Week 1:- Introduction to BiW and Fixtures Challenge

1.What is BIW & define its parts?

• Body in white ( B.I.W) refers to the welding sheet metal components to form the vehicle structure before the other parts will assemble i.e..seats,engine and lights etc. 
• To achieve body in white colour(GREY) we use primer to our welded sheet metal components.     

                                                                 BIW parts

•  BODY SIDES
• UNDER BODY
• CLOSURES
• ROOF
• FENDER

                        BODY SIDES refers to car  innner and outer body side.

                        UNDER BODYrefers to front end frame (i.e) engine assembly area and rear end under frame (i.e)rear assembly area and aslo main floor(i.e)seat assembly.

                        CLOSURES refers to doors that is front,rear,hoood,decklid and trunks.

                        ROOF refers to car inner and outer roofs.

                        FENDER refers to the part which asembled in top of the wheel.

 

2.What do you understand by BIW nomenclature?

                                                   BIW nomenclature define the parts of car assemblying parts name which we use but  the name varies in standards wat we are using in describing the name of parts.

 

3.What is fixture & its types?

                              Fixture is used to hold the components by using 3-2-1 principle without any deviations during the time of operations (i.e) welding,drilling,cutting etc.and it also to arrest the 12 degrees of freedom to complete the operations and get the finished components with in the size .

FIXTURES TYPES;.

• Production fixtures
• pre production fixtures 
• Checking fixtures            

 Production fixtures;

                                 Production fixtures refers to  mass production for car assembly

Pre production fixtures;

                                 It refers to the development fixtures of initial stage of new product development

Checking fixtures;

                               It refers to the checking the welded parts and assembly parts by using cmm., measuring instruments etc. To check the co ordinates, hole sizes etc,  

4.What is the basic principle of fixture design?

                                                        In fixture desidn the major portion to design to locate the work piece in the fixture.

                                                         in any free body there is twelve degrees of freedom in total ( six transtational degree and six rotational degree)

                                                         Six transtational degree (X+,X-,Y+,Y-,Z+,Z-)

 Six rotational degrees are; 

                                      Clockwise in X axis(CROT X)

                                      Anti clockwise in X axis(ACROT X)

                                       Clockwise in Y axis(CROT X)

                                       Anti clock wise in Y axis (ACROT Y)

                                       Clockwise in Z axis(CROT Z)

                                      Anti clock wise in Z axis (ACROT Z)

5.Elaborate types of BIW Stations?

                                                      BIW stations are mainly calssified into four stations that are TOOLS,GRIPPERS,STANDS AND MISCELLANEOUS

 

                                                                                                    TOOLS

In TOOLS is a fixture which consist number of units together to hold a car parts, that are divided into many types;

GEO TOOLS;

                Geo tools is the fixture to weld the different car panelparts,in geo tools the locating pin hole are should be lesser than actual size and also with in the tolerance size (i.e

if ahole size is diameter 60mm and our pin size sould be minus 0.20mmthat are 59.80)

RE SPOT TOOLS;

                      Re spot tool is the fixture to do spot weld which are not done in geo tools ,re spot tool is majorly used for fast production and reduce the cycle time in geo tools in re spot tool the pin hole size should be minus0.28mm(i.e if the hole size is diameter 35mm the size should be 34.78mm)

                       in this fixture the locating pins are less precise comparing to geo tools because we do remaining spot weld only in already assembled panel so that re spot fixturedoes not wants to be more accuracy 

MARRIAGE TOOLS;

                         Marriage tool is the fixture to assemble the both inner and outer panel ,it ia also known as hemmming tools.

                        In this fixture the panel should be assembled by welding or by hemming in closuer panels.

                                                                                                             GRIPPERS

GRIPPERS is a device are mostly used to hold the car panel with help of robot and end effector and it is also known as EOAT(END OF ARM TOOLING) and it has different type of grippers that are;

MATERIAL HANDLING GRIPPERS;

                                                 material handling grippers are designed to handling the panel from one tool station to another tool station.

PROCESS GRIPPER;

                           process gripper are designed to handling the car panel from one tool station another process station like gluing,sealing and pedestal etc.

COMBO GRIPPERS;

                            Combo grippers are designed to handling the panel from one tool station to another tool station and addition of welding gun in other end of grippers .

DUAL GRIPPERS;

                         Dual grippers are designed to handling the panel from one tool station to another tool station in this both end are attached with grippers it used to carry simuntaneously carry the panel .

                                                                                                                   STANDS

GLUING ANS SEALER STANDS;

                                            It is fixed the standard stand and permanently which are mounted in the floor without any deviations for gluing and sealing operations.

DOCKING STAND;

                         it is used the kept the  gun and gripper in the multi tasking operations due to some limitations of robots .

DATE STAMP STAND;

                            Date stamping device is mounted in the stand to emboss the date adn batch no like this in car panel.

                                                                                                                MISCALLEANOUS

MISCALLEANOUS  is used to storage the panel,moving panel by using trolley and conveyors.

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

Basic terminologies used in the BIW fixture;

• NC/MYLARS/FINGERS the part which holding the panel both top and bottom side,in top we said clamping mylar and bottom is resting mylar and every clamping mylar must have a resting mylar.

• PLP( PRINCIPLE LOCATING POINT) defines to locating the panel in fixture by using pins and the locting pin should be more accuracy.

• BLADE is the plate mounte in riser and clamp cylinders and clamping arm

• RISERS is the plate used to increase the height and holding the blades ,risers are should be l type plate and square tube welded plates

• SHIMS are used to add height in clamping arm or in between mylar and clamp arm to holding the panel without disturb.shims are various sizes like 0.2mm,0.5mm,0.8mm,1 and 2mm.

• ROUGH LOCATORS is also used as fool proofing location to avoiding mistakes in locating the panel in fixturees

• HARDWARES is known as fasteners like screws and dowels

• CMM( CO ORDINATES MEASURING MACHINING) is used to measure the co ordinates of fixtures in assemblyby using cadd data and in CMM 0.8mm ball tip is used to measuring the co ordinates

• UNITS is the total assembly of risers,blade,cylinder and mylars ,in fixture there are many units.

• NUMBER PLATES is refers to fixture and units  number,date serial no etc.

• CLAMP ARM is the assembly attached with one side on cylinder and other end mylar to move and hold the panel.

• PIVOT is a pin to assemble the clamp arm ic cylinder to move up and down or left and right

• CLASS A SURFACE OR SKIN SURFACE is a good surface finish for that we use soft materia,s in fixture like nylon ,pu.

• REED SWITCHES 

• SENSORS is used to sense the job is kept in fixtue for operations  to avoid rejections and mistakes