Académique Documents
Professionnel Documents
Culture Documents
Table of Contents
6. Locating and Clamping .......................................................................................................................................... 3
6.1 Introduction _______________________________________________________________________ 3
6.2 Locating Selection Criteria ___________________________________________________________ 3
6.2.1 Gage Holes as Primary Locators ......................................................................................................................... 4
6.2.2 Functional Surfaces Used as Primary Locators ................................................................................................ 6
6.2.3 Locating Parts with Product Design Gaps _____________________________________________________ 7
6.3 Standard Locating Holes, Pins and Tolerances __________________________________________ 7
6.4 Undersized Pins to Support Hole to Hole Initiative _______________________________________ 8
6.4.1 Undersized Locating Pin Error Proofing ............................................................................................................. 9
6.4.2 Undersized Pin Clamp Error Proofing (BTM Only) ........................................................................................... 10
6.5 Locating Pin Criteria _______________________________________________________________ 11
6.5.1 Panel Engagement .............................................................................................................................................. 11
6.6 Tool Nominal Locating Pin (TNLP) ___________________________________________________ 11
6.7 Retractable Pins __________________________________________________________________ 13
6.7.1 Retractable Pin Units ______________________________________________________________ 15
6.7.2 Standard Locating Holes, Pins and Tolerances for Retractable Pin Units .................................................... 15
6.7.3 In-Line Pin Attachment ....................................................................................................................................... 15
6.8 Non-Standard Locating Pins Not Preferred ___________________________________________ 16
6.8.1 Non-Standard Retention..................................................................................................................................... 16
6.8.2 Blunt Locator Pin Design ................................................................................................................................... 17
6.9 Typical Adjustable Standard Locator Pin Unit Arrangement ______________________________ 18
6.9.1 Adjustment for Locating Pins ............................................................................................................................ 19
6.9.2 Locator Hole Not Square to Body Grid ............................................................................................................. 20
6.10 Locator Block Sizes and Material ____________________________________________________ 21
6.10.1 Material ....................................................................................................................................................... 21
6.10.2 General Assembly Engineering (GAE) Conditions ................................................................................. 21
6.10.3 Regional Guidelines (other than GMNA) ................................................................................................. 21
6.10.4 Surface Math Data ..................................................................................................................................... 21
6.10.5 Sizes ........................................................................................................................................................... 21
6.11 NAAMS Locator Block Blanks _______________________________________________________ 21
6.12 Locator Block Criteria ______________________________________________________________ 22
6.12.1 Locator Block Deflection .......................................................................................................................... 22
6.12.2 Locator Block Contacting a Single Surface ............................................................................................ 23
6.12.3 Locator Block Contacting Two Surfaces................................................................................................. 26
6.13 Pressure Feet Criteria ______________________________________________________________ 28
6.13.1 Adjustment................................................................................................................................................. 28
6.14 Guidelines for Block Relationships to Trim Edges and Radii _____________________________ 29
6.15 L-Blocks _________________________________________________________________________ 30
6.16 Guidelines for Blocks and Pressure Feet (Legacy Designs Only) __________________________ 30
6.17 Fasteners for Locating Pin Retainers, NC Blocks, and L-Blocks ___________________________ 31
The Common Datum & Locating Strategy (CDLS) specifies which datums are nominal non adjustable and
which datums are nominal adjustable. For nominal adjustable datums please refer to GMD1 Section 06
Locating and Clamping. For Nominal Non Adjustable tooling please refer to GMD1 Section 05 Locating
and Clamping - Lean. Section 05 provides examples of both pin units and clamp packages that are lean
Nominal Non Adjustable tooling solutions.
6.2 Locating Selection Criteria
The criteria for locating a part is dependent on the type of work a tool is expected to do. Rest fixtures or
holding bucks are used to hold the parts between processes. Parts in this type of application are not
precisely held in location. Part transfer (linear or rotational) must be able to locate and properly position
the part from one station to another with a high degree of repeatability. A weld tool must repeatedly locate
the same part or parts with the same degree of accuracy within a tolerance limit. This will assure that the
finished sub-assemblies will be the same throughout the system. Refer to the MPM (Master Process
Model) or Coordination Drawing (CD) Lead sheet for specific datum location and control direction. Refer to
the examples shown on the following page.
It is preferred to use the most cost effective approach in the design of locator units (i.e. pins, pin retainers,
locator block, pressure foot blanks, shims, spacers and riser brackets).
For all new designs using the global hole tolerance scheme, use NAAMS APQ series locating pins.
When a locating pin is used, a stationary, non-retractable pin shall always be the primary selection.
A stationary pin package is more stable dimensionally, less costly and easier to maintain than a
retractable pin package.
There are instances where a retractable pin package may be required. See this section for further
definition.
The preferred width for NC Locators, L-Blocks and Pin Retainers is 19mm - 20mm. NAAMS NC Locators,
L- Blocks and Pin Retainers are available at 20mm wide with a 8mm dowel hole pattern. Legacy
programs may use NAAMS components with 8mm or larger dowel sizes as required.
A Pressure Foot without a matching NC locator will be identified as either a Locator or Pusher.
