AZ Automotive Weld Tooling & Assembly Equipment Standards Revision 1.8 11Jan2005
PRINTED COPIES ARE UNCONTROLLED
Deviations that improve safety, quality, or cost ARE ALWAYS WELCOME.
SECTION 5
5.
Piping
5.1.
Design
5.1.1.
A separate
controllable pressure system shall be supplied for each of the following:
A.
Direct weld guns.
B.
Push-pull guns
C.
Self Contained guns
Note: Different
electrode forces (different stock thickness) will require their own circuit.
5.1.2.
All hydraulic
circuits shall be engineered so that the maximum oil velocity will not exceed
15 feet per second.
5.1.3.
All supply piping
drops to the fixture (hydraulic, water, and air) shall include 90-degree ball
type manual shut off valves (same size or larger than drop lines).
5.1.4.
Zoning. (See
illustration 5-1.0)
5.2.
Construction/Installation
5.2.1.
Teflon tape thread
sealant is prohibited and shall NOT be used.
5.2.2.
The locations of all
water, hydraulic and pneumatic manifold connection blocks to their main supply
shall be determined with AZ Automotive Launch Technician approval.
5.2.3.
All Hydraulic and
Pneumatic valves and manifolds will be floor mounted. Where floor mounting is
not feasible all hydraulic equipment shall be mounted on balcony.
5.2.4.
Any hose run over
five (5) feet in length must be approved by an AZ Automotive Launch Technician. The
Supplier shall provide and install commercial cable tray for this purpose.
These cable trays shall be installed according to all appropriate codes.
5.2.5.
No manifolds, pipe,
hose, wiring conduit, etc., shall be routed under the fixture base without
AZ Automotive Launch Technician approval. Locations of manifolds, pipe, hose, wiring
conduit, etc., shall be on the side or elevated above the fixture base. All
lines to manifolds (air, water, or hydraulic) must be spaced to provide wrench
clearance.
5.2.6.
Provide flow
controls in both directions on all air and hydraulic cylinders, except on weld
guns and as indicated by an AZ Automotive Controls Design Coordinator and/or AZ Automotive
Launch Technician.
A.
Hydraulic flow controls
shall be mounted at outer edge of the fixture for ease of adjustment and
serviceability with AZ Automotive Launch Technician approval.
B.
Flow controls shall
be the same size or larger than the ports on the actuators that they control.
C.
All flow controls
shall be adjusted so as to ensure positive operation of movement without
hammering.
D.
Air flow controls
shall be mounted at the cylinder.
5.2.7.
Air and water
headers are required the full length of all systems. Location and mounting of
headers must provide free access to all perishable service items.
5.2.8.1
On Multi-station
lines the facility water supply and return drops shall be on opposite ends of
the line to equally balance differential pressure to all stations. Shut-offs
shall be added as required.
5.2.8.
Supplier shall
provide and install approved 90-degree shut-off valves (same size or larger
than the header) at the plant supply end(s) of all main headers.
5.2.9.
All manifolds on
entire system shall be thoroughly blown out and cleaned before installation.
5.2.10.
Hydraulic and
pneumatic installations to manifold blocks shall be provided with at least one
(1) set of hose connections for a vibration joint.
5.2.11.
The size of
directional valves, installation runs, and all components (flow controls,
deceleration valves, etc.), must be of the same size or larger down to the last
manifold block or as close to the actuator ports as possible.
5.2.12.
5.2.13.
All air and/or water
hoses up to and including 3/4" shall utilize push on type hose and
fittings. All Hardware and materials shall be selected from "Manufacturing
Standards Volume "A" Approved Source List". Hoses larger than
3/4" shall use heavy-duty two-piece bolt type clamps.
5.2.14.
Supplier shall
furnish all directional valves (Excluding the valves that are mounted on AZ Automotive
power units and two post presses.)
5.2.15.
Hydraulic
directional valves shall be a minimum 3/4-inch. Air directional valves shall be
minimum 125 series (3/8"NPT) automotive sub base.
5.2.16.
Material on air and
water fittings shall be brass for sizes 3/4" and less. Fittings larger
than 3/4" may be cadmium or zinc dichromate plated steel.
5.2.17.
All air, water and
hydraulic manifolds will have a minimum 15% spare ports, drilled, tapped and
plugged (Minimum of four (4) holes).
5.2.18.
Rotating unions shall be Deublin 355-021-002.
5.2.19.
All piping used on
pneumatic installation main runs shall be black pipe.
5.2.20.
