DESIGN GUIDELINES 1.Introduction to welding fixtures for B.I.W. a. Bonnet welding line b. Tailgate welding line c. Roof welding line d. Body side welding line e. Door assembly line f. Underbody welding line. Each welding line consists of different types of fixtures1.Geometric welding fixture- Accurate fixture where the geometry of the fixture is prepared. a. MSM -Manual welding fixture b. MSR -Robotic welding fixture c. MSA -Automatic welding fixture. 2.Respotting fixture-Not so accurate fixture. In this case geometry of the panel is already defined and this fixture is required to weld those spots, which cannot be achieved in geometric welding fixture. 3.Grippers/Prehenseurs-Used for handing the panels in the line. 4.Table for Grippers/Poste de depose prehenseur-An area where the grippers can be parked. 5.Poste de depalletisation-An area where the panels are downloaded by pallets one at a time. 6.Poste de accumulator-An arrangement for downloading the panels by conveyors, in which the fixture is mounted on the conveyor, which carries a number of panel with them. 7.Hemming fixtures-Fixture where there is marriage of inner and outer panels. This goes on a Hemming Press. 8.MEF–Montage En Finition. In this type of Fixture the Finish Component like Doors, Tailgate, Bonnet are assembled to BIW-Body In White ( Welded Assly of Underbody, Body Side & Roof from Main Jig/Main Frame Stn) with the help of Screws/Rivets with the help of Nut Runner.
SWING:-(Will be updated with more details) In a swing where there is a pair of appui and touché usually shim box is given for appui only and not on the touché which is mounted on the swing arm. But in case there is only touché on the swing and no appui then we need to give shim box for it. For a swing unit the kinematics is good for an opening angle of 60deg.If the opening angle is more than 60 we can go for an electric cyl. but it is expensive than a normal cyl. Adjustment on appui and touche always reqd. on ht. and in case of changing cross sections but not along the length which continues to have the same section. Now only the touché undergoes a heat treatment and not on appui. SHIM BOX:Shim box is for customer and never used for adjusting the machining problem. Usually au montage on appui and touché is for adjusting and in case an adjustment reqd. in 3rd direction a shim is provided. SENSOR:C26x26 Sensor if the panel matl is aluminium.(type of sensor depends on panel matl.)If it is of steel then dia18 sensor. dia18 sensor.-specific application ?? SQ Sensor always to detect the main panel. Sensor reqd for the work table if the panel is picked by a robot otherwise no sensor reqd. All the movements done by robot requires a sensor. For Manaul gripper no suction cups and clamping to be operated by one handle, should be always compact and avoid hanging parts. No calculations involved like a robotic gripper. If the base is of Aluminum matl (Fortal) usually it is when it is mounted on Turn table then use helicoil M10 need to write a special note for it. VV IMP. 014 PANEL INFO:The panel which r directly in contact with appui /touché and the thickness is to be calculated by the adjuster then to be indicated in the TRIANGLE and those panels which r welded together r indicated W/O TRIANGLE.
