Production is being mechanized. The level and degree of mechanization of production processes and vehicles
Topic 13. Assembly of devices, modern methods of mechanization and automation production processes
Tests of assembled products
Testing of assembled products is the final control operation of the quality of their manufacture. Machines are tested under conditions approaching operating conditions. All types of tests can be carried to acceptance, control and special.
During acceptance tests, the actual operational characteristics of the machine are revealed (accuracy, productivity, power, speed, accelerations, angles, energy costs, etc.), as well as the correct operation of various mechanisms and devices of the machine.
Control tests are carried out on products that have previously been found to have defects. With particularly high requirements for products, they are subjected to a run-in after assembly and tested. Then disassemble (partially or completely), check the condition of the parts, reassemble and subject to short-term control tests.
Special tests are performed to study wear, check the failure-free operation of individual devices, establish the suitability of new grades of materials for critical parts, and investigate other phenomena in machines. Special tests are very long. Their program is developed depending on the purpose of the test. These tests are subjected not only to assembled products, but also to their components (gearboxes, pumps). Tests are carried out on special stands.
One of the main directions for improving the technology of instrumentation is to reduce the degree of employment of workers in the maintenance of technological equipment by increasing the level of mechanization and automation of production processes. Let us establish a number of definitions related to the mechanization and automation of production.
Mechanization- direction of development of production, characterized by the use in the production process of machines and devices (devices) that replace physical work worker.
Mechanization can be partial or complete.
Partial mechanization or, as it is often called, small mechanization - this is the mechanization of part of the movements that are necessary for the implementation of the production process: either the main movement, or auxiliary and installation movements, or movements associated with the movement of parts (assemblies, products) from one working position to another.
Complete or complex mechanization- mechanization of all main, auxiliary and transport movements that are performed during the production process. With full mechanization, the worker exercises only operational control of production processes (switching on and off at the right moments the required mechanisms and controlling the mode and nature of their work). Full or complex mechanization of production processes creates the conditions and is a necessary prerequisite for the automation of production.
Automation- the direction of development of production, characterized by the release of the worker not only from physical efforts to perform certain movements that are part of the production process, but also from the operational control of the mechanisms that perform these movements.
The degree of automation of production processes can be different.
Partial automation there is the automation of part of the operation to control the production process, provided that the other part of the control operations is performed by the worker.
Complete or complex automation characterized by the automatic execution of all functions of the production process control. The duties of a worker include only setting up a machine or a group of machines and control systems, turning on and monitoring the operation of machines. Thus, the various stages of mechanization and automation are determined by the interaction between man and machine, that is, by the continuity of the production process. The greater the degree of continuity, the more automated the production process and the more perfect this automatic system.
There are manual and complex mechanization, automation and robotization.
Mechanization is the replacement of manual labor by the work of individual machines and mechanisms.
Mechanization is divided into partial and complex, semi-automatic and full automation, recently the use of robotics has been used.
Partial mechanization - means the use of mechanisms in the performance of individual operations. At the same time, a number of related and subsequent works are performed manually.
In the production of installation work - in the vast majority of cases, only one process is partially mechanized - installation. In turn, it consists of such operations as equipping the mounting element with lifting devices - i.e. slinging, moving the prefabricated element in space, laying the prefabricated element, its temporary fixing and bridging. Of these operations, only movement is mechanized, although there are significant labor costs here too.
In earthworks, only 35% of the volume of earthworks is carried out manually (rework, work in cramped conditions, backfilling).
Significant success has been achieved in the production of monolithic works, only 8% of the total volume of concrete is laid by hand, before the mechanization of production processes, labor costs were 70%.
Integrated mechanization - means the implementation of all, without exception, simple processes that are part of the process, a set of machines and mechanisms interconnected by technology and productivity and ensuring the effective implementation of the construction process.
At present, the concept of complex mechanization is undergoing a transformation stage in the concept of a system of machines.
The system of machines is a set of main and auxiliary machines, vehicles, means of mass mechanization and mechanized tools, dynamically changing in time, formed in accordance with promising technology and providing complex-mechanized performance of all types of construction and installation works.
The system of machines consists of ten subsystems, which include technological complexes of machines and mechanization tools of various composition, but all these sets are organized according to the principle of basic machines.
Depending on the degree of mechanization, all workers are divided into 4 main groups:
Workers performing work in a mechanized way with the help of machines and mechanisms;
Workers performing work manually, employed with machines and mechanisms;
Workers performing work manually not with machines and mechanisms;
Workers performing manual work on the adjustment and repair of machines and mechanisms.
Semi-automation consists in the partial use of automatic machines for certain operations, for example, when moving cranes, when spot welding, when applying paint layers. The design features of automatic machines are the presence of a certain control system that coordinates work movements according to a certain program.
Automation - assumes that all operations included in a certain process are performed according to a pre-developed program through a system of interconnections in the technological sequence of automata. Workers in this case only control their work.
Robotization is the execution of work according to the program with programming, and making adjustments to the process.
The flow organization consists in the rational combination of repeatable construction processes (types of construction work) in time at the sites of buildings and structures.
The flow organization of construction and installation works can significantly reduce the duration of work compared to a sequential organization, while it is characterized by a greater intensity of resource consumption and the complexity of organizational work.
The flow organization of work allows to ensure the rhythm and continuity of the process.
The highest efficiency of the flow organization of construction is achieved in the presence of the following signs of the construction flow:
1. The division of the front of work into sections, grips, plots, tiers;
2. The division of the process of erecting buildings and structures into separate works;
3. Establishing an expedient sequence of works of the dismembered process of erecting objects and combining interconnected works into a common cumulative process;
4. Assigning certain types of work to certain teams, establishing the sequence of inclusion in the stream of individual teams;
5. Equipping brigades of workers with construction machines, mechanisms, tools and inventory that ensure the performance of the work assigned to the brigades within the estimated time frame.
6. Ensuring the simultaneous execution of all or most of the work and the consistency of the quantitative ratios between the duration of the performance of certain types of work with the number of work teams.
Standardization is the establishment of uniform standards for types, brands, and quality of products, as well as for measurement values, test methods, control and rules for labeling and storing products, as well as production technology.
In Ukraine apply state standards(GOST), in their absence, technical conditions are applied - TU, the use of GOSTs and TU is mandatory for all sectors of the country's economy.
Typification is the reduction of the variety of shapes, sizes, properties to an optimally limited number.
Unification is the use of the same resources, tools, materials for different purposes. For example, unified formwork shield designs can be used in the construction of various concrete structures.
The main directions for increasing the efficiency of capital construction:
1. Increase technical level construction:
Perfection design work, the widespread introduction of integrated and parallel design;
Variant design;
Application of new materials;
Introduction of new efficient technologies.
2. Integrated automation and mechanization of construction:
Introduction of complex mechanization and system of machines;
Reducing the cost of manual labor;
Development and implementation of new machines and mechanisms
3. Improving the technologies for organizing and managing construction:
Introduction of progressive methods of construction organization;
Implementation scientific organization labor;
Reducing the loss of working time;
Widespread use of computers in the organization of construction;
Improving logistics systems.
4. Improvement of socio-psychological factors at work and at home:
Development of creative activity and initiative;
Ensuring job satisfaction and reducing employee turnover;
Strengthening discipline and increasing material interest;
Improvement of housing and communal conditions;
Raising the educational level and qualifications.
MECHANIZATION OF PRODUCTION, replacement of manual means of labor by machines and mechanisms using for their action various types of energy, traction in the branches of material production or labor processes. M. p. also covers the sphere of mental labor (see, for example, Mechanization of accounting, Information retrieval and etc.). Main The goals of M. p. are to increase labor productivity and free a person from performing difficult, labor-intensive, and tedious operations. M. p. contributes to the rational and economical use of raw materials, materials and energy, reducing costs and improving the quality of products. Along with the improvement and updating of technical means and technology M. p. is inextricably linked with an increase in the level of qualification and organization of production, a change in the qualifications of workers, and the use of methods of scientific organization of labor. M. p. is one of the main areas of technical. progress, ensures the development of productive forces and serves as a material basis for increasing the efficiency of societies. production, developing by intensive methods. To tech. The means of M. p. include working machines with engines and transmission devices for them that perform specified operations, as well as all other machines and mechanisms that are not directly involved in these operations, but are necessary so that this production process can be carried out at all e.g. ventilation and exhaust systems.
Depending on the degree to which production processes are equipped with technical means and the type of work, a distinction is made between partial and complex production.
At partial L. the item mechanizes otd. productions, operations or types of work, Ch. arr. the most time-consuming, while maintaining the share of manual labor, especially in auxiliary. loading and unloading and transp. works.
A higher level is the complex M. p., at which manual labor is replaced by machine labor on all basics. technological operations. process and auxiliary works of productions, process. Integrated production is carried out on the basis of a rational choice of machines and other equipment operating in mutually agreed upon modes, coordinated in terms of productivity and ensuring the best performance of a given technological process. Manual labor with complex M. p. can be preserved on a separate. non-labor-intensive operations, mechanization to-rykh is not essential for facilitating labor and is not economically feasible. The person also has the functions of managing the process of production and control. Complex production predetermines the possibility of using in-line methods of production, helps to improve its quality, and ensures the preservation of uniformity, the degree of accuracy, and the constancy of the specified parameters.
The next step after the complex production process, the stage of improving production processes is their partial or complete automation (see. production automation).
The means of labor, being an integral part of the productive forces, are created and improved in the process of social production. The invention of new tools and the introduction of new technologies. processes are directly related to the development of natural science and are carried out on the basis of the knowledge and use of its laws. Before industrial revolution 18th-19th centuries the tools of labor remained manual and the number of working tools with which a person could act simultaneously was limited by his natural tools, i.e., the organs of his body. The forces of nature used included water, wind, and domesticated animals. In the manufacturing period, preceding the prom. revolution, the division of handicraft labor and its professions, as well as the specialization of tools, reached such a high degree that prerequisites arose for the connection of tools in a machine and the replacement of the worker's hand with the tool by a mechanism. “As a machine,” K. Marx noted, “the means of labor acquires such a material form of existence, which causes the replacement of human power by the forces of nature and empirical routine methods - by the conscious application of natural science” (Mark K. to Engels F., Soch., 2 ed., vol. 23, p. 397). Improvement of tools and methods of labor, the emergence of a universal steam engine, the use of machines and mechanisms to facilitate labor was called into con. 18-beginning 19th centuries a sharp jump in the level and scale of production. Replacing manual labor in the implementation of technological. and transp. functions, mechanical the means of labor were the starting point of tech. progress in various branches of industry, played an important role in the formation of capitalist. production method. Prom. The revolution created the conditions for the manufacturing industry, primarily weaving, spinning, metalworking, and woodworking. The possibility of using the power of a steam engine to drive a number of working machines led to the creation of a wide variety of transmission mechanisms that grew into many. cases in a widely branched mechan. system.
With an increase in the size of the motor and transmission mechanisms, with the complication of working machines, with the advent of new materials that are difficult to process, there is an objective need to use various machines and mechanisms in the machine building itself. production Having started the production of machines by machines, large-scale industry has thereby created a technical equivalent to it. basis. Throughout the 19th century Industrial production quickly penetrates not only into individual links of production and process, but also conquers one branch of industry after another, displacing old traditions. forms of production based on manual labor and primitive technology. Mechanizir. production is widespread in all developed countries.
With the development of large-scale industry, the design is being improved, the power and productivity of the means of M. p. 19th century along with the steam engine, a more economical and compact internal combustion engine, to-ry allowed to create new workers and transp. tractors, automobiles, excavators, motor ships, airplanes, etc. New methods of energy conversion are emerging, based on the use of steam and hydraulic power. turbines connected to electric generators. current. Development and improvement of electric. machines leads in the first floor. 20th century to the widespread introduction of group and individual electric drives of working machines in metal-cutting, woodworking, weaving and other machine tools, forging and pressing, mining, hoisting and transport machines, rolling mills, etc.
In the system of machines, the object of labor sequentially passes through a series of interconnected partial processes, which are carried out by a chain of heterogeneous, but mutually complementary machines, mechanisms, and apparatuses. Mechanical system means of labor leads to continuous production in a developed form.
The further development of M. p. cycle, the release of labor, the implementation of complex mechanization in the most labor-intensive industries of production.
Among the technical means of M. p. have been developed combined machines - combines, in which units located in the technological. sequences automatically affect the object of labor. The development of combination, complex mechanization and automation led to the creation automatic lines machines, workshops-automatic and automatic. factories with high production efficiency.
Under the conditions of capitalism of society and the production relations inherent in it, the means of labor, having acted as a machine, immediately becomes a competitor of the worker, one of the main means of his exploitation and the most powerful weapon in the hands of the capitalists to suppress the indignations of the workers. "... The introduction of machines increased the division of labor within society, simplified the functions of the worker inside the workshop, increased the concentration of capital and further dismembered the person" (Marx K., ibid., vol. 4, p. 158). The expediency of using new means of production under capitalism is ensured by the fact that their value must be lower than the value of the labor power they replace.
In the socialist machine society and all other technical. means of labor mechanization are created and used not for competitive purposes and not for the exploitation of the worker, but to increase labor productivity, the economic efficiency of social production, to facilitate and improve the conditions of labor processes, which is ultimately aimed at raising the material well-being and cultural level of the people. “Earlier,” V.I. Lenin wrote, “the whole human mind, all its genius created only in order to give some all the benefits of technology and culture, and to deprive others of the most necessary - education and culture. Now all the miracles of technology, all the conquests of culture will become the property of the whole people, and from now on the human mind and genius will never be turned into means of profit, into means of exploitation" (Poln. sobr. soch. 5th ed., vol. 35, p. 289).
In a planned socialist x-va creates the most favorable conditions for the rational use of M. p. as the basis of technical. progress in the industry and with. x-ve. "Large-scale machine industry and its transfer to agriculture is the only economic basis for socialism..." (V. I. Lenin, Poli. sobr. soch., 5th ed., vol. 44, p. 135). In the socialist M.'s society of the item is the powerful tool of the person for all-round simplification of work and steady growth of social pro-va. The introduction of mechanization in the socialist. national economy also occurs in those cases when its result is not only a material effect, but also an improvement in working conditions, an increase in its safety. Contributing to the elimination of heavy manual labor, the reduction of the working day and the improvement of cultural-but-technical. and the material level of workers, M.p. plays an important role in the implementation of scientific. organization of production, in the erasure of creatures, the differences between mental and physical labor.
In the USSR, industrial production was the basis for the industrialization of the country and the collectivization of the village. x-va; it predetermines the rate of growth in the productivity of societies and labor on the basis of the further development of comprehensive mechanization and automation of production and processes.
Implementation of M.p. depends primarily on the equipment of industry, construction, transport, etc. x-va the most advanced machines, mechanisms and devices (see table.). The most rapidly developing in the USSR was the production of machines, mechanisms, installations and equipment in the leading branches of industry (energy and electrical engineering, machine tool building, mining and chemical engineering). High growth rates are also characteristic of instrument making, production of radio equipment, automation and computing equipment, equipment, household appliances and mechanisms. The level and efficiency of M. p. of a certain branch of production or process, in practice, is evaluated according to various indicators. Such indicators can be: the level of mechanization of labor, the level of mechanization of work, the mechanical and power-to-weight ratio of labor, etc. The level (coefficient) of labor mechanization is understood as the share of mechanizir. labor in the total labor costs for the manufacture of certain products or for the performance of work in a section, workshop, enterprise, etc. This indicator is determined by the ratio of the time spent on the execution of mechanization. And handmade. A similar purpose has an indicator of the degree of coverage of workers mechanizir. labor, to-ry is determined by the ratio of the number of workers performing the work of the machine. way, to the total number of workers. The specificity of certain types of production necessitates the introduction of such an indicator as the level (coefficient) of mechanization of work - the ratio of the volume of production performed by mechanization. way, to the total volume of production. This indicator is used in the foundry and forging industries, in transport and construction work, etc. The mechanical-labor ratio of labor is usually estimated by the cost of machines and mechanisms in production, per worker on average. The power-to-weight ratio of labor (or, in some cases, the electrical power-to-weight ratio) is expressed by the ratio of the number of mechanical. and electric (or only electric) energy consumed in the production process per 1 man-hour worked or per 1 worker. These indicators are used conditionally for a comparative assessment of the mechanization of individual processes. When choosing technical means of small-scale production, the cost of which is included in the capital costs and is transferred to the cost of the product for the entire time of their use, the weight and dimensions, payback periods, energy consumption, and reliability in operation are taken into account;
Development of the production of some of the most important means of mechanization in the USSR
Means of mechanization
Metal-cutting machines, thousand pieces
Forging and pressing machines, thousand pieces
Turbines, thousand tons no
Generators for turbines, thousand tons no
AC motors current, thousand n no
Metallurgical equipment, thous. T
Coal cleaning combines, pcs.
Trucks, thousand units Tractors, thousand units
Combine harvesters, thousand units
Diesel locomotives main, sections.
Mainline electric locomotives, pcs.
Excavators, pcs.
Weaving machines, thousand pieces
wear resistance of components and parts, maintaining the constancy of the main parameters for the entire period of operation, speed of adjustment, the ability to readjust to perform other similar operations, ease of maintenance, technical. inspection and repair.
M. p. in the sectors of the national economy of the USSR. Creation of a major socialist prom-sti, capable of solving the most complex scientific and technical. problems and national economies. tasks, is the greatest conquest of owls. people, the triumph of Lenin's socialist ideas. industrialization. Revolutionary. important are the major measures for the mechanization of work in various sectors of the national economy, carried out during the years of Soviet power. Developed and implemented in the production of thousands of samples of modern. high-performance dit. gun machines. Machine systems are being created for the integrated mechanization and automation of the main industries, processes in industry, construction, and village. x-ve and on transport. Based on technical improvement the level of production is consistently reduced the use of manual and heavy, as well as unskilled labor in all sectors of the national economy. At the same time, the need for technical means to complete complex mechanization in all sectors is steadily increasing.
M. p. in the energy sector is associated with the commissioning of large electric. stations and the creation of unified energy systems. Consolidation of the capacity of power plants makes it possible to significantly reduce the cost of labor, materials and fuel for the production of electricity, to apply effective means of monitoring, regulating and managing both individual units and power plants as a whole. The energy capacities of the USSR will increase Ch. arr. due to the construction of thermal power plants with large power units with a capacity of 300, 500, 800 MW, and in the future with a capacity of 1000 MW and higher. The maintenance of such power units is fully mechanized, which significantly reduces the need for labor per unit of installed capacity. The standard of production in the thermal power industry is aimed at improving the means of preparing, loading, and supplying fuel, methods of water treatment, ash removal, and so on. Turbines with a capacity of 500 MW(Bratskaya HPP) and turbines with a capacity of 630 MW(for the Sayano-Shushenskaya HPP). At nuclear power plants, reactor plants with a capacity of 1000 MW and more. A distinctive feature of nuclear power is the complex mechanization and automation of technological processes. processes, which allows, due to the reduction of labor and material costs, to ensure its high competitiveness in relation to traditional energy industries.
In the mining industry, mining is aimed at reducing the time required for opening, preparing, and putting into operation new deposits and horizons, as well as at reducing the cost of maintaining working workings, which is associated with the expansion of complexity in the mechanized processes of underground and open-pit mining. In mines are applied vysokoproizvodit. narrow-cut combines and plows operating in combination with moving face conveyors and individual metalworkers. or hydrofic. fasteners (see Coal complexes). As a result of the introduction of machines and mechanisms, in 1972 the level of mechanization of coal heaping in flat and sloping longwalls amounted to sv. 90%; delivery of coal, underground haulage of coal and rock and loading of coal into the railway. wagons are fully mechanized. Methods are being introduced deserted coal mining, providing a significant increase in labor productivity. Hydraulic coal mining is developing. way (see Hydromechanization). Developing rapidly open pit mining with the use of complex M. p. on the basis of high-performance equipment: draglines, bucket-wheel excavators, transport-and-shaft bridges, powerful dump trucks, electric locomotives, dump cars, diesel trolley cars, etc.
In the gas and oil industry, the application is highly productive. The financial resources of the fuel supply contributed to an increase in oil and gas production and an increase in their share in the country's fuel balance. Powerful drilling equipment is used in the oil fields, including rigs for drilling deep wells, and integrated hydroficers are being introduced. drilling rigs with discrete tripping, mechanization and automation of all drilling processes. The equipment of oil-producing enterprises with block-complete automation continues. installations that provide significant savings in labor, cost and time. An increase in the level of mechanization and industrialization of the construction of gas fields, underground gas storage facilities, gas processing plants is ensured by the use of block and block-but-complete technological. installations, prefabricated buildings and structures with metal frames. For gas transportation, gas pipelines with a diameter of 1420 are widely used. mm at working pressure 7.5 MN/m2. As a result of the introduction of complex mechanization and automation, the compressor stations of gas pipelines being built in the Arctic and other hard-to-reach regions of the country operate practically without service personnel.
In metallurgy, metallurgy is aimed at completing the mechanization of individual labor-intensive work and at carrying out integrated metallurgy in blast-furnace, steel-smelting, and rolling shops. The most difficult work at the hearths of blast furnaces, all the necessary operations for servicing tapholes, have been mechanized. The production of mechanized equipment for servicing blast furnaces with a volume of 3200 m 3, developed a set of mechanizir. equipment for blast furnaces with a volume of 5000 m 3. The operation of new units with increased blast pressure and the use of oxygen makes it possible to accelerate the melting process, reduce fuel consumption and improve the quality of cast iron. In the steelmaking industry, advanced filling machines are used, the processes of breaking and laying the lining of ladles, loading large-capacity electric furnaces are mechanized, and the use of automatic systems is expanding. regulation of oxygen consumption in converters, control of carbon content in metal, systems for controlling the thermal regime of open-hearth furnaces, etc. The converter method of steelmaking using converters with a capacity of 250-300 T and continuous casting of steel with a high level of complex metallurgy. To improve the quality of steel, the development of such mechanized processes as metal processing with synthetic slags, out-of-furnace evacuation, and electroslag and vacuum remelting of metal is envisaged. For new technological processes created machines and equipment that operate on the principle of automatic. regulation of production processes and complex mechanization of operations for the preparation of charge, loading units and pouring metals. In the steelmaking industry, natural gas is widely used. In the rolling industry, a complex-mechanism is put into operation. mills for hot and cold rolling of sheet steel with aggregate lines for applying metal sheets to sheets. and non-metallic coatings; provides for the creation of precision and special. mills for the production of high-precision rolled products and economical profiles, mechanized and automated lines for finishing (adjustment), straightening, sorting, stacking and packaging of sheet and rolled products. In mechanical engineering M. the item is connected hl. arr. with quantities, composition and structure of the metalworking park. equipment, since the most time-consuming in the manufacture of products is the operation of mechanich. detail processing. In mass engineering. pro-ve complex mechanization of mechanical processes. processing is carried out by using aggregate, special. and a specialist machine tools, machine tools and semi-automatic machines. The fleet of machine tools for electro-physical. and electrochemical processing methods that allow you to replace many time-consuming, tedious and even unhealthy manual operations in the manufacture of dies, molds, turbine blades, carbide tools, as well as parts of a particularly complex shape or from materials that are difficult to process with conventional tools, the use of machine tools with numerical control and adaptive devices is expanding, and in the future, it is planned to create and use various types of programmable manipulators And robots. It means that the development of the production of blanks, in terms of norm and size, as close as possible to finished parts, will have an impact on the production of manufacturing in mechanical engineering. For this purpose, the reconstruction of existing and the creation of new specializations is carried out. enterprises for the production of castings and forgings. The specific gravity of metal forming is increasing (see. Forging and stamping production). For foundry equipment will be created in the form of a technological sets, for example, equipment for sand preparation areas, sets of equipment for investment casting, mechanizir. lines for molding, pouring, knocking out castings, etc. Complex metallurgy will be developed significantly in the processes of welding, heat treatment of parts, and assembly of machines.
A significant influence on the level of mechanical engineering in mechanical engineering is exerted by the widespread development of the unification and standardization of assemblies and parts for general machine-building applications (bearings, gearboxes, couplings, flanges, chains, etc.). as well as normalized tools and standard equipment, the manufacture of which is organized at specialized enterprises.
In hoisting-and-transport and loading and unloading operations, L. p. is achieved by using lifting cranes, reloaders, means of floor lifting and transport. equipment, containers, building, lifts, lifts, ropeways, monorail feeding systems. Among the lifting and transport. means also include small-scale mechanization: blocks, cats, chain hoists and other lifting mechanisms. The choice of mechanization means for lifting and transporting and loading and unloading operations is determined by the type of cargo (piece, long, liquid, bulk), the type of vehicles (cars, ships, cars), containers, the volume of work performed, the distance of movement of goods and the lifting height. Of great importance is the complexity and mutual conformity of the methods of lifting, moving, loading, unloading and stowage of goods at the points of departure and arrival. The volume of these types of work depends on the number of cargo transshipments. The level of mechanization of hoisting-and-transport and loading and unloading operations is determined by the ratio of the amount of goods processed with the help of mechanization means to the total volume of processed goods. Important to reduce labor costs for prom. enterprises has the introduction of mechanization in order to completely replace manual labor in the intrashop and intershop loading and unloading of materials, parts, semi-finished products, loading and unloading railway. wagons, trucks and trailers, stacking semi-finished products and finished products in shop and factory warehouses. Main ways of implementing a comprehensive M. item of these works: the rational organization of the warehouse x-va enterprises, max, the approximation of warehouses to consumer shops, the unification of transport and warehouse operations with technological. basic processes. production; equipment of loading areas and warehouses modern. means of mechanization (stacker cranes, floor electric stackers, loaders, etc.); centralization of the work of intra-factory transport, the introduction of route transportation; the use of progressive transp. funds (conveyors And monorails with automatic addressing of cargoes, electric tractors, pneumatic transport), introduction of uninterrupted transportation of goods based on the widespread use of package and container traffic from using a unified reverse packaging; mechanization of auxiliary operations at the loading and unloading operations themselves, related to the slinging and unslinging of goods, the use of containers with autoslings, the formation and disbanding of packages on pallets, etc.
In the construction of M. p. associated with the peculiarities of the technology of construction, production, to the Crimea include a large load capacity and a change in the scope of work. Small-scale production in construction facilitates work and shortens the time for putting objects into operation. It is directed to arr. on the transformation of construction production into mechanizir. in-line process of assembly and installation of buildings and structures from large-panel elements and assemblies manufactured for a special purpose. w-dah. An increase in the production of construction equipment, the widespread introduction of prefabricated reinforced concrete structures, new builds, materials, high-performance. methods of work ensured in 1960-70 the growth of labor productivity in construction by 60%. Achievements in the field of creating new structures of structures, improving technological. construction methods, production, an increase in the volume of mounted elements contributed to a change in a number of parameters of construction, machines, and sometimes their radical reconstruction, led to the emergence of new, previously unused machines. Powerful earth-moving, road-building, construction machines, such as bucket-wheel excavators, rotary and chain trenchers, wheeled shovel loaders, etc., have been created and are being successfully used. Loading and unloading of stone, sand, gravel, crushed stone, wood, metal are mechanized by 97%. The mechanical-labor ratio of labor in construction increased 2.5 times in 1960-72. The construction of large-sized buildings, elements, assemblies, panels and blocks with a complete assembly of load-bearing and enclosing structures is approx. 4/4 of the total volume of construction and installation work, labor is being mechanized at a high rate in the preparation of concrete, the preparation of mortar. Fundamentally new designs of small-scale mechanization and manual machines: self-propelled machines for rolled and non-rolled coatings prom. buildings, machines for applying and grouting plaster, painting nozzles with protective air screens, etc. A further task of the construction industry is the introduction of machines for loading and unloading cement, for plastering, painting and plumbing. works, the implementation of an integrated M. item in the construction and industry of building materials.
On transport M. p. determined by the specifics of the vehicles. On the yellow On the roads, the production of mass production is achieved by using progressive means of traction (electric and diesel locomotives), increasing the power of locomotives (with a corresponding increase in the mass of trains and their speed), using heavy-duty and self-unloading cars, and equipping railroads. automatic blocking lines, dispatcher centralization, etc. The level of mechanization of loading and unloading operations is increasing based on the use of lifting and transporting machines on railroads. roads and access roads enterprises. If in 1960 at the freight yards of the main railroads. roads was carried out in a complex-mechanizir. 50% of the total volume of loading and unloading operations, then in 1972 this indicator of mechanization amounted to 84%. The mechanization of road transport is being further developed. In the car park, the proportion of heavy-duty vehicles and road trains is increasing. The use of truck cranes, machines with a tail lift, semi-trailers-container carriers, self-unloading road trains-metal carriers will make it possible to mechanize loading and handling operations in a number of industries. A high level has been reached by international transport in water transport. By 1972, the sea and river fleets included more than 90% of diesel-electric ships and motor ships, including dry-cargo and oil tankers equipped with the latest navigation and navigational instruments. Sea and river ports have such means of mechanization as portal cranes, electric forklifts, special equipment. hold machines, floating loaders, etc. St. 90% of the total volume of cargo in seaports is processed in a complex-mechanized manner. way. On river transport with the use of mechanization, 99% of loading and unloading operations are performed. It means that the expansion of the capacity of sea and river ports, the creation of special. highly mechanized transshipment complexes for loading and unloading containers, bulk and timber cargo. In connection with the increase in the country's fuel balance of the share of liquid and gaseous fuels, fully mechanized fuel is developing at a high pace. pipeline transport for oil(see section Oil production), oil products and natural gas. Length oil pipelines in the USSR in 1973 amounted to 42.9 thousand. km, gas pipelines - St. 70 thousand km. The world's largest oil pipeline was put into operation "Friendship from the USSR to the countries of the socialist community.
In agricultureM.p. is one of critical issues in the matter of increasing the efficiency of production and improving working conditions. Productivity with. x-va, along with selection, chemicalization and moisture regulation, is determined by the level of mechanization of all types of agriculture. works. In 1972 energetic. power with. x-va amounted to approximately 265 million. ket(362 million l. from.), of them to the share of mechanical. engines accounted for St. 99%. The power-to-labor ratio in 1973 was 10.3 ket(14 l. from.) for 1 worker. Agricultural Park machines totaled in 1973 St. 2.1 million tractors, more than 670 thousand combine harvesters, approx. 1.3 million trucks, St. 40 thousand cotton pickers. A high level of mechanization has been achieved on collective farms and state farms in the basic field work (plowing, sowing grain, planting potatoes, cotton and sugar beet, harvesting grain, tea, silage crops, etc.), in the inter-row cultivation of sugar beet, cotton, and cleaning grain, harvesting corn for grain by combines, loading grain when hauling it from the currents, etc. At the same time, sowing and planting vegetables in 1972 were mechanized only by 72%, hay stacking by 74%, loading potatoes by 37%, distribution of feed on farms cattle by 17%, pig farms by 39%. Kolkhozes and sovkhozes will be equipped with tractors of increased power and high productivity. grain combines, wide-cut and multi-row machines, as well as combines. machines that perform several passes in one pass. operations. The supply for the village is significantly increased. stores of earth-moving and reclamation equipment, off-road vehicles and load-carrying capacity, dump trucks, automobile and tractor trailers, specialized vehicles. In animal husbandry and poultry farming, the development trend is to create large specialized industrial-type farms, introduce electric machine technology, use production lines (milking and primary processing of milk, preparing and distributing feed, etc.). In the timber industry, lumber production is also primarily aimed at lightening the work of heavy and labor-intensive timber harvesters. works (see logging equipment). The most mechanized processes are felling timber, transporting timber to the upper warehouses and hauling it out. For logging. enterprises by 1973 had St. 72 thousand tractors of various types, St. 35 thousand cars, 1.6 thousand diesel locomotives; various machines and mechanisms were used for felling trees, debarking logs, loading, skidding and hauling wood, etc. of work is 99% of the total volume of work performed on felling timber, transporting wood to the upper warehouses - 98%; timber haulage is fully mechanized. In felling trees, hydraulic wedges, electric and chainsaws operated by one person and allowing cutting trees with trunks up to 1 m. Machines for chokerless forest skidding have been created. For the transportation of timber to the railway. transport uses powerful timber trucks with special. trailers. Developed high-performance semi-automatic lines for cutting tree-lengths, machines that comprehensively perform tree felling, delimbing, cutting wood and forming packages. 75% of all wood is sent for processing, used for the production of furniture, how to build, material and raw materials for pulp and paper industry.
In the light and food industries, production is aimed at facilitating labor-intensive and tedious operations, for which the labor of women is mainly used. Small production in the light industry is associated with the organization of new types of production from newly created materials and raw materials, as well as with the expansion and rapid change of the range of products. Light industry is equipped with a mechanizir. production lines, has almost 500 thousand units of automatic. and semi-automatic equipment. In the industry, they work in a complex-mechanic-nisir. sites, workshops, entire enterprises. The enterprises set high-productivity. carding machines, draw frames with high output speed, spinning-twisting and pneumo-mechanical. spinning machines, automatic looms to replace obsolete machines, etc.
Mechanism is being introduced in the food industry. and complex mechanizir. lines for the production of bread and bakery products, prepare dough. units of continuous and periodic. actions, production lines for the production of confectionery. The level of mechanization in the meat industry is increasing: conveyor lines for slaughtering and cutting livestock, a flow-mechanizer are being put into operation. lines for the processing of by-products, the production of semi-finished products, the manufacture of sausages, dumplings, cutlets, etc., systems are being introduced
complex mechanization and automation of workshops-refrigerators. The fishing industry is replenished with ships equipped with machinery. fish processing lines that provide comprehensive processing of the catch and the full use of waste for the production of feed flour.
In consumer services, mechanical engineering is aimed at equipping domestic service enterprises with means of mechanization and at home using various machines, instruments, and devices that replace manual labor in food processing and cooking, washing and ironing linen, cleaning rooms, etc. utility vehicles).
Further development and improvement of the means of M. p. associated with the use of technical achievements and scientific discoveries based on the development of natures. Sciences. The most important areas of scientific and technical. progress and the creation of new means of labor are: the further development of synthesis, the direct transformation of energy, the depth of
The mechanization of the production process is understood as the replacement of manual labor in it by the work of machines and mechanisms, as well as the replacement of less advanced machines and mechanisms with more advanced ones.
The assessment of the mechanization of the production processes of TO and TR is carried out according to the production methodology for two indicators: the level of mechanization and the degree of mechanization. The basis for determining these indicators is a joint analysis of the operations of technological processes and the equipment used in the performance of these operations.
The level of mechanization (Y,%) is determined by the percentage of mechanized labor in total labor costs:
where T m - the complexity of the mechanized operations of the process from the applied technological documentation, pers. min; T 0 - total labor intensity all operations, people min.
The degree of mechanization (C, %) is determined by the percentage of replacement of human work functions by the equipment used in comparison with a fully automated technological process:
where M is the number of mechanized operations;
4 - maximum link for ATP;
H is the total number of operations;
Z 1 , Z 4 - links of the equipment used, equal to 1, 4, respectively;
M 1 , M 4 - the number of mechanized operations using equipment with links Z 1 , ..., Z4.
According to the methodology, all means of mechanization, depending on the functions to be replaced, are divided into:
1) for hand tools (wrenches, screwdrivers) - Z = 0;
2) manual machines (drill) - Z = 1;
3) mechanized manual machines (electric drill) - Z = 2;
4) mechanized machines (presses) - Z = 3;
5) semi-automatic machines - Z = 3.5;
6) automatic machines (automatic car washes) - Z = 4.
The calculation of mechanization indicators is carried out:
1) for maintenance processes - for one impact;
2) TR processes - per one TR;
3) warehouse and auxiliary work - in relation to the conditional quantity of stored goods or the volume of each type of auxiliary work.
Indicators of mechanization of maintenance and repair, freight ATP are calculated according to the most numerous model of a truck, and for road trains
2 Classification of technological equipment and requirements for it
For modern motor transport enterprises (ATP) and stations Maintenance automobiles (STOA), the industry produces a large range of technological equipment, which differs both in design and in principle of operation. In accordance with the “Table of technological equipment ...” in force in the motor transport system of Russia, 241 models of technological equipment are recommended for use in LTP and motor transport associations. At the same time, the aforementioned normative and technical document does not contain many names of equipment samples that are widely used at auto enterprises and at other objects of the national economy of a different profile (machine tools, woodworking, welding, forging, etc.).
The total number of models of technological equipment for various purposes used at each of the country's auto enterprises ranges from several tens to several hundred items.
However, upon careful consideration of the entire range of technological equipment that a modern auto enterprise is equipped with, two large groups can be distinguished.
The first includes specialized technological equipment that is used directly in the technological processes used in auto enterprises in order to maintain the rolling stock in a technically sound condition.
Technological equipment included in this group can be divided into 6 subgroups:
1. Equipment for cleaning and washing.
2. Lifting-inspection and handling equipment.
3. Equipment for lubricating, washing and filling vehicles with air, oils and working fluids (lubricating and filling equipment).
4.Equipment, instruments, fixtures and tools for assembly, dismantling and assembly and repair work.
5. Control and diagnostic equipment.
6. Tire fitting and tire repair equipment.
The second group includes general-purpose equipment, which is widely used not only in auto enterprises, but also in other national economy facilities and is universal in nature of its use.
This equipment can be divided into two subgroups:
1. Technological equipment for performing blacksmithing, welding, coppersmithing, battery, electrical repair, radio engineering, woodworking and other works.
2. Equipment used for the operation of engineering networks and structures of a car company: heating, ventilation, water supply, sewerage, power supply, etc.
In Russia there is a whole network of design organizations and factories for the design and manufacture of such equipment, but a significant amount of it is purchased abroad.
At the same time, general-purpose technological equipment is mainly manufactured and supplied to auto enterprises from other industries.
3. Cleaning and washing equipment: purpose and design features
According to the functional purpose, equipment for washing rolling stock is divided into: installations for washing cars, trucks, buses.
According to the degree of specialization, this equipment is divided into: highly specialized (washing only the bottom of the car, only wheel rims, etc.), specialized, universal
According to the degree of mobility, they distinguish: stationary and mobile equipment. Stationary washing installations have a large throughput. In such installations, the car is moved using a conveyor
Mobile washing units are used for a small washing program. At the same time, washing installations on a self-propelled chassis, which move around the car during operation, have the highest degree of mobility.
The following methods are most commonly used for car washing:
1. hydrodynamic (jet);
2. hydroabrasive; 3 wet wiping; 4 combinations of the first 3 methods.
Jet (hydrodynamic) method. The essence of the method is the transformation of the static pressure of the liquid into a dynamic one. The condition for cleaning the surface is the excess of the dynamic pressures of the washing liquid over the strength properties of the contaminants. In this case, the cleaning factors for contaminated surfaces are:
Liquid jet speed
Washing liquid temperature
Chemical activity of the cleaning solution;
Nozzle profile;
Spreading angle of the jet.
The advantages of this washing method are as follows:
1.easy to use;
2. the ability to easily adjust the technological modes of washing;
3. absence of intensive destruction of the paintwork and glazed surfaces during its use;
4.Versatility of use for various types of automotive rolling stock. The hydroabrasive method differs from the hydrodynamic method by the presence of special abrasives in the washing liquid. This mixture, under the action of compressed air, is ejected at high speed onto the surface to be cleaned. This increases the efficiency and quality of cleaning contaminated surfaces, but increases the possibility of damage to the surfaces being cleaned and the power consumption for supplying the hydroabrasive mixture.
Wet wipe. The essence of the method is that the wetted surface is wiped with a soft material; rotating brushes, wet cloths, etc. can be used as a working body.
Advantages: low consumption of washing liquid, unlike other methods, the removal of the thinnest mud layer from paintwork and glazed surfaces is ensured.
Disadvantages; the complexity of the design of brush washing installations, lower reliability compared to jet installations, high cost.
4. Alternative ways to clean automotive rolling stock
In the context of the impending water "hunger", some companies in Western countries are creating waterless washing installations and installations with partial use of water.
Thus, the firm "OBAG" (Germany) has developed the design of the unit model 1/4/70/6 for washing cars without using water. The principle of its operation is as follows. Three electrode emitters are mounted in a conventional washing compartment, moving on rollers along rails. Powered by 220V, they send out electrode microwaves. Under the influence of such irradiation, dust and dirt (usually of mineral origin) on the surface of the car causes a molecular vibration and they lag behind. In this case, the use of water is completely excluded. The power consumption is only 2000W. The washing process takes about 5 seconds (during this time, the washing compartment passes once over the car along its entire length). The only drawback of the installation is a slight heating of the treated surface (up to approximately 40 "C). However, tests conducted by the company showed that such heating does not cause harmful effects.
The washing plant without brushes was created by the Italian company IALA. The car body is first bombarded with negatively charged small droplets of the detergent composition. Droplets strike dust and dirt particles, tearing them off the surface of the body. Then a positively charged shower is given. In this case, the dirt is completely removed. At the end of the wash, the car is rinsed and dried with hot air. The entire procedure takes less than 4 minutes.
In Germany, a method for washing various objects made of electrically conductive materials, in particular, a car body, has been patented. The new method is characterized by the fact that a jet of cleaning solution is used as a conductor. Electric current, passing through the jet, significantly speeds up and improves surface cleaning. The object to be cleaned and the nozzle with which the cleaning solution is sprayed; connected to two poles of a direct current source, which is a voltage generator of the "leander" type with a small pulse frequency. To increase the electrical conductivity of the jet, additives are introduced into the washing solution. A smooth change in the electric current of the jet is provided with the help of a rheostat included in the electric circuit "nozzle - jet - object to be cleaned". The washing effect is also increased by periodically changing the polarity and, consequently, the direction of the current in the jet. Polarity reversal takes place with the help of a switching device.
Patented are also methods for cleaning the surface of the car with “washing sheets”. In one case, the washing installation contains a frame with an opening into which the car passes, moving relative to it along a certain longitudinal trajectory, and at least two cleaning
devices installed on the frame in the opening one near the other across the trajectory of the vehicle. Each cleaning device contains a rigid support element mounted on a frame and having the ability to swing, several panels suspended from the support element, and several plates (at least one for each panel), which provide rigid fastening of the panels to the support element. The panels are suspended in parallel so that each of them runs across the trajectory of the vehicle. The side of each panel extends beyond the side of the vehicle. The panel consists of several hanging flexible tapes side by side. They move freely when the panels are not in contact with the vehicle, and continuously touch the surfaces of the vehicle due to the rocking of the support element when the panels interact with the moving vehicle. At the same time, the strips of the panels act on the upper, side, front, rear and recessed surfaces of the body, on the lower parts of the bumper, cleaning them.
In another case, the frame of the device consists of transversely spaced arcuate parts. Each part of the frame is located in a plane parallel to the trajectory of the vehicle. The panels pass across between the arcuate parts of the frame and place the gay at a certain distance from one another along the trajectory of the car.
In the third case, the car washing device consists of a frame and a drive mechanism with a primary motor mounted on the frame. Round holders are installed on the frame, in which groups of washing cloths are fixed. The individual tape elements of these canvases are located one against the other when they are not in working condition, and are connected after they are moved by a car when entering a car wash. The drive mechanism rotates the web in the opposite direction along with the belt elements. Elements of different webs interlock randomly with each other when moving in the opposite direction, thereby improving the quality of washing.
5. Ways to improve the design of washing installations
Cost-effectiveness and efficiency of washing equipment is achieved mainly due to the following design solutions:
Creation of installations with changing angles of attack directly in the process of washing;
Increasing the pressure of the washing liquid up to 3-4 MPa;
Creation of suspended jet washing installations (similar to some foreign designs);
The use of various detergents and heating of the cleaning solution with devices included in the installation kit;
Multiple use of working water (regeneration, recycling water supply system);
Reducing the consumption of electricity and especially water by improving the process and the use of water-air pulsating jets for washing;
Creation of jet-brush installations, as they are more versatile and help save water;
Creation of washing installations according to the principle of subject specialization;
Creation of cleaning and washing complexes according to the modular principle of construction;
Application of alternative cleaning methods (electromagnetic waves, jet pulsation, etc.);
Ensuring the optimal distance from the nozzle to the surface using either measuring sensors, proximity detectors, photo relay devices, etc., or power devices and pneumatic cylinders, which helps to reduce the specific consumption of water and electricity and increase the washing efficiency;
The use of nozzles with variable diameter, with alternating pitch depending on the type of nozzle, the angle of attack of the jet and the configuration of the car (degree of pollution according to the height of the car);
Software control of the speed of movement of the car, depending on its brand and degree of pollution;
6. Lifting-inspection and handling equipment
One of the effective means to increase the productivity of the TP is the use of lifting-inspection and lifting-transnorg equipment, since it is known that when performing the full scope of work on the maintenance of a medium-duty vehicle, the following distribution by type of work is obtained: from below - 40-45 , from above - 40-45 and 10-20% - work performed from the side. Therefore, when performing work on the maintenance and repair of a car, it is necessary to have equipment that provides its service from all sides and at the same time contributes to an increase in the productivity and quality of work of repair workers.
According to NIIAT, the use of modern lifting equipment makes it possible to increase the productivity of repair workers during maintenance and repair by about 25%.
The group of technological equipment under consideration is divided (Fig. 1.1) according to its functional purpose into two subgroups: lifting and inspection and lifting and transport.
Rice. 1.1. Classification of hoisting-inspection and hoisting-and-transport equipment
Lifting and inspection equipment includes equipment that provides convenient access to units, mechanisms and parts located below and on the side of the car. At the same time, work performed using this
equipment from below, can be made with full or partial hanging of the car. Lifting and inspection equipment includes inspection ditches, overpasses, lifts, tippers, jacks.
Lifting and transport equipment includes equipment for lifting and moving a car or its units and assemblies in the zones and sections of the ATP, which is used in the case when the movement of the car on its own is impossible or not rational.
Handling equipment includes: cargo trolleys, crane beams, hoists, hand hoists, mobile cranes, jib cranes, conveyors, loaders.
Inspection ditches. On the motor transport enterprises countries widespread as a means of providing maintenance and current repair received inspection ditches. At the very beginning of the motorization of our country, due to the lack of lifts, there was no alternative to them. However, in subsequent years, when lifts were widely used both abroad and in our country, our motor transport enterprises still preferred to use inspection ditches and are currently widely used.
This is explained, on the one hand, by subjective reasons: established traditions and habits, low technical culture of the performing personnel and the management of fleets, and on the other hand, by objective reasons: an insufficient number of lifts manufactured by the domestic industry, the presence of design flaws in them, the lack of necessary equipment for posts, equipped with floor-type lifts, as well as certain advantages of inspection ditches in comparison with floor lifts:
Inspection ditches are universal, they can serve almost any brand of car;
Inspection ditches provide a wider scope of work for servicing one vehicle, since operations can be performed simultaneously from above, from the side and from below, which cannot be done on conventional lifts without balconies;
Ditches do not require additional costs for electricity (except for lighting and compressed air supply for power plants);
Inspection ditches practically do not require maintenance and repair, while the lifts need constant maintenance and repair with the corresponding costs of time, materials and funds;
Ditches do not require high ceilings of buildings, unlike floor lifts that hang the car up to a height of 1800 mm;
Inspection ditches are not limited by carrying capacity; if necessary, vehicles with a load can be serviced on them;
Convenient location of containers for centralized supply of oils and lubricants, as well as tools and spare parts in specialized niches.
According to the way the car enters the ditch, there are dead-end and rectangular (travel) ditches (Fig. 1.2).
Rice. 1.2. Classification of inspection ditches
The width of the ditches are narrow and wide.
According to the device, the ditches are divided into inter-track and lateral, with gauge bridges, with an additional overpass, trench and isolated.
The length of the ditch should not be less than the length of the car, but not exceed it by more than 0.5-0.8 m. The depth should take into account the ground clearance of the car and be for cars -], 4 m. And for trucks and buses - 1.2-1.3 m. The width of the inter-track ditches is usually not more than 0.9-1.1 m.
To remove exhaust gases, the ditches must have special exhaust devices.
Depending on the purpose, the ditches are equipped with lifting devices (ditch lifts), mobile funnels for draining used oil and devices for filling vehicles with oil, lubricants, water and air.
And yet, the massive use of inspection ditches cannot be considered justified, since it does not meet modern requirements for the working conditions of maintenance personnel and hinders the introduction of modern technologies for maintenance and current repairs at the ATP.
The main disadvantages of inspection ditches are as follows:
Inspection ditches do not fully provide free access to all components and assemblies of the vehicle, as they limit the freedom of action of workers;
Workers are forced to go down into and out of the ditch many times per shift for tools, parts and material, which takes a lot of time, negatively affects the working capacity of workers and, ultimately, reduces labor productivity;
The fixed depth of the ditch and its limited width, insufficient lighting and ventilation, accumulation of dust, dirt, oils, cleaning materials - all this worsens the working conditions of workers and also reduces labor productivity, does not meet sanitary and hygienic standards, is one of the causes of injuries; in addition, if there are no cars on the ditch, a person may also fall into it;
Inspection ditches can only be used on the first floors of buildings that do not have basements;
On ditches, it becomes more difficult, if necessary, to change the technological route of TO and TP;
Keeping ditches constantly clean is difficult and requires additional personnel; ladders, trench fencing and ditch ventilation are also required to be maintained.
Flyovers. The overpasses are a track bridge located 0.7-1.4 m above the floor level, with ramps for entering and exiting the car, having a slope of 20-25 °. Overpasses can be dead-end and direct-flow, stationary and mobile (collapsible), reinforced concrete and metal. Because of large- square occupied by overpasses, they are used mainly in the field, in the arrangement of highways. at recreation sites, roadside gas stations or in the courtyard of the ATP. Lifts. Lifts are used to hang vehicles above the floor at a height convenient for maintenance or repair of units and assemblies from below and from the side.
7. Classification of car lifts
Rice. 1.3. Classification of car lifts
On fig. 1.3. classification should note the aspects characterizing the type of lift, and in some cases, the full name of the lift. For example, the method of its position during operation is indicated - stationary or mobile (rolling), in addition to indicating the type of drive and the number of working plungers or racks, it is advisable to indicate the type of lifting frame or grips indicating the type of the main lifting mechanism - block-rope, with a working pair of "screw -nut", etc. For example, “Stationary, two-column lift mod. P-145, with offset posts, with a working pair - a screw-nut, with lifting side carriages with cantilever beams and mobile pickups", or "Mobile, electromechanical lift mod. 11238 for trucks, with a set of mobile racks with fork lifts under the wheels.
There are a large number of various designs of lifts, which can be classified according to five characteristic features:
1. according to the principle of operation: with lifting the car on racks, with lifting the car on a platform (or ladders) of a parallelogram type;
2. by technological location: floor, trench (on the ditch flanges), ditch (on the ditch wall or at the bottom of the ditch);
3. according to the type of drive of the working bodies: electro-hydraulic, electro-mechanical, electro-pneumatic, pneumo-hydraulic and manual, i.e. driven by the muscular strength of the worker (hydraulic and mechanical);
4. according to the degree of mobility: stationary, mobile;
5. by the number of racks (plungers): single-column, two-column, three-column, four-column and multi-column.
The most commonly used are electro-hydraulic and electro-mechanical lifts. The vast majority of manufactured lifts are stationary. They are intended for permanent maintenance and TP posts on ATPs of various types and fashions. Compared to mobile lifts, stationary lifts have the advantage that they provide greater stability to the lifted vehicle and thus increase the safety and convenience of work. However, mobile lifts also find use. They do not require assembly and installation work and foundation, which allows them to be used on any flat area, including outdoors. After the work is completed, the lifts can be removed from their place, which can be used for other work or equipment. The maneuverability of mobile lifts allows, if necessary, to change the technological route of TO and TP of cars, which is often used at small ATP and service stations or in the case of cramped industrial premises of zones and areas
8.Mechanization of technological processes TO and TP at ATP and STOA
The mechanization of technological processes of maintenance (TO) and repair (R) of cars at auto enterprises is understood as the complete or partial replacement of manual labor with machine labor in the part where the technical condition of cars changes, while maintaining human participation in driving the machine.
The mechanization of technological processes is divided into partial and complete.
Partial mechanization is associated with the mechanization of individual movements and operations, due to which labor is facilitated and the execution of the corresponding technological processes is accelerated.
Full (or complex) mechanization covers all the main, auxiliary and transport operations of the technological process and represents the almost complete elimination of manual labor and its replacement by machine labor. The activity of the worker is reduced to the control of the machine, the regulation of its work and the control over the quality of the operations. Integrated mechanization is a prerequisite for the automation and robotization of technological processes, which is the highest degree of mechanization.
Automation of the technological process eliminates manual labor. Here, the functions of the worker include monitoring the progress of the technological process, monitoring the quality of its implementation and adjustment and adjustment work.
Automation of technological processes involves the automation of some operations of the management of machines and mechanisms with full (complex) mechanization of all labor-intensive operations.
9.Techno-economic and social significance of mechanization technological processes
According to statistics, approximately 60% of the total increase in pond productivity in all sectors of the economy is provided by the introduction new technology, more advanced technology, mechanization and automation of production processes, about 20% - as a result of improved organization of production, and the remaining 20% - due to advanced training of workers.
The mechanization of technological processes of maintenance and TP of automobile rolling stock is of great technical, economic and social importance, which is expressed in reducing the number of repair workers by reducing the labor intensity of maintenance and TP of cars, improving the quality of maintenance and TP, improving working conditions of repair workers. decline
the labor intensity of maintenance and TP is achieved by reducing the time required to perform the corresponding operations as a result of the introduction of mechanization.
Thus, the use of the M-118 automatic line for washing cars makes it possible to reduce the labor intensity of these works by 7.5 times, the 468M electromechanical lift - 2 times, the IZOZM electric wrench for wheel nuts - 1.5 times, the Sh509 stand for dismantling truck tires cars - 2 times, etc.
The mechanization of technological processes has a great influence on the quality of maintenance and repair. This is especially true for control and diagnostic, washing and refueling, cleaning and washing, assembly and dismantling.
In turn, improving the quality helps to increase the reliability of the car on the line, reduce the flow of failures and, consequently, reduce the amount of work performed, reduce the required number of repair workers, vehicle downtime in MOT and repair and waiting for MOT and repair, increase the time of the car on the line.
Improving the working conditions of repair workers is one of the main tasks to be solved by mechanizing the technological processes of maintenance and repair of rolling stock. There is still a large proportion of technological operations performed using unskilled manual labor, mainly heavy, monotonous, tiring and unhealthy repair workers. Such operations include, first of all, dismantling, installation and intra-garage transportation of components and assemblies of trucks and buses (front and rear axles, engine, gearbox, gearbox, springs, etc.), cleaning and washing of bus interiors and truck bodies, washing of all types of cars and buses, vulcanization of tires, etc.
The mechanization of these works, on the one hand, contributes to an increase in the labor productivity of repair workers and an increase in the quality of their maintenance and repair of vehicles (due to less fatigue and increased efficiency), which entails a reduction in the required number of repair workers, a reduction in the downtime of vehicles in maintenance and repair and in anticipation of maintenance and repair, increasing the time of the car on the line.
On the other hand, the mechanization of heavy and hazardous work allows to reduce the number of cases of industrial injuries and occupational diseases among repair workers and the associated loss of working time.
The social significance of the mechanization of maintenance and repair is expressed in improving the working conditions of workers, reducing the turnover of personnel, in a comprehensive and general increase in the cultural and technical level of repair workers.
Improving working conditions during mechanization is achieved through the organization of jobs (selection and rational arrangement of technological equipment in accordance with the requirements of the scientific organization of labor). At the same time, the operational manufacturability of the equipment used is of great importance, i.e. ease of use in maintenance and repair of vehicles.
The decrease in staff turnover during mechanization occurs due to the satisfaction of workers with the nature and working conditions. The consequence of this is an increase in the productivity of repair workers, an improvement in the quality of the work they perform due to the growth of their professional qualifications.
10. Influence of the provision of ATP with mechanization means on the efficiency of their activities.
Before starting work on the mechanization of technological processes of maintenance and repair of cars, it is of particular importance to evaluate the final results of mechanization, i.e. its impact on the performance of the auto enterprise.
Integrated mechanization and automation allow:
Reduce the labor intensity and cost of maintenance and repair of rolling stock;
Improve the quality of their implementation;
Reduce the required number of maintenance workers;
Reduce vehicle downtime in maintenance and TP;
Increase the time of cars on the line;
To improve the performance indicators of the automobile enterprise (technical readiness coefficient, output coefficient, etc.).
NIIAT conducted studies to determine the impact of the level of provision of ATP with technological equipment on such indicators of their activities as the number of repair workers per 100 vehicles, the technical readiness factor (KTG) of the car fleet, the fleet output ratio, the consumption of spare parts and fuel and lubricants. At the same time, the level of provision of ATP with equipment was determined by the present value of technological equipment per 100 vehicles.
For a comparative assessment, 40 freight transport vehicles and 40 bus fleets were taken, and the listed rolling stock ranged from 65 to 716 units. All ATPs were subjected to a detailed examination in order to collect the necessary data.
The results of the analysis indicate a significant impact of the level of provision of ATP with technological equipment on the indicators characterizing the results of their activities. With the increase in the equipment of the ATP with technological equipment, the required number of repair workers per 100 vehicles is significantly reduced, K11 and the fleet output ratio increase sharply (by reducing the days of downtime in repairs and waiting for repairs), which ultimately leads to a decrease in the wage fund and increase the income of ATP.
At present, the task of comprehensive mechanization of production is still far from being solved. Therefore, it is relevant to study the actual levels of mechanization of technological processes of maintenance and repair at auto enterprises.
11. Factors taken into account when mechanizing the processes of TO and TP at the ATP and STOA
When implementing complex mechanization of maintenance and TP processes, the following should be taken into account:
1. For each ATP there is an optimal level of mechanization, in the presence of which it receives the maximum profit from mechanization work.
2. When carrying out the retrofitting (resupplying) of the ATP, a reasonable continuity of the decisions taken must be observed. It is necessary to "start from the results achieved", gradually bringing mechanization at workplaces, sections and zones of the ATP to a technically optimal level.
3. The largest increase in profit (more than 50%) is achieved primarily in the zones TP, TO-1, TO-2, EO (with 20% in the TP zone). The second group of divisions (carpentry, electrical, engine repair, metalwork, welding, assembly, painting, blacksmithing, tire fitting) brings about 40% of the profit. The third group of divisions (copper, wallpaper, fuel, battery) brings about 10% of the profit.
4. It is necessary to take into account the influence of the size of units on the increase in labor productivity of repair workers, profit growth. In small subdivisions (less than 4 workers), the increase in the level of mechanization has little effect on labor productivity. In them, each worker has a narrow specialization, for example, there is one tinker. Therefore, with a constant number of cars in the ATP after the mechanization of the technological process, the same amount of work is performed by the same number of workers, i.e. the release of the worker does not occur, but the degree of its loading is simply reduced. The way out is the enlargement of the ATP, cooperation between the ATP, since mechanization has a tangible effect in large subdivisions. there is a decrease in the rate of profit growth with an increase in the level of mechanization by the same amount. An increase in the level of mechanization by 1% for an initial level of 10% leads to an increase in profit by 3.6%, and for an initial level of 45% - only 0.4%.
5. The greatest impact on reducing the need for spare parts is provided by the mechanization of operations in those technological areas where repairs and restoration of parts are carried out.
6. The greatest impact on the technical readiness coefficient of the fleet is exerted by the mechanization of work in units that perform maintenance and TP operations directly on the vehicle (maintenance zones and TPV posts
7. The implementation of complex mechanization of maintenance and TP processes must begin with the widespread introduction of small-scale mechanization and, above all, a mechanized tool, the use of which can significantly (from 20 to 60%) reduce the complexity of dismantling and assembly work.
12. Economic fundamentals of machine design
The economic factor plays a primary role in the design. Design details should not overshadow the main design goal - to increase the economic effect of machines.
Many designers believe that designing economically means reducing the cost of manufacturing a machine, avoiding complex and expensive solutions, using the cheapest materials and most simple ways processing. This is only a small part of the task. Of main importance is the fact that the economic effect is determined by the value of the useful return of the machine and the amount of operating costs for the entire period of its operation. The cost of the car is only one, not always the main, and sometimes a very insignificant component of this amount.
Economically oriented design must take into account the whole complex of factors that determine the efficiency of the machine and correctly assess their relative importance. This rule is often ignored. In an effort to reduce the cost of production, the designer often achieves savings in one direction and does not notice other, much more effective ways to increase efficiency. Moreover, private savings, carried out without taking into account the totality of all factors, often leads to a decrease in the total efficiency of machines.
The main factors that determine the economy of machines are the amount of useful output of the machine, durability, reliability, labor costs for operators, energy consumption and the cost of repairs.
13. Unification of parts, components and assemblies
As noted earlier, the economic factor plays a paramount role in the design. A great economic effect is provided by the unification and normalization of parts, assemblies and assemblies.
Unification consists in the repeated use of the same elements in the design, which helps to reduce the range of parts and reduce the cost of manufacturing, simplify the operation and repair of machines.
The unification of structural elements makes it possible to reduce the range of processing, measuring and assembly tools. Unifications are subjected to landing mates (by bore diameters, fits and accuracy classes), threaded connections (by diameters, fits and accuracy classes, turnkey sizes), keyed and splined connections (by diameters, shapes of keys and slots, fits and accuracy classes), gears (by modules, tooth types and accuracy classes), chamfers and fillets (by size and type), etc.
The unification of original parts and assemblies can be internal (within a given product) and external (borrowing parts from other machines of a given or adjacent plant).
The greatest economic effect is obtained by borrowing the parts of mass-produced machines, since the parts can be obtained in finished form.
Borrowing machine parts of a single production, machines that have been removed or are to be removed from production, as well as those that are in production at enterprises of other departments, when it is difficult to obtain parts, has only one positive side: the verification of parts by operating experience. In many cases, this justifies unification.
Unification of brands and assortment of materials, electrodes, standard sizes of fasteners and other normalized parts, rolling bearings, etc., facilitates the supply of the manufacturer and repair enterprises with materials, standards and purchased products.
14. Formation of derivative machines on the basis of unification.
Unification is an efficient and economical way to create, on the basis of the original model, a number of derived machines of the same purpose, but with different indicators of power, productivity, etc., or machines for various purposes that perform qualitatively different operations, as well as designed to produce other products.
Currently, there are several ways to solve this problem. Not all of them are universal. In most cases, each method is applicable only to certain categories of machines, and their economic effect is different.
One method is partitioning. The sectioning method consists in dividing the machine into identical sections and forming derivative machines with a set of unified sections.
Many types of transport-lifting devices (belt, scraper, chain conveyors) lend themselves well to sectioning. Sectioning in this case comes down to building a frame of machines from sections and composing machines of various lengths with a new, non-drying canvas. Machines with a link bearing web (bucket elevators, plate conveyors with a web based on bush-roller chains) are especially easily sectioned, in which the length of the web can be changed by removing or adding links.
The economics of forming machines in this way depends little on the introduction of separate non-standard sections, which may be needed to adapt the length of the machine to local conditions.
Method for changing linear dimensions. With this method, in order to obtain different performance of machines and units, their length is changed, while maintaining the shape cross section. The method is applicable to a limited class of machines, the performance of which is proportional to the length of the rotor (gear and vane pumps, Root compressors, agitators, roller machines, etc.).
The degree of unification with this method is low. Only end caps of cases and auxiliary parts are unified. The main economic effect is the preservation of the main technological equipment for processing the rotors and internal cavities of the housings. A particular case of applying this method is to increase the load capacity of gears by increasing the length of the teeth of the wheels while maintaining their module.
Basic aggregate method. This method is based on the use of a basic unit, which is turned into machines for various purposes by attaching special equipment to it. The method finds the greatest application in the construction of road machines, mobile cranes, loaders, stackers, as well as agricultural machines.
The basic unit in this case is a tractor or automobile chassis, which is mass-produced. Chassis mounted optional equipment, get a series of machines for various purposes.
The attachment of special equipment requires the development of additional mechanisms and units (power take-offs, lifting and turning mechanisms, winches, reversers, friction clutches, brakes, control mechanisms, cabins) which, in turn, can be largely unified.
Converting. With the conversion method, the base machine or its main elements are used to create units for various purposes, sometimes close, and sometimes different in workflow. An example of conversion is the transfer of reciprocating internal combustion engines from one type of fuel to another, from one type of thermal process to another (from a spark ignition cycle to a compression ignition cycle).
Gasoline carburetor engines are easily converted to gas. To do this, it is enough to replace the carburetor with a mixer, change the compression ratio (achieved by changing the height of the pistons) and some minor structural alterations. In general, the engine remains the same.
Converting a gasoline or gas engine to a diesel engine is more difficult, mainly due to the higher operating forces inherent in diesel engines due to the high compression ratio and high flash pressure. Therefore, a convertible engine must have large margins of safety. The conversion in this case consists in replacing the carburetor with a fuel pump and injectors, changing the compression ratio (changing cylinder heads, increasing the height of the pistons and changing the configuration of their bottoms).
15.Normalization of parts, components and assemblies
Normalization is the regulation of the design and standard sizes of widely used machine-building parts, assemblies and assemblies. Almost every specialized design organization normalize typical parts and assemblies for a given branch of mechanical engineering. Normalization speeds up the design, facilitates the manufacture, operation and repair of machines, and, with the appropriate design of normalized parts, helps to increase the reliability of machines.
Normalization has the greatest effect when reducing the number of normal sizes used, i.e. in their unification.
The advantages of normalization are fully realized with the centralized production of normals at specialized factories. This relieves machine-building plants from the laborious work of manufacturing normals and simplifies the supply repair enterprises spare parts. Standardization is an essential factor in reducing the cost of machines and speeding up design. However, a prerequisite is the high quality of the standards and their continuous improvement. In addition, the use of normals should not hamper the designer's creative initiative and hinder the search for new, more rational design solutions. When designing machines, one should not stop at the difficulties of applying new solutions in areas covered by the standards, if these solutions have clear advantages.
16. General design rules
The principles of rational design, as a set of general rules for mechanical engineering, look like this:
Do not copy existing samples, but design meaningfully, choosing from the entire arsenal of design solutions developed by modern engineering, the most appropriate in given conditions;
Be able to combine different solutions and find new, improved, i.e. to design with creative initiative, with an inventive spark;
To take into account the dynamics of industrial development and create durable, flexible machines rich in reserves capable of satisfying the growing demands of the national economy.
When creating machines, you must also adhere to the following:
Subordinate design to the task of increasing the economic effect, determined primarily by the useful return of the machine, its durability and the cost of operating costs for the entire period of use of the machine;
To achieve the maximum increase in useful returns by increasing the productivity of machines and the volume of operations performed by them;
To achieve an all-round reduction in the cost of operating machines by reducing energy consumption, the cost of maintenance and repair;
Maximize the degree of automation of machines in order to increase productivity, improve product quality and reduce labor costs;
To increase the durability of machines in every possible way, increasing the actual number of machine park and increasing their total useful return;
Prevent technical obsolescence of machines, ensuring their long-term applicability, laying in them high initial parameters and providing for reserves for development and subsequent improvement;
To lay in machines the prerequisites for intensifying their use in operation by increasing their versatility and reliability;
Provide for the possibility of creating derivative machines with the maximum use of the structural elements of the base machine;
Strive to reduce the number of standard sizes of machines, seeking to meet the needs of the national economy with a minimum number of models by rationally choosing their parameters and increasing operational flexibility;
To strive to meet the needs of the national economy with a minimum output of machines by increasing the useful output and durability of machines;
Design machines with the expectation of non-repair operation, with the complete elimination of major repairs and with the replacement of restorative repairs with a complete set of machines with replaceable units;
Avoid making rubbing surfaces directly on the parts bodies; to facilitate the repair of the friction surface, perform on separate, easily replaceable parts;
Consistently adhere to the principle of aggregation; design nodes in the form of independent units installed on the machine in assembled form;
Exclude the selection and fitting of parts during assembly; ensure complete interchangeability of parts;
Exclude operations of reconciliation, adjustment of parts and assemblies in place; provide for fixing elements in the design that ensure the correct installation of parts and assemblies during assembly;
To ensure high strength of parts and the machine as a whole in ways that do not require an increase in mass (giving parts rational shapes with the best use of material, the use of high-strength materials, the introduction of hardening treatment);
Pay special attention to increasing the cyclic strength of parts; to give parts rational in terms of fatigue strength forms; reduce stress concentration; introduce fatigue-hardening treatment;
In machines, components and mechanisms operating under cyclic and dynamic loads, introduce elastic elements that soften shocks and load fluctuations;
To give structures high rigidity by expedient methods that do not require an increase in mass (the use of hollow and shell structures, blocking deformations with transverse and diagonal braces, rational arrangement of supports and stiffeners);
Make cars unpretentious in care; reduce the volume of maintenance operations, eliminate periodic adjustments, implement mechanisms in the form of self-service units;
Prevent the possibility of overvoltage of the machine during operation (introduce automatic regulators, safety and limit devices that exclude the possibility of operating the machine in dangerous modes);
Eliminate the possibility of breakdowns and accidents as a result of inept or careless handling of the machine (introduce locks that prevent the possibility of improper manipulation of the controls; automate machine control as much as possible);
Eliminate the possibility of incorrect assembly of parts and assemblies that need precise coordination relative to each other; introduce locks that allow assembly only in the desired position;
Eliminate periodic lubrication; ensure continuous automatic supply of lubricant to friction joints;
enclose mechanisms in closed cases that prevent the penetration of dirt, dust and moisture on the rubbing surfaces and allow for continuous lubrication:
Reduce the mass of machines by increasing the compactness of structures, using rational kinematic and power schemes, eliminating unfavorable types of loading, replacing bending by tension-compression, and also by using light alloys and non-metallic materials;
To ensure the maximum manufacturability of parts, assemblies and the machine as a whole, laying in the design the prerequisites for the most productive manufacturing and assembly; reduce the amount of machining, providing for the manufacture of parts from blanks with a shape close to the final shape of the product; replace mechanical processing with more productive methods of processing without chip removal;
To carry out the maximum unification of structural elements in order to reduce the cost of the machine, reduce the time of its manufacture, fine-tuning, as well as to facilitate operation and repair;
To expand in every possible way the use of normalized parts; comply with the current state and industry Standards, industry standards, limits on the applicability of normalized elements;
Do not use original parts and assemblies where you can get by with standard, normal, unified, borrowed and purchased parts and assemblies;
Save expensive and scarce materials by using their full-fledged substitutes; if the use of scarce materials is inevitable, reduce their consumption to a minimum;
striving for cheap manufacturing, not limiting the cost of producing parts on which the durability and reliability of the machine depend to the maximum; make such parts from high-quality materials, apply technological processes for their manufacture that provide the greatest increase in reliability and service life;
Ensure the safety of operating personnel; prevent the possibility of accidents by maximizing the automation of work operations, the introduction of interlocks, the use of closed mechanisms and the installation of protective fences;
In machines-tools and automatic machines, provide the possibility of regulation and adjustment by mechanisms of manual scrolling, slow turning from the drive motor (with reverse, if required by the conditions of adjustment);
In machines driven by an electric motor, take into account the possibility of incorrect starting of the engine, and in machines driven by an internal combustion engine - backfires; provide the possibility of reverse operation of the machine or introduce safety devices (overrunning clutches);
To study the development trends of the sectors of the national economy that use the designed machines; conduct advanced design, designed to meet the needs of machine users in the future.
17. Manufacturability of designed products
When creating a product, one should strive not only to achieve a high technical level, but also to reduce as much as possible the costs of labor, materials and energy for its design, production, operation and disposal. All this characterizes the product as an object of production.
The design of the product is primarily determined by its service purpose. However, the design of the product may be different, while the cost of resources will also be different. This difference is the result of a different level of manufacturability of the product.
Manufacturability is a set of product properties that determine the adaptability of its design to achieve optimal resource costs in its production, repair and disposal.
It should be emphasized that the manufacturability of the product design reflects not the functional properties of the product, but its properties as an object of production and operation.
A product can be considered technological if it corresponds to the state of the art, economically and conveniently in operation, it takes into account the possibility of using the most economical, productive manufacturing, repair and disposal processes. It follows from this that manufacturability is a complex concept.
On the other hand, manufacturability is a relative concept, since with a different product release program, manufacturing and repair technologies differ significantly.
The processes of manufacturing, repair and disposal impose their own requirements on the design of the product, which may contradict each other.
Let's take a detail as an example. The life cycle of a part is associated with processes such as obtaining a workpiece, processing a workpiece, operating the part, repairing it, and recycling it. Depending on the physical nature of the listed processes, each of them imposes its own requirements on the material of the part. If, for example, the workpiece is obtained by cold stamping, its material must have the properties of plasticity. For the machining of a workpiece, it is necessary that the material has machinability properties. The process of operation of a part requires from the material, for example, high strength and wear resistance, and repair requires the ability to restore its properties.
If these requirements turn out to be in conflict, the designer should first of all seek to meet the operational requirements, then determine those methods for obtaining the workpiece, its processing and repair of the part that allow minimizing these contradictions. If these measures fail to eliminate the contradictions, then the designer, where it is permissible, should revise the requirements for the material from the point of view of the operation of the part. The point is that the effectiveness
is evaluated not only by the efficiency of the operation process, but also significantly depends on the manufacturing and repair processes. Given this, the total economic effect should be taken into account. Therefore, when the designed product turns out to be so low-tech that it either cannot be manufactured, or its manufacture turns out to be very expensive, which negates the economic effect of the operation of the product, it is necessary to go to a decrease in performance. This leads to a decrease in the efficiency of using the product during operation, but the total economic effect will be higher.
Manufacturability of the product is evaluated using indicators of rationality, continuity, resource intensity.
The rationality of the design of the product is characterized by complexity, ease of removal of structural elements, accessibility, distribution of tolerances between manufacturing and assembly, etc.
Product design continuity includes structural and technological continuity, variability and repeatability of element materials, design layouts and manufacturing, repair processes, etc.
All these indicators characterize the manufacturability of the product in its production, operation, repair and disposal.
Characteristic of the manufacturability of the product is that it is not evaluated by absolute indicators, but is known in comparison.
Improving the design in the direction of reducing the cost of resources is called testing the design for manufacturability.
Mechanization of production, i.e. the replacement of manual labor with machine labor is one of the main directions of scientific and technological progress in industry. Consistent introduction of mechanization is the most important source of facilitating labor, increasing its productivity, increasing the volume of production and saving labor costs.
The level of mechanization of the main production (workshops, enterprises) is determined by the following indicators: the degree of mechanization of labor Cm.t, the level of mechanization of production processes Um.p.p.
The degree of labor mechanization (in%)
where Chm - the number of workers in the main production engaged in mechanized labor; H - the total number of workers in the main production.
Level of mechanization of production processes (in %)
where Tz - total labor costs in the main production, expressed in conventional norms of manual labor, man-hour; Tr - the cost of the remaining manual labor in the main production, man-hours.
The labor costs of production workers are taken as conditional norms of manual labor per unit of production of the main production, provided that all labor processes are performed manually without any elements of mechanization.
Total labor costs for the main production shop expressed in conventional manual labor rates (in man-hours)
where T1, T2, ..., Tn - conditional norms of manual labor per 1000 gave of products for each scheme (operation) of processing wine materials, man-hours; Р1,Р2,…,Рn - volume of processing of wine materials according to each scheme (operation) of processing, thousand decalitres; n is the number of operations.
Total labor costs in the main production of an enterprise (association), expressed in conditional norms of manual labor (in man-hours)
where Тзц - total labor costs in the main production of the i-th workshop, expressed in conventional norms of manual labor, man-hours; n is the number of workshops of the enterprise.
The cost of the remaining manual labor (in%):
where Tm is the actual technological labor intensity of the production of the shop (enterprise), man-hours; Cm - the degree of mechanization of labor in the shop (enterprise),%.
Actual technological labor intensity of products (in man-hours)
where N is the number of workers in the workshop (enterprise) employed in the main production; t is the annual fund of working time of one worker, h.
Determination of the level of mechanization of auxiliary production and PRTS (loading and unloading, transport and warehouse work) work. When determining the level of mechanization of auxiliary production of secondary winemaking enterprises, it is necessary to proceed from the same methodological provisions as when determining the level of mechanization of the main production. At the same time, the structural subdivisions of the auxiliary production of the enterprise should be considered as independent production units that produce the corresponding products.
Total labor costs in auxiliary production winery, expressed in conventional norms of manual labor, Tz (in man-hours) can be calculated using the formula:
where Тз р.о - total labor costs for the repair and maintenance of equipment for the year, man-hours; Tz t.x - total labor costs for maintenance of thermal and refrigeration plants for the year, man-hours; Тз з.с - total labor costs for maintaining buildings and structures in working condition, man-hours; Tz p.r - total labor costs for PRTS works, man-hours.
The total labor costs for the repair of equipment for the year, expressed in conventional norms of manual labor, Tz r.o (in man-hours) will be:
where Er.o - the conditional rate of manual labor for the repair and maintenance of equipment in 1 conventional repair unit (Repair unit is a conditionally selected amount of repair work performed at a certain ratio of labor costs of repair workers of various professions. The value of the labor intensity of one repair unit for overhaul is 35 normo-h.), man-h.; Vр.о - the average annual volume of repair work, conditional repair units.
The formula for determining the level of mechanization of production in the whole winery is as follows:
where Tz O - total labor costs in the main production in the conditional norms of manual labor per annual production volume, man-hour; Tz E - Total labor costs for the maintenance of thermal and refrigeration installations, expressed in conventional norms of manual labor, man-hours; Tz Z.S - total labor costs for maintaining buildings and structures at the enterprise in working condition, expressed in conventional norms of manual labor, man-hours; Tz G - total labor costs in the enterprise's cargo flows, expressed in conditional manual labor rates, man-hours; Tz P.O - the cost of the remaining manual labor in the main production, based on the annual volume of production, man-hours; Tz R.V - the cost of the remaining manual labor in auxiliary production, man.h.
Calculation of production mechanization indicators for departments and for the plant as a whole is made on the basis of data on the number of workers in the main, auxiliary production and PRTS works.
According to the above methodology, we calculate the indicators of the level of mechanization of production processes by type of production (table 4).
Table 4
Indicators of the level of mechanization by type of production
The relatively high level of mechanization of the main production of the enterprise is explained primarily by the fact that the vast majority of technological processes are associated with the pumping of wine materials, which, as you know, is carried out in a mechanized way, in addition, in the bottling shops such labor-intensive operations as washing bottles and bottling wine into bottles, and also grading of finished products and labeling, fully mechanized.
In order to identify the reserves of labor mechanization at the winery, it is advisable to analyze the structure of the number of workers by type of production.
Currently, 63 people are employed in the main production of Udarny OJSC, which is 37.3% of the total number of workers; 43 people, or 25.4%, in auxiliary production, 63 people, or 37.3%, in PRTS jobs (Table 5).
Table 5
The structure of the number of workers by type of production
Table 5 shows that in general, in the surveyed enterprise, more than half of the workers (54.2%) are engaged in manual labor. Particularly large is the proportion of workers engaged in manual labor in PRTS jobs (58.8%). In auxiliary production, this figure was 51.2%.
The results of the analysis of the structure of the number of auxiliary workers and workers employed in the PRTS works are shown in tables 6-7.
Table 6
The structure of the number of auxiliary workers
|
Support production functions |
Number of workers |
|||||
|
specific weight, % |
employed in manual labor |
employed in mechanized labor |
||||
|
total person |
specific weight, % |
total person |
Specific weight, % |
|||
|
Repair of equipment |
||||||
|
Energy supply |
||||||
|
Maintenance of buildings and structures in working condition |
||||||
Thus, despite a significant degree of labor mechanization at the Udarny OJSC enterprise, more than half of the total number of workers are employed by manual labor, which is a large reserve for further labor mechanization (see tables 5, 6, 7).
Table 7
The structure of the number of workers employed in PRTS works
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