We have adopted a planned warning system in our country Maintenance and car repair. The essence of this system is that maintenance is carried out according to plan, and repairs - on demand.
The fundamental foundations of the preventive maintenance and repair system for vehicles are established by the current Regulations on the maintenance and repair of rolling stock road transport.

Maintenance includes the following types of work: cleaning and washing, control and diagnostic, fastening, lubricating, refueling, adjusting, electrical and other work performed, as a rule, without disassembling the units and removing them from the vehicle individual nodes and mechanisms. If during maintenance it is impossible to verify the full serviceability of individual components, then they should be removed from the vehicle for control on special stands and instruments.

By frequency, car maintenance according to the current Regulations, it is divided into the following types: daily (EO), first (TO-1), second (TO-2) and seasonal (SO) maintenance.

The Regulation provides for two types of repair of vehicles and its units: current repairs (TR), performed in motor transport enterprises, and overhaul(KR), performed at specialized enterprises.

Each type of maintenance (TO) includes a strictly established list (nomenclature) of works (operations) that must be performed. These operations are divided into two components - control and performing.

The control part (diagnostic) of maintenance operations is mandatory, and the execution part is performed as needed. This significantly reduces material and labor costs during maintenance of the rolling stock.

Diagnostics is part of the maintenance workflow (TO) and current repair(TR) of cars, providing initial information about the technical condition of the car. characterized by purpose and place in the technological process of maintenance and repair.

Daily maintenance (EO) is performed daily after the car returns from the line between shifts and includes: inspection and inspection work on mechanisms and systems that ensure traffic safety, as well as the body, cab, lighting devices; cleaning and drying operations, as well as refueling the car with fuel, oil, compressed air and coolant. Car washing is carried out on demand, depending on weather, climatic conditions and sanitary requirements, as well as on the requirements for the appearance of the car.

First maintenance. TO 1

TO-1 consists in an external technical inspection of the entire vehicle and the performance of control and diagnostic, fixing, adjusting, lubricating, electrical and refueling work in the prescribed amount, checking the operation of the engine, steering, brakes and other mechanisms. The complex of diagnostic works (D-1), performed at or before TO-1, serves to diagnose the mechanisms and systems that ensure the safety of the vehicle.

TO-1 is carried out between shifts, periodically at established intervals for mileage and should ensure the trouble-free operation of the units, mechanisms and systems of the vehicle within the established frequency.

In-depth diagnosis of D-2 is carried out 1-2 days before TO-2 in order to provide information to the TO-2 zone about the upcoming scope of work, and if a large amount of current repair is detected, redirect the car to the current repair zone in advance.

Second maintenance. TO2

TO-2 includes the performance of fixing, adjusting, lubricating and other works in the prescribed volume, as well as checking the operation of units, mechanisms and instruments during operation. TO-2 is carried out with the removal of the car for 1-2 days from operation.

At ATP, D-1 and D-2 are combined in one area using combined stationary stands. At large ATPs and at centralized service bases, all diagnostic tools are centralized and optimally automate the repair and maintenance of the vehicle.

Determination of the place of diagnostics in the technological process car maintenance and repair allows us to formulate the basic requirements for its means. To diagnose D-1 mechanisms that ensure traffic safety, high-speed automated tools are required for diagnosing brake mechanisms and steering.

To diagnose the car as a whole (D-2) and its units, stands with running drums are needed to determine the power and economic indicators, as well as the state of systems and assemblies, as close as possible to the conditions for their diagnosis to the conditions of the car. For diagnostics combined with maintenance and repair, mobile and portable diagnostic tools and devices should be used.

Seasonal maintenance

SA is carried out 2 times a year and is the preparation of rolling stock for operation in cold and warm seasons. It is recommended to conduct a separate SS for the rolling stock operating in the cold climate zone. For other climatic zones, CO is combined with TO-2 with a corresponding increase in the labor intensity of the main type of service.

Current repair and maintenance of cars

The current repair and maintenance of the car is carried out in motor transport enterprises or at HUNDRED and consists in the elimination of minor malfunctions and failures of the car, contributing to the fulfillment of the established norms for the car's mileage before overhaul.

The purpose of diagnosing during current repairs is to identify a failure or malfunction and establish the most effective way their elimination: on the spot, with the removal of the unit or assemblies with their complete or partial disassembly or adjustment. The current repair and maintenance of the car consists in carrying out dismantling, assembly, plumbing, welding and other work, as well as replacing parts in units (except for basic ones) and individual components and assemblies in a car (trailer, semi-trailer), requiring current or major repairs of the car, respectively.

During the current repair, the units on the car are changed only if the unit repair time exceeds the time required to replace it.

Car overhaul

KR of cars, units and assemblies is carried out at specialized repair enterprises, factories, workshops. It provides for the restoration of the performance of vehicles and units to ensure their mileage until the next overhaul or write-off, but not less than 80% of their mileage from the mileage standards for new vehicles and units.

During the overhaul of a car or unit, it is completely disassembled into components and parts, which are then repaired or replaced. After completing the parts, the units are assembled, tested and sent to the assembly of the car. With the impersonal method of repair, the car is assembled from previously repaired units.

Cars and buses are sent for overhaul if a major overhaul of its body is necessary. Trucks are sent for overhaul if overhaul of the frame, cab, as well as overhaul of at least three main units is necessary.

During its service life, a complete car is subjected, as a rule, to one major overhaul.

The purpose of diagnostics during a major overhaul is to check the quality of the repair.

Professiogramspecialty "MAINTENANCE AND REPAIR OF AUTOMOBILE TRANSPORT",

qualificationTECHNICIAN

Maintenance and repair of motor vehicles and transport equipment in accordance with the requirements of regulatory and technical documents;

Selection of vehicle components and assemblies for replacement during the operation of road transport;

Carrying out maintenance and repair of vehicles;

Efficient use of materials, technological equipment of enterprises;

Adjustment and operation of equipment for the maintenance and repair of vehicles;

Implementation of technical control during the operation of vehicles and transport equipment;

Carrying out standard and certification tests;

Own computer methods of collecting, storing and processing information;

Analyze and evaluate the state of safety at the production site;

- to drive a car.

