Week 6:- Clamp Unit & Pin-Clamp Unit Design Challenge

WEEK 6 CHALLENGE

Clamp Unit & Pin-Clamp Unit Design Challenge

AIM

• Design 3 Different types of Swivel Clamp Unit with Different Riser, Blade, and Clamp Arm for the given Car Panel. Maintain the stroke as 100mm.

• Design a Pin-Clamp Unit for the given Car Panel.

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

DETAILS

• 3-2-1 principle achievement:
  • 3-2-1 principle is basis of any fixture design. Holding fixtures used in assembly operations often follow a 3-2-1 locating scheme to position parts. Under this scheme,
    • 3 point - Locate or Stablilize the part in a datum
    • 2 point - Position
    • 1 Point - Clamp
  • Fixture must correctly locate a workpiece in a given orientation with respect to a cutting tool or measuring device, or with respect to another component.locating and clamping are the critical functions of any work holding fixture.
  • A workpiece free in space can move in an infinite number of directions.For analysis,this motion can be broken down into twelve directional movements or "degres of freedom". All twelve degrees of freedom must be restricted to ensure proper referencing of workpiece.

• By this, DOF of an part got arrested and will be ready for manufacturing process needed;
  • Translational - X+, X-, Y+, Y-, Z+, Z-
  • Rotational - XCW, XCCW, YCW, YCCW, ZCW, ZCCW
• Clamp unit is unit designed to clamp / hold the car panel with NC blocks/ mylar/ rest by using a pneumatic clamp cylinder & below are different parts of a clamp unit in general. Usually clamp open position is 90°. Fingers are attached to clamp mylar. In clamp unit shim to one side is more enough because it will restrict translation motion in upward & downward direction only. There is another type of clamp unit knows as swivel type. There is pivot pin around which clamp arm rotate.
• Factors for designing Clamp Unit: -
  • There should be adequate space between the cylinder & another part like riser, car panel because cylinder moves or swing while opening & closing
  • Pin clamp unit used where two panel or component are located for welding.
  • Clamping make in such way that it clamps two car panels at once
  • All parts should snap & butt properly to each other.
  • Make sure that parts of the clamping unit are 10 to 12 mm away from car panel so they do not damage car panel
  • Avoid any clash. It will not arises issue at assembly.
• Used Clamp Cylinder: - CKG_1B_63_100Y
  • CKG_1 = Series of cylinder
  • B = Clevis Width as 19.5mm
  • 63 = Bore Size
  • Y = End Bracket i.e., double knuckle joint (M6 without Tap)

PARTS OF A CLMP UNIT: -

• Mylar/NC block/Finger: Finger is a movable part which is used to hold the car part from top against backup and they are usualy mounted on the clamp arm.
• L-block: L - shaped blocks are used to ount the finger to clamp arm, besides allowing adjustments for locator pin in two directions.
• Shim/Spacer: They allow the finger to be moved to the correct xyz locating and allow the customer to make adjustments to improve the quality of their product.
• Blade: Part onto which the aforeside element are attached to.
• Riser: L- shaped or T shaped tall block which regularly patterened holes to attach the above mentioned parts in modular way blade space.Riser is either a make part or standard part.
• Stopper: The function of stopper is to restrict clamp going beyond the limit.Stopper is mounted between clam arm and rest/blade.Stopper has two parts male and female , when this two parts meets they restrict motion.

DESIGN CONSIDERATIONS: -

• STUDY OF PROCESS PLANNING DOCUMENT
• CAD SOFTWARE USED
• HEIGHT SELECTION
• PANEL SELECTION CREATION
• CONSIDERATION OF REST AND CLAMP BLOCK
• CLAMP CYLINDER SELECTION
• RISER
• HARDWARES
• CLAMP ARM OPEN POSITION

REPORT

• P001_Z003_ST010_00_00_FINAL

• P001_Z003_ST010_01_00_INPUT PANEL

• P001_Z003_ST010_02_00_PIN - CLAMP UNIT

• P001_Z003_ST010_03_00_CLAMP UNIT - 1

• P001_Z003_ST010_04_00_CLAMP UNIT - 2

• P001_Z003_ST010_05_00_CLAMP UNIT - 3

• STRUCTURE OF TREE
  • Structuring a design tree implies process where all the assemblies & parts are named in specific manner. Different customers have different set of standard like how to structure a design tree? So they will be give standard template based on that design tree structured, which helps us to identify specific part of assembly. It specifies the Project number, station number, unit number; part number of each component so that it is easy to identify the parts.
  • It is an important process which helps us to identify a specific part or assembly as to which project, tool or unit, it belongs to.
  • This helps us to avoid error during design study, manufacturing, assembly, inspection etc.
  • If parts or assemblies are not named properly or the design tree is not structured properly, it will create confusion to understand & create major possibilities of making an error.
  • Naming of a fixture, a unit or a part gives the information as to which project or zone or assembly they do belong.
  • It can help us to identify quantity of items of same type or different types that are being used in assembly for e.g. bolt. It actually tells you how many bolts are particularly required in that assembly or unit.

• CONCLUSION
  • Thus i had designed,

    • Design 3 Different types of Swivel Clamp Unit with Different Riser, Blade, and Clamp Arm for the given Car Panel. Maintain the stroke as 100mm.

    • Design a Pin-Clamp Unit for the given Car Panel.

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