Organization of the workplace in the forging and welding workshop. Blacksmith's workplace. Correct organization. Interior arrangement of the forge, basic fixtures

Self-made decorative forged products will require a special facility for the production of blacksmith and welding work. Traditionally, this room is called a forge or blacksmith workshop.

Placement of equipment in the forge: 1- emery machine; 2 - forging machine; 3. pipe bender; 4 - cabinets for tools; 6 - vice; 6 - workbench; 7 - fan; 8 - tank with water; 9 - bugle; 10 - tool hangers; 11- table for tools; 12 - anvil; 13 - boxes with coal.

The work in the forge is to process metal parts, usually hot. Welding with an electric or gas apparatus also involves working with an open flame and metal heated to a high temperature. This places special demands on the forge at home.

How to build a blacksmith and metalwork workshop with your own hands?

It is best to build a forge from materials that are not easily flammable:

Layout of equipment in a rural forge.

• bricks;
• cinder block;
• asbestos cement sheets.

In the event that the forge is forced to be placed in a building with wooden walls, they must be plastered. The floor in the forge is paved with bricks, poured with concrete or made from a mixture of clay and sand, wetting and carefully ramming it. For a locksmith workshop, a garage, barn or utility room in the house. Cold forging machines can also be placed there, since this method of metal processing does not require the use of open fire.

The area of ​​the room for forging decorative elements can be relatively small and dictated only by the convenience and freedom of movement of the blacksmith.

For the production of small-sized products, the optimal area of ​​​​the forge can be considered 16 sq.m.

Tools in the forge: hammers, vise, tongs, sharpeners.

Such a workshop makes it possible to place all the necessary equipment under one roof. Welding work should only be done outdoors.

When performing blacksmithing work indoors, it is necessary to take care of sufficient ventilation. A forced ventilation device of a supply and exhaust type would be ideal. In this case, exhaust equipment is placed above the mountain. The height of the ceilings should not be less than 2.5 m. The forge under a canopy does not need ventilation, but it will be quite uncomfortable to work in it in winter.

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Interior arrangement of the forge, basic fixtures

The specifics of the work of a blacksmith implies the placement of characteristic devices in the workshop:

Forge forge device.

• blacksmith forge;
• anvils and shperaks;
• correct plate;
• bending plate;
• vise;
• hammers, handbrakes, sledgehammers;
• tools for cutting, sharpening, drilling, cutting;
• locksmith's workbench.

In addition, be sure to equip the forge with a container of water to cool the forging, which will always be at hand, and a box for fuel with a poker and a shovel. Ensuring fire safety dictates the placement of a fire extinguisher in an accessible place.

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The most necessary tools

Heating metal blanks to a high temperature before processing requires the presence of a forge in the workshop. This is a kind of open-type furnace, on the hearth of which high-temperature fuel is burned - wood or hard coal. The forge is usually located at the wall farthest from the entrance so that the blacksmith can have access to it from 3 sides. This allows you to heat both long workpieces and small parts for the manufacture of decorative metal elements.

Anvil with a fixture for clamping workpieces.

For a small workshop or for making small parts, a portable forge is well suited, which can be made from sheet metal or from a cut gas cylinder. The processing of larger workpieces (parts of railings, fences, etc.) will require the installation of stationary equipment. Traditionally, such a hearth is made of brick: the base is laid out of brick or cinder block, leaving a place in the center for an ash pan and air flow to the grate. You can also weld the base from a steel corner by making an ash pan from sheet metal. For forced blasting in order to increase the combustion temperature of the fuel, a pipe is laid. A vacuum cleaner can be used to blow air. A grate is installed on top of the ash pan, and the walls around it are laid out of refractory bricks, forming a hearth nest where burning fuel is located.

Processing of a hot workpiece is carried out on an anvil. For this purpose, you can adapt a piece of rail, one end of which is grinded in the form of a cone. If possible, it is better to purchase a professional anvil, but a piece of thick (2-3 cm) steel plate with a smooth surface is also suitable for making decorative parts.

You can install the anvil:

• on a wooden deck ("chair");
• on the basis of monolithic concrete;
• in a barrel of sand.

With any method of installation, the height above the floor of the working surface of the anvil (platband) is determined individually and should approximately correspond to the level thumb on the hand of a forger standing next to her.

Auxiliary devices (bending and straightening plate, vise, shperak) serve to fix and process workpieces. The bending plate has holes into which, if necessary, segments of the rod are inserted according to the pattern; identical elements are bent between them in in large numbers(curls, snails, etc.). On the right plate, you can bend at right angles or straighten long workpieces. Shperaks are mini-anvils for small items. In a vice, the ends of the part are clamped during twisting, bending, or some tools (shperaks, lowers) for processing workpieces.

Percussion tools should be represented by a set of hammers and sledgehammers of various weights (4-16 kg) for striking when forging large products. For the final processing of the workpiece, handbrakes weighing 800-2000 g with a handle length of about 35 cm are used. The handbrake is used to deliver precise blows and correct the shape of the product. Hammers with shaped strikers are used for forgings of a special configuration. Such hammers are usually purchased or made for a specific task.

Various power tools for metal processing must have cables with a cross section corresponding to the load.

A locksmith's workbench is a table of a height convenient for the owner, on which you can install a power tool, lay out workpieces and finished parts, perform cold operations for processing products: sharpening, grinding, cutting, etc.

All forge equipment must be placed with regard to individual requirements masters to the convenience of work and an unhindered approach to the main workplaces: a forge, an anvil, a workbench. Making a forge at home is quite affordable, and working in it will bring pleasure and allow you to independently make various things from metal.

TOOLS AND ACCESSORIES

Blacksmithing requires a wide variety of tools and fixtures. The main supporting blacksmith tool is an anvil (Fig. 8).

Modern anvils are made of steel 45L by casting weighing from 10 to 270 kg. Anvils are of different types: hornless, one-horned, two-horned. The most convenient and versatile in work is the so-called two-horned anvil, shown in Fig. 8a (right). The upper horizontal polished plane at the anvil is called the face, or platband, it performs all the basic blacksmithing work. The lateral faces of the anvil form an angle of 90° with the front surface; the edges of the anvil should be quite sharp, without chips and jams. On the ribs, bending and distribution of material, as well as some auxiliary operations, are carried out.

The conical horn of the anvil is designed for radius bending of strips and bars, as well as for rolling and welding of ring blanks.

Rice. 8. Anvils and shperaks: a - hornless, one-horned and two-horned anvils (1 - face; 2 - square hole; 3 - tail; 4 - brackets; 5 - chair; 6 - paws; 7 - conical horn; 8 - unhardened platform; 9 - round hole); 6 - shperaks (1 - inserted into the anvil; 2 - driven into the ground; 3 - for small work); c - portable sledgehammer; g - anvil mounted on a chair

On the opposite side of the horn is a tail used for bending and straightening closed rectangular products. In the area of ​​​​the tail there is a square hole measuring 35X35 mm, which is used to install a backing tool - bottoms. Near the horn there is a round hole with a diameter of 15 - 25 mm for punching holes in blanks.

From below, at the anvil, the paws necessary for attaching the anvil (using staples) to a wooden chair or metal stand. A massive block or stump (oak, maple, birch) with a diameter of 500 - 600 mm is usually used as a chair. When it is not possible to pick up the necessary block, then they take a metal or wooden barrel, stuff it with sand, clay, earth, tamp it well, put a thick layer on top. wooden spacer, on which the anvil is attached.

Lightweight portable (camping) anvils have special legs.

Anvils are sold in hardware stores. If it was not possible to buy an anvil, then for the first time it can be replaced with a piece of rail or a massive rectangular metal bar.

Great attention should be paid to the installation of the chair, which should stand upright and not vibrate. To do this, the chair is buried to a depth of at least 0.5 m, and the ground around it is well tamped. The height of the chair depends on the height of the blacksmith and is usually 600 - 700 mm. The most convenient height for work is when the blacksmith, standing next to the anvil, without bending down, reaches the casing with slightly bent fingers.

A quality anvil produces a high and clear sound when lightly struck with a hammer, and the hammer rebounds with a ringing sound.

For small work, blacksmiths use small anvils or special anvils - shperaks (Fig. 8, b). Some spurs are installed with their tetrahedral shanks in the square hole of the anvil, others, having an elongated vertical rack, are driven with a pointed end into a wooden block or into the ground.

Percussion tools include hand hammers, war hammers and sledgehammers (Fig. 9). The handbrake is the blacksmith's main tool, with which he forges small items or controls the forging process with hammers.

Usually handbrakes have a mass of 0.5 - 2 kg, but often blacksmiths also use heavier hammers weighing up to 4 - 5 kg. Handbrake handles are made from hardwood (hornbeam, maple, dogwood, birch, mountain ash, ash). The handles should be smooth, without cracks, lie comfortably in the hand, their length is 350 - 600 mm.

War hammers are heavy hammers weighing 10 - 12 kg, with which hammerers work with two hands. War hammer heads come with a one-sided wedge-shaped back, as well as with a two-sided back (longitudinal or transverse). The lower working surface of the head (chip) is intended for basic forging, and the upper wedge-shaped back is for dispersing the metal along or across the axis of the workpiece. The hammer handle is made from the same tree species as the handbrake; the length of the handle is selected depending on the mass of the hammer head, the height of the hammer and reaches 70 - 95 cm.

Sledgehammer - a heavy (up to 16 kg) hammer with flat heads is used for heavy forging work, where a large impact force is required.

Rice. 9. Impact tool: 1 - with a ball back; 2, 4 - with a wedge-shaped one-sided back; 3, 6 - with a bilateral longitudinal back; 5 - with a double-sided transverse back

All percussion instruments must be as reliable as possible, with particular attention paid to the fastening of the handle with the head. The shape of the hole in the hammer head - the hole where the handle is inserted - is made elliptical and has a two-sided slope of 1:10 from the middle to the side faces. This facilitates the insertion of the handle into the hammer head and ensures that it is securely fastened after driving the wedge. It has been established by practice that the most reliable are metal wedges, which enter to a depth equal to 2/3 of the width of the hammer head and are hammered at an angle to the longitudinal axis of the sledgehammer (hammer).

When working with war hammers, three types of blows are used: light (elbow), medium, or shoulder (shoulder strike), strong (mounted), when the hammer describes a full circle in the air. Hammerers work with hanging blows when forging large mass workpieces and when forge welding massive parts (Fig. 10).