Place of work

A vehicle maintenance and repair technician is a middle manager in production management or a specialist in the operation of technological equipment. He can work as a foreman, head of the site at the enterprise, or he can work individually for the maintenance of vehicles or special equipment. Specialists of this profile are also in demand in state structures.

Professional growth can take place as part of continuous professional development: performing increasingly complex and large-scale work, mastering new areas and specializations (for example, a vulcanizer, auto electrician, etc.), becoming a car mechanic - station wagon. The career path can take place along the line of administrative growth: foreman of the shift (section), head technical center, deputy director for after-sales service of cars, director of the auto center.

When choosing an administrative direction of a career, it is recommended to develop additional managerial skills, to master the profession of a manager. If the option of mentoring, transferring one's unique experience to young people is closer, it is useful to develop pedagogical skills in oneself, to master the profession of a master of industrial training.

The organization of one's own business assumes that a qualified worker with a profession technician over time, he develops his unique professional experience and can create his own business by opening a car service, a car repair and maintenance workshop, or working with clients on individual orders (this area brings stable, decent income), but this ability to repair cars is not enough, knowledge in the field is required management, economics, jurisprudence.

Maintenance and repair of motor vehicles

Road transport is one of the most important and basic elements of any production. More than 50% of the total volume of transportation is partially or completely carried out by road transport.

In the current economic situation, the problem of reorganization and restructuring of existing motor transport enterprises is acute. Recently, the need for cargo transportation by trucks has sharply decreased, so large motor transport enterprises are forced to look for additional sources of profit, master the repair of modern equipment, and introduce new types of services. It is necessary to clearly formulate the goals set, try to maximize profits and, to the extent possible, minimize production costs.

One of the most important tasks in the field of vehicle fleet operation is the further improvement of the organization of maintenance and current repair of vehicles in order to increase their performance and at the same time reduce operating costs. The relevance of this task is also confirmed by the fact that many times more labor and money are spent on the maintenance of a car than on its production.

At present, on the basis of scientific and technological progress, the planned preventive maintenance and repair system for the rolling stock of the timber industry complex as a whole, proven by many years of experience, is being further developed.

Both in the field of organization of road transport and in the field of technical operation cars begin to apply various economic and mathematical methods of analysis, planning and design. New methods and means of diagnosing are being developed and implemented more and more widely. technical condition and predicting the uptime resources of vehicles. New types of technological equipment are being created that make it possible to mechanize, and in some cases even automate, labor-intensive operations for the maintenance and repair of rolling stock. Modern forms of production management are being developed, which are designed for the use of electronic computers with a further transition to an automated control system.

With the ever-increasing saturation of the national economy with cars modern system management provides for new structural divisions of road transport - auto plants and production associations, repair and maintenance bases, which potentially contribute to the transition to a centralized production of car maintenance and repair.

The most important task in any economy is the organization of maintenance and current repair of cars.

Calculation of the number of technical maintenance of rolling stock per year

We determine the total mileage of cars for the planned period L total.

L total = ? ss * A ss * D k * b c \u003d 110 * 25 * 251 * 0.8 \u003d 552200 km.

where? ss - average daily mileage of the car, km.

And ss - the average number of cars, units.

D to - the number of calendar days in a year

b c - coefficient of production of cars per line.

Number of maintenance #2 (N then -2)

N then -2 = = = = 43.8 units. = 44 units.

where L total is the total mileage of cars, km

Number of maintenance #1 (N then -1)

N then -1 = = = - N then -2 = 131.3 = 131 units

Quantity daily services N eo

N eo = = = 5020 units

Quantity seasonal service N co

N co \u003d 2 * A ss \u003d 2 * 25 \u003d 50 units

Calculation of the labor intensity of maintenance and current repairs of rolling stock

Maintenance #2

maintenance complexity

Annual labor intensity of maintenance No. 2 ()

= * N then -2 = 37.605 * 44 = 1654.6 man-hours

Maintenance #1

= * = 7.9 * 1.15 = 9.085 man-hours

= * N then -1 = 9.085 * 131 = 1190.1 man-hours

Daily Maintenance

= * = 1.15 * 1.15 = 1.3225 man-hours

\u003d * N eo \u003d 1.3225 * 5020 \u003d 6638.95 man-hours

Seasonal Service

t co \u003d * \u003d * 37.605 \u003d 7.521 man-hours

T co auth * N co \u003d 7.521 * 50 \u003d 376.05 man-hours

where P co - labor intensity standard for seasonal maintenance, %

Maintenance

Correction of the labor intensity of current repairs per 1000 km of run

= * =7.0 * 0.828 = 5.796 man-hours

The resulting correction factor of labor intensity tr

0.9 * 0.1 * 0.1 * 0.8 * 1.15 = 0.828 annual labor intensity tr

T tr = = = = 3200.55 man-hour

The total labor intensity of technical maintenance and current repairs of rolling stock

T then, tr \u003d T to-2 + T to-1 + T eo + T co + T tr \u003d 1654.6 + 1190.1 + 6638.95 + 376.05 + 3200.55 \u003d 13060.25 man-hours

Calculation of the number of repair workers

Total number of repair workers

6.91 people = 7 people

where FRV is the annual fund of working time of a repair worker, hour.

(take 1800 hours).

h - coefficient taking into account the growth of labor productivity of repair workers. Take from 1.05 to 1.08.

Number of repair workers by types of impacts

1.07 = 1 person

0.62 = 1 person

3.51 = 4 people

1.69 = 2 people

1 + 1 + 4 + 2 = 8

Maintenance worker payroll

Calculation of tariff rates by categories

Hourly rate of a time worker:

14.99 rub.

where C months - the minimum tariff rate of a worker, rub.

166.3 - average monthly working time fund, h.

