Week 3:- BiW Fixture Design Methodologies Challenges
question no.1 – what is design methodologies?
answe
design methodologie
in this methodology we learn about three design processes, we're going to study how do we proceed while doing a design. and one of the things that we take care of structuring or design tree so we'll be learning how to structure the design tree, and how to name the particular component or particular assembly, or the part of an assembly, which is very easy to read and very easy to understan
design methodologies is nothing but the steps followed during the concept designing stages of fixture design. the various stages of design methodologies ar
purchase orde
inputs from customer
percentage of completion criteria
design outputs
week 3:- biw fixture design methodologies challenges : skill-lyn
1. purchase orde
a purchase order (po) is a commercial document and first official offer issued by a buyer to a seller indicating types, quantities, and agreed prices for products or services. it is used to control the purchasing of products and services from external suppliers. purchase orders can be an essential part of enterprise resource planning system orders. purchase order is a order from customer for start of the work. after offer has been finalized customer will be releasing the loi/po(purchase order
once po is released we have to start the wor
after po from the customer we have to prepare the schedul
purchase order is the confirmation document from customer to proceed the committed work for the
2. inputs from customer
the inputs from the customers are as belo
functional requirements
the purpose or the function of the fixture will be given as inputs from the customers like what are the process the fixture is going to do i.e welding, riveting, gluing or whether it is a checking fixture, et
preferred standard
as we know different companies follow different standards, we will be following the standards, we will be following the standards followed by the customers. by following standards the time of designing and manufacturing of parts will be saved, which will be automatically minimizing the time of the projects. as for the standards parts, it can be easily replaced from the used fixture to the new fixture which reduce the cos
car products
the inputs we get from car products are gd&t, part list, cad files of car part, clamp plan, product assembly process shee
layou
layout shows the entire assembly plan to understand the process. layout provides the information of flow of parts, station pitch, robot stations, accessories like tool changers & tip dressers, sub assembly links, plat form height, loading/unloading sequence/heigh
ergo dat
as same as preferred standards, different companies follow different standards of ergo data. we have to follow the customer standards of ergo data. the inputs of ergo data will given by the customer mostly in case of manually operated fixtures/manual fixtures. the ergo data is mainly used to make the operator comfortable which may lead to improve the efficiency in cycle time& production. ergo data provides inputs like platform height, maximum & minimum reach from operator to fixture, maximum & minimum height of the fixture, whether the child parts/assemblies are visible while clamping or loading & unloading. also provises information like loading height, working safety zone of operator, et
weld study
weld study is the important inputs given by the customer. it gives details about the study of particulars gun that we use for welding. also the dates like no/ of weld, position of weld in the components will be given. in short, weld study includes weld gun details, weld matrix & weld point
standard detailing template
this inputs include the detailing templates of 2d cad drawing as per the customer standards. so, we have to follow the detailing templates as per the customer standard
3. percentage of completion criteria
percentage completion criteria is basically schedule. what time that we can complete the entire process again this is more detailed. so when we are going to complete the in entire designing, then we're going to move on to simulation on all these subcategories would be considered in percentage completion criteria like a probability to when we can complete the entire fixture desig
it is followed in the designing stages & dispatch stages of welding fixtures. it helps to track or identify how much task completed & how much to go further for completing a fixtur
inputs & concept design – 0 to 2
concept approval & simulation check – 25 to 4
design freezing & detailing – 40 to 8
check & final dispatch – 85 to 10
the above mentioned percentage are the percentages of stage wise completion criteria of the project
4. design output
in biw fixture design or any industry. we don't only just design a particular component and just give the cad file to the customer, we have to give a lot of documents like 3d documents,2d documents, which is the detailing part, and as well as other factors as well like bom, bom bill of material and other documents as well about this particular component and their standards, all has to be submitted to the custome
question no.2 – what are the inputs required from the customer to start designing a fixture
answe
the inputs required from the customer to start designing a fixtur
fundamental requirement
preferred standard components
car products
layout
ergo – data
weld study
standard detailing templates
1. functional requirement
the purpose or the function of the fixture will be given as inputs from the customers like what are the process the fixture is going to do i.e welding(spot or seam weld), gluing, riveting, hemming or whether it is a checking fixture or a storage racks et
it is one of the basic requirements to get from the customer to start designing a fixtur
2. preferred standards
as we know different companies follow different standards, we will be following the standards, we will be following the standards followed by the customers. by following standards the time of designing and manufacturing of parts will be saved, which will be automatically minimizing the time of the project
