Project 2

                                                               PROJECT -2

A fixture is a work-holding or support device used in the manufacturing industry- fixture are used to securely locate (position in a specific location or orientation) and support the work , ensuring that all parts produced using the fixture will maintain conformity and interchangeability . using a fixture improves of production by allowing smooth operation and quick transition from part to part. 

following part is giving for the fixture design which includes 5 parts shown by different colors as well .

first to understand scope of the work , means what is expected by customer . every customer has its specific requirement and it may own material electric , pneumatic cad design standards every customer also different inputs and expects out e.g 2d drawing ,process sheet in xls,pdf , CAD format of layout format, OLP.

Functional requirement is the basic requirement which defines the function of fixture  whether it is being used for welding, hemming , checking fixture or storage racks . Depending on this the design considerations are going  to change while designing the fixture.

• Bill of material (BOM) Of the components to be welded-spot welding.
• CAD panel data or least 2D drawing of assembly and individual panel data .
• sheet metal panel thickness . plays major role to decides 2 metal or 3 metal weld .
• spot metal panel thickness , plays major role to decides 2 metal or 3 metal weld
• weld information like total no spots and spacing between the spots.
• weld information clarity from drawing like 2 metal or 3 metal welding 
• PLP(Principle location scheme ) of the individual panel and metal welding 
• cycle time - if calculated or can be found out as per manual or robotic welding process.
• process time -if process engineering is done - where loading sequence , no of clamp data and gun data is mentioned. 
• All clamping cylinder  and fixture standards. 
• CAD -Software guidelines 
• Raw material standards 
• Design guidelines
• Bought out item  (purchased parts) standard like pneumatic items , toggle clamp , bearing screw’s , dowel etc. company information

The fixture will be the spot welding where robotic gun will be used for spot welding hence the fixture have ample of the space that spot gun should come in do its work should go out without striking to the any of parts of the fixture . The green spots shown in the image are the spot welding will done by the welding gun . so we have to place the fixture parts by considering the spot weld & also by doing the gun study we have to check the  fouling parts with the gun.

 

 

By considering any fixture 3-2-1 principle is the most important thing to be considered here also 3-2-1 principle is taken into consideration while designing. Different unit are used are used to fulfill the requirement of constraining the DOF  of different parts like Fix pin units , retractable pin units ,power clamp units , rest unit etc.

Designing of Various Units

Base unit

.

Pin unit

Clamping  Unit

SWIVEL CLAMP

 

REST UNIT

TOTAL ASSEMBLY

 3D Finish

3D Finish is the process where design is being completely finish & to be ready for final simulation & 2d detailing 

following point are taken into consideration while finishing the design.

• Hole concentricity & hole aizes -All parts hole concentricity is checked  & confirmed while finishing the parts.
• Machining area -The machining area in every parts is defined & the machining area is highlighting by using orange color.
• Nominality :- All units dimensions are maintained nominal to facilitate easy assembly of the unit .
• Hole coloring standard:-color codes standard used in the 3d finishing.

1.Cyan - Simple 

2. Yellow- Threaded Hole 

3.Orange - Machining area 

4.Blue - Dowel pin Hole 

• Fasteners Implementation-Fasteners are implemented in all per the requirement & load on the parts .
• Avoiding clash between different parts - Parts gap is maintained between parts to avoid the clash.
• Mylar spitting as per panel profile:-Mylar spitting are confirmedwhile finishing of parts & assemblies are done while finishing the design hence we can identify each & every parts easily with unique identification.

2D DRAWING