Week 5:- Rest Unit & Clamp Unit Design Challenge

Master's Certification in BIW Fixture & Plastic Design

(Automotive BIW Fixture Design)

REPORT

Assignment-5

By Ravi Ahuja

Fixed pin Unit design:

• I started with watching tutorial videos first then I would start my designing to understand the concept and procedure followed in the designing of the fixed pin unit.
• Then I opened the car panel part file by selecting File>Open then I selected the igs file named as Then I saved the file as .CATpart format.
• Then I opened a new file in CATIA and imported the car panel part file in assembly design environment.
• I named the assembly as P001_Z01_ST010_00_00 and the following product were named as P001_Z01_ST010_01_00 and the following parts in the products were named as P001_Z01_ST010_01_01.
• Here P001 stands for First Project.
• Z01 stands for first zone.
• ST01 stands for first station.
• Then numbers after them represent the product and part numbers respectively.
• Then I created a product in the assembly environment and named it P001_Z01_ST010_01_00_FIXED_PIN_UNIT naming can also be done after the completion of project.
• Then I created a part in this product and named it P001_Z01_ST010_01_01_ Then to create a point to start at the circular hole in the panel I needed a point.
• I selected Point option from the toolbar and then selected option for circle and then I selected the hole in which I needed the pin to be designed around.
• Then after clicking OK there appeared a point on which I now have to make a plane with selecting the point and one of the plane perpendicular to the panel surface for reference.
• This can be done by selecting plane feature from the same toolbar and after getting plane we can start designing our pin.
• Now I started my sketch on the same plane by selecting the plane then sketch feature from the toolbar.
• I the selected profile option and made a sketch for pin with an axis around witch it was going to roll and extrude.
• After giving appropriate dimensions to the profile sketch I selected shaft feature and selected the sketch then clicked on ok.
• After that I would profile one side of the pin with a pocket feature and restrict the rotation of the pin.
• To place the pin in its initial position and stop it from rotation another part is used it is called pin retainer.
• Pin retainer is designed in a way that it stops the motion of the pin by obstruction and engaging the pin through the cutout.
• Then we would need a hole in a position under the pin and concentric to pin to bolt them together.
• Then I would create a new part and sketch on the pin retainer surface parallel to the car panel and make an L block and then Pad it out to create a l block to bolt pin retainer and riser together.
• Then I would create riser according the base level and bolting positions in block.
• The shapes and dimensions are not standard except some bolting holes and their clearances and threading conditions.
• The same process is repeated for the second design of the fixed pin uit with same pin but different designs for pin retainers, block and risers.
• After this we need to design the fixed pin unit for retractable pins.
• For retractable pins we used diamond shaped pins by first copying the old pin design with breaking the link and then editing it to make it diamond shaped.
• Then I imported the retractable cylinders for each design.
• Then I designed pin retainers, blocks and risers for the same.
• For the first retractable design cylinder has single pin while for the second design cylinder has double acting pin slots.

Clamp Unit design:

• I designed my first clamp unit after watching the tutorial videos and following the exact same steps.
• It included design of Clamp Mylar, Rest Mylar and riser with the imported cat-part file of clamp arm with cylinder.
• I named them with product as P001_Z03_ST010_02_00_CLAMP_UNIT and then parts were named as
• After watching the tutorials I designed 2 more clamp units with different type of risers and rest mylars.
• One of the design had “I” shaped rest mylars and clamp mylars with a blade which connects the rest mylars to the clamp arm cylinder.
• Clamp Mylar was bolted to the clamp armand moves with clamp arm.

Fig. 2^nd clamp unit design with I shaped Clamp mylar and a blade

Fig. 2^nd clamp unit without the panel

• Other design had a widened clamp mylar to increase the area with an I shape.
• Rest mylars are also widened and extended to the clamp arm cylinder directly to bolt the rest mylar directly to the clamp arm cylinder.
• Riser was attached on the rear side of the clamp arm cylinder.
• Riser was given a height equal to the height of the base from the point of bolting on clamp arm cylinder.

Fig. 3^rd clamp unit design with widened mylars

Fig. Widened Mylars for better contact