05 .0.25 = 37615.2625 people. h.

T ATPtot. = T ATP + T pop = 150461.05 +37615.2625 = 188076.3125 people hour

Table 9.

Distribution of enterprise self-service work

Type of work		Place of execution
1. Works on self-service ATP, including: electrotechnical mechanical locksmith welding tin copper pipeline blacksmith repair construction and woodworking	24 10 16 4 4 1 22 2 16	Chief Mechanic's Department (OGM) Locksmith and Mechanical Shop OGM Welding Shop Reinforcement and Tinsmith Shop Copper Shop OGM Forging and Spring Shop OGM
2. Transport
3. Driving cars
4. Acceptance, storage and delivery of material values
5. Cleaning of premises and territory

2.6 Determination of the annual scope of work of the projected site

In this subsection of the diploma project, it is necessary to make a technological calculation of the workshop (site, zone), which consists in establishing the most rational method for organizing the technological process of maintenance and repair, determining the number of posts and lines of maintenance and repair, and calculating the area of ​​premises.

The choice of the method of organizing the maintenance and repair of cars. More than 50% of the scope of maintenance and repair work is carried out at posts. The number of posts determines the choice of the planning solution of the enterprise and depends on the type, program and labor intensity of work, the method of organizing maintenance and repair and diagnostics of vehicles, the operating mode of production zones.

The expediency of using one or another method of organizing maintenance is mainly determined by the number of posts, i.e. depends on the daily (shift) program and the duration of exposure. Therefore, as the main criterion for choosing a maintenance method, a daily (shift) production program of the corresponding type of maintenance can serve.

The operating mode of the TO and TR zones. The working hours of the zone must be coordinated with the schedule of departure and return of vehicles from the line.

The mode is characterized by the number of working days per year, the duration of work (the number of work shifts, the duration and time of the beginning and end of the shift), the distribution of the production program according to the time of its execution. The number of working days of the zone depends on the number of days of operation of the rolling stock on the line and the type of maintenance. The duration of the operation of the zones is determined by the daily production program and the time during which a given type of maintenance and repair can be performed.

TO-2 is performed in one or two shifts. The daily regime of the TR zone is two, and sometimes three work shifts, of which all production-auxiliary sections and TR posts work in one (usually day) shift. In the rest of the work shifts, checkpoint work is carried out by the TR, identified during maintenance, diagnostics or at the request of the driver.

Since the maintenance and repair of the lubrication system of cars is performed in the engine compartment (section), then we determine the labor intensity of this department for current repairs will be:

T tr. motor. dep. = T tr. With motor. = 1025,28 .0 ,25 =25632 person-hour,

where C is the share of work coming to the unit shop is 0.2

Determine the complexity of TO-1, TO-2 and CO

T to-1. city ​​dep. =tthen1. With motor = 11071,35.0,25 =2767,84 person-hour;

T to-2. city ​​dep. =tthen2. With motor. = 113664,6.0,25 =28416,15 person-hour.

The total amount of work on maintenance and repair of the department is determined by summing the values ​​\ u200b \ u200bof labor intensity:

T. g. Dep = T tr. motor. det + T to-1. city ​​dep. + T to-2. city ​​dep. = 25632 +2767,84 +28416,15 = 56815.99 man-hour.

2.7 Determining the number of manufacturing jobs

Production workers include workers in various zones and sections who directly carry out work on the T O and TR of the rolling stock. With this calculation, the technologically necessary (attendance) and staff (payroll) number of workers are distinguished:

P i = T i / F R. M.

where T i = 3604.57 - annual labor intensity of the forging and spring department, man-h;

Annual production fund of the workplace for one-shift work, h.

The annual production fund of the worker's time is determined by the calculation:

where is the duration of the work shift, h;

The number of calendar days in a year;

D B = 103 - the number of days off per year;

Holidays per year;

D PP = 8 - the number of pre-holiday days in a year;

The hour to shorten the working day before the holidays.

Let's calculate the annual production fund of the worker's time,

F RM = 8.0. (365 - 103 - 11) - 1.7 = 8.251 - 8 = 2000

Let's calculate the technologically necessary number of workers of the forging and spring department of the ATP;

P i = 3604,57/2000 = 1,8 ≈ 2 [ human] .

The nominal number of working areas of TO and TR ATP is determined by the formula;

,

where T i is the total labor intensity of the maintenance and repair of the ATP,

Annual time fund of one production worker in one-shift work, h.

The accepted average number of workers at one post, for the TO-1 zone (4 - TO-2);

The utilization rate of the working time of the post for an individual post;

Knowing the formula, we will determine the total number of posts for the TO and TR zone;

NSi = 19488,05 .1, 1/251 .2.8.2.0, 98 = 21436.855 / 7871.36 = 2.72 = 3 [post]

Depending on the number of posts for a given type of maintenance and the level of their specialization in the maintenance of vehicles, the method of universal and the method of specialized posts is acceptable. Posts with any method can be dead-end or travel (direct-flow).