as for the standards parts, it can be easily replaced from the used fixture to the new fixture which reduce the cos
some of the preferred standard components used in biw fixtures are given belo
standard like abb, naams, destaco, zytran, tunkers are used in design & manufacturing of fixture
standard parts like risers, l-blocks, retainers, pins, nc blocks, shims, etc
components like clamps, cylinders, slides, switches, sensors, etc
weld guns, tip dressers, tool changers, etc. tip dressers are to sharpen the tip of the tools whereas tool changes are used in robots to do various process. as robots are too costly, tool changers are used
abb – it is a robots manufacturing compan
some example of description of standard robots are, robust irb 7600 robots, which can, hold the panels securely and accurately in place while irb 6640 robots perform the weldin
the below picture shows the welding line is installed at great wall motors (gwm) recently opened and internationally acclaimed automotive plant in tianjin, china. one of the factory’s most highly publicized and productive manufacturing lines is the abb welding line, which comprises among other things a fleet of abb robots and patented abb framing and hemming technologie
3. car products
the inputs we get from car products are: gd&t, part list, cad files of car part, clamp plan, product assembly process shee
gd&t: it provides information of locating pins, rest, clamp, damp & slide unit informationof each station. also includes the information of sequence of openings of clamps, dumps & slide stroke informatio
part lists: it gives the lists of parts which are going to assembled in the fixture. the list contains the information of part number, part name, revision of fixture, part thickness, etc
clamp plan: clamp plan provides the information of location of pins, rest units, clamp unit, dump etc. it is the important input from customer. the clamp plan/position should not be changed without the knowledge of customer
3d cad file: the 3d model of the car part will be given from customer. from that 3d model we will be developing our fixture design process. the 3d cad file will be in the format of step file (stp) or iges file (igs)
product assembly process sheet: it gives the information of stage wise assembly process like how the parts move from one assembly process like how the parts move from one assembly station to other after the completion of joining process.
4. layout
layout shows the entire assembly plan to understand the proces
layout provides the information of flow of parts, station pitch, robot stations, accessories like tool changers & tip dressers, sub assembly links, plan form height, loading/unloading sequence/heigh
biw fixtures pre - design process ( design methodology & structuring a design tree ) : skill-ly
5. ergo dat
as same as preferred standards, different companies follow different standards of ergo data. we have to follow the customer standards of ergo dat
the inputs of ergo data will given by the customer mostly in case of manually operated fixtures/manual fixture
the ergo data is mainly used to make the operator comfortable which may leads to improve the efficiency in cycle time & productio
rivaa-global - manufacturing engineering services, digital manufacturi
ergo data provides inputs like platform height, maximum & minimum reach from operator to fixture, maximum & minimum height of the fixture, whether the child parts/assemblies are visible while clamping or loading & unloading
also provides informations like loading height, working safety zone of operator, et
biw fixtures pre - design process ( design methodology & structuring a design tree ) : skill-ly
6. weld study
weld study is the important inputs given by the customer. it gives details about the study of particular gun that we use for weldin
also the datas like no. of weld, position of weld in the components will be given. in short, weld study includes weld gun details, weld matrix & weld points. generally weld points will be given in sphere
7. standard detailing templates
this inputs include the detailing of 2d cad drawing as per the customer standarrd
so we have to follow the detailing templates as per the customer standard
week 3:- biw fixture design methodologies challenges : skill-ly
question no. 3 – what is the inputs we get from car products
answe
inputs we get from car products include
gd&
part lists
3d cad file
clamp plan
product assembly process sheet
1. gd&t
gd&t – geometric dimensioning & toleranc
it provides information of locating pins, rest, clamp, damp & slide unit information of each station. also includes the information of sequence of openings of clamps, dumps & slide stroke informatio
tolerance importan
assemblies – parts will often fit together if their dimensions do not fall with in a certain range of value
interchangeability – if a replacement part is used, it must be a duplicate of the original part within certain limits of deviatio
the relationship b/w functionality and size or shape of an object varies from part to par
digital gd&t series part 1 - embedded gd&t in catia, nx and cr
when to use gd&
when part features are critical to a function or interchangeabilit
when functional gaging is desirabl
when datum references are desirable to ensure consistency between desig
when standard interpretation or tolerance is not already implie
when it allows a better choice of machining processes to be made for production of a par
datum in gd&
a datum is theoretical exact plane, axis or point location that gd&t or dimensional tolerances are referenced to you can think of them as an anchor for the entire part, where the other features are referenced from a datum feature is usually an important functional feature that needs to be controlled during measurement as wel
2. part list
it gives the lists of parts which are going to assembled in the fixture. the list contains the information of part number, part name, revision of fixture, part thickness, et
3. 3d cad file
the 3d model of the car part will be given from customer. from that 3d model we will be developing our fixture design proces
the 3d cad file will be in the format of step file (stp.) or iges file (igs.) or sometimes it may be in part file (prt.
