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MODULAR FIXTURE

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For welding the 304 stainless steel frame accurately, ... the ABI TSV-30 transit bus uses a welded stainless steel frame and bonded composite side and roof panels. – PowerPoint PPT presentation

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Title: MODULAR FIXTURE


1
SEMINAR ON
  • MODULAR FIXTURE

2
MODULAR FIXTURE
  • Introduction to modular fixture
  • -components
  • Advantage of modular fixture
  • Application
  • Conclusion

3
fixture
  •  
  • A fixture is primarily a holding device. A
    fixture anchors the workpiece firmly in place for
    the machining operation, but it does not form a
    guide for the tool.
  •  
  • The jig is a guiding device.
  • The fixture is a holding device.

4
Components of modular fixture
5
What is Modular Fixturing?
  • A modular fixturing system is composted of
    standardized components that allow for flexible
    arrangement and interchangeability between
    different applications. The versatility of the
    components makes it a viable alternative to
    traditional fixturing methods because a single
    modular fixture system is capable of doing the
    same work as numerous dedicated fixturing
    systems.

6
Modular Fixturing Components
  • Tooling Plates and Blocks
  • The fundamental components
  • of a workholding or modular fixturing system
    are the tooling plates or tooling blocks, which
    are commonly referred to as fixture plates, grid
    blocks, or tombstones

7
Tooling Plates Blocks
  •     The fundamental components of a workholding
    or modular fixturing system are the tooling
    plates or tooling blocks, which are commonly
    referred to as fixture plates, grid blocks, or
    tombstones. The multipurpose holes (MTP holes) on
    both the tooling plates and blocks allow for
    accurate aligning or fastening of other
    components in a number of locations.
  •     Flex plates offer the ability to work on any
    given fixture away from the machine, free from
    any space constraints. A flex base plate resides
    on a machining center pallet and will accept
    other flex tooling plates or blocks to be
    fastened onto it, which allows for fast
    changeover between applications. The two tapered
    pins allow for accurate and consistent locating
    when mounting other flex plates to the base.
  • A few of the immediate benefits from using a flex
    plate modular fixturing system include
            - Fast and accurate changeover        -
    Flexible mounting of a single fixture on
    different machines        - Machining a part
    from 5 sides on a single pallet        - Reduced
    setup time compared to other conventional
    methods

8
Flexible tooling plate bases
Flex plates offer the ability to work on any
given fixture away from the machine, free from
any space constraints
9
Flexible Tooling Plates and Bases
  • Flexible tooling plates (called flex plates for
    short) expand even further on modular style
    tooling plates. Essentially, the flex plate is a
    special tooling plate designed to independently
    fasten to a flex tooling base. The ability to
    change out an entire tooling plate between
    dissimilar jobs, as opposed to reworking fixtures
    on a dedicated tooling plate, reduces machine
    downtime due to fixture set up. Multiple fixtures
    can be arranged independently from the machine
    pallet and quickly changed out.
  • The flex tooling base is designed with two
    locating pins, which are used to accurately
    position the flex tooling plate. The locating
    pins ensure accurate locating repeatability.
    Additionally, flex plates also utilize the grid
    of locating holes, which gives it the flexibility
    to mount other modular components to correctly
    position and hold a work piece.

10
Modular clamp and accessories
  • Modular clamps and accessories
  • are extremely versatile and flexible,
  • which allows them to be used in a
  • wide variety of workholding
  • applications.

11
Modular Clamps Accessories
  •         The standard modular clamp is designed to
    exert a downward clamping force on the work
    piece, similar to that of a strap clamp. Balanced
    and level clamping is maintained with the use of
    a socket toggle screw a threaded bolt with a
    swiveling contact pad on its end. Standard
    modular clamps can also be fastened to a sliding
    mount unit, which then allows the clamp to be
    positioned in the proper location.
  •     The high-rise modular clamp is comprised of a
    clamp assembly with any number of modular risers.
    The primary difference is that multiple modular
    risers can be quickly and easily stacked on top
    of one another to accommodate any variable
    clamping height needed in a particular
    application. When assembled, the modular risers
    and clamp assembly are held together by
    tightening the lock nut on top. This pulls the
    couplers upward into the devices which hold the
    corresponding lock buttons tightly and securely,
    preventing movement or disassembly.

12
Advantage of modular fixture
  • It reduce the setup time
  • It reduces storage space
  • A very high degree of accuracy can be achived
  • Support from various service provider
  • It is very flexible

13
Time saving
  • There are three options to choose from when you
    get a new part to run. One can build an open
    setup which eats up a lot of machine time and may
    be difficult to repeat otherwise build a
    dedicated fixture which eats up a lot of lead
    time (average 6 weeks). Or build a modular
    fixture in 4 hours or less and accurately repeat
    the setup any time you want. For short runs, the
    choice is easy modular fixturing wins, hands down

14
Accuracy
  • Machining fixtures need to be both rugged and
    accurate to meet the demands of today's machining
    centers. Bluco's modular fixturing offers the
    best of both worlds. All baseplates, cubes and
    angles are made of cast iron for excellent
    vibration dampening. Each element of the system
    has an alternating pattern of tapped holes and
    accurately located precision steel bushings. The
    bushings are located /-0.0018 over 12".

