Week 11:- 2D Detailing Challenge 2

Challenge:

1. Create 2D Drawing for each Clamp Units with all child parts and also create Child part drawing for the same for the Fixture assembly created in challenge 8.

2. Create 2D Drawing for each Pin Units drawings with all child parts and also create Child part drawing for the same for the Fixture assembly created in challenge 8.

Answer

Clamp unit: - A clamp unit is a unit designed to clamp/hold the car panel with NC blocks/ Mylar/ rest by using a pneumatic clamp cylinder & below are different parts of a clamp unit in general. Usually clamp open position is 90°. Fingers are attached to the clamp Mylar. In a clamp unit shimming to one side is more than enough because it will restrict translation motion in upward & downward directions only. There is another type of clamp unit known as the swivel type. There is a pivot pin around which the clamp arm rotates.

Factors should be considered while designing a clamp unit:

• There should be adequate space between the cylinder & another part like the riser, car panel because the cylinder moves or swing while opening & closing
• Pin clamp unit used where two panels or components are located for welding.
• Clamping is make in such a way that it clamps two car panels at once
• All parts should snap & butt properly to each other.
• Make sure that parts of the clamping unit are 10 to 12 mm away from the car panel so they do not damage the car panel
• Avoid any clash. It will not arise an issue at assembly.

Types of Clamp Units:

1. Swivel cylinder clamp unit.

2. Power Clamp unit.

Swivel cylinder clamp unit:- In this type of clamp unit clamp will be operated using a hydraulic cylinder.

Swivel cylinder clamp unit-1

Fig-01: Swivel Cylinder Clamp-1_Key sheet

Fig-02: Rest Mylar-1

Fig-03: Rest Mylar-2

Fig-04: Blade

Fig-05: Clamp Mylar-1

Fig-06: Clamp Mylar-2

Fig-07: Arm

Fig-08: Arm Plate

Fig-09: Riser

Fig-10: Stopper Part-1

Fig-11: Stopper Part-2

Fig-12: Bush-1&Bush-2

Fig-13: Arm Pin with Cotter Pin

Swivel cylinder clamp unit-2

Fig-14: Swivel Clamp Unit-2 Keysheet

Fig-15: Rest Mylar-1

Fig-16: Rest Mylar-2

Fig-17: Blade

Fig-18: Clamp Mylar-1

Fig-19: Clamp Mylar-2

Fig-20: Arm

Fig-21: Riser

Power Clamp Unit:- In this type of clamp unit clamp will be operated using Power cylinder.

Power Clamp Unit-1

Fig-22: Power Clamp Unit-1 Keysheet

Fig-23: Rest Mylar-1 & Rest Mylar-2

Fig-24: Rest Block

Fig-25: Clamp Mylar-1 & Clamp Mylar-2

Fig-26: Clamp Block

Fig-27: Blade

Fig-28: Riser

Power Clamp Unit-2

Fig-29: Power Clamp Unit-2 Keysheet

Fig-30: Rest Mylar & Clamp Mylar

Fig-31: Shim Assy

Fig-32: Riser

Fig-33: Blade

Pin Unit:- A Pin unit is generally designed to locate the car panel using Pin. The pin unit is used to lock the rotational position of the panel.

Fundamentals of pin unit design

• It is necessary to have 2 pins to locate a car panel & here one pin must arrest 4 way (4 translational) & other must arrest 2 way (i.e. 2 rotational) of a car panel.
• The axis of the car panel hole & the axis of the pin should be the same (in general)
• The pin tolerance for a geo pin will be of closer tolerance i.e. -0.15mm & for a re-spot pin is -0.28mm
• Pin should engage 3 to 5 mm from the car panel entry surface.
• All pins should be accommodated with 2-way adjustable shims irrespective of the direction of arresting.
• Round pins should be used if the hole is round in case of 4-way arresting of the car part.
• Round pins can be used for 2 way arresting of car parts only if the hole is slot.
• Diamond pins should be used in case of 2-way arresting of car part if the hole is round
• Diamond pins should be used in case of 4-way arresting of the car part if the hole is slotted.

There are mainly 2 types of pin units

• Fixed Pin Unit
• Retractable Pin Unit

Fixed Pin Unit:- In this type of unit, the pin is fixed & it does not have any movement up & down

Fixed Pin Unit

Fig-34: Fixed Pin Unit Keysheet

Fig-35: Diamond Pin

Fig-36: Retainer

Fig-37: L-Block

Fig-38: Blade

Fig-39: Riser

Fig-40: Shim Assembly

Retracted Pin Unit:- This type of Pin Unit, Pin will be mounted a retractable pneumatic cylinder. Retractable pin units are particularly useful for unloading complex panels after welding, as the ability to retract the pins allows for easier access to the welded areas.

Retracted Pin Unit-1

Fig-41: Retracted Pin Unit-1 Keysheet

Fig-42: Round Pin

Fig-43: Retainer

Fig-44: Shim Assy

Fig-45: L-Block

Fig-46: Blade

Fig-47: Riser

Retracted Pin Unit-2

Fig-48: Retracted Pin Unit-2 Keysheet

Fig-49: Diamond Pin

Fig-50: Retainer

Fig-51: Shim Assy-2

Fig-52: Block

Fig-53: Riser

Clamap with Pin Unit

Fig-54: Clamp with Pin Unit Keysheet

Fig-55: Rest Mylar & Clamp Mylar

Fig-56: Blade

Fig-57: Arm

Fig-58: Riser

Fig-59: Round Pin

Fig-60: Retainer

Fig-61: Block

Conclusion: Detailed drawings were created for all Swivel Clamp Units, Power Clamp Units, Fixed Pin Unit, Retracted Pin Units & Clamp with Pin Unit.