To improve the quality of manufactured products and increase productivity, blacksmiths often use various backing tools installed under the hammer or on the anvil. To work under the hammer, simple and shaped blacksmith chisels, punches, trowels and rolling are used (Fig. 11). Undercuts, conical mandrels, bending forks, nailers, various brackets and devices for special types of forging are installed on the anvil.

A paired backing tool is also used, which includes crimps, punchers, nailers with hat hammers, special stamps for figured products.

The handles of the backing tool are made of wood, thick wire or elastic cable. Handle length 500 - 600 mm. wooden handles clog heads without wedging. This is done so that vibration and shock are not transmitted through the handle. The wire handle is twisted around the head in a hot state, and the cable handle is wedged and soldered in the seat.

Consider some of the features of the backing tool.

Let's start with the backing tool under the hammer. Blacksmith chisels are subdivided into chisels for cutting heated and cold workpieces. Chisels for cold cutting are made more massive, with a knife sharpening angle of 60 °, knives for hot chisels are made thinner, with a sharpening angle of 30 ° (Fig. 11, a).

Knife shape for chisels artistic forging is made either rectilinear or with curvature in one plane (or even in two planes).

Rice. 11. Backing tool: a - chisels (1 - for transverse cutting of cold metal; 2 - for transverse cutting of hot metal; 3 - for longitudinal cutting; 4 - for cutting along the radius; 5 - for shaped cutting); b - punch (made with round, square and other sections of the beard); in - firmware (1 - conical; 2 - cylindrical); g - ironers; d - rolling

Chisels with a straight knife are made for both transverse and longitudinal cutting, with one-sided sharpening or two-sided. The chisel knife for transverse cutting is parallel to the axis of the handle, and the chisel knife for longitudinal cutting is perpendicular to the handle. One-sided sharpening of the chisel is used when it is required to obtain a cut with a perpendicular end, and if the product has an inclined end or a chamfer is needed, then chisels with double-sided sharpening are needed. Chisels with a blunt knife are used to apply various ornaments to products.

Chisels with a knife curvature in a horizontal plane are used to cut out various curvilinear elements from sheet material, such as flowers, acanthus leaves.

Shaped chisels with a double curvature of the knife are used for cutting out any elements from bulk workpieces.

When working with a chisel, blacksmiths must keep in mind the following: so that the knife does not dull, a gasket (iron or copper sheet) must be placed under the workpiece. By the way, the gasket will protect the face of the anvil from damage.

When cutting off a part from a workpiece, certain rules must be observed. So, the initial and final blows to the chisel must be applied very carefully: at the beginning - so that the chisel correctly cuts into the workpiece, at the end - so that the cut off part does not fly away and injure someone. The place where the cut is made must be fenced with a net.

Punches are designed for punching holes, various recesses in relatively thin workpieces and for ornamenting products. Depending on the shape of the punched holes, the section of the beard (the working part of the punch) can be round, oval, square, rectangular or shaped (Fig. 11, b).

For punching holes in thick workpieces, piercings and special punches are used, which differ from punches in that they do not have handles and are held with tongs (Fig. 11, c).

It is known from blacksmithing practice that, in order to facilitate the removal of the piercing from the punched hole, a little fine coal is poured into the previously marked recess (during the piercing process, the gases formed from the coal contribute to the ejection of the tool).

The trowels are used to smooth out irregularities on the surface of the forging after it has been hammered. Smoothers come with flat and cylindrical working surfaces of various sizes and shapes. For leveling large planes, trowels with a working surface of 100X100 mm are usually used, for leveling small surfaces - trowels with a size of 50X50 mm. Smoothers with a cylindrical surface are necessary for leveling fillets and radius surfaces (Fig. 11, d).

The rolling is intended to accelerate the distribution (elongation) of the metal along and across the axis of the workpieces, as well as to knock out cylindrical grooves on the workpieces and to ornament the products (Fig. 11, a).

Let's get acquainted with the backing tool installed on the anvil. Such a tool is equipped with a square shank, which is inserted into the corresponding socket in the anvil (Fig. 12).

Undercuts are used for cutting workpieces with a handbrake. The workpiece is placed on the cutting blade and, hitting it with a handbrake, cut off the necessary part. The angle of sharpening the cutting edge is 60°. It should be remembered that the cutting of the workpiece cannot be completed to the end, so as not to spoil the cutting blade. First, a deep hemming of the workpiece is carried out, and the final separation of a part of the workpiece is carried out at the edge of the anvil with a light stroke of the handbrake.

Rice. 12. Backing tool installed on the anvil: 1 - notches; 2 - conical mandrels; 3 - fork; 4 - 6 - mandrels

Tapered mandrels are used to enlarge holes in a forging, expand rings and perform bending operations.

Forks are used for bending and curling workpieces. In addition, backing tools include various mandrels for slope forging, bending and forge welding of chain links.

The paired backing tool includes a lower tool (izhnyak), which is inserted into the anvil hole with a square shank, and top tool(top), having a handle for holding (Fig. 13, a).

This group includes crimps (to give the pre-forged workpiece the correct cylindrical, rectangular or polyhedral shape) and tamps (for longitudinal or transverse distribution of metal). For special artworks, special stamps with reliefs such as leaves, peaks, rosettes, etc. are used.

A nail plate with special through holes of various sizes for landing nail heads, bolts and fasteners can also be attributed to the backing tool (Fig. 13, b).

To give the head of a nail, bolt or rivet the required shape (sphere, prism, square, hexagon), special hat hammers are used.

Rice. 13. Paired backing tool: a - crimps (1 - 3) and tamper (4); b - fixtures for landing nails, bolts, rivets

A massive steel plate will also be of great help in forging art products - a shape about 300X400 mm in size and 150 - 200 mm thick, on the four side faces of which there are recesses of various configurations and sizes: semicircular, triangular, rectangular, etc. The plate is necessary when forging various shaped elements and is used instead of backing stamps. On the end surfaces of the mold there are through round, square, triangular and shaped holes for punching holes using special punches or punches (Fig. 14).

For the manufacture of large artistic products such as fences, balcony railings, canopies, porches, you will need a large and thick plate, on which the products are assembled and straightened. The plate provides through holes for installing pins, bolts, thrust squares and various devices for profile bending of profiles, assembly of structures and other technological operations.

It is convenient to assemble artistic products of complex shape (with a convex surface) on plates with an appropriate surface shape. For welding large products, it is necessary to have special racks.

To work with hot metal, of course, you need flares. According to the shape of the jaws, the pliers are divided into longitudinal, transverse, longitudinal-transverse and special. Forging tongs should be light, with springy handles, to securely hold the forgings during operation, the handles of the tongs can be pulled together with a special ring - a spanner (Fig. 15, a).

If the flares do not grip the workpiece tightly, then the jaws of the pliers are heated in the forge and, having captured the workpiece with them, they are pressed with a handbrake.

A chair vice (Fig. 15.6) and various clamps are used to clamp hot workpieces. Such vices are fastened with powerful screws, bolts or rivets on the main support of a metal workbench or on a separate chair - a massive log well fixed in the floor of the forge. The upper level of the jaws is usually located at a height of 900 - 1000 mm from the floor level.

To measure workpieces and products in the forge, steel rulers 250, 500 and 1000 mm long, metal meters, calipers, squares, etc. are used. In addition, blacksmith artists widely use various templates and gauges made of wire and sheet materials when performing mass production (Fig. 16).

Rice. 14. Forging mold

To care for the forge, you will need a coal shovel, a poker, a pike or a crowbar for punching baked coal, a whisk for cleaning the furnace from fine coal and slag dust, a sprinkler for wetting coal when sintering a dome (cap) over the hearth, tongs for coal.

It should be noted that all the tools necessary for forging should be located on a special table in the immediate vicinity of the blacksmith's workplace. Table height 600 - 800 mm.

In addition to the main and auxiliary tools, the forge always has a box for dry sand, a rack for storing tools, water tanks, a box for coal, racks for storing tools and metal, a workbench for metalworking, etc.

It is good when the workshop of a blacksmith-artist is spacious, bright, includes several rooms for certain types of work: sketch-graphic, metalwork-assembly and blacksmith-welding. In addition, a room for storing materials, various semi-finished products, etc. is desirable.

Rice. 15. Blacksmith tongs (a) and chair vise (b): 1 - handle; 2 - clamping ring; 3 - rivets; 4 - sponges; 5 - blank; 6 - loop

For sketching and graphic work, you will need large tables, since some elements have to be drawn in full size, a drawing board for drawing individual components and parts, as well as various tablet stands, cabinets for storing sketches and drawings.

The room for metalwork and assembly work is equipped with a metalwork bench with a vice, a drilling machine, a grinder and other equipment necessary for assembling and finishing forged products.

The forge for one anvil is shown in fig. 17, a. A horn with a fan is set up against the wall opposite the entrance. At a distance of 1.5 - 2 m from the forge, an anvil is installed, which should be positioned so that its horn is to the left of the blacksmith when he stands with his back to the forge. Enough free space is provided around the anvil for the hammer to work. Near the anvil there is a tank with water for cooling the blacksmith's tools and hardening products. The blacksmith's tool is placed on a metal table with two shelves. The upper shelf is for frequently used tools (hammers, chisels, tongs, etc.), the lower one is for less frequently used tools. For the convenience of work, the blacksmith puts the tool on the table so that its handles protrude beyond the edge of the table.

Spare and rarely used tools are stored in a cabinet. A box for storing coal is installed in the corner near the hearth. A chair forging vise is placed near the wall, on which landing, bending, and twisting are carried out. Next set locksmith workbench. Dry sand is stored in a convenient place for backfilling wet places on the floor of the site and rag ends for cleaning tools and other purposes.