All pressure
regulators shall be equipped with a gage piped into the reduced pressure line.
Isolators shall be provided on all hydraulic gages.
5.3.
Pneumatic
5.3.0.
Coalescent filters are required and should be mounted as close to the application as practical. The filters should have a method to service them, without shutting down air, such as a pipe bypass around the filter.
Coalescent filters must be one size larger than the pipe required, to reduce restriction.
5.3.1.
Surge tanks for
counterbalance systems shall be sized to insure that the pressure differential
does not exceed 5% of the system pressure.
5.3.2.
Surge tanks for
counterbalance and all related air accessories shall be provided, installed and
connected by Supplier.
5.3.3.
Surge tanks and
related equipment for fixture air operated movement shall be provided,
installed, and connected by the Supplier.
5.3.4.
Steel tubing may
only be used with lubricated air or on a non-lube system downstream of the
coalescent filter.
5.3.5.
Provide service air
drop(s) to fixture(s) with quick disconnect(s) and shut off valves for air
powered hand tools. Service is required on both sides of the line.
5.3.6.
Air filters and
lubricators shall be provided for all air-operated devices. Standard
lubricating oil for general-purpose use in air line lubricators of production
machines shall be Vesco P/N 600 684-D, Mobil Velocite 10, or equivalent. Exceptions to this item
addressing air systems, which require service without the need for lubrication
equipment, shall comply with project specific standards for non-lube systems
available from an AZ Automotive Controls Design Coordinator.
5.3.6.1.
Air filters shall be
provided after all surge tanks.
5.3.6.2.
A check valve shall be
provided between the safety air dump valve and the surge tank.
5.3.6.3.
Manual drain valves shall be
provided for the surge tank.
5.3.7.
All counterbalance
cylinders shall have mufflers.
5.3.8.
Automatic drain type
pneumatic filters shall be used.
5.3.9.
Single point
lubricators shall be used on all air tools.
5.3.10.
All counterbalance
cylinders shall conform to MMAC 100 or 200 specifications. And have the
following features on blank end counterbalance cylinders:
A.
Elimination of rod
seal from the front cartridge.
B.
Elimination of the
top piston seal (counterbalance cylinders use one seal on blank end).
C.
Ensure the rod
bearing has approximately .005 additional clearance to eliminate galling.
D.
All counterbalance
cylinders must be capable of service without the need for lubrication
equipment.
5.3.11.
Counterbalance cylinders
should be attached to the item they counterbalance, not simply pushing against it.
5.4.
Hydraulic
5.4.1.
Provide
Standard manifolds for all hydraulic (4)-way valves. Location to be approved by
an AZ Automotive Launch Technician.
A.
Provide drip pans
with drain for all hydraulic manifolds.
B.
Provide 90 degree
ball shut-off valves for pressure and tank lines on all manifolds.
5.4.2.
Hydraulic valve
manifolds shall be selected as shown on the piping sheet of fixture control
diagram.
5.4.3.
Hydraulic gun
distribution manifolds servicing (16) or less guns will be a minimum size of
1-1/4" double extra heavy pipe. Manifolds servicing more than (16) guns
will be a minimum of 1-1/2" double extra heavy pipe.
5.4.4.
Each hydraulic valve
manifold shall have the capability of adding one valve with an isolated
pressure port (Maximum (5) position).
5.4.5.
All tanks must have
drain lines.
5.4.6.
All hydraulic lines
shall be schedule 80 black pipe, heavy-duty hydraulic seamless steel tubing or
double braided hose with female swivel fittings at both ends. No galvanized
piping shall be allowed.
5.4.7.
All drip pans ON
BALCONIES shall be connected to a common drain line (3/4"minimum) with a
90-degree ball shut-off at its end and are accessible from floor level without
entering safety-gated area.
5.4.8.
Supplier shall
provide the AZ Automotive Specified hydraulic fluid used in try-out. After try-out, the supplier shall remove all
hydraulic fluid from the system for shipment.
5.5.
Water
5.5.1.
Machine and fixture
shall be water tested in the presence of a AZ Automotive Launch Technician.
5.5.2.
Supplier to provide
1/2" 90 degree ball type shutoffs to water piping at each heat exchanger
for each hydraulic power unit.
5.5.3.
All welding and
induction curing components with water supply connections, must run directly to
distribution manifolds (no series installations).
5.5.4.
All water and air
distribution manifolds must be made of extruded aluminum, brass or approved nylon. 1
1/4" inlet, 1 1/2" outlet.
