AMS 7110 Resistance Weld Gun Specification

Resistance Weld Gun Specification
Advance Manufacturing Engineering AMS 7110
Advance Manufacturing Engineering
Revision Date: 09/12/2005 Page 1 of 26 Revision: 02

File Name: AMS 7110 Resistance Weld Gun Specification
PROPRIETARY
TABLE OF CONTENTS PAGE

1.0 GENERAL ................................................................................................................................................. 3
1.1 PURPOSE ........................................................................................................................................... 3
1.2 SCOPE ............................................................................................................................................... 3
1.3 TERMS AND DEFINITONS ..................................................................................................................... 3
2.0 DESIGN AND BUILD REQUIREMENTS .................................................................................................. 3
2.1 GENERAL ........................................................................................................................................... 3
2.2 MODULAR AND DIMENSIONAL REQUIREMENTS ..................................................................................... 5
2.3 CONSTRUCTION REQUIREMENTS ......................................................................................................... 6
2.4 WELD GUN ACTUATORS..................................................................................................................... 8
2.5 WELD GUN EQUALIZER ...................................................................................................................... 9
2.6 ELECTRODE CAPS, CAP ADAPTORS AND SHANKS .............................................................................. 10
2.7 LAMINATED LEAF SHUNTS ................................................................................................................. 10
2.8 TRANSFORMERS ............................................................................................................................... 10
3.0 DESIGN PROCESS AND BUYOFF REQUIREMENTS ......................................................................... 11
3.1 DESIGN PROCESS ............................................................................................................................ 11
3.2 BUY-OFF PROCEDURE ...................................................................................................................... 12
4.0 WELD GUN DESIGN DOCUMENTATION ............................................................................................. 12
4.1 DESIGN PROPOSAL PACKAGE ........................................................................................................... 12
4.2 DRAWING FORMAT ........................................................................................................................... 13
4.3 CAD DELIVERY ................................................................................................................................ 15
5.0 WELD GUN INTEGRATION REQUIREMENTS ..................................................................................... 16
5.1 GENERAL ........................................................................................................................................ 16
5.2 SERVO WELD GUNS .......................................................................................................................... 16
6.0 VALIDATION,RELIABILITY AND MAINTENANCE REQUIREMENTS................................................. 17
6.1 VALIDATION REQUIREMENTS ............................................................................................................ 17
6.2 RELIABILITY AND WARRANTY ............................................................................................................. 18
6.3 MAINTENANCE AND SPARE PARTS ..................................................................................................... 18
6.4 TRAINING ......................................................................................................................................... 19
6.5 SUPPLIER SERVICE........................................................................................................................... 19
6.6 SERVICE MANUAL ............................................................................................................................. 19
7.0 SHIPPING................................................................................................................................................ 19
8.0 REFERENCE DOCUMENTS .................................................................................................................. 20
9.0 GLOSSARY............................................................................................................................................. 21
10.0 PUBLICATION, CONTACT LIST AND REVISION HISTORY ............................................................... 22
APPENDIX ........................................................................................................................................................ 23
A. AME WELD GUN COORIDNATION PROCEDURES .................................................................................... 23
B. CHRYSLER GROUP WELD GUN DESIGN REVIEW FORM .......................................................................... 25
C CHRYSLER GROUP WELD GUN BUILD BUY-OFF FORM ........................................................................... 26

PROPRIETARY
1.0 GENERAL
1.1 PURPOSE
This specification provides the Chrysler Group standard requirements for all resistance weld guns. In
conjunction with the current Quality Management System requirements, this specification is intended to
promote safety, quality, delivery, low cost and standardization of weld guns.
1.2 SCOPE
• This specification covers weld gun build and performance requirements for supplier designed weld
guns, while the Do’s and Don’ts, Section 6, covers Chrysler Group standard weld gun design and
integration requirements. In case of conflict between this specification and the “Do’s and Don’ts”, this
specification shall govern.
• This specification applies to all new, retooled and rebuilt equipment, which contain resistance weld
guns. It applies to all parties involved with selection, design, construction and testing of resistance
weld guns including weld gun suppliers, process, design sources and build sources.
• DaimlerChrysler encourages innovation, so it is not the intention of this specification to limit or inhibit
the development of any improvement or new technology.
1.3 TERMS AND DEFINITIONS
• May – defines a requirement that is condition dependent.
• Shall/Must – Mandatory requirements of this specification.
• Should – defines a recommendation.
• See 9.0 Glossary for additional definitions.
1.4 DEVIATIONS/REVISIONS
1.4.1 Request of deviations to the requirements of this specification shall be submitted to DCX/CG AME
Weld Gun Group and approved by the DCX/CG AME Core Group.
1.4.2 Revisions to this specification shall be forwarded to the AME Weld Gun Group for consideration.
2.0 DESIGN AND BUILD REQUIREMENTS
2.1 GENERAL
2.1.1 Non-Productive Material
All equipment covered by this specification shall meet the requirements of AMS 0021 General
Requirements for Non Productive Material.
2.1.2 DCX Weld Gun Process
Weld Gun Source(s) and Process Integrator(s) must follow AME Weld Gun Group Coordination
Procedures (Appendix A). The activities of weld gun model/concept review, design review and
build buyoff must be completed based on the program timeline to fully support weld gun
deliveries.
2.1.3 Weld Gun Library for Process Design
The selected weld gun supplier must have a DCX approved weld gun library as described in
Section 2.2 in order to limit the number of new weld gun designs. The library must consist of an
assembly drawing and a solid model per design. The approved library shall be uploaded to a DCX
Weld Gun Group designated database by the weld gun supplier prior to program start.
2.1.4 Weld Force Requirements and Cap Sizes
Prior to the selection and/or design of weld guns, the equipment integrator and weld gun suppliers
shall obtain the current DaimlerChrysler Process Standard PS-10947 to determine weld force
requirements and cap sizes.
2.1.5 Tooling and Product Constraints
The weld gun design and performance must be considered prior to tooling and product design.

PROPRIETARY
2.1.6 Weld Gun Strength Requirements
2.1.6.1 Pneumatic Weld Guns
Plant Maximum Air Pressure PSI Size to PSI Stress to PSI
100 80 100
110 90 110
Pneumatic weld guns shall be sized per plant requirements. Weld guns shall not be
designed to operate under 30 psi.
2.1.6.2 Servomotor Weld Gun
The weld gun shall be designed to run 25% above the upper weld schedule, which is the
minimum force requirement. In case of product or tooling constrains, a deviation must be
approved by DCX Process Group.
2.1.7 Weld Gun Cap Displacement
The Stationary cap displacement shall not exceed 4.6 mm (0.18 in) at maximum rated weld gun force
(Fig. 1). The servo stroke times the transmission ratio minus the stationary cap movement shall not
exceed 4.6mm. The measuring method of the deflection shall be approved by AME weld gun group
prior to the program starting.
2.1.8 Electrode Alignment and Weld Gun Skidding
Electrodes or caps shall be concentric within a diametral tolerance of 1.0mm (0.04in)
without tip force. Skidding of weld caps shall be concentric within a diametral tolerance
of 1.6mm (0.06in) at maximum rated weld gun force (Fig. 2).
2.1.9 Non- Rotating ‘C’ Gun Requirements