4. clamp pla
clamp plan provides the information of location of pins, rest units, clamp unit, dump, et
it is the important input from customer. the clamp plan/position should not be changed without the knowledge of customer
it gives the detail of the exact position of the clamping unit
5. product assembly process shee
it gives the information of stage wise assembly process like how the parts move from one assembly to other after the completion of joining proce
it shows the sequence of operations/process to be done in a part or a pane
also what are the parts to be joined with the panel will shown in sequenc
from this sheet we can trace out the pending process which has to further go on for completion of par
from this product assembly process sheet designer can understand the sequence for designing the fixture
week 3:- biw fixture design methodologies challenges : skill-lyn
question no.4 – what is the clamp pla
answe
clam
a clamp is a fastening device used to hold or secure objects tightly together to prevent movement or separation through the application of inward pressur
essential requirements of clamp
all clamps must fulfill four essential requirements. they ar
the work piece must be held rigid while undergoing operation
the time required for loading / unloading the tool must be as short as possible, which means the clamping device must be quick acting
when subjected to vibration, chattered, heavy pressure the clamping must be positive
the clamp must not damage the work piece
clamp plan
clamp plam is very important input that we get in the car products is where exactly we can place those clamping units are the particular pin unit
we should never change the position of the particular clamp or the pin, which is given in these dat
we can change our design a little bit here or there, but we should not change the input design data about the clamp position or the pin position
in the clamp plan there is clamp unit,pin unit and it is more detailed. it also gives the exact location of y and z coordinates designing as well you can just input these coordinates and we can start designing from there
if the three coordinates,whole diameter and everything is already given to design the entire future design phase, and it sometimes ministry as well. it happens that another thought position, also given very close to the clamp, or the clamp location. so always ask to whether you have changed the clamp position
we should never change the vent position or the clamp position without asking it so always be vary about these situations so the tool might get damaged or department get damaged so for that itself need to clarify once again before doing any changes in the clamp
question no.5 – what is the purpose of the layou
answe
the purpose of the layou
the purpose of the layout is to understand the information about where the fixture & robots are been placed, working area covered by the robot, what are the fixtures assigned for the robots to do the process, etc. layout shows the entire assembly plan to understand the proces
the circle around the robot is the swept area of the particular robot which shows the reachability of the robots particularly with the confine cir
layout provides the information of flow of parts, station pitch, robot stations, accessories like tool changers & tip dressers, sub assembly links, plat form height, loading/unloading sequence/heigh
layout sheet will give you information about all the fixtures are placed, the robots are going to work on i
in layout sheet the circle around the robot is called trapped area of that particular robo
so, this is basically the reachebility of the robot which is confined to the particular circl
flow of parts: it shows the flow of the parts/panel in the assembly line or shop floor like how component move from one station to other station after the completion of proces
station pitch: the distance between two stations is known as station pitch. it shows the space constraints between the two stations, which shows in layou
robot stations: it shows the position where the robots & their accessories placed, which is shown in the layou
sub assembly link: sub assembly link is nothing but the link between the assembly fixtures & the main assembly line. it shows that how the sub assembly fixtures are linked with the main assembly lin
the main purpose of the layout is to understand the entire plan of the assembly lin
the layout providing the above information like flow of parts, station pitch, robot stations, etc used to understand the working process of robots, what are the fixtures assigned for the robots, space constraint, et
by considering the layout, the designers can develop the concept sketches of fixtures without any clash in the assembly line
one of the main purpose is to get the information about the space constraint which helps to develop the robotic cell without any clash during workin
biw fixtures pre - design process ( design methodology & structuring a design tree ) : skill-ly
question no.6 – what is ergo-data
answe
ergo dat
ergo data is nothing but the data or inputs which gives the human factors engineering data, between the operator & his working environment. before detailing about ergo data we should know about ergonomics in detai
ergonomic
ergonomics also known as human engineering & human factors engineering is the scientific study of the relationship between man and his working environment
industrial ergonomics | trest
objectives of ergonomic
the fundamental objective of the study of ergonomics is to optimize the integration of man & machine so as to improve the productivity & accurac
in short, the objective of ergonomics is designing for human use & optimize working & living conditio