The hourly rate of a worker pieceworker:

16.28 rub. = *

Calculation of hourly tariff rates for repair workers II-VI categories

14.99 * 1.09 = 16.34 rubles. \u003d 14.99 * 1.54 \u003d 23.08 rubles.

14.99 * 1.20 = 17.99 rubles = 14.99 * 1.80 = 26.98 rubles.

14.99 * 1.35 = 20.24 rubles = 104.63: 5 = 20.93

16.28 * 1.09 = 17.75 rubles. \u003d 16.28 * 1.54 \u003d 25.07 rubles.

16.28 * 1.20 = 19.54 rubles. \u003d 16.28 * 1.80 \u003d 29.30 rubles.

16.28 * 1.35 = 21.99 rubles. = 113.65: 5 = 22.73

Average hourly rates for maintenance workers

Average tariff coefficient

\u003d + () * (P s - P m) \u003d 1.09 + (1.20 - 1.09) * (3.6 - 3) \u003d 0.72

where is the tariff coefficient corresponding to the smaller of two adjacent categories of the tariff scale, between which there is an average tariff category.

The tariff coefficient corresponding to the larger of the two adjacent categories of the tariff scale, between which there is an average tariff category

R s - average tariff category

R m - the smaller of two adjacent categories of the tariff scale, between which there is an average tariff category.

= * = 14.99 * 0.72 = 10.79 rubles.

C h to-1 (to-2, tr) \u003d * \u003d 16.28 * 0.72 \u003d 11.72 rubles.

Piece rate for one TO-2 ()

= * = 11.72 * 37,605 = 440.73 rubles

Piecework wages of repair workers employed at TO-2 ()

18468.68 rub.

maintenance repair cost price

Piece rate for one CO ()

\u003d * t w \u003d 11.72 * 7.521 \u003d 88.15 rubles.

Piecework wages of repair workers for the implementation of CO ()

4197.6 rub.

Piecework wages of repair workers employed in TO-2 and CO ()

18468.68 + 4197.6 = 22666.28 rubles

Piece rate for one TO-1 ()

= * = 11.72 * 9.085 = 106.5 rubles.

Piecework wages of repair workers employed at TO-1 ()

13287.14 rub.

Time wages for maintenance workers. Employed on EO ()

68223.1 rub.

Piece rate for 1000 km. car mileage per TR ()

= * = 11.72 * 5,796 = 67.9 rubles.

Piecework indirect wages of repair workers employed in TR ()

35709 rub.

Surcharges for unfavorable working conditions

D nebl.us.t. = = = = 23388.4 rub.

where - the average hourly wage rate of a repair worker employed at TO-2 or Tr

Percentage of additional payment for unfavorable working conditions

accept from 8% to 10%

Number of employees employed in jobs with unfavorable working conditions, pers. In calculations, take - 10%

12 is the number of months in a year.

Night work allowance

D n.h. = * * T n.h. * D r.n.ch. * = * 21.8 * 8 * 60 * 2 = 8371.2 rubles.

= * (1 +) = 11.72 * (1 +) = 11.72 * 1.86 = 21.8 rubles.

where 40 is the amount of additional payment for night work. %

The average hourly wage rate of a repair worker employed in the corresponding type of To or TR, taking into account unfavorable working conditions, rub.

Piecework or hourly wages of repair workers employed in the corresponding type of service

T n.h - the number of hours worked by one worker at night, h.

D r.n.h. - the number of working days per year with work at night, days.

Number of repair workers working at night, pers.

Extra pay for evening work.

D w.h. = * * T w.h * D r.w.h * = * 21.8 * 60 * 8 = 2092.8 rubles.

where 20 - the amount of additional payment for work in the evening,%

T v.h - the number of hours worked by one worker in the evening hours, i.e. from 18 to 22 hours.

D r.v.h - the number of working days per year with work in the evening, days.

Number of repair workers working in the evening hours, pers.

Surcharge for leading a brigade by a foreman (D br)

D br \u003d * N br * 12 \u003d 4958.56 * 1 * 12 \u003d 5982.72 rubles.

498.56 rub.

where - additional payment for the management of the brigade per month, rub.

br - percentage of additional payment for the leadership of the team

N br - the number of foremen

With a team of up to 10 people - 20%

over 10 people - 25%

over 25 people - 35%

Calculation of premiums for repair workers employed in EO, TO and Tr.

P p = = = = 16255 rubles.

where P p - the size of the premium,%. In calculations, take 60 - 80%

Wage fund of repair workers for hours worked.

FZP otvV. = + D negl.cons.t. + D.n.h. + D w.h. + D br. + P r = 27091.85 + 23388.4 + 8371.2 + 2092.8 + 5982.72 + 16255 = 83181.97 rub.

FZP ot.v = + + + = 22666.28 + 13287.14 + 68223.1 + 35709 = 139885.52 rubles.

Wages for unworked time for all types of impacts.

RFP neot.v = = = = 21682.25 rub.

where is the percentage of wages for unworked time

FZP ot.v - wage fund for hours worked for all types of impacts.

1 = + 1 = + 1 = 15,5%

where D o - duration of paid leave (24 days)

D to - the number of days of work in a year

D in - the number of Sundays

D p - quantity public holidays - 10

Wage fund of repair workers for all types of impacts.

FZP = ? FZP from.v. +? FZP neov.v. = 139885.52 + 21682.25 = 161567.77

Deductions for social needs

About social = = = = 45077.4 rub.

where is the percentage of contributions for social needs

Material costs

For maintenance No. 2

M to-2 \u003d * N to-2 \u003d 7.62 * 44 \u003d 335 rubles.

For maintenance No. 1

M to-1 \u003d * N to-1 \u003d 2.75 * 131 \u003d 360 rubles.

For daily service

M eo \u003d * N eo \u003d 0.49 * 5020 \u003d 2459.8 rubles.

For current repairs

M tr = = = = 2186.7 rubles.

where, is the cost rate for materials per impact, rub.

