Week 8:- 3D Finishing - Challenges 1

1. What do you understand by the 3D finish process?

1. 3D finish process is the process in which finishing of fixture is done means making fixture ready for final 2D detailing and simulation.

Steps followed while doing 3D finish:

2. The points need to be taken care of while finishing the design.

1. Hole concentricity & Hole sizes
2. Machining area
3. Normality
4. Holes colouring standard
5. Pneumatic lay-outing
6. Gaps checking
7. Fasteners implementation
8. Avoiding clash between different parts
9. Mylars Splitting as per panel profile
10. Proper renaming of parts/assemblies as per the standard.

3. What are rough Locators & what is their use?

Rough locators are to locate the car panel and also guide the operator to load the car panel in the fixture perfectly. Standard Rough locators are also available.

Uses:
1. It is used to locate the car panel in the fixture.
2. It is also known as Poka-yoke or Fool Proofing as the part is located in fixture accurately
3. Accuracy is maintained due to the use of rough locators.

4. What are the points you need to consider while designing a rough locator?

The points you need to consider while designing a rough locator:

The height of rough locators should not be more than the permissible ergo height of the fixture.

The entry point/ top point of the rough locator must be 10mm-15mm above the panel surface

Rough locators should have adjustments in the direction of the guiding plane.

2mm gap to be maintained between rough locator and panel at the time of design and we can provide adjustment of 5-10mm in the positive or negative direction of guide plane.

Rough locators can be rod type or flat type, depending upon the standards and other conditions.

5. What is the gun study process?

Gun study is the process of checking whether the gun is able to weld the selected car panels. The below images shows the weld gun dong spot welding and the weld location where the spot is created on the car panel. Gun study is necessary as the BIW car panels are complex in share and sixe. In 3D software, the gun study is done by actually introducing a welding gun in fixture that we have designed. According to that units are designed so that there's no problem while the welding process.

6. What are the points that need to consider during the gun study?

1. The axis of weld spot along weld direction must be normal to the weld surface
2. Total no. of weld spot and time required for each is calculated for knowing the total time required for welding that car panel.
3. Robot cycle time is calculated while doing the proper gun study.
4. Collision checking is done on simulation software to check whether the welding process is done without any collision with any units in the fixture.

7. What is pneumatic routing?

Pneumatic Routing a planning tube lines route properly, leak-proof and efficient working of pneumatic devices used in a fixture like cylinders, solenoid, etc.

8. What is the solenoid valve?

Solenoid valves are used to actuate the airflow in cylinders as per the sequence through a manual or PLC-operated system. It is a mechanical device used to control or regulate the flow of fluid.

components of the solenoid valve are as shown below.

9. Valve banks are basically a system in which n numbers of solenoid valves are mounted, in order to maintain one common inlet and outlet of air to all the valves.

Valve banks are mostly mounted on the fixture sides or on the base plate depending upon the various conditions.

10. A sensor is a device that produces an output signal for the purpose of sensing of a physical phenomenon. In the broadest definition, a sensor is a device, module, machine, or subsystem that detects events or changes in its environment and sends the information to other electronics, frequently a computer processor.

Application:

1. To check the presence of car panel
2. To detect the position of the sliding unit
3. When there is no. of similar car panels weld on same fixture sensor are used to detect car panel place in fixture.

11. Type of sensor:- The following is a list of different types of sensors that are commonly used in various applications. All these sensors are used for measuring one of the physical properties like Temperature, Resistance, Capacitance, Conduction, Heat Transfer, etc.

Temperature Sensor

Proximity Sensor

Accelerometer

IR Sensor (Infrared Sensor)

Pressure Sensor

Light Sensor

Ultrasonic Sensor

Smoke, Gas, and Alcohol Sensor

Touch Sensor

Color Sensor

Humidity Sensor

Tilt Sensor

Flow and Level Sensor

Some of them are described below
A) proximity sensor Proximity Sensor is a non-contact type sensor that detects the presence of an object. Proximity Sensors can be implemented using different techniques like Optical (like Infrared or Laser), Ultrasonic, Hall Effect, Capacitive, etc.

12) What are the fundamental points that need to consider while designing or selecting the sensor?

Basic Fundamentals for sensor unit design:

A sensor unit is a unit designed to sense the car panel by using Electrical sensors.

The signal from sensors will be fed to the PLC and the next process that will be executed will be this signal.

Sensors are used the confirm there is a panel/component present or not.

it helps to avoid human error.

Basically, sensors should be equal numbers as cameras to numbers of panels in an assembly. for (EX. If 9 panels are in assembly, so there should be at least 9 sensors used.)

sensors should be Slot is designed in such a way that they can be adjusted in 3 directions.

Sensors are also used for the safety purposes of the operator.

Typically Proximity, LASER, Photoelectric Sensors are used in fixtures.

Some Major sensor manufacturers are IFM, Pepperi-Fuchs, SICK, OMRON, etc