5/19/2016

CATIAV5:BIWWELDINGFIXTUREDESIGN

BIW WELDING FIXTURE DESIGN

BIWWELDINGFIXTUREDESIGN
Nomatterwhatyourknowledgeaboutfixturedesign,youusethefollowingstagesin
designofyourBIWweldfixture:
Studyandunderstandingofprocess
Conceptdesign
Create3DModeling

Youstudyyourprocess
Youstartdesignbystudyproductionprocessofbodyinwhite(BIW)thisprocess
providesvaluableinformationforthedesignphase.
ThepurposeofstudyBIWprocessincludesthefollowing:
Thespecialfocusonthestructureofabody(BIW)enablesyoutofindthelogicand
flowofbodypanels,andtherelationshipsbetweenthem.
Theselectofmastercontrolpoint,whichareholesorsurfacesrelatedtoyourbody
part&assemblytoarriveatthedimensionalintegrityoftheBIWbygivingthesteel
partsinthecorrectpositionduringjoining.
Theanalyzingofbodyismadeupofseveralhundredsofstampedcomponents
whicharejoinedtogetherbyspotweldingwithweldinggunforunderstandingof
weldingpointsandallocatethemtoweldingoperations.
Studyofcycletimediagrams,forcheckreachabilityandoptimizingit.Cycletimeis
estimatingtherequiredworkingtimeforeachstation.
Youcreateyourconceptdesignbasedonprocessstudy
Nowyoucanuseofprocessstudyfordefiningthedesigncriteriaandfindingorverifying
theconcepts.
Theweldingfixturedesigniscreatedwiththefollowingsteps:
Theclampingplansforaccuratepositioningofcomponents,whilethecomponents
arealignedtoasuitableplaneforweldingtheyaredesignedinthecarlineplane
(asinBIW).
Designoftheweldfixtureisunitbasedonclampingplan,thereforetherearea
numberoffixtureunittypesusedintheweldingfixturesforthepurposeofeachunit
andduetothecomplexityandshapeofthecomponentgeometry,thechoiceof
elementsaswellasconfigurationofeachunittendstochangefromcasetocase.
Thecheckofweldaccessibilityandspotweldforunrestrictedaccesstoeachweld
point,beforeandafterthefixturedesign,theaccessibilityoftheweldgunstoallthe
data:text/htmlcharset=utf8,%3Ch3%20class%3D%22posttitle%20entrytitle%22%20itemprop%3D%22name%22%20style%3D%22margin%3A%2020p

1/5

5/19/2016

CATIAV5:BIWWELDINGFIXTUREDESIGN

spotpointscanbesimulatedandstudiedthoroughlytoavoidgunscollidingwith
otherfixtureelements.

Youcreate3DModelingfixture
Youneedknowledgeandexperiencein3DModelingsoftwareforcreating3DModeland
2Ddrafting,detailing&3Dconceptdesign.
The3DModelingbecomesthebasicforfollowingitem:
Create3DModelingoftheweldfixtureforvisualizingtheentirefixtureinathree
dimensionalenvironment.
3DModelingofweldfixturegeneratedbycadsoftware,whichletsyoudetect
collisions,checkreachabilityspotweldandcarryoutweldaccessibilitystudyfor
ensuringyourfixtureefficiency.
The3DCADModelofweldfixtureunitenablesyoutomakeCADModelofclamp
locationplanforensuringthatplanproblemsandwastearediscoveredbeforeyour
fixturedrawingtosendformanufacturing.
By3DModelingofweldfixture,youcanquicklypreparemanufacturingdrawings.

PRODUCTIONPROCESSOFBODYINWITHE(BIW)
Inthestudyphaseofplanningprocessyoufindorverifytheconceptsofthebody
inwhitemanufacturingprocess.Fordesignweldingfixture,tryingtounderstand
processesisessential.Itisstartingwithprocesslogicandflow,anddefinesthe
relationshipsbetweenoperations.
Theprocessstudyisasolutionthattohelpyouquicklydefineandevaluate
processtoarriveatthebestplanfordesigningyourfixture.Theresultisprocess
studycontainingafulldescriptionofhowaproductisassembled,manufactured
andincreasesyourprofitabilitybyimprovingcriticalsuccessfactorsinyourfixture
design.
Theprocessstudyallowsdesignertoleverageandoptimizeexistingresourcesand
tobetterintegratethedesigningprocessfrombeginningtoendcannotonlyhelp
designercreatefixturefaster,butyoucanalsobegindesignearlierintheoverall
cycleorevenstartlater,inordertoaccommodateunanticipatedchanges.
TheAssemblyProcessstudyingallowsevaluatingalternatives,coordinating
resources,optimizingthroughput,planformultiplevariants,implementchanges
andestimatecostsandcycletimes,fromtheveryearlystagesofconceptplanning
throughprocess.
Studying,AnalyzingandManagingManufacturingProcessesenablesyouto
collaborativelyplanandanalyzingmanufacturingprocessesforyourfixture.You
cancreateoptimaldesignandaccommodatemultipleplanvariations,quickerand
fasterthaneverbefore.
Processstudyprovidesacollaborativeenvironmentforplanningdesigning
processes.Abroadrangeofapplicationsenableyoutodefineandverifybody
assemblysequences,createclampingplanlayout,definetherequiredtimefor
eachoperation,verifyplanperformance,performplanbalancingandanalyzeof
spotweldingandguns.
data:text/htmlcharset=utf8,%3Ch3%20class%3D%22posttitle%20entrytitle%22%20itemprop%3D%22name%22%20style%3D%22margin%3A%2020p

