12028128, 3:16 AM BIW Fisture Design Methodologies Challenges - Student Projects = SKILL@LYNC Week 3:- BiW Fixture Design Methodologies Challenges ‘what is design methodology? Answer: Design methodology design methodology is nothing but the steps follow during the concept designing stage of fiture design, Below are the steps followed during design methodology Purchase ordor Purchase order Is basically confirmation from customor side that we ore ready to start a Abhijeet Magdum ces on 23602029 (Boome Project eto + |. What is design methodology? Answer: Design methodology design methodology is nothing but the steps followed during the concept designing stage of fixture design. Below are the steps followed during design methodology. urchase order is basically confirmation from customer side that we are ready to start work, A purchase order (PO) is a commarcialdocument and first official offer issued by a buyer to a seller indicating types, quantities, and agreed prices for products or services. itis used to control the purchasing of products and services from external htpssiskl-yne.comistudentprojectshweek-3-iv-foture-design-methodologies-challenges-2 us.12728128, 9:16 AM BBW Fisture Design Methodologies Challenges - Student Projects SKILL@LYNC Designer needs following basic information to start the BIW fixture. + First understand scope of the work. Means what is expected by customer. Every customer has its specific requirements and it may have own raw material, electric, pneumatic,cad, dosign standards. Every customer also gives different inputs and expacts output e.g 24 drawing, process sheet in xls, pat, CAD format of design, layout format, OLP. + Bill of material (BOM) of the components to be welded- spot welding + CAD panel data or at least 20 drawing of assembly and individual panel data, + Sheet metal pane! thickness plays major role to decide 2 metal or 3 metal weld + spot Detail information lke total no of spots and spacing between the spots, + Weld information clarity from drawing like 2 metal or 3 metal welding. + PLP (Principle location scheme) of the individual panel and total assembly. + cycle time it calculated or can be found out as per manual or robotic welding process. + Process sheet i Process engineering is done - where loading sequence, ne of clamp data ‘and gun data is mentioned * Allclamping cylinder and fixtures standards + CAD Software guidelines. + Raw material standards. + Design guidelines + Bought out item (Purchased parts) standards like pneumatic items, toggle clamp, bearing screw, dowel ete company information, « srcentage completion Criteria. * It consists planning of completion of total project. How much days the project will take to complete, * tis followed in designing stages & dispatch stages of the welding fixture, * Itensures that how much task that we have decided to complete within the stipulated time is complete or not & how much of it is rest to complete & whether itis going to be complet: ‘or not in given time. Design output Book Free Demo -ntps:isklyne.comstudent-projectsveek-3-bifxture-design-methodologes-challenges-2 218312728128, 9:16 AM ‘BIW Fisture Design Methodologies Challenges - Student Projects SKILL@LYNC + 1. Key shoot- It shows the indox of the unit & their placement on tool base. * 2. Layout sheet- It is the detailed drawing individual unit to include all their components. * Non unitized tools which can be completely detailed on layout sheet. 2. What are the inputs required from the customer te start designing a Fixture? Answer The following are the inputs we required from the customer to start the fixture design work. Fuctional requirments: This basically what kinds of function that fixture design have e.g, welding, gluing, fastening, riveting. This kind of information will be given to us in functional requirement ie. it serve basic or main purpose like itis used for welding, gluining or checking fixture. so from that design concept generate. Preferred standard: Every industry has its own standard & they follow that standard. n this requirement, preferred standard component is basically what kind of standard componen customer already has. An input actually saves lots of time, cost & effort. Because don't need to design that component. It is purchased fram outside from that make. + Standard lke ABS, NAAMS, FAUNC, FESTO, TUNKERS, ZYTRAN, DESTACO, Siemens ete. are used for robot, pneumatic parts, motor & gearbox, electric parts + Standard parts like riser, L-block, retainer, pins many other company actually manufacture this. + some component lke clamp, cylinder, slides, switches, sensors. Car product: car product include 2). GD&T- GD & T provides information of locating pins, rest clamp, dumps & slide information of each station. Sequence of opening of clamps, dumps & slide stroke information -ntps:isklyne.comstudent-projectsveek-3-bifxture-design-methodologes-challenges-2 318312728128, 9:16 AM BBW Fisture Design Methodologies Challenges - Student Projects SKILL@LYNC b). Part ist: Part list is nothing but listing down all parts of assembly. It includes informatior ‘about the part name, Part number, Tooling revision, Part thickness etc. Assembly is broken down into each & every single part. First assembly has gone between hood inner panel & latch which going to attach next hinge going to attach. So there are different list of assembly we are going to perform. So every assembly will have different fixture unit. ¢).CAD file: 20 file of that car product require trom customer. 