Cost rate for materials for TR per 1000 km, rub.

M then, tr \u003d M to-2 + M to-1 + M eo + M tr \u003d 335 + 360 + 2459.8 + 2186.7 \u003d 5335.5 rubles.

Spare parts costs for TR

ZCH tr = = = = 4511.47 rubles.

where is the cost rate for spare parts per 1000 kilometers.

The initial cost of a rolling stock unit (From the first)

From the first \u003d C aut * K ext \u003d 200,000 * 1.05 \u003d 210,000 rubles.

where Caut - the price of the car, rub.

To dost - coefficient taking into account the cost of delivering a new car to the ATP, take from 1.05 to 1.07.

The cost of the BPF serving the process of maintenance and TR

1312500 rub.

where A ss - the average number of cars, units.

25 - for the cost of fixed production assets from the cost of rolling stock,%

Depreciation of fixed production assets serving the maintenance and repair process

131250 rub.

where N am - the average depreciation rate of buildings and equipment serving the process of TO and TR,% (take 10-12%).

Execution costs production program enterprises for maintenance and repair of rolling stock.

Z then, tr \u003d ?

Calculation of the full cost of one service

Wage fund for repair workers employed at TO-1 for hours worked.

13287.14 rub.

Wage fund for repair workers employed at TO-1 for unworked time

2059.50 rub.

Wage fund of repair workers employed at TO-1

FZP to-1 = + = 13287.14 + 2059.50 = 15346.64 rubles.

Deductions for social needs from the wage fund of workers employed at TO-1

4281.71 rub.

Material costs for TO-1

M to-1 \u003d 360 + 15346.64 + 4281.71 \u003d 19988.35 rubles.

Depreciation of fixed assets serving the TO-1 process

13125 rub.

where 10 is the share of depreciation of fixed assets serving the TO-1 process,% (accept 10 - 12%).

General business expenses (costs)

13185.4 rub.

The amount of costs for TO-1

Z to-1 \u003d \u003d 15346.64 + 4281.71 + 19988.35 + 13125 + 13185.4 \u003d 65927.1 rubles.

Full cost of one service

S then-1 = = = 503.2 rub.

Calculation of financial indicators from the performance of technical services by third parties.

Calculation of the price for the performance of one service

C to-1 \u003d S to-1 + \u003d 503.2 + \u003d 503.2 + 201.28 \u003d 704.48 rubles.

Rent - the level of profitability, taking into account profit (take 40%).

The number of services performed by third parties.

N then-1 = = = = 26.2 units.

where P store - the number of actions performed by third parties,%.

Income from the provision of services to third parties

D to-1 \u003d C to-1 * N to-1 \u003d 704.48 * 26.2 \u003d 18457.37 rubles.

Profit from the performance of services to third parties

P to-1 \u003d D to-1 +? Z to-1 \u003d 18457.37 + 65927.1 \u003d 84384.47 rubles.

Bibliography

• 1. Maintenance and repair of cars: A textbook for students. medium institutions. prof. education V.M. Vlasov, S.V. Zhankaziev, S.M. Kruglov and others; edited by V.M. Vlasov. - 2nd ed., Ster.-M .: Publishing Center "Academy", 2004, - 480s.
• 2. Sukhanov B.N., Borzykh I.O., Bedarev Yu.F. Maintenance and repair of automobiles: a guide for coursework and diploma design. -M.: Transport, 1985, - 224s.
• 3. Turevsky I.S. Diploma design of motor transport enterprises: a study guide. -M.: Publishing House "Forum": Infra-M, 2007, - 240s.: ill. - (Professional education).
• 4. Buraev Yu.V. Life safety in transport: textbook. For students of higher educational institutions / Yu.V. Buraev - M.: Academy 2004. - 272s.
• 5. Napolsky G.M. Technological design motor transport enterprises and service stations - M.: Transport, 1993. - 272p.
• 6. Regulations on the maintenance and repair of the rolling stock of road transport. - Minavtotrans RSFSR. - M.: Transport, 1986. - 73s.
• 7. Afanasiev L.L. and others. Garages and car service stations, M .: Transport, 1980 - 261s.
• 8. Methodology for assessing the level and degree of mechanization and automation of the production of maintenance and repair of the rolling stock of the ATP. MU - 200 - RSFSR - 13 - 0087 - 87. M .: Minavtotrans, 1989. - 101s.
• 9. Kurchatkin V.V. Reliability and repair of machines. - M.: Kolos, 2000.
• 10. E.I. Pavlova, Yu.V. Buravlev. "Ecology of transport". M.: Transport, 1998.

The basis for the maintenance and repair of vehicles is a preventive maintenance and repair system with forced maintenance in a planned manner and repairs as needed.

The following types of vehicle maintenance are provided:

• daily maintenance (EO)
• first maintenance (TO-1)
• second maintenance (TO-2)
• repairs - current (TP) and capital (KR)

Current repairs are divided into current repairs of the car and current repairs of units, assemblies and mechanisms.

Capital repairs are subdivided into major repairs of the car (trailer) as a whole and major repairs of units, assemblies and mechanisms.

The frequency of maintenance is standardized depending on the category of operating conditions.

With an average monthly mileage of rolling stock less than the frequency of TO-1, it is carried out at least once a month, and TO-2 at least twice a year.

A brief description of each type of maintenance and repair is given below.

Daily Maintenance(EO) has as its purpose the control of the technical condition of the rolling stock in order to ensure traffic safety on the roads, refueling with operational materials and maintaining proper appearance rolling stock.

Daily maintenance performed between shifts includes inspection and inspection work on control mechanisms, lighting devices, body, cab, as well as cleaning and washing and cleaning and drying operations and refueling with fuel, oil, compressed air and coolant.

The first and second maintenance (TO-1 and TO-2) are intended to reduce the wear rate of the units and mechanisms of the car by timely detection of faults and their prevention.

