welding fixture design guidelines.docx
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welding fixture design guidelines.docx
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weldingfixturedesignguidelines
Automotiveweldingfixturedesign
First,thepurposeoffixturedesign
Doonething,theclearpurposeofdoingthingsisveryimportant,so-calledpurposeofthisthingisthatyoudowhatyouhavetomeetthefinalresult,thatisyourgoal!
Thatisthedirectionthatyoudothings,thereisadirectionyoudonotlose,youtrytodothingstheresultwillbeperfect!
Weldingfixturedesignalsohasitspurpose,onlyaclearpurposeweldingfixturedesign,inordertodesignabetterfixture,thenwhatisthepurposeweldingfixturedesignisit?
Simplymeansthattomeettheproductionweldingfixturerequirements,thenhowcanwesatisfytheweldingproductiondemands?
1fixturedesigntomeetpositioningrequirementsofautomotivebodyparts
Theso-calledpositioningrequirementisdesignedfixturecanbeagoodcarweldingpartsgoodlocation,goodweldingqualityassuranceTheamount.Tomeetthesepositioningrequirementsinthedesignofthefixturewhennecessaryinstrictaccordancewiththemanufacturertoprovidelocationinformationtodesigndrawingsclampingfixture.
LocatingandclampingInformationInadifferentprojectname:
VolkswagenprojectRPS
AUDIProjectRPS
BMWprojectASP
CommonitemsGDΣT(maindowelpins)+CDPoints(positioningsurface)AcarprojectCKface
.........Designtips:
VolkswagenprojectdrawingsRPSpointuppercaseandlowercaselettersmeaning
HxzHOnbehalfofthehole(pressingdirectionzTo)xzOnbehalfofthepositioningholedirectionHyHRepresentativesKongydirectiononbehalfoftheholelocation
DirectionfxfsupportrepresentativesupportrepresentativedirectionxFxFxpressedrepresentativesofsupportandthesupportofacarprojectonbehalfofthemeaningoftheletters:
Benchmarkexplanatory
PositivereferenceauxiliaryHelpbenchmarkAdjustthebenchmarkrelationship
S
Primarydatum
s
Auxiliaryplane
H
Mainreferenceholes
h
Auxiliaryreferencehole
E
Mainreferenceedge
Sk
Tentativeprimarydatumreference
sk
Tentativebenchmarkauxiliaryplane
Ck
Correctionbenchmark
Cs
Temporarybasisauxiliaryplane
cs
Interimbenchmarksprimarydatum
J
Preventdeformationofpartsandsetupbase
Quasi-surface
O
Basedsinglepieceofmold&gagesused
Quasi
S
Benchmarksub-assemblyjigused
K
Gageusedonthebenchmarksub-assembly
C
Baseassemblyjig&fixtureuse
Quasi
2fixturedesigntomeettheweldingrequirementsBIWisweldedout.Thatiswhatwecallthefixtureweldingfixture,bodypartsmainlybyspotwelding
IntooneofthemostimportantpurposeofourfixtureisdesignedtomeettherequirementsBIWweldingparts,weldingfixtureasadesignershouldalwaysdeeplyengravedinthemindsoftheweldingoftheword,howtoweld,howtoBetterwelding!
Here'sonebyoneonthefollowingaspectsoftheweldingfixturedesignrequirementsareintroduced:
⑴operatingheight
Operatingheightreferstotheheightofthegroundbetweentheweldingclamphandle,whentheoperatorheightof175cm,theheightoftheweldingoperationisgenerallyflatpliers800-1100mm,Weldingclampstandupgenerally1200-1500mm.
⑵weldingclampthroughsexual
Weldingclampweldingclampthroughsexualmeanswhenweldingiseasytoweld,weldingclampjudgedmainlyfromthefollowingaspectstobeconsideredgoodorbadbynature,
①aslittleaspossiblebackintothegunandthegun.Tomeetthisrequirementon,youshouldconsiderthedesigntominimizetheoperatingsideweldingclamplocators,trytolocateonefromanother
Sideofthedesign,weldingclampoperatingsidetrytostayoutoftheweldingspace.Specifically,asshownbelow:
Torchoperatingside
Locatordesignside
②weldingprocessofweldingandnotlikelytointerferewiththefixture.
Trytopayattentiontojointsshouldbedesignedtomeettwonearbypositioningblockwithcompactdesign,thepositioningblockdesigncompactsthemaximumextentpossibletoavoidweldingtongs.
Consider⑶operatorpositionDependsonthepositionoftheoperatorofthedistributionoftheweldingtorch,whichsideoftheoperatortomoreeasilywhichsideofthewelding,iftheweldingofsingle
Sideofanoperatorcannotachievewelding,youneedtoincreasetheoperatorontheothersideorchangetheformofthefixture,intotherotationfixture.