4) Clamp plan: It provide information about position of clamp unit, pin unit, rest unit ete, this is major input from customer & it should be never be changed without permission of customer, ¢) Product assembly process sheet: It gives detail process of the completion of the part from scratch to the finished product assembly. It will give detailed plan of component how they welded as well how product is moving from one assembly to other? Layout: Layout provides information about Flow of parts, Station pitch, Robot stations, and ‘accessories like tool changers, Tip dressers, Platform height, Sub assembly links & loading/Unloading sequence. Ergo data: This data given when any manual operation involves. Ergonomics refers to stud of human behavior & movements during the assembly work. It provides data regarding loading height, working safety zone of the operator etc as per standard that company follow. Weld study: It include information of weld gun detail, weld matrix & weld points. There are two types of weld points geo weld point & respot weld point. Geo weld points defines the geometry of part & respot do all other remaining weld points also add strength to geo wel points. ‘Standard detailing template: Detailing is 20 representation of 30 part, Customer has standard detailing template. These detailing formats are used for dratting of part. 3, What is the input we get from “Car products”? Answer: Following input we get from car product, 2). 6D &T - Geometric dimensioning & Tolerance of the part for which the fixture have to be designed. GD & T provides information about Locating pins, Rest, Clamp, Dumps & slide: information of each station & Sequence & opening of clamps, Dumps & slide stroke information, Book Free Demo -ntps:sklyne.comstudent-projectsveek-3-bifxture-design-methodologes-challenges-2 418312728128, 9:16 AM SKILL@LYNC BBW Fisture Design Methodologies Challenges - Student Projects b). Part list: Part list is nothing but listing down alll parts of assembly. it includes informatior ‘about the part name, Part number, Tooling revision, Part thickness ete. Suppose first ‘assembly has gone between hood inner panels & latch which going to attach next hinge going to attach. So there are different list of assembly we are going to perform. So every ‘assembly will have different fixture unit. ¢).CAD file: 20 file of that car product require from customer. The 3D model fle of the car part is given trom the customer to study on it. The car partis designed by using 3D Book Free Demo -ntps:sklyne.comstudent-projectsveek-3-bifxture-design-methodologes-challenges-2 512312728128, 9:16 AM SKILL@LYNC BBW Fisture Design Methodologies Challenges - Student Projects 4) Clamp plan: it provides information about position of clamp unit, pin unit, rest unit, dump unit ete. This is major input from customer & it should be never be changed without permission of customer. Clamp plan provide exact location of pins, rest, clamp etc. Itis in more detail. It gives exact location in X,Y & Z co-ordinates value to start designing ©) Product assembly process sheet: Product assembly process sheet is sheet that gives following detail + part assembly sequence + sequence of operation + cycle time, It gives detail process of the completion of the part from scratch to the finished product ‘assembly. It will give detailed plan of component how they welded as well how product is moving from one assembly to other? & this process plan should not be changed without permission of customer. Below figure shows. Book Free Demo -ntps:isklyne.comstudent-projectsveek-3-bifxture-design-methodologes-challenges-2 612312728128, 9:16 AM BBW Fisture Design Methodologies Challenges - Student Projects SKILL@LYNC 4. Whatis clamp plan? ‘Answer: A clamp is « force-actuating mechanism of a fixture. The forces exerted by the clamps hold a part securely in the fixture against all other external forces. Clamping surfaces are subjected to the clamping forces for obtaining invariant location. To fix a part at a particular position, we use 3-2-1 principle in all types of fixtures to restrict degrees of freedom. Each Panel is fixed keeping 3-2-1 principle in mind This principle requires us to use minimum 3 rests, 2 pins and | clamp to fix a panel. While w receive the panel, the customer also gives us the coordinates of panel where he wants us to rest, clamp and locate the panel. We can directly input these coordinates and start designing rests clamps and pins. Clamp Plan document serves this purpose. Clamp plan provide location of pins, rest, clamp, dump ete. tis in more detail. Clamp Plan is a document that contains the panel drawing mentioning all the places where clamps ‘and rests are to be given. It