Rice. 16. Control and measuring tool: a - caliper; b - calipers; c - inside gauges; g - combined measuring tool

Rice. Fig. 17. Placement of equipment and tools in the forge: a - forge for one anvil (1 - fan; 2 - forge; 3 - tool table; 4 - water tank; 5 - anvil; 6 - tool cabinet; 7 - grindstone; 8 - workbench; 9 - blacksmith vise; 10 - box for coal); b - forge for two anvils (1 - anvil; 2 - table for tools; 3 - 4 - work tables; 5 - cabinet; 6 - barrel of water; 7 - forge; 8 - hangers for ticks; 9 - grindstone; 10 - pneumatic hammer; 11 - hand scissors; 12 - straightening plate; 13 - chair vise; 14 - rack for blanks

The location of the main and auxiliary equipment, as well as tools in a larger forge, is shown in fig. 17, b. A horn for two fires is provided at the far wall. To place ticks on the forge, there are hangers - steel brackets welded to the table. To the left and to the right of the forge, tanks with water with a capacity of 30 - 40 liters each are placed. At a distance of 1.5 - 2 m from the forge, two anvils are arranged, and between them are tables on which the blacksmith's tool is placed. The distance between the anvils is at least 2.6 - 3 m. The emery sharpener is placed against the wall at a sufficiently large distance from the anvil. Modern blacksmith shops are usually equipped with a small pneumatic hammer with a mass of falling parts of 50, 75 or 100 kg.

Forging stations are often equipped with mobile hand scissors for sheet metal cutting, correct cast iron stove size 1500X1000 mm, chair (claims, and in some cases also a bench workbench, a bench drilling machine, an assembly table, a rack for blanks, and sometimes a mechanical hacksaw for cutting dimensional blanks from rolled products. Installed above the mountain to remove smoke and gases exhaust hood. The organization of such forges requires a rather long time and large funds, but such forging sites can be organized simply in the open air or under a small shed.

Amateur blacksmiths almost always have difficulty acquiring hammers and presses. For this reason, we want to show homemade designs molotov. In these designs, the hammer blow occurs as a result of pressing the foot on the pedal, and the rise is done with the help of springs (Fig. 18).

It should be noted that when working in one hand, many blacksmiths feel that they do not have enough third hand to simultaneously hold the handbrake, workpiece and backing tool. In this case, we can advise the method used by sickle blacksmiths when drilling sickles. The heated billet is slipped under the cable ring, which, under the action of a foot pedal, presses it against the anvil. Or the workpiece is pressed by chains with loads. As a result left hand the blacksmith is freed from the tongs holding the workpiece, and can hold the necessary backing tool (chisels, trowel, etc.).

Screw presses with a manual drive are used for embossing, bending, forming, punching shaped holes in sheet blanks.

For spinning work, you can use a lathe (Fig. 19), on the spindle of which a wooden (or metal) mandrel of the required shape and a blank-circle of sheet material are fixed.

A round metal blank made of sheet copper, brass, aluminium, low-carbon steel grades is pressed. to the mandrel with a special clamp using the tailstock of the machine.

To extrude the product, presses of various configurations are used, which are made of steel, brass, bronze, and even hard rock tree. The length of the crusher handle is 40 - 60 cm. The working end of the mandrel has a spherical or rounded shape.

During operation, pressure gauges rely on special pins, which are installed on the stop. The height of the stop is just below the axis of rotation of the workpiece. The squeezer must be held so that its handle is directed towards the armpit. Before starting the process, the workpiece and tool are wiped with wax or grease. Extrusion lead from the center to the edges. If folds form on the workpiece during the formation of the product, then it must be squeezed out, and then the process should be continued. After the end of the extrusion, the edges of the workpiece are trimmed with a cutter, the surface is treated with an ironing press, and then ground and polished.

Rice. 18. Homemade hammers

Safety engineering. All blacksmithing works are classified as high-risk work, so there are special requirements for the clothes of blacksmiths, as well as for the tools and equipment used in forging.

The blacksmith's clothes are made of dense fabric, the jacket should cover the waist part, trousers - upper part boot, apron - chest (the length of the apron is slightly below the knees). Gloves, a headgear and an eye shield are required when working.

Cracks, chips and burrs are not allowed on percussion instruments and on their handles. The floor at the workplace must be flat and dry, it should not be cluttered with blanks, waste and products. The instrument cooling container must always contain pure water, and in a box of sand - dry sand.

The presence of persons not participating in work is not allowed at the workplace. When doing work, one must be attentive, not be distracted by extraneous matters or conversations, and not distract others from the work.

The tool, heated during operation, is cooled with water, and then dried.

Before forging, scale is removed from the workpiece with a metal brush, scraper or light hammer blows. The forging is taken with pliers so that the jaws of the pliers fit snugly against it. The workpiece is laid on the anvil with its entire surface.

When working with a hammerer, make sure that he stands half-turned to the blacksmith, and not opposite him. Commands are given clearly, in a loud voice and show the place of impact with a hammer.

Hammer strikes on tongs, tool handles, idle blows with a sledgehammer on an anvil are prohibited. The end of forging is done on command "stop" and not by removing the forging from the anvil. Putting any tool on the forging or changing its position is allowed only after warning the hammerer.

When cutting metal, the chisel is set strictly vertically. Cutting is carried out on the edge of the anvil, the first and last blows are made weak. The cut off end of the forging should be directed away from you.

Rice. 19. Device for spinning works (a) and crushers (b): 1 - lathe; 2 - extruded workpiece on the mandrel; 3 - clamp; 4 - support pin; 5 - emphasis; 6 - tailstock

workplace called that part of the workspace where the production equipment is located, with which a person interacts in the working environment.

Welding sites are divided into permanent and temporary. Permanent (stationary) places are intended for work that is carried out in specially equipped workshops, workshops, etc. Install the welding machine in a weatherproof environment, welding table, manipulator, exhaust hood, etc. in a well-ventilated area of ​​at least 3 m2. It is best if the floor is concrete, and the walls of the room should not reflect welding glare, which can be dangerous to the eyes.

Fig.14 Layout of the welding booth:

1 - arc power supply; 2 - grounding; 3 - power supply starter; 4 and 5 - direct and reverse conductive wires; 6 - table; 7 - ventilation; 8 - rug; 9 - electrodes; 10 - shield; 11 – electrode holder; 12 - chair;

13 - waste box; 14 - doorway

Fig.15. Workplace of the welder

Passages between multi-station welding units and between automatic welding units must be at least 1.5 m; passages between single-station welding transformers or between welding generators, as well as passages on each side of a rack or table for performing manual welding - at least 1 m. The distance between a stationary welding unit and a wall or column should be at least 0.5 m, and the distance between a wall or a column and a welding machine - at least 1 m. Passages between spot and seam (roller) welding machines with workplaces opposite each other must be at least 2 m, and between butt welding machines - at least 3 m. of the machines listed above with their back sides to each other, the width of the aisles should be at least 1 m, and if the front and back sides are located to each other - at least 1.5 m.

For each stationary workplace during plasma and gas-plasma processing of metals, > 4m 2 should be allocated, and when working in the cabin > 3m 2.

Zones with hazardous production factors must be fenced off, safety signs are designed in accordance with GOST 12.4.026-76*.

Depending on the dimensions of the products to be welded and the nature of the production, the welder's workplace can be located either in a special cabin, or in a workshop or directly at the assembly facility. Cabin dimensions must be at least 2x2 m 2 .

Fig.16. Contact welding booths.

The walls of the cabin are made 1.8-2 m high. For better ventilation, a clearance of 150-200 mm is left between the floor to the lower edge of the wall. The cabin wall material can be thin iron, as well as plywood, tarpaulin, read with a fire retardant compound, or other fire retardant materials. The cabin frame is made from metal pipes or angle steel. The doorway of the cab is usually closed with a canvas curtain mounted on rings. Plywood and tarpaulin should be impregnated with a fire-resistant composition, such as a solution of potassium alum.

The floor in the cabin must be made of fire-resistant material (brick, concrete, cement), non-slip and non-slip, and have low thermal conductivity.

The walls are painted in light gray with paints that absorb ultraviolet rays well (zinc or titanium white, yellow crown). Painting welding shops and booths in dark colors is not recommended, as this worsens the overall illumination of the welding site.

Combined lighting should be provided for work of high and highest accuracy (I-III grade), in particular, when welding and soldering materials with a thickness of 0.06 ... 0.5 mm, when flaw detection of welds and other similar works.

For lighting workshops, it is necessary to use, as a rule, gas-discharge light sources: DRL, DRI lamps; for illumination of high workshops (up to 4 m) of a large area - fluorescent lamps. Incandescent lamps are allowed.

Cabin illumination should be at least 80-100 l.

In industrial premises of welding and assembly and welding shops, the microclimate parameters should be taken in accordance with GOST 12.1.005-88 (rooms with slight excesses of sensible heat, moderate work of categories IIa and IIb).

In the cold period of the year, the permissible microclimate parameters for works IIa and IIb are respectively equal: air temperature 17 ... 23 and 15 ... 21 0 С, relative humidity< 75%, скорость движения воздуха < 0,3 и 0,4 м/с.

The cabin is equipped with local ventilation with an air exchange of 40 m3/h for each worker. The ventilation suction must be located so that the gases released during welding pass by the welder.

Fig. 17. Exhaust hood: 1- air duct; 2-gate; 3-air inlet; 4- stamped grating; 5- visor.

When welding in closed volumes, air is extracted to the suction duct of the workshop exhaust system. It is possible to supply air under the welder's mask, equal to 110 ... 140 l / min.

Fig.18. Air inlets built into welding torches for mechanized welding in CO 2 . a, b - annular symmetric and asymmetric, respectively; V-conical perforated; d- cone-slit; ----- - suction aerosol; - - - - - shielding gas.

In the organization of welding work, the correct placement of equipment is important. Multi-station units and installations, consisting of several welding units, are located in a separate room or on the area of ​​​​the general production room, fenced with permanent partitions with a height of at least 1.7 m. During operation, welding converters create noise that has a harmful effect on the human nervous system, causing a decrease in attention and decreased performance. For this reason, all welding converters must be isolated in the workshop room or taken out of the production room, fenced off from all sides and covered from atmospheric precipitation.

In stationary multi-station welding installations, the welding stations are connected to the electric welding unit through a common shield, on which the necessary measuring instruments, protective equipment, signal lights, circuit breakers and clamps for connecting the welding stations should be located. In case of single-station welding, individual shields must be provided, equipped with a voltmeter and a signal light indicating to the welder the presence or absence of voltage in the welding circuit.

Passages between multi-station welding units and between automatic welding units must be at least 1.5 m; passages between single-station welding transformers or between welding generators, as well as passages on each side of a rack or table for performing manual welding - at least 1 m. The distance between a stationary welding unit and a wall or column should be at least 0.5 m, and the distance between a wall or column and a welding machine - at least 1 m. Passages between spot and seam (roller) welding machines with workplaces opposite each other must be at least 2 m, and between butt welding machines - at least 3 m. of the machines listed above with their back sides to each other, the width of the aisles should be at least 1 m, and if the front and back sides are located to each other - at least 1.5 m.