If the Pressure Foot is used to locate the part and is positioned by a hard stop, then it becomes
a Locator. This type of locator is normally indexed to the work position before the part is
loaded. Locators are identified in the MDM and ARE Certified.
If the Pressure Foot does not locate against a hard stop and only appliers a force after the part
is loaded, then the Pressure Foot is considered a Pusher. Pushers are not in the MDM and
ARE NOT Certified.
Pins used in the weld gun loop area, (consumed between the gun arms or located within the weld
loop), are to be made of Non-Magnetic Stainless Steel (NMSS).
GLOBAL:
The best method of part location supporting the nominal build philosophy is a 3-2-2 locating method
outlined and illustrated as follows:
(3) - Minimum of three locator blocks to establish part plane.
(2) - Round locating pin in a round hole that defines location in four directions (4-way)
perpendicular to the plane previously established (primary pin).
(2) - Round locating pin in a round hole that defines location in four directions (4-way)
perpendicular to the plane previously established (mating pin).
(3)
(3)
(2)
(2)
(3)
LEGACY:
Legacy programs will use the 3-2-1 method to establish the part location method when a hole and a
slot are present as outlined and illustrated below:
(3) - Minimum of three locator blocks to establish part plane.
(2) - Round locating pin in a round hole that defines location in four directions (4-way)
perpendicular to the plane previously established (primary pin).
(1) Round locating pin in a slot that defines two directions (2-way) of the primary pin.
The part is now located in all three planes, while maintaining no stress in the panel.
Locating Pin:
Hole Hole Pin Pin Tolerance NAAMS
Size Tolerance Size (h6) Code
8.1 +0.1/-0.0 8 +0.000/-0.009 APQ081-086
10.1 +0.11-0.0 10 +0.000/-0.009 APQ101-108
13.1 +0.11-0.0 13 +0.000/-0.011 APQ131-138
16.1 +0.11-0.0 16 +0.000/-0.011 APQ161-168
18.1 +0.11-0.0 18 +0.000/-0.012 APQ181-188
20.1 +0.11-0.0 20 +0.000/-0.013 APQ201-208
25.1 +0.11-0.0 25 +0.000/-0.013 APQ251-258
30.1 +0.11-0.0 30 +0.000/-0.013 APQ301-308
35.1 +0.11-0.0 35 +0.000/-0.014 APQ351-358
40.1 +0.11-0.0 40 +0.000/-0.016 APQ401-408
The separate locating pin and external clamp provide the greatest product flexibility, but is the more
costly solution compared to a pin clamp. A 30.0mm round embossment (tangent to tangent) is the
minimum requirement for the separate pin and clamp solution. This should be 6 way locators with
a hole diameter of 10.1mm or smaller.
30mm
Dia. 5.0 mm Radius Locating Pin for a 10
1.0 mm clearance btw pin and pres
6.5 mm pressure foot patch on each
1.5 mm of clearance between press
along the hypotenuse
Minimum Requirement for a 10.1m
30mm flat for 6 way locating pin
12.5 mm
12.5 mm
6.5 mm
5 mm
13.46 mm
+1.5mm
= 15.0mm
25 mm
Pin Retainer
When space is available, a pin clamp should be used to reduce the overall cost to GM. The
minimum product diameter size is 13.1mm for a pin clamp. For this locating hole size, the round
embossment requirement increases to 34.0mm. The embossment size increase with the size of
the hole for pin clamps. Verify the embossment requirement from the selected Pin Clamp Supplier.
Allow for 2.0mm of radial clearance between the pin clamp collar to any product features.
Undersized Pins
bushing
standard washer size A
M8 fastener
standard retainer
and / or standard shot pin component
Sizes
Sizes
40.0, 35.0, 30.0,
25.0, 20.0 etc 39.8, 34.8, 29.8,
24.8, 19.8, etc
Pin Clamps
For legacy product not utilizing Global die and pin sizes, see GMD1 Section 34 for legacy tooling
components (e.g. Hole size 16.0 = Pin Size 15.72).
6.5.1 Panel Engagement
Panel engagement should be as close as possible to the minimum value to avoid panel bind.
Tangent on Pin
2mm-4mm Panel
Engagement
The tool design deliverable shall designate the Tool Nominal Locating Pin (TNLP) on the assembly
drawing and/or Process Planner. The TNLP of a tool is typically identified as the locating pin with NO
spacers. The TNLP shall be physically identified on the weld tool to ensure proper set- up and certification
of fixtures. The TNLP can also be considered a Primary Locator for a particular part or sub-assembly. The
TNLP shall be identified in tool design and pass information back to Processing.
TNLP Examples:
TNLP using standard L Blocks and Pin Retainers with NO Grind Spacers or Shims
L-BLOCK
MOUNTING
SURFACE
OR BLADE
NAAMS APQ205
LOCATING PIN (REF)
LOCATING PIN
RETAINER
If a retractable non-rotating locating pin unit is required, then the preferred solution should be an In-line
locating unit followed by a side-by-side solution. The side loading on the retractable pin unit will determine
the engineering solution for each application. The figure below shows graphically the retractable pin
hierarchy. Please refer to the regional commercial component list for the approved supplier.
