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Figure 2. NAAMS standard locating pin (6 way small head) - Make: MISUMI
b. Pin retainer:
b eta e
Pin retainer is used to hold the locating pins firmly.
Figure 5. Shims
Application of shims:
1. In automobiles, shims are commonly used to adjust the clearance or space between two parts. For example, shims are
inserted into or under bucket tappets to control valve clearances. Clearance is adjusted by changing the thickness of the
shim.
2. In assembly and weld fixtures precision metal shims are used between two parts so that the final production parts are
created within the product drawing's specified tolerance.
Types of shim: Types of shims are,
1. wood shim.
2. stone shim.
3. plastic shim.
4. metal shim.
5. Paper shim.
Figure 6. Shim
d. Riser:
Riser is a manufacturing part used to raise/height the assemblies of fixtures.
One end of the raiser will be attached to the base unit while the other end will be attached to the Blade.
Raiser can be of two types.They are,
1. 'L' type risers.
2. Square tube risers.
'L' TYPE RISERS: 'L' type risers are of welded type.Where the stiffner will be added at the centre for support.As shown in
the below figure the wedge shaped structure is known as stiffner which is used as a support / to withstand load.
Figure 8. Square Type Riser (Frame type)
e. Blade:
Blade are the plates which are attached to raiser.
Blade is also attached or mounted with cylinders,arms etc.,
Figure 9. Blade
Hence, the different parts of fixed units are explained in detail.
Question No.14 - What is a purpose of making a rest unit ? & describe its parts.
Answer:
PURPOSE OF MAKING A REST UNIT:
Rest unit is a unit designed for the pupose to rest/support the car panel using NC block or mylars
The mylars in rest unit is known as resting mylars.
In this unit the part or the panel will be rested, it will not have clamps or force applied on to it .
Rest units consist of few mylars, risers & blades.
Figure 1. Section view of Rest unit
PARTS OF REST UNIT: The parts of rest unit are as follows,
a. NC block/mylars.
b. Risers.
c. Blades.
a. NC blocks/mylars:
Mylars are the part which are holding the panel from top & bottom.
It is a Jaw type, during welding it wont deforms from its position.
It is also known as fingers.
It dont allow the deformation of the part due to welding stresses.
Mylars are of two types,they are
1. Clamping mylars.
2. Resting mylars.
Only resting mylars can be seen in Rest unit.
The panel which rests on the part is known as Resting Mylars.
Figure 5. Blade
Hence, the purpose of making rest unit and the parts of rest unit are explained in detail.
Question No.15 - What are the basic fundamentals to design a sensor unit ?
Answer:
SENSOR UNIT:
A sensor unit is a unit designed to sense the car panel by using electrical sensors.
This signals from the sensors will be fed to the PLC and so the next process will be excecuted by this signal.
Figure 2. Rough locator
Hence, the rough locator unit and their basic fundamentals to consider while designing are explained clearly.
Question No. 17 - What is a base unit ? & describe its parts.
Answer:
BASE UNIT:
Base unit is the unit designed to mount all the other units like clamp unit, pin unit, rest unit, etc. of the tool, also other parts
like pneumatic valve box, truncking cable path will also be mounted on to a base unit.
Figure 1. Dump unit
Hence, Dump unit & its functions are explained.
Question No. 19 - What are slide units ? Mention where slide units are commonly used.
Answer:
SLIDE UNITS:
Slide units are positioning units, which are used to position the car part or panel,units,weld gun, robots for further
operations.
Slide units may be classified into two types based on the type of guide ways.They are,
a. Hardend guide way.
b. LM guideway.
Slide units may further classified into three types based on the prime mover. They are,
i. Manual slides.
ii. Hydraulic/pneumatic slides.
iii. CNC slides.
It may be further classified depending on the application as
α. Horizontal slide unit.
β. Vertical slide unit.
γ. Angular slide unit.
LM guide ways are preferred over hardend guide ways due to the least co-efficient of friction.
ESSENTIAL PARTS OF SLIDE UNIT:
Slide unit essentially consists of guide blocks, guide rails, position lock unit, stopper block, sensors, linear cylinders.
Guide block & guide rail helps to the guide the slide unit. The rail should always be covered to protect against weld spatter
& dust by a bellow or a sheet metal cover. Guideways to be lubricated for long life.
Position lock unit helps the slide to be locked/clamped in the working position.
Stopper block helps to stop/control the entire moving of a slideunit from certain distance, which is placed at the end of
the guide rail.
Sensors - The two end limits to be sensed externally by a proximity sensor.
Figure 1. Slide unit in working & retracted position
Basic fundamentals of slide unit design:
1. Reverse stroke of 10mm to be considered in both forward & retracted condition.
2. Cylinder & LM guides to be validate for load & stroke.
3. LM guide rail length should be standard & should be more than the actual stroke.
4. Master guideway should be constrained & the subsidary guideway to be free.
5. Mechanical hard stop to be considered for both extended & retracted condition.
6. Shock absorber should be used for both extended & retracted condition to reduce impact load.
7. Slide to be locked/clamped in the working position.
8. Slide to be locked with a safety pin in the retracted position during transportaion.
9. The two end limits to be sensed externally by a proximity switch.
10. The LM rail should always be covered to protect against weld spatter & dust by a bellow or a sheet metal cover.
11. The design should be checked for screw accessibilty, ease of assembly, machinability of parts.
12. The LM guide & rails are integral assemblies and should not be separated at any cost.
13. The shock absorber should be mounted such that it is perpendicular to the pivot at mid stroke or within +/- 5 degree.
14. LM guideways to be lubricated for long life.
Figure 3. Slide unit
Hence, Slide unit and their common uses are explained in detail.
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