Week 3:- BiW Fixture Design Methodologies Challenges
1. What is Design Methodology?
Ans- design methodology is nothing but the steps followed during
the concept design stage of fixture design is called design methodology
farther steps of design methodology
- What are the inputs required from the customer to start designing a Fixture?
Ans- 1) GD & T
2) part list
3) cad files of car part
4) clamp plan
5) product assembly process sheet
- What is the input we get from "Car Products"?
Ans - 1) GD & T
2) part list
3) cad files of car part
4) clamp plan
5) product assembly process sheet
4. What is the Clamp plan?
Ans – clamp plan provides the location of pins, rest, clamp, dumps
5. What is the purpose of a Layout?
Ans -1) To provide optimum space to organize equipment and facilitate movement of goods and create a safe and comfortable work environment.
2) To promote order in production towards a single objective
3) To reduce the movement of workers, raw materials, and equipment
4) To promote the safety of the plant as well as its workers
6. What is Ergo data?
Ans – Ergo data is operated is required it refers
to the study of human behavior and movement is provide information is loading hight,
working, safety zone operator is called as ergo data
7. What do you understand about Weld’s study?
Ans - WELD STUDY- weld study includes weld of details, weld matrix and
now geo weld point this is an example is weld matrix includes geo and respot weld points
geo sport is denoted by red point and re- sports is denoted by green point and one component and the
other station.
8. What are the criteria for percentage completion in the designing stage? Explain it in detail
Brief about "Output" in design?
Ans – percentage completion criteria are followed during the designing stage and dispatch stages of the welding
fixture.
0-25% - input and concept design
25-40% - concept approval and simulation check
40-85% - design freezing and detailing
85-100% - check and final dispatch
so for example to complete the fixture design within the 4 days so we have got 25% and then go from
concept simulation check so we can complete 25-40% and the next process is the design is final and now
detailing is started we are moving on from 40-85% and the final stage is a check of final dispatch which is output give costumer from 85-100%
9. What do you understand by structuring a design tree? How does it reduce errors during the design process?
Ans - Design output –
design output is a 3D model and 2D drawing of the tools and tools used in types of unitized and non unitized
A) unitized tool- unitized tool is required two types of drawing sheets
a) key sheet- an index of unite and their placement on the tool base
c) layout sheet – a detailed growing of individual units to include all of their components
B) non-unitized tool – a tool that can stand alone and can be detailed completely on the layout sheet
10. What are Units? Mention 5 types of units.
Ans – 1) structuring a design tree is the process in of all assemblies and parts are named in a specific standard
and the customer is set a different standard to structure a design tree
2) structuring a design tree is an important process is help us to identify the part or assembly as to which project toll or unit
3) this helps avoid errors during design study, manufacturer, assembly, inspection, etc.
4) if the part of the assembly is not named and the design tree is not structured properly it will create confusion to understand the design.
How does a reduce error?
- if the part and assembly is named properly and the design tree is structured properly then all of the error is reduced
11. Describe Fixed Pin units & their purpose?
Ans - fixed pin unit – fixed pin unit is a unit designed to locate the car panel using a pin and below are the different parts
of a fixed pin unit in general
Rest unit – a rest unit is a unit designed to rest/support the car panel and using NC blocks/mylar/rest below are the different parts of a rest unit in general
retractable pin unit – a retractable pin unit is a unit designed to locate the car panel using a pin but the entire pin package parts will be mounted on the retractable pneumatic cylinder
clamp unit – A clamp unit designed to clamp/ hold the car panel with the NC block/mylar/rest by
using a pneumatic clamp cylinder and below are the different parts of a clamp unit in general.
SENSOR UNIT – A sensor unit is a unit designed to sense the car panel by using electrical sensors
These signals from the sensors will be fed to the PLC and so the next process will be executed by this signal.
TYPE OF SENSOR USED IN GENERAL
1. proximity sensor
2. laser sensor
3. photo elecatric sensor
12. What are the different parts of a fixed unit?
Ans –1.. locating pin
2.. Pin retainer
3.. Shim pack
4.. L- block
5.. Blade
6.. Riser
13. What is the purpose of making a Rest unit & describe its parts?
Ans –it is the simplest unit to design because it has fewer parts to design & the purpose is only resting on the car panel. Because of the simplicity, the rest unit is combined with another unit
a rest unit is a unit designed to rest/support the car panel and using NC blocks/mylar/rest below are the different parts of a rest unit in general
14. What are the fundamentals to design a Sensor unit?
Ans - fundamental of sensor unit design :
c) Every single loose panel which is being welded in a tool should be sensed.
B) each panel sensed by 1to2 sensor depends on the size of the panel, preferred to be
in diagonal opposite ends of the panel.
D) every sensor should be mounted in a 3 direction adjustable way in general.
15. What is a Rough locator unit & what are the fundamentals to consider while designing it
Ans - Rough locator is apart designed to guide the operator, to locate the car panel onto the pins
accordingly. A rough locator can be of standard part or take the part.
FUNDAMENTALS OF ROUGH LOCATOR DESIGN
a. rough locator should be placed at the edges of the car panel, which it has to guide
b. rough locator has to be placed at the same angle of the car part edge with a minimum
distance of 2-5mm from the edge of the car part
c. rough locator should guide the panel in pin arresting direction
d. rough locator should start guiding the panel before 10to15mm to the start of the pin engagement.
E. rough locator should be designed with entry angle for car part entry.
F. Rough design should be with two slots to mount for easy adjustment
G. The slot should be in a direction of the car part guiding.
16. What is a Base unit and describe its parts?
Ans – a) A unit used to mount all units over it like a clamp pin likewise.
B) also it will rest in a subpart of the main unit like the pneumatic valve box which is used to supply air to the inlet of oil pneumatic cylinders.
C) it has trunking a channel base plate value box, measuring hole cover, eye bolt, pedestal, weld bars, floor
plat etc.
PART OF BASE UNIT
1) TRUNKING CHANNEL
2) BASE PLATE
3) VALVE BOX
4) MEASURING HOLE COVER
5) EYE BOLT
6) PEDESTAL
7) WELD BARS
8) floor plate
17. What is a Dump Unit and what are its functions?
Ans - Dump unit is a complex unit to design due to space constraints there is less space available & have to adjust all the parts in available space. It consists of a dump cylinder to operate clamping & unclamping car panel.
function of dump unit :
To ensure there is enough clamping
force in the cylinder so that it doesn’t
move while welding
18. What is a Slide unit? Mention where Slide units are commonly used.
Ans -
A sliding unit can have a clamp or a pin or a rest unit attached to it which slides forward and performs the
the required operation on completion of the operation slide move back
Slide units commonly used are places, enough space, resting location, clamping, sensing, and guide rails.