Stationary Pin Example Linear Retractable Pin Example Side-By-Side Retractable Pin
st nd rd
1 choice 2 Alternative 3 Alternative
For strokes greater than 50mm, a commercial pin package is preferred. The commercial pin package
does not require any additional guides. They can also be ordered with a rap coupler to help retract them
from a binded hole.
For make pin units with a stroke greater than 50mm, an external pin guide may be required. The GM
Manufacturing Engineer must approve application of additional guides.
If a commercial unit cannot be used and a retractable pin package must be designed, use a slide
arrangement. See GMD1 Section 10.
Modify a standard NAAMS pin to provide an undercut around the full diameter of the pilot shank as
shown. Providing an undercut as shown, allows rotation of pin in the plant if wear is evident.
Legacy locating criteria requires 5.0mm standard shim pack and 5.0mm grind spacer.
Legacy locating criteria requires 5.0mm standard shim pack and 5.0mm grind spacer.
2-WAY:
One plane (2-way) of adjustment is required for a slot that is oriented square to body.
NAAMS
NAAMS STD APQ205
Fitting Spacer Locating Pin
(REF)
Direction of
Adjustment
Legacy locating criteria requires 5.0mm standard shim pack and 5.0mm grind spacer.
Example: A round pin should be used in a slot as shown below utilizing a standard pin retainer. Do
not use flat or diamond pins.
NAAMS
Locating Pin
NAAMS STD
Fitting Spacer
NAAMS STD
Fitting Spacer
Direction of
Adjustment Direction of
Adjustment
Legacy locating criteria requires 5.0mm standard shim pack and 5.0mm grind
spacer.
For Closure Panels, Urethane Rollers are the preferred method to support the outer skin. The
rollers increase the contact surface which reduces/eliminates dings in the sheet metal. Deviation
from Urethane Rollers in any closure panel designs requires approval from the GM Zone Engineer.
Urethane blocks are the preferred method when the potential exists for marring a Class A surface
(i.e. manual load/unload, non-precision conveyors, etc.). Urethane with a Shore A 50-85 hardness
is recommended. The Urethane hardness must be called out in the Bill of Material for that detail. If
a Urethane locator requires tapping, a threaded / doweled insert from an approved source must be
used. For mounting, see GMD1 Section 4.
Locators used in the weld field are to be made of non-magnetic stainless steel (NMSS).
6.10.2 General Assembly Engineering (GAE) Conditions
The following are exceptions for General Assembly Engineering (GAE) using Ultra High Molecular
Weight (UHMW) / polymer:
Nest Blocks for delivery / transport racks that contact Class A painted surfaces shall be
constructed using urethane with a Shore A hardness of 60-85
Nest Blocks (V-blocks) for panel build and delivery carriers shall be constructed using urethane
with a Shore A hardness of 85
6.10.3 Regional Guidelines (other than GMNA)
Regions other than North America shall follow guidelines above but, refer to the equivalency
material chart in Section 1, Global Regional Metric Stock Specifications.
6.10.4 Surface Math Data
The design source shall be responsible for providing the construction source with a solid model of
the NC detail that is trimmed to the panel. The construction source will use this model for their build
requirements.
6.10.5 Sizes
The standard block size can range from 18.90mm to 20mm. This range allows the construction
source to provide the blocks at the leanest cost. Any deviation from standard block size requires
approval from the GM Manufacturing Engineer.
Legacy locating criteria requires 5.0mm standard shim pack and 5.0mm grind spacer.
One-Directional Set-up:
When contacting a single angle surface or a compound surface where either angle of the part
contact surface are 15 degrees or less, only one plane of adjustment is required for setup as
illustrated below. Position the datum on the dowel hole that has the most accessibility (see
illustration).
Legacy locating criteria requires 5.0mm standard shim pack and 5.0mm grind spacer.
Two-Directional Set-up:
When contacting a compound surface where one angle of the part contact surface is less than 15
degrees and the other angle is greater than 15 degrees, two planes of adjustment are required for
setup as illustrated below.
Legacy locating criteria requires 5.0mm standard shim pack and 5.0mm grind spacer.
Three-Directional Set-up:
When contacting a compound surface where both angles of the contact surface are greater than 15
degrees, three planes of adjustment are required for setup as illustrated below.
Legacy locating criteria requires 5.0mm standard shim pack and 5.0mm grind spacer.
Legacy locating criteria requires 5.0mm standard shim pack and 5.0mm grind spacer.
Three-Directional Set-up:
When contacting two surfaces and one or both of the surfaces is greater than 15 degrees in the
opposite direction of the two-way adjustment, three directions of adjustment are required for setup as
illustrated below.
Legacy locating criteria requires 5.0mm standard shim pack and 5.0mm grind spacer.
6.13.1 Adjustment
Single Angle:
When contacting a non-compound single surface at angles less than 45, provide adjustment in one
direction as shown.
Legacy locating criteria requires 5.0mm standard shim pack and 5.0mm grind spacer.
Dual Angle:
When contacting two surfaces, provide adjustment in two directions as shown. L-blocks are used to
provide adjustment in two directions.
Direction of Adjustment
Direction of Adjustment
Legacy locating criteria requires 5.0mm standard shim pack and 5.0mm grind spacer.
Begin with standard 20mm square block, only machining reliefs as required.
