Shakagal BIW Welding Fixture Design It involves numbers of fixture units and due to the complexity and shape of the component geometry, the choice of elements as well as configuration of each unit tends to change from case to case. Load condition and configuration are not uniform, so it is impossible to set a base shape in general. Skip wdlding main content. The framework of the base is usually made of shape steel. The taper lead angle is large, 60 degrees or less, for small-size body parts and manual operation, but it is frequently between10 and 30 degrees for large-size body parts that are difficult to handle.
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In Geo fixture tack welding done for all the parts to be assembled in that fixture. The geo fixture defines the geometry of the part. Where as positional accuracy of pin should be within Geo fixture control the sub assy accuracy in all the 3 axis. In Re-spot fixture remaining tacks are completed.
By performing this kind of operation no station will be ideal Hence we use Re-spot fixtures. Re-spot jig pin tolerance will be C Marriage Fixture- - As name suggests the marriage of different assemblies is carried out in this fixture.
This station is called as marriage tool. D Framer Fixture - - Framer fixture is next station after the marriage fixture. The easier way to describe a gripper is to think of the human hand.
Just like a hand, a gripper enables holding, tightening, handling and releasing of an object. A gripper is just one component of an automated system. A gripper can be attached to a robot or it can be part of a fixed automation system.
Different grippers are used in BIW as follows, A Material handling gripper - - As the name suggest These grippers are used for material handling. B Process grippers - - These grippers are used to carryout some specific process like gluing, welding, riveting etc.
Different stands are used in BIW A Pedestal stands - - Weld gun is mounted on the fixed stand which is mounted to the floor permanentaly.
The gripper can carry the panel under the stand to do the operation. D Date stamp stand - - Every manufactured product have some data to stamped or to be embossed on it like serial no, batch no, Date etc.
B Buffer stand- After some operation we can put the no. They are also used to store the inventory while the machine is under going for some maintainence.
C Take out trolleys - It used to take out some panels for inspection to rectify the process is going in right or not between the cycle. D Conveyor - Conveyor is the rotating path which tranport the parts to the next station which are kept over it. Every clamping Mylars have resting Mylars.
It dont allow deformation of the part due to welding stresses. B Principle locating point PLP - These are the points which are used for the accurate location of the part to maintain the geometry of the assembly. There are lots of holes on the panel which are not accurate due to stamping operation.
The PLP are defined in the drawing. C Risers - Risers are of different type like L-typer rises, Square tube riser etc. Riser is the manufacturing part which gives height to the assemblies. D Blade- Blades are plates mounted on the riser. Other parts like cylinder, arms etc are mounted on the blade. E Shims - Shims are the small part which comes with the thickness of 0. These will compensate the stackup tolerance which reflects at the panel holding part called Mylars.
We give tolerance to all the parts of the fixture. Due to this tolerance the Mylars will either lift up or goes down from its defined position. If the Mylars goes down from the defined height it will make impression or dent on the panel. If the Mylars lift up then there will be a distorsion due to welding stress. F Rough locators - The operator can place the part in wrong orientation mistakanely. It is a part of fool proofing. It is a device that measures the geometry of physical objects by sensing discrete points on the surface of the object with a probe.
It generates report my comparing the data with the CAD file data. I Unit - The fixture is the assembly of different types of units to form a fixture. There are different units like pin unit, base unit, clamping unit etc. J Number plates - Number plate is the aluminium embossed plate placed on the each unit for easily recognising the unit. K Name plate - The data like manufacturing company name, fixture type, Fixture weight etc. L Clamp Arm - Clamp arm is the part of clamp unit which moves over a axis.
Over clamp arm the Mylars are mounted. M Pivot - It is a axis about which the clamp arm will rotates. The outer panels should be asthetically very good. No any scratches or dent is acceptable over it. While designing the fixture to the skin surface the clamping material should be soft, so that it could not able to left any impression or dent over skin.
The reed switch is an electrical switch operated by an applied magnetic field. The detects the panel is loaded or not is done by sensors.
Sheet Metal Fixtures
BIW Fixture Design