7. Adjust the height of your chair so that your work is at a comfortable eye level.

1. Sitting at your desk, you should see front door.

In order to fully concentrate on work, a person needs to feel a sense of complete security. Our survival instincts never sleep, and whenever we feel vulnerable, part of our attention is diverted and subconsciously focused on any sounds, shadows, and vibrations that may indicate that someone is approaching us.

Place a mirror in the room so that you can see the front door through it.

Attach an object to the door that makes a sound when it is opened, such as a bell.

2. Make sure there are no aisles behind your chair.

If someone walks behind you, it is very unnerving. Here again our instinct for self-preservation comes into play. We are programmed to be alert if we feel that our rear is not protected and we are vulnerable.

If you cannot provide this condition:

· Place a mirror on the wall facing the direction of the passage.

· Fence off the workplace with a screen, plant, or some other object that is perceived as a wall or barrier.

· Place an object that reflects the image in a place where it will distract from you the attention of someone who passes by you.

3. Position your desk so that it is not directly opposite the entrance to the room.

If your desk is in line with the door, you will often be the first to be asked to complete a task, and most likely you will be burdened with more work than you are required to do.

The best way out in this situation is to move the table so as to divert the attention of the incoming person, which is usually focused on the one sitting directly in front of the door, so that it is scattered on those who sit to the side of it.

If you cannot provide this condition:

Place an object on the left side of the table that refracts light and faces the door with its refracting side. The object will attract the eye of the incoming person and divert his attention from you.

4. All aisles that you can see from your workplace should be well lit.

The person entering the room must see you clearly, just as you can see him. It is always more pleasant to communicate with someone who immediately recognizes us and addresses us by name.

If you cannot provide this condition:

Hang a poster or emblem in bright yellow on the wall. Objects become more clear against a yellow background. Contrast will give the person who enters a better chance of getting your attention.

5. Direct light should be directed to your non-working hand.

Do not agree to work in a room lit only by overhead fluorescent light. Such a deadening light is found only in barren deserts. Place the lamp on the side of your non-working hand so that no shadows form on the work surface when you use your working hand.

The light source should be located on the opposite side of your working hand, so as not to obscure the work surface and not make you strain your eyesight.

If you are right-handed, the light source should be on the left side, if you are left-handed - on the right. The area of ​​work that you are looking at should be illuminated by a light source that does not give a shadow.

If you cannot provide this condition:

Write with a yellow pen or pencil. Yellow draws attention and can soften shadows somewhat.

6. Place the materials you use most often within reach of the swivel chair.

Imagine that you are sitting at the control panel. Arrange everything that you may need for work so that any item can be easily reached without making unnecessary movements. Spreading everything nearby necessary materials, you will save a lot of time, because you do not have to go to cabinets and shelves for them during the day. What you use on a daily basis should be within easy reach.

If you cannot provide this condition:

At the beginning of each day, assessing the upcoming tasks, lay out on the table or next to necessary tools and materials.

· Consider your running around as a gymnastics that disperses the blood. Any physical movement is good for health.

7. Adjust the height of your chair so that your work is at a comfortable eye level.

When I first started working on the computer, my eyes were terribly strained. I wore bifocals, and in order to clearly see the image on the monitor, I had to tilt my head at an unnatural angle. Finally, I thought to put a pillow on the seat of the chair. Take the time to adjust the height of your chair so that your eyes can comfortably look at the monitor.

Even the smallest inconvenience can slow down your productivity over time.

If you cannot provide this condition:

· Use the lower or upper half of the screen - the one where you feel comfortable looking. Let the screen be better than less than your neck muscles or eyes will hurt.

8. Place the phone on the side of the dominant ear, that is, the one to which you press the handset, and not on the side of your dominant hand.

Many people put the phone on the side of the hand that is more convenient for them to pick up the phone, and not on the side of the ear that is more comfortable to listen to. Since much more time is spent on listening than on dialing, it is wiser to put the phone on the side of the dominant ear.

If you cannot provide this condition:

· Extend the cord to put your phone where you want it.

9. Post slogans and inspirational messages within good visibility.

If someone else takes over your desk and doesn't have to remove any personal items from it, it means that you haven't brought any of your unique personality traits into your workplace. If your desk is as impersonal as a motel room, you need to bring it to life.

If you cannot provide this condition:

· If company policy prohibits the use of desktop decorations, decorate the background on your computer screen with family photos, landscapes, or images that please you.

· If company policy prohibits decorating a computer screen, put trinkets, postcards, photographs, or other personal items inside the top drawer of your desk where you can see them every time you open the drawer to get your work items.

10. Protect your workplace from the eyes of other people.

Feeling open to other people's views can make you feel uncomfortable. A plant or screen above your chair will give you the security you need to be productive.

If you work in a room with other employees, try to separate your seat from other tables. This is very important, especially if the tables are close to each other. Feeling protected from the invasion of personal space and from the views of other people makes it possible to concentrate on work as much as possible. The feeling of being put on public display is tolerable, and sometimes even pleasant, but only as long as you have the opportunity to be alone if you wish.

If you cannot provide this condition:

· Arrange folders or boxes for incoming documents on the table so that they close the immediate place of your work.

· Build a styrofoam screen as shown in the picture and tape it to the edges of the tabletop.

Keeping your workplace at least partially hidden from prying eyes will give you the feeling of a protected personal niche, and this is very important for maintaining self-respect and a sense of worth.

11. Make sure that the area where your desktop is located can be turned into a convenient place for communication if necessary.

Communication at work is a natural process. Therefore, it is good to have a place in the office where employees can exchange ideas, discuss work matters or just have a casual conversation. Having an idea of ​​what kind of interior is most suitable for different types of communication, you can arrange a place for communication in the office in such a way that it is in harmony with each situation.

Placement in the spirit of the metal element.

By seating people at a round table, you fill the situation with an element of metal. Since no authority is visually emphasized, all participants in the meeting tend to take responsibility for the problem under discussion and make every effort to solve it. Placement in the spirit of the metal element promotes oral exchange of views.

Placement in the spirit of the metal element ensures that the exchange of ideas will go smoothly and the opinions of all participants in the conversation will be considered equally valuable.

Placement in the spirit of the tree element.

In a situation where it is necessary to take definite decision, a long rectangular meeting table would be ideal. The tree encourages decision-making and eliminates the fear that they will seem too innovative. When several people are seated in a row, the connection that develops between them is not as close as when they are sitting at a round table, because they are not as comfortable talking to each other. When people sit in a row, their communication is limited for the most part to short statements of the essence of the matter.

Sitting around a rectangular table infuses the situation with the spirit of the wood element, which facilitates the decision and eliminates the fear that it will seem too innovative.

Placement in the spirit of the element of fire.

When power should remain with one person, it is preferable to place the element of fire in the spirit. In this arrangement, one person sits opposite everyone else. The most typical example of such a situation is a lecturer in an audience. Although this type of placement is sometimes mistakenly used in a situation where the participants in the conversation act as equal partners.

For example, in the offices of interior designers, architects, marriage consultants, and in other situations where the customer of the service and its provider must cooperate on an equal basis, you should not use the location in the spirit of fire. At the same time, those who sit alone feel more psychological pressure. When decisions are made jointly with the client, this placement is best avoided. It is appropriate when you seek and/or need to be in control of a situation.

Placement in the spirit of the element of fire, that is, any configuration where one person is at the top of the triangle, gives him power and responsibility.

Placement in the spirit of the element of water.

When you want to freely express feelings, the placement in the spirit of the element of water is best. When we are not constrained by the framework of a given behavior, our reactions are distinguished by sincerity and immediacy. In situations that require the need to adapt to previously unknown criteria, people tend to view each other as allies.

The placement in the spirit of the water element is random and optional. Easy friendly communication in such an environment is guaranteed.

Placement in the spirit of the earth element.

Only groups of four or eight people can comfortably sit in the shape of a figure corresponding to the element of earth, that is, in the form of a square. The square symbolizes stability and respect for each participant in the conversation.

Placement in the spirit of the earth element evokes a feeling of belonging to the group and security.

If you cannot provide this condition:

· If it is not possible to arrange the chairs around the table, arrange them around a square rug or simply arrange them so that they form a square.

12. Make sure you use all five senses when you are at work.

We cannot live according to our natural biological rhythms because we have to go to work every day. We get up, eat and go to bed not when we feel like it, but when we need to. In ancient times, people lived in the open air, and the organs that receive information from the outside world were much better developed in them than in modern people. When people began to spend more time indoors, the load on the senses decreased. Basically, we use our eyesight at work, and hearing, smell and touch are involved only in so far as. To Vital energy functioned effectively enough in the body, make sure that all your senses receive as uniform a load as possible.

If you cannot provide this condition:

Drape velvet and satin around the edge of the table, the arm of the chair, and under the mouse pad.

· The wrist is especially sensitive, and touching different textures throughout the day will give you a variety of tactile sensations.

· Introduce a variety of flavors into your workplace.

13. Surround yourself with objects whose color is pleasant to you.

What if the office environment doesn't suit your specific emotional needs? If the office color scheme doesn't suit you, here are a few ideas:

Use complementary color on your desk to neutralize color that doesn't match the style of work you're doing. For example, if your job is energy intensive and your office is blue, add some splashes orange color, for example, place an orange cloth under your computer keyboard or phone.

· If blue doesn't suit you, use orange.

· If orange doesn't suit you, use blue.

· If red doesn't suit you, use green.

· If green doesn't suit you, use red.

· If yellow doesn't suit you, use purple.

· If purple doesn't suit you, use yellow.

14. Keep your work area clean.

All areas of the workplace must be clean, including the surface of the desktop, and all drawers that you open at least once a day.

If you cannot provide this condition:

Throw away postcards you've saved because they're cute, all unlabeled floppy disks, old receipts, half-written notepads, desk knick-knacks you've been given that you don't want to put on the table, old pens, and anything else you didn't need. during three months.

Remember, you only need one bottle of white correction fluid, one roll of tape, one box of paper clips, and one box of staples.