two main objectives of ergonomics ar
to enhance the efficiency and effectiveness with which the work is carried out so as to increase the convenience of use, reduced errors & increase in productivit
to enhance certain desirable human values including safety, reduced stress & fatigue and improved quality of life
ergonomics involves the design
a work place suitable for the worke
machinery & controls, so as to minimize physical strain on the worker to enable the improvement in the efficiency
an environment for performing a task most effectively and conducive
a conducive task & work organization
benefits of ergonomics
improved working conditio
reduce physical workloa
improved work posture
reduced efforts of certain movement
better reading instrument displays, handling of machine levers & control
reduced unnecessary information recall effort
below, i have given a basic example of ergonomics in the workstatio
ergo dat
ergo data is nothing but the data or inputs which gives the human factors engineering data, between the operator & his working environmen
ergo data is mostly needed while there is a need of manual operator/operatio
ergo data will be given from customer as per their standard. every customers follow different ergo data standard
as per customer standards, we have to consider the ergonomics in the fixture while designin
from ergo data we get the details or inputs related between the operator and his working fixtur
the ergo data is mainly used to make the operator comfortable which may leads to improve the efficiency in cycle time & productio
principles of biw fixtures desi
question no.7 – what do you understand by weld stud
answe
weld stud
weld study is the important inputs from the custome
it gives the study of particular gun that we use for weld, no. of spots to be welded, sequence of weld, position of weld in the component
in short, weld study includes weld gun details, weld matrix & weld point
generally the weld points will be given in sphere
red sphere represents the geo spot weld points whereas green sphere represents the respot weld point
the weld points are classified a
geo weld point
the geo weld points are which is planned in the geo fixture
these weld will determine the position of the panels as per the given data in drawin
the geo weld points are represents in red sphere in the weld study inputs given by the customer
respot weld point
the respot weld points are planned in the respot tool
these weld will determine the strength/stiffness of the panel/component
the respot weld points are represent in green spheres in the weld study inputs given by the customer
design of flexible spot welding cell for body-in-white (biw) assembl
question no.8 – what are the criteria for percentage completion in the designing stage? explain in detail
answe
the percentage completion criteria is followed in the designing stages & dispatch stages of welding fixture
this percentage completion criteria is followed to trace the project whether it matches the committed date given to the customer for hand over the projects to the
also it helps us to identify the stages in the projects like how much the project is completed and what are the further stages are in pending, to complete which helps us to complete the projects on the committed time and dat
the percentage completion criteria is divided into four stages to identify the percentage of the completion of wor
the four stages of percentage completion criteria are as follow
input & concept desig
concept approval & simulation check
design freezing & detailing
check & final dispatch
1. input & concept design
if the project is in the stage of input & concept design then the percentage completion criteria of the project will be between 0 – 25
after the completion of input & concept design then the project will be moved to concept approval & simulation check which is the second stage in percentage completion criteri
2. concept approval & simulation chec
if the project is in the stage of concept approval & simulation check then the percentage completion criteria of the project will be between 25% - 40
after the completion of concept approval & simulation check then the project will be moved to design freezing & detailing which is the third stage in percentage completion criteri
3. design freezing & detailin
if the project is in the stage of design freezing & detailing then the percentage completion criteria of the project will be between 40% - 85
after the completion of design freezing & detailing then the project will be moved tp check & final dispatch which the fourth & the last stage in percentage completion criteri
4. check and final dispatc
if the projects is in the stage of check & final dispatch then the percentage completion criteria of the project will be between 85% - 100
after the check the project will be finally dispatched successfully to the custome
question no.9 – brief about output in design
answe
output in desig
in biw fixture design or any industry. we don't only just design a particular component and just give the cad file to the customer, you have to give a lot of documents like 3d documents,2d documents, which is the detailing part, and as well as other factors as well like bom, bom bill of material and other documents as well about this particular component and their standards, all has to be submitted to the custome
the output is 3d models and the 2d drawing of the too
1.unitized too
2.non-unitised too
1.unitized tools
in the unitized tools testing requires two types of drawing sheet,which is one key sheet and layout shee
so example of a unitized tools are fixtures,tools so where exactly multiple units are a placed.for example, the entire assembly welding fixtures,where a pin unit,clamp unit,rest unit and the panel, everything is included so that for those thing
