Catia v5_ Biw Welding Fixture Design

8/16/2019 Catia v5_ Biw Welding Fixture Design

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5/19/2016 CATIA V5: BIW WELDING FIXTURE DESIGN

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BIW WELDING FIXTURE DESIGN

BIW WELDING FIXTURE DESIGN

No matter what your knowledge about fixture design, you use the following stages indesign of your BIW weld fixture:

Study and understanding of process

Concept design

Create 3D-Modeling

You study your process

You start design by study production process of body-in-white (BIW) this processprovides valuable information for the design phase.

The purpose of study BIW process includes the following:

The special focus on the structure of a body (BIW) enables you to find the logic andflow of body panels, and the relationships between them.

The select of master control point, which are holes or surfaces related to your bodypart & assembly to arrive at the dimensional integrity of the BIW by giving the steel

parts in the correct position during joining.

The analyzing of body is made up of several hundreds of stamped componentswhich are joined together by spot welding with welding gun for understanding of welding points and allocate them to welding operations.

Study of cycle time diagrams, for check reach ability and optimizing it. Cycle time isestimating the required working time for each station.

You create your concept design based on process study

Now you can use of process study for defining the design criteria and finding or verifyingthe concepts.

The welding fixture design is created with the following steps:

The clamping plans for accurate positioning of components, while the componentsare aligned to a suitable plane for welding they are designed in the carline plane(as in BIW).

Design of the weld fixture is unit based on clamping plan, therefore there are anumber of fixture unit types used in the welding fixtures for the purpose of each unit

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.

The check of weld accessibility and spot weld for unrestricted access to each weldpoint, before and after the fixture design, the accessibility of the weld guns to all the


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spot points can be simulated and studied thoroughly to avoid guns colliding withother fixture elements.

You create 3D Modeling fixture

You need knowledge and experience in 3D Modeling software for creating 3D-Model and2D drafting, detailing & 3D concept design.

The 3D Modeling becomes the basic for following item:

Create 3D Modeling of the weld fixture for visualizing the entire fixture in a three-dimensional environment.

3D Modeling of weld fixture generated by cad software, which lets you detectcollisions, check reach ability spot weld and carry out weld accessibility study for ensuring your fixture efficiency.

The 3D CAD Model of weld fixture unit enables you to make CAD Model of clamplocation plan for ensuring that plan problems and waste are discovered before your fixture drawing to send for manufacturing.

By 3D Modeling of weld fixture, you can quickly prepare manufacturing drawings.

PRODUCTION PROCESS OF BODY-IN-WITHE (BIW)

In the study phase of planning process you find or verify the concepts of the body-in-white manufacturing process. For design welding fixture, trying to understandprocesses is essential. It is starting with process logic and flow, and defines therelationships between operations.

The process study is a solution that to help you quickly define and evaluateprocess to arrive at the best plan for designing your fixture. The result is processstudy containing a full description of how a product is assembled, manufacturedand increases your profitability by improving critical success factors in your fixturedesign.

The process study allows designer to leverage and optimize existing resources andto better integrate the designing process from beginning to end can not only helpdesigner create fixture faster, but you can also begin design earlier in the overallcycle or even start later, in order to accommodate unanticipated changes.

The Assembly Process studying allows evaluating alternatives, coordinatingresources, optimizing throughput, plan for multiple variants, implement changesand estimate costs and cycle times, from the very early stages of concept planningthrough process.

Studying, Analyzing and Managing Manufacturing Processes enables you tocollaboratively plan and analyzing manufacturing processes for your fixture. Youcan create optimal design and accommodate multiple plan variations, quicker andfaster than ever before.

Process study provides a collaborative environment for planning designingprocesses. A broad range of applications enable you to define and verify bodyassembly sequences, create clamping plan layout, define the required time for each operation, verify plan performance, perform plan balancing and analyze of spot welding and guns.


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The body-in-white Manufacturing Process includes:

Automotive body assembly

Electric resistance welding

Cycle time diagrams

Automotive body assembly

The major process of an automotive body is electric resistance welding. Resistancewelding is a group of fusion welding processes that use a combination of heat andpressure to accomplish coalescence and where electric resistance welding is notapplicable ,CO2,ARC WELDING and MIG-BRAZING are performed.

The body of automotive is made up of several hundreds of stamped componentswhich are joined together by spot welding process.

Overall quality of the car body (BIW) and quality of the sub assemblies, apart fromquality of each stamped part, depends remarkably on quality of the welded joint.

You should study of part joining, welding operations such as spot-welding anddefine welding points and allocate them to welding operations.

The study of welding process can be classified as follow:

The number of welding spot

The position and volume number of welding spot

The type of welding gun

The material and sheet metal thickness for setting of welding condition

Cycle time diagrams

The cycle time is estimating the required working time of each station.

Cycle time study is based on the information such as:

Part loading

Clamping

Gun forward

Welding

Gun retreat

Unclamping

Part unloading

PORTABLE WELDING GUN

Almost all of the automotive body parts are assembled by resistance spotwelding.

A spot welder consists of a transformer to obtain a large welding current, timer to control the time in which to feed the current, electrodes to hold weldedarticles, pressurizing cylinder to apply the necessary for the material beingwelded.

Secondary cable lets necessary current through transformer flow to gun,


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spring balancer to lighten the welding gun and the cable.

Resistance spot welding is passed between two copper electrodes, theprocess can be performed by the operator holding a portable welding machineand moving it around the parts being welded.

These portable machines called portable welding guns. The manual weld gunscan have easy access to weld the components together.

The resistance spot welding machines are classified according tocombinations of individual sections as follows:

Fixed type

Stud type

Portable type:

Conventional weld gun

Integral weld gun

Conventional weld gun

Conventional weld guns have a large transformer located remotely from theweld gun. The welding current is delivered to the weld gun arms through alarge, water-cooled secondary cable.

J type or C type

S type or X type

The conventional weld guns were used in various applications because theweld controllers did not have the ability to detect and react to any hazardassociated with using primary power connected directly to the weld gun.

Integral weld gun

Integral weld gun or tarn's guns have a smaller transformer located right onthe weld gun, from which the current is delivered through short jumpers or shunts that are air cooled.

Tran's guns are also called weld guns, because the transformer is part of theunit.

The two configurations of portable tarn's guns are:

C gun

Scissors gun

For example C gun for welding around a door opening on a small flange andScissors gun for welding large, deep boxes requiring a long reach.

There are following characterizes for tarn's guns:

Design

Flexibility


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Ergonomics

Cost efficiency

Catia v5_ Biw Welding Fixture Design

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