· Throw away all the things, papers and folders that you tend to put outside the door, assuming that they will lie there temporarily. Temporarily - how much? I made it a rule on the first of every month to sort out what I put aside for temporary storage, and throw out what turned out to be unnecessary so as not to clutter up the space outside the door.

· Things outside the door serve as a signal that we can't handle our workload. Sometimes there are so many of them that the door does not open all the way. By the way, a blocked entrance symbolizes obstacles to self-realization.

· Regularly empty drawers of unnecessary papers. Put the folders you use the most in the file cabinet closest to your workspace. If you have not used the folder for a month, it means that you need to put it in another, more distant cabinet. Folders with documents that you use constantly should be no further than three to five steps from your desktop.

15. Put a potted plant in your office and take care of it.

Often the condition of a plant reflects the physical and spiritual condition of its owner. When the plants wither, ideas also cease to arise in the head of the owner. When there are so many plants that they threaten to occupy your desktop already, this can serve as a signal that you have outgrown your work.

16. Use plants that clean the air well.

In most offices, the air is not fresh. Toxic substances released by plastic, paint and other facing materials in the office can poison the air you breathe. Plants absorb some of these substances.

If you often experience headaches, drowsiness, or unusual irritation, try placing a pot of one of the following plants in your room.

Plants that absorb formaldehyde.

Formaldehyde is used in the manufacture of many types of wood chipboard flooring and furniture.

· Fern.

Chrysanthemum.

· Daisy.

· Date palm.

wine raffia.

Plants that absorb ammonia.

Ammonia is found in many cleaning products.

Liriope.

Chrysanthemum.

Plants that absorb benzene.

Benzene is found in fumes from fresh paint and cleaning fluids.

· Daisy.

Chrysanthemum.

· English ivy.

Plants that absorb xylene.

Xylene is a solvent used in paints and varnishes.

· Dwarf palm date.

The dragon tree.

Plants that absorb several poisonous substances.

· Lily: ammonia, benzene, formaldehyde, xylene.

· Ficus: ammonia, formaldehyde, xylene.

· Tulip: ammonia, formaldehyde, xylene.

· English ivy: ammonia, benzene, xylene.

17. Locate electrical outlets so that you do not have to bend down to reach them.

The amount of wires and equipment used on each desktop is mind boggling. It is unlikely that crawling on the floor in an attempt to determine which wire corresponds to which car in order to plug it into the outlet contributes to creative inspiration and peace of mind.

If you cannot provide this condition:

· Tape the wires to the side of the table that faces the wall.

· Fold long wires so that none of them touches the floor.

The state of our workplace reflects the internal state of our consciousness. In order for us to think clearly, work effectively and generate new ideas, our external environment must match our internal aspirations.

18. If you want to make changes in the situation, move twenty-seven items to another place.

If you want changes to take place in your life, you must first get rid of the trappings of the old life. If this is not done, then the energy of old things simply will not allow the energy of renewal to enter your life, including promotion. This applies to tangible items that you don't use that just take up space, including both clothes and work supplies.

Why twenty-seven items? In traditional feng shui, the number twenty-seven symbolizes preparation for change. This is just such a number of items that is not too small and not too large. Making change isn't easy, and it's the ability to take the lead in preparing for it that separates those who really want change from those who just dream about it.

If you cannot provide this condition:

· Throw away any office supplies that you never use that just rust or get covered in dust.

· Rearrange your desktop. This alone can already make a dozen changes.

· Move the wastebasket to another place.

· Go through the drawers of the table and put things in them differently.

Change the pictures on the walls.

19. Personalize the piece of office equipment you use the most.

During the working day, you use one type of equipment most often, right? As for me, I look at my laptop most of the day. How dreary he would look if he did not bear the imprint of my personality. We have already said that any object sends us messages. Send yourself a life-affirming message "I am". Whether it's a phone, a computer, or an adding machine, make sure that these things send you messages that inspire you to work.

If you cannot provide this condition:

Place your favorite picture as a background on the monitor.

Attach your favorite stickers, figurines, etc. to the wall near your workspace.

On holidays, attach a balloon to your desk or work equipment.

20. Clean your work area at the end of each day and keep furniture and equipment free of dust.

How long will it take you before you stop paying attention to the clutter on your desktop? We very easily get used to the disorder in our habitat. Usually, cleaning starts only when the office is about to visit a client, and you look at the situation, so to speak, with a “fresh” look. Of course, we can ignore the chaos on the table, but this does not mean that it does not negative impact on our performance.

If you cannot provide this condition:

· If you constantly see mountains of papers in front of you, a dirty window or an empty boring wall, remember that your subconscious mind receives negative signals. It reminds you that if you forget to satisfy your aesthetic needs and do not consider it necessary to spend energy on cleaning, then this will not work for you. Sooner or later, the work will begin to annoy you, and you will not even be aware of its true reason. Do not wait for this moment, decorate your office with photographs, paintings, emblems, calendars, etc. Don't just hang them on the wall, but choose the appropriate design - enclose them in beautiful frames so that your office acquires the atmosphere of a habitable and cozy place where you are pleased to come every day.

Get rid of unnecessary things and make the place of work comfortable and attractive. This is important not only from an aesthetic, but also from a psychological point of view. You will acquire the clarity of thought that is necessary to succeed in your career.

To Category:

Repair of forest machines

Repair and mechanical workshops

Repair and mechanical workshops are part of the repair and maintenance base of logging enterprises and work in close cooperation with other facilities.

The scope of work on the current repair of logging equipment attributable to the RMM of the enterprise depends on the composition of the repair and maintenance base (ROB), the equipment and capacity of individual links.

The workshops carry out current repairs of automobiles, tractors and machines based on them, and lower warehouse equipment.

The initial data for determining the annual production program of workshops are taken on an aggregate basis depending on the capacity of the logging enterprise or by calculation, depending on the specific composition of the fleet of machines and mechanisms and its load.

In the absence of data on the composition of the fleet of machines, the annual production program of the RMM can be adopted on an enlarged basis on the basis of the All-Union Norms for the Technological Design of Logging Enterprises (ONTP 02-80), depending on the capacity of the enterprise.

The category of others includes work on the fulfillment of orders of items Maintenance, workshops and production sites of the enterprise, for the repair and manufacture of parts, tools and non-standard equipment, maintenance of the building and utilities. Maintenance of own equipment includes the costs associated with its maintenance.

Calculation of the need for production space, workers, equipment. The calculation of the areas of the RMM premises is carried out on the basis of a preliminary calculation of the production program, the establishment of the operating mode of production and its individual sections, the calculation of the number of jobs, posts, the number of production workers required to carry out the production program, the calculation and selection of equipment for organizing the technological process of the current repair of the logging equipment.

RMM operating mode. To determine the number of production workers, posts and technological equipment RMM you need to know production assets time.

The production time fund is the actual number of working hours per year of one worker, as well as one workplace, post, machine and

For enterprises in the Far North and areas equated to them, the annual fund of working time is reduced due to an increase in the duration of vacation.

The annual labor intensity of work on production sites is distributed as a percentage of the total annual labor intensity of current repairs attributable to the RMM.

Based on the estimated annual labor intensity of work at production sites and the actual annual time funds of production workers, their estimated number for production sites is determined, which is adjusted in accordance with the load and the combination of a number of works similar in nature to the technological process.

The number of auxiliary workers, engineering and technical workers, junior service personnel is taken as a percentage of the number of production workers.

When designing and reconstructing production sites, the number of main technological equipment is calculated according to the annual scope of work and annual time funds.

Typical site equipment is selected according to catalogs, industry price lists, and non-standard equipment - according to projects of design organizations. In the absence of the necessary equipment, a technical task for its design is drawn up.

With small amounts of work and a small load of equipment, a stand for disassembly and assembly work, as well as production inventory are selected without calculation from the conditions of the set of the necessary kit to perform certain technological operations.

RMM layout. The development of a master plan for a repair and mechanical workshop with a complex of auxiliary facilities is carried out in accordance with the requirements of SNiP II-89-80 “General plans for industrial enterprises” and taking into account the requirements of SNiP II-93-74 “Automobile maintenance enterprises”.

RMM is placed on the site provided by the scheme or project for the development or reconstruction of the enterprise. When designing a RMM, it is necessary to strive to ensure that the RMM is located on the same site with other ROB facilities operating in a single complex (PTSTO, TOP).

The most acceptable for RMM is a frame-type building with a grid of columns having the same pitch for the entire building, equal to 6 or 12 m, h with a span width of 12, 18, 24 m.

Separate production facilities should be provided in the RMM building to accommodate the following areas: - zones for the current repair of machines and mechanisms; - aggregate, metalwork and mechanical, repair of electrical equipment, power supplies, hydraulic equipment; - thermal (forge, coppersmith, welding); - accumulator;
repair of petrol engine tools; - tire shop.

The height of the premises in the current repair area is taken based on the dimensions of the machines being serviced (including attached technological equipment). So, when repairing LP-19 machines, the height of the room must be at least 8 m.

The layout of the production building. The main requirements for the layout of the RMM production building are as follows: the area for the current repair of cars and tractors by nature production process should be directly connected with all production sites. Production sites that tend by the nature of production to work performed at specialized current repair posts should be located in close proximity to them. It is advisable to locate the mechanical and aggregate sections near the warehouse of spare parts and materials; it is recommended to place a tool-distributing pantry adjacent to them, since largest number requirements for tools and fixtures come from these sites.

When laying out, special attention should be paid to the location of the areas where the most accurate work is performed (electrical, fuel equipment and hydraulic equipment, mechanical, motor tools). These areas require good lighting, they are recommended to be located around the perimeter of the building, using natural light. A maintenance area with ditches, lifts and floor posts can be located in the central part of the building.

When developing planning solutions for production sites and zones, the following requirements must be met: - with a small amount of work and incomplete loading, work sites similar in type of production should be combined in one room (forge and copper, fuel equipment and hydraulic equipment, aggregate and metalwork-mechanical ); - the width of production sites should be at least 3 m; the volume of industrial premises per worker must be at least 15 m3, and the area of ​​​​the premises must be at least 4.5 m2; - technological equipment of production sites should be placed in accordance with the norms of distances between equipment and elements of buildings, the norms of the width of passages and driveways.

Norms of distances between equipment, objects of repair, elements of buildings, norms for the width of passages and driveways. The area for the current repair of machines is equipped with dead-end posts, while the arrangement of posts can be rectangular and oblique.