“C” type weld guns shall be designed with non-rotating moveable arm.
2.1.10 Symmetrical Design
Weld gun design should be symmetrical. Right hand and left hand design should be avoided.
2.1.11 Weld Gun Mounting Application
Weld gun frame shall be designed and incorporate three (3) common mounting positions.
2.1.12 Robot Adaptor Plate and Pedestal Weld Gun Mounting Plate
Mounting hardware shall be designed and provided by the tooling integrator.
2.1.13 Castings
Copper casting construction shall meet RWMA Class 2 or 3 copper specifications. Cast aluminum
shall not be used for weld gun arms.
2.1.14 Electrical Contact Surfaces
All machined electrical contact surfaces shall have a maximum roughness of 0.80 μm (32 μin).
2.1.15 Aluminum to Copper Surface Coating Requirement
Aluminum alloy components that contact a copper surface must be silver or nickel-plated or
equivalent.
PROPRIETARY
2.2 MODULAR AND DIMENSIONAL REQUIREMENTS
2.2.1 Modular Weld Gun and Modularity
Weld guns shall be modular with as many common parts as possible to reduce the number of
components and spares. A family of modular designs shall exist with pre-defined graduated
dimensions prior to process design start. The pre-defined family of weld guns shall be
documented in a DCX weld gun library.
2.2.2 Weld Gun Commonality
Design and build cost of weld gun and component shall follow the blanket ordering system. The
amount of design hours shall be determined based on the categories of blanket ordering set-up
during Weld Gun Model and/or Design Review. Any unique weld gun design shall be a spot buy.
MEDDS specifications and details shall be completed by AME weld gun group.
2.2.3 Weld Gun Dimensions (Fig. 3 & 4)
“Lettered” dimensions of weld guns shall be reviewed by AME Weld Gun Design Group prior to
program starts. The increments should be in multiples of 10mm and should be determined based
on the characteristic of the designs of the selected weld gun supplier.
2.3 CONSTRUCTION REQUIREMENTS

2.3.1 Weld Gun Labeling
2.3.1.1 Weld Gun Body Labeling (Fig. 5)
A lamocoid tag shall be attached to the weld gun in a visible location. Lamocoid tag
fasteners shall not interfere with weld gun performance. An additional lamocoid tag shall
PROPRIETARY
be shipped to the plant or equipment integrator along with the weld gun. Lamocoid tags
shall be white in color approximately 110mm/4.25in wide by 60mm/2.25in tall, with
black letters 5mm/0.18in high, containing the following information.
• DaimlerChrysler Weld Gun Assembly Number
• Total Weight of Weld Gun (lbs/kg)
• Maximum Rated Force (lbs/kg) @ xx psi for pneumatic weld guns
• Maximum Rated Force (lbs/kg) for servomotor weld guns
• Stationary Cap Displacement (in/mm) at maximum rated force (Fig 1.)
• Maximum Tip Opening (in/mm)
W/GUN NPM XX-XXX-XXXX
WEIGHT XXX lbs / XX kg
MAX RATED FORCE XXXlbs/XX Kg
STA. CAP DISPLACEMENT XXX in/XX mm
MAX TIP OPENING XXX in / XX mm

Fig. 5– Lamocoid Tag
2.3.1.2 Weld Gun Component Labeling
All weld gun components, including cap adaptors, weld and equalizer cylinders,
servomotor, actuator and transformers etc., shall be stamped or permanently labeled with
their assigned NPM code number. The NPM Code number shall be legible when the
weld gun is assembled.
2.3.1.3 Air Cylinder Labeling
Oil resistant labels shall be on both weld and equalizer cylinders. Labels shall contain the
following information:
• Manufacturing Company Name and Address
• Service Telephone Number
• Supplier Cylinder Number
• Serial Number
2.3.1.4 Air Cylinder Port Identification
The cylinder ports shall be clearly stamped on the housing showing the function of each
port.
Port Call out Stamped on Housing
Weld Stroke Forward WF
Weld Stroke Return WR
Retract Forward RF
Retract Returned RR
Vent/Exhaust V
Boost B
2.3.1.5 Servo Motor Labeling
Oil resistant labels shall be mounted on the servomotor.
• Manufacturer’s name.

PROPRIETARY
• Manufacturer’s model.
• Maximum voltage rating.
• Maximum current rating.
• Maximum peak stall force rating.
• Maximum speed rating.
• Maximum stroke.
• Manufacturer date code.
2.3.1.6 Transformers Labeling
It is the responsibility of weld gun supplier to attach the additional label onto the
transformer at a visible location after the weld gun is assembled, if the original label is
covered by brackets.
2.3.2 Weld Gun Cooling
Weld gun shall be designed and manufactured to operate at the specified weld current and duty
cycle without overheating. The temperature of weld gun surface excluding weld electrodes and
shanks shall not exceed 54°C (130°F) under normal plant cooling conditions.
2.3.2.1 Robot Transguns, Portable, Manual and Remote Weld Guns
Three cooling circuits shall be considered as standard method. Weld gun transformer and
each arm shall be cooled separately.
2.3.2.2 Machine Weld Guns
A minimum of two cooling circuits is acceptable.
2.3.2.3 Water Flow Rate Requirements
All weld guns shall be tested to meet the following minimum water flow rates. The
testing shall be at a maximum water pressure differential (supply-to-return) of 30psi,
circulating all cooling loops simultaneously. This test will be conducted prior to build
buyoff.
• 1.0 GPM for AC transformers
• 2.0 GPM for 100 and 150 KVA MFDC transformers. Reference the manufacturer’s
recommendation and request for any other MFDC transformers that are utilized per
process requirement.
• 1.5 GPM for each weld electrode of portable, robot and pedestal guns
• 1.0 GPM for each weld electrode of machine and fixture guns.
• Approval per Section 1.4 of this specification shall be required for any weld gun
which has lower water flow rate due to the special conditions, such as tight section,
non standard caps, double and triple bend shanks, etc.
2.3.3 Water & Air Fittings
2.3.3.1 Fitting design Requirements
All water and air fittings threads are to be National Pipe Thread (NPT).
All efforts should be made to reduce the number of fitting connections to eliminate
potential leaks. No soldered water fittings to weld gun components.
2.3.3.2 Fitting Size
Material on air and water fittings shall be brass and size shall be no larger than 3/4" for
standard package.
2.3.4 Weld Gun Dense Packages
Unless directed otherwise by AME, air manifolds, air valves, water manifolds and all controls for
operation of the weld gun shall be mounted on the gun. The manifold blocks shall be designed to
prevent air and water misapplication for plant maintenance personnel. Installation of all air, water
and control devices is to be performed by weld gun supplier prior to shipment to OEM/Plant.

PROPRIETARY
2.3.5 Teflon Thread Sealant
Non-hardening Teflon gels shall be used for thread sealant.
2.3.6 Component Color Codes
2.3.6.1 Air and Water Hosing
Reference: AME Tool Design Do’s & Don’ts Section 5 (Piping)
2.3.6.2 Weld Gun Hanger
Weld gun hanger shall be painted orange. Contact Chrysler Group Safety personnel for
detailed information.
2.3.7 Fasteners
2.3.7.1 Accessibility
Fasteners shall be easily accessible for maintenance, particularly in the shunt, cylinder
and servomotor areas.
2.3.7.2 Fasteners
All fasteners, with the exception of the shunt/kickless cable fasteners, shall conform to
the NAAMS metric fastener standards (Section F of the NAAMS Global Standards
Components – Assembly). Additional locking mechanism, for example, lock washer and
other type of locking elements, might be requested base on the components and work
conditions. Weld Gun Supplier shall review with AME Weld Gun Group for all fasteners
prior to program starting.
2.3.7.3 Non-Magnetic Fastener
Shunt fasteners, which are inside the secondary field, shall be non-magnetic stainless
steel. Proper torque must be applied during weld gun assembly for stainless steel bolts
and nuts.
2.3.7.4 Supertanium Bolts
All kickless and dry shunt cables shall be bolted to transformer lug adapters with the
“Supertanium Kickless Cable Bolt Assembly” with proper torque value.
2.3.7.5 Heli-coil inserts
Non-ferrous material components, with the exception of T7075-T6 aluminum alloy or
higher grade material, shall require heli-coil inserts for threaded fasteners for locking and
strength purpose.
2.4 WELD GUN ACTUATORS
2.4.1 Actuator Interchangeability
The weld gun shall be designed to allow interchangeability between the pneumatic cylinder and a
servo motor drive unit. The mounting footprint and envelope size of the servomotor actuator shall
be similar to the comparable stock pneumatic cylinder for interchangeability.
2.4.2 Force Repeatability
The weld force shall be achieved and maintained within +/-5 % for pneumatic and servomotor
weld guns.
2.4.3 Pneumatic Weld Cylinder Requirements
2.4.3.1 Type of Weld Cylinders
When a program requires limited amount of pneumatic weld guns, due to equipment
reutilization, a 4-port cylinder shall be the first choice. 5-port cylinders shall require a
deviation from AME process group and shall require a pressure restriction device
installed by weld gun supplier. Weld cylinders shall be lubed for life. The type and
design of cylinders must be approved by AME Weld Gun Group, Process and Plant
representatives prior to the program starts.
2.4.3.2 Weld Cylinder Design Requirements
All cylinder rebuild kits shall be common for same style and bore size cylinders for the
program or user plant. It’s required to use the same rod diameter for piston rods per
PROPRIETARY
program or user plant. Cylinder strokes shall provide a minimum of 0.75 inches of travel
to compensate for tip wear.
The time required for the movable component to move the first 25 mm shall require no
more than 0.18 seconds (11cycles). The time required for each 25 mm segment of
distance shall require no more than 0.12 seconds (7 cycles). This rule shall apply to both
forward and return strokes.
2.4.4 Electrical Servo Actuator Assemblies and Servo Motors

