WEEK-1 Challenge- BIW

1.What is BIW & define its parts?

BIW-Body in white is a metal sheet/Aluminium sheet components joined together using differnet techniques like welding,Brazing,Riviting etc to form a vehicle structure. Doors,seats,dashboard,Engine motors,Chasis etc., will be fixed in this frame structure.

BIW Parts are listed below 

• Body side Structure
• Underbody Structure
• Frontend Structure
• Closure
• Roof

Bodyside Structure: It consists of A,B,C,D Pillar, Ring pannel,bodyside outer and inner frame etc.,

Underbody Structure: It consists of Dashboard panel,Seat base,Raisers,Wheel house,Main floor,main floor etc.,

Frontend Structure: It Consists of Upper and lower tie bar,Wing panel,Cowl,wheel house etc.,

Closures: It Consists of hoods,front door, rear door,decklid

Roof Structures: It Consists of roof inner and outer surface

                           An Image which supports some of the above said structures and substructure

2.What do you understand by BIW nomenclature?

The word BIW Nomenclature is a term used to choosing of names for things or parts. BIW Nomenclature is used in Automobile industries throughout the earth.Differnet region have the different names for the parts

Example:

• Tyre vs Tire
• Petrol tank vs Gas Tank
• Wing vs Fender
• Bonnet vs Hood

Some of the Part names are listed below in the image

3.What is fixture & its types?

A fixture is a  device which holds the workpiece to be processed by using 3-2-1 Principle. These fixtures are stationery with rotating arms to hold the parts which are used for welding to ensure the proper points to avoid the disturbance and to maintain manufacturing standards & OEM\'s.

Types of Fixtures

• Production Fixture: This fixture is used for mass production purpose and requires unifromity throughout the operation, necessary maintainces should be taken care off in these fixtures, Dimension and tolerence are also checked during the operation
• Preproduction Fixture: Before the start of the batch production, a model or prototype is made according to the OEM\'s and is used to check the feasibility, from this it is easy to rectify and correct the erros which are occured during the testing of prototype, It is a Time and Cost Consuming method but it is so usefull after the start of batch production in order to eliminate the delay in the stations or in operational Areas
• Checking Fixture:After the completion of production of the part, The quality,Dimensional tolerneces etc., will be checked and confirmed after the part found ok and rejected if the part found not ok and data will be recorded to make the necessary action plan to eliminate the rejection. In this fixture no operations will be carried out.

4.What is the basic principle of fixture design?

For a fixture designer, the major portion of design time is spent deciding how to locate the work piece in the fixtures. Any free body has a total of twelve degrees of freedom in which 6 are Translational degrees of freedom :+X,-X,+Y,-Y,+Z,-Z and another 6 are Rotational degrees of freedom: CROT-X,CROT-Y,CROT-Z,ACROT-X,ACROT-Z,ACROT-Z.

Where CROT-Clockwise around X or Y or Z axis

           ACROT-Anticlockwise around X or Y or Z axis

You must fix all the 12 degrees of freedom in order to locate the workplace in fixture.

5.Elaborate types of BIW Stations?

In the Assembly line, BIW station is a part of assembly line, and these are divided in to stations.

The BIW station are classified as below:

• Tool Stations
• Gripper Stations
• Stand Stations
• Miscellaneous Station

Tool Stations: A tool is a fixture which consists of number of units together to hold car part in general

• Geo Fixture: A Geo Tool is a fixture in which the geometry of the panels are welded together is defined accurately, and these parts are located with 2 locating pins
  • Eg: If 20mm pannel hole is given the pin diameter should be of 19.85
• Respot Fixture: It is a fixture in which the remaining weld spots which are not achieved in geo tool are welded for the prewelded panel frm the geo tool
  
  • Eg: Panel hole 20 mm , then pin diameter should be 19.72
• Marriage Fixture:  In this Fixture , Inner panel of the assembly and Outer panel of the assembly are joined together using the techniques like welding,Riveting etc., the roof will be attached after the completion of maarriage fixture operation and that is called as framer tool.
• Checking Fixture: As the name indicates it is used to check the assembly parts, dimesion and tolerences & Co-ordinates, there are 2 types of fixtures, Guage type, Automated checking fixture. CMM[Co-ordinate measuring machine] is used to measure differnent points in the panel or assembly.

Gripper: A Fixture which holds the car panel and is fixed to the manipulating at end of a robot

• Material Handling Gripper[MH]: These grippers are designed for handling the car panel from one tool to another tool
• Process Gripper:These Grippers undergo same operation as MH and in addition it carry out specific process like Gluing, Welding,Riveting,Sealing etc.,
• Combo Gripper: These are the grippers which undergoes multiple task like material handling and process at a same time
• Dual Gripper: These are same as MH but with dual side LH+RH

Stands: Stands are used to mount the parts when they are not in operation

• Gluing or Sealer stands: Gluing gun or sealer gun is fixed to a welded stand
• Docking stands: It is a stand used to put some equipment which is not required for current operation but used for later operation
• Date Stamp Stands: The required data is stamped on the stand by using stamping device

Miscellaneous stand: 

• Curing: To cool down the gluing part , mean while the assembly will be carried out to some other station
• Buffer stand: Some sets of same parts manufactured and kept in a stock, and will carried to another station which is easy to be transported
• Conveyor: It is a Rotating part which is connected to next station and the material kept on this rotating part will be carried over
• Take out trolley: It is used to take some parts for inspection in order to make sure wheather the process is going correct or not

6.What are the basic terminologies used in the BIW fixture?

The basic Terminologies used in the BIW fixtures are

• NC/MYLARS/Fingers: A Component which holds the panel
• PLP: Used to locate points of the parts
• BLADES: Plates mounted above the risers
• RISERS:  It is a manufacturing part which gives height to assemblies
• SHIMS: To adjust desired positions shims are used
• ROUGH LOCATOR: These works as a guides to wrongly placed parts
• Hardwares: Fastners are used
• CMM: CMM[Co-ordinate measuring machine] is used to measure different points in the panel or assembly
• UNIT: Parts of asembly
• NUMBER PLATE: It is used to recognise the unit
• NAME PLATE: A Set of data like name,weight, material used etc are marked in this plate
• CLAMP ARM: It is a part of Clamp unit
• PIVOT: The clamp arm rotates about its axis
• SKIN SURFACE: The visible area to the customer should be clean without any dents or scratches
• REEDS/SENSORS:AN Electric component used in automated fixtures