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

REPORT ON

CLAMP UNIT AND PIN CLAMP UNIT

UNIT AND PIN CLAMP UNIT

OBJECTIVE:

TO design 3 different type of swivel clamp unit with different reiser , blade and clamp arm for the given car panel and to design a pin clamp unit for the given car panel.

CAR PANEL:-

There are 5 parts in the given car panel , 4 small parts and 1 larger part which is main part of the car panel . there are 5 parts needed to be welded together , for that these parts needs to be fixed using clamp and pin units.

Two type of clamp unit used to clamp the car panel. they are:

• power clamp unit
• swivel clamp unit.

To weld these parts, they must be fixed using 3-2-1 principle :

3-2-1 PRINCIPLE :

Fixed 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 function 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 movement or "degree of freedom " . all twelve degrees of freedom must be restricted to ensure proper referencing of workpiece.

The best and most effective method of part location is referred to as the 3-2-1 method.

6 Translational degree of freedom :+x,-x,+y,-y,+z,-z.

6 Rotational degree of freedom :

1.C-ROT around x-axis

2.AC-ROT around x- axis

3.C-ROT aound y-axis

4.AC-ROT aound Y-axis

5.C-ROT aound z-axis

6.AC-ROT aound z- axis

If we fix the clamp as per the 12 degree of freedom listed above , then we can arrest the panel in a fixed position.

6-degree of freedom are restricted by 2- pin units.

6-degree of freedom are restricted by 3- clamp unit and rest unit .

CLAMP UNIT:

Clamp unit is a unit designed to hold / clamp the car panel with NC blocks / mylars / rest by using a pneumatic a clamp cylinder.

PARTS OF CLAMP UNIT:

1. Mylar / NC block / Finger :Finger is a movable part which is used to hold the car part from top against backup and they are usually mounted on the clamp arm.

2. L- block:L- shaped blocks are used to mount the finger to clamp arm, besides allowing adjustment for locator pin two directions

3. Shim/ spacer : They allows the finger to be moved to the correct xyz location and allow the customer to make adjustments to improve the quality of their product.

4. Blade :-Part onto which the forside element are attached to.

5.Riser :L-Shaped or T shaped tall black which regularly patterened holes to attach the above mentioned parts in modular way blade space . Riser is either a make part or standard part.

6.Stopper :The function of stopper is to restrict clamp going beyond the limit. Stopper is mounted between clamp arm and rest/blade. Stopper has two parts male and female, when these two parts meets they restrict motion.

CONSIDERATION WHILE DESIGNIG CLAMP UNIT:

1.STUDY OF PROCESS PLANNING DOCUMENT :

Process planning document is the document which contains the date and other information related to deisgn clamp unit.

process document should contain following informations which are necessary to design clamp unit.

• No. of sheet metal pannels to be welded.

In this project there are 5 sheet metal parts needs to be joined or welded together.

• Total no.of spots .
• Weld gun details if its is already recommended by process engineer study it in details like shape and its type (c,x or Y)
• Study the PLP (principle points) data along with the nearby spot data.
• Study the PLP(principle locating points) data along with the nearby spot data.

2.HEIGHT SELECTION:

Take an overview of the working height if you are having manual welding for robtic welding its important to see the working height in consideration of the robotic gun turntable height if manual loading is done.

3.PANEL SELECTION CREATION:

Take an section at PLP either in clamp opening direction or normal direction. Sections should be normal to the base plate. Panel section through x,y,z direction passing through PLP. Section will be finalising the shape of the clamp and rest block.

4.CONSIDERATION OF REST AND CLAMP BLOCK:

If standard mylar has to be used (few companies make standard height and length of sheet blank with few holes and dowels for clamping) then selcted blank size as per requirement; consider 5mm above panel.

5.CLAMP CYLINDER SELECTION:

Select the clamping cylinder as per the pivot point distance from the plp. You may choose various cylinder 50 dia , 63 dia ,80 dia as per the requirement.

In this project , I choose 63 dia clevis cylinder and the bore capacity is 100mm.

ADD all the hardware screws, dowels and washer as per the size . ensure all these hardware are easy to dismantel.

CLAMP CYLINDER :

Clamp cylinder can order by giving following input manufacturer.

clamp cylinder used in this project is CKG_1B_100Y

EXPLATION:

CKG- SERIES OF CYLINDER

1B- CLEVIS WIDTH=19.5

63- BORE SIZE

100-CYLINDER STROKE IN MM

Y-END BRACKET i.e DOUBLE KNUCKLE JOINT(M6 WITHOUT TAP).

HERE ARE SOME THE IMAGE OF THIS SWIVEL CLAMP UNIT PROJECT.

Swivel Clamp Unit-1

Swivel clamp unit-2

Swivel clamp unit-3

Swivel clamp unit-4

FINAL DESIGN

FACTORS SHOULD CONSIDERED WHILE DESIGING CLAMP UNIT:

• Should use standard part as possible i:e. NAAMS standard.
• There should be adequate space between cylinder and other part like riser , car panel . becouse cylinder moves or swing while opening and closing.
• Pin clamp unit is use where two panel or component are locating and clamp for welding

• Clamp make in such a way that it clamp two car panel
• Every clamp mylar / NC block have rest mylar or unit.
• Clamp unit has shims in only one direction.
• All parts should snap and butt properly to each other .
• Make sure that parts of clamp unit 10-12 MM away from the car panel.
• Design three should structured in way that make parts on the top and followed standard part.
• The position of clevies joint pin will be on one line .
• Avoid any clash , it will not rise issue at assembly.
• Product should designed in such a way that it will easy to make . assembly and quality check.
• We should preferably use quick acting clamps , the clamping method must not damage our work piece.
• Clamp must be open in such a way that clamp arm moves away from the operator.
• There must be adequate clearance for loading and unloading. So that the process becomes fast easy. The variation in size must be accepted.
• Avoid sharp edges and corner, they can harms operator and cause to the serios injury. Provide chamfer or fillet to the corner

CONCLUTION:-

In this we learn how we design the swivel clamp unit with different riser, blade and clamp arm for the given car panel.