2.4.4.1 Motors shall operate at 460VAC and minimum 6-pole.
2.4.4.2 Type and manufacturer shall be approved by DCX.
2.4.4.3 Servo motors and electrical servo actuators assemblies shall be design to be cooled by
ambient air; water cooling is prohibited.
2.4.4.4 Motors shall be equipped with a thermal sensing device, interfaced to the controller, for
monitoring motor over-temperature. A fault shall be issued if maximum motor
temperature is exceeded.
2.4.4.5 In-line electrical servo actuator assemblies shall be used.
2.4.4.6 All external metal components shall have a non-corrosive protective finish.
2.4.4.7 Servo motor and servo actuator assemblies shall be capable of providing rated peak stall
force for no less than 5 seconds at 3 times per minute at the rated temperature.
2.4.4.8 A minimum number of servo actuator assemblies shall be available to cover a weld gun
tip force range from 300 lbs to 1900 lbs.
2.4.4.9 The actuator assembly shall have a manual override capability so the actuator and
connected gun component may be moved without power to the motor.
2.4.4.10 Servo actuator assemblies shall operate in any orientation without modification or
adjustment.
2.4.4.11 Servo actuator assemblies shall be engineered to provide lateral stability or rigidity
against side loading required for resistance welding. The actuator system shall allow for
accurate, mechanical tip alignment.
2.4.4.12 Servo actuator assemblies shall be repairable.
2.4.4.13 Servo actuator assemblies shall be constructed such that damage will not occur if the
actuator is driven against a stop at full torque.
2.4.4.14 The driving mechanism of the actuator assembly shall be protected from contamination.
2.5 WELD GUN EQUALIZER

2.5.1 Weld Gun Equalizer
2.5.1.1 Weld Gun Equalization Methods for Servo Weld Guns
Robot compensation software for tip wear and gun deflection shall be considered prior
to utilizing the mechanical equalizer for weld applications. Dual pedestal weld guns shall
require a mechanical EQ Package. The robot manufacturer shall develop this software
package and have approval by the DCX robot specialist and Weld Gun Group prior to
program starts.
2.5.1.2 Equalizer Package
Pneumatic weld guns shall include an equalizer package (air equalizer or air with spring
assist) as a standard feature. The equalizer is an optional package for servo motor weld
guns. Servo motor weld guns shall be designed with the capability to add an optional
equalizer package in the field. The equalizer control devices shall be designed to be
mounted on weld gun when an equalizer is utilized or needed based on program
requirement or individual application. The EQ package must be approved prior to the
program starts.

PROPRIETARY
2.5.1.3 Equalizer Air Cylinder
All equalizer air cylinders shall be sized and operated above 30 psi, and capable of
running with unregulated air to 110 psi. All equalizer air cylinders shall be lubed for life.
2.6 ELECTRODE CAPS AND CAP ADAPTORS
2.6.1 Female Caps
Chrysler Group standard female electrode caps shall be used, reference DaimlerChrysler Process
Standard PS-10947 for the detail information.
2.6.2 Male Caps
Chrysler Group standard male electrode caps shall only be used when the tip angle is greater than
15 degrees.
2.6.3 Straight Shanks and Hex Adaptors
Hex adaptors shall be used wherever possible. Conductive lubricant shall be used on threads
during weld gun assembly.
2.6.4 Combo Holder Clamp
All combo holders are required to be held in place by a clamp and screw arrangement, which
prevents the combo holder (shank) from pulling out or/and rotating. The design shall be approved
by AME Weld Gun Group during design review.
2.7 LAMINATED LEAF SHUNTS

2.7.1 Insulation
Leaf shunts shall be insulated or covered by resistance yarns both inner and outer.
2.7.2 Sizing
Leaf shunts shall be sized correctly for thermal loading (actual ECTC) and located at the optimum
position so that no evidence of physical damage occurs when the weld gun closes or opens.
2.7.3 Installation and Removal
Leaf shunts shall be designed for ease of installation and removal, without affecting the
mechanical and electrical function.
2.7.4 Shunt Adaptor
Solid shunt adaptors shall be used (soldered shunt adaptors are not allowed).
2.8 TRANSFORMERS
2.8.1 Approved Source
Transformers shall be supplied by an approved Chrysler Group source.
2.8.2 RWMA Standards
Transformers shall comply with all the applicable RWMA standards.
2.8.3 Rating
All transformers (AC and DC) shall be rated at 50% duty cycle based on a one-minute integrating
period at the rated primary voltage, rated water flow and temperature as manufacturer
recommended.
2.8.4 Selection and Sizing
AME Process Group shall direct all parties for the type of transformer, AC or DC per program.
It’s the process integrator’s responsibility to size the weld gun transformers. The transformer
sizing program/formula shall be approved by AME Weld Gun Group prior to program starts.
Weld Gun supplier shall provide the information of weld gun dimensions and material
characteristic to process integrator.
Process integrator shall provide transformer size, weld schedules and other welding data to weld
gun supplier through the weld data sheet. A copy shall be delivered to AME Weld Gun Group
during weld gun model (concept) review.

PROPRIETARY
2.8.4.1 Standard AC Transformers
When applicable, the following AC transformers shall be used.
DCX/NPM Code KVA PRI V/ FREQ V/SEC Turns Ratio

91-901-1213 65 480/60 6.3 76:1
91-901-1214 93 480/60 10.9 88:2
91-901-1215 136 480/60 16.0 60:2
Table 1 - Standard AC Transformers
2.8.4.2 150 KVA Transformer
When 2.7.4.1 can not satisfy the KVA requirement for machine weld guns, DCX
standard 150KVA shall be used.
DCX/NPM Code KVA PRI V/ FREQ V/SEC
41-704-0222 150 480/60 Min 9.23, Max 15.00
Table 2 - 150 KVA Transformer
2.8.4.3 Standard DC Transformers
When applicable, the following DC transformers shall be used.
DCX/NPM Code KVA PRI V/ FREQ V/SEC Turns Ratio
91-680-0515 100 650/1000 9.0 72:1
91-901-1217 150 650/1000 13.0 50:1
Table 3 - Standard DC Transformers
2.8.4.4 Standard transformers for Remote Weld Guns
Remote (hip mount) weld guns shall use the following transformers.
DCX/NPM Code KVA PRI V/ FREQ
91-901-1218 200 480v/60Hz
91-901-1219 265 480v/60Hz
Table 4 - Standard Transformers for Remote Weld Guns
2.8.5 Weld Gun Secondary Grounding
Secondary grounding strap shall be supplied with the transformer (AC and DC) by the welding
transformer manufacturer(s). Utilizing secondary grounding strap to ground weld gun shall be the
standard method except specified by DCX process group. It’s the responsibility of process
integrator to remove the grounding strap in case a grounding reactor is required.
All robotic and pedestal welding applications shall have the secondary circuit of the welding
transformer connected directly to ground. This connection shall not be through the robot structure
or other machine elements
All manual welding applications shall utilize grounding reactors on the secondary of welding
transformers.
2.8.6 AME/ASME Process Group shall be responsible for determining whether a hard wire or quick
disconnect (Metric or English) is used for primary connection. All transgun drawings shall show the
primary connector. It’s the responsibility of process integrator(s) to use proper size of cable(s).
2.8.7 Transformers Labeling
Oil resistant labels shall be on the transformer and shall contain the following information:
• Manufacturing Company Name and Address
PROPRIETARY
• Service Telephone Number
• Serial Number
• KVA rating at 50% duty cycle
• Primary voltage and frequency
• Transformer turn ratio
• Water Flow Rate
An additional label shall be shipped to the weld gun supplier by the transformer manufacturing
company for attachment at gun construction.
3.0 DESIGN PROCESS AND BUYOFF REQUIREMENTS
3.1 DESIGN PROCESS