15
Storage
  • Floor space is at a premium in most shops. Many
    fixtures are saved for spare parts. Chances are
    these fixtures were built for machines long since
    gone. A single modular fixturing kit neatly
    organized in a few cabinet drawers can easily
    replace 100's of these old fixtures saving
    valuable space and precious time. When a fixture
    is needed, simply pull out a setup drawing, a CAD
    file or a picture and gather the modular
    components. In under a half hour, your machine
    will be up and running.

16
support
  • Along with our free training videos, on-site
    training, free fixture designs and CAD database,
    our trained applications engineers can help with
    all aspects of your new Demmeler modular
    fixturing system. And to make buying decisions
    easier, all of our equipment comes with a 1-year
    exchange policy allowing users to return
    exchange unused components free of charge.

17
Saving
Conventional Modular
How often do you have to buy a fixture? Every time you make a new part Once
How long does it take to build a fixture? 1 -2 weeks Less than a day
How easy is it to make changes to a fixture? Don't ask A matter of seconds
Where do you store these fixtures? Out back, on shelves, in trailers, on the floor On a tooling cart and in a computer (CAD)
What if a job repeats? After hours of looking, you find a fixture with missing parts Build one in minutes
18
APPLICATION
Using a little creativity and a modular fixture,
this casing is setup with access to both the
front and rear bore faces. A fixture like this
will take about 90 minutes to design and build
the first time around. If the job were to repeat
some time down the road, the same fixture can be
rebuilt in under 20 minutes.
19
Spindle clearance is always a concern when
working with a horizontal machining center. There
are a number of ways to raise the part off the
baseplate. As is the case with these manifolds,
4-sided precision ground consoles (yellow cubes)
are doweled and bolted to the baseplate and the
hardened locating components are dowelled and
bolted on top. Consoles can be stacked on top of
one another for taller applications.
20
Spindle clearance is always a concern when
working with a horizontal machining center. There
are a number of ways to raise the part off the
baseplate. As is the case with these manifolds,
4-sided precision ground consoles (yellow cubes)
are doweled and bolted to the baseplate and the
hardened locating components are dowelled and
bolted on top. Consoles can be stacked on top of
one another for taller applications.
21
Engine Room Piping Pipe shops
in the shipbuilding industry face a never-ending
demand for tubes and pipes that carry everything
from gas, steam, hydraulic fluid, oil, compressed
air, sewage, etc.  Each of these pipe assemblies
has a different requirement which is why a
universal jig system is essential to have on
hand.  Regardless of the complexity of pipe
weldments, there is a simple solution waiting to
be built with our modular fixturing Engine Room
piping
22
  • Fire Truck
  • A number of emergency vehicle manufacturers use
    modular fixture to build everything from doors
    and ladders to cabs and chassis. The flexibility
    of our work benches offers an unlimited variety
    of applications for welding. Rather than using a
    solid 16 x 10 table, the smaller 5 x 10 weld
    table with outriggers allows easier access for
    the welders.

23
 Thinned walled aluminium structure
  • This thin-walled electronics enclosure needs the
    superior strength and rigidity of the Bluco
    system to negate any chatter during machining.
    With added vibration dampeners (orange handled
    unit) and various top, front and side clamps, the
    part remains stable during the entire machining
    process.

24
Automotive component
  • Second operation fixtures pick up machined
    locating features from the first setup. Hardened
    and ground modular fixturing components with
    controlled dimensions of /-0.0004" are critical
    to making accurate parts.

25
Prototype large and small part
  • Modular fixturing is best suited for short runs.
    The prototype aluminum housing and the banister
    support both proved to be simple parts but
    difficult to fixture. Design and build time for a
    modular fixture was under an hour for each part.

26
Modular Welding Fixturing Ups Outputof Armored
Vehicle Components by 40
27
Designed with sports car styling, the ABI
TSV-30transit bus uses a welded stainless steel
frame andbonded composite side and roof panels.
For welding the 304 stainless steel frame
accurately, the Demmeler modular fixturing system
provides a positional accuracy of 0.0015"/ft.
28
CONCLUSION
  • Jigs and fixtures are essential elements of a
    manufacturing system. Responsible for holding the
    work accurately and securely during its
    manufacture, they determine to a large extent its
    relevant quality and their rate at which it can
    be produced. Good design to jigs and fixture
    ensure that they fullfill their fuction
    economically is vital to the success of the
    manufacturing system .
  • With use of modular fixture one can cut cost and
    time both without compromising on accuracy and
    quality very effectively

29
  • THANK YOU
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