2 MM FROM
TRIM EDGE
(MIN)
2 MM FROM
TRIM EDGE
(MIN)
Relieve blocks only to achieve required trim edge and radii clearances shown.
Typical conditions when only locator (pressure foot with a hard stop) is used with no NC block for back-up.
Below is an example of a Hem Flange:
2 MM FROM
2 MM FROM
TRIM EDGE (MIN)
TRIM EDGE (MIN)
2 MM BEHIND BREAK 2 MM BEYOND
LINE TANGENT (MIN) BREAK LINE
TANGENT (MIN)
2 MM FROM
TANGENT (MIN)
2 MM FROM
TANGENT (MIN)
6.15 L-Blocks
L-Blocks are used in conjunction with locator blocks and/or pressure feet to provide additional planes of
adjustment when required.
All blocks that are 19 - 20mm in width may refer to the NAAMS web site for ordering information and
drawings. Legacy programs may use NAAMS locator block with 8mm or larger dowels as required.
6.16 Guidelines for Blocks and Pressure Feet (Legacy Designs Only)
Use only NAAMS standard shims and construction spacers.
Use the following combination of shims to acquire the 5.00mm stack up:
(2) - 0.25mm
(3) - 0.50mm
(1) - 1.00mm
(1) - 2.00mm
5.00mm
Design shims in an attitude that will accommodate easy access. Design shim packs so they will not fall
out due to gravity.
Pressure foot design will incorporate 5mm construction spacer in addition to a 5mm shim pack, for each
plane of adjustment.
Locator block design will incorporate 5mm construction spacer in addition to 5mm shim pack for each
plane of adjustment.
There are two acceptable clamp styles, Open Clevis and Power Clamps. The open clevis style
clamp unit utilizes a separate cylinder with custom details for the clamp arm and blade. NC-
surfaces for the open clevis style clamp can be bolt on blocks or machined in the arm and blade
details. The power clamp unit has an enclosed cylinder and an integral arm. The integral arm can
mount on either side of the clamp body or as a wish bone configuration. Both arms have bolt-on
NC blocks.
Either example above is not the single correct solution to apply across all weld tools; rather it can be
one or a combination of both styles. THE SPECIFIC CLAMP APPLICATION DRIVES THE CLAMP
STYLE SELECTION. A few examples are illustrated below:
The standard clamp unit shall be designed to provide 445 N +/- 10% (100 lbf.) of force at the part
clamping point for most applications. Part stack-up or tooling application may generate the need to
alter the standard clamp package / force. Larger metal stack-ups may drive a higher clamp force
and smaller metal stack-ups may require less force.
Applications that should be considered as requiring greater clamp force includes thicker stamped
parts (single parts that are greater than 2.5mm thick), large metal stack-ups, (greater than 4.0mm),
three part metal stack-up and applications that involve high strength steel parts. In these
applications, consider designing the clamp unit to provide two to four times more clamp force (890 to
1780N / 200 to 400 lbs.). Forces that oppose the clamp force such as, the weight of the part, lifting
forces due to pushers, weld gun and piercing equalizing forces, etc., shall be considered when
assessing the clamping application.
Applications that should be considered for a clamp force less than 445N (100 lb f) include two sheet
metal part stack-up less than 1.7mm thick. The reduction in clamp force yields a cost effective tool
that allows for maximum weld density.
The clamp unit shall be constructed with blade and riser type mounting. To contribute in minimizing
the overall size of each tool the blade style design should be used to extend or cantilever the clamp
unit beyond the footprint of the base. Each of the typical types of clamp units can be designed in this
fashion.
The locator block is typically attached by way of two dowels and one fastener. A two dowel, two
fastener hole pattern should be used when the locator exceeds 200mm. To enable the shim-less
nominal build philosophy a 5.0mm solid spacer shall be included between the locator and the
locator-mounting surface.
Pressure-foot (Fingers) details shall be designed as separate bolt-on, non-integral, details of the
clamp arm. The open clevis pressure foot clamp shall be mounted with no spacer or shims.
However, if an open clevis pressure foot requires a hard stop, then a 5.0mm shim pack under the
pressure foot must be included with this design. When a hard stop is used in the design, the
pressure foot is secured by a single fastener and two 8mm dowels. The 5.0mm shim pack is
utilized to assure proper adjustment of the gap between the locator and finger. Refer to the local
regions Statement of Requirement, SOR, and bid packages for any regional specific criteria.
The clamp arm shall be welded construction including a 20.0mm thick arm with an integral pivot to
accommodate a 19.50mm wide clevis. The female portion of the clevis shall always be part of the
arm. The male portion of the clevis shall always be part of the blade.
The clevis clamp cylinder shall be the round body design typically with front clevis attachment and
magnetic sensing switch attachment rod. Rear clevis mounting can be utilized for special situations.
The cylinder shall have built-in adjustable speed (flow) controls and cushions at retracted end of the
stroke.
The cylinder shall be attached by way of a 19.00mm thick blade locally machined to fit the 19.50mm
clevis-mounting lug. The clevis cylinder shall be ordered with the cylinder manufacturers standard
clevis pin assembly and rod clevis assembly that include a non-lube bearing to accommodate the
clevis pin of the cylinder.