2.8 Calculation of the area of ​​the projected site (zone)

According to their functional purpose, ATP areas are divided into three main groups: production and storage, storage of rolling stock and auxiliary.

The structure of the production and warehouse premises includes the zones of maintenance and repair, production areas of the TR, warehouses, technical rooms of energy and sanitary services and devices (compressor, transformer, pumping, ventilation chambers, etc.).

The areas of the TO and TR zones are calculated by the formula:

F 3 = f a x 3 k n

where f a - the area occupied by the car in the plan (in terms of overall dimensions), m 2;

x 3 - number of passes; k - coefficient of density of arrangement of posts, depending on the overall dimensions of the vehicle and the location of posts.

The areas of sites (workshops, departments) are calculated by the area of ​​the room occupied by the equipment and the density coefficient of its arrangement. Then we calculate the area of ​​the department using the formula:

F dep = f sum. K pl,

where f is the total area of ​​the horizontal projection in terms of the overall dimensions of the equipment, m 2, K pl is the density coefficient of the arrangement of equipment for the forging and spring department has a value of 4.5 - 5.5.

Table 10.

Density factor of installed equipment

Based on the choice of the appropriate equipment and production calculations, the layout of each site is developed, while the minimum area of ​​the premises per worker must be taken into account at least 4.5 m 2.

Total:

F dep = f sum. K pl = 9.2731 .4, 5 = 41.728 m 2,

We accept the size of the department, according to the size of the selected room, equal to 6 x 9 meters. Then the area will be 54 m 2.

3. The economic part

3.1 Payroll

Wages are calculated based on the tariffs established at the enterprise, piece rates, salaries and information on the time actually worked by employees or information on the volume of products produced. Payroll is calculated based on documents such as staffing, pay clauses, hiring orders and employment contracts. These documents establish the size and form of remuneration for a particular employee. The wage fund consists of the main fund, the supplementary fund and the social insurance fund.

The repair shop employs 2 people. The work is carried out in one shift. Shift - 12h. Workers have III and IV respectively. We find the average hourly rate of a worker according to the formula C h = C months / 166.3, where C h is the minimum monthly wage rate of workers of the 1st category established by the Industry Agreement on road transport, 166.3 is the average monthly working time, hours. The minimum wage in Irkutsk region is 5205 rubles, then

C H = 5205 / 166.3 = 31.3 rubles per hour for an employee of the 1st category.,

then, according to the condition, having employees of the III and IV categories, the hourly tariff rates will be found according to the following formula:

C h = C month / 166.3 * K tar.,

K tar - tariff coefficient (for reference).

Respectively:

From h III time. = C month / 166.3 * K tar. = 31.3 * 1.2 = 37.6 rubles. h

From h IV time. = C month / 166.3 * K tar. = 31.3 * 1.35 = 42.3 rubles. h.

We find the wages fund of repair workers of the III and IV categories.

Considering that the northern coefficient and the northern allowance are taken into account when calculating wages, the payroll will be found according to the following formula:

FZP I. = C h I times + (C / H + R / K) * Q,

where FZP I. - wages fund of the employee of the 1st category; From the 1st time - the hourly wage rate of the worker; С / Н * Р / К - northern allowance and regional coefficient, respectively; Q is the number of working hours per year. (166, 3 * 11) - 11-the number of working months in a year.

Thus, the wage funds, taking into account the annual volume of working hours 1760), workers of the III and IV categories will be equal:

FZP III P = (37.6 * 1760) + 60% = 105881.6;

FZP IV P = (42.3 * 1760) + 60% = 119116.8.

Table 18.

Tariff coefficient, rates

3.2 Payroll taxes and contributions

Given that the worker is obliged to pay personal income tax (monthly), the rate of which is 13%, the workers' wage funds will be:

FZP III P = 105881.6-13% = 92117 rubles.

FZP IV P = 119116.8-13% = 90396.4 rubles.

FZP total = 92117 + 90396.4 = 182513.4

Contributions to the Pension Fund will be 23726,7 rub.

3.3 Calculation of the cost of performing work in the department

Maintenance includes the following types of work: cleaning and washing, control and diagnostic, fastening, lubrication, filling, adjusting, electrical and other work, performed, as a rule, without disassembling the units and removing individual components and mechanisms from the car. If during maintenance it is impossible to make sure that individual units are in full serviceability, then they should be removed from the car for control on special stands and devices.

According to the frequency, list and labor intensity of the work performed, maintenance according to the current Regulation is divided into the following types: daily (EO), first (TO-1), second (TO-2) and seasonal (CO) maintenance.

We find the cost of materials for TO-2, TO-1, EO:

Material costs are calculated using the following formulas:

On TO - 2, rub .: M to-2 = H to - 2 * N to-2;

2. On TO - 1, rub .: M to-1 = H to - 1 * N to-1;

On EO, rub .: М ео = Н ео * N ео;

On TR, rubles: M tr = H tr * L rev / 1000;

5.M to-2 + M to-1 + M eo + M tr., Where

M to-2, M to-1, M eo, M tr - the cost of materials for TO - 2, TO - 1, EO, TR, respectively;

N to - 2, N to - 1, N eo, is the rate of costs for materials per impact (for reference). N tr - the norm of the cost of materials for TR per 1000 km of run, rubles.