It is preferred that the aluminum is anodized to reduce electrolytic corrosion.
5.5.5.
Supplier shall
provide and install a flow switch in the 1-1/2" fixture water return line.
Supplier shall wire the switch as an input to the PLC and program the input, to
prevent the initiation of the welder control, if the water is off.
5.5.6.
A water flow switch
shall be provided for each fixture, and for each welding robot.
5.5.7.
All outlet water
lines shall be one nominal size larger than the inlet water line size.
5.5.8.
Water Cooling
requirements
A.
Welding transformers
1 GPM no restrictors
B.
Kickless cable 2.0
GPM
C.
Weld controls SCR
1.5 GPM each
D.
Welding electrodes 0.5
GPM each
E.
Hydraulic power unit
as per manufacturer's recommendation.
5.5.9.
All main water drops
shall be made of approved nylon pipe and have strainers installed. A union
shall be installed before the strainers to facilitate maintenance, and a ball
shut off valve installed before and after the strainer to prevent back flow.
5.5.10.
Water lines and fittings
shall be made of copper or brass.
5.6.
Identification
5.6.1. Omitted.
5.6.2.
Tags for valves
Indicating HVB or PVB for work position (Extended) (Raised) OR HVA or PVA for
home position (Retracted) (Lowered).
Note: For an example
of approved tag format contact a AZ Automotive Controls Design Coordinator (reference
WD_TAGS)
5.6.3.
Remote mounted flow
controls (hydraulics) shall be identified with a standard tag for field
devices. The tag shall indicate the actuator being controlled and the direction
of movement.
5.6.4.
Pneumatic
lubricators shall be identified with a standard tag for field devices. Tag
shall be indicate the oil used is #NP-6317.
5.6.5.
Operating pressures
for individual pneumatic and hydraulic circuits shall be indicated on an
approved tag affixed adjacent to the corresponding regulator or
pressure-reducing valve. Use actual operating pressure settings if they differ
from the design. Pressure setting is after weld certification.
Note: For an example
of approved tag format contact a AZ Automotive Controls Design Coordinator (reference
WD_TAGS)
5.6.6.
Filter assemblies
shall be identified with a metal tag indicating the manufacturer and model
number of the replacement filter.
5.6.7.
For cylinder
identification procedures see "Section 3", Mechanical, item 3.2.1
5.6.8.
The following color
codes will be followed for all air and water hosing:
Air hoses
|
Blue
|
Water hoses for
supply
|
Green
|
Water hoses for
return
|
Red
|
5.7.
Air Logic Controls
5.7.1.
Air logic control
designs shall be identified with WD numbers for tracking.
5.7.2.
All motions shall be
palm button initiated. Sequencing exclusively with limit valves, or
"cascading" of sequences should be avoided.
5.7.3.
Pressure indicating
devices shall be liberally applied to aid in troubleshooting. These devices
shall be installed at any point in the circuitry where the airflow direction is
altered or logic signal conditioning occurs.
5.7.4.
Clear vinyl
"Aquarium type" tubing and the appropriate fittings are acceptable
for use within a protective enclosure. Vinyl or Plastic tubing is not permitted
outside of the enclosures on body shop tooling.
5.7.5.
Circuit conductors
entering or leaving protective enclosures shall use individual bulkhead
connectors or approved fittings.
5.7.6.
All air logic
designs shall include particulate and coalescing filters so that logic
functions are performed with clean, dry (non-lubricated) air.
5.7.7.
WD drawings for air
logic shall conform to the following format.
A.
Sheet #1-Bill of
Materials1.Complete listing of purchased material including; Detail number,
Quantity required, Description, Part number, Manufacturer, and AZ Automotive Commodity
Code number.2.Pneumatic requirements/demand chart.3.Sequence/Timing
chart.4.Cylinder and switch/valve layout.
B.
Sheet #2 - S?? -
Schematic Circuitry1.Circuits shall be designed using ANSI valve
symbols.2.Control circuit and all actuators shall be shown in "Home"
position with all stored energy removed.3.All fluid conductors shall be
numbered and size shown.4.All valves shall be labeled with a device
identifier.5.All valve ports (i.e. Pressure, exhaust, cylinder, pilot etc.)
Shall be labeled with appropriate port identifiers.6.Pressure indicating device
shall be shown.7.All devices itemized in the Bill of Materials shall be
"Ballooned" in the schematic.
C.
Last sheet - Relay
Valve Enclosure Layout (when required)
Note: All sheets
shall include an alphanumeric grid, which shall be used to clarify line
referencing.