The width of the driveways in the area of ​​the current repair of vehicles depends on the condition of the vehicles being repaired, the angle of the posts, equipment and the method of arranging the vehicles at the posts.

All distances are indicated from the extreme positions of the moving parts of the equipment, as well as from the dimensions of the repaired units installed on the stands.

Production sites and zones. Current repair area. Diagnostics, disassembly and assembly and adjustment work are carried out at the posts of the current repair zone. The planning decision of the zone depends on the type of posts, the way they are arranged. Posts for the current repair of tractors and machines based on them, as a rule, are located separately from the posts for car repair. The most widespread are dead-end posts with a rectangular, oblique and combined arrangement.

Maintenance posts are equipped with inspection ditches and lifts. In the absence of work from below the repaired machine, floor posts are used without special inspection and lifting equipment.

The choice of the most effective inspection devices for posts is dictated mainly by the conditions for ensuring the minimum length of time the machines are under repair. In addition, inspection devices should ensure the convenience and safety of work, the possibility of simultaneous participation of several performers, the repair of various types of machines, the necessary sanitary and hygienic working conditions.

Work on the replacement of units and assemblies, as a rule, is carried out at two levels, above and below the machine, therefore, a dead-end ditch is most acceptable for removing and installing the main units.

The inspection ditch must have a mechanized ditch hoist and be located in the area of ​​operation of a crane-beam or other lifting equipment. The design of universal dead-end ditches is shown in fig. 30 and fig. 31.

The walls of the ditches are tiled, the width of the ditch must be at least 1150 mm, the depth - 1100 mm. For heating and ventilation of the ditch, it is equipped with supply and exhaust ventilation. Ditches must be waterproofed by laying during the construction of a clay castle with a thickness of at least 300 mm. The walls of the ditches, after pouring with concrete, are plastered with cement mortar with the addition of liquid glass and lined with light-colored tiles.

Rice. 30. Universal inspection ditch dead-end type:
1 - niche for lamps; 2 - a niche for a drain funnel; 3 - a niche for a tool; 4 - ventilation duct

The ditches are illuminated by lamps installed in niches. It is allowed to use lamps with a voltage of 127 ... 220 V with an internal (closed) power supply having reliable electrical and waterproofing. In addition to niches, niches for tools and fixtures are provided for fixtures in the ditch. Niche designs for fixtures and tools are shown in fig. 32.

Rice. 31. Location of inspection ditches:
1 - chipper; 2 - emphasis; 3 - transitional bridge; 4 - ditch fencing

The ditches are equipped with a supply of compressed air and electricity (36 V). With a parallel arrangement of three or more dead-end ditches, they can be connected by an open trench along the wall of the room, while the width of the trench should not be less than 1.5 m, the number of entrances to the trench is determined at the rate of one exit for five inspection ditches. The trenches are protected by railings 0.9 m high.

If the inspection ditches are not interconnected, then each ditch has an individual exit, which should not be located under the machine at the post, or go out in the way of traffic.

For maintenance of machines repaired by replacing components and assemblies, inspection ditches are equipped with ditch lifts. Outdoor posts are serviced by garage hydraulic jacks with manual drive P-307, P-308, P-403.

Aggregate area. The site is designed to restore the performance of units and assemblies during the current repair of logging machines and equipment using the aggregate method of repair.

Units that require repair are removed from the machine at the posts of current repair, maintenance or directly at the place of operation of the machine and sent to the warehouse of the company's working units. From the warehouse, the units, as necessary, enter the aggregate section to specialized repair posts, having undergone a preliminary external washing. Repair of units and assemblies is carried out on universal or specialized stands.

Technological equipment of the site, production inventory, fixtures, stands for disassembling and assembling units are selected from the conditions of the set of kit required to perform technological operations, and the estimated number of jobs.

After repair, the unit is sent to the warehouse of working units or directly to the current repair area for installation on the machine. In accordance with the distribution of the labor intensity of repairs, 18% of the total annual labor intensity attributable to mechanical repair shops falls on the aggregate section. It is expedient to place the aggregate site directly near the zone of the current repair of machines. Next to it should be a warehouse of spare parts, a warehouse of working units and a tool-distributing pantry.

When planning the workplaces of locksmiths of the aggregate section, the following should be provided:
places for storing large parts and assemblies of repaired units;
passages and driveways in accordance with the dimensions of vehicles and transported parts, assemblies and assemblies.

The number of units and assemblies to be repaired at the workplace should not exceed the daily requirement; all materials, components and assemblies should be stored on racks and stands; it is not recommended to store them on the floor.

The equipment and equipment of workplaces should ensure the performance of technological operations in a convenient working area accessible to the arms and legs, so that the movements of the arms, legs, head and torso are the least tiring. The equipment must have protective devices defined by the safety regulations.

On fig. 33 shows the layout of the locksmith's workplace. The workplace is equipped with a locksmith's workbench, a rack for parts, a stand or a stand for repaired units and assemblies. When using mechanized washing of components and parts, the washing machine is located separately from the main equipment, for this it is separated by a partition not lower than 3 m high.

Dismantling and assembly stands should be arranged in groups in accordance with the types of work and the technological process of repairing units. An approximate layout of the aggregate section is shown in fig. 34.

The area of ​​the aggregate area is calculated by the area of ​​the floor occupied by the equipment, multiplied by a density factor equal to 4.5. The density coefficient takes into account the standard distances between equipment, equipment and building structures, workplaces, passages and driveways, as well as places for storing parts and assemblies of disassembled units. The unit repair area is separated from other areas by partitions.

Rice. 33. Organization of the workplace of a mechanic for the repair of units:
1 - locksmith workbench; 2 - cabinet for instruments and tools; 3 - stand for the repair of units; 4 - rack for parts and assemblies; 5 - beam crane (13 = 1.5 t); 6 - bath for washing parts (mobile)

The height of the room should ensure the installation of lifting and transport vehicles (crane, monorail) for moving units and machine assemblies to repair posts, but not less than 3.5 m.

The size of the doorways must be at least 2 × 2 m. The floors on the site must be made of polished concrete, the walls must be painted in bright hues, ceilings - lime whitewash.

Thermal area. The thermal section is intended for the manufacture of simple parts of logging equipment by forging, repairing and straightening springs, gas and electric welding and surfacing of parts, repairing components and parts of metal structures of attachments for logging equipment, checking and maintenance of radiators, fuel and oil tanks.

Blacksmithing and welding work occupy an important place in the performance of repair work, their role is increasing with the introduction of operational logging operations equipped with complex attachments. At the site, deformed units and parts of metal structures are straightened, cracks are welded, reinforcements are made and applied.

Copper-tinsmith work performed on the site is associated with the repair of radiators, fuel and oil tanks, the repair of cabins and their plumage, the manufacture of parts from sheet iron.

With a large annual labor intensity of work attributable to the heating section, it can be divided into independent sections: forging and spring, welding, copper and tinsmith. It has been established that the thermal section accounts for 15% of the total labor intensity of repair shops (forging 4%, welding 8%, copper-tinsmith 3%).

A forge, an anvil, a pneumatic hammer, equipment for coppersmithing and welding, tilters for repairing metal structures are installed in the heating section. The number of welding stations is taken according to the number of welders.

When placing the equipment of the heating section, the following basic provisions must be observed: - the hearth in relation to the hammer and other equipment must be located so that the workplaces are not exposed to the radiant radiation of the hearth; - the area on which the forging and other equipment is located must be sufficient for the free performance of work; - an area for storing materials and hot forgings should be provided at the workplace of the blacksmith; - on the site, compliance with the rules of safety and labor protection must be ensured; – welding places should be separated from other posts protective screens protecting workers of neighboring posts from radiation arising from welding work; - when arranging equipment on the site, it is necessary to provide places for repairing parts and assemblies of metal structures of attachments for technological equipment of logging machines.

The workplace of a blacksmith is equipped with a forge, a blower, an anvil, a hammer, a chest for blacksmith tools, and exhaust ventilation. Workplaces for gas and electric welding work are equipped on the site for welding. A special table, a rack for parts and welding materials, and a welding unit are installed at the welder's workplace. A cabinet for cylinders is installed at the gas welder's post. When working with acetylene generator the latter must be installed in a special room.

The arrangement of technological equipment on the site is carried out by groups in accordance with the types of work performed. On fig. 35 shows an approximate layout of the thermal section.

The production area of ​​the thermal section is taken depending on the number and dimensions of the installed technological equipment and equipment. The density coefficient of equipment in the design of the site is 4.5 ... 5.

The premises of the thermal section must have fireproof walls and ceilings, adobe or brick floors (on edge); paths for passage and passage are concrete or asphalt concrete. The height of the room in accordance with the norms of technological design should be at least 6 m.

Locksmith-mechanical department. The locksmith-mechanical section is designed for preliminary and final mechanical and locksmith processing of repaired and manufactured parts. In addition to the logging equipment repair program, the section fulfills orders for the repair of lower warehouse equipment, as well as orders for housing and communal services.

The locksmith-mechanical section accounts for 14% of the total labor intensity of the RMM. The approximate annual labor intensity of the site at different capacities of the enterprise is presented in Table. 5.4. The main machine equipment of the site is determined by calculation on the basis of the annual labor intensity of the work. The approximate distribution of the labor intensity of machine work by type as a percentage of the total labor intensity of machine work is as follows:

Rice. 35. Thermal section:
1 - high pressure fan; 2 - chest for blacksmith tools; 3 - chest for coal; 4 - blacksmith's forge; 5 - bath for hardening parts; 6 - two-horned anvil; 7 - pneumatic hammer; 8 - stand for checking and repairing radiators; 9 - mounting table; 10 - rack for radiators and tanks; 11 - table for tin works; 12 - stand for disassembly and assembly of springs; 13 - rack for springs; 14 - dust collecting installation; 15 - roughing and grinding machine; 16 - hanging beam crane (Q = l t); 17 - cabinet for cylinders; 18 - gas welder's table; 19 - racks for parts; 20 ~ electric welder's table; 21 - welding transformer

Rice. 36. Locksmith and mechanical section:
1 - racks for parts; 2 - plate, calibration; 3 - desktop drilling machine; 4 - stands for equipment; 5 - locksmith workbenches; S - manual press; 7 - vertical drilling mill; 8 - universal milling machine; 9 - tool cabinets; 10 - cross-planing machine; 11 - screw-cutting lathe; 12 - screw-cutting lathe; 13 - roughing and grinding machine; 14 - dust collecting installation

The arrangement of machines and workbenches on the site is regulated by the size of the gaps (gaps) between the machines in the longitudinal and transverse directions, the size of the distances from the walls and columns. These dimensions should ensure the convenience of performing work on machines and workbenches, the safety of workers, sufficient freedom of movement for people and vehicles with cargo, and the possibility of repairing machines. An approximate layout of the locksmith-mechanical section is shown in fig. 36.