⑷weldingfixturedesigninvolvedweldingmethodscommonlyusedclassificationandabriefintroduction:
①spot
Spotweldingisusuallydividedintotwo-sidedandsingle-sidedweldingtwocategories.Whenthedouble-sidedspotweldingelectrodesfrombothsidesoftheworkpiecetoWeldedatthefeeder.Atypicalspotweldingmethodisthemostcommonway,whenboththeelectrodesonbothsidesoftheindentationoftheworkpiece.Alargeweldingareatomakethelowerelectrodeconductiveplate,whichcaneliminateorreducetheindentationbelowtheworkpiece.Commonlyusedinthedecorativesideoftheplatewelding.Meanwhilespotweldingspotweldingoftwoormore,theuseofatransformerinparalleltoeachoftheelectrodes,whentheimpedanceofthecurrentpathmustbeallsubstantiallyequal,andthesurfacestateofeachoftheweldedparts,thematerialthickness,electrodeforcearesubjecttothesame,inordertoensureconsistentuseofdouble-sidedmultipletransformercurrentthrougheachsolderjointmulti-spotwelding,toavoidshortageofc.
Forsingle-sidedspotwelding,theweldingelectrodesfromthesamesideoftheworkpiecefeed,atypicalsingle-sidedspotwelding,asingle-sidedspotwelding,anelectrodepadisnotformedwithlargediameterandalargecontactsurfacetoreducethecurrentdensity.Nodiversionofsingle-sideddoublespotwelding,whentheweldingcurrentflowsthroughalltheweldingzone.Therearesingle-sideddoubleshuntlittlewelding,thecurrentflowingthroughthetopoftheworkpiecewithoutweldingarea,formingromantic.Toprovidealowresistanceweldingcurrentpath,theworkpieceunderneaththecopperplate.Whenthedistancebetweenthetwosolderjointsllarge,suchasduringtheskeletonboardmemberandcomplexwelding,inordertoavoidundueheatingcausedbycomplexboardwarpageandreducetheresistancebetweentwoelectrodes,usingaspecialcopperbridgesA,Atthesametimetheelectrodeispressedagainsttheworkpiece.
②MIG,MAGwelding
MAG(MetalActiveGas)weldingMag(activegaswelding)
Whenusingtheactivegasshieldinggas.UsuallyuseCO2.Thegasisdecomposedinthearc,andthusincreaseordecreasethefusionrange.
BecauseCO2asthemaingas,itisoftenreferredtoasCO2weldingturnMAGwelding.
FeaturesandUses:
ThemainadvantageoftheprotectionofMIGarcweldingcanbeeasilyweldedvariouslocations,butalsoWithaweldingspeed,depositionrateandsoon.Metalactivegasshieldedarcweldingcanbeappliedtomostofthemajormetals,includingcarbonsteel,alloysteel.
MIG(MetalInertGas)weldingMig(inertgaswelding)
Whentheprotectivegasisaninertgastoavoidreactionwithothersubstances.TheinertgasisusuallyargongasArorhelium
He.
SometimesaninertgasmixedwithasmallamountofadditionalO2,CO2,orH2.
Uses:
metalinertgasweldingforstainlesssteel,aluminum,magnesium,copper,titanium,zirconiumandnickelalloys.WiththisweldingArcweldingmethodmayalsobe.
③studwelding
studwelding
Studweldingprocessofmanually
Oneendofthestudandtheplate(ortube)surfacecontact,powerarc,afterthemeltsurfacetobecontacted,acertainpressuretocompletethestudweldingmethod.
Mainlybystudweldingpowersourceandtorchcomponents.
Thebasicprincipleofarcstudweldingstudistobeweldedbetweenthepilotarctotheworkpiecewhenthestudandtheworkpieceisheatedtoanappropriatetemperature,theexternalforce,thestudintotheweldpoolontheworkpiecetoformaweldjoint.Differentweldingprocessweldingpowersource,thetraditionalarcstudweldingcanbedividedintotwogeneralarcstudweldingandcapacitordischargearcstudweldingmethodinaccordancewiththebasic
Studweldingtorchshape
Isaprocessofmanualstudweldingstudweldinggunbytheoperatormanuallywiththestudweldingworkpiecestogether,andthedetailedprocessisasfollows:
Prerequisiteweldingprocessweldingdowelcontactwiththeworkpiecesurfacetosoldercircuitwiththestartcommandissuedbygeneratinganelectricalshortdowelandtheworkpiece.Aftertheinitialpowerstability,linearmotorthepinboltgunawayfromtheworkpiece,initialcurrentarcignitionundertheprogrammingcurve.Initialcurrentarctoignitethemainarc.Aftersolderingdowelreacheditsbackhaulheight,themainweldingcurrentthatisswitchedon,itwillstrengthenthearc,makingdowelfaceandtheworkpiecesurfacemelting.Arcontheendfaceoftheworkpieceanddowelgenerateabathprocess,linearmotorcommutation.Cottersbyacontrolledmovementofthemechanicalpressureintothebath.Stayinthelinearmotoraccordingtoapredeterminedpositionontheresttime.With
Thedoweldippedinthepool,thearcisextinguished,makingahomogeneousmeltsolidification,andthetorchcanleavedowelafterweldingcurrentshutdown.
Note:
Withthegunawayfromtheweldingprocessdowelends,afteradditionaldowelcanbere-welded.
Compositionlocatorstudwelding
StudweldingpositionerTherearebasicallycomposedofthefollowingparts:
theguidesleeve,theguidesleeveadjustment,studweldingsupport,insulationsystems,bearingsanddrivecylinderasshownbelow:
Designrequirementsforthepositionbetweentheguidesleeveandstudweldingworkpieces
Thefollowingfigureshowsthepositional
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