GUN GUIDE :For Gun Guide ( Guide Point ) mounted on Swing unit material to be considered as CESTILENE HD1000R ,but if plaque insolent is used then the matl of guide pt is CuCr1Zr. For Gun Guide ( Guide Point ) Fixed Type material to be considered as CuCr1 Zr ( Chromium Coper ) For Plaque Isolante material to be considered is CELORON. MABEC Ref no. for all this Isolante plaques ( thicknesswise ) is specified in Std. File Ref. Psa114e9.doc ( For X6 Project ). For mentioning the hardware notes of Guide Point :1 or 2 Vis H M8 ( H for Hex Screw ) 1 or 2 Rondelle Plate X511 125 200 CADMEE 1 or 2 Rondelle Isolante A615 962 313 1 or 2 Douille Isolante Dia 8 x Dia 12 P909 208 901 ( For Dowel ) For taking holes on Guide Point take Dia 13 hole for M8 Screw & Dia 12 H7 hole for Dia 8 H7 Dowel hole. Plaque Interface:For weldment-Matl E24-2,FIXE. For single plate with bend-Matl E24-2,BRUNI.Bend allowed upto 15 mm. For more than 15mm go for welding. In ALU welded structure no bending on the plate,only welding. This information is for X6 Project. Please refer new std. For New Project. Steps to be follow Prior to start of design:-Assly of Panel -Weld Spot Point in Panel Assly file wrt x,y,z Coordinates. -Positioning of Weld Gun/ Torch at respective point -Conceptual Design of Fixture(AVP) with Weld Gun Simulation -Design Review related to PCI Stds. -Robcad Study -Design Changes wrt Robcad Study/Design review -Finishing of 3D Designing/ modeling -2d Detailing -Nestor ( Bill of Material)
-DRF ( Pneumatic Layout) -AMDEC ( Sheet for Maintenance of Critical parts of Fixture)-PCI Scope Fixation for Cylinder Make Genus: For Porte pilote /Bride tournante cylinder -the application ( Opening Of Clamp is different depending upon type Lh or Rh) but the fixation is same So for sym opp station for two different/ same type of cylinder need TWO DIFFERENT MFG DWG for MOUNTING of Cyl. Make Mechacrome : As the cyl is having interchangeable inserts at four places ( 2dowels/2 tappings) So for sym opp station for two different/ same type of cylinder THE MOUNTING DWG OF ONE WILL BE EXATLY SYM OPP TO OTHER. Guideline to select the type of clampMPNI-without lock(this lock is the 3 pt system inside the cyl.) to be used when the air pressure is cut off suddenly it does not open usually clamp placed vertically with levelarm parallel to base. MPVI-with lock (with 3 pt lock inside) to be used when the air pressure is cut off suddenly the clamp will open and the panel can fall down( for e.g in gripper where the clamp is upside down) MPMI-clamp with handle. For Aluminium weldment matl is AG3 For single Aluminium piece AU4G No paint or Bruni for Aluminium part.
Anglage Marriage Fixture Guide lines SCOPE OF WORK : 1) The predisposed anglage unit concerns only the anglage unit. 2) The final 3D model contains all units – predisposed anglage ,in base ,all clamps & dies 3) ONLY IN GA do not show the predisposed anglage ( Kxxx) 4) All clamp units near by to predisposed anglage have to be : -detailed -included in 001 -included in GA sheet -included in 014 sheet -all MATRICES have to be detailed DESIGN GUIDE LINES: a) confirm the GAP between Anglage Blade & Matrice ( Fouling/Heating) in close position b) put chamfer with DEPTH on Matrice with keeping min. 40/50 mm distance from TOP ( allowance for CNC machining) c) keep extra machining allowance for appui/touché i.e CNC Machining
Touche debit Inner panel
Outer panel
d) Use 5 mm CALE for porte pilote oriented in CAR LINE UCS ( XYZ) e) Keep part SENSOR position in the area where marriage/joining of TWO CAR PANEL POPSITION is important for ASTHETIC. Point of view. f) UCS of the MODEL FILE & CAR PANEL should be the SAME. g) For panel loading/unloading fixture can be in ANGLE with CAR UCS i.e G9
h) Put Altimetry Block of size 120x50x18 ( stamping of Geometrical Tolerance i.e flatness) on BASE PLATE & do the machining with open tolerance for thickness.(to be put if the fixture is at an angle otherwise this area is painted for parallel base) i) Put Sensor/Ventouse PERPENDICULAR to car panel BUT try to keep only one Angle On mounting plate with hole inclined on the face. ( ref B58 Capot Anglage -3d project G670234066_01_01_A1.e2)-----point in discussion j) Try to put the pinnules at the longer distance without support romer & Pinnules (3 nos.) can be at different LEVEL on the base plate. k) Add a protection plate for Bride Tournante (BT). l) It is not sufficient to check, if the pinnule is in the ball of the romer ; You have to check the accessibility too, if necessary (Doubt for the access).