Operating environment category	Characteristics of operating conditions	TO-1	TO-2
		Periodicity, km
1 (light)	Country roads predominantly with asphalt concrete and other improved hard surfaces in good condition	1600-1800	8000-9000
2 (medium)	Country roads are predominantly with crushed stone, gravel, cobblestone and other stone pavements that are in a satisfactory condition. Working in busy city traffic	1300-1500	6500-7500
3 (heavy)	Dirt, mountain, or faulty roads with crushed stone, gravel, cobbles, or other hard surfaces. Work in conditions of increased maneuvering (on road construction, in quarries, pits, in logging)	1000-1200	5000-6000

Note. For each category of operating conditions, the highest maintenance interval is taken for cars and buses, the average between the largest and smallest - for cargo onboard vehicles and the smallest - for road trains and dump trucks

First maintenance(TO-1) consists in an external technical inspection of the entire vehicle and the performance of control, fixing, adjusting, lubricating, electrical and refueling works with a check of the operation of the engine, steering, brakes and other mechanisms on the move of the vehicle without fail between shifts periodically through the runs established depending on the operating conditions.

Second maintenance(TO-2) includes a more in-depth check of the condition of all the mechanisms and devices of the car (with the removal of power devices and electrical equipment for control and adjustment in the shops), the performance of fixing, adjusting, lubricating and other works in the prescribed amount, as well as checking the units, mechanisms and devices while driving.

Current car repair has as its purpose the elimination of malfunctions by means of minor repairs or replacement of parts, assemblies and assemblies and is carried out as needed in the inter-shift time without disturbing the normal operation of the vehicle. During current repairs, they eliminate damage and minor malfunctions found during inspection of the car upon returning from the line, during maintenance or at the request of drivers.

Current repair of the unit consists in eliminating its malfunctions by replacing or repairing damaged parts, except for the basic ones.

The base part is the part whose wear and damage has a major impact on the performance of the parts and assemblies associated with it or the unit as a whole. If the time required to repair the unit directly on the car exceeds the time required to replace it, the car is repaired in this case by replacing the faulty unit with a serviceable one.

Current repairs include dismantling and assembly, metalwork, electrical, copper, welding, blacksmithing and other works.

Car overhaul produced according to the need identified as a result technical inspection, and aims to fully restore its technical condition in accordance with the specifications. During this repair, most of the car's components, including the engine, and for passenger cars as well as the body, at the same time undergoing a major overhaul. During a major overhaul, the car is completely disassembled into separate units, and the units into components and parts. The parts of the disassembled unit are controlled and sorted into suitable, requiring repair and unusable. Unusable parts are replaced with new ones, and parts that require repair are restored. After completing the parts, the units are assembled, tested and adjusted. With an impersonal repair method, a car is assembled from previously repaired units and subjected to a mileage test. The car is sent for overhaul in the case when most of its main units, including the cab and frame for trucks or car body, require major repairs. During its entire service life, the car, as a rule, should be subjected to no more than two overhauls. As an exception, average car repairs are allowed for difficult conditions operation In this case, the purpose of the average repair is to replace the engine (requiring a major overhaul), in-depth monitoring of the technical condition of the car and troubleshooting units and assemblies with the replacement or repair of parts, as well as body painting and other restoration work.

Capital repairs of the main units aims to restore their technical condition; this repair is carried out as needed in the case when the technical condition of the unit has deteriorated due to significant wear of parts, does not ensure its normal operation and cannot be restored by current repairs, and also when the base part needs to be repaired or replaced due to its condition.

1. INTRODUCTION

The efficiency of the use of motor vehicles depends on the perfection of the organization of the transport process and the properties of vehicles to maintain within certain limits the values ​​of parameters characterizing their ability to perform the required functions. During the operation of the car, its functional properties gradually deteriorate due to wear, corrosion, damage to parts, fatigue of the material from which they are made, etc. Various malfunctions appear in the car, which reduce the efficiency of its use. To prevent the appearance of defects and timely eliminate them, the car is subjected to maintenance (TO) and repair.

Maintenance is a set of operations or an operation to maintain the operability or serviceability of a car when used for its intended purpose, when parked, stored or transported. Maintenance is a preventive measure and is carried out forcibly in a planned manner, after strictly defined periods of vehicle operation.

Repair is a complex of operations to restore the working capacity and restore the resource of a car or its components. Repair is carried out according to the need, which is identified in the maintenance process.

The performance of work on the maintenance and repair of a car is preceded by an assessment of its technical condition (diagnosing). Diagnostics during maintenance is carried out to determine its necessity and predict the moment of occurrence of a faulty state by comparing the actual values ​​of the parameters measured during the control with the limit values. Diagnostics during car repair consists in finding a malfunction and establishing a repair method and scope of work during repairs, as well as checking the quality of performance repair work. Timely maintenance and current repair of rolling stock allows you to keep cars in a technically sound condition.

Untimely maintenance creates favorable conditions for traffic accidents and extreme wear and tear of vehicle components and parts. Most often, failures occur on the engine. In terms of the number of failures, the car engine accounts for approximately half of all failures. Therefore, in this project, a section for the current repair of car engines has been developed.

2. CALCULATION AND TECHNOLOGY PART

2.1. Calculation of the annual mileage of the park.

2.1.1. Correction of overhaul run is carried out according to the formula:

where is the standard mileage to the Kyrgyz Republic, according to Table. 2.3. for the PAZ-672 bus, we accept = 320 thousand km; (one)

- correction factor, taking into account the category of operating conditions, for category III = 0.8 (Table 2.8); (one)

- correction factor, taking into account the modification of the rolling stock, for the base model = 1.0 (Table 2.9); (one)

- correction factor, taking into account the natural and climatic conditions of operation, for the Vladimir region, located in the zone of moderately cold climate = 0.9 (Table 2.10); (one)

2.1.2. The average overhaul run of the fleet is determined by the formula:

thousand km,

where and - respectively, the number of cars that did not pass and passed a major overhaul, = 295, = 70;

2.1.3. Correction of specific downtime in TO and TR is carried out according to the formula:

days/1000 km,

where is the normative specific downtime in TO and TR, according to Table. 2.6 accept = 0.4 days / 1000 km;

- the average correction factor, taking into account the mileage of cars, is determined by the formula:

,

where , ,…, is the number of cars in the mileage intervals specified in Table. 2.11;

, , …, are the correction coefficients corresponding to the given intervals (1)

Days/1000 km,

2.1.4. The calculation of the coefficient of technical readiness is carried out according to the formula:

,

where - the number of days of operation of the car in the cycle:

- days of vehicle downtime in MOT and TR per cycle:

- days of the car's stay in the Kyrgyz Republic, consists of the days of stay directly in the Kyrgyz Republic, according to Table. 2.6 we accept 20 days, and days of transportation to the Kyrgyz Republic, we accept 2 days. (one)

.

