Week 3:- BiW Fixture Design Methodologies Challenges
AIM:- Biw Fixture Design Methodologies challenges.
1)What is Design Methodology?
Ans: - Design Methodology is nothing but the step followed during the concept designing stages of fixture design.
Design Methodology.
<!-- [if !supportLists]-->1) <!--[endif]--> Purchase order, 2) Input from Customer, 3) Percentage Completion criteria, 4) Design Output.
1)Purchase Order: - Purchase order is the order from customer for start of work.
2) Input from customer: -1) Functional Requirement,
2) Pre-ferried standard component,
3) Car Product,
4) Layout,
5)Ergo Data,
6) Wed Study,
7) Standard Detailing Templets.
3)Percentage Completion Criteria: - Percentage Completion criteria are followed in the designing stages and dispatch stages of the welding fixture.
4) Design Output: - 1) Approval Standard component are to be used wherever possible.
2) Design Must be as simple economical as possible.
2)What are the inputs required from the customer to start designing a Fixture?
Ans: - 1) Functional Requirement,
2) Pre-ferried standard component,
3) Car Product,
4) Layout,
5)Ergo Data,
6) Wed Study,
7) Standard Detailing Templets.
3) What is the input we get from "Car Products"?
ANS: - Car product: - We have “3D” Files, “2D” Files as well as to learn and to study what kind of geometrical tolerance and what kind of PLP point tolerance level that the particular car product has.
PLP is principle locating point where we can fix those pin units and or the clamp units that perpendicular position.
<!-- [if !supportLists]-->1) <!--[endif]-->GD &T
<!-- [if !supportLists]-->2) <!--[endif]-->Part List
<!-- [if !supportLists]-->3) <!--[endif]-->Cad file and Cat part
<!-- [if !supportLists]-->4) <!--[endif]-->Clamp plan
<!-- [if !supportLists]-->5) <!--[endif]-->Product Assembly product sheet.
4)What is the Clamp plan?
Ans: - Clam plan is very important input we that in the car product is where exactly we can place those clamping units or the particular pin unit.
So, one more very important point we should never change the position of the particular clamp or the pin which is give in this data, we can change over design a little bet in here but we should not about the clamp position or the pin position.
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5)What is the purpose of a Layout?
Ans: - Layout provide information of: -
<!-- [if !supportLists]-->1) <!--[endif]-->Flow of part,
<!-- [if !supportLists]-->2) <!--[endif]-->Station rich,
<!-- [if !supportLists]-->3) <!--[endif]-->Robot station,
<!-- [if !supportLists]-->4) <!--[endif]-->Accessories like tool changer and tip dresser,
<!-- [if !supportLists]-->5) <!--[endif]-->Sub Assembly,
<!-- [if !supportLists]-->6) <!--[endif]-->Platform height,
<!-- [if !supportLists]-->7) <!--[endif]-->Loading-Unloading sequence/Height.
Basically, layout sheet gives you an information fixture is a placed, the robot a gone work on it.
In manufacturing engineering, a product layout refers to a production system where the work station and equipment are located along the line of production as with, assembly line. Usually, work units are moved along line (not necessarily a geometric line, but a set of interconnected work station) by s conveyor.
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6)What is Ergo data?
Ans: - 1) Ergonomic refers to the study of human behavior and movement.
<!-- [if !supportLists]-->2) <!--[endif]-->Ergo data provide information of loading height, working safety zone of operator etc.
7)What do you understand by Weld study?
Ans: - We study include: -1) Weld gun Details.
2) Weld matrix and weld points.
(A) Geo Weld Point.
(B) Re-Spot Weld Point.
Generally, the data of weld metrics and weld point will be given to you in a form of space green and red piece the were the welding is going to happen and Geo spot, Re-spot which is Geo Spot red and re- spot are green.
8) What are the criteria for percentage completion in the designing stage? Explain it in detail
Ans: - Percentage completion criteria are followed in the designing stages and dispatch stages of the welding fixture.
