DESIGN GUIDELINES1.Introduction to welding fixtures for B.I.W.a.Bonnet welding lineb.Tailgate welding linec.oof welding lined.Bod! side welding linee.Door asse"bl! linef.Underbod! welding line.Eachwelding line consists of different types of fixtures-1.Geo"etric welding fixture- Accurate fixture where the geometry of the fixture is prepared.a. #S# $#anual welding fixtureb. #S $obotic welding fixturec. #S% $%uto"atic welding fixture.&.es'otting 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.(.Gri''ers)*re+enseurs-sed for handing the panels in the line.,.Table for Gri''ers)*oste de de'ose 're+enseur-An area where the grippers can be par!ed.-.*oste de de'alletisation-An area where the panels are downloaded by pallets one at a time...*oste de accu"ulator-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./.0e""ing fixtures-"ixture where there is marriage of inner and outer panels. #his goes on a $emming %ress.1.#E23#ontage En 2inition. In this type of "ixture the "inish &omponent li!e'oors, #ailgate, (onnet are assembled to (I)-(ody In )hite * )elded Assly of nderbody, (ody +ide , -oof from .ain /ig0.ain "rame +tn1 with the help of +crews0-ivets with the help of Nut -unner.SWING4$5Will be u'dated wit+ "ore details6In a swing where there is a pair of appui and touch2 usually shim box is given for appuionly and not on the touch2 which is mounted on the swing arm. (ut in case there is only touch2 on the swing and no appui then we need to give shim box for it."or a swing unit the !inematics is good for an opening angle of 34deg.If the opening angle is more than 34 we can go for an electric cyl. but it is expensive than a normal cyl.Ad5ustment on appui and touche always reqd. on ht. and in case of changing cross sections but not along the length which continues to have the same section.Now onl! t+e touc+7 undergoes a +eat treat"ent and not on a''ui.S0I# B894$+him box is for customer and never used for ad5usting the machining problem.sually au montage on appui and touch2 is for ad5usting and in case an ad5ustment reqd. in 6rd direction a shim is provided.SENS84$&73x73 +ensor if the panel matl is aluminium.*type of sensor depends on panel matl.1If it is of steel then dia89 sensor.dia11 sensor.$s'ecific a''lication ::+: +ensor always to detect the main panel.+ensor reqd for the wor! table if the panel is pic!ed by a robot otherwise no sensor reqd.All the movements done by robot requires a sensor."or .anaul gripper no suction cups and clamping to be operated by one handle, should be always compact and avoid hanging parts. No calculations involved li!e a robotic gripper.If the base is of Aluminum matl *"ortal1 usually it is when it is mounted on #urn table then use helicoil .84 need to write a special note for it. ;; I.%.;1, *%NEL IN284-#he panel which r directly in contact with appui 0touch2 and the thic!ness is to be calculated by the ad5uster then to be indicated in the #-IAN #-IANf &lamp is different depending upon type =h or -h1 but the fixation is same +o for sym opp station for two different0 same type of cylinder need #)> 'I""E-EN#."< ')< for .>N#IN< of &yl.#a?e #ec+acro"e A As the cyl is having interchangeableinserts at four places * 7dowels07 tappings1 +o for sym opp station for two different0 same type of cylinder#$E .>N#IN< ')< >" >NE )I== (E E@A#=G +G. >%% #> >#$E-.Guideline to select t+e t!'e of cla"'$#*NI-without loc!*this loc! is the 6 pt system inside the cyl.1 to be used when the air pressure is cut off suddenly it does not open usually clamp placed vertically with levelarm parallel to base.#*@I-with loc! *with 6 pt loc! inside1 to be used when the air pressure is cut off suddenly the clamp will open and the panel can fall down* for e.g in gripper where the clamp is upside down1#*#I$clamp with handle."or Aluminium weldment matl is A-H A81 #he predisposed anglage unit concerns only the anglage unit.71 #he final 6' model contains all units I predisposed anglage ,in base ,all clamps , dies61 >N=G IN %EA-A#>-.o1 'rageoirMfor detail dwg ,first ;I+A=I?E the %->"I=E of the panel to be m0c , then decide todo the &N& or &=A++I& machining."6 2or >8#*8UND %NGLE ")c use one *INNULE A %U9 Biew to obtain t+e true Biew for ")c of T+ic?ness)Dowel +oles.$$$to be discuss wit+ BUN8 n1All the ad5usting shim have to be fixed by"hc srew * &ounter sun! +crew1#he angle countersin! is N#IN< %A-#.n6 Add the co-ordinates of the O+P point for all dwgs * Internal0External +ym1**( ,emar- . &hi" i" to under"tand the fg( Supplier for ,//0/ 1/2 "ide(+o6 "or A (ended %iece A 'epending upon the Amount of material -emoval we can decide either by m0c0 (ended %iece >- )elded %iece for final cost of manufacturing.p1se a cross fixations to avoid symetric part

'6 "or weldment design I #ry to use the niform thic!ness of the %arts..i.e #h! 84,87 onlyQQ do not use the variety of thic!ness for part debit li!e i.e 9,84,87,8B,89

=6 "or! A Gou have to put a shim on both the side to ad5ust the sliding piece.* shim-dar! blue1

r1"INA= &$E&HIN< for bought out bush is normally "Df3.7.Heyway NChC.6.+upport