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OBJECTIVE: To design 3 types of Swivel Clamp unit and 1 Pin-Clamp unit with different Riser, Blade and Clamp arm while maintaining the stroke of cylinder as 100mm. INPUT FUNDAMENTALS: 3-2-1 principle: Our ultimate intention for using pin unit is to fix the work piece so that it does not deviate from the position…
KAMBHAMPATI DURGA PRASAD
updated on 02 Jul 2021
OBJECTIVE: To design 3 types of Swivel Clamp unit and 1 Pin-Clamp unit with different Riser, Blade and Clamp arm while maintaining the stroke of cylinder as 100mm.
INPUT
FUNDAMENTALS:
3-2-1 principle: Our ultimate intention for using pin unit is to fix the work piece so that it does not deviate from the position while the operation is being performed on it. For this reason we use 3-2-1 principle.
Every component we know has 6 degrees of freedom. They are listed below:
FIG. DEGREE OF FREEDOM
Degrees of freedom can be simply understood as the direction in which any component can move. These 6 degrees becomes 12 if we consider translation along negative and rotation in anti-clockwise direction too. That means, every component can move in all the direction when it is free. But processes like welding, stamping or others and in fact every other cannot be carried out on such free to move body for obvious reasons. Thus the body must be constrained in all the major direction in order for the workman to work upon it. This constrain on motion is achieved by 3-2-1 principle.
In 3-2-1 principle we make use of locating pins in the given order to fix it on a fixture:
FIG. LOCATING PINS
Thus we can constrain all the degrees of freedom of a body using 3-2-1 principle which used 6 pins for the same.
When we use clamps we restrict following motions:
sign two Rest units and three Power Clamp units with different Riser, Blade and Clamp arm.
Clamp unit: 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 should be considered while designing a clamp unit:
CLAMP PLAN:
Swivel Clamps :
The primary components of the clevis clamp include clamp arm, blade, cylinder, angle riser, locator block, and finger. Swivel clamps shall typically be designed with the center of the clamp cylinder, the center of the locator, and the center of the clamp arm on a common line. However, it is acceptable to offset the clamp point from the clamp cylinder to allow for improved access for welding and part load and unload.
The clamp arm shall be welded construction including a 20.0mm thick arm with an integral pivot to accommodate a 19.50mm wide Swivel. The female portion of the clevis shall always be part of the arm. The male portion of the Swivel shall always be part of the blade.
Below are general parts of swivel clamp unit.
Clamp Cylinder:
Cylinder designation: In this unit we used Clevis cylinder for clamping designated as CKG_1B_63_100Y
Nomenclature of cylinder as belows:
CKG1: Series of cylinder
B: Clevis width as 19.5 mm.
63: Bore size
100: Stroke of cylinder
Y: End bracket i.e. double knuckle joint (M6 without tap)
FIG:Clevis cylinder
Clamp arm: It is part to which clamp mylar mounted & also clamp cylinder is attached to the end of arm with the use of clevis pin. It has two plates of 8 mm thickness welded & helps in rotating of clamp arm about pivoting point of blade.
Below figure shows 100 mm stroke achieved & clamp arm end in line with cylinder rod. See Y & Z values.
NC block/Mylar:
Few points to remember about Mylar:
FIG: CLAMP &REST MYLAR
FIG: CLAMP &REST MYLAR
1mm is the component thickness.so the distance between the clamp and rest mylar is 1mm.
Stopper:
The function of stopper is to restrict motion of clamp arm. It avoids clamp arm to rotate beyond limit. It has two parts male & female.
Blade: Blade is part to which all other units are attached for e.g. mylar, stopper, clamp cylinder, riser. Blade is designed according to position of all other parts.
FIG: BLADE
Bush: Bush is friction type bearing. It is lubricated with grease, oil. It permits relative motion between two mating parts. It is made of hard material also its ID & OD are precisely machined or grinded. It press fitted & after worn out it is replaced with new one instead of replacing other part which save cost. Mostly phosphor bronze or gun metal material used for making bush. In this unit three bushes are used of same internal (12 mm) & external diameter (18 mm) but different length.
Pin
Typically, locating pins are used for controlled, fine tolerance positioning of a, For example, a pallet that is moved along one axis, where the drive mechanism is not accurate and stable enough to place it in a position sufficiently accurate to execute a particular process, the use of locating pins may be the best solution.
The Diamond Shape is a critical feature that helps with machining inaccuracies and smoother locating When two round headpins are installed onto one plate, the distance between two mounting holes must be extremely precise and even then, the workpiece will not be placed on the base as easily as it would with the use of a diamond shape pin.
There are several styles of Pin Head They serve different purposes and can be utilized in a variety of applications.
Shim:
FIG: SHIMS
Riser:
Hardware: These are standard parts. Parts are assembled together with help of washer and bolt. for better assembly should use two dowels and four bolts for riser and blade. Where for bolting one part should have tapping hole and on other part simple hole (1 to 2 mm larger from bolt size.)
Length of the bolt is decided by width of part + (1.5*D)
For ex. where
L=Length of Bolt
D=diameter of bolt to be used
Let’s, take M8 Bolt
L= 25 + (1.5 * 8)
L=25+12
L=37 mm.
Dowel pins: These are standard part. There are various types of dowel pin like split, parallel, taper, clevis, and spring, grooved. Dowel pins are used to locate part precisely & to restrict movements. For mylar dia. 6 or 8 dowel pins should be used. For blade, shimming block dia.8 dowel pin should be used & for riser base dia. 10 or 12 pins are used.
Washer: Standard steel grade A plain normal series washer used.
FIG:S001_Z01_ST010_01_00_CLAMP_UNIT
S001_Z01_ST010_02_00_CLAMP_UNIT
S001_Z01_ST010_03_00_CLAMP_UNIT
S001_Z01_ST010_04_00_PIN_CLAMP_UNIT
FIG: COMPONENT WITH CLAMP UNITS AND BASE UNIT
FIG: CLAMP UNITS
FIG: COMPONENT WITH CLAMP UNITS
CONCLUSION:
Hence as per objective, the 3 different types of SWIVEL clamp unit by validating & pin clamp units are designed in catia v5 software.
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