Week 3:- BiW Fixture Design Methodologies Challenges
1.Design Methodology in Technology While design methodology is employed in many industries, it is commonly applied in technology fields, including those using the internet, software and information systems development. Several design methodology approaches have developed in the technology industry. Each was a reaction to a different type of problem.
2.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 etc. It is one of the basic requirements to get from the customer to start designing a fixture.
3.The inputs that we get from the care products are as follows: GD&T; Part Lists; CAD Files; Clamp Plan; Product Assembly Process Sheet. GD&T; The input about the geometric dimensioning and tolerance of the part for which the fixture is being designed.
4.The commonly known 'plan clamp' is also known as a plan binder, plan holder, plan hanger, plan rack or plan drawing hanger. They are available in 4 different sizes ranging from A0, B1, A1 and A2.
5.the purpose of the layout: 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 process
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6. Ergo data is nothing but the data or inputs which gives the human factors engineering data, between the operator & his working environment.
7.Welding is a fabrication process whereby two or more parts are fused together by means of heat, pressure or both forming a join as the parts cool. Welding is usually used on metals and thermoplastics but can also be used on wood. The completed welded joint may be referred to as a weldment.
8. The four stages of percentage completion criteria are as follows, Input & concept design. Concept approval & simulation check. Design freezing & detailing. Check & final dispatch.
9.Design Output: It includes data to be given to customer after completion of design stage. The output is 3D models & 2D drawings of the tool.
UTILIZED TOOL,NON UTILIZED TOOL
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The first stage of the design process is to understand the perspective of the target audience/customer/consumer to identify and address the problem at hand. To do this, design thinkers are encouraged to cast aside all assumptions (because assumptions can stifle innovation !) about the problem, the consumers, and the world at large.
11.1) clamp unit. 2) pin unit. 3) rest unit. 4) combination of clamp & rest unit. 5) dump unit.6)Rough locator
Body in White (B.I.W.) is a welded sheet metal parts (components) that form the vehicle’s structure to assemble with other components i.e., engine, chassis, exterior, and interior trim. At Weld Shop, we call this BIW. It is the Sheet Metal body before heading to the paint shop.
Fixtures, Grippers, Clamping Units, Locating Units, and Dump Units & Pin Units are all covered in-depth in this course.
This Domain Training of BIW Fixture Design gives the insight to Study, understanding, and gaining knowledge of Process Design, 3D Concept Design, Validation, Gun Study, Modification, 3D Finish, and 2D Drafting using GD&T.
The course is structured to start with the fundamentals of fixture design and proceed to the final design. If the fundamentals of fixture design aren’t followed, it can lead to poor productivity and quality issues. The apparent advantages include reduced setup and cycle times, increased component accuracy, and deskilling the job setting operation.
The course emphasizes further on the Fixtures, Grippers, Clamping Units, Locating Units, and Dump Units & Pin Units.
Training also gives an exposure to the Automotive Industry Standards, Design & Manufacturing methodology, and it will help the fresh Engineer to join the industry confidently
For 3D modeling, assembly, bill of materials, and 2D drafting, we use CATIA V5 software. This training is conducted on live and recently executed projects, with a minimum of 5 different projects. POKA YOKE, 3D modeling of parts and assembly, using popular design CAD tools, and preparing the final manufacturing drawings. During the course, topics such as Design for accuracy, manufacturing, and assembly will be covered. It will be a very interactive and hands-on training session that will cover all aspects of fixture design from every angle
12.Fixed supports inhibit all movement, including vertical or horizontal displacements as well as rotations. On the other hand, pinned supports (also called hinged), inhibit displacements but permit rotations to occur freely.
13. Fixed pin unit is a unit designed to locate the car panel using pins. Pin, pin retainer, shims, blocks, blade, riser are the part of fixed pin units in general
14.PURPOSE OF MAKING A REST UNIT: Rest unit is unit designed to support car panel using Mylar/ NC block/ rest.REST UNIT:The rest units are designed to rest/support the car panel by using NC blocks/Mylar/Rest.It is the simplest unit to design because it has fewer parts to design & the
15.fundamentals to design a sensor unit: Every single loose panel which are being welded in a tool should be sensed. 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 panel.
Sensors, in their most general form, are systems possessing a variable number of components. Three basic components have already been identified: a sensor element, sensor packaging and connections, and sensor signal processing hardware. However, there are additional components to certain sensors.
16.Rough Locators:A rough locator is a part designed to guide the operator,to locate the car panel on the pins accordingly.A rough locator can be of standard part or make part
17.Base Unit: Base unit is the unit of the fixture which is designed as such so that other units of the fixture can be mounted on it
18 DUMP UNIT: Dump unit is where you assemble component if you have certain constrain
Dump unit is the complex unit to design due to space constains there is less space avilable & have to adjust all the parts in available space. It consist of dump cylinder to perform the operation of clamping & unclamping car panel.
19.Compact slide unit This compact slide unit is ideal if the installation of all components must be carried out from the split line face and a small installation space is required
BIw, Components. design, analysis, assembly, ... overall design of a new model of a car is determined by the time taken to design the bodywork Engine and chassis units are easily