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.

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Benefits

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


Inspection and Welding Fixture for TIG welding Machine

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

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

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