Fixture For Center Stand

Fixture For Center Stand


Requirements

To design an assembly line fixture for holding a 2 wheeler by using center stand

To prevent 2 wheeler from tilting during assembly processes on assembly line.

To clamp a 2 wheeler in 20 sec. on a fixture


Our Solution

Define the DOF of center Stand & Finalize the DOF to be restricted

Constrain all DOF of center stand.

Use of quick clamping & De-clamping mechanisms to achieve takt time of 20 Sec


Benefits

Restrict two wheeler movements during assembly

Created simulation videos for training of operators

Less Fatigue to Operator


Welding Fixture For Bogie Frame

Welding Fixture For Bogie Frame


Requirements

Must not interfere with the welding process.

Fixture must not allow the un-welded part to change its orientation in relation to the welder during the welding operations

Ensure that the quality of parts to be joined is maintained (Dimensions, Tolerances, No Warpage)

Fixture must be compatible with straight and curved faces


Our Solution

L clamps were used to constrain the X-axis and Y-axis.

Locking Plate and bolts were used to constrain the Z-axis.

For easy access to welding, the fixture could be rotated in step angles, aligned and locked in any angle as per the welding requirement.


Benefits

Cycle time reductionr

Ease of welding

Increased productivity and quality

Device For Joining Dissimilar Metals

Device For Joining Dissimilar Metals


Requirements

To design a spool gun or solder wire feeder that dispenses flux and solder wire from the same device.

Fixture must not allow the un-welded part to change its orientation in relation to the welder during the welding operations

Ensure that the quality of parts to be joined is maintained (Dimensions, Tolerances, No Warpage)

Fixture must be compatible with straight and curved faces


Our Solution

Inductive Flux Heating Unit Design.

Design of Solder Wire Feeder Mechanism, Wire Heating Unit, Flux Heater and Feeder Mechanism.

Separate Heating control for Solder and Flux.

  • Wire Feed Rate Calculations to calculate Motor specifications and Worm Gear feeder mechanism
  • Calculations for Heat generated at the Tip to avoid metal and Solder from Burning
  • Electrical circuit design for Induction coils
  • Temperature Rise Calculations


Benefits

Portable Device designed for joining Aluminum with Cold Rolled Cold Annealed (CRCA) metal