The density coefficient of the equipment of the metalwork-mechanical section is assumed to be 3 ... 3.5.

Fuel equipment repair shop. The site is intended for current repair and adjustment of fuel equipment units of tractors and vehicles with diesel and carburetor engines.

Works on the current repair and adjustment of the fuel equipment are carried out after removing them from the machines using stationary repair and diagnostic equipment or directly on the machine in the current repair area using portable devices. Faulty appliances power systems are removed from the machines at the current repair posts and sent to the warehouse of working units or directly to the fuel equipment repair site, units from the working capital are installed on the machine. The removed power devices are cleaned of dirt and washed in a mobile washing bath using a washing solution.

Check and adjustment fuel pumps high pressure is carried out at the stand KI-921. If defects are found, the fuel pump is disassembled at a special post using a diesel engine maintenance tool kit. Testing and adjustment of the fuel pump assembly with the regulator and booster pump are carried out on the bench at an ambient temperature of 18 ... 22 °C.

Nozzles and sprayers are cleaned of dirt and washed in a washing bath in kerosene, sprayers are cleaned of carbon deposits. After cleaning, the injectors are subjected to an injection start pressure test. The test is carried out using a device for checking the technical condition of injectors KI-562-GOSNITI.

Fuel filters are thoroughly washed and cleaned of dirt. After washing and assembly, 3 ... 5 liters of clean fuel are pumped through the fine filters in the forward direction, then a hydraulic test is carried out. The coarse and fine filter under fuel pressure of 0.2 MPa for 2 minutes should not let fuel through in the connections, and there should be no leakage and sweating at the seals and on the outer surface.

The fuel lines removed from the engine are checked for cracks, dents, damage or wear on the tips and union nuts. Worn tips are cut off and new ones installed. A cylindrical sleeve is put on the places where cracks form, and its ends are soldered to the pipeline with copper.

The fuel equipment of carburetor engines includes: a carburetor, a gasoline pump, a filter and fuel lines. The parameters of the fuel pumps are checked by the NIIAT-577B instrument. Disassembly is carried out in a special vice using a set of tools for a carburetor adjuster. During repair, the gasoline pump is disassembled only if it does not develop the necessary pressure and does not supply enough fuel. If the pump is working properly, then it is not repaired, but tested and used for further work.

Checking the carburetor and accelerator pump is carried out on the NIIAT-577B installation for checking the carburetor in a non-motorized way. At this installation, the operation of carburetor assemblies is checked for the consumption of standard fuel at certain air flow rates. During the test, the throughput of the jets and the serviceability of the dosing systems of the carburetor are determined. If it is necessary to disassemble the carburetor, work is carried out in a special vice using a set of tools for a carburetor adjuster. After disassembly, a check is made for the tightness of the valve and float jets, the elasticity of the diffuser plates. The calibrated holes of the jets are blown with compressed air using the NIIAT-528A device.

In accordance with the distribution of the labor intensity of repairs by type of work, the fuel equipment repair section accounts for 4% of the total annual labor intensity of the current repair of the RMM machines of the enterprise. The approximate annual labor intensity of work on the current repair of fuel equipment units of machines is presented in Table. 5.4. On fig. 37 shows the layout of the fuel equipment repair site.

In case of insufficient loading of the fuel equipment repair site, it can be combined with the repair site for hydraulic equipment units. To carry out the current repair of the fuel equipment in the RMM, an area of ​​​​12 ... 20 m2 with natural lighting is provided. The site is located in close proximity to the current repair zone and the unit repair site. The height of the room should be at least 2.8 m, the dimensions of the doorways should be at least 1 × 2 m.

Floors are recommended to be made of ceramic tiles, with the exception of the carburetor test section, where it is necessary to apply a non-sparking coating of mosaic mortar with lime aggregate in accordance with the requirements of SNiP II-13 “Floors. Design standards". Walls and ceilings are painted with white lime paint, wall panels are faced with glazed ceramic tiles to a height of at least 1.8 m.
Electrical equipment repair shop. The vast majority of work on the repair of automotive and tractor electrical equipment is carried out by repair shops, only complex repairs of starters, generators and other devices that require the restoration of parts and the use of complex technological equipment and processes are carried out by repair plants. When disassembling machines, units and electrical equipment are removed, cleaned of dirt and oil, and in assembled transferred to the electrical equipment repair shop. After inspection and testing, if necessary, disassembly into assemblies and parts, washing and fault detection are carried out.

Rice. 37. Fuel equipment repair area:
1 - cabinet for instruments and tools; 2- stand for equipment; 3 - hydraulic press (force 100 kN); 4 - mobile washing bath; 5 - a device for checking jets and shut-off valves; 6 - workbench for repairing carburetors; 7 - a device for checking carburetors and gasoline pumps; I am a bath for washing precision parts; 9 - fixture for disassembly and assembly of fuel pumps; 10 - mounting table; 11 - device for testing and adjusting nozzles; 12 - stand for testing fuel equipment; 13 - rack for parts and assemblies

Rice. 38. Electric equipment repair shop
1 - rack for components and parts; 2 - cabinet for instruments and tools; 3 - electrician's workbench: 4 - assembly table; 5 - a device for cleaning spark plugs; 6 - a device for cleaning spark plugs; 7 - a device for checking the anchors of generators and starters; 8 - stand for testing electrical equipment; 9 - mobile washing bath; 10 - hydraulic press (force 100 kN); - stand for equipment; 12 - desktop drilling machine; 13 - desktop machine

When repairing autotractor electrical equipment, the following characteristic works can be distinguished: monitoring the technical condition of the electrical and mechanical parts by inspection, testing and measurement; dismantling and assembly and troubleshooting works; repair and restoration of individual parts of electrical equipment; assembly, testing and running-in of repaired units.

In repair shops, as a rule, units are disassembled and assembled without depersonalization of the main parts. The variety of work performed at the site requires the use of various technological equipment for checking, disassembling, repairing, assembling electrical machines, apparatus and instruments. The equipment of the site should include control and measuring stands, instruments and various technological equipment for performing various technological operations.

The serviceability of autotractor electrical equipment supplied for repair - direct and alternating current generators, starters, relay-regulators, transformers, coils, electric motors and other devices is determined on the KI-968 universal stand.

Electrical equipment is tested on the stand in the mode in which it operates during operation. During testing, it is determined electrical characteristics equipment in all respects. The stand is equipped with a two-speed electric motor with a power of 1.7 ... 2.2 kW with a rotation speed of 1440/2880 rpm and a V-belt variator. As a result, the product under test can have a rotational speed of 0 to 6000 rpm. Voltage is measured up to 30 V, current strength 1500 A.

To control the technical condition of electrical equipment components, the E-202 device is used, which serves to check electrical equipment installed on vehicles operating on direct current (generators, starters, small engines). Using the device in the armature windings and in the excitation winding, an open or short circuit between turns, a short to ground and other technical data on the state of the winding (number of turns, their direction, type, etc.) are determined.

The KI-959 portable flaw detector can be used to detect defects (break, short circuit) in the coils of DC and AC machines. Checking and cleaning the spark plugs of carburetor and starting engines are carried out on the 514-2M device. Work on the repair of automotive and tractor electrical equipment is carried out on a special workbench equipped with the necessary instruments and fixtures. An approximate arrangement of the site equipment is shown in fig. 38.

In accordance with the distribution of the current repair labor intensity by types of work, the electrical equipment repair site accounts for 6% of the total annual labor intensity of the current repair. The height of the premises of the electrical equipment repair site to the bottom of the protruding building structures must be at least 2.8 m. The walls of the room are painted oil paint light colors, whitewashed ceiling.

Battery area. Battery maintenance work is carried out directly on the machine in the current repair area. For work related to repair and charging, the batteries are removed from the machine and sent to the site.

Over time, batteries reduce their capacity and voltage and fail, most often as a result of improper care behind them during operation. Battery failures that indicate a need for repair include broken plates due to sulfation, warped plates, damaged separators, and cracked cans.

When the plates are sulphated, a dense coarse-grained coating of lead sulfate is deposited on them, which conducts current poorly, almost does not dissolve when the battery is charged, and makes it difficult for the electrolyte to access the active mass of the plates. Sulfation of the plates can be the result of long-term storage of the battery in a discharged state, the use of an electrolyte of increased density and its contamination. Warping of the plates occurs due to charging the battery with a large current. This is associated with damage to the grids of the plates and the loss of the active mass from them, as well as the closure of the plates to each other and increased self-discharge of the battery.

Before repair, the battery is checked to detect these malfunctions, since it may turn out that the battery cells are in good condition and need only to be charged. Batteries are checked by external inspection and with the help of instruments. An external inspection checks the condition of the jars and lids, the presence of cracks in them and the oxidation of the contacts, then they check the electrolyte level, its density, however, it does not fully characterize the condition of the battery, therefore, the density check is combined with a check with a load plug.

Battery repair consists in disassembling, checking and restoring individual parts, assembling and charging battery cells. Before disassembly, the battery must be discharged, then drain the electrolyte and remove the jumpers between the cells, remove the mastic and remove the covers. After removing the covers, take out the plate blocks. The plates are washed with distilled water and dried.

Cracks in the banks are sealed with ebonite mastic (isonite). Defective plates are discarded and plate blocks are completed with new ones. The assembled blocks of plates are inserted into jars and closed with lids. Assembly is carried out in the reverse order. After assembly, the battery is filled with electrolyte, kept for 5 ... 6 hours and put on charge. The repaired batteries are charged in several cycles, first they are charged with a current equal to V16 of the battery capacity, until abundant gas evolution and a voltage of 2.4 V on each bank. After that, the charging current is halved and charging continues until the electrolyte density stops increasing, then the discharge is 1.7 V in the bank and charge the battery again.