key sheet - an index of units and their placements on the tool base.it will have an orthogonal view of the fixtures including a numbered balloon drawing mentioning the unit
biw fixtu
layout sheet - a detailed drawing of individual units to include all of their components.for the non unitized tool no need of key sheets. as they can stand alone, the drawing can be detailed completely on a layout sheet
so, it is basically an index of units and placements on the tool base, so the key sheet going to show you the placement and the location of that particular tool on the tool base where exactly the tool is placed. and what is his exact position in a particular plac
2.non-unitized to
tools that can stand alone and can be detailed completely on a layouy shee
non unitized tools are basically tools like stands and tool changers is also an example of an non unitized tools where you don't need key sheet, you can actually used to layout sheet and complete the entire documentation of the particular component. so this is as known non unitized tool
the design output should compile following point
approved standard components are to be used wherever possibl
design must be as simple & economics as possible
design must be comply with all current safety & ergonomic requirements
design must provide for controlled & damage free handling of product
adequate error proofing provision must be incorporated into each design by proving proximity switches, rough locators, etc
the weight of the moving parts must be kept to a minimum while maintaining maximum strength
frames & structures are to be simple & study
design clearance & accessibility for routine maintenance & service
motion control must be considered on any moving equipments
designer is responsible to validate clamps & weld guns
question no.10 – what do you understand by structuring a design tree? how does it reduce errors during the design proces
answe
structuring a design tre
structuring a design tree implies to process where all the assemblies & parts are named in a specific standard. different customers have different set of standards to structure a design tre
it is an important process which helps us to identify a specific part or assembly as to which project, tool/unit, it belongs t
this helps us to avoid the errors during design, manufacturing, assembly, inspection, et
if the parts or assemblies are not named properly or the design tree is not structured properly, it will create confusion to understand the design & may create major possibilities of making an erro
naming of a fixture or a unit or a part, gives the information as to which project or zone or assembly do they belon
it can help us to identify the quantity of items of same types or different types that are being used in the assembl
while start designing a fixture, the first unit will be the base uni
in structure tree all the manufacturing parts should be first and the standard parts should be at the las
structure tree helps to study or understand the parts in the assemblies easil
steps to structuring a design t
step 1: create new à product à click ok (by clicking ok now you will enter into a product windo
step 2: then right click product in a structure tree à go to properties à rename in part number (as we created a product we have to mention the total assembly name of the fixture) à click o
the naming of the assemblies / parts / units have certain standard procedures, which i have clearly explained belo
the product name is title of the fixture. the renamed titled should be à p001_z03_st09_00_00
p001 – represent the project nam
z03 – zone nam
panel name will also be mentioned in some cas
st 09 – station name / j03 – jig name will be mention sometime
00 – unit nam
00 – part numbe
r/l – is representing the right hand side / left hand side of the pane
the other renamed title explained in video
h1l_19a_rrfra_jg3_00_00_
h1l_19a – project nam
rrfra – panel nam
jg3 – jig name/numbe
00 – unit na
00 – part numbe
r – indicates right sid
question no. 11 – what are units? mention 5 types of un
answe
unit
a unit is a device that has a specified function, especially one forming part of a complex mechanis
a welding fixture is assembly of different types of unit
as name refers, the different units will be only seen in the unitized too
a units are classified into two, they ar
simple unit: in a simple welding fixture, the combination of these different units will be see
rest uni
fixed pin units
retract pin units
rough locator unit
sensor unit
base unit
complex unit: in a complex welding fixture, in addition with some of the simple units these complex units will also see
slide uni
dump unit
five types of units
base uni
base unit is the unit designed to mount all other units such as clamp unit, pin unit, rest unit etc., of tool, also other parts necessary for a tool like pneumatic valve box, trunk cable path will also be mounted on to be a base unit
fixed pin u
fixed pin unit is a unit designed to locate the car panel using pins.tabl
pin, pin retainer, shims, blocks, blade, riser are the part of fixed pin unit
pin retainer is used to hold the pin firml
typically, the locating pins are used to locate a body part in a position sufficiently accurate to execute a welding proces
the body part is constrained by a set of appropriately locating pin so total constraint by locating pin should be fully constrained at all times to prevent any movemen
retractable pin u
retractable pin unit is unit designed to locate the car panel using pins, but the entire pin package parts will be mounted on the retractable pneumatic cylinder as shown in below fig 3