Reference Appendix B for the DCX Weld Gun Group Design Review Form.
3.1.1 Weld Gun Concept Review
The design of the weld gun shall be considered prior to the design of the tooling. AME Weld Gun
Design coordinator shall participate in the weld gun concept review along with DCX BIW Process
Engineer, Plant representatives, OEM and the weld gun supplier. The OEM is responsible to hold
this activity at its location and with regular meeting schedules to ensure all weld gun concepts are
completed and approved to meet program timeline.
3.1.1.1 Weld Gun Selection
Weld gun selection shall proceed as following guideline:
• Weld gun design in the predefined process library;
• Weld gun design with standard chassis from previous programs, but not the one in
the predefined process library;
• Modification of cap adaptor(s), arm(s) from existing gun design with a standard
chassis;
• A unique design from previous programs;
• A new unique design.
3.1.2 Design Review
The AME Weld Gun Group shall evaluate all new weld gun designs to ensure that they will meet
the requirements of this specification, prior to release for build. The build supplier or weld gun
manufacturer shall contact an AME Weld Gun Group Design Coordinator to arrange this review
in a written notice (e.g. e-mail, fax etc.) at least two (2) business days in advance. Design reviews
shall be completed within 3 weeks after the concept approval.
3.2 BUY-OFF PROCEDURE

3.2.1 Testing and Documentation
All weld guns shall complete a testing procedure before shipping from the weld gun supplier.
Documentation shall be provided by the weld gun supplier to prove that the weld gun meets all
requirements of this specification. The AME Weld Gun Build Buy-Off form shall be completed
for each weld gun (Appendix C). The original form shall be given to the AME Weld Gun Group
representative. A copy shall be retained by the weld gun supplier for the duration of the warranty
period.
3.2.2 Build Buy-off
All weld guns shall be checked by a member of the AME Weld Gun Group before the gun is
shipped to the OEM or DCX plant. The weld gun manufacturer shall contact the AME Weld Gun
Group Design Coordinator to arrange the build buy-off by a written notice (eg. e-mail, fax etc.) at
least two business days prior to the event.

PROPRIETARY
3.2.3 Requirements at System Build Supplier
It is the responsibility of the AME Process and OEM to assure that the build buyoff procedure is
followed. Any modifications on weld gun or components made during equipment integration
requires notification of the AME Weld Gun Group and AME Process Engineering Group
immediately. Major modifications may require another buy-off.
4.0 WELD GUN DESIGN DOCUMENTATION
4.1 DESIGN PROPOSAL PACKAGE
4.1.1 Design Approval Guidelines
A. Weld gun design approval shall adhere to the following guidelines. Weld Gun supplier shall
submit a design proposal package for approval to the AME Weld Gun Group. The design
proposal package shall include the layout drawing of the weld gun containing the following
information:
• Stress Calculations
• Welding Transformer Location • Lube Location if required
• Composite Part Sections (screen dump) • Type of Lubricant if
• Equalizer or locking device required.
• IN/OUT Water Locations • Weld Schedule(s)
• Center of Gravity • Duty Cycle (spots per job)
• Total Weight • Line Speed (jobs per hour)
• Nugget size
• Total Opening
B. Upon approval of the design proposal the Weld Gun Supplier shall submit two (2) copies
of the preliminary drawing, including all known detail part numbers, to the AME Weld
Gun Group. The Weld Gun Supplier shall indicate "NEW" on the drawing if new detail
components are required.
C. One preliminary drawing shall be returned to the Weld Gun Supplier with Chrysler NPM
code numbers added along with requests for modifications. AME Weld Gun Group
personnel shall assign new weld gun numbers and detail part numbers. The Weld Gun
Supplier shall update and verify the final weld gun drawing.
4.2 DRAWING FORMAT
4.2.1 Drawing Format
The AME Weld Gun Group must approve a new drawing format before the design begins.
4.2.2 Drawing Projection
Current drafting practices pertaining to multi view and sectional view drawings are defined
and illustrated in the current revision of ANSI Y 14.5M. All drawings should be drafted
using third angle projection on orthographic views.
4.2.3 Drawing Scale
For general design work, drawing scales shall be metric full size wherever possible.
4.2.4 Sheet Sizes
Drawings shall be drawn on A, D, E or 11 x 17 size sheet depending on the size of the
component. Excluding tabulations, only one detail shall be drawn per sheet. Chrysler Group
NPM code number shall be displayed in the Tool Number area of the title block. 11 x 17
drawings must be legible for assembly and build purposes.
4.2.5 Lettering
All text height shall be 3mm minimum on all drawings. Notes and descriptions shall be 5mm
minimum. View call-outs, section, and cylinder call-outs shall be 7mm minimum.

PROPRIETARY
4.2.6 Reading Direction
Unless otherwise specified, all dimensions and notes should be placed on the drawing using
the unilateral method, so that they may be viewed from the bottom of the sheet.
4.2.7 Dimensioning and Tolerancing

Dimensioning and tolerancing practices shall be as defined and illustrated in the current
revision of ANSI Specification #Y14.3M. A zero before the decimal point shall be used for a
number less than 1.0
Example 0.5
4.2.7.1 Assembly Drawing Dimensions
Weld gun assembly drawing dimensions shall consist of Jaw Depth, Jaw Throat,
Total Tip Opening, Weld Opening, Movable Height and Stationary Height.
4.2.7.2 Assembly Drawing Notes
Assembly drawing notes shall consist of Maximum Weld Tip Force (i.e. DO NOT
EXCEED 800 lbs. WELD TIP FORCE), KVA Rating and Total Weld Gun Weight.
Note the water flow "IN" or "OUT" at each water port.
4.2.7.3 Detail Drawing Dimensions
Detail drawing dimensions shall be displayed in metric with inches in parentheses.
Example: 10.0 (0.39)
4.2.8 Dimension Arrangement

Dimensions should be shown in true views and should not be taken from hidden lines.
4.2.8.1 Location
Dimensions should be located outside the outline of the detail wherever possible.
4.2.8.2 Screws and Dowels
Screw and dowel sizes shall be written along the centerline, of the fastener in its
profile on assembly drawings
4.2.9 Holes and Slots

All tapped, dowel and clearance holes on details are assumed to be through. It is not
necessary to specify on a drawing that the hole is “THRU”.
4.2.9.1 Depth
When a hole requires that a depth be specified, the depth shall be incorporated into
the hole callout.
4.2.9.2 Construction Hole
Construction holes are assumed to be through or to a cross-hole if applicable.
4.2.9.3 Counterbore Depth
Depths for counterbore holes shall not be specified unless they are non-standard, in
which case “AS SHOWN” should be noted on the drawing.
4.2.9.4 Tapped Hole
All tapped holes should be Unified National Coarse threads.
4.2.9.5 Tabulation
On detail drawings with three or more hole sizes, holes shall be tabulated using the
label shown (Fig. 6).