The 19.00mm thick blade shall also act as the mounting surface for the locator. One typical method
of attachment for the blade is that the blade be mounted to the tool base or frame with a NAAMS
angle riser. Units that are excessively tall, (greater than 600mm) shall incorporate the blade as a
custom weldment with mounting pad and vertical ribs to reduce deflection.
Clevis clamp cylinders are available in multiple bore sizes. The three recommended bore sizes for
GM Global BIW Tool Designs are: 40mm, 50mm, and 63mm. These cylinders are available in both
a locking and non-locking version. The locking cylinders are required for all EOAT applications.
The locking cylinders are shipped to the build facility without the lock engaged for tool assembly.
The cylinder must be altered to allow the rod lock to perform properly when there is air loss during
normal production. Appendix C1 contains the instructions for the SMC locking cylinder. Please
provide to the build facility prior to tool construction.
There are two recommend strokes for these three bore sizes are 100mm and 150mm. However,
50mm and 75mm strokes are available when necessary for a lean design. The correct bore and
stroke for any cylinder is based upon the desired clamp opening and the minimum clamp pressure
of 445 N.
Use the suppliers setup table for pedestal mount option as a guideline for cylinder mounting design.
Safety Concern:
Consider the movement of the
cylinder body throughout the
entire stroke of the cylinder.
Allow sufficient clearance in
design to avoid hard
interferences and potential pinch
points when valve for cylinder is
manually actuated.
PINCH POINT!
MAINTAIN
30.0mm
MINIMUM
CLEARANCE
The Force Ratio of (2.4) can be used for 50mm bore cylinders to calculate the relationship between
the distance from cylinder clevis to clamp arm pivot, L1, and the distance from clamp arm pivot to
the center of the pressure foot/locator, L2. The Force Ratio to guarantee a minimum of 445N of
clamping force for a 50mm bore cylinder is shown below:
Then L2 F1L1
F2
L2 2.4 L1
The table shown below illustrates the acceptable distances from clamp arm pivot to the center of the
pressure foot, L2 , when the distance between the cylinder clevis to clamp arm pivot, L 1, is given to
be 75mm.
Now that F1 is calculated, (1714 N), and knowing that the Clamping Force, F 2, must have a
minimum clamping force value of 445N (100lbf)
The Force Ratio of (3.8) can be used for 63mm bore cylinders to calculate the relationship between
the distance from cylinder clevis to clamp arm pivot, L1, and the distance from clamp arm pivot to the
center of pressure foot/locator, L2. The Force Ratio to guarantee a minimum of 445N of clamping
force for a 63mm bore cylinder is shown below:
Then L2 F1L1
F2
L2 3.8 L1
The Table shown below illustrates the acceptable distances from clamp arm pivot to the center of
the pressure foot, L2 , when the distance between the cylinder clevis to clamp arm pivot, L 1, is given
to be 100mm.
1714
Arm Length L2
(mm from pivot point) Clevis Clamp Force (N)
100 1714
125 1371
150 1143
175 979
200 857
225 762
250 686
275 623
300 571
When a hard stop is required, the associated pressure foot must be precisely located using
dowels in the clamp arms.
A hard stop is not required on clevis clamps in applications of clamping non-show surfaces.
However, in the situation of excessively long arms a hard stop should be considered to
minimize the amount of miss-match between the locator and finger. A clamp arm length is
considered excessive if greater than 200mm from pivot point to part contact point.
Typical
Typi cal Pin
Pi n // B
Bearing
eari ng / / Blade
e Stack-up
Arm Blade
0.004 to 0.035 Press Fit
Keeper
Plate
Bearing
Bearing ID
0.006 to 0.035 Clear
18.035
18.022
Bearing OD
Tolerance p6
60
Thrust Washer
Required (red)
Gravity
Examples of a Clevis Clamp Section Clamp Arm and Blade Pivot with Thrust Washer
. Arm
Lubo Bearing
Blade
Thrust Washers
Gravity
Thrust Washer
Required (red)
CLAMP FORCE:
445 N (100 lbf.) MIN. AT
PART CONTACT POINT
BEARING:
PART # LBB1215 (OR EQUIVALENT)
PURCHASED COMPONENT
LUBO INDUSTIRES, INC.
BEARING:
PART # S01115012018019
(TOLERANCE 12H7 &18p6)
PURCHASED COMPONENT
LUBO INDUSTIRES, INC.
Attention must be paid to distance from Clamp Arm Pivot for Part Load/Unload
BEARING:
PART # S01115012018019
LOCATOR: (tolerance 12H7 & 18p6)
5.0mm SOLID SPACER PURCHASED COMPONENT
NO SHIM REQUIRED. LUBO Industries, Inc.
ONE FASTENER, TWO DOWELS PREFERED
TWO FASTENERS & TWO DOWELS
OPTIONAL FOR EXCESSIVE LENGTH.
HARD STOP
(LOCATING BLOCK)
Part #CVTB19 SMC CLAMP CYLINDER:
PURCHASE COMPONENT EXAMPLE ORDER NUMBER:
MISUMI # CKP1B50TF-100Y-P74SE-
X1840 (19.5mm CLEVIS
WIDTH, 50mm BORE, 100mm
STROKE, G-PORT, WITH (2)
REED SWITCHES).