retractable pin unit is the opposite of fixed pin unit which can be moved up & down also which can be retracted till certain distanc
it is mainly used for unloading the complex panel after weldin
clamping u
clamp unit is a unit designed to clamp or hold the car panel with nc block / mylars by using a pneumatic clamp cylinder
clamping unit is used to clamp the part which is to be welded after location using pin uni
clamping is achieved with the help of pneumatic cylinders and clamp arm
clamping arm, finger, rest, shims, standard riser, pneumatic cylinder are the parts of clamping unit in genera
week 3:- biw fixture design methodologies challenges : skill-ly
slide uni
slide unit is found mostly in complex fixture, where the sliding mechanism will be involved
this type of unit used when there is some space constraint
guide block, guide rail, position lock unit, stopper block, sensors are the parts of slide unit in genera
guide block & guide rail helps to the guide the slide unit. the rail should always be covered to protect against weld spatter & dust by a bellow or a sheet metal cove
position lock unit helps the slide to be locked/clamped in the working positio
stopper block helps to stop/control the entire moving of a slide unit from certain distance, which is placed at the end of the guide rai
sensors – the two end limits to be sensed externally by a proximity senso
question no. 12 –describe fixed pin unit & their purpos
answe
fixed pin uni
fixed pin unit is a unit design to locate the car panel using pin
pin, pin retainer, shims, blocks, blade, riser are part of fixed pin unites in genera
pin retainer is used to hold the pin firml
purpose of fixed pin u
as by 3-2-1 locating principle, the introduction of two pins helps to arrest the 6 degrees of freedom (4 axial & 2 radial movements) whereas other 6 degrees of freedom are arrested by introducing minimum three support
typically, the locating pins are used to locate a body part in a position sufficiently accurate to execute a welding process a welding proces
the body part is constrained by a set of appropriately locating pin so total constraint by locating pin should be fully constrained at all times to prevent any movemen
question no.13 – what are the different parts of the fixed pin uni
answe
different parts of the fixed pin uni
the different parts of the fixed pin units are as follow
pi
pin retainer
shims
blade
riser
1. pin
it is used for the location purpose of the panel. typically, the locating pins are used to locate a body part in a position sufficiently accurate to execute a welding proces
the body part is constrained by a set of appropriately locating pin so total constraint by locating pin should be fully constrained at all times to prevent any movemen
there are dozens of styles of locating pins that can be utilized in a design. one of the most common pins is a stepped pin with either small or large hea
round pin
these can be screw secured (pnrs) or grub screw secured (pnrg) or thread secured (pnrt) for prototype build only. one of the most common pins is a stepped pin with either small or large hea
diamond p
the diamond shape is a critical feature that helps with machining inaccuracies and smoother locating operation. when two round head pins are installed onto one plate, the distance between two mounting holes must be extremely precise and even then, the work piece will not be placed on the base as easily as it would with the use of a diamond shape pin. these can be screw secured (pnds) or grub screw secured (pndg) or thread secured (pnrt) for prototype build onl
2. pin retaine
pin retainer is used to hold the locating pins firmly. pin retainer is designed to hold the pin in its place and is also used as a rest for the pin. a counter hole drilled on which pin is fit
naams pin retainer apr336m | freer tool & supp
3. shims
in general, a shim is a thin and often tapered or wedged piece of material, used to fill small gaps or spaces between object
shims are typically used in order to support, adjust for better fit, or provide a level surfac
shims may also be used as spacers to fill gaps between parts subject to wea
shims are the small parts which comes with the thickness of 0.1mm, 0.2mm, 0.5mm, 1.0mm et
these will compensate the stack up tolerance which reflects at the mylar
we give tolerances to all parts of the fixture. due to this tolerance the mylars will either lift up moves down from its defined position. to adjust the mylars for getting the defined position we use shim
shims will be added above the mylar for adjusting according to toleranc
why is shimming required in a biw fixture? - quoraweek 3:- biw fixture design methodologies challenges : skill-ly
types of shim
types of shims ar
wood shi
stone shim
plastic shim
metal shim
paper shim
4. riser
riser is a manufacturing part used to raise / height the assemblies of fixtur
one end of the raiser will be attached to the blad
raiser can be of two types. they ar
‘l’ type riser
square tube risers
l type risers: l type risers are of welded type. where the stiffner will be added at the centre for support, as shown in the below figure the wedge shaped structure is known as stiffner which is used as a support/to withstand load
naams risers by misumi | misumi online shop - select, configure, orde
square tube risers: square tube risers are of frame typ
week 3:- biw fixture design methodologies challenges : skill-lyn
5. blade
blade are the plates which are attached to raise
blade is also attached or mounted with cylinders, arms et
week 3:- biw fixture design methodologies challenges : skill-ly
question no.14 – what is a purpose of making a rest unit? and describe its part
answe
purpose of making a rest uni
rest unit is unit designed to support car panel using mylar/ nc block/ rest. component is rested only, no upper clamp or force applied ther