gives exact location in X, ¥, Z co-ordinate values to start designing. We should never change clamp position without permission of customer. Pa Below fig shows clamp plan. Book Free Demo -ntps:sklyne.comstudent-projectsveek-3-bifxture-design-methodologes-challenges-2 7312728128, 9:16 AM BW Fisture Design Methodologies Challenges - Student Projects SKILL@LYNC 5. Whatis the purpose of a layout? Answer Plant layout is plan of an optimum arrangement of facilities including personnel, operating ‘equipment, storage space material handling equipment and all other supporting services along with the design of best structure to contain all these facilities, An overall objective of plant layout is to design a physical arrangement that meets the required output quality & quantity most economically. It shows all the objects of manufacturing line lke robots, Fitures, Racks etc. & also shows the reach ability of the robot to the fixtures also called the swept area of the robot (indicated by circle around robot). It aiso shows the constraint of space or the space available for the fixture that we are designing, Layout provides information about flow of parts, station pitch, robot station, accessories lik tool changer & tip dresser, sub assembly links, platform height, loading & unloading sequence. Book Free Demo -ntps:sklyne.comstudent-projectsveek-3-bifxture-design-methodologes-challenges-2 812312728128, 9:16 AM ‘BIW Fisture Design Methodologies Challenges - Student Projects SKILL@LYNC enhance the quality of work life (QWL). Ergonomics is concerned with man & his working conditions. Ergonomics aims at providing comfort & improved working conditions so as to channelize energy, skills of workers into consecutive work. This account for increased. productivity, safety & reduces fatigue. Ergo data is given when manual operator involved t« do operation, so this input is given regards how their standard of ergo data is. Ergo data Provides information of loading height, working safety, zone of operator ete. The final assembly of an automobile involves tasks of complex nature. These processes are on the least priority for automation. Manual labor is best suited for assembly operations with the aid of minimal level of automation. All the processes have to be improved continuously in order to reduce the costs and increase productivity. The workers attain various postures; exert force and works continuously in cycle time to accomplish the assembly task. Working along automobile assembly lines is characterized by repetitiveness. Ergo data is studied to identify and quantity ergonomics working postures that contributec to the serious development of muscle skeletal injuries and thus investigated possible contributory their related causes, Below figure show ergonomically correct seating positior while working, Below fig show ergo data provided by customer. Book Free Demo -ntps:sklyne.comstudent-projectsveek-3-bifxture-design-methodologes-challenges-2 914312728128, 9:16 AM BBW Fisture Design Methodologies Challenges - Student Projects SKILL@LYNC 7. What do you understand by weld study? Answer: It include information of weld gun detail, weld matrix & weld points. There are two types of weld points geo weld point & respot weld point. Geo weld points defines the geometry of part & respot do all other remaining weld points also add strength to geo welc points. Weld study consists of spots in case of spot welding fixture that gives us the positior of spot in the form of coordinates. Itis most important input that we get from customer. These are the points where the panel is welded, The spots can be geo spots or respots ‘shown in figure. Book Free Demo -ntps:isklyne.comstudent-projectsveek-3-bifxture-design-methodologes-challenges-2 014312728128, 9:16 AM SKILL@LYNC BW Fisture Design Methodologies Challenges - Student Projects The front door inner panel and side bracket of GM sedan car are to be spot welded as shown in Figure 1. The previously spot welded inner panel assembly is then welded with the cross bracket as shown in Figure 2. The work cell and modular fixture designed must be compatible for both the assemblies to be spot welded, Weld spots for each weid assembly are highlighted in Fiqure 1 and 2 as WPI, WP2, WPS and Book Free Demo -ntps:isklyne.comstudent-projectsveek-3-bifxture-design-methodologes-challenges-2 ies12728128, 9:16 AM ‘BIW Fisture Design Methodologies Challenges - Student Projects SKILL@LYNC we ‘The weld spot locations with respect to the body line of car are as shown in Table 2. Pa ‘8. What are the criteria for percentage completion in the designing stage? Explain it in detai Answer: + Percentage completion criteria are followed in the designing stage & dispatch stage of welding fixture, The percentage completion criteria contain the current status of a task, expressed as the percentage of the task’s duration that has been completed. You can ente percent complete, or you can have Project calculate it for you based on actual duration * Itis followed in designing stages & dispatch stages of the welding fixture. + Itensures that how much task that we