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
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
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
Inspection and Welding Fixture for TIG welding Machine
Requirements
Combine horizontal and vertical welding operations
Avoid oxidation of the welding between Kovar to Kovar and SS to Kovar
Runout inspection in the same machine
Reduce rejection rate in runout (Current is 10 %)
Camera to monitor the welding process
Tack welding
Bluetooth or wireless dial gauge
Double hand operation for starting the process
Our Solution
Design of the mechanism to hold the electrode for horizontal + vertical welding
Design of a canopy for enclosing the components to be welded
Integrate inspection mechanism with the machine
Selection of dial gauges, pneumatic clamps, rack and pinion and motor
Prototyping and testing
Benefits
Reduced operator involvement.
In situ welding monitoring camera
Run out inspection can be carried out in the same setup
HMI with GUI for easy operations
Design of Car Door Paint Shop Fixture
Requirements
Fixture for car door E-coating
Fixture should carry 12 doors at a time
Fixture should travel on the existing pendulum conveyor
Fixture should ensure the complete doors are fully dipped in the paint tank
Fixture can accommodate 3 variant of car doors
Fixture should sustain 165ºC for 15 mins
The door should not fall when the fixture is moved (+45° to -45°)
It should be easy to maintain
Our Solution
Design of the mechanism to hold the electrode for horizontal + vertical welding
Design of a canopy for enclosing the components to be welded
Integrate inspection mechanism with the machine
Selection of dial gauges, pneumatic clamps, rack and pinion and motor
Prototyping and testing
Benefits
Inbuilt door size variation mechanism – Can accommodate different size and shape doors
Low maintenance
Less material handling
Firm clamping of the components on the fixture – Avoids falling into paint tank
Less paint deposition leads to less maintenance and frequent cleaning
Optimized weight to suit conveyor loading capacity
CAE verification for deformation
Assembly Fixture for FC Door
Requirements
The operator should not be harmed by the sharp edges of the FC door
Assembly of top cap, end cap, handle, deco plate should be assembled in one fixture
Eliminate unsafe conditions
Minimize operator hand movement
Free up operators to reduce manual work from 6 to 2 operators.
Our Solution
Dimensional analysis of FC door parts
Determination of fixture specifications
Finalize the fixture design using concept selection tools
Checking manufacturing feasibility using fixture standards
CAE verification of fixtures
Prototyping of the model
Testing of the prototype
Testing the actual working of the mechanisms
Benefits
Assembly of FC door can be done with less effort
The fixture is of a rotating type which ensures all the locations for placing child parts can be easily accessed
Sticking of tape on all parts is easy
Design is ergonomic
Plunger is available for locking of rotation
Disassembly of fixture is easy