it is the simplest unit to design because it has fewer parts to design & the purpose is only resting of the car panel. because of this simplicity the rest unit is combined with other unit to reduce the cost of the overall projec
it can be combined with clamp unit to clamp as well as to rest the car panel. it can be combined with locating unit to locate as well as to rest the car panel. also locating, clamping & rest unit can be combined together in one unit to reduce cos
there is no cylinder attached to it. it has rest mylar, blade & riser & below is different parts of rest unit. rest unit is also divided into simple support unit, multiple support units & retractable support uni
parts of rest u
the parts of rest unit are as follow
nc block/mylar
risers
blades
shim
1. nc blocks/mylars
mylars are the part which are holding the panel from top & botto
it is a jaw type, during welding it wont deforms from its positio
it is also known as finger
it wont allow the deformation of the part due to welding stresse
mylars are of two types, they a
clamping myla
resting mylar
only resting mylars can be seen in rest unit
the panel which rests on the part is known as resting mylar
2. risers
riser is a manufacturing part used to raise/height the assemblies of fixture
one end of the raiser will be attached to the base unit while other end will be attached to the blad
riser can be of two types, they ar
l type rise
square tube riser
l type risers: l type risers are of welded type. where the stiffner will be added at the centre for support, as shown in the below figure the wedge shaped structure is known as stiffner which is used as a support/to withstand load
naams aab riser (misumi) | misumi | misu
square tube risers: square tube risers are of frame typ
week 3:- biw fixture design methodologies challenges : skill-ly
3. blade
blade are the plates which are attached to raise
blade is also attached or mounted with cylinders, arms et
week 3:- biw fixture design methodologies challenges : skill-lyn
4. shim
a shim is a thin and often tapered or wedged piece of material, used to fill small gaps or spaces between objects. shims are typically used in order to support, adjust for better fit, or provide a level surfac
shims may also be used as spacers to fill gaps between parts subject to wea
shimpacks series 4015- t
question no. 15 – what are the basic fundamentals to design a sensor unit
answe
sensor uni
a sensor unit is a unit designed to sense the car panel by using electrical sensor
this signals from the sensors will be fed to the plc and so the next process will be executed by the signa
week 3:- biw fixture design methodologies challenges : skill-ly
fundamentals to design a sensor uni
every single loose panel which are being welded in a tool should be sense
each panel should be sensed by 1 or 2 sensors depend on the size of the panel, preferred to be in diagonal opposite ends of pane
every sensor should be mounted in a 3 direction adjustable way in genera
we should try to minimize the size of sensor as much as possibl
some major sensor manufacturers are ifm, pepperl – fuchs, sick, omron, et
types of sensor used in genera
proximity senso
a proximity sensor often emits an electromagnetic field or a beam of electromagnetic radiation and looks for changes in the field or return signa
the object being sensed is often refered to as tge proximity sensors targe
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laser senso
these laser distance sensors use a focused, coherent light to measure distance to a target object. in factory automation applications, the target is usually a product or a machine elements. they detect any solid object and produce an output proportional to the measured distance – independent of material, color and brightnes
the high resolution output provided by laser distance sensors is used to provide position or displacement, usually to the input of some type of industrial controller such as plc. the output signal is often highly accurate, and it includes temperature compensation to enhance stabilit
there are several types of laser distance sensors including diffuse, background suppression and retroreflective. these sensors use cmos or transit time technologies providing accurate distance measurement
laser sensor, displacement/rpm measurement, m12, 300mm/100m | ato.c
photoelectric sensor
a photoelectric sensor or photo eye is an equipment used to discover the distance, absence or presence of an object by using a light transmitter often infrared and a photoelectric receive
they are largely used in industrial manufacturin
there are three different useful types opposed, retro-reflective and proximity sensin
photoelectric sensor, photo sensor, photoelectric proximity sensor, retro reflective sensor, photo reflective sensor, photo electric sensor in poonamallee, chennai , sree nidhi enterprises | id: 89730170
question no. 16 – what is rough locator unit & what are the basic fundamentals to consider while designing it
answe
rough locator uni
rough locator unit is a unit designed to guide the operator to locate the car panel on the oins accordingl
a rough locator can be standard part or make par
biw fixtures-3d-finishing & design of rough locators : skill-lyncbiw fixture basic - 4 : skill-ly
the basic funtamentals to concidar while desiging a rough locato
rough locator should be placed at the edges of the car panel, which has to guid
rough locator should be placed in the same angle of the car part edge with a minimum distance of 2 – 5 mm from the edge of car par
rough locators should guide the panels in a pin assemble direction in genera
rough locators should start guiding the panel before 10 t0 15mm to the start of the pin engagemen
rough locators should be designed with entry angle for car part entry as shown in the above figur
rough locators should be designed with two slots to mount for easy adjustment in genera
the slots should be in the direction of car part guidin
question no. 17 – what is a base unit? and describe its parts
answe
base uni
base unit is the unit designed to mount all the other unit like clamp unit, pin unit, rest unit, etc. of the tool, also other parts like pneumatic valve box, trunk cable path will also be mounted on to a base uni
parts of base u
parts of base unit are as follow
valve bo
trunking channel
measuring hole cover
eye bolt
pedestal
floor plates
1. valve box
valve box is basically a box which supplies air to all the pneumatic cylinders assembled in the fixtur
valve box consist of one solenoid valve is used to collect the air from the pneumatic cylinders to valve bo
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2. trunking channel
trunking channel is a kind of cable duct, which helps to guide and protect the wirings/tubes used in the fixture
25x25 mini cable trunking - a pl
3. measuring hole cove
in the measuring hole cover the coordinates points are engraved on i
the hole which mention the coordinates gives the position & placements of the particular unit
the measuring hole helps in cmm inspection & qc inspectio
4. eye bol
an eye bolt is a bolt with a loop at one end. they are used to firmly attach a securing eye to a structure, so that ropes or cables may then be tied to it for lifting purpos
eyebolt is used to frag or lift the base unit while relocatin
mild steel ms eye bolt, size: m6 to m64, features: rust resistant, rs 60 /kilogram | id: 146608849
5. pedesta
pedestal is a stand like structure where the entire unit of the base will be mounte
6. floor plate
floor plates is used to mount the entire base with the floo
also it helps to achieve the flatness of the fixtur
question no.18- what is dump unit & what are its function
answe
dump uni
dump unit is where you assemble component if you have certain constraint. here you will have clamp unit, pin unit attached & panel will be assembled. so if you have certain constraint you cannot assemble in normal wa
dump unit use in different way. it has dump cylinder & complex design. it consists of dump cylinder to perform the operation of clamping & unclamping car panel. a dump unit can have more than one cylinder to perform such operatio
the first cylinder dumps the assembly carrying clamp mylars, pins and then this assembly performs the required operation. in this unit, we should make sure that in the open position of panel, we should be able to remove the panel. below fig show dump uni
week 3:- biw fixture design methodologies challenges : skill-ly
question no. 19 – what are slide units? mention where slide units are commonly used
answe
slide unit
slide units are positioning units, which are used to position the car part or panel, units, weld gun, robots for further operation
slide units may be classified into two types based on the type of guide ways. they ar
hardend guide wa
lm guideway
slide units may further classified into three types based on the prime mover. they are
manual slide
hydraulic/pneumatic slides
cnc slides
it may be further classified depending on the application a
horizontal slide uni
vertical slide unit
angular slide unit
basic fundamentals of slide unit design
reverse stroke o 10mm to be considered in both forward & retracted conditio
cylinder & lm guides to be validate for load & strok
master guideway should be constrained & the subsidiary guideway to be fre
mechanical hard stop to be considered for both extended & retracted conditio
shock absorber should be used for both extended & retracted condition to reduce impact loa
slide to be locked/clamped in the working positio
slide to be locked with a safety pin in the retracted position during transportatio
the two end limits to be sensed externally by a proximity switc
the design should be checked for screw accessibility, ease of assembly, machinability of part
the lm guide & rails are integral assemblies and should not be separated at any cos
lm guide ways to be lubricated for long lif
slide units are commonly used
slide unit is found mostly in complex fixture, where the sliding mechanism will be involve
this type of unit used when there is some space constraints in locating the pane
slide application will be easy for weldin
slide unit can be minimize the cost of robot as slide unit provided to move weld gun from one weld spot to other weld spot instead of weld robot. g.l.d. in:e.t.s.h.n.n.d.n.e.e.n.:..t.s..s.,.y.e,s.s:r:?
Master guideway should be constrained & the subsidiary guideway to be free.
Mechanical hard stop to be considered for both extended & retracted condition.
Shock absorber should be used for both extended & retracted condition to reduce impact load.
Slide to be locked/clamped in the working position.
Slide to be locked with a safety pin in the retracted position during transportation.
The two end limits to be sensed externally by a proximity switch.
The design should be checked for screw accessibility, ease of assembly, machinability of parts.
The LM guide & rails are integral assemblies and should not be separated at any cost.
LM guide ways to be lubricated for long life.
SLIDE UNITS ARE COMMONLY USED IN:
Slide unit is found mostly in complex fixture, where the sliding mechanism will be involved.
This type of unit used when there is some space constraints in locating the panel.
Slide application will be easy for welding.
Slide unit can be minimize the cost of robot as slide unit provided to move weld gun from one weld spot to other weld spot instead of weld robot.