What are the requirements for 3D flexible welding fixture clamps

The 3D flexible welding fixture is a versatile fixture that can be freely combined to adapt to different workpiece shapes. Several fixture systems can replace a large number of high cost fixtures. After using this fixture, the cost and time of tooling investment due to product changes can be saved. In the production of multiple varieties and personalized automobiles, its economy is particularly evident. There is data indicating that the cost of nine or more sets of welding fixtures exceeds that of one set of flexible fixtures. At present, it is common for Chinese automobile manufacturing enterprises to add dozens of sets of welding fixtures every year, and the economic feasibility of using flexible fixtures is obvious. Flexible combination fixtures can be combined in three-dimensional space. The modular system reasonably embodies its universal function in the installation, adjustment, and clamping of workpieces, and this feature is increasingly prominent in the welding of large workpieces. The other side of flexibility is reflected in its ease of operation.

(1) The fixture should have sufficient strength and rigidity. When fixtures are put into use in production, they must withstand various forces, so fixtures should have sufficient strength and rigidity.

(2) When clamping, the positioning position of the workpiece and the shape and size of the product should not be damaged, and they should meet the requirements of the drawing. It is not allowed for the workpiece to loosen or slip, and the constraint on the workpiece should not be too large, resulting in significant constraint stress.

(3) Flexibility in welding operations. Use fixtures to produce sufficient welding space, allowing operators to have a good view and operating environment, and keeping the entire welding production process in a stable working state

(4) Facilitating the loading and unloading of welded components. When operating, it should be considered that the product can be smoothly removed from the fixture after assembly positioning welding or welding, and the product should also be flipped or lifted to avoid damage.

(5) Good craftsmanship. The designed fixtures should be easy to manufacture, install, and operate, as well as facilitate inspection, maintenance, and replacement of vulnerable parts. When designing, factors such as the existing clamping power source, lifting capacity, and installation site in the workshop should also be considered to reduce the manufacturing cost of fixtures.

All modules of the flexible combination fixture have high processing accuracy, and the position error of the positioning hole on the working platform is within ± 0.1mm within a range of 2000mm, which can meet the needs of welding processing. During assembly or welding, the use of positioning blocks, connecting blocks, clamps, and support blocks can accurately position the workpiece, and the workpiece that needs to be welded can be stably fixed at various positioning points or surfaces. If the geometric dimensions of the workpiece itself are not accurate, they can also be quickly detected during the initial machining process. By using CAD and Pro/E design systems, it is very easy to simulate assembly of samples, and accurate module dimensions can ensure assembly accuracy. In the design of the work platform and module structure, the requirements for rigidity and strength have been fully considered. Each standard 2000mm × 1000mm work platform can carry a load of up to ten tons and has the accuracy of repeated positioning and clamping. The surfaces of the work platform and modules have been specially treated to prevent splashes generated during welding from easily sticking to their working surfaces. The surface of the positioning and clamping pin is quenched to prevent wear and tear.