Week 1:- Introduction to BiW and Fixtures Challenge

Answer 1 - Body in white (BIW) refers to the welded sheet metal components which form the vehicles structure to which the other components will be married, i.e engine, chassis, exterior and interior trim.

BIW parts are as follow:

Body sides: in body sides consist of the inner body side and outer body side.

Under body: in under body it consist of Engine compartment, main floor, rear compartment.

Closures: in closures it consist of front door,rear door, hood and Tail gate (decklid).

Roof: in Roof it consist of inner and outer roof.

Fender: it is a part which cover the wheels.

Answer 2: BIW structure consist of number of components or parts.

there is small difference between US English and UK English. components of BIW structure having different nomenclature.

UK US

Inner wing panel motar compartment side panel

Suspension tower shock tower

Engine (longitudinal) tunnel motar compartment lower rail

Rear parcel tray package shelf

Backlight frame rear header or backlite header

Central (longitudinal) tunnel tunnel

B-pillar B-pillar

C-pillar C-pillar

D-pillar D-pillar

Answer 3: Fixture is basically used for assembly of different components to hold and fix for which the ficture designed. The fixture is a device which holds the workpiece to be processed (welded) by using 3-2-1 principle it is also know as Principle of locations. These fixture designed in sucha way that holding component should not be vibrate or distract due to tight hold and clamping

Types of Fixtures:

i- Production Fixture: Production fixture used for mass production. They have a high rigidity and easy in operational activities for operator. These type of ficture maintained periodically or time to time.

ii- Pre-production Operation Fixture: it is a prototype of a production fixture , it is used for new component and parts.

iii- Checking fixture: These fixture are used for inspection purpose or checking the parts ot components. checking the parts or components are manufactured accurately or not without defects.

Answer 4- Fixture are used to hold or fix the components. To fix the component we have 12 degree of freedom to keep part or component stable while processing.

Fixture are designed using 3-2-1 principle of locations.

12 degrees of freedom are:

• +X direction
• -X direction
• +Y direction
• -Y direction
• +Z direction
• -Z direction
• Clockwise along X axis
• Counter-clockwise along Y axis
• Clockwise along Y axis
• Counter-clockwise along Y axis
• Clockwise along Z axis
• Counter-Clockwise along Z axis

Answer 5 - Types of BIW stations are:-

1- Tool station:-

i- Geo Fixture:- For accurate geo fixtures are used and pin tolerance is -0.15

ii- Re-spot Fixture:- Missing spots are processed in this fixture having pin tolerance of -0.28

iii- Marriage Fixture:- Marriage are used for assemble the inner and outer panel.

iv- Frame fixture:- Component assemble in marriage fixture are asssemble with roof.

v- Checking fixture:- it used to check the components.

2.Gripper station:-

i- material handelling gripper- it is used to move component from one to another station.

ii- process gripper- along with holding component it also used for completing processes.

iii- combo gripper - it is used for holding and processing.

iv-Dual gripper- it hold two components on both the sides.

3- Stand station:-

i-Pedestal stand - In this station component are hold as it is that the stand tools are mounted easily along the movement.

ii-Gluing or sealer stand - this is a fixed stand where the gluing and sealing applied.

iii- Docking stand - limitation of load capacity docking stand is used.

iv- Date stamp stand - date stamp stand is to mention the date of manufacturing or fixture numbers.

4-Miscellaneous station -

i- Curing- These stand is used to provide curing timme to the components or parts.

ii- Conveyor - Conveyors are used material handling

iii-Take out trolley- It is used to take out component or parts in assembly line for inspection purpose.

iv- Buffer stand- These stand is used to store components.

Answer 6:- Basic terminologies used in the BIW fixture.

• NC or Mylars or Fingers- it direct contact with the fixture from both the sides.
• PLP- it helps to locate the component with accurate the geometry.
• RISERS-it used to give the height to the units fixture.
• BLADES- blades are mounted on risers.
• SHIM-it is used to adjust the stability of the fixture by using plates of 3mm or 5mm.
• ROUGH LOCATORS- it hold the component in correct manner and also support or rest the component.
• HARDWARE- it consists if nuts or bolts etc.
• CO-ORDINATE MEASURING MACHINE (CMM)- it is used to measuring the geometry of the component.
• NUMBER PLATE-it is used to mention the numbe on parts.
• NAME PLATE- it is used to mention the name of parts.
• CLAMP ARM - it used to clamping the component securely.
• PIVOT- it is axis along wich arm rotates.
• CLASS A SURFACE/SKIN SURFACE- outer visible surface of components knows as class A or skin surface.
• SENSORS- it used to sense and send some inputs to electronic or mechanical devices for better result of understanding.
• REED SWITCHES.- it is used to operate the cylinder in fixtures.