have decided to complete within the stipulated time is complete or not & how much of itis rest to complete & whether it is going to be complet or not in given time. 0-25%- Input & concept design: ‘This is initial stage of project. put data provided by customer lke functional requirement, puistrmer staneinrel ate & after sturivine thase innits the eancant af fivtire rlacian is Book Free Demo -ntps:sklyne.comstudent-projectsveek-3-bifxture-design-methodologes-challenges-2 1218312728128, 9:16 AM BBW Fisture Design Methodologies Challenges - Student Projects SKILL@LYNC approval from the customer after study of simulation contributes only 15% of total design work. But with completion of this task 25-40% works completed, 0 to 85: Design freezing & detailing- ‘his phase involve design freezing after approval of concept design. Freezing means finalizing concept design. Then next step is detailing as per customer standard template. With completion of this stage, almost 85% of work is completed in designing stage. Check & final dispatch- 85 to 100" After detailing the quality checking team starts inspection of all the data & it will dispatch to the customer if itis ok as per customer standard. If there isin error in drafting it will create issue or mistake in manufacturing stage. ‘Thus, a percent completion criterion helps us to know where we are in design process. 9. Brief about “output” in design? Answer * Itincludes data to be given to customer after completion of design stage. The output is 3D models & 2D drawings of the tool. * In the fixture element design output contains detailed design of locators, detailed design 0 clamps, detailed design of supports, positions of locators, positions of clamp, positions of supports if any, type of locators, types of clamp, types of supports, clamping forces & supports, + There are two types of tools in fiture design unitized tool & non unitized tool In unitized tool there are multiple units on common base for e.g. geo fixture, respot fixture, checking fixture, hemming station etc. Unitized tools require two types of sheet key sheet & layout sheet, Non- unitized tools that can stand alone & can be detailed completely on a layout sheet. £.g. Rack, take out trolleys, turn tables, grippers etc. * Key sheet: an index of units & their placement on the tool base. Key sheet shows placement & location of that particular unit on tool base where exactly & exact position of tool base. Key sheet is showing orthogonal or isometric view of that entire component. Book Free Demo -ntps:isklyne.comstudent-projectsveek-3-bifxture-design-methodologes-challenges-2 1318312728128, 9:16 AM BBW Fisture Design Methodologies Challenges - Student Projects SKILL@LYNC * Layout sheet: A detailed drawing of individuals units to include all of their units. Layout sheet is detail drawing of that particular tool where we are going detail of component. Gric view in below figure tells that where exactly component is located in geometry. This is also helpful in CMM inspection of fixture, Book Free Demo -ntps:sklyne.comstudent-projectsveek-3-bifxture-design-methodologes-challenges-2 4ias12728128, 9:16 AM BBW Fisture Design Methodologies Challenges - Student Projects SKILL@LYNC * The output should compile following point- ©), Approved standard parts should be used wherever possible, This saves lots of time, effort & economical. »). Design should be as simple & economical as possible, Geometry is complex then fixture designis complex but approach is trying to design as simple as possible. c). Design must comply with all current safety & ergonomics standard 4). Design must provide for controlled & damage free handling of product. it should not damage other part @). Adequate error proofing provision must be incorporated in each design by providing proximity switches, rough locators ete. Proximity switches are basically sensors which tells part is present or not in fixture, Rough locators work as pokayoke to guide entire panel orientation £). The weight of moving part must be kept to minimum while maintaining maximum strength. Weight of moving component kept as minimum as possible but it shouldn't compromise on strength. There is balance between these two things. 9). Frames & structures are to be simple & sturdy. 1). Design clearance & accessibility for routine maintenance & service. Fixture need to maintain after cortain period of time s0 itis easily accessible for maintenance. i) Motion control must be considered on any moving component. Adequate to control the motion of component like slider, clamp arm so that it does not give any vibration & stays on particular limit by use of hard stopper, shock absorber. }). Designer is responsible to validate all clamps & weld guns. So that all clams & gun should perform its function without fa 10. What de you understand by structuring a design tree? How does it reduce error durin; the design process? Answer: 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 Book Free Demo -ntps:sklyne.comstudent-projectsveek-3-bifxture-design-methodologes-challenges-2 1518312728128, 9:16 AM SKILL@LYNC This helps us to