PROPRIETARY
Fig. 6-Detail Drawing Tabulated Label
4.2.9.6 Call Outs

For slots, call-outs for “CENT.”, “TYP.”, and “RADIUS” or “R” are assumed, and
are not required.
4.2.10 Details of the Weld Gun
If a detail is shown & opposite on a particular weld gun, separate consecutive numbers shall
be allocated with “SHN.” and “OPP.” written alongside the balloon.
4.2.11 Out of Scale
Dimensions out of scale should be avoided, but when a dimension cannot be made to scale
(because of a drawing revision), then the dimension should be underlined.
Example: 5.62 DIA
4.2.12 Revision Level
The information recorded in the change column should be brief and accurate, but complete to
the extent that the drawing could be reverted to its original form.
4.2.12.1 Affected Sheets
A change letter used when recording a change should continue to be used on all of
the affected sheets (assembly, B.O.M., etc.) pertaining to that change.
4.2.12.2 Change Balloon
A change letter (upper case) should be enclosed in a 6mm-diameter balloon.
4.2.12.3 Recorded
All changes should be recorded in the change column on the affected sheet or sheets
after 40% design review.
Change letters should be placed in a vertical row in the change column.
4.2.12.4 Placement
A change letter and balloon should be placed near the revision on the affected sheet.
4.2.13 Controls Documentation
All controls requirements and documentation shall be on shown on WD’s, but not on weld
gun mechanical drawings. Weld gun supplier shall contact AME Control Design
Coordination Group for any additional information.
4.2.14 NPM Code Numbers
New NPM code numbers shall be assigned to all weld guns and their components, by an
AME Weld Gun Group Design Coordinator after the design review is completed. Weld gun
suppliers are responsible to show existing NPM codes on drawings.
PROPRIETARY
4.3 CAD DELIVERY

4.3.1 Hard Copy Print Requirement
A copy of the weld gun assembly shall be shipped to the user plant with the weld gun. The
minimum size shall be 11x17 inches and must meet text size requirements. It’s the
responsibility of the process integrator to ensure the weld gun drawings are shipped to the
DCX plant with the equipment for a new program. New prints shall be furnished to the user
plant if changes occur during launch by the weld gun supplier.
4.3.2 Preliminary weld gun drawing delivery
Ten business days following weld gun approval, weld gun suppliers shall supply an assembly
drawing and model to the AME Weld Gun Group CAD Coordinator. The drawings shall be
in the format of Catia or AutoCAD 2000 or other approved software. The file name must
contain the Chrysler NPM code or in the case of a Chrysler weld gun, the Chrysler number.
File name example: NPM code: 91-814-1712.DWG
or Chrysler Gun #: CHR116-1C-1F.DWG
Twenty business days following weld gun approval, weld gun suppliers shall supply a detail
drawing for each new detail that was created for the assembly. The drawings shall be in the
format of Catia or AutoCAD 2000 or other approved software. The file name must contain
the Chrysler NPM code.
Drawings attached through Email must not exceed 20 megabytes per business day.
4.3.3 Final Weld Gun Drawing Delivery
All new weld gun drawings shall be delivered to the AME Weld Gun Group in CATIA
format no later than 60 days following the official vehicle launch date. The drawings shall
meet the following requirements:
4.3.3.1 CATIA
All new assembly and detail drawings to be supplied in CATIA by the weld gun
supplier. One (1) complete drawing shall reside in one (1) model.
4.3.3.2 Vector Elements
Models may consist of "draw" or "space" vector elements. No scanned data.
4.3.3.3 Translations
Models may be translated from other CAD systems, provided no data is lost or
altered due to the translation process.
4.3.3.4 Storing Models
Model shall be stored with a draw window, displaying the complete drawing.
4.3.3.5 Electronic Data Transfer
All models shall be shipped via electronic data transfer per platform requirement.
4.3.4 Solid Model Weld Guns
Any new weld gun designs, which are solid modeled in CATIA per platform requirement,
shall be delivered to the AME Weld Gun Group no later than 60 days following the official
vehicle launch date. The solid model shall be drawn to the latest revision level of the
assembly drawing with the following requirements.
• Solid model to be supplied by the weld gun supplier.
• Model to show the entire outline of the weld gun as shown on the assembly drawing,
including water fittings. Internal components are not required.
• Show mounting holes on the weld gun frame/cradle.
• The weld point of the weld gun shall be located on the origin (axis1) of the CATIA
model. Align the weld gun to X-direction and Z-direction of axis 1 as follows:
"X" - positive direction towards the fulcrum
"Z" - "normal" to weld spot, with the positive direction toward the movable gun body.
PROPRIETARY
• Show open and retract position of weld tips, gun bodies, and servo actuator/cylinder in
phantom.
• Store model with default isometric window displayed with the weld gun being in the
weld position.
• All models shall be shipped via electronic data transfer.
5.0 WELD GUN INTEGRATION

5.1 GENERAL
AME Weld gun group will make every effort to ensure each weld gun is designed and built according
to the specification contained herein, prior to shipping to process integrator’s location. The integrator
has the responsibility to pipe and wire properly as specified by the approved WD’s from AME Control
Design Coordination Group. If any other weld gun performance or quality issue arises, contact AME
Weld Gun Design Group to coordinate with the weld gun supplier for a resolution.
5.2 SERVO WELD GUNS
Weld gun supplier, Servo Control System and/or Robot Manufacturer and Process Integrator shall
understand their responsibilities to deliver the best results of servo weld guns.
5.2.1 Weld Gun Supplier Responsibilities
Initial set-up shall be completed at weld gun supplier location. The configuration file shall be
delivered to process integrator or DCX plant along with the weld gun through electronic
media.
• Servo motor parameters shall be configured to include the following:
--Maximum speed
--Maximum current
--Maximum torque
--Number of poles pairs
--Resistance
--Inductance
• Weld Gun Parameters
--Maximum opening
--Tip displacement (transmission) ratio
-- Stationary Cap Displacement at maximum rated gun force, if the force vs. deflection is
nonlinear relationship, then two or more points shall be required.
--Maximum weld gun tip force
• Force Table set-up.
5.2.2 Servo Control System and/or Robot Manufacturer’s Responsibilities
● Servo control system and/or Robot manufacturer shall provide the proper software and
information to weld gun supplier for the initial set-up prior to the program start. Contact
AME Robot/Control group for further detail requirements on servo motor control system.
Servo parameters and variables that characterize the weld gun dynamics shall be
calibrated automatically and without the aid of an oscilloscope or other special
instrumentation.
● Servo control system and/or Robot manufacturer shall provide the proper software and
information to process integrator(s) to fine tune individual weld guns to achieve the
maximum performance. Auto tuning procedure shall be requested and approved by AME
Robot and Weld Gun Group prior to program starts.
● Servo control system or Robot manufacturer shall provide the proper software and
information of tip wear and gun deflection to process integrator(s) prior to program start.

PROPRIETARY
● Servo control system shall have software stroke limit settings to protect the gun from
damage during opening and closing in automatic or jog modes.
● Zero position setting shall be set without the aid of alignment tools or instrumentation.
The servo control system shall be accurate and simple enough to allow plant maintenance
personal to perform the tip force check with a regular force gauge.
● Servo control system and/or Robot manufacturer shall provide servo motor weld gun
operation setting definitions and instruction to DCX, weld gun supplier and process
integrator prior to program start.
5.2.3 Process Integrator’s Responsibilities
● Install, dress and program servo weld gun to program requirements to achieve weld
quality, product quality and production rate.
6.0 VALIDATION, RELIABILTY AND MAINTENANCE REQUIREMENTS

6.1 VALIDATION REQUIREMENTS
All new weld gun concepts shall require validation tests by the weld gun supplier. A design concept
shall be considered as new if one or more of following items occur:
• New construction methods (e.g. bar stock);
• Change in material for weld gun body and components;
• Change in the supplier of servomotor, actuator or pneumatic cylinder;
• Change in equalizer package;
• Change in pivot design;
• Change in water circuit.
6.1.1 Test Plan
Supplier will submit a test plan to the AME Weld Gun Group prior to validation tests. At a
minimum, the testing shall consist of following requirements:
6.1.1.1 Test Set Up
• Air pressure per this specification or servo motor weld gun per design force.
• Water cooling circuits and differential pressure per this specification.
• Accelerated validation test of 10 million weld strokes for durability test.
• One-hour thermal capability test to demonstrate that weld gun is designed to
operate at specified weld current and duty cycle without overheating.
6.1.1.2 Measurement Items
• All items, which have potential to be worn out during operation, shall be
measured per this specification prior to and post of test, including weld gun and
key component design tolerances, structural integrity and performance
requirements. Components shall be inspected at 5 million and 10 million
strokes. AME Weld Gun Group representative(s) must be notified.
• Weld gun tip force repeatability per this specification (2.4.2).
• Weld gun cycle time per this specification (2.4.3.2).
6.1.2 Validation Testing Summary
Weld gun supplier shall submit a validation test summary to the AME Weld Gun Group and
AME Process Engineering Group (if applicable) for review and approval. The test summary
must demonstrate that the requirements of this specification are met.
6.1.3 Approval
Approval for a new weld gun design must be granted by the AME Weld Gun Group in
writing.