INCLUDES 200MM LONG
SWITCH CORD WITH M12
THREADED CONNECTOR
ON EACH SWITCH.
REQUIRES ADDITIONAL
Y-CORD ORDERED ON
CONTROLS BOM.
.
BEARING:
PART # S01115012018019
(TOLERANCE 12H7 &18p6)
PURCHASED COMPONENT
LUBO INDUSTIRES, INC.
Below is the required clearance between the Open Clevis Clamp Arm and the blade. This
clearance must be maintained regardless of the starting stock size or the clamp application
(tooling or end effectors). The material for the arm must be a Hot Rolled Steel. the
common callout is A36. This material is more conducive to welding.
The standard commercial components are also identified in the section below (bearing and
shaft).
NOTE: Arm design should maximize the amount of overlap between the arm detail and
pivot plate to allow for greater stability of the pivot plate during the manufacturing process.
5 mm
Max
PURCHASED COMPONENT:
PURCHASED COMPONENT
LUBO INDUSTIRES, INC. 12.00mm PIN
0.075mm Clearance
(EACH SIDE)
0.15mm OVERALL
SECTION A -A
End Effector Tooling - Open Clevis Clamp Arm and Blade Section
CYLINDER CLEVIS
19.50 CLEVIS
PURCHASED COMPONENT
BEARING:
PART # LBB1215
(OR EQUIVALENT)
PURCHASED COMPONENT
LUBO INDUSTIRES, INC.
SECTION B-B
Example of a Clevis Clamp Section Blade and Clamp Arm Hard Stop
25.00
0.50mm CLEARANCE
BOTH SIDES
SECTION C-C
To allow for proper function and placement of the switches the piston of the cylinder must
travel at least 50mm, not including the stroke to go, between open and closed positions.
Standard open clevis locking style clamp cylinders do not come equipped with built-in
flow controls. Locking style clamp cylinders are typically ordered on end of arm tooling
applications. Actuation of the clamp cylinder is not conducive to panel damage therefore;
flow controls are not typically required. When applications dictate, i.e. clamping on a show
surface, order an in-line style flow control for these types of cylinders.
All power clamps shall be selected from the program specific approved ACCS-1 / ME NACCL
located on GM Supply Power. The wishbone arm is the preferred configuration for a power clamp
unit. The only acceptable alternative is a single arm mounted on either side of the clamp body as
required. Avoid welding or otherwise altering a standard arm. If a clamp arm is to be modified by
welding, it should be done in such a manner as to prevent weld current from passing through the
clamp linkage bushings/bearings.
Specify the correct cylinder port position for installing fittings and hoses when ordering clamps.
Select the port position for fittings based upon clearance condition, adjacent units, and maintenance
accessibility. Power clamp suppliers shall approve design clearances and access to the clamp.
IMPORTANT: Power clamps must be described individually for ordering on the Bill of Material
(BOM). The clamps must be identified for L.H. and R.H. usage on the BOM.
GM approved power clamps do not have internal flow controls that limit air flow. Therefore,
all power clamps shall be ordered with external flow controls. All approved power clamps
have an internal fixed hard stop to set the position of the clamp arm in the clamped
position. Clamp position is verified by means of an internal switch cartridge. The specific
switch manufacturer, (Allen Bradley, Pepper & Fuchs, Turck, etc..,), is identified at the end
of the clamp order string. The Switch Application guideline defines when a switch is
required.
6.18.3.2 Applications
0
Clamp Arm Openings greater 90 - Part clamping requiring a clamp arm rotation greater
than 90 degrees between the open and closed position should select the power clamp for
this application. The typical clevis style clamp is limited to a 90-degree opening unless
additional linkages are part of the design. The additional linkages will drive cost and
complexity into the tool where a single power clamp can be utilized. Power clamps come
standard with up to with a standard 135-degree opening maximum. Arm style and
mounting position may restrict maximum opening.
Greater Clamp Force Some part clamping applications require greater clamping force.
Applications that should be considered as requiring greater clamp force includes thicker
stamped parts (single parts that are greater than 2.5mm thick), large metal stack-ups,
(greater than 4.0mm) and applications that involve high strength steel parts. Commercial
power clamps can generate more clamp force and offer more design clearance when
compared to an equivalent bore clevis clamp depending on the distances from the pivot.
For example, the typical 63.0mm bore equivalent commercial power clamp generates
approximately the same force as an 80mm bore clevis clamp with the cylinder 80mm from
the pivot.
Slip Plane / Two Surface Contact Clamping on a show surface or on two unique
surfaces with an open clevis clamp drives an external hard stop to stop the clamp swing at
the work position. Power clamps have internal fixed hard stops that position the clamp
arm in the closed position and may be the better solution in this application. External hard
stops in conjunction with commercial power clamps shall not be used at any time. Internal
switches read this position. External hard stops will not improve the arm position and not
allow the internal switch to read the closed position.
If using a blank arm for modification, the arm must be machined while attached to the clamp to maintain
the dimensional relationship of these two components.
Pin clamps and hook clamps are generally used in Underbody clamping applications. In this application
the pin clamp or hook clamp eliminate the need for an excessively long clevis style or power clamp arm.