avoid error during design study, manufacturing, assembly, inspection etc ‘BIW Fisture Design Methodologies Challenges - Student Projects 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 @ part gives the information as to which project or zone or ‘assembly they do belong. It can help us to identity 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. Below figure shows design tree structure properly & component ‘shown in key sheet. Each unit has a separate name. Structuring the tree is important as it is easier to differentiate the manufacturing parts fron standards, bought outs and hardware’s. Order of tree from top to bottom is: designed or manufacturing parts, after those standards parts from customer, bought outs parts are at bottom as shown in below figure. Every design tree base unit is first unit. Pa Book Free Demo -ntps:sklyne.comstudent-projectsveek-3-bifxture-design-methodologes-challenges-2 618312728128, 9:16 AM BBW Fisture Design Methodologies Challenges - Student Projects SKILL@LYNC ‘As shown in above figure naming is done as HIL-T9A: Project name. RRFRA: Panel name rear panel. G3~: Jig no3 (00-00: Unit no, part no respectively. OR: Right side panel 11. What are units? Mention 5 types of units. ‘Answer: Welding line fixtures support, clamp & locate two or more panels of a car body it welding process so that they will get welded accurately at the desired position. AFixture may comprise a single or more units where the product will be placed for holding ‘or clamping or locating in order to perform operations like welding or clinching -ntps:isklyne.comstudent-projectsveek-3-bifxture-design-methodologes-challenges-2 sas12728128, 9:16 AM SKILL@LYNC BBW Fisture Design Methodologies Challenges - Student Projects Aunit which may has NC block (Mylar), Locating pin, Shim sets, Blade (Dolly Plate), Power clamp, Air cylinder, Riser, Rough locator, Weld gun, Frame etc. to hold or clamp or locate or weld the product at the specified location, According to the 3-2-1 principle of fixture desigr the units are designed to locate & clamp the car pane! to its specified position in fixture while operation is going on Ex. Clamping unit, Locator unit, locating pin unit, Rest unit, Weld gun unit, Base frame unit. Atypical unit is shown below. Book Free Demo -ntps:sklyne.comstudent-projectsveek-3-bifxture-design-methodologes-challenges-2 1618312728128, 9:16 AM BBW Fisture Design Methodologies Challenges - Student Projects SKILL@LYNC Unitized too!- Unitized tool are basically tool which is part of multiple units or multiple part inside it. These are represented by key sheet. Unitized tools have two types as simple unit & ‘complex unit. Simple unit has simple design & approach for manufacturing is also simple, whereas complex unit has complex design. Non unitized tools: Non unitized tools are basically one unit. it doesn't have any process functionality init. It have function to keep component stable. Example of non unitized tools are stands, takeout trolleys, conveyor, turntables etc. where we don't need key sheet for that only layout shoot is enough to tell orientation as well as position. Below shortly described unitized tool types. + Rest unit- Rest unit is unit designed to support car panel using Mylar/ NC block/ rest. ‘Component is rested only, no upper clamp or force applied there, + Fixed pin unit- itis unit designed to locate car panel using pins. tis unit pin is already fixec it cannot moved. * Retractable pin unit~ itis opposite of fixed pin unit which can be moved up & down. It can be retracted to certain distance. A retractable pin unit is designed to locate the car panel using pins, but the entire pin package parts will be mounted on the retractable pneumatic cylinder. Each pneumatic cylinder will receive air through valve. When air is given to cylinder it is extended in forward motion & if air is given out it is retracted, Now day's pneumatic cylinder come with locking mechanism in forward motion. Below are parts in general Book Free Demo -ntps:sklyne.comstudent-projectsveek-3-bifxture-design-methodologes-challenges-2 918312728128, 9:16 AM SKILL@LYNC BW Fisture Design Methodologies Challenges - Student Projects + Clamp unit: Clamp unit is unit designed to clamp / hold the car panel with NC blocks/ mylar] rest by using o 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 anether type of clamp unit knows as swivel type. There is pivot pin around which clamp arm rotate. Book Free Demo -ntps:sklyne.comstudent-projectsveek-3-bifxture-design-methodologes-challenges-2 2018312728128, 9:16 AM BW Fisture Design Methodologies Challenges - Student Projects SKILL@LYNC + Rough locator unit- It roughly guides the operator for locatting the part. + Sensor unit- itis designed to sense car panel using electrical sensor. * Base unit- itis the unit on which all other units are mounted. It supports all other units. 