<!-- [if !supportLists]-->n <!--[endif]-->0-25% Input and concept design
<!-- [if !supportLists]-->n <!--[endif]-->25-40% Concept approval and simulation check.
<!-- [if !supportLists]-->n <!--[endif]-->40-84�sign freezing and detailing.
<!-- [if !supportLists]-->n <!--[endif]-->85-100% Check and final dispatch.
9)Brief about "Output" in design?
Ans: - -- The output is 3D model and the 2D drawing of the tool.
<!-- [if !supportLists]-->n <!--[endif]-->Unitized toll: - (Multiple units are on a common base) require two type of drawing sheets.
<!-- [if !supportLists]-->n <!--[endif]-->Key sheet – An index two of unit and their placement on the tool base.
<!-- [if !supportLists]-->n <!--[endif]-->Layout Sheet: - A detailing drawing in of individual unit to include all of their component’s.
<!-- [if !supportLists]-->n <!--[endif]-->Non-Utilized tool: - Tool that can stand alone and can be detailed completely on a layout sheet.
E.g.: - Fixture, tool, where exactly unit are placed. So e.g. entire assembly welding fixture where you have a pin unit, clamp unit and the panel everything is include so that so things you need. To tell you which unit is tell you exactly drawing of each and every unit that is the layout sheet.
10) What do you understand by structuring a design tree? How does it reduce errors during the design process?
Ans: -
<!-- [if !supportLists]-->n <!--[endif]-->Structuring a design tree implies to a process where all the assemblies & part are named in a specific standard. Different customer is having different set of standards to structure a design tree.
<!-- [if !supportLists]-->n <!--[endif]-->It is an important process which help to identify a specific part or assembly as to which project, tool or unit it belongs to.
<!-- [if !supportLists]-->n <!--[endif]-->This helps us to avoid the error during design study, manufacturing, assembly, inspection etc.
<!-- [if !supportLists]-->n <!--[endif]-->If the part or assemblies are not named properly or the design tree is not structured properly, it will create confusion to understand the design and nay create major possibility of making an error
<!-- [if !supportLists]-->n <!--[endif]-->Naming of a fixture or a or a party gives the information as to which project or zone or assembly do they belong.
<!-- [if !supportLists]-->n <!--[endif]-->It can help us to identify the quantity of items of same type or different types that are being used is an assembly.
11) What are Units? Mention 5 types of units.
Ans: -
Units: - Mechanical design is to design parts, components, product, or system of mechanical nature. For example, design of various machine element such as shaft, bearing, clutches, gears, and fasteners fall into the scope of mechanical design. Numerous primary design criteria include function, safety, reliability, manufacturing, weight, size, wear, maintenance, and liability. In general, a mechanical design problem should be formulated with clear and complete statement of function, specification, and evaluation criteria.
Different types of units: -
<!-- [if !supportLists]-->n <!--[endif]-->Simple unit: -
-- Rest Unit
-- Fixed pin unit
-- Retract pin unit
-- Rough pin unit
-- Rough locator unit
-- Sensor unit
-- Base unit
<!-- [if !supportLists]-->n <!--[endif]-->Comport unit: -
-- Slide Unit
-- Dump unit
12) Describe Fixed Pin units & their purpose?
Ans:- Fixed pin unit is a unit designed to locate the car panel using pins.
And below are the different parts of a fixed pin unit in general.
<!-- [if !supportLists]-->n <!--[endif]-->Pin retainer
<!-- [if !supportLists]-->n <!--[endif]-->Shim/ Spacer.
<!-- [if !supportLists]-->n <!--[endif]-->Block.
<!-- [if !supportLists]-->n <!--[endif]-->Blade or adapter plate.
<!-- [if !supportLists]-->n <!--[endif]-->Riser.
13) What are the different parts of a fixed unit?
Ans:-
<!-- [if !supportLists]-->n <!--[endif]-->Pin retainer
<!-- [if !supportLists]-->n <!--[endif]-->Shim/ Spacer.
<!-- [if !supportLists]-->n <!--[endif]-->Block.
<!-- [if !supportLists]-->n <!--[endif]-->Blade or adapter plate.