PROPRIETARY
6.1.4 Machine FMEA
A machine FMEA shall be required per Chrysler Group Supplier Quality requirements.
6.2 RELIABILITY AND WARRANTY
All components, except perishable items, shall have a minimum mean time between failures (MTBF)
of 30 million weld stokes or 3 years of production, which ever comes first.
Warranty shall meet the requirements of DaimlerChrysler program specifications.
6.3 MAINTENANCE AND SPARE PARTS
6.3.1 Mean Time to Repair (MTTR)
Mean time to repair or replace major components, for example, actuator, slide, transformer,
arms and mounting brackets, etc, shall not exceed 45 minutes during production. Time to
replace shunts, jumper cables, and cap adaptors shall be less than 15 minutes for common
weld gun designs. The above tasks and repair times are for ordinary maintenance personnel
from the user plant.
6.3.2 Maintenance Manual
Weld gun supplier shall provide maintenance manual to DCX user plant and AME weld gun
group.
6.3.3 Manual Contents
Maintenance manual shall be reviewed and approved by DCX user plant and weld gun group
prior to program production start. Minimum contends shall include:
• Weld gun and components replacement procedure.
• Adjustment procedure for any components if required.
• Basic mechanical and electrical troubleshooting.
• Pneumatic schematic and components listing
• Schematic of proprietary items detailing manufacture’s part numbers
• Lubrication schematic showing lube points, type of lubricant and component listing
• Locations of insulation
• Servo motor and gun operation instructions and troubleshooting techniques.
6.3.4 Preventative Maintenance
The maintenance manual shall contain the required PM activities as well as the activity
frequency. The manual shall contain recommended spares as well as all replacement part
information.
6.3.5 Spare Parts
Weld Gun Supplier shall provide a spare part list to DCX user plant and AME Weld Gun
Group with the appropriate manufacturer and part numbers, both NPM and supplier’s
number.
The spare list shall be delivered to DCX as the progressive of the program and assembly areas
within 30days or 90% weld gun design completion, which ever comes first.
In the event that a supplier cannot furnish replacement parts and assemblies to meet DCX
plant needs, the supplier shall be required to surrender any specific details, including any
“proprietary” design and components, to AME weld gun group and DCX plant.
6.4 TRAINING
Weld gun supplier shall provide onsite and offsite training.
Training shall utilize the maintenance manual supplied by weld gun supplier.
6.5 SUPPLIER SERVICE
24 hours emergency assistance from supplier shall be available to the user plant maintenance manager.

PROPRIETARY
The supplier shall have a permanent office or representative company in the United States, through
which contacts shall be made. This arrangement shall last for the life of the vehicle program to
address orders, components issues, replacement parts, service and warranty issues.
A supplier repair person or crew shall be on site within 24 hours of notification from a DCX
representative.
7.0 SHIPPING
All air, hydraulic and water connections and manifolds shall be thoroughly drained, blown out and plugged
prior to shipping.
A layout drawing of the weld gun assembly along with the entire gun test results, including calibration
information shall accompany the gun to its destination.
If any disassembly is required, all break points or areas must be identified.
8.0 REFERENCE DOCUMENTS

The design, construction and shipment of all weld guns shall conform to the latest version of all applicable
DaimlerChrysler Standards. These shall include but are not limited to the following:
Doc. No. Title
WDFM003 Weld Gun Build Buy-Off Form
WDFM002 Weld Gun Design Form
PS-10947 Resistance Spot Welding Automotive Components
AME Do’s and Don’ts
AMS0021 General Requirements for Non-Production Material Used in Industrial Machinery

PROPRIETARY
9.0 GLOSSARY
9.1 ACRONYMS &TERMS
Acceptable Minimum criteria the product shall meet.
An alternate method may be used where specified. Approval of a product using an
Alternate
alternate method may be revoked at any time.
AME Advance Manufacturing Engineering
ASME Advance Stamping Manufacturing Engineering
CD Compact Disc
Configuration The electronic file contains the information of servo motor and servo weld gun setting
File parameters.
A part that gets used up as part of the manufacturing process. This part usually makes
Consumable direct contact with the body-in-white. (i.e. weld caps, adapters, cables, shunts, bushings,
etc.)
The complete series of motions performed by the weld gun during use, which originates
Cycle
at a starting position and ends at the same, starting position.
DCX DaimlerChrysler Corporation
DCX/CG DaimlerChrysler Corporation / Chrysler Group
Differential Water pressure difference between water inlet and outlet on a weld gun
ECTC Equivalent Continuous Thermal Current
The component of the resistance welding process that contacts the work piece and
Electrode Cap
carries current to affect the weld.
Electrode
Refers to the part that the electrode cap fits on.
Shank
Refers to equipment, old or new, that currently exists as referred to in the project
Existing
specification (i.e. the equipment is not supplied explicitly for this project’s use)
Any event, which requires skilled-trade intervention to correct (except for consumable
Failure
and perishable items).
Force Table The process of establishing a relationship between a range of servo motor torque
Setup commands and the resultant weld gun tip force.
GPP Global Project Procurement
The process of setting the basic servo motor and weld gun parameters to ensure weld
Initial Setup
gun delivering force and speed requirements.
JPH Jobs Per Hour
The first day in which the Plant produces 5% of the contracted daily volume of the new
Launch
model.
Life Cycle Expected time frame (or cycles) the component is to be designed to and utilized for.
MCBF Mean Cycles Between Failures
ME Manufacturing Engineer
MEDDS Manufacturing Equipment Development Description Systems

PROPRIETARY
MQAS Manufacturing Quality Assurance System

MSDS Material Safety Data Sheet
MTTR Mean Time To Repair
N/A Not Applicable
The term operator is used generically to describe a support person. An operator may be
Operator
production, maintenance or engineering personnel depending on the specific application.
A part that degrades, deteriorates, or wears out over time, and is not expected to last per
Perishable
reliability requirements (i.e. shanks and shunts).
PM Preventive Maintenance
Tuning Setting servo parameters to optimize the performance of servo motor.
WD Wiring Diagram
10.0 PUBLICATION INFORMATION AND REVISION HISTORY

10.1 PUBLICATION INFORMATION
Contact/Phone No: Feng Cao, 248.944.6144
Alternate Contact/Phone No: Mark Garnett , 248.944.6223
Dept. Name & No: AME BIW Core Group, Dept. 8410/8402
10.2 AME WELD GUN GROUP CONTACT LIST

Name Job Function Telephone Email
Mark Garnett Welding COC Manager 248-944-6223 mdg4@dcx.com
Feng Cao Tool Design Supervisor 248-944-6144 fc27@dcx.com
James Clancy Weld Gun Coordinator 248-944-6168 jpc1@dcx.com
Mihal Dukhan Weld Gun Coordinator 248-944-6178 md32@dcx.com
Ron Klonowski Weld Gun Coordinator 248-944-6153 rk21@dcx.com
John Rudnicki CAD Coordinator 248-944-6134 jfr7@dcx.com
Mark Carlson Weld Gun Coordinator 248-944-6117 mac14@dcx.com
10.3 REVISION HISTORY

Revision
Date NAME Description (include pages affected)
Number*
11/30/04 01 F. Cao Initial Full Release