12, Describe fixed pin units & their purpose? Answer: Fixed pin unit itis unit designed to locate car panel using pins. tis unt pin is already fixed it cannot moved & below ore different parts of unit in general. Fixed pin unit basically have pin, pin retainer, shims/ spacers, block, blade or adaptor plate Pin retainer support that pir -ntps:sklyne.comstudent-projectsveek-3-bifxture-design-methodologes-challenges-2 ries12728128, 9:16 AM SKILL@LYNC BW Fisture Design Methodologies Challenges - Student Projects Every pin unit will have two directional shims. the block is used to mount entire pin unit, Shims are used to avoid stack up tolerance while assembling entire component. Shims are ‘come in pack of 03, 0.2 & 0.5 mm. Ee Purpose of fixed pin uni in is most important part of fixture & used to restrict rotational a well as translational degrees of freedom of that particular component. Purpose Book Free Demo -ntps:isklyne.comstudent-projectsveek-3-bifxture-design-methodologes-challenges-2 2aies12728128, 9:16 AM SKILL@LYNC we BBW Fisture Design Methodologies Challenges - Student Projects 13, What ar the different parts of a fixed unit? Answer: Fixed pin unit consist of riser, blade, block, shims or spacer, pin retainer & pin. All parts are described below. «@). Riser: Risers can be of l-type, welded or square tube or trame type. These are basically manufactured parts are used to give height to assembly. -ntps:sklyne.comstudent-projectsveek-3-bifxture-design-methodologes-challenges-2 2318312728128, 9:16 AM SKILL@LYNC BIW Fisture Design Methodologies Challenges - Student Projects b) Blade: Blades are plates attached to riser. Other part likes cylinder, arms ete are mounted on the blade. Chamfer is given here to strengthen the blade. Two Dowel Four Hole arrangement is used to butt blade to the riser. )-L-Blocks: | Block is used just to provide the necessary shimming for adjustment. In case cof mounting an L block, we should check bolting access as there is already a bolt to tight the pin. Hence, clear hole should be given from L block. Book Free Demo -ntps:sklyne.comstudent-projectsveek-3-bifxture-design-methodologes-challenges-2 aia12728128, 9:16 AM BBW Fisture Design Methodologies Challenges - Student Projects SKILL@LYNC d). Shims/spacer: In fixture, we are providing tolerance to each part mostly manufactured Those tolerances tend to stack up & reflect together. In order to avoid that we use shims sc we can easily adjust after assembly so whatever stack up there we will rectify it through shims. Shims come in thickness of 01, 02, 05 etc. ¢).Pin:Itis used for the location purpose of the panel. Standard Pins should be used as far <8 possible and the lengths of pins should be reduced to maximum possible. Generally, pir diameter should be cylindrical grinded to maintain its dimension accurate. Usually two locating pins are enough to properly locate the work piece on one plane. There are dozens of styles of locating pins that can be utilized in a design. We will explain the structure and show an example of how each style can be applied. The different types of Standard Pins are as follows: Round Pins: These can be Serew secured (PNRS) or Grub Screw secured (PNRG) or Thread ‘secured (PNRT) for Prototype build only. One of the most common pins is a stepped pin with either small or large head Book Free Demo -ntps:isklyne.comstudent-projectsveek-3-bifxture-design-methodologes-challenges-2 2518312728128, 9:16 AM BBW Fisture Design Methodologies Challenges - Student Projects SKILL@LYNC Diamond Pins: The Diamond Shape is « critical feature that helps with machining inaccuracies and smoother locating operation. When two round head pins are installed conto one plate, the distance between two mounting holes must be extremely precise and ‘even then, the work piece will not be placed on the base as easily as it would with the use ‘of a diamond shape pin. These can be Screw secured (PNDS) or Grub Screw secured (PND) oF Thread secured (PNRT) for Prototype build only Pa Book Free Demo -ntps:sklyne.comstudent-projectsveek-3-bifxture-design-methodologes-challenges-2 2618312728128, 9:16 AM BIW Fisture Design Methodologies Challenges - Student Projects SKILL@LYNC #).Pin retainer: Pin retainer support that pin. Pin Retainer is designed to hold the pin in its place and is also used as a rest for the pin, A counter hole is dlled on which pin is fit 14. What is the purpose of making a rest unit & describe its parts? Answ Rest unit Rest unit is unit designed to support car panel using Mylar/ NC block/ rest. ‘Component is rested only, no upper clamp or force applied there. Its the simplest unit to design because it has fewer parts to design & the purpose is only resting of the car panel. Because of this simplicity the rest unit is combined with other unit to reduce the cost of the overall project. It can be combined with clamp unit to clamp as well as to rest the car panel, It can be combined with locating unit to locate as well as to rest the car panel. Also locating, clamping & rest unit can be combined together in one unit to reduce cost. Book Free Demo -ntps:isklyne.comstudent-projectsveek-3-bifxture-design-methodologes-challenges-2 ries12728128, 9:16 AM BBW Fisture Design Methodologies Challenges - Student Projects SKILL@LYNC Book Free Demo -ntps:sklyne.comstudent-projectsveek-3-bifxture-design-methodologes-challenges-2 