2.1.5. The output ratio is calculated using the formula:

where is the number of working days, = 305 days,

- the number of calendar days;

- downtime coefficient, which does not depend on the technical condition of the rolling stock, we accept = 0.97 (2)

2.1.6. The calculation of the annual mileage of the park is carried out according to the formula:

Table 1.

2.2. Calculation of the production program.

2.2.1. Correction of the periodicity of maintenance is carried out according to the formula:

km,

where is the standard mileage to maintenance, according to Table. 2.1 accept = 3500 km and = 14000 km; (one)

0.8 (Table 2.8); (one)

0.9 (Table 2.10). (one)

The obtained values ​​of the frequency of maintenance are corrected taking into account the average daily mileage: , we accept = 9.

From here km, km.

The results of the calculations are summarized in the table:

Table 2.

Types of maintenance

2.2.2. The calculation of the annual production maintenance program is carried out according to the formula:

Calculate the replacement maintenance program:

With these values ​​of the shift maintenance program, it is advisable to use one TO production line, with TO-2 being carried out in two shifts, and TO-1 on the same line between shifts.

2.2.3. Correction of the labor intensity of maintenance is carried out according to the formula:

man-hour

where - the initial standard of labor intensity of TO, taken according to Table. 2.2 = 5.5 man-hours, = 18.0 man-hours (one)

1.0 (Table 2.9) (1)

- correction factor, taking into account the size of the vehicle and the number of technologically joint groups of rolling stock; with the number of cars = 365 units. and the number of technologically joint groups is less than 3, = 0.85 (Table 2.12) (1)

2.2.4. The annual scope of maintenance work is calculated by the formula:

The results of the calculations are summarized in a table.

Table 3

Types of maintenance

2.3. Calculation of the annual labor intensity of current repairs.

2.3.1. Correction of the specific labor intensity of the current repair is carried out according to the formula:

Man-hours/1000 km,

where is the initial standard of labor intensity of TR, Twenty-two points, plus triple-word-score, plus fifty points for using all my letters. Game "s over. I" m outta here. accept according to the table. 2.2 = 5.3 man-hours/1000 km; (one)

1.2 (Table 2.8) (1)

1.0 (Table 2.9) (1)

1.1 (Table 2.10) (1)

0.85 (Table 2.12) (1)

Man-hours/1000 km

2.3.2. We determine the annual labor intensity of the maintenance work:

The results of the calculations are summarized in a table.

Table 4

man-hours/1000 km						man-hours/1000 km

2.4. Calculation of the labor intensity of the work of the motor section.

2.4.1. The calculation of the labor intensity of the work of the motor section can be performed by the formula:

where FROM- the percentage of TS work performed on the motor section, we accept FROM = 13%

2.5. Calculation of the number of workers in the motor section.

2.5.1. The secret number of workers (number of jobs) is determined by the formula:

accept \u003d 12 people;

here frm- the annual production fund of the working time of the workplace.

2.5.2. The staffing number of performers is calculated by the formula:

accept = 13 people;

here Fair- the annual fund of working time of a production worker.

3. ORGANIZATIONAL PART

3.1. The choice of the method of organizing maintenance and repair.

Car maintenance is carried out in order to reduce the wear rate of parts, identify and prevent failures and malfunctions. During TO-1 and TO-2, control and diagnostic, adjustment, fixing, electrical, lubrication and cleaning work, maintenance of engine power systems are performed, and at the same time, concomitant repairs of components and assemblies are usually performed as necessary.

In the practice of ATP, two methods of organizing the technological process of car maintenance are usually used: at universal and at specialized posts.

When servicing at universal posts, the entire scope of work of this type of technical impact is performed at one post, except for the operation of cleaning and washing the car, which, with any organization of the service process, is performed at separate posts. With this method, mainly dead-end, parallel posts are used. The entry of the car to the post is carried out in front, and the exit from the post is in reverse.

Universal travel posts are used only for road trains and for the production of cleaning and washing operations. At each universal post, it is possible to perform a different amount of work, which allows you to simultaneously service different types of vehicles and perform related repairs.

When performing work at specialized posts, only a part of the work is performed at a separate post, and the entire amount of work is performed at several posts. Specialized posts are located sequentially in the direction of vehicle movement, which ensures the flow of the maintenance process. A set of sequentially located specialized posts forms a service production line. The movement of cars along the posts of the production line is carried out using a batch conveyor at a speed of 10 ... 15 m / min.

Works on the current repair of cars are carried out at posts and in production divisions. At the posts, work is carried out directly on the vehicle without removing components and assemblies, and in the production departments, parts, components and assemblies removed from the vehicle are repaired. The need for current repairs is identified when carrying out TO-1 and TO-2 using control and diagnostic equipment, visually and at the request of the driver.

Control, dismantling and assembly, adjustment and fastening works are usually carried out at the posts, they make up approximately 40 ... 50% of the total volume of work on the TR. Components and assemblies removed from the vehicle for subsequent repair are sent to repair sites in accordance with their specialization.

