Week 5:- Rest Unit & Clamp Unit Design Challenge

AIM

1) To design 3 different types of Power Clamp Unit with Different Riser, Blade and Clamp Arm for the given Car Panel.

2) To design 2 different types of Rest Unit for the given Car Panel.

CLAMP UNIT

• Clamp unit is designed to clamp/hold car panel with NC blocks/ Mylars/ rest by using a pneumatic clamp cylinder.
• Clamp unit consists of Finger, Clamp Mylar, Rest Mylar, Shims, Clamp arm, Block, Pneumatic Clamp Cylinder, Riser, Blade.

FINGER

A finger is a NC block which is mounted on the clamp arm of the cylinder and will press the car panel towards the rest so that it holds the car panel.

CLAMP UNIT 1

CLAMP UNIT 2

CLAMP UNIT 3

REST MYLAR

It is used to fix the unit to support the car panel and also it resists the clamping force of the finger and thus clamp the car panel.

CLAMP ARM

• A clamp arm is a bought out part to which all the movable parts are fixed.
• In general a clamp arm is a part of clamp cylinder.
• Clamp arms are available in different hole pitch.
• Clamp arms are available as Middle arm- A10, Right arm- A11, Left arm- A12

CLAMP CYLINDER

• A clamp Cylinder is pneumatic device works with pressurized air
• The clamp cylinder is used to open and chose the parts fixed to the clamp arm fixed to the clamp body.
• Clamp cylinder are bought out parts, some of the manufacturers are Tuenkers and Destaco.
• Clamp cylinder are in general 40, 50, 63 and 80 bore capacity.
• It opens up to 135 degree for horizontal clamp mounting.
• It opens up to 105 degree for vertical clamp mounting.

DESIGN METHODOLOGY

STEP 1

• After receiving a workpiece for which we need to design, Clamp units and Rest units are designed following the 3-2-1 Principle.
• It should be ensured that the units properly clamped the workpiece during welding or riveting operations.
• The surface of the panel should be selected to design the clamp unit and the rest unit on that specific area which ensures that the panel is clamped properly.

STEP 2

• The clamp mylars and rest mylars are designed and positioned in such a way that the movement of the car panel is restricted.
• Later, the clamp mylars will be attached to the cylinder arm for the opening and closing of the clamp arm.

STEP 3

The Standard Pneumatic cylinders which is a bought out part is downloaded from the Tuenkers website and it is opened In a catia file and is copied to the Clamp assembly from that file.

STEP 4

• Blocks are designed wherever needed.
• It is used to fix the blade which supports the mylars and also bridges the gap between the blade and the riser.

STEP 5

• Blades are designed to mount the rest mylar with the riser or the block.
• The blades are used to hold the mylars and it gives sufficient strength to the rest mylar.
• The design of blade depends upon the riser and the position of the rest mylar.

STEP 6

• The risers are designed such that all the above parts are mounted on it.
• The risers are fixed to the base of the fixture.

STEP 7

• Shims are designed and mounted wherever necessary.
• Shims or spacers are used to bring the adjustments in joining the blocks or blades to the risers.

ASSEMBLY OF CLAMP UNITS

TYPE 1

TYPE 2

TYPE 3

REST UNIT

• The rest unit are designed to support the car panels using mylar.
• The primary purpose of the rest unit is to rest the car panel.
• The rest unit has different parts and they are as follows.

1. Mylar
2. Blade
3. Block
4. Risers

MYLAR

• Mylar is the part that hold the panel from above and below during the operation.
• The top side of mylar is called clamping mylar whereas the bottom side mylar is known as resting mylar.
• Every clamping mylar will have a resting mylar.
• Resting mylar holds the panel and ensures that the panel doesn’t deform during the welding operation.

RISER

• A riser is a part that is used to raise the height of the fixture.
• The riser is fixed to the base of the fixture and the blade is mounted on the riser.

DESIGN METHODOLOGY OF REST UNIT

• The rest mylars are placed below the panel in order to support the panel.
• The blades were designed to support the rest mylar with the riser
• Shim is added between the rest mylar and the riser. It is also placed between the rest mylar and the block.
• The risers are designed differently for 2 different Rest unit in such a way that it supports the entire rest unit properly.

ASSEMBLY OF REST UNITS

TYPE 1

TYPE 2

ASSEMBLY OF CLAMP UNIT AND REST UNIT IN A CAR PANEL

CONCLUSION

Thus the designing of 3 different types of Power Clamp Unit with Different Riser, Blade and Clamp Arm for the given Car Panel and the designing of Rest units of the given car panel is completed as per the design considerations.