8/1/06 02 F. Cao Revised by AME Weld Gun Design Coordination Group

PROPRIETARY
Appendix A
AME Weld Gun Group Coordination Procedures
Related Procedures
Documents & Responsibilities
Processes Notification of New Model
Launch and Carry-Over
programs and
AME & ASME Process Management
WDFM001 Weld Gun CWO Request Initiate CWO Request for
Welding CoC Manager
ASME New Launch Program
Tool Design Coordination Supervisor
Only
Meeting Minutes - platform quality record

Do's & Dont's Section 6 Attend Program Kickoff Meeting: AME & ASME Process Group
Resistance Weld Gun Specification AMS 7110 Review weld gun requirements Weld Gun Design Coordination
Program Weld Gun Tracking Form with DCX Process and/or plant Group
WDFM00408 and/or OEM
MEDDS Specification
Create MEDDS Specifications Weld Gun Design Coordinator,
APWI 257
Per Sub Assembly Systems AME & ASME Process Group
APFM 111
Weld Gun Design Form

WDFM002 Weld Gun Model Review Weld Gun Design Coordinator,
Platform Specification No Use Process Library gun or AME Process Group
an existing weld gun design? Weld Gun Design Source
Modify an existing & O.E.M
gun or Design a new
weld gun Yes
Weld Gun Design

Weld Gun Coordinator,
Standard
Design Stds AME Process Group,
Weld Gun Design Weld Gun Body
Review Assemly? Yes Weld Gun Design Source
WDFM002 - Weld & O.E.M
Gun Design Form
No
Issue NPM Codes for new weld
guns and components enter into
ODIMS Weld Gun Design Source Submits Weld Gun Design Coordinator,
Spot Buy Quote to DCX Purchasing,
AME Process and Weld Gun Group Weld Gun Design Source
Weld Gun Design Coordinator:
Return marked up dwgs. to
Marked -up Design Source. File copy. DCX Purchasing
Drawing Weld Gun Design Source: Approved By AME & ASME Process Group
File Finalizes design upon receipt of DCX Weld Gun Design Coordination
dwgs. Group
MEDDS Specification
Complete Weld Gun MEDDS
APWI 257 Weld Gun Design Coordinator
Information
APFM 111
--Blanket Order
--Spot Buy
Use of MCN MCN if Required Weld Gun Design Coordinator
APWI 114
Release Design and MEDDS for
Weld Gun Design Coordinator
Build
AME & ASME Process Group
Continued

PROPRIETARY
Related Procedures
Documents & Responsibilities
Processes Continuation
Complete Spare list Weld Gun Build Source

Recommendation
WDFM003 - Weld Gun
Buy-off Form
Build shop to rebuild
gun to conform to Weld Gun Build Source
Design Review
Complete MEDDS and
MEDDS Specification
Release if Required by Weld Gun Design
APWI 257
User Plant and AME & Coordinator
APFM 111
ASME Process Group
WDFM003 - Weld Gun No

Buy-off Form,
Weld Gun
Build Source: Does the Weld Gun Design Coordinator,
Weld Gun (As-built) Weld Gun Build Source
conform to Design Review?
Re-Install
Weld Gun Design Coordinator: Writes req'd
WDFM005 - Weld Gun Installation until
changes in Weld Gun Installation
Correction Log, installation Yes
Correction Log
Do's and Don'ts Section 6 meets
O.E.M: Makes the corrections.
Resistance Weld Gun Spefication Daimler
Tool Follow-up: Monitors that changes get made
AMS 7110 Chrysler
Stds.
WDFM005 - Weld Gun Installation

Correction Log, No Has the
Do's and Don'ts Section 6 Weld Gun been installed Weld Gun Design Coordinator,
Resistance Weld Gun Spefication AMS per DaimlerChrysler O.E.M
7110 standards for 20hr. Run?
Yes
For Reference Only: TFDP001 Buy-off @ Tier one Supplier Tool Follow-up
(Tool Follow-up Dept. Procedure)
For Reference Only: WDOP005

Control of weld gun design master Archive design documentation Weld Gun CAD Coordinator
drawing
END

PROPRIETARY
Appendix B
Chrysler Group Weld Gun Design Review Form
C HRYSLER W ELD G UN G ROUP
Program: ________ Plant: ____________________ Major: _____________ Item: _____________
Area: Assembly Stamping Sub Major: ____________________
Pedestal / Robot No.: ___________________________________________________________
Qty: _____ ___________________________________________________________
WELD GUN CONCEPT / MODEL Target Completion Date: ____________

Chrysler Weld Gun NPM: ____________________ Supplier Weld Gun No.: ____________________
CARRY-OVER WELD GUN Application Sections (Screen Dump)
STANDARD WELD GUN Weld Schedule Sheets
NEW WELD GUN with STD. B.G.A.
UNIQUE (SPOT BUY) WELD GUN
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - MEDDS (PURCHASING) NPM CODES - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
BODY GUN ASM .......... _____________________ ACTUATOR........................_________________________
TRANSFORMER .......... _____________________ CONNECTOR ...................._________________________
EQUALIZER N/A _________________________
DESIGN COSTS BUILD COSTS FOR ARM ASSEMBLY
DESIGN CHARGE - 5 HOURS ......48-225-0003 STANDARD ARM ASM ......................................... n/a
DESIGN CHARGE - 15 HOURS ....48-225-0004 ONE SPECIAL ARM ASM............................ 91-689-1000
DESIGN CHARGE - 28 HOURS ....48-225-0001 TWO SPECIAL ARM ASM ........................... 91-689-2000
DESIGN CHARGE - 33 HOURS ....48-225-0002 TWO ALUMINUM ARM ASM ....................... 91-689-3000
Remarks: _________________________________________________________________________________
_____________________________ ____________________________ ______________________________
Chrysler Weld Gun Group Representative/ Date Chrysler Process Representative / Date O.E.M. Representative / Date
DESIGN REVIEW shall be completed within 3 weeks from WELD GUN CONCEPT/MODEL approval date.
DESIGN REVIEW Target Completion Date: ____________

Chrysler Weld Gun NPM: ____________________ Supplier Weld Gun No.: ____________________
Est. Weight: _________ lbs. (_______kg) Max. Tip Opening: _______in. (_______mm)
Max. W/Gun Rated Force: _____lbs. (_____kg) and Estimated Total Deflection: ______in. (____mm)
Description NPM Code Description NPM Code
____________________............ ___________________ ____________________ .........____________________
____________________............ ___________________ ____________________ .........____________________
____________________............ ___________________ ____________________ .........____________________
____________________............ ___________________ ____________________ .........____________________
____________________............ ___________________ ____________________ .........____________________
____________________............ ___________________ ____________________ .........____________________
Remarks: _________________________________________________________________________________
_____________________________ _____________________________ _____________________________
Chrysler Weld Gun Group Representative/ Date Chrysler Process Representative / Date Supplier Representative / Date
BUILD BUY-OFF Target Completion Date: ____________

Remarks: ________________________________________________________________________________
N E W D E S I G N C A T I A D E L I V E R AB L E Target Completion Date: ____________

Assembly Model (3D Solid) Assembly Model (2D Drawing) Detail Models (2D Drawings)
Remarks: _____________________________________________________________________________
___________________________________
Chrysler Weld Gun Group Representative/ Date
For current revision of this form reference AME MQAS Document WDFM002 Weld Gun Design (Revision D)

PROPRIETARY
Appendix C
Chrysler Group Weld Gun Build Buy-Off Form
DaimlerChrysler
CHRYSLER GROUP WELD GUN BUILD BUY-OFF FORM
(FOR BUY-OFF @ WELD GUN SUPPLIER OR OEM)

PROJECT ID (Program year and Program ID):
DaimlerChrysler WELD GUN NO. DATE:
OEM: WELD GUN SUPPLIER: SPARE: Y__ N__

SERIAL NUMBERS INCLUDED IN THIS REVIEW (ATTACH ADDTL SHEETS IF NECESSARY):
ROBOT_____ PORTABLE_____ PEDESTAL_____ PNEUMATIC_____ SERVO_____
Weld Gun DC Weld Gun

