Technological process of car ATP. Organization of the technological process of maintenance. Development of technological processes of maintenance and repair of machines

Organization of the technological process of the EO, then diagnosis

The technological process of EO, D-1, D-2, TO-1, TO-2 can be performed on universal and specialized posts.

When organizing service at universal postsall the works of this one are performed in one post by a group of performers, which includes workers of all specialties (locksmiths, lubricants, electricians, etc.) or workers of universal. Each worker performs its part of the work in a certain sequence. Universal posts may be dead-end and travel (for road trains).

TP organization on specialized postsit lies in the division of the work of this one and the distribution of it in several posts. At the same time, performers and equipment specialize in a specific form of work.

TP organization on specialized posts is divided into power methodand operationable

With flowing methods, specialized posts are located one by one in the direction of the car movement.

With an operating station, the specialized posts are arranged in parallel. Each post is enshrined a certain group of works or operations.

Figure 10 - Process Process EO

Figure 11 - organization of the technological process

Figure 12 - Process Process D-1

The technological process of D-2 is developed in accordance with the diagnostic work with the type and brand of the car.

Organization of technological processes Tr

The technological process of current repairs is performed on posts (universal, specialized or special) and in the shops.

At universal posts (UE)artists (1-2 people) produce a replacement or repair without removing any failed aggregates, nodes and elements of the car design. For Equipment UP, see Appendix A.

On specialized (SPP) and special (joint ventures) postsa replacement of one or more units or any one type of work is performed. Posts specialize in aggregates or systems. For various NGN equipment, see Appendix A.

In the workshops, work is performed on the repair of aggregates, nodes and systems of the car.

Figure 13 - Process Process Process Zone Tr

Figure 14- diagram of the technological process of motor and aggregate workshops

Figure15 - Technological Process Scheme Tire Ship

Figure 16 - Scheme of the technological process of the vulcanization shop

Figure 17 - Scheme of the technological process of fuel equipment repair shop

Fig 18. - scheme of the technological process of the electrical workshop

Figure 19-diagram of the technological process of the battery workshop.

Figure 20- diagram of the process of the painting shop

Choosing equipment

The list of equipment necessary to perform technological processes is given in Appendix B. The choice of equipment model is carried out according to "catalogs ...", specialized journals and on the Internet. Data on selected equipment is recorded in Table 1.

Table 1 - Statement of Technological Equipment Zone (shop)

10.1. The concept of technological process

Data on the reliability of cars systematized in the form of relevant recommendations (system of both repair, species and repair, standards of periodicity of the resource of aggregates, lists of operations and repair, etc.) determine what needs to be done to ensure the performance of cars. These technical effects can be performed in various ways (sequence, equipment, personnel, etc.), i.e. Applying the appropriate technology that establishes how it is necessary to provide the necessary level of technical condition for maintenance and repair.

In general, technology (from Greek. Τεχνοσ - art, skill, skill + λογοσ - the concept, teaching, science, knowledge of knowledge) is a set of knowledge about ways and means of change or ensure the specified states, shapes, properties or position of the object of exposure.

With reference to the technical operation of cars, the purpose of the technology is to provide a given level of the working capacity of the car or the park in the most efficient ways.

Technological process – This is a certain set of impacts rendered by a systematic and consistently in time and space to a specific object. In technological processes, the repair objects (car, unit, system, node, part, compound or material), place, content, sequence, and result of the impacts conducted, their labor intensity, equipment requirements, personnel qualifications and working conditions are determined.

The combination of technological processes is the production process of the enterprise. Optimization of technological processes allows for specific production conditions to determine the best sequence of performance, providing high labor productivity, maximum safety of parts, cost-effective choice of mechanization and diagnostics.

The completed part of the technological process performed by one or more performers in one workplace is called a technological operation. (more often - operation).

Part of the operation, which is characterized by the invariance of equipment or tools, is called the transition . Process transitions can be dissected on movements artist. The combination of these movements is a technological method.

To perform technological processes, technological equipment, equipment, tool are needed.

Technological equipment – These are the manufacturers of production and repair of cars used in the performance of work from the beginning to the end of the technological process. The equipment is divided into a specialized, manufactured directly for the purposes of technical operation of cars (washing machines, lifts, diagnostic devices, lubricating devices, etc.), and general purpose (metal-cutting and woodworking machines, presses, crane-beams, etc.).

By appointment, the technological equipment is divided into lifting and inspection, lifting-transport, specialized for the specialized for Tr.

The first group includes equipment and devices that provide convenient access to aggregates, mechanisms and details located below and from the side of the car. Here includes inspection ditch, overpass, lifts, tippers, garage jacks.

The second group includes equipment for lifting and moving units, knots and car mechanisms. These are mobile cranes, electrothels, crane beams, cargo trolleys and conveyors.

The third group is an equipment designed to perform specific technological operations that: cleaning and washing, fastening, lubricants, diagnostic, adjustment, filling.

The fourth group is an equipment designed to perform technological operations of TR: discernment and assembly, mechanical and mechanical, electrical, body, welding, medical, tire fitting, vulcanization, etc.

Technological equipment - Tools and means of production added to technological equipment to perform a specific part of the process.

10.2. Car as an object of labor with technical

maintenance and repair

The initial base in the design of technological processes is information on a car as an object of influences at a repair, including features and specifics of its operation (modes of operation on line, restrictions on duration and repair, equipment, etc.).

The car is a complex object of labor, and work performed on it during maintenance and repair is not always compatible; They can be performed in various manufacturing units of automotive transportation using performers of various specialty and qualifications. Therefore, the car as any product has the property of technological, which is very important to ensure its workable state in the process of repair.

Technologicalness - the compliance of the product with the requirements of production and operation. The manufacturability is ensured at the stage of development of the car's design and should provide simplicity of layout, perfection of forms, convenience and minimal laboriousness at the same repair.

The laboriousness of the technological process is an indicator that characterizes the costs of working time to perform an element of work (operation, transition, etc.) or the entire technological process as a whole. The laboriousness of the performance of work on the repair of cars depends on both types (cars, cargo, buses) and the state of the car (mileage from the beginning of operation, operating conditions, features of the design) and from the perfection of the production and technical base (production area, equipment and equipment ) Enterprises and qualifications of personnel.

Depending on the type of rolling stock of works on cars performed in the process and repair, it is distributed unequal by type of technical influences in a motor transport enterprise (Fig. 10.1).

Fig.10.1 - Distribution of total labor intensity, and repair by vehicle vehicles,%: and - cargo and passenger cars; B - buses

The operations of technological processes and repair of cars are subdivided into the execution, from above, from below, in the cabin or cabin. The quantitative distribution of these works depends on the type of rolling stock (Fig. 10.2). For trucks, the number of works performed in the cab is significantly less than for passenger cars and buses in the body.

A number of factors affect the formation of technological processes (Fig. 10.3). These factors are primarily determined by the design of the car, the complexity and manufacturability of which establishes the requirements for industrial areas, technological equipment and equipment, staff, etc.

Fig. 10.2 - distribution of work at the place of implementation,%: and - passenger cars; b - trucks; in - buses

Fig. 10.3 - Factors affecting the design of technological processes and repair

10.3. Classification of technological processes

car maintenance and repair

The main signs of the classification and direction of improving technological processes of car repair are as follows:

1. On the target function. Share technological processes of maintaining and restoring car performance.

The technological process of maintaining performance is a complex of work that ensures the normal functioning of technically serviceable systems in order to maintain operational parameters within providing a given level of security, efficiency and aesthetics.

The technological process of restoring performance is a complex of work in order to eliminate a specific refusal or malfunction of the technical system in cases where any of the security, efficiency or aesthetic parameters does not correspond to the field of permissible values \u200b\u200bor reaches the limit value.

2. By the nature of the repair effects. Share technological processes of maintenance and repair.

Maintenance is a complex of operational operation of a car, including control and diagnostic, fastening and other works that do not regulate the deep subraction of the repair facility.

Repair - a set of operations to restore or maintain performance with the restoration of the product resource and includes a complex of dissemination and assembly work.

3. According to the method of organizing the technological process. Individual and aggregate repair methods.

With an individual repair method, the technological process is built in such a way that repaired aggregates, systems and nodes are not deleaded and installed after work on the same car.

The aggregate repair method is the repair method in which the faulty aggregates are replaced with new or pre-renovated. Under the unit is understood as an assembly unit, which has the property of complete interchangeability, independent assembly and self-fulfillment of a certain function in products of various purposes, for example, a motor, gearbox, pump, etc. Replacing the unit can be performed after refusal or by plan. The list of replaceable aggregates, the procedure for conducting replacements and instructions on the organization of repair is established by typical regulatory and technological documentation.

4. According to the degree of reference to the technological process to the basic rolling stock. Technological processes and repair of a family of cars based on the basic model and unified technological processes of car repair are independent of their brand. For example, technology is a typical technological process, and painting works are unified.

5. According to the degree of participation in the technological system as a whole, the technological processes of the main production, production preparation processes and auxiliary technological processes are distinguished.

The main technological processes are all processes regulating the direct impact on units and components of the car, providing its performance and safety.

Examples of auxiliary processes are cleaning and washing works, and the production preparation complex provides storage, storage, issuance and accounting of spare parts, tools, etc.

6. According to the degree of mechanization and automation of operations and repair. There are complexes of manual work, mechanized operations and automated technological processes.

Handworks are works performed using a set of standard tools and fixtures.

Mechanized operations are performed using standard garage equipment, such as a lift, a tire stand, etc.

Automated technological processes are carried out using, for example, automated diagnostic stands.

7. In terms of the safety of technological processes. There are technological processes that provide normal working conditions, traumatic, fire hazardous and electric harassment.

For example, it includes all complexes of dissemination and assembly works, fire hazardous - painting work, electric haraging - work in the battery workshop.

8. In terms of environmental safety. There are technological processes affecting the ecology of the soil, the water basin, the air pool. A characteristic example of a technological process affecting the ecology of the soil is a complex of lubricant work, water basin - cleaning and washing, air pool - rechargeable.

9. At the place of repair of the repair exposure. Technological processes are divided into post-work and shops.

10. According to the degree of specialization of posts and jobs - in the shops. Distinguish universal and specialized technological processes.

11. According to the method of organizing the movement of the car by post. Technological processes are allocated to provide work on deadlocks, travel posts and technological lines.

12. According to the method of organizing post work under the bottom of the body. The technological processes implemented on the dwarf posts and using lifts are distinguished.

10.4. Stages of development of technological processes

The source data for the development of technological processes and repair cars are:

1. Type of maintenance and repair.

2. Impact implementation object (car, unit, knot, detail).

3. Assembly drawing of a product that must contain all the necessary information for the design of TP:

• 
  projections and cuts that ensure fast and complete development of the design;
• 
  Specifications of all parts, nodes and assemblies included in the disassembled product;
• 
  Dimensions specifications that need to be observed when assembling or adjusting.

5. Production program (annual or daily), from the value of which depends on the degree of economically justified mechanization of operations.

6. Information about the applied equipment and tool.

7. Information on the reliability of product details, possible concomitant repairs.

8. The mass of the product or car to select lifting vehicles.

The technical condition (TU) is a regulatory and technical document establishing requirements for a specific product. It is an integral part of the requirements for the product and is most often set in the absence of technical standards. TU is the main legal document that characterizes the quality and repair in the delivery of work performed, the conclusion of contracts for services for both repair, as well as the presentation of complaints.

The sequence (algorithm) of the technological process is as follows:

• 
  The design of the product is studied,
• 
  A plan of work is drawn up,
• 
  The sequence of operation and transitions is determined,
• 
  Set the pace (tact) of the work of work,
• 
  Definitions of time to perform each operation,
• 
  Equipment, performers, fixtures and tools are selected,
• 
  Designed technological documentation .

The duration of the work of the technological process of a new time . The technical rate of time is the regulated time of the technological operation in certain organizational and technical conditions with one or more performers of relevant qualifications.

The rate of time is determined by analytical and research, analytical and consolidated integrated methods. The first method is based on the data obtained using a working day of a working day or timekeeping obtained in the workplace, the second - on the calculated data, taking into account the performance of the equipment. In road transport, the third method is most often used, in which the time standards are determined by the integrined complexes of work techniques. This rationing is based on the use of operating cards on typical operations previously disturbed by calculations and timing, followed by adjustment in relation to the new product design.

The sequence of performance of maintenance and repair works is reflected in the primary document TP - technological map. The card also indicates equipment, tools, devices used for each operation or transition; The qualifications of the performers, the rate of time for individual operations and transitions and on the entire technology as a whole.

Designing the technological process, it is necessary to consider possible options for working, providing for their time combination, place and performers, taking into account the equipment used. The correctly selected option allows you to build operations and transitions in such a sequence when it takes the minimum time spent when the quality of work is guaranteed.

When developing TP, it is necessary to take into account the volume of work performed and their repeatability to strive for the most fully and economically justified mechanization, the fullest reduction of the resource, energy and labor costs, alleviating manual labor.

The optimal version of the technological process is the maintenance of the following advantages:

• 
  high labor productivity and quality of work;
• 
  eliminate skipping or repetition of individual operations and transitions;
• 
  rationally use the means of mechanization;
• 
  Complete the desired organization and job development.

Jobs include basic and auxiliary manufacturing equipment, technological and organizational equipment, fixtures and tools. When organizing jobs, anthropometric data, achievements in the field of scientific organization of labor, advanced experience, recommendations of physiology, psychology and hygiene, labor protection, ergonomics, engineering psychology and technical aesthetics are taken into account.

Depending on the number of performers enshrined by the technological process for the workplace, workplaces are individual and collective.

The work post is a workplace on the square of which a car is installed or several cars, i.e. The work post is a type of workplace.

In road transport, jobs can be classified as follows:

• 
  by category of employees – workers, managers, specialists serving;
• 
  by profession – those. on the main working professions (auto show, diagnostic, electricians, batteryers, welders, etc.);
• 
  In terms of the type of production and repair (EO, T-1, TO-2, TR, etc.);
• 
  According to the degree of mechanization of operations performed – automatic, semi-automatic, machine, mechanized (machine-manual) and manual (non-mechanized) processes;
• 
  by placement in space – fixed and movable (route);
• 
  By alignment workers – individual and complex (brigadic);
• 
  By the number of served posts – one-bed and multipos;
• 
  by the number of shifts;
• 
  Under working conditions, normal, with severe physical labor, with harmful production conditions.

10.5. Registration of technological documentation

For the most rational organization of work, the repair and diagnosis of cars, its aggregates and systems are made up various technological maps. Based on the cards, the scope of work on technical influences is determined, and the work distribution (operation and transitions) between the performers is determined.

The most important law of production is the observance of technological discipline. The technological map is a guide for each performer and serves as a document for technical control of the work of maintenance and repair. In practice, you can meet the following types of technological maps:

• 
  for a specialized post (postpone map);
• 
  for car diagnostics (diagnostic card);
• 
  specialized turning link (brigades) workers when using the method of specialized posts at the enterprise;
• 
  Technological map for a certain type of work, Tr, diagnostics (operational card);
• 
  Technological card for a specific operation performed by one or more performers on one workplace (card for workplace).

The developers of technological documentation adopted typical technological maps to combine into a single document - a guide for or repairing a car of a certain model. At the same time, the technology of current repairs are divided into post-departments and workshop (precinct) works.

Typical technologies and guidelines for both R cars may include additional information that will be necessary when organizing technological processes on a motor transport enterprise. For example, this information includes a list of equipment, tools and devices for work; Data on possible accompanying repairs or need for spare parts. In addition, technological maps have illustrations in the form of drawings, drawings, schemes, etc.

All technology documentation is necessarily drawn up on sheets with a standard framework and the main inscription.

The first reliably well-known technological processes were developed in the ancient Sumer - on the clay table with clocks, the procedure for preparing beer was described on operations. Since then, ways to describe the technologies for the production of food, tools, homemade utensils, weapons and jewelry - all that mankind has manufactured, they have become more complicated and improved. The modern technological process may consist of dozens, hundreds and even thousands of individual operations, it can be multivariate and branch depending on the various conditions. The choice of this or that technology is not easy to choose from those or other machines, tools and snap. It is also necessary to ensure compliance with the requirements of technical conditions, planned and financial indicators.

Definition and characteristics

GOST gives scientifically strict, but formulated by too dry and thoroughly definition of the technological process. If we talk about the concept of technological process with a more understandable language, then the technological process is a combination of operations built in a certain order. It is aimed at turning raw materials and billets into the final products. For this, they make certain actions that are usually performed by mechanisms. The technological process does not exist in itself, but is the most important part of a more general, incorporating in general also the processes of contracting, procurement and logistics, sales, finance management, administrative management and quality control.

Technology at the enterprise occupy a very important position. They are a kind of intermediaries between designers who create the idea of \u200b\u200bthe product and producing its drawings and production to which these ideas and drawings in metal, wood, plastics and other materials have to be implemented. When developing a technical process, technologists work in close contact not only with designers and production, but also with logistics, purchases, finances and quality control service. It is the technical process and is the point in which the demands of all these units agree and is a balance between them.

The description of the technological process should be contained in such documents as:

• Route map - a description of the high level, it lists the routes of movement of the part or billet from one workplace to another or between the shops.
• Operating card - A mid-level description, more detailed, lists all operational transitions, setting operations, used tools.
• Technological map - low-level document, contains the most detailed description of the processing processes of materials, blanks, nodes and assemblies, parameters of these processes, work drawings and used tooling.

Technological card Even for a simple, at first glance, the product may be rather thick volume.

For comparison and measuring the technological processes of mass production, the following characteristics are applied:

The manufacturing program of the enterprise develops from the production programs of its workshops and plots. It contains:

• List of products manufactured with type details, sizes, quantity.
• Calendar issues of release with reference to each control date of a certain amount of products manufactured.
• The number of spare parts to each position as part of the product life cycle support process.
• Detailed design and technological documentation, three-dimensional models, drawings, details and specifications.
• Technical conditions for the production and methods of quality management, including programs and testing techniques and measurements.

The production program is a section of a general business plan of an enterprise for each planning period.

Types of technical processions

The classification of technical processing is carried out in several parameters.

By the criterion of the frequency of repetition in the production of products, technological processes are divided into:

• a single technological process is created for the production of unique in constructive and technological parameters of the part or product;
• typical technical process is created for a certain number of similar products similar to its constructive and technological characteristics. A single technical process, in turn, may consist of a set of typical process machines. The more typical process equipment applies in the enterprise, the less costs for the preparation of production and the higher the economic efficiency of the enterprise;
• group technical process is prepared for details, various constructive, but similar technologically.

According to the novelty and innovation criterion, such types of technological processes are distinguished as:

• Typical. The main technological processes use traditional, proven structures, technologies and processing operations, tools and snaps.
• Promising. Such processes use the most advanced technologies, materials, tools characteristic of enterprises - industry leaders.

According to the degree of detail, the following types of technological processes distinguish:

• The route process is executed as a route card containing top-level information: a list of operations, their sequence, class, or a group of equipment used, technological equipment and a total rate of time.
• The operational process contains a detailed processing sequence up to the level of transitions, modes and their parameters. Executed as an operating card.

The open process was developed during World War II in the United States in the conditions of a lack of qualified labor force. Detailed and detailed descriptions of each stage of the technological process made it possible to attract people who did not have production experience to perform large military orders. In the conditions of peacetime and the presence, well-trained and fairly experienced production personnel, the use of such a type of technological process leads to non-production costs. Sometimes there is a situation in which the technologists diligently publish thick volumes of operating cards, the technical documentation service replicates them in the prescribed number of copies, and production does not open these Talmuda. In the workshop, workers and master over for many years of work have accumulated sufficient experience and have gained a fairly high qualification in order to independently perform the sequence of operations and select the operating modes of the equipment. Such enterprises make sense to think about the refusal of operating cards and replace them with route.

There are other classifications of types of technological processes.

Stages TP

During the design and technological preparation of production, these stages of writing the technological process are distinguished as:

• Collection, processing and study of the source data.
• Determination of basic technological solutions.
• Preparation of a feasibility study (or justification of feasibility).
• Documenting the technical process.

It is difficult to find technological solutions from the first time ensuring both planned time and the required quality, and the planned cost of the product. Therefore, the process of developing technology is a multivariate and iterative process.

If the results of economic calculations are unsatisfactory, the technologies are repeated the main stages of the development of the technological process until the parameters required required by the plan.

Essence of the technological process

The process is called a change in the state of the object under the influence of internal or external conditions with respect to the object.

External factors will be mechanical, chemical, temperature, radiation exposure, internal - the ability of the material, parts, products to resist these effects and maintain their original shape and phase state.

During the development of the technical process, the technologist selects the external factors under the influence of which the material of the workpiece or raw materials will change its shape, dimensions or properties in such a way as to satisfy:

• technical specifications for the final product;
• planned indicators for the timing and volume of product output;

During the long time the basic principles of building technological processes were developed.

Principle of enlarging operations

In this case, within the framework of one operation, a larger number of transitions are collected. From a practical point of view, such a campaign makes it possible to improve the accuracy of the mutual location of the axes and the treated surfaces. Such an effect is achieved by performing all transitions united to the operation for one stop on the machine or multi-rigorous processing center.

The approach also simplifies the inner logistics and reduces intracacual expenses by reducing the number of installations and settings of the operation modes.

It is especially important for large and complex parts whose installation takes a lot of time.

The principle is applied when working on revolving and multi-track lathes, multi-riddled processing centers.

Principle of dismemberment of operations

The operation is divided into a number of simple transitions, the adjustment of the operation modes of the processing equipment is performed once, for the first part of the series, then the remaining parts are processed on the same modes.

Such an approach is effective for large sizes of series and relatively simple spatial configuration of products.

The principle provides a significant effect of reducing relative labor intensity due to an improved organization of jobs, improving the working skills of monotonous movements to decorate billets, manipulations with tools and equipment.

The absolute number of installations is growing, but the time is reduced to set the equipment modes, due to which a positive result is achieved.

To get this positive effect, the technologist will have to take care of the use of specialized equipment and fixtures that allow you to quickly and, most importantly, to accurately install and remove the workpiece. The size of the series must also be significant.

TREE TREE AND METAL

In practice, the same detail, of the same size and weight, from the same material can be made different, sometimes highly different from each other by methods.

At the stage of design and technological preparation of production, designers and technologists jointly work out several options for describing the technological process, manufacturing and processing sequence. These options are compared by key indicators as far as they satisfy:

• specifications on the final product;
• the requirements of the production plan, timing and volume of shipment;
• financial and economic indicators laid down in the business plan of the enterprise.

At the next stage, there are comparison of these options, the optimal one is selected. A large influence on the choice of option is provided by the type of production.

In the case of a single, or discrete production, the probability of repetition of the release of the same part is small. In this case, an option is selected with minimal costs for the development and creation of a special snap, tools and devices, with the maximum involvement of universal machines and customizable snapshots. However, exceptional requirements for accuracy of compliance with sizes or conditions of operation, such as radiation of high-aggressive environments, can force apply and specially made tooling, and unique tools.

In the serial release, the production process is divided into release of repeated batches of products. The technological process is optimized with the existing equipment, machine, machine and processing centers at the enterprise. Equipment is provided with specially designed tooling and fixtures that reduce unproductive time loss at least for a few seconds. On the scale of the entire party, these seconds will be populated together and will give a sufficient economic effect. Machine tools and processing centers are subject to specialization, a certain group of operations are fixed behind the machine.

With mass production, the sizes of the series are very high, and the outputs manufactured quite a long time are not subjected to constructive changes. Equipment specialization comes even further. In this case, it is technologically and economically justified by the consolidation of the same operation for the same operation for the entire time of the series, as well as the manufacture of special equipment and the use of a separate cutting tool and measuring instruments and controls.

Equipment in this case is physically moved to the workshop, having it in order of operations in the process

Means of performing technological processes

The technological process exists first in the heads of technologists, then it is fixed on paper, and in modern enterprises - in the database of programs that ensure the process of managing the life cycle of the product (PLM). The transition to automated storage, writing, replication, and verification of the relevance of technological processes is not a matter of time to the issue of enterprise survival in a competitive struggle. At the same time, enterprises have to overcome the strong resistance of highly qualified technologists School School, accustomed to the long years to write technical processing technicians, and then give them to a reprint.

Modern software makes it possible to automatically check the instrument, materials and equipment for applicability and relevance mentioned in the process and relevance, reuse previously written technical processes or partially. They increase the labor productivity of the technologist and significantly reduce the risk of human error when writing the technical process.

In order for the technological process from ideas and the calculations to become a reality, physical means of its implementation are needed.

Technological equipment is intended for installation, fixing, orientation in space and feeding in the processing zone of raw materials, blanks, parts, components and assemblies.

Depending on the industry of production, there are machines, processing centers, reactors, melting furnaces, blacksmith presss, installations and whole complexes.

Equipment has a long service life and can change its functions depending on the use of a technological equipment.

The technological equipment includes a tool, foundry, stamps, fixtures for installation and removal of the part to facilitate the access of the workers to the operation zone. Equipment complements the main equipment, expanding its functionality. It has a shorter term of use and is sometimes specifically manufactured for a particular batch of products or even for one unique product. When developing technology, it is widely used to use a universal snap-in, applicable for several product sizes. This is especially important in discrete industries, where the cost of the equipment is not distributed to the entire series, and fully falls at the cost of one product.

The tool is intended to provide direct physical impact on the workpiece material in order to bring its shape of the size, physical, chemical and other parameters to those specified in technical specifications.

The technologist when choosing a tool should take into account not only the price of its purchase, but also a resource and versatility. It often happens that a more expensive tool allows it without replacing it to release several times more products than a cheap analog. In addition, a modern universal and high-speed tool will also reduce the time of machine processing, which also directly leads to a decrease in cost. Every year, technologies acquire more and more economic knowledge and skills, and writing the technological process from the pure technological business turns into a serious tool for increasing the competitiveness of the enterprise.

The overall characteristics of the process of car. Maintenance is a combination of work of a certain purpose, each of which, in turn, consists of operations performed in a certain technological sequence, which is generally a technological process.

The operation is a complex of consistent actions for servicing the unit or a group of car units (for example, oil change in the engine crankcase, clutch adjustment, etc.).

With reference to the TEA, the purpose of the technology is to provide a given level of the working capacity of the car or the park in the most efficient ways.

The main task of the technological process is, is the high quality of the work performed at the lowest cost of working time, and therefore, with the greatest labor productivity.

The car consists of a large number of technological operations, which, in its intended, the nature, the conditions for the implementation, the equipment, tool, and the qualifications of the fulfillment, are combined into certain groups of work. The latter in one way or another are included in the maintenance of works on EO, T-1 and TO-2.

Regardless of the type, with the exception of the EO, it contains the following main works: cleaning and washing and unforgettable (external care), control and diagnostic, control and fastening, adjustment, electrical, lubricant, tire and filling. In addition, the complex of work includes: control and inspection work before EO, T-1 and TO-2 and work on checking the car after maintenance.

Cleaning and washing and unobed Works are in the internal cleaning of the driver of the driver, the platform of the truck or the inner salon of the car of the passenger car and the bus; Outdoor washing of chassis and body car and wipes its outer parts, side and front windows

Control and diagnostic Works are to control the state or performance of aggregates, mechanisms, instruments, systems and car as a whole on external features (output parameters) without disassembling or opening mechanisms.

Diagram of the diagnostic work of aggregates at that car

Adjusting work include Adjustable operations to restore the performance of aggregates, mechanisms and aggregates at the adjustment devices provided in them, to the level required by the rules for the technical operation of the car or technical conditions (for example, the frequency of the engine crankshaft at idle, the free move of the clutch pedal, etc.)

Fastenersworks consist of checking the state of threaded compounds of parts (bolts, spills, plintes) and fastening them (suspenders), setting fasteners instead of lost and replacement of unsuitable.

Electrotechnicalworks are to verify the external state of electricity sources (battery battery, generator with a relay-regulator and an AC rectifier) \u200b\u200band electricity consumers (instruments of the ignition system, starter, lighting and alarm systems and control measuring instruments), cleaning from dust, dirt and traces The oxidation of contact compounds, troubleshooting as a result of the diagnosis of car electrical systems ..

Food system work Engine include external check

the states of the power supply system (carburetor, fuel pump,

air filter, etc.), tightness of pipelines, elimination

faults and adjustment based on the results of diagnostics.

Lubricating and cleansing Works include periodic replenishment and oil change in the cards of aggregates (engine, gearbox, etc.), lubrication of bearings and hinged transmission connections, chassis, steering and body, fueling the vehicle with special liquids (brake, amortized), clean all filters, Replacing filter elements and lubrication systems

Tire work Consist from verifying the external state of tires (tires) in order to establish the need for repair, removal from tread tires stuck sharp items, checking internal pressure and bring it to the required. In addition, tire work at that may include the permutation and replacement of tires.

Control work after service Consist from checking engine operation, brakes, steering and other aggregates and mechanisms.

Filling work Include the fuel tank of the vehicle and the replenishment of the engine cooling system.

Such a unit of basic work is due to, firstly, the use of workers' appropriate specialty and qualifications when performing each type of work and, secondly, the use of special equipment equipment and tools at the site of the specified work. In addition, it is necessary for the organization of rational, consistent their execution.

Regardless of the type, the priority are cleaning and washing works, one of whose tasks is the preparation of the car to subsequent operations and give it a proper appearance.

The fuel supply of the car can be made before leaving the line or before performing it to the parking lot.

The territory of the room designed to perform one or more homogeneous work or process operations or repair, equipped with appliances, devices, tools and other equipment, is called work post.

Production plot on the operating post served by one worker is called workplace. The work post may consist of one or more jobs.

Washing work- The operation of cars in various road and weather conditions is accompanied by various kinds of body pollution and chassis.

The reason for the contamination of truck bodies can also be the remnants of the cargo transported - sand, soil, coal, building material, food products, etc.

Under the influence of ambient temperature, atmospheric influences and adhesion on the body of dirt containing organic and inorganic acids, irreversible changes, chemical and physical properties of paint and varnish coatings occur.

As a result, the lacquer film of the car's body (mostly passenger and buses) gradually collapses and fastens. The change in the properties of paintwork coatings "is called their aging or manifestation of degradation characterized by oxidative, thermal and photochemical processes.

The loss of the elasticity of the paint coating of the body occurs as a result of chemical changes, under the influence of deformations and body vibrations when the car moves, as a result of which microcracks are formed on its surface, the metal is exposed, which contributes to its corrosion.

The lower surfaces of the car are contaminated with clay, sandy, organic and other impurities forming a strong film, which makes it difficult to inspect and carry out the necessary work. Chrome body parts lose glitter under the influence of sulfuric compounds contained in the air, as well as a cook salt, which will be sprinkled during ice.

To maintain the coloration of the body and ensuring high-quality inspection and performing work at the same repair and repair, cleaning, washing, drying, as well as wipe and periodic body polishing are carried out.

10/10/2012

Cleaning car body.

Case In the removal of dust and garbage from the body and cab cabins, wipes of seats, glasses, and fittings inside the body, as well as in the engine wipes, cytins and the inside of the hood

Body auto specials. Appointments. (sanitary, with translation. Prod. and dr. and buses Periodic. They are subjected to disinfecting and washing floors and walls.

For cleaning a car used: old men. And portable vacuum cleaners, hair (brushes, scrapers optimating material)

Car washer

The sink of the outer parts of the body and the chassis of the car produce cold or warm + 25-30 degrees Celsius with water. In order not to cause the destruction of the color of the body The difference between water temperature and body surface should not exceed 18-20 degrees Celsius

When the water jet was washed during dust and dense contaminants on polished body surfaces, small (up to 30 microns) dust particles are left, which are held with a thin water film and leaving a matte gray flare on the surface of the body surface.

This is explained by the fact that the water is moving on the surface of the body in the radial direction. And between this stream and the surface of the body are formed a thin border layer in the form of a film (several tens of microns), in which the water speed is very small. And, consequently, the efficiency of the water jet is sharply reduced. For improving the efficiency of washing with the use of N ?? It is necessary to apply technical effects (brush, sponge or suede)

To improve the quality of washing and reduce water consumption

The lower layers of pollution with water are not washed away, therefore, various detergents are used.

The detergent solutions reduce the strength of the surface tension of the water film, formed on the washed surface, and dissolve oily deposits, give emulsions and suspensions that are easily flushed.

Methods of car wash

According to the method of execution, the sink is manual, mechanized and combined.

Manualthe car wash is made from the hose with a fetal or washing pistol with a low water jet (0.2-0.4 MPa) or high (1.0-2.5 MPa and more) pressure.

The mechanized car washing is carried out using special installations that are classified according to its device and conditions:

According to the construction of the working body of the installation - on inkjet, brush and jet-brush;

On the relative movement of the car and the working bodies of the installation - on travel and movable;

Under the application condition - on stationary and mobile;

By control method - on sets with manual control and automatic.

IN inkjet washer The installation as a working body uses nozzles or nozzles installed in fixed or movable manifold pipelines for which water or washing solution is supplied. Their main purpose is the cargo car wash. When using detergent solutions, they are used for car wash.

IN brush washer Installation of the working body are cylindrical rotating rotary brushes with a water or detergent to them. Used installations for washing buses and passenger cars.

Inkjet-brush Installations have a combined device from brushes as a working body, as well as nozzles for which water or detergent solution is supplied. Used for washing buses, passenger cars and cargo cars.

Freight washers Installations are stationary devices through which the processed car is moved using a conveyor or self-propeller.

Movable washers Installations are devices with working bodies moving relative to a fixed vehicle.

Stationary washers Installations - devices installed fundamentally on a warm post

Mobile washers Installations are self-propelled installations mounted on the car chassis and used for washing the rolling stock of automobile transport operating in the separation from the main base.

Hand-controlled washers are characterized by turning on (off) by manually into operation.

Automatic washing installations are driven by either when the wheel of the car's wheel on the pedal, built into the floor, or with the help of a photocell, when crossing the light beam car, or when lowering the coin in the cash register. In addition, there are warm installations with software control.

Washing combined settings combine the device for inkjet sinking chassis nose and a mechanized brush installation for kneading the outer parts of the body.

Mechanization of the car washing process significantly reduces the time spent on it, which is 1.5-3 minutes instead of 10-20 minutes with a manual washing (depending on the type of car), as well as water consumption. Technical and economic calculations show that saving from reducing the amount of annual expenses in the mechanization of the washing process compared to the manual way is relatively small. So, for the fleet of trucks and buses, it is 1-3%. More significant savings (25-30%) is obtained for the park of passenger cars. This is due to smaller cargo costs of water (2-4 times) and electricity (2-4 times) and electricity (on the drive mechanisms of the washer), and therefore, the cash costs for them. In addition to economic efficiency, the mechanization of car washing allows you to free the washers from heavy physical work and improves the quality of the washing.

Polishing body of a passenger car.

The body is polished to provide long-term preservation of the paintwork.

Under the polishing of the paint and varnish coating means the process of surface treatment, as a result of which irregularities are smoothed, pores and microcracks are filled.

The aging of the paintwork is the loss of 40% shine, the cat. Comes in 2-3 years of operation

Such a state of LCP is called weathered, unlike the "new", as well as the "old" loss of gloss which exceeds 40%

The main goal of polishing is the creation of a resistant protective layer on the surface of the body of the protective metal base of the body from aggressive environmental influence. Therefore, both new and old bodies are subjected to periodic processing with polyrollas.

New bodies are processed by 1 times one and a half - 2 months

Car corrosion combat

As studies show, in the bodies of passenger cars after three years of operation there are many corrosion foci, a total area of \u200b\u200blesion of 150-230 thousand cm2. At the same time, up to 65% of corrosion centers cannot be suspended during the operation of cars.

Corrosion distinguish: by the nature of destruction - on the general and local; by type of corrosion medium - on atmospheric, gas, soil, acid, salt, water; According to the type of process - on chemical and electrochemical.

Chemical corrosion consists in direct exposure to the active substances of the environment for metal. Electrochemical corrosion arises due to the formation of a galvanic element, whose electrodes are different metals (steel - aluminum, steel - copper, steel - zinc, etc.).

General corrosion occurs on large unprotected body surfaces under the action of moisture saline solutions.

Corrosion occurs with the maximum intensity at a saline concentration of 2-5%

The intensity of corrosion in the cities and on the roads, respectively, is 30 and 5 microns per year)

With an increase in air humidity from 60 to 90%, the intensity of corrosion increases by 3 times.

Local corrosion occurs in limited areas and manifests itself in the form of a slit, point and sublayer corrosion.

Slit corrosion occurs in small gaps and slots where there is no moisture or dirt for a long time, for example, in the location of the body welding.

Point corrosion occurs in places of mechanical damage to the paintwork due to shocks or gravel shocks, on brake pipelines made of steel with a protective layer of copper, as well as on details having decorative chromium-nickel coatings.

The sublayer corrosion is a consequence of the porosity and hygroscopicity of non-metallic (paint and varnish) coatings through which corrosion-active substances penetrate to the surface of the metal.

At the auto plants, the bottoms and wings of cars are mainly bitumen. The term of their action, depending on the operating conditions from 1-2 years.