Pure maintenance of cars that have undergone major repairs is usually 3-5 times more than in the first cycle of the car run. According to NIIAT, from 12 to 30% of vehicles enter the TR only because of untimely and poor-quality maintenance. At high quality TO frequency of TR increases by 2.5 times. Therefore, improving the quality of maintenance is a huge reserve for reducing costs and downtime of vehicles in TR.

3.2. The structure of production management.

Production management provides the necessary conditions for the effective use of the production base, production personnel, process equipment, spare parts and materials. The quality of production management in general and in individual areas depends primarily on the qualifications of engineering and technical personnel who directly manage the work, and is ultimately verified by the amount of vehicle downtime and the cost of maintenance and repair of rolling stock. The organization of production management depends on the size of the ATP, the organization of work of workers and the structure of production.

Control technical service ATP is headed by a chief engineer. He exercises general management of production through the head of production directly subordinate to him.

Production management is fully entrusted to the head of production through the heads of production units subordinate to him. The management of production units in their areas of work is carried out by the heads of structural units.

The structure of the production control center (PMC) includes an information processing and analysis group and an operational management group, which combines production dispatchers. Production managers provide operational control and management of all production departments. The staff of large ATPs has several dispatchers that make up the operational management group. They lead in different shifts and in various production areas.

The production dispatchers are responsible for organizing the execution of work at the posts in the shortest possible time, ensuring the fulfillment of the plan for the release of rolling stock, and the effective use of the production base and personnel.

All employees working at maintenance and repair posts, and in the absence of the head of production, the entire production team are promptly subordinate to the production manager.

Information about what work needs to be done, the dispatcher receives when he gets acquainted with the work in progress, when accepting a shift, according to the records in the accounting sheets that he receives from the KTP, according to the diagnostic posts and messages from the heads of departments.

3.3. Organization of the technological process.

The technical condition of vehicles is monitored during release and return from the line. During release, the state of the systems and assemblies of the vehicle that ensure safety is monitored traffic. The main control of the technical condition should be carried out when the rolling stock is returned from the line.

Planning of work on maintenance and repair of rolling stock is carried out in the group for processing and analyzing information by a maintenance and repair technician based on the actual mileage of vehicles. Maintenance quantity targets for the month and working day are given by the planning department. The Maintenance and Repair Technician draws up a maintenance schedule, which is approved by the chief engineer of the ATP, the Maintenance and Repair Technician, based on the study and accounting of the actual mileage, draws up an order in agreement with the mechanic of the convoy to put cars on TO-1 for 1-1, and on TO-2 2-3 days before the maintenance. The order is approved by the chief engineer and transferred by the dispatcher of the operation service to the dispatchers of the automated workplace and the head of the quality control department to organize control over the work.

Before carrying out the work, a diagnostic map must be drawn up (D-1 and D-2, respectively). The diagnostic map is transferred to the production manager for planning and accounting of work.

Upon returning the faulty car and the line, the ATP mechanic draws up an application for repairs in the prescribed form. The application is registered in a special log and transmitted together with the car to the dispatcher of the MCC. Then the car enters the MMR zone, and then, if there are free posts, respectively, to the diagnostic posts or TR. If there are no free places at the posts, the car enters the waiting area (Fig. 2).

Rice. 1. Block diagram of the technological process TO and TR.

The vehicle is placed at the maintenance and repair posts by order of the production manager. Upon completion of the maintenance and repair work, the vehicle is accepted by the QCD master. In order to check the quality of the work, it is possible to carry out diagnostics, after which the car is placed in the storage area.

After registration of the necessary documentation for maintenance and repair (application sheets, diagnostic cards, accounting cards for turnaround units, etc.), they are processed and deposited with the operational accounting and information analysis group of the MCC.

3.4. The choice of operating modes of production units.

The mode of operation of production is understood as the duration and time of work of various divisions of the ATP. It is determined by the operating mode of the rolling stock on the line, the size of the production program, the number of maintenance and repair posts, the availability of technological equipment and production facilities.

The modes of operation of the EO and TO-1, since they are usually given between shifts, are established based on the results of an analysis of the rolling stock work schedule on the line and the time they spend on the ATP. TO-2 is also expedient to carry out between shifts, as this allows you to significantly increase the coefficient of technical readiness of vehicles. When the production works in one first shift, the best use of the working time of specialists is achieved, but at this time the largest number of vehicles on the line is also required.

Repair areas in the presence of a circulating warehouse are practically independent of the operation of vehicles on the line, so they can work most efficiently on the first shift.

Rice. 1. Combined work schedule for ATP production.

3.5. Selection of technological equipment.

The motor section is intended for the repair of mechanisms and individual parts of the engine. Typical works during the current repair of the engine are: replacement piston rings, pistons, piston pins, replacement of connecting rod and piston bearing shells with liners of operational dimensions, replacement of the block head gasket, elimination of cracks and breakdowns (in the welding department), lapping and grinding of valves.

After performing the current repair of the engine, it is imperative to carry out cold and hot running in order to ensure reliable grinding of components and parts after repair without load, which ensures their greater durability under operating conditions. The choice of technological equipment is determined by the types of work performed and the technical characteristics of the rolling stock. The list of technological equipment is given in table 5.

Table 5

List of technological equipment

No. p / p	Name, designation, type, model of equipment, accessories	Qty	Technical specifications
	Stand for testing engines MPB 32.7		200 kW, 3660´2200
	Engine Repair Stand 2164		1300´846, mobile
	Cathead		3 t, 4.5 kW
	The device universal for editing of rods of fashions. 2211		Desktop
	Cylinder boring machine mod. 2407		275´380, 1.5 kW
	2291A Cylinder Polishing Machine		425´172, 1.5 kW
	2414A Valve Grinding Machine		Desktop, 0.27 kW
	Universal valve seat grinder, 2215		Desktop, 0.6 kW
	Desktop drilling machine NS-12A
	Pneumatic Valve Lapping Drill, 2213
	Compressometer, mod. 179
	Mobile hydraulic crane, 423M
	Washing plant, mod. 196-II		2250´1959, 465 kW
	Washing installation, mod. OM-5359 GOSNITI
	Hydraulic press OKS-167IM		1500´640, 1.7 kW
	Device for disassembly and assembly of cylinder heads, mod.		Desktop
	Locksmith workbench for one workplace, ORG-1468-01-060A
	Locksmith workbench for two workplaces, ORG-1468-01-070A
	Engine Storage Rack
	Tool storage cabinet, ORG-1603
	Cabinet for storage of materials and measuring tools, ORG-1468-07/-040
	Rag chest
	sand box
	Fire extinguishers OHP-10
	Fire extinguishers OU-5

In total, the area occupied by the equipment is 53.95 sq.m.