These clamps also have a greater clamping force compared to the same size power clamp.
Pin clamps and hook clamps can be used in robotic transfer applications. However, the application should
be reviewed to determine if the unit might require a locking mechanism in case of loss of power. If
required, a locking mechanism may be a special item with some manufacturers. Clamps with a locking
mechanism may be considered special by some manufacturers and may have a longer lead-time.
Contact manufactures to obtain the latest pin sizes available.
The CC-101 specification has criteria required for pneumatic pin clamps and hook clamps. The ECC-101
specification has criteria required for electric pin clamps and hook clamps. Contact the GM Manufacturing
Engineer for copies of these manuals.
The General Motors CC-101 and ECC-101 outlines provisions for features, performance, reliability, and
maintainability.
Within the CC-101 and ECC-101 specifications, are the mechanical and the operational requirements and
guidelines to follow for locator block sizes and their relationship to pin sizes. In addition, there are X, Y,
Z dimensions to follow when designing in these units. The X, Y, Z dimensions are shown in the
NAAMS catalog as well as in the CC-101 and ECC-101 specifications. These dimensions were
established by the Auto Steel Partnership to allow any suppliers unit to be used without having to redesign
in order to fit another unit in. The supplier is to furnish a unit and the necessary brackets to arrive at the
X, Y, Z dimensions.
The CC-101 and ECC-101 specification includes dimensions to follow to design pin clamps or hook
clamps mounted on C Flex Units. The supplier is to furnish a unit and the necessary brackets to arrive at
the X, Y, Z dimensions.
The CC-101 and ECC-101 specification shows clearance paths (outlines) to follow when designing. The
clearance paths allow for interchangeability of suppliers units as well as replacing cartridge switches.
Pin clamps and hook clamps shall have the ability to clamp around the hole on flat panels as well as
panels with upturned flanges.
The examples below show the various types of applications and their relationship to the clamping units.
Alternatives based upon certain manufactures units.
Pin Clamp on up-turned flange Pin Clamp on flat area next to an up-turned flange
Use the same size locator block (back-up) for hook clamps as would be used if a pin were going to be
locating the panel. Example: If the hook clamp is going to be clamping through a 25mm hole, use a
locator block with a diameter of 55mm.
The X, Y, Z dimensions are to a standard NAAMS riser bracket hole pattern. The manufacturer
shall provide any necessary bracket(s) mounted to their unit to provide for a common mounting pattern.
95.00 mm 35.00 mm
"X" "Y"
70.00 mm TOP OF PART
REST BLOCK
35.00 mm
140.00 mm
35.00 mm
"Z"
11.0 DIA.
ACCESS AREA FOR: (4) HOLES *
- ELECTRICAL CONNECTORS 170.00 mm
- MANUAL PUSH BUTTONS 150.00 mm
* "NAAMS" RISER
- VISUAL FOR LED LIGHTS
BRACKET HOLES
- MANUAL RELEASE
All Blades shall have tapped holes for mounting to the riser. The hole pattern must match the NAAMS
pattern to accommodate by NAAMS risers or unique design weldments. The riser shall have clearance
holes that allow the hex head fasteners to secure the blade to the riser.
NAAMS LOCATOR
BLOCK
NAAMS STD
FITTING SPACER
For single surface angular clamping, the centerline of the clamp pivot should be positioned on a plane
that is created by the surface being clamped (as shown by the blue line). The maximum deviation from
the standard is 15 off normal to the pivot location (as shown by the green lines).
The clamp size and blade thickness from the chart below applies to this application
It is not required to finish cold/hot rolled steel for rough locator mounting.
Use NAAMS standard rough locators when possible.
If possible, do not place rough locators in positions that force the operator to lift and load, or
unload the part over the rough locators.
Rough locators must be designed with slots for ease of adjustment.
Rough locators should have minimal part contact so that the operator can load the part to work
location with ease. Excessive part contact may cause difficult part loading and unloading.
Rough locators must never touch the part when it is nested or controlled by the primary tool
locators.
If the rough locator requires a unique design, use the design parameters for the standard
NAAMS rough locator as a guide.
1 2
Commercial dumps and slides are available which state the maximum load that each unit can move. The
calculation below only pertains to cylinders used in make dumps or slides. Refer to manufacturers
specifications for size, payload, range, etc. When designing a make dump or slide, refer to the drawing
below for nomenclature used for the calculations below.
The calculations and examples shown on the following pages are used to determine cylinder size and
force required to move a mass M about a pivot point.
This picture is shown below solely for the purpose of demonstration of values.
5.5 bar (80 psi) line pressure used for this example. Consult the GM Manufacturing Engineer for
actual requirements.
A lever arm to work arm (A/B) ratio of 2:1 is the most desirable ratio. (A/B) ratios between 1:1 and
1:2 are acceptable. However, (A/B) ratios above 1:2 must be discussed with the GM Manufacturing
Engineer.
When sizing a cylinder, if the force required falls between two cylinder bore sizes, round to the next
bore size after calculating cylinder force required.
To determine the value of C, divide the stroke of the cylinder about a line from the centerline of
pivot unit, perpendicular to the mid stroke of the centerline of the cylinder to achieve one leg of
angle C.