The battery repair section is located in two rooms: a room for repairing and charging batteries and a pantry for storing and preparing electrolyte. The site is completed with the necessary equipment, tools, fixtures and instrumentation.

Maintenance and charging works batteries make up 2% of the total annual labor intensity attributable to the RMM of the enterprise. The approximate annual labor intensity of work on maintenance and charging of batteries is presented in Table. 5.4. On fig. 39 shows the layout of the battery area.

With a larger amount of work, the batteries are charged in a separate room, equipped with an independent system of supply and exhaust ventilation. The walls of the premises of the site must be plastered cement plaster primed and painted with acid resistant paint. The floor in the premises is laid out with acid-resistant tiles, the gaps between the tiles (5 ... 8 mm) are filled with a hot mixture of asphalt and coal tar. In addition to tiles, you can use brick or concrete pavement. The height of the room must be at least 3 m.

Hydraulic equipment repair site. Repair of hydraulic equipment in the workshops of logging enterprises consists in replacing worn seals or individual components and parts with new or repaired ones.

All incoming components and assemblies of hydraulic equipment are washed in a washing bath diesel fuel or kerosene. After washing the units, their performance is checked on a stand of the KI-4815 type. During the inspection, defects are identified and the possibility of their elimination is determined.

Hydraulic equipment units are disassembled only if defects are found that cannot be eliminated without disassembly. Each disassembly of hydraulic units leads to a violation of the interfaces between individual parts. When repairing, it is necessary to disassemble the nodes only to the extent necessary to eliminate the detected defects.

After fault detection of the parts of the disassembled unit, the defective part is replaced, the unit or unit is assembled and tested on a test stand with adjustment to the operating pressure. After repair, safety and control valves must be sealed.
When repairing hydraulic units, their dismantling is not allowed. Complicated repair of hydraulic units with the processing of working surfaces of parts and their restoration is carried out at specialized enterprises.

Gear pumps are inspected and tested. If, after changing the seals, the performance of the pump is less than 60%, the pump must be sent for repair to a specialized company.

Repair of hydraulic cylinders on the site consists mainly in straightening the rod and replacing seals. Defects in the sleeves usually occur at the points of attachment of the tips, where tears and swelling are formed. When repairing sleeves, the damaged part is cut off and a new tip is installed by crimping. From the cut off part of the sleeve, the nipple and nut are removed, which are reused.

The site is completed with equipment and fixtures in accordance with the technology of repair work and the equipment sheet. For testing hydraulic units, the site is equipped with a stand KI-4815 or KI-4200. Repairs are made on special workbenches with the use of fixtures. Repair of high-pressure hoses is carried out by the compression method. The current repair of units and units of hydraulic equipment of logging machines accounts for 4% of the total annual labor intensity of the RMM of the enterprise.

The premises of the hydraulic equipment repair site must meet the following requirements: - the height of the premises must be at least 3.2 m to the bottom of the supporting structures; - the floor must have a coating that excludes the formation of dust; – the room should have good natural light; - the walls should be painted with light-colored oil paint, the ceiling should be whitewashed.

Tire shop. The site is intended for minor repair of pneumatic tire chambers of logging vehicles and wheeled tractors and machines based on them. At the site, dismantling and installation of tires, vulcanization of chambers are carried out. Restorative repair of tires is carried out at specialized enterprises.

Wheels of timber trucks and wheeled tractors to be repaired are delivered to the site from the current repair area. Wheels are dismantled, tires and tubes are checked for serviceability at the site. To determine the location and nature of the damage, the chamber is filled with air and immersed in a bath of water, and, slowly turning, determine the place where the air exits. Chambers with signs of aging of rubber, impregnated with oil products, with a gap of more than 300 mm in length, as well as with ring cuts along the entire circumference, are not subject to repair and are rejected. When repairing chambers with punctures and cuts, the surface area around the damage is cleaned. The treated area is smeared twice with glue, consisting of one part of adhesive rubber and eight parts of Galosha gasoline.

Damage up to 30 mm in size is repaired with raw rubber, for large damage sizes a patch of high-quality rubber is used, raw rubber is laid between the patch and the chamber. The repaired site is vulcanized at a temperature of 143°C for 25 minutes. The quality of the repair of the chambers is checked by a leak test. To do this, a chamber filled with air to a pressure of 0.03 ... 0.05 MPa is immersed in a bath of water.

A stand for dismantling and mounting tires is installed on the site trucks and buses, a bath to check the integrity of the chambers and detect damage. The repair of the chambers is carried out by a vulcanizing apparatus of the OSH-5312 type, operating from a 220 V network, with a power of 800 W. The set of the device includes onboard and tread matrices for tire repair. A constant temperature on the working surface of the board 143±3°С is supported by a bimetallic thermostat; warm up time to operating temperature 40 min.

A set of tire repair tools is used to perform various repairs. It is designed to perform preparatory operations for local repair of tires and tubes. The number of items in the set is 41. A set of roughening tools with an electric drive is used to clean up repair sites.

Inflating tires after repair is carried out in a specially designated place. The inflated wheel is closed with a safety grill to ensure the safety of work. In addition to the specified equipment, racks for wheels and tires, hangers for cameras are installed on the site. Works on the current repair of tires and chambers of cars and wheeled tractors account for 2% of the total labor intensity of work attributable to the RMM of the enterprise.

The height of the room must be at least 3.2 m to the protruding building structures. The floor is asphalt concrete, the walls are painted with light-colored oil paint, the ceiling is whitewashed. On fig. 41 shows an approximate layout of the site.

Service and repair shop for gasoline-powered tools. The site is intended for centralized maintenance and current repair of gasoline-powered tools. It produces the most complex and labor-intensive types of maintenance and repair work. The structure of the specialized section includes: department for maintenance and repair of gasoline-powered saws; repair and sharpening department saw chains; pantry for storing gasoline-powered tools, saw chains and materials.

When a gasoline-powered tool is received for repair or service, it is accepted, and the completeness is checked and probable malfunctions and operating time from the last service are recorded. After acceptance, before being serviced or repaired, the gasoline-powered tool is cleaned and washed.

Rice. 41. Tire shop:
1 - peeling grinding machine; 2 - dust collecting unit; 3 - cabinet for tools and materials; 4 - tire repair workbench; 5 - mounting table; 6 - vulcanizing apparatuses; 7 - bath for checking chambers; 8 - air distributing column; 9 - safety grill when inflating tires; 10 - swivel crane; 11 - stand for dismantling and mounting tires; 12 - rack for wheels

Rice. 42. Area for maintenance and repair of gasoline-powered tools:
1 - chest for waste and rags; 2 - stands for equipment; 3 - stand for adjusting and testing the hydrocline; 4 - locksmith workbenches; 5 - cabinets for tools; 6 - mounting table; 7 - a device for cleaning and checking candles; 8 - control panel; 9 - magneto test stand; 10 - rack for parts; 11 - washing bath; 12 - disconnector; 13 - riveting and running device; 14 - machine for sharpening saw chains; 15 - machine for sharpening and jointing saw chains; 16 - baths for washing and lubricating saw chains; 17 - rack for storing saw chains; 18 - rack for petrol saws

Repair of a gasoline-powered tool is carried out by replacing worn or faulty components and parts with serviceable ones from a set of spare parts. After disassembly, the components and parts of the tool are washed in a washing bath with unleaded gasoline and blown with compressed air. Gasoline tool after maintenance and repair is tested and installed on racks in the pantry for storage.

Testing and adjustment of the units of the power supply and ignition system is carried out on stands and devices from the RBI-1 set, which is the basis of the site equipment. The kit allows you to perform in full all operations for maintenance and repair of gasoline-powered saws "Ural", "Taiga", hydraulic wedges KGM-1A. The kit also includes tools for disassembling and assembling saw chains. In addition to the equipment and tools of the RBI-1 set, the site is equipped with workbenches, racks and other necessary equipment.

The site equipment and the number of workers serving the site are calculated and accepted depending on the specific load.

The height of the premises of the site must be at least 3.2 m to the protruding building structures. The premises of the site should be isolated from other sites, have a separate entrance and preferably close to the exit to the street. The floor in the room is covered ceramic tiles. Cement, asphalt or wood floors are not recommended. The walls are painted with light-colored oil paint. The ceiling is whitewashed. On fig. 42 shows a typical site layout.

Auxiliary production. Tool-distributing pantry. The tool-distributing pantry (IRK) is intended for storage and distribution of assembly, cutting tools, instrumentation, devices necessary for work at current repair posts and production sites. It is located in close proximity to the main consumers, metalwork and mechanical and aggregate sites.

The area of ​​the IRC during design is taken for two-shift operation at the rate of 0.6 ... 0.7 m2 per one metal cutting machine; 0.4 ... 0.5 m2 per grinding machine and 0.3 ... 0.35 m2 per worker working in the current repair area. When the enterprise operates in one shift, a correction factor of 0.85 is taken. The number of storekeepers is taken at the rate of 1 storekeeper per 40 ... 50 employees. In the IRC, the instrument is accepted, it is regularly checked and the degree of suitability and the need for sharpening and repair are determined.

Control and measuring instruments are periodically checked and adjusted. The issuance of tools, fixtures and instruments is recorded in the cards entered for each worker. Storage of tools and devices is carried out on shelf racks, instrumentation is stored in cabinets.

Warehouse of spare parts and turnaround units. Works on the current repair of logging equipment are carried out in the RMM by the aggregate method. To ensure this technology of current repair at RMM, a revolving fund of the main components and assemblies of logging machines and mechanisms is organized. The volume of the revolving fund of units and assemblies depends on the capacity of the enterprise (the number of operated logging equipment) and is determined by the "Regulations on the aggregate repair of logging machines and equipment".

Storage of spare parts and assemblies is carried out in a closed heated room on multi-tiered racks and stands. The issuance of spare parts and units of the working capital is carried out according to special cards for the consumption of spare parts and materials, wound up for each payroll machine.

Approximate (enlarged) calculation of the area of ​​warehouses is made according to the specific load per 1 m2 of usable area of ​​​​the warehouse, after determining the stock of stored spare parts and circulating units necessary for the estimated capacity of the RMM.

The specific load per 1 m2 of the warehouse area for spare parts stored on racks, with a storage height of 4 m, is 1.8 ... 2.2 t/m2, for circulating units stored on stands, 0.9-1.3 t/m2.

To Category: - Repair of forest machines