<!-- [if !supportLists]-->n <!--[endif]-->Riser.
14) What is the purpose of making a Rest unit & describe its parts?
Ans: - A rest unit is a unit designed to rest/ Support the car panel using NC block/ Maylor / Rest and below is the different part of a rest unit in general.
Rest unit is basically unit where the part is rested there is no a part clamp to it there is no force applied to it there is no cylinder attach to it just usually it will have a riser a blade a few Mylar that’s it.
15) What are the basic fundamentals to design a Sensor unit?
Ans:-
Fundamental of sensor unit design.
<!-- [if !supportLists]-->n <!--[endif]-->Every single loose panel which are being welded in a tool should be sensed.
<!-- [if !supportLists]-->n <!--[endif]-->Each panel should be sensed by 1 to 2 sensor depend on the size of panel, preferred to be in diagonal opposite ends of panel.
<!-- [if !supportLists]-->n <!--[endif]-->Every sensor should be mounted in 3 direction adjustable way in general
<!-- [if !supportLists]-->n <!--[endif]-->Some major sensor manufacturing safe IFM, prep pert-Fuchs, Stack, OMRON, etc.
16)What is a Rough locator unit & what are the basic fundamentals to consider while designing it?
Ans:- Rough locator should be placed at the edge od the car panel which is the two guide.
Fundamentals of rough locator design: -
<!-- [if !supportLists]-->n <!--[endif]-->Rough locator should be placed at the edge of the car panel, which is the guide.
<!-- [if !supportLists]-->n <!--[endif]-->Rough locators have to be placed in the same angle of the car part edge with a minimum distance of 2-5mm from the edge of the car part.
<!-- [if !supportLists]-->n <!--[endif]-->Rough locators should guide the panel in pin arresting direction (in general)
<!-- [if !supportLists]-->n <!--[endif]-->Rough locator should start guiding the panel before 10 to 15mm to the start of the pin engagement.
17) What is a Base unit and describe it's parts?
Ans: - A base unit is the unit designed to mount all the other units (clamp unit, pin unit, rest units, etc.)
Of the tool also, other part necessary for a tool also other part necessary for a tool like pneumatic valve box, trucking cable pin will also be mounted on to a base unit.
Are below the same of a base unit in general
<!-- [if !supportLists]-->n <!--[endif]-->Trucking channel.
<!-- [if !supportLists]-->n <!--[endif]-->Base plate
<!-- [if !supportLists]-->n <!--[endif]-->Valve box
<!-- [if !supportLists]-->n <!--[endif]-->Measuring hole cover
<!-- [if !supportLists]-->n <!--[endif]-->Eye bolt.
<!-- [if !supportLists]-->n <!--[endif]-->Pedestal
<!-- [if !supportLists]-->n <!--[endif]-->Weld parts
<!-- [if !supportLists]-->n <!--[endif]-->Floor plate.
18) What is a Dump Unit and what are its functions?
Ans:- Dump unit is a unit where you assemble component which you have certain constrain.
<!-- [if !supportLists]-->- <!--[endif]-->Open position
<!-- [if !supportLists]-->- <!--[endif]-->Clamp cylinder unit
<!-- [if !supportLists]-->- <!--[endif]-->Dump cylinder.
19) What is a Slide unit? Mention where Slide units are commonly used.
Ans: - Sliding unit are basically uses in places we have a lot of constrain or space constrain where you cannot use different, different units to design entire assembly so here you will use these sliding unit.
<!-- [if !supportLists]-->n <!--[endif]-->Close position.
<!-- [if !supportLists]-->n <!--[endif]-->Guide rail
<!-- [if !supportLists]-->n <!--[endif]-->Open position
<!-- [if !supportLists]-->n <!--[endif]-->Guide block
<!-- [if !supportLists]-->n <!--[endif]-->Position locking units
<!-- [if !supportLists]-->n <!--[endif]-->Slide cylinder.
<!-- [if !supportLists]-->n <!--[endif]-->Stopper cylinder
<!-- [if !supportLists]-->n <!--[endif]-->Sensor unit.