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Hi ! Welcome to the a domain all about welder, This a domain was created as a means to provide a variety of learning, especially relating to welder events. this time me will discuss about"BIW WELDING FIXTURE DESIGN" clearly, let's go see in detail...



By 3D Modeling of weld fixture, you can quickly prepare manufacturing drawings.

In the study phase of planning process you find or verify the concepts of the body-in-white manufacturing process. For design welding fixture, trying to understand processes is essential. It is starting with process logic and flow, and defines the relationships between operations.

The process study is a solution that to help you quickly define and evaluate process to arrive at the best plan for designing your fixture. The result is process study containing a full description of how a product is assembled, manufactured and increases your profitability by improving critical success factors in your fixture design.

The process study allows designer to leverage and optimize existing resources and to better integrate the designing process from beginning to end can not only help designer create fixture faster, but you can also begin design earlier in the overall cycle or even start later, in order to accommodate unanticipated changes.

The Assembly Process studying allows evaluating alternatives, coordinating resources, optimizing throughput, plan for multiple variants, implement changes and estimate costs and cycle times, from the very early stages of concept planning through process.

Studying, Analyzing and Managing Manufacturing Processes enables you to collaboratively plan and analyzing manufacturing processes for your fixture. You can create optimal design and accommodate multiple plan variations, quicker and faster than ever before.

Process study provides a collaborative environment for planning designing processes. A broad range of applications enable you to define and verify body assembly sequences, create clamping plan layout, define the required time for each operation, verify plan performance, perform plan balancing and analyze of spot welding and guns.

The body-in-white Manufacturing Process includes:

  • Automotive body assembly
  • Electric resistance welding
  • Cycle time diagrams

  • Automotive body assembly

    The major process of an automotive body is electric resistance welding. Resistance welding is a group of fusion welding processes that use a combination of heat and pressure to accomplish coalescence and where electric resistance welding is not applicable ,CO2,ARC WELDING and MIG-BRAZING are performed.

    The body of automotive is made up of several hundreds of stamped components which are joined together by spot welding process.

    Overall quality of the car body (BIW) and quality of the sub assemblies, apart from quality of each stamped part, depends remarkably on quality of the welded joint.

    You should study of part joining, welding operations such as spot-welding and define welding points and allocate them to welding operations.

    The study of welding process can be classified as follow:
  • The number of welding spot
  • The position and volume number of welding spot
  • The type of welding gun
  • The material and sheet metal thickness for setting of welding condition
  • Cycle time diagrams

    The cycle time is estimating the required working time of each station.

    Cycle time study is based on the information such as:
  • Part loading
  • Clamping
  • Gun forward
  • Welding
  • Gun retreat
  • Unclamping
  • Part unloading

    Almost all of the automotive body parts are assembled by resistance spot welding.

    A spot welder consists of a transformer to obtain a large welding current, timer to control the time in which to feed the current, electrodes to hold welded articles, pressurizing cylinder to apply the necessary for the material being welded.

    Secondary cable lets necessary current through transformer flow to gun, spring balancer to lighten the welding gun and the cable.

    Resistance spot welding is passed between two copper electrodes, the process can be performed by the operator holding a portable welding machine and moving it around the parts being welded.

    These portable machines called portable welding guns. The manual weld guns can have easy access to weld the components together.

    The resistance spot welding machines are classified according to combinations of individual sections as follows:

  • Fixed type
  • Stud type
  • Portable type:
  • Conventional weld gun
  • Integral weld gun

  • Conventional weld gun

    Conventional weld guns have a large transformer located remotely from the weld gun. The welding current is delivered to the weld gun arms through a large, water-cooled secondary cable.

  • J type or C type
  • S type or X type

  • The conventional weld guns were used in various applications because the weld controllers did not have the ability to detect and react to any hazard associated with using primary power connected directly to the weld gun.

    Integral weld gun

    Integral weld gun or tarn's guns have a smaller transformer located right on the weld gun, from which the current is delivered through short jumpers or shunts that are air cooled.
    Tran's guns are also called weld guns, because the transformer is part of the unit.

    The two configurations of portable tarn's guns are:

    For example C gun for welding around a door opening on a small flange and Scissors gun for welding large, deep boxes requiring a long reach.

    There are following characterizes for tarn's guns:
  • Design
  • Flexibility
  • Ergonomics
  • Cost efficiency


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