ITEM
Supplier Rep. Rep.
LAMACOID IDENTIFICATION TAGS (2)

ACCEPTABLE NON-CONDUCTIVE FULCRUM COVER (with snaps - no screws)
ACCEPTABLE SHUNT COVERS
BEND RADII FOR SHUNTS PER DESIGN DWG
ACCEPTABLE FULCRUM TOLERANCE (IF LOOSE - TIGHTEN)
ANTI-ROTATION DEVICES ON ELECTRODES (KEYS)
COMPONENTS IDENTIFIED WITH DAIMLERCHRYSLER NPM CODES PER ASM7110 or DO'S&DON'TS
ACCEPTABLE WATER FITTING CLEARANCE
TIP ALIGNMENT WITHIN 0.5MM (0.020”)
TOTAL DEFLECTION WITHIN 4.6MM (0.180") AT MAXIMUM RATED FORCE
MECHANICAL EQUILIZER PERFORMS AS REQUIRED
1/4" CLEARANCE TO PREVENT ELECTRICAL SHORTS ( OR INSULATE )
MOUNTING / ATTACHING SCREWS / NUTS SELF-LOCKING WHERE APPLICABLE
DOCUMENTAION AND NO VISIBLE EVIDENCE OF WATER AND/OR AIR LEAKS
BURRS AND SHARP EDGES REMOVED
ACCESS FOR MAINT. (FITTINGS, FSTNRS., SHUNTS, TRANSFS.)
WELD GUN PORTS LABELED IN & OUT FOR WATER
GUN BODY AND COMPONENTS FREE OF VISIBLE CRACKS AND VISIBLE SURFACE POROSITY
NO INTERFERENCE BETWEEN MOVABLE COMPONENTS
ADAPTOR OR HOLDER STICKOUT LIMITED TO SIX INCHES OR PER DESIGN DWG
PINCH POINTS COVERED (MANUAL WELDGUNS ONLY) PER DO'S & DON’T'S
SOFTWARE LIMITS ( MAXIMUM TIP OPENING LIMITS)
BIAS SETTING SCRIBED (CENTERLINE GUNS ONLY)
IF NEEDED
PLASTIC PLUGS IN ALL PORTS
MINIMUM WATER FLOW OF GUN ASSEMBLY@30PSI D IFFERENTIAL:
1.50 GAL/MIN EACH ARM ASSEMBLY FOR ROBOT/PORTABLE & PED WELDERS
1.00 GAL/MIN EACH ARM ASSEMBLY FOR MACHINE/FIXTURE WELDERS
1.00 GAL/MIN TRANSFORMER (AC)
2.00 GAL/MIN TRANSFORMER (MFDC)
____GAL/MIN FOR OTHER TRANSFORMER PER MANUFACTURER'S REQUEST
"O" SETTING TOOL (SERVO GUN ONLY)
WITH MANUAL OPENING TOOL (SERVO GUN ONLY)
VERIFY VENDOR'S DOCUMENTATION OF SERVO GUN SET-UP PER ASM7110 REQUIREMENTS
GUN CHECKED TO DESIGN DWG.: REV LEVEL / DATE: ______
ADDITIONAL COMMENTS:
Weld Gun Build Source Signature: _________________________ Date: ______________
DaimlerChrysler Weld Gun Coordinator Signature: _________________________Date: ______________
ACCEPTANCE DOES NOT RELIEVE WELD GUN SUPPLIER'S RESPONSIBILITY.

For current revision of this form Ref: AME MQAS Document WDFM003 Weld Gun Build Buy-off Rev. D

PROPRIETARY

AMS 7110 Resistance Weld Gun Specification

Transféré par

Informations du document

Description originale:

Copyright

Formats disponibles

Partager ce document

Partager ou intégrer le document

Options de partage

Avez-vous trouvé ce document utile ?

Ce contenu est-il inapproprié ?

Droits d'auteur :

Formats disponibles

AMS 7110 Resistance Weld Gun Specification

Transféré par

Droits d'auteur :

Formats disponibles

Resistance Weld Gun Specification

Advance Manufacturing Engineering AMS 7110

Advance Manufacturing Engineering

Resistance Weld Gun Specification

Revision Date: 09/12/2005 Page 1 of 26 Revision: 02

TABLE OF CONTENTS PAGE

Revision Date: 09/12/2005 Page 2 of 26 Revision: 02

Revision Date: 09/12/2005 Page 3 of 26 Revision: 02

2.1.9 Non- Rotating ‘C’ Gun Requirements

2.3 CONSTRUCTION REQUIREMENTS

W/GUN NPM XX-XXX-XXXX

WEIGHT XXX lbs / XX kg

MAX RATED FORCE XXXlbs/XX Kg

STA. CAP DISPLACEMENT XXX in/XX mm

MAX TIP OPENING XXX in / XX mm

Revision Date: 09/12/2005 Page 6 of 26 Revision: 02

Revision Date: 09/12/2005 Page 7 of 26 Revision: 02

2.4.4 Electrical Servo Actuator Assemblies and Servo Motors

2.5 WELD GUN EQUALIZER

Revision Date: 09/12/2005 Page 9 of 26 Revision: 02

2.7 LAMINATED LEAF SHUNTS

Revision Date: 09/12/2005 Page 10 of 26 Revision: 02

DCX/NPM Code KVA PRI V/ FREQ V/SEC Turns Ratio

3.1 DESIGN PROCESS

3.2 BUY-OFF PROCEDURE

Revision Date: 09/12/2005 Page 12 of 26 Revision: 02

Revision Date: 09/12/2005 Page 13 of 26 Revision: 02

4.2.7 Dimensioning and Tolerancing

4.2.8 Dimension Arrangement

4.2.9 Holes and Slots

Revision Date: 09/12/2005 Page 14 of 26 Revision: 02

Fig. 6-Detail Drawing Tabulated Label

4.2.9.6 Call Outs

4.3 CAD DELIVERY

5.0 WELD GUN INTEGRATION

Revision Date: 09/12/2005 Page 17 of 26 Revision: 02

6.0 VALIDATION, RELIABILTY AND MAINTENANCE REQUIREMENTS

Revision Date: 09/12/2005 Page 18 of 26 Revision: 02

Revision Date: 09/12/2005 Page 19 of 26 Revision: 02

8.0 REFERENCE DOCUMENTS

Revision Date: 09/12/2005 Page 20 of 26 Revision: 02

Revision Date: 09/12/2005 Page 21 of 26 Revision: 02

MQAS Manufacturing Quality Assurance System

10.0 PUBLICATION INFORMATION AND REVISION HISTORY

10.2 AME WELD GUN GROUP CONTACT LIST

10.3 REVISION HISTORY

11/30/04 01 F. Cao Initial Full Release

Revision Date: 09/12/2005 Page 22 of 26 Revision: 02

Meeting Minutes - platform quality record

Weld Gun Design Form

Weld Gun Design

Revision Date: 09/12/2005 Page 23 of 26 Revision: 02

Complete Spare list Weld Gun Build Source

WDFM003 - Weld Gun No

WDFM005 - Weld Gun Installation

For Reference Only: WDOP005

Revision Date: 09/12/2005 Page 24 of 26 Revision: 02

WELD GUN CONCEPT / MODEL Target Completion Date: ____________

DESIGN REVIEW Target Completion Date: ____________

BUILD BUY-OFF Target Completion Date: ____________

N E W D E S I G N C A T I A D E L I V E R AB L E Target Completion Date: ____________

Revision Date: 09/12/2005 Page 25 of 26 Revision: 02

CHRYSLER GROUP WELD GUN BUILD BUY-OFF FORM

OEM: WELD GUN SUPPLIER: SPARE: Y N

ROBOT___ PORTABLE_ PEDESTAL_ PNEUMATIC_ SERVO___

Weld Gun Build Source Signature: ___________ Date:

DaimlerChrysler Weld Gun Coordinator Signature: ___________Date: