AZ Automotive Weld Tooling & Assembly Equipment Standards Revision 1.4      11Jan2005

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SECTION 11

11.            Principle Locating Points (P.L.P's)

11.1.        General

 

11.1.1.                                          

All PLP blocks, locators, clamping details, and auxiliary locators will be established in concept for preliminary location, control, and master section numbering system by the User, through the provision of preliminary marked up part drawings, PLP charts, and weld studies.

 

11.1.2.                                          

The PLP blocks and locators will be used in the process equipment as per the preliminary PLP charts and configuration sheets provided by the User.

 

11.1.3.                                          

All certifiable metal and no-mar surface PLP'S will be provided with certification reports.

 

11.1.4.                                          

Non-PLP locators, rests, and clamp details are identified on the User supplied preliminary configuration sheets. The Supplier is responsible for them, but they are not required to be certified. They are to be set up to approved sheet metal.

 

 

11.2.        Design

 

11.2.1.                                          

All PLP's blocks will be SAE 4140 with a hardness of Rockwell C-52-60, 1.5 mm deep. If the block is located in the field of weld it may be made of non-magnetic stainless steel at the option of the platform/plant. Refer to Illustration 11-4.0 for information regarding no-mar requirements.

 

11.2.2.                                          

All locating pins will be NAAMS (SAE 8620 steel or equivalent). Hardened to Rockwell C-58-62 to a depth of 0.5 mm -2.0 mm.  Locating pins in and around weld areas shall be coated with titanium nitride P.V.D.

 

11.2.3.                                          

All PLP rest and clamp details to be 25.0 mm wide.

 

11.2.4.                                          

All PLP's and locators will be designed with adjustment parallel to body coordinates unless requested by AZ Automotive program engineer.

 

11.2.5.                                          

All "L" Blocks and N.C. Block assemblies shall be installed with (2) 5 mm grind spacers. The spacer next to the "L" Block shall be ground to suit, and then tack welded after certification. The spacer next to the N.C. Block must be 5mm and free of weld.
If the spacers are both standard, and total 10mm, the lower one does not have to be tack welded in place.

 

11.2.6.                                          

The PLP's, locators, and clamp details will be held in place by 2 screws and 2 dowels where possible.

 

11.2.7.                                          

For PLP's rest and clamp blocks that contain external angles that contact with the part, a chamfer will be cut at a 45 degrees and will be made in such a way that it will not interfere with or mar the part. (See Illustration 11-1.0)

 

11.2.8.                                          

To accommodate a part that makes an internal angle in a PLP, there will be a circular section cut in the PLP, designed in such a way that the radius doesn't interfere with or mar the part. (See Illustration 11-2.0)

 

11.2.9.                                          

The X, Y, & Z coordinates stamped on the detail will be the mounting surface and the two centerline values that pass thru one of the dowels. This surface is not to be covered or view impeded. (See Illustration 11-3.0)

 

11.2.10.                                       

The PLP block dowel attachment will be fit as follows:

  1. For "L" block - press fit
  2. For PLP block - slip fit

 

11.2.11.                                       

Movable PLP blocks must have a positioning tolerance for repeatability that falls within 0.05mm tolerance. The end of the cylinder stroke is determined by the position of the stop block, so that the cylinder piston is never in the fully extended position. External stop blocks and side guides are required when a pin locator is carried on a movable arm. External stop blocks are required when a surface locator is on a movable arm. External side guides and stop blocks are required when the plane of a surface locator is not perpendicular to the plane of the arc or motion of the tool.

 

11.2.12.                                       

For PLP'S on pivot arms, dump units, etc., the following apply:

Total positioning tolerance for the repeatability of the pivot arm is 0.2mm measured under load of contact surfaces of the PLP'S.

The working position of the pivot arm (theoretically) can be easily verified within the reference system of the machine, by pivoting holes for setup balls.

 

11.2.13.                                       

PLP locating pins shall be designed nominal to size of the gage hole minus 0.15 mm + 0.00/-0.02 as per NAAMS, Assembly and Fabrication.

 

11.2.14.                                       

PLP locating pins should extend through the gage holes a minimum length of 5mm, not including taper lead.

 

11.2.15.                                       

PLP locating pins will be mounted in such a manner as to allow it to be removed from it's mounting. The mounting plane must be perpendicular to the axis of the mounting pin. Use locating pin retainers, where possible, shown in the NAAMS, Assembly and Fabrication Standards.

 

11.2.16.                                       

Rotated locating pins will be designed in such a manner that the angle of its center axis can be referenced to a setup ball that lies within the body coordinate system.

 

11.2.17.                                       

For Class A Surfaces;
No-mar Certified PLP blocks will conform to the following criteria:

  1. They will have a metal insert consisting of a blank cut block.
  2. The urethane is to be between A-90-96 Durometer in order that the blocks can be Neck's to within 0.2mm tolerance for the surface and yet not hard enough to cause surface damage.
  3. The urethane shall be secured as shown. (See Illustration 11-4.0)

 

11.2.18.                                       

Rotated blocks and PLP'S are to have work lines related to specific body lines and angles of rotation shown. (See Illustration 11-5.0)

 

11.2.19.                                       

The Supplier will draw the design of the blocks on the User provided "PLP Locator Detail Drawing". (Manual design only) They are responsible for filling in the chart in full and keeping them updated throughout the program.

 

11.2.20.                                       

All PLP Blocks and fingers shall be drawn in as many views as needed to accurately convey all requirements of the detail.

 

11.2.21.                                       

The contact surfaces of all PLP blocks and fingers shall be relieved 2.0 mm from all trim edges and tangents (See Illustration 11-1.0).

 

 

11.3.        Construction/Installation

 

11.3.1.                                          

The User reserves the right to approve and inspect the Supplier's CAD, NC, build, and certification facilities and/or sub-contractor's.

 

11.3.2.                                          

The Supplier shall be able to create block sections, surfacing, and NC data from the following types of User supplied product information:

 

  1. Must be able to digitize mylars.
  2. Trace from die models.
  3. Read and manipulate CAD data on a system that can interface with UG or CATIA.

 

The User reserves the right to inspect and approve the Supplier's facilities and/or sub-contractors.

 

11.3.3.                                          

If the CAD data, complete with surfacing, is provided, it is to be the information that will be used as the theoretical data for block certification and the information from which the NC programming shall be done. If the CAD data is provided without surfacing or the information is obtained from the sources in 11.3.2, then the Supplier will create the surface from character lines and cut sections. In either case, the Supplier will cut two (2) sections in the PLP block's location: one (1) at each edge of the PLP block's surface. The data from these sections must be both numerically and graphically provided to the User.

 

11.3.4.                                          

The blocks shall be built exactly according to the design on the "PLP Locator Detail Drawing".

 

11.3.5.                                          

At the time of build, the Supplier is to complete all remaining parts of the "PLP Locator Detail Drawing" pertaining to the build.

 

11.3.6.                                          

A "PLP Locator and Detail Timing Chart" shall be furnished to the User (Build Follow-Up) by the Supplier at the time of the 40% Design Review. It will depict, in detail, the start and finish timing per locator block unit, etc., by fixture proposed by the Supplier. The build of the blocks and locators will not commence until the User has approved the timing.

 

11.3.7.                                          

Throughout the build program, the PLP Supplier shall supply the User (Build Follow-Up) with "PLP Status" reports on a weekly basis. There will be two types of these reports:

 

  1. By numerical PLP and locator order.
  2. By all the PLP's per fixture.

 

These reports will have the following information:

 

    1. PLP number.

2.        Part Number - the part, parts, or assembly on which the PLP is found and their metal thickness. It shall be compared to the PLP locator detail drawing and if a variance is found the PLP User shall be notified.

3.Block coordinates: a reference of the body coordinates of where the PLP block, locator, clamp, etc., are located (x, y, z or work line ref. point).

    1. Revision to which block was cut.
    2. Revision to which block is applicable.
    3. Present revision of product (part or assembly with respect to PLP).
    4. Number of times block has been cut.
    5. Tool number.
    6. Unit number.
    7. Detail number.
    8. Date block started.
    9. Proposed delivery date.
    10. Date shipped.
    11. Status, e.g.; in build, NC programming.
    12. Side of metal cut: in or out.
    13. Type of block: should tell what material (metal, no-mar, etc.) and type and number of surfaces      (simple, compound, or complex).

 

11.3.8.                                          

The edges of the contact surfaces of all blocks will be sharp. The edges are not to be rounded.

 

11.3.9.                                          

The sides of all blocks shall be black oxide, with the exception of the contact surfaces, and shall be clearly stamped.

 

11.3.10.                                       

The side of the block shall be stamped with the following information:

  1. Tool Number and/or Station Number.
  2. Unit Number.
  3. Detail Number.
  4. PLP Reference Number.
  5. "O" line coordinates close to their location on the detail

 

11.3.11.                                       

The Supplier shall have available both the block and its certification report 3-7 days prior to mounting on the specific tool. The original certification report will be given to the User, while the Supplier keeps a copy for reference.

 

11.3.12.                                       

All NC programs will become the property of AZ Automotive at the end of the program.

 

11.3.13.                                       

Tolerances of the reference system, which the PLP's are:

 

A.      Contact surface with respect to the "O" coordinates  ± 0.13mm

B.       Surface quality 125

C.       Checking fixture ± 0.05mm

D.      Width of PLP ± 0.2mm

E.       Diameter of mounting holes  ± 0.13mm

F.       Center to center dimension  ± 0.13mm

G.       Diameter of dowels H7

H.     The tolerance for the perpendicularity between the reference surface and the surface plate is ± 0.05mm.

I.      The tolerance regarding the parallelism between the base plate and a PLP surface or edge is ± 0.05mm.

J.        The tolerance for angular orientation of a PLP reference surface or edge in relation to the base plate is ± 0.05mm.

K.      The tolerances for locating pins are:

L.       Diameter ± +0.00/-0.02

M.     Rest/Stop on shoulder ± 0.1mm

N.      Locating pins must meet NAAMS, Assembly and Fabrication Standards for dimension and construction.

 

11.3.14.                                       

Minimum sheet metal thickness shall be used for design, construction, and certification of all PLP blocks.

 

 

11.4.        Certification

 

11.4.1.                                          

The Supplier will provide a certification report with each PLP block. This report will contain the theoretical, actual, and variance of the points using vector coordinates i, j, and k shall be provided.

 

11.4.2.                                          

The Supplier must inform the User, at the time of quote if he will be doing the certifications of the fixtures or not, and the type of equipment he will use. If this certification is being outsourced, both the proposed sub-contractor and his equipment must be presented to the User for approval at the time of quote.

 

11.4.3.                                          

If an agreement is reached between the integrator and the User's Certification Group to do all or part of the certification together then all articles in this procedure, which apply to the User certification, will apply to User/Supplier joint certification.

 

11.4.4.                                          

At the User's request, the Supplier shall supply his certification schedule to the User's Certification Group. The schedule should be in chart form and detail timing and major measuring equipment to be used.

 

11.4.5.                                          

Any revisions to the Supplier's certification schedule must be transmitted immediately to the User's Certification Group and Build Follow-UP.

 

11.4.6.                                          

The User's Certification Group shall be allowed access to the Supplier's facility at any time during the Supplier's build and certification phase.

 

11.4.7.                                          

The User's Certification Group timing will depend on whether the User certification will be independent or in conjunction with the Supplier's certification period. The User will make every effort to certify in conjunction with the Supplier.

 

11.4.8.                                          

The Supplier shall delegate one (1) fully qualified representative to receive and transmit all communication to and from the User's Certification Group.

 

11.4.9.                                          

The Supplier shall supply technical assistance to the User's Certification Group as required. This applies to operation of the assembly equipment so that all of the required points can be certified.

 

11.4.10.                                       

The Supplier shall supply labor for any fixture adjustment, which will have to be made during the User's certification phase.

 

11.4.11.                                       

The Supplier certification shall be accomplished using a tool measurement system meeting all accuracy and repeatability requirements set by AZ Automotive Corporation. All equipment must have proof of being recently certified.

 

11.4.12.                                       

The Supplier shall supply all miscellaneous layout accessories such as angle plates, risers, scribes, clamps, magnets, gauge blocks, etc.

 

11.4.13.                                       

The Supplier shall supply a cleared, clean, traffic free area around the fixture during User certification.

 

11.4.14.                                       

The Supplier shall not do any work on the fixture, which will slow the User's certification process or affect dimensional results.

 

11.4.15.                                       

The tolerance on the grid lines is to be ± 0.15mm with the tooling holes (minimum of 5) as the absolute reference.

 

11.4.16.                                       

The Bench Marks (minimum of 6) are to be used as the reference points for the planes at right angles to the base plate. Two of the Bench Marks are to be at intersecting grid lines.

 

11.4.17.                                       

All Bench Marks and auxiliary reference holes must be located so that they are easily accessible by any approved tool certification system.

 

11.4.17.1

Identify all benchmark locations with red paint. Do not paint face of benchmark.

 

11.4.18.                                       

For User or Supplier certification, all PLP points on any given fixture which are geometrically related must be certified in one (1) measuring system setup. If more than one (1) setup is unavoidable, at least three (3) points certified in the first setup must be rechecked in the second setup to verify compatibility. The second reading for each rechecked point must be within ± 0.125mm of the reading from the first setup

 

11.4.19.                                       

Any reference points used by the supplier's certification group must be recorded on a supplier provided certification form.  This form must comply with the conditions stated in Section 13.

 

11.4.20.                                       

The Supplier is responsible to record all measurement data on the User provided certification forms and provide copies of all to the User's Certification Group.

 

11.4.21.                                       

All additional paperwork, which is computer, generated by the CMM or certification system is also to be given to the User's certification team for review.

 

11.4.22.                                       

All blocks shall be certified individually by the Supplier on a CMM. The designated PLP Suppliers will have these capabilities.

 

11.4.23.                                       

The contact surface(s) of the PLP must be within a tolerance of ± 0.13mm with the "O" line coordinate as a reference.

 

11.4.24.                                       

The User's Certification Group will designate all blocks as (S) Standard or (C) Complex surfaces.

 

11.4.25.                                       

The Supplier shall certify all "O" line coordinates of (C) blocks on the assembly using the equipment specified in 11.4.11.  The acceptable tolerance for heel surface or "O" line coordinates certification is ± 0.13mm.

 

11.4.26.                                       

For blocks designated (S) the contact surface or "O" line coordinates can be used to set the PLP location on the fixture. The heel surface or trihedron must still be within ± 0.13mm.

 

11.4.27.                                       

This results in a maximum PLP contact surface tolerance of ± 0.25mm for (S) or (C) blocks.

 

11.4.28.                                       

Whether setting by the contact or "O" line coordinates, the actual "O" line coordinate dimensions after assembly must be on the block as specified.

 

11.4.29.                                       

The Supplier shall certify all pin diameters to a tolerance of +0.00mm/-0.02mm. Pin diameter to be obtained from the fixture drawing.

 

11.4.30.                                       

The Supplier shall certify all center line coordinates to the tolerance of ± 0.15mm.

 

11.4.31.                                       

The Supplier shall certify all clamping contact surfaces, acting as PLP's, to a tolerance of ± 0.10mm with the heel surface of "O" line coordinates as references.

 

11.4.32.                                       

The Supplier will backspot all clamps to the specified sheet metal thickness using feeler gauges or existing parts and using full clamping pressure.

 

11.4.33.                                       

The User's Certification Group will do a complete visual inspection of all items, which affect geometry for every fixture before approval is given.

 

11.4.34.                                       

Fixtures can be rejected for any of the following reasons:

A.      Geometrically unfinished fixtures.

B.       Poor workmanship, which deters from the geometrical integrity of a fixture.

C.       Base plate not level within specification.

D.      Grid lines not within positional tolerance.

E.       PLP contact surface not within positional tolerance with respect to "O" line coordinates or furnished CAD sections.

F.       "O" line coordinates not within positional tolerance on the assembly fixture.

G.       "O" line coordinates not identified or incorrectly identified on the PLP.

H.      Detail number and PLP number not marked on the PLP or incorrectly marked on the PLP.

 

All dimensional errors found during the User's certification will have to be corrected by the Supplier. If more than ten percent (10%) of the measurements or PLP's are found to be out of tolerance, either in position or dimension, the complete fixture must be re-certified by the Supplier. A new date for re-certification by the User must be provided by the Supplier at that time.

 

11.4.35.                                       

The Supplier shall provide a certification with all of the required data after approval by the User's Certification Group.

 

11.4.36.                                       

All rest blocks, pins, and clamps shall be identified with the PLP number and Detail number.

 

11.4.37.                                       

The body coordinates of the three "O" line coordinates shall be identified on rest blocks and clamps.

 

11.4.38.                                       

All identification described shall be easily visible and permanent (etched, engraved, stamped, or equivalent).

 

 

11.5.        Assembling P.L.P. Block to "L" Block

 

11.5.1.                                          

PLP Blocks shall be mounted with two (2) dowels and two (2) screws unless otherwise approved by AZ Automotive.

 

11.5.2.                                          

The PLP mounting surface on the modified grind spacer will be located within + .12 mm to the factored N.C. Block "O" line coordinate set-up points.

 

11.5.3.                                          

The modified grind spacers shall be within + 2.00 mm after final set-up.

 

11.5.4.                                          

After fixture certification, the modified grind spacer shall be tack welded four (4) places to the mating "L" Block. The remaining standard 5.00 mm grind spacer will remain free of weld.

 

11.5.5.                                          

PLP Block Assemblies to "L" Block. (See Illustration 11-7).