6.25.3 Calculating Adjusted Mass (M1)
When moving a mass (M) using a lever, the force needed to move mass (M) is determined by the
ratio A/B and will be referred to as adjusted mass (M1).
1. Ratio (R) = lever arm (A) divided by work arm (B) = A/B
2. Mass (M) = total weight of rotating assembly + 25%. The 25% is the safety factor used in
this example.
3. Adjusted mass (M1) = M/R
Match adjusted mass (M1) to cylinder force using line pressure of 5.5 bar (80 psi) to determine
cylinder bore size used in calculating adjusted cylinder force (F1). If M1 falls between two bore
sizes, use the larger of the bore sizes.
6.26 Air Cylinders
6.26.1 General Information
The following information pertains to general air cylinder usage on all tools. Use of air cylinders that
are an integral part of welding guns, commercial clamps, or special equipment will have their own
criteria.
Use only approved air cylinders, flow controls, and proximity switches.
All cylinders will have bore, stroke, and stroke-to-go (including zero) noted on the layout
drawing at the cylinder outline.
Show outline of flow controls and proximity switches when used. In phantom, show
clearance area required to remove flow controls, switches, and hoses for maintenance.
Show centerlines only for air hoses and electrical wiring for clearance and accessibility
considerations in congested areas.
Illustrate any movement of pivoting cylinders to determine clearance conditions.
For any rodless cylinder application, the GM Manufacturing Engineer shall work with the supplier to
complete the Commercial Component Application Buy-off Form (download from BIW Forms
Library).
The use of this type of cylinder requires prior approval from the GM Manufacturing Engineer.
Cylinders that contain built-in guide rails on both sides of the sealing slot shall not be used.
REASON: Cylinder expansion under pressure may cause binding.
Mount cylinder with the carriage mounting bracket facing down to minimize contamination
entering the cylinder.
When using single cylinders, anti-rotation features are required in tool design.
Intermediate Trunnion:
The Intermediate Trunnion mount is more expensive than a rear clevis mount. The intermediate
trunnion provides space savings in length over clevis assembly but the mount is wider.
When an intermediate trunnion mount is not suitable, a cap or head mount trunnion for pivoting and
straight-line cylinders is an option.
1. The cylinder movement at the cap end must be checked for up/down clearance conditions.
2. Cylinder movement is created by the rod clevis moving through the travel arc (Point A to
Point B), rotating on a Pivot Point C.
3. Cylinder trunnion C/L Pivot Point D should be on a line through Points A and B if the
design permits.
4. Clevis centerline and trunnion centerline must be parallel.
6.27 Couplers
6.27.1 Cylinder Rod End Couplers
For any cylinder rod end couplers application, the GM Manufacturing Engineer shall work with the
supplier to complete the Commercial Component Application Buy-off Form (download from BIW
Forms Library).
Base mounted cylinders will use self-aligning rod end couplers to provide for possible cylinder
misalignment.
Self-aligning coupling threads, which attach to the receiving detail, (not the cylinder side), must be
verified by the design activity, to ensure proper thread attributes exist on all receiving details.
If positive stops are used, the proximity switch operating range must be considered at the end of the
stroke.
For any hydraulic cylinder application, the GM Manufacturing Engineer shall work with the supplier to
complete the Commercial Component Application Buy-off Form (download from BIW Forms Library).
Do not use cylindicator proximity switches internally on hydraulic cylinders. All switches for motion control
of the hydraulic cylinder shall be external adjustable proximity switches.
The switches shall read the position of the object being moved, not the position of the cylinder rod. Do not
use mechanical limit switches without approval from the GM Manufacturing Engineer.
Hydraulic forces shall be calculated at 500 PSI unless otherwise informed. With hydraulic cylinders,
consider use of shock absorbers because of high cylinder forces and heavy loads being moved.
All hydraulic cylinders will provide for a 3.0mm adjustment at the clevis assembly with a positive
adjustable stop. The return stroke will bottom out at the cylinder end.
Use ISO 1179-1 threads for all hydraulic system threaded joints.
Approved weld guns are internally insulated; therefore, tooling used in conjunction with approved
weld guns does not require insulation except for the following:
1. Tooling in the loop area of a weld gun. Make every attempt to avoid this situation.
2. C-Flex units used in a welding environment (See GMD1 Section 14 for details).
Nut welding equipment or series welding with a copper back up generally require insulating.
Consult with the GM Manufacturing Engineer to determine correct insulation method.
Commercially available stock of 1/8 thickness is usable within this tolerance range.
Insulated Washers
FSD Number: Screw + .076 + .127
Diameter: I.D.: O.D.:
FSD-41405-51 M6 or 1/4 7 20
FSD-41405-52 M8 or 5/16 8 24
FSD-41405-53 M10 or 3/8 10 29
FSD-41405-54 M12 or 1/2 13 35
Make every attempt to keep loop area free of steel details. If steel details fall within the loop area, they
require insulation or must be made from non-magnetic stainless steel. Both of these methods are costly
and must be avoided.
Loop area calculations do not require the use of precision geometric equations. Use scaled dimensions of
area segments to arrive at a total.
Minimize use of cable adapters because they add resistance to the loop, resulting in loss of weld current.