2818312728128, 9:16 AM BBW Fisture Design Methodologies Challenges - Student Projects SKILL@LYNC a). Mylar/ NC blocks/ Fingers: These are parts are used to hold panel. They are globally called as Mylar. Top side Mylar is called as clamping Mylar & bottom side is called resting Mylar. Every clamping Mylar should have resting Mylar. Itis jaw type. it prevent panel from deforming while welding, itis hardened to increase its wear strength, b). Riser: Risers can be of L-type, welded or square tube or frame type. These are basically manufactured parts are used to give height to assembly. itis machined at mounted ends only to save cost. Book Free Demo -ntps:isklyne.comstudent-projectsveek-3-bifxture-design-methodologes-challenges-2 2918312728128, 9:16 AM SKILL@LYNC BIW Fisture Design Methodologies Challenges - Student Projects ¢).Blade: These are plates mounted on the riser. Other parts like cylinder, arms etc are mounted on the blade. 4). Shims/spacer: In fhcure, we are providing tolerance to each part mostly manufactured Those tolerances tend to stack up & reflect together. in order to avold that we use shims se we can easily adjust after assembly 20 whatever stack up there we will rect through shims, Shims come in thickness of 01,02, 05 ete Book Free Demo -ntps:isklyne.comstudent-projectsveek-3-bifxture-design-methodologes-challenges-2 0183ranaza,a18 AM SW Fire Design Metodlogies Calenges- Stent Projects SKILL@LYNC thore are 8 no's of par require for assembly then we have that no. of sensor at least. Whenever operator manually assemble entire component they do the process like fastening, gluing, The sensor will show that particular component is there or if component i missing it will give an error. Fundamental of sensor unit design: * Every signal loose panel which are being welded in tool * Each panel should be sensed by | to 2 sensor depends on size of panel, preferred to be in diagonal opposite ends of panel. * Every sensor should be mounted in 3 directions adjustable way in general, + Some major sensor manufactures are IFM, Pepperi-fuchs, SICK, OMRON etc, Types of sensor used in general Proximity sensor- It has sensing range 5 to 6 mm. It is based on magnetic field principle. A proximity sensor is a sensor able to detect the presence of nearby objects without any. physical contact. A proximity sensor often emits an electromagnetic field or a beam of electromagnetic radiation (infrared, for instance), and looks for changes in the field or return signal Laser sensor: It has sensing range is farther away from proximity sensor. Photo electric sensor: A photoelectric sensor is equipment used to discover the distance, ‘absence, or presence of an object by using a light transmitter, often infrared, and a photoelectric receiver. They are largely used in industrial manufacturing, Below fig shows Pa 16. What is a rough locator unit & what are the basic fundamentals to consider while designing it? Answ Rough locators: Rough locators are usually used in loading & unloading of particular part. Itis also used to guide. Rough locator unit is apart designed to guide the operator to locate car panel on the pins accordinalyv. They have slot for adiustment. A rouah locator can be o! Book Free Demo -ntps:sklyne.comstudent-projectsveek-3-bifxture-design-methodologes-challenges-2 118s12728128, 9:16 AM BBW Fisture Design Methodologies Challenges - Student Projects SKILL@LYNC Fundamentals of rough locator design. + Rough locators should be placed at the edge of car panel, which it has to guide using locating pins one can easily restrict movement of entire car panel. * Rough locator has to be placed in the same angle of the car part edge with minimum distance of 2.5 mm from the edge of car part, so it should no damage panel. * Rough locators should guide the panel before 10 to 15 mm. to the start of the pin ‘engagement. + Rough locators should guide the panel in pin arresting direction in general + Rough locators should be designed with two slots to mount for easy adjustment. (in general) * The slot should be in the direction of car panel guiding 17. Whatis a base unit & describe its parts? Answer Base unit: A base unitis the unit designed to mount all other units ( clamp unit pin unit, rest unit) of the tool, also other parts necessary. For a tool ike pneumatic valve box, trucking cable path will also be mounted on to base unit & below are the some part of base unit in general -ntps:isklyne.comstudent-projectsveek-3-bifxture-design-methodologes-challenges-2 214312728128, 9:16 AM BW Fisture Design Methodologies Challenges - Student Projects SKILL@LYNC a). Base Plate: Base Plate is a machined plate made of steel or Aluminum of thickness 25mm to 4omm on which the holes are drilled to mount different units lke rest units, clamp units, pin units ete. b). Pedestal: Pecestal is « part or an assembly (welded structure) that joins the base plate to the floor plate, Pedestal can be a standard part or a make part, depending on size and height of fixture. standard pedestals are available in different heights. Pedestals are also available