Bituminous coatings are well confronted by the action of moisture, water and salt, but not resistant to strokes of gravel and sand., Not frost-resistant, as well as sensitive to temperature drops.

General characteristics and content of diagnostic and adjustment

Control and diagnostic works are used to determine the technical condition, car, its aggregates, and nodes without disassembly and are an element of controlling technological processes of maintenance and repair of rolling stock. The volume of monitoring and diagnostic work for modern cars is about 30% in relation to the volume of the performer.

Diagnosing cars, the technical condition of which does not meet the safety requirements, and before that determine the need to eliminate malfunctions or repairing the quality of the quality and TP, determine the possibility of a good operation of the aggregates and car mechanisms in the upcoming intercontrol mileage, collect and process information, Needless to managing production.

In the management system of the Technical Service ATP, diagnostics is an information and control unit subordinate to the production management department.

But the appointment, periodicity, laboriousness, the list of work performed and the place in the technological process is the Tri periodic diagnosis, as mentioned earlier, is divided into D-1 and D-2.

D-1 is intended mainly to diagnose mechanisms that ensure the safety of the vehicle (brakes, control mechanisms, the angles of the front wheels, the lighting devices), the level of toxicity of the exhaust gases and its fuel efficiency. It can either be limited only to the determination of the suitability of the object to further operation (express diagnostics), or include the definition of basic faults and accompanied by adjusting work with the subsequent quality control of their implementation. The express D-1 is performed at the control point when the car returns to the park, and D-1 at the time-1 or in front of it. In addition, for conducting it-1, use information obtained by means of built-in diagnostics.

D-2 is intended to diagnose a car as a whole on traction and economic indicators and identifying the faults of its main units, systems and mechanisms.

D-2 is carried out in front of it-2 to prepare production to perform repair work and reduce the veins of the car with a planning of TO-2. Simultaneously with D-2, some technologically acquitted adjustment work and subsequent quality control of their conduct are performed. D-2 is also carried out on requests before TP in cases of the need to identify faults and determine the required amount of repair.

The information needed for conducting TO-2 and repair is obtained using diagnostic stands and portable devices. To detect faults and failures in the process of execution and TP (on specialized posts, lines and in workshops), operational technological diagnostics (DR) are carried out using portable devices and desktop installations. On major ATP, operational diagnosis is also performed by the need (on request) on specialized posts equipped with stands.

Adjustment work It is restored without replacing parts and mechanisms of the parameters of the technical condition of the object to the norms established by the technical documentation, the values \u200b\u200bof the gaps, hollows, free moves, drive efforts. Conduct them according to the results of diagnosing and controlling the quality of completed or repair.

Diagnosing a car as a whole. The diagnosis of the car is generally carried out to determine the level of indicators of its operational properties: power, fuel economy, motion safety and environmental impact. Having retentioning a decrease in these indicators compared to the established norms, an in-depth diagnostation is carried out, specific malfunctions are determined, adjust the mechanisms and perform the final control.

Diagnosing a car is possible with driving tests or the use of stationary bench. In operational conditions, the running tests are used limited, mainly for the inspection of the brakes and linear fuel consumption.

The intensive diagnosis of the vehicle is more effective using special stands that allow you to set the speed and load test modes of the car.

The main diagnostic parameters (Table 3.1.) The operational properties of the car are: wheel power NK and its derivatives; The speed of movement Va, the strength of the RK. resistance to the RF movement and sb; SB path, TP time and acceleration JF acceleration, specific fuel consumption q on characteristic high-speed and load modes, brake path ST brake power PT, path S3, time T3 and deceleration value J3; The lateral forces of the Republic of Belarus, operating in the spack of contact of tires with an expensive; The toxicity of exhaust gases with CO, noise level A.

Similar information.

When organizing processes and repair, technological maps are widely used, which determine the rational use of working hours and jobs, compliance with quality requirements, ensuring the synchronization of posts, etc.

The ATP uses usually process cards of two types: operational and technological and posts.

Operational and technological maps contain a list of works performed in this post, at each workplace. Operations from operational and technological maps correspond to the sequence number of operations of post-cards. Technological cards are developing in an enterprise or are based on reference data.

The decline in the volume of work is unacceptable. It is also unacceptable to also perform work on TP, which are not included in the list of works of the TP, recommended for execution together with that.

The flow line is 1 - 1 is designed to perform the entire volume of preventive work on - 1, as well as to perform related work on repair.

The line consists of two posts.

Before making a car for the first post, the car rises to the post of the backrest for heating and drying.

The first post is designed to perform work on the brake mechanism, wheels, suspension, transmission and lubricants. The post is operating two locksmiths for car repair 3 and 4 discharges.

The second post is designed to perform work on the engine, adhesion, steering mechanism and electrical equipment. The post work: a mechanic for repairing a car 4 discharge and a mechanic - electrician 4 discharge.

Posts that - 2 are designed to perform lubricants and work on transmission, etc., to perform the entire amount of preventive work on TO- 2, as well as to perform related work on the repair.

Table 2.10 - List of works at that engine

Table 2.11 - List of work at the power system

Table 2.12 - List of works at that clutch

Table 2.13 - List of works at that transmission

Table 2.14 - List of works at the wheels and hubs

Table 2.15 - List of works at that suspension

Table 2.16 - List of works at that bodies and cabins

Table 2.17 - List of works at the brake system

Table 2.18 - List of works at that electrical equipment