2/5

5/19/2016

CATIAV5:BIWWELDINGFIXTUREDESIGN

ThebodyinwhiteManufacturingProcessincludes:
Automotivebodyassembly
Electricresistancewelding
Cycletimediagrams

Automotivebodyassembly
Themajorprocessofanautomotivebodyiselectricresistancewelding.Resistance
weldingisagroupoffusionweldingprocessesthatuseacombinationofheatand
pressuretoaccomplishcoalescenceandwhereelectricresistanceweldingisnot
applicable,CO2,ARCWELDINGandMIGBRAZINGareperformed.
Thebodyofautomotiveismadeupofseveralhundredsofstampedcomponents
whicharejoinedtogetherbyspotweldingprocess.
Overallqualityofthecarbody(BIW)andqualityofthesubassemblies,apartfrom
qualityofeachstampedpart,dependsremarkablyonqualityoftheweldedjoint.
Youshouldstudyofpartjoining,weldingoperationssuchasspotweldingand
defineweldingpointsandallocatethemtoweldingoperations.
Thestudyofweldingprocesscanbeclassifiedasfollow:
Thenumberofweldingspot
Thepositionandvolumenumberofweldingspot
Thetypeofweldinggun
Thematerialandsheetmetalthicknessforsettingofweldingcondition
Cycletimediagrams
Thecycletimeisestimatingtherequiredworkingtimeofeachstation.
Cycletimestudyisbasedontheinformationsuchas:
Partloading
Clamping
Gunforward
Welding
Gunretreat
Unclamping
Partunloading

PORTABLEWELDINGGUN
Almostalloftheautomotivebodypartsareassembledbyresistancespot
welding.
Aspotwelderconsistsofatransformertoobtainalargeweldingcurrent,timer
tocontrolthetimeinwhichtofeedthecurrent,electrodestoholdwelded
articles,pressurizingcylindertoapplythenecessaryforthematerialbeing
welded.
Secondarycableletsnecessarycurrentthroughtransformerflowtogun,
data:text/htmlcharset=utf8,%3Ch3%20class%3D%22posttitle%20entrytitle%22%20itemprop%3D%22name%22%20style%3D%22margin%3A%2020p

3/5

5/19/2016

CATIAV5:BIWWELDINGFIXTUREDESIGN

springbalancertolightentheweldinggunandthecable.
Resistancespotweldingispassedbetweentwocopperelectrodes,the
processcanbeperformedbytheoperatorholdingaportableweldingmachine
andmovingitaroundthepartsbeingwelded.
Theseportablemachinescalledportableweldingguns.Themanualweldguns
canhaveeasyaccesstoweldthecomponentstogether.
Theresistancespotweldingmachinesareclassifiedaccordingto
combinationsofindividualsectionsasfollows:
Fixedtype
Studtype
Portabletype:
Conventionalweldgun
Integralweldgun

Conventionalweldgun
Conventionalweldgunshavealargetransformerlocatedremotelyfromthe
weldgun.Theweldingcurrentisdeliveredtotheweldgunarmsthrougha
large,watercooledsecondarycable.
JtypeorCtype
StypeorXtype
Theconventionalweldgunswereusedinvariousapplicationsbecausethe
weldcontrollersdidnothavetheabilitytodetectandreacttoanyhazard
associatedwithusingprimarypowerconnecteddirectlytotheweldgun.
Integralweldgun
Integralweldgunortarn'sgunshaveasmallertransformerlocatedrighton
theweldgun,fromwhichthecurrentisdeliveredthroughshortjumpersor
shuntsthatareaircooled.
Tran'sgunsarealsocalledweldguns,becausethetransformerispartofthe
unit.
Thetwoconfigurationsofportabletarn'sgunsare:
Cgun
Scissorsgun
ForexampleCgunforweldingaroundadooropeningonasmallflangeand
Scissorsgunforweldinglarge,deepboxesrequiringalongreach.
Therearefollowingcharacterizesfortarn'sguns:
Design
Flexibility
data:text/htmlcharset=utf8,%3Ch3%20class%3D%22posttitle%20entrytitle%22%20itemprop%3D%22name%22%20style%3D%22margin%3A%2020p

4/5

5/19/2016

CATIAV5:BIWWELDINGFIXTUREDESIGN

Ergonomics
Costefficiency

data:text/htmlcharset=utf8,%3Ch3%20class%3D%22posttitle%20entrytitle%22%20itemprop%3D%22name%22%20style%3D%22margin%3A%2020p

5/5