Week 5:- Rest Unit & Clamp Unit Design Challenge

Design 3 Different types of Power Clamp Unit with Different Riser, Blade and Clamp Arm for the given Car Panel.

Design 2 Different types of Rest Unit for the given Car Panel.

Write a Detailed Report describing the process and attach relevant images.

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NOTE- While designing all these units, I faced a issue with mulitiple parts (repeated) in hardware like M8 bolts, M6 bolts, Dowel pins etc. As my software is of lower version, was facing lot issues to save files.

STill, I tried to atleast provide 1 M8 bolt for clamp arm and Clamp Mylar to present OPEN position of the cylinders in 2-3 units. Later this was also not working. Every time a different prob was arised.

I already had an One on one seesion , treid to resolve the same but it coundnt help.

Hence I am submitting the challenge except remaining hardwares.

Kindly concider my submission.

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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.

Introduction and Theory:

A Clamp Unit is a unit designed to clamp or hold car panel with NC block or Mylar by using pneumatic clamp cylinder.

Various parts of a clamp unit are as shown in figure.

While designing a clamp unit , following parts as required to design and manufacture (make parts) or can be used as standard parts-

Clamp arm/finger, Rest/backup, riser, pneumatic cylinders are the typical parts of clamp unit. These are standard or bought out parts.

Finger/Clamp Mylar - It is NC block, mounted on clamp arm. It will press car panel towards rest Mylar.

Rest Mylar / Back up - It is NC block, fixed to unit. It resists clamping force of finger and clamps the panel.

Clamp Arm- It is a part to which all movable parts fixed. Calmp arm is actuated by pneumatic cylinder.

Clamp Cylinder- These are pneumatic cylinders used to clamp and hold the panel firm while particular process is going on.

Power clam cylinder and Swivel cylinders are types of cylinders. Depending on applications, they can be selected as per need.

For the curren challenge, 2 power clamp cylinders and 3 swivel cylinders are selected as not more information is avalble.

few points followed for designing all clamp units-

1. Min distance of clamp arm from panle edge 10 mm to 30 mm. (atleast 10 mm)

2. No clamp position over an uneven surface og panel.

3. mostly tried to desgn make parts with some nominal dimensions. (blade, riser thickness and width)

4. for each pin, 2 way shimming of 5 mm is provided.

5. shims iare located in the direction of DOF restriction.

6. All holes and dimensions are nominal.

7. For risers, same dimension bolts and dowels are used.

8. Min distance between panel and near by article is 10-30 mm.

9. Sufficent space for all units for assembly and maintenance purpose.

Clamp Unit Design for this project-

Input- A panel and Base plate –

To design 3 types of Clamp Units. And 2 Types of Rest Units.

1. Clamp Units.

Depending on geometry and profile of panlel, 5 areas are finalized for clamp location.

Namely Clamp Unit 1, Clamp Unit-2, Clamp Unit-3, Clamp Unit-4 and Clamp Unit-5.

Clamp Unit-1 (clamp –Pin)

Clamp_unit_1: -Different views are shown for the clamp unit 1.

Two clamp points and two Pins are used for this design.

Power clamp cylinder is chosen for this unit.

Clamp and rest mylars Section- 10 X 10 at mating point, as surface area is available on the panel.

Clamp arms are bolted to clamp arm and rest mylars are bolted to spacer.

Each Mylar is assembled using 2 dowels od Dia. 8 mm and a M8 bolt.

Spacer block to rest the rest Mylar’s is designed as per requirement.

1 Round Pin. 1 Diamond Pin, Pin retainers and Shim Packs.

2 Directional shims of 5mm thickness are used for each pin.

A L riser is designed with 4 M12 bolts and 2 M10 Dowels to connect to base plate.

Clamp Unit-2 (clamp –Pin)

This clamp unit is designed to clamp panel at 3 points and 2 pins, a round pin and a diamond pin.

Swivel type Cylinder is selected for this unit.

Blade is designed to connect cylinder and riser. On base of blade a spacer block is designed to support rest mylars.

Stopper is welded to clamp arm to lock its downward movement.

Clamp Unit-3 (clamp)

This unit is designed to clamp the panel at two Mylar pints.

Swivel cylinder is selected. Blade, spacer block are designed for the Mylar’s.

Clamp Unit-4 (clamp-Pin)

This clamp unit is dsigned to clamp at two points and two holes on a blue color panel. Cross section of clamp mylar and rest mylar is 10 X 10, for getting sufficient plane area of contact.

Clamp Unit-5 (clamp-Pin)

Rest Unit- A rest unit is designed to rest or support the panel using NC block.

Mylar in rest unit is known as rest mylar.

No. of rest mylars can be one or more, depending on geometry of the panel.

Mylar, blade and a riser are the parts of a rest mylar.

In current project I have designed two rest units.

One is Pin Rest unit and another is Plane Rest unit.

Rest Unit 1- Pin Rest Unit -

Materials For different parts of a Clamp and Rest Unit-

1. Shim- Metal shims- Carbon Steel, stainless steel,
2. Locating Pin- 16MnCr5, 20MnCr5, (45-55 HRC) , SAE8620 (58-62 HRC)
3. Pin- Pins are made of C45, EN31 steel
4. Pin Retainer, Blades , Riser are made of Steel
5. Dowel pins –Metallic Dowel pins- High Carbon steel, SS or Zinc Plated steel, Aluminum, Brass, Titanium,

   In Non Metal - Wood and plastic dowels are also available.

6. Mylar- For clamping A type surface –Nylon, Teflon, PP, UHMW (50-60 Shore D)

For other surfaces, steel mylars- C45, SAE4140 40 (- 50HRC)

7. Stopper Block- C45, SAE1060
8. Weld Part- St37-2, St 52-3, MS.
9. Rough Locator- St-37-2, St37-2K.