Week 1:- Introduction to BiW and Fixtures Challenge

1. What is BIW & define its parts?

 Body in White (BIW) refers to the stage in automobile manufacturing where the car body’s components have been joined together. This is done using various techniques like welding (spot, MIG/MAG), riveting, clinching, bonding, laser brazing etc. The term BIW is used before painting and before the motor, chassis sub-assemblies, or trim (glass, door locks/handles, seats, upholstery, electronics, etc.) have been assembled into the frame structure.

2. What do you understand by BIW nomenclature?

BIW nomenclature is essentially the naming convention used for different parts of the Body in White. Since the automotive industry is spread worldwide, different countries use different names for automobile parts. For example, a component of the BIW is called a suspension tower in the UK and the same component is called a shock tower in the US.

3. What is fixture & its types?

A fixture is a device that holds the workpiece to be processed (like welding) by using a principle known as 3-2-1. In BIW fixture design, fixtures are designed to hold several parts during welding. It’s necessary to hold the parts at a proper location to avoid distortions and maintain the required geometry of the parts. There are several types of fixtures used in BIW such as production fixtures which are used for mass production.

4. What is the basic principle of fixture design?

The basic principle of fixture design involves two main aspects: location and clamping. Between these two functions, all six degrees of freedom are constrained while effectively positioning and orienting the part during processing. The 3-2-1 principle is commonly used in fixture design where six locators are sufficient to restrict the required degree of freedom of any workpiece.

5. Elaborate types of BIW Stations? In BIW fixture designing, there are various stations which are used to locate the panels so that joining processes can be done. Some of these stations include:

<!-- [if !supportLists]-->·         <!--[endif]-->Geo Station: Geometry of two parts is fixed here.

<!-- [if !supportLists]-->·         <!--[endif]-->Re-spot Station: Left out spots where spot welding or riveting is to be done are addressed here.

<!-- [if !supportLists]-->·         <!--[endif]-->Pedestal Station: Pedestal gun is mounted on a tool and panel is manipulated manually or by robot to weld the panels.

<!-- [if !supportLists]-->·         <!--[endif]-->Loading Station: This station is used for loading of panel and changing its orientation if required in upcoming stations.

6. What are the basic terminologies used in the BIW fixture?
7. Some basic terminologies used in BIW fixture include:

<!-- [if !supportLists]-->·         <!--[endif]-->Mylar: A block that touches and holds or clamps the panel.

<!-- [if !supportLists]-->·         <!--[endif]-->Pin: Used to lock the rotational movement of the panel.

<!-- [if !supportLists]-->·         <!--[endif]-->Blade: The plate which connects Riser to the Clamp cylinder.

<!-- [if !supportLists]-->·         <!--[endif]-->L Block: A plate shaped as L used as a connection between mylar and Blade.