in different inclinations, Depending on the size of base plate; the number of pedestal for a fixture can vary for load distribution ¢). Valve box: Pneumatic valve box includes solencid valve which supplies cir to pneumatic cylinder & their coil Sometimes a bunch of valve is mounted is called as valve blank 4). Trunking channel: Trunking channel which mounted on base is used to guide all electrical cable, pneumatic pipe. Base support entire fixture unit. Trunking Channel is « duc that carries all the electrical and pneumatic connections (wires and pipes) for units of the tool. It has a thickness of few millimeters. Book Free Demo -ntps:sklyne.comstudent-projectsveek-3-bifxture-design-methodologes-challenges-2 314312728128, 9:16 AM BBW Fisture Design Methodologies Challenges - Student Projects SKILL@LYNC ¢). Eye bolt: They are used to lit entire base unit, pedestal to support base plate #).Floor plate: they are used to mount entire unit & a leveling arrangement such as leveling bolt & pad are provided to base unit to level the entire unit 's functions? 18. What is a dump unit & what ari Answer: Dump unit: Dump unit is where you assemble component if you have certain constraint. Here you will have clamp unit, pin unit attached & panel will be assembled, So if you have certain constraint you cannot assemble in normal way. Dump unit use in different way. It has dump cylinder & complex design. It consists of dump cylinder to perform the operatio ‘of clamping & unclamping car panel. A dump unit can have more than one cylinder to perform such operation. The first cylinder dumps the assembly carrying clamp mylars, pin: ‘and then this assembly performs the required operation. In this unit, we should make sure that in the open position of panel, we should be able to remove the panel. Below fig show dump unit. -ntps:sklyne.comstudent-projectsveek-3-bifxture-design-methodologes-challenges-2 ies12728128, 9:16 AM BBW Fisture Design Methodologies Challenges - Student Projects SKILL@LYNC Book Free Demo -ntps:isklyne.comstudent-projectsveek-3-bifxture-design-methodologes-challenges-2 3518312728128, 9:16 AM SKILL@LYNC BIW Fisture Design Methodologies Challenges - Student Projects 19. Whats a slide unit? Mention where slide units are commonly used Answer Slide unit: Siding unit consist of sliding cylinder. It slides between open & close position. At the end it has shock absorber & after that hard stopper. Ithas guide rail. it uses sliding mechanism. It also has position locking unit for maintenance purpose doesnt allow to move entire unit & sensor unit to sense entire component reached at either side or not & ‘stopper block to control moving. When cylinder opens position locking mechanism unlock the panel, Then entire pane! move to open position using frictionless guide block. Guide block need to lubricated periodically -ntps:isklyne.comstudent-projectsveek-3-bifxture-design-methodologes-challenges-2 3618312728128, 9:16 AM BBW Fisture Design Methodologies Challenges - Student Projects SKILL@LYNC Sliding unit are basically use in places where you have certain constraint, space constraint, Sometimes, there are too many small panels near each other and there is not enough space as each panel requires resting, location using 2 pins, clamping and sensing. This becomes even more difficult when panel is at angles. To solve this problem, c slide unit mounts rest, clamp or pin unit or all of them on a slide using guide rails, guide blocks, a cylinder, locking mechanism, stop blocks and sensors. When a particular panel is to be welded, this slicle moves forward, fixes the panel and on completion of operation, slide moves back and gets locked at its position. Similarly, the same is done for other panels, Leave a comment ‘Thanks for choosing to leave @ comment. Please keep in mind that cl the comments ore moderated as per our comment poley, ang your email will not be published for privacy reasons, Please leave a personal & meaningful conversation. Please login to add a comment Other comments... -ntps:isklyne.comstudent-projectsveek-3-bifxture-design-methodologes-challenges-2 ries12728128, 9:16 AM ‘BIW Fisture Design Methodologies Challenges - Student Projects SKILL@LYNC Bo the first to add a comment Read more Projects by Abhijeet Magdum (22) Week 9 - Project 1 - Door Applique De: Fraineerina Features Objective: Aim Create door appique trom given class A suriace, Then create attachment feature le locators & heat stoke considering Perform draft design rules ysis on class A, 07 Jun 2021 08:53 PMIST Week 9 - Attachment Feature Creation - Challer 2 object Air: Create the boss and Dog Hous the Centre console coin holaer considering the design rules. theory Clase A surface: is outermost sure bile which gives ossth (03 Jun 202110:51 AM IST Showing 1 of 22 projects -ntps:sklyne.comstudent-projectsveek-3-bifxture-design-methodologes-challenges-2 3814312128123, 9:16 AM ‘BIW Fisture Design Methodologies Challenges - Student Projects SKILL@LYNC Skill-Lync Reviews Terms Privacy Polic Epowerx Learning Technologies Pvt Ltd. 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