The rates are set in accordance with the governing documents, taking into account a correction factor that takes into account the rise in prices.

Spare parts costs for routine repairs

6. ZCh tr = H tr. zch * L rev / 1000., where ZCh tr - the cost of spare parts

Taking into account the fact that the car has L about - 43,000 km of run per year and taking into account the fact that the frequency of maintenance is 2 after 11,000 km., Maintenance is 1 after 2600, then

N then-2 = 4; N then-1 = 16; N eo = 287;

H then - 2 = 143 rubles.; H then - 1 = 101 rubles.; H eo = 45 rubles.; H tr = 525 rubles. (for reference, taking into account inflation)

M TO-2 = 4 * 143 = 572 rubles.

2.M TO-1 = 16 * 101 = 1616 rubles.

M EO = 45 * 287 = 12,915 rubles.

M tr = 525 * 43000/1000 = 22,575 rubles.

The total cost of materials for TO - 2, TO - 1, EO, TR per year will be:

5. =572+1616+12915+22575=37678 rub.

The cost of spare parts per year will be:

ZCh tr = 4500 * 43000/1000 = 193500 rub.

The cost of fixed assets for depreciation is determined as a percentage of the cost of rolling stock or the cost of equipment required for the repair and maintenance of a car. In our case, it is necessary to find the amount of depreciation of the equipment used for maintenance and repair of the ZIL 130 brake system.

The initial cost of a piece of equipment is found by the formula:

From the lane. = D rev. * To access.,

where C rev. - equipment price, rub., To delivery. - delivery rate; accept 1.05 (according to the methodological letter).

Table 1.

List and cost of equipment required for transmission repair

Let's find the initial cost of the equipment:

From the lane. = D rev. * To access. = 370649 * 1.05 = 389181,5 rub.

Depreciation of fixed assets serving the process of maintenance and repair, rubles:

A opf = C lane. * H a / 100,

where H a is the average depreciation rate of equipment serving the process of maintenance and repair,% (take 10%).

A opf = 389181.5. * 10/100 = 38918,2 rub.

Let's find the total cost of one repair on average, rubles.

where З to- i is the amount of all maintenance costs, N i is the number of TO-1, TO-2, TR, EO.

S = (FZP total + Z m + Z zp + A opf) / N i = (38918.2 + 37678 + 193500 + 182513.4) / 307 = 1474 rubles. for repairs.

Table 2.

Costing

Conclusion

When training specialists for the maintenance and repair of cars, the main attention is paid to the study of changes in the technical condition of cars during operation, the reasons and patterns of these changes, as well as assessments of their impact on the reliability and performance of cars.

In the course of the development of this diploma project, issues were considered on the organization of the forging and spring department. To do this, I chose the necessary standards, chose and justified the initial data: KEU, the composition of the fleet, the operating mode and other data, the choice of which influenced the results of all my calculations. Then he determined the values ​​of the frequency and labor intensity of all services, the number of production workers required, and developed flow charts.

In the organizational part of the project, I chose the method of organizing production, selected the premises, the necessary equipment for the unit department, and calculated the area of ​​the department. He took into account that the growth of production labor depends on the conditions of mechanization and automation. In order to avoid injuries and preserve the health of workers, he provided for labor protection rules. Further, taking into account the importance of work on labor protection, he established industrial hazards, fire safety, electrical safety, environmental protection. He also completed the design of the aggregate department.

The work carried out allows you to improve work, reduce the cost of maintenance and repair of cars in a motor transport company.

Literature

1. Bednarsky V.V. Maintenance and repair of cars: textbook - 2nd edition - Rostov n / a: Phoenix, 2005.

Vlasov V.M., Zhankaziev S.V, Kruglov S.M., et al. Maintenance and repair of cars: a textbook for students of vocational education, - Moscow: Publishing Center "Academy", 2008.

G.V. Kramarenko Technical operation of the car: a textbook for students specializing in road transport of higher educational institutions, - Moscow: "Transport" 1979.

Rumyantsev S.I. Car repair: a tutorial, - Moscow "Transport" 1988.

B.A. Titunin Repair of KAMAZ vehicles: a tutorial, - Moscow "Agropromizdat" 1998.

Turevsky I.S. Diploma design of motor transport enterprises: textbook, - M: ID "FORUM"; INRA-M, 2012.

Chumachenko Yu.T., Chumachenko G.V., Fimova A.V. Operation of automobiles and labor protection in transport: textbook, - Rostov - on - Don: "Phoenix", 2001.

Appendix 2

Scheme of the technological process of maintenance and repair of a unit (unit)

Appendix 3

Layout

Departments (workshops) and workplaces of mechanics for repairing engines