3.6. Calculation of the production area of ​​the motor section.

The area of ​​the motor section is determined by the formula:

sq. m

where is the density coefficient of the equipment arrangement, we accept = 4 for the motor section; (2)

- the total area of ​​​​equipment in the plan, from the table. five

Based on SNiPs, we accept the width of the premise of section B = 12 m, then the length of the premise of the site will be: 216:12 = 18 m.

4. SAFETY.

4.1. Safety requirements for tools, fixtures and basic technological equipment.

To ensure labor safety, it is necessary to ensure the safety of production equipment and technological processes. To do this, the available tool, technological equipment must comply with the requirements of the labor safety system standards (SSBT), norms and rules for labor protection and sanitary standards. In order to ensure electrical safety, all process equipment with an electric drive must be reliably grounded. Grounding resistance should be no more than 4 ohms. Checking the grounding and insulation resistance is carried out once a year.

When working on an asphalt concrete floor at a workbench, a wooden grate is placed near the workbench to prevent colds and protect against electric shock. Distances between workbenches are taken depending on overall dimensions and layout schemes in accordance with ONT-01-86. It is possible to install workbenches close to the walls only if heating radiators, pipelines and other equipment are not placed there. Chairs should be with height-adjustable seats and preferably with adjustable backs. Workbenches for disassembly and assembly work, in order to make it convenient to work, are adjusted according to the height of the worker using stands under the workbench or footrests. The working surface of the workbench is covered sheet metal or linoleum, depending on the types of work performed. On the site, when using multi-seat workbenches or placing them against each other, a mesh metal separating partition is installed to prevent injury to those working nearby by flying pieces of the material being processed. The height of the partition should be at least 750 mm, and the size of the cells should not exceed 3 mm.

All workplaces must be kept clean, not cluttered with parts, equipment, tools, fixtures, materials. Parts and assemblies removed from the engine during repair must be carefully placed on special racks or on the floor.

Hand tools must be in good condition, clean and dry. Its culling, as well as the culling of fixtures, must be carried out at least once a month. The tool must be firmly seated on the handle and wedged with sharpened mild steel wedges. The axis of the handle must be perpendicular to the longitudinal axis of the tool. The length of the handle is chosen depending on the mass of the tool: for a hammer 300 - 400 mm; for a sledgehammer 450 - 500 mm. The handles of hacksaws, files, screwdrivers, scrapers must be tightened with bandage rings.

4.2. Safety requirements for performing basic work on the site.

When washing engines and parts, the concentration of alkaline solutions should not exceed 5%. Engine parts running on leaded gasoline are washed after tetraethyl lead deposits have been neutralized with kerosene. After washing parts and assemblies with an alkaline solution, they must be washed hot water. It is strictly forbidden to use flammable liquids for washing. When using synthetic detergent surfactants, they are pre-dissolved in special containers or directly in containers washing machine. In this case, the water temperature should not exceed the temperature of the parts by more than 18 - 20 ° C. To protect hands and prevent splashing of the solution on the mucous membrane of the eyes, workers must use goggles, rubber gloves and dermatological products (Silicone cream, IER-2 paste).

When working on grinding machines Special attention should be given to the abrasive wheel. It must be examined, checked for the absence of cracks (when tapped in a suspended state with a wooden mallet weighing 200-300 g, it makes a clear sound), tested for strength, balanced.

Only workers who have been instructed in safety precautions and trained in the correct methods of performing work are allowed to perform work on the motor section.

When performing boring work of cylinders, block-cylinders must be securely fixed on the machine bed with the help of conductors, it is forbidden to hold the workpieces with hands.

When performing disassembly and assembly work, wrenches must be matched to the size of nuts and bolts. The size of the gap of the keys should not exceed the dimensions of the heads of the bolts and the faces of the nuts by more than 0.3 mm. Wrenches should not have cracks, nicks, burrs, non-parallelism of the jaws and the development of a pharynx. It is forbidden to unscrew the nuts with wrenches large sizes with the insertion of metal plates between the faces of the bolts and nuts and the jaws of the key.

For yews, the sponges should have an unfinished surface - a notch. The screws holding the jaws must be in good condition and tightened. The clamping screw must be free of cracks and chips.

4.3. Premises safety requirements.

The production area of ​​the motor section must be kept clean. It should regularly be wet cleaning, cleaning the floors from traces of oils, dirt and water. Oil spilled on the floor must be immediately cleaned up using absorbent materials such as sawdust, sand. The room must be equipped with supply and exhaust ventilation.

In order to protect workers from noise, the test bench room must be isolated from the rest of the room by a partition. The test room must be equipped with a local exhaust gas exhaust.

LITERATURE

1. Regulations on the maintenance and repair of rolling stock of road transport. M.: Transport, 1986.

2. Sukhanov, B.N. and other maintenance and repair of automobiles. Diploma design guide. M.: Transport, 1991.

3. Rumyantsev S.I. and other maintenance and repair of automobiles. Textbook for vocational schools. M.: Mashinostroenie, 1989.

4. Kramarenko G.V., Barashkov I.V. Car maintenance. M.: Transport, 1982.

6. Semenov N.V. Maintenance and repair of buses. M.: Transport, 1987.

7. Mechanization of maintenance and repair of vehicles and restoration car tires. Ed. S.I. Shchuplyakova. Moscow: VDNH, 1962.