m) Put reinforcement on the Riser i.e on the THICKNESS of the SQ.TUBE if required depending upon the function of the part to be mounted on the Riser. n) I would like you propose to us, a stronger and more simple design for this riser ---
m) Before making Internal/External Symetrie, confirm that if you can use the SAME part Only by changing the orientation & corresponding it’s QUANTITY in the 001 sheet. **( If we provide detail dwg with Internal/External Symetrie quotation will more EXPENSIVE from Manufacturing Supplier as compared to detail dwg with QUANTITY i.e 2/3 nos.) n) Do not put chamfer on all Drawings as UNMENTIONED CHAMFER is mentioned in the templet. (i.e CASSER LES ANGLES VIFS , sauf indications) Put chamfer on the Part IF it is OUT of the BASE/FRAME & may be HIT the OPEARATOR. o) Drageoir—for detail dwg ,first VISUALIZE the PROFILE of the panel to be m/c & then decide to do the CNC or CLASSIC machining. m) For COMPOUND ANGLE m/c use one PINNULE & AUX view to obtain the true view for m/c of Thickness/Dowel holes.---to be discuss with BRUNO n) All the adjusting shim have to be fixed by Fhc srew ( Counter sunk Screw) The angle countersink is 90° and no 120° Keep the Shim FIXED on the FIX MOUNTING PART. n) Add the co-ordinates of the “S” point for all dwgs ( Internal/External Sym) **( Remark : This is to understand the Mfg. Supplier for RH/LH +/- side.) o) For A Bended Piece : Depending upon the Amount of material Removal we can decide either by m/c/ Bended Piece OR Welded Piece for final cost of manufacturing. p) Use a cross fixations to avoid symetric part
p) For weldment design – Try to use the Uniform thickness of the Parts..i.e Thk 10,12 only ** do not use the variety of thickness for part debit like i.e 8,10,12,15,18 q) Fork : You have to put a shim on both the side to adjust the sliding piece.( shim-dark blue)
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FINAL CHECKING for GAP/CLEARENCE between Sub Assly:- Don’t forget to place the Concerned gripper/weld gun/frame/sub assly in the fixture for a last checking of 3D assly file.
Main remark for the construction of the 3D File 1. When you have many time the same detail (Shim box for example) in a 3D, each of this detail has to be a Xref and not a component. 2. Each part (and the opening postion) of the same section has to be on the same layer (named with the PCM Reference) MAIN IMPORTANT REMARK OF DESIGN : - All the fixation holes have to been positionned at a minimum of 15 mm from the edge of the casting block. - Take care of the gap you leave between a fixation plate of a weldment and the step of machining you have to leave a minimum of 5 mm. - Take more care of all the environement stress (Strenghness of the welment, simplicity of making, possibilities of machining........) when you re designing; Think of machining.Place a round cylinder as if it is a tool and move it in steps until the machining face is covered to have a good check on machining accessibility. - Put all the screws and washers for all the mounting positions to check if it misses the welding line as well as can be removed easily. - Understand the functional requirement of any unit and then start the design.Please check for interferences with all the moving parts in steps and not in work and no work position. - No Bruni for Z6CN18/10,this is the material used for appui,touché and pin if they come in the magnetic field of welding. - For aluminium panel use PAIB sucker pads and for steel use SAPELEM sucker pads. -
In Hemming fixture tolerances to be followed on some std parts are : 1.Eccentric shaft the combination of fit with FIBRO bought out bush is normally F7f6. 2.Keyway N9h9. 3.Support Guidage and Reprise H8f7. 4.for slot 0 to +0.1 and counter part 0 to –0.1,tolerance value depends on function. For flat or slot machining : tolerance below 0.1 surface finish R12.5. tolerance above 0.1 surface finish R25. For holes : H7 Tolerance surface finish R6.3. H8,H9…surface finish R12.5. tolerance 0.1 and above surface finish R25. For shafts : f6,f7,f8,g6 surface finish R6.3. tolerance above 0.1 surface finish R25. All Cales and rondelle de frottment : surface finish R12.5. POUR THK. parallelity.
