AZ Automotive Weld Tooling & Assembly Equipment Standards Revision 1.3 23Sep2004
PRINTED COPIES ARE UNCONTROLLED
Deviations that improve safety, quality, or cost ARE ALWAYS WELCOME.
SECTION 13
The Objective of these procedures is to establish a set of guidelines for tool certification with the use of various measurement systems. These systems will determine the build, inspection and certification functions regarding automated fixtures/tooling and gages for assembly operations.
The Certification of a tool/fixture or gage is done to determine its dimensional integrity to the design intent. To achieve this integrity the following shall be adhered to.
All tool certification equipment must perform and pass a 10-1-1GR (gage repeatability) study utilizing the same techniques for tool certification before the original certification is to commence. A passing GR requires a 30% or less repeatability error determined from a standardized formula obtained from the AIAG manual. When performing a GR an AZ Automotive representative must be present. A 10-1-1 study consists of 10 different checks of the tool where the certification equipment is set-up and torn down between each check. The tool/fixture being checked must stay in a stationary position as to not effect the results. The selected tool/fixture for performing the GR is recommended to be the largest available (as to check the repeatability over the largest volume).
At initial build certification, the integrator must identify the system type to be used for all certification procedures and provide accuracy and repeatability data, which demonstrates adequacy for this application.
Whenever a tool has moving part locators, all part locators on the tool must be machined, mounted, and welded prior to:
1. Passpoints/benchmarks creation.
2. PLP blocks and locating pins certification
3. Re-certification at using plant
Moving part locators on the tool are subject to a 10-1-1 GR (or other repeatability study approved by the platform team) to determine the repeatability of the tool/fixture itself. A 10-1-1 GR consists of 10 different checks of the actuated tool (the movement of dumps, slides, locators, clamps, etc.) while maintaining the position of the tool certification equipment, as to not effect the results. For GR approval requirements see 13.2.1
If the tool/fixture design is such that power is required to hold the tooling in weld position, the certification procedures shall be performed with power on.
Certification of all stop blocks, dump locks, slide position locks, etc. to ensure net (lock out condition) must occur before certification of the remaining tooling is to commence.
When there are large dump units that may cause the part locators to deflect while in a welded position, the dumps shall have passpoints/benchmarks and shall be in body position during the certification process.
Where applicable, locators that index for different models shall be certified in each model location.
The certification of the base (tool/fixture) shall be accomplished to determine the flatness of the surface and the dimensional integrity to the body coordinate.
In order to create a coordinate system that is universal (accessible to various measurement systems) and repeatable, there must be precise locations, which will be used to establish the reference system.
Bases must be designed and built with uncovered areas on the base surface. These areas shall be large enough to allow the placement of an invar or graphite scale (or some other measurement length that is certified and traceable to NIST) adjacent to each leveling screw. This must be done to achieve repeatable leveling of the bases.
The build source shall provide one 6.35mm.(.2500") diameter target hole in each corner of the fixture/tool base located approximately 50 mm from each edge. These holes must be located so that the theoretical lines through adjacent holes are parallel and square to each other within +/- .125 mm (.005"). They shall also be parallel and square to the base datum within +/- .125 mm (.005") and identified 1-4 in a clockwise position, one (1) being the point closest to the origin. (See Illustration 13-1.0)
The points will provide a fixed reference system that will be used by the supplier. These four points will allow for redundancy; thus the accuracy of set-up and fit of the coordinate system may be tested and checked.
A title page consists of the following information.
1. Tool/fixture number.
2. Tool/fixture name.
3. Build source location.
4. Certification source.
5. A sketch showing the tool/fixture with developed pass points/benchmarks.
6. Initial RMS axis error (minimum of 5 points).
7. Initial scale factor.
8. List passpoints/benchmarks with their x, y and z values (See Illustration 13.2.0).
A work sheet consists of the following information.
1. Date of certification.
2. Page number 1 of.....to the total # of pages.
3. Orientation - Rotation about the mounting surface, heeling surface and the locator dowel.
4. Position - number of certification stations.
5. Two "X" readings, two "Y" readings and one "Z" reading.
6. Tool axis showing FOL (X), CL (Y), and BOL (Z) with nominal value, actual value and a variance.
7. Grind spacers in FOL (X), CL (Y), and BOL (Z) showing a controllable or non-controllable axis.
8. The certification representatives for the supplier, certification source and AZ Automotive Corporation (See Illustration 13-3.0).
Mandatory conditions for certification
1. An electronic version and a hard copy of the certification report shall be made and provided to AZ Automotive.
2. No certification shall begin unless the tool is completely built or (unless otherwise authorized by AZ Automotive Corporation Tool Follow-up and Certification).
3. No welding shall be performed on any tool after certification unless the tool is to be recertified.
4. Certification must be performed in a right hand coordinate system format.
5. A minimum of three (3) individual points must be shot on any block, locator or template plus (2) points for pin locators to determine axis orientation.
The build source certification team is responsible for placement of benchmarks/passpoints.
1. A minimum of six (6) is required, preferable ten (10) depending on tool/fixture size.
2. Passpoints/benchmarks must be placed on the tool/fixture in such manner that they will be visible from at least two angles in one set-up.
3. Benchmarks/passpoints shall have on 1/4" (6.35mm) reamed hole 3/4" (19.05mm) deep for locator pin placement. (See Illustration 13-4.0)
4. Benchmarks/passpoints shall be securely welded, and identified given XYZ locations after getting into the three (3) planes of the fixture (fixture coordinate system established).
5. All discrepancies shall be settled between the build source, AZ Automotive's re-certification source or tool follow-up and certification where applicable.
The format of the floppy disk and/or hard copy must contain the following:
1. The AZ Automotive cover sheet information, specification and procedures attachment to be followed.
2. All calibration information (three (3) planes orientation, bundling, scale bar shot (invar or graphite bar etc.) are to be shown on the hard copy printouts.
3. A grind spacer sheet showing final size of tack welded spacer after the certification is completed, or record on work sheets. (See Illustration 13-3.0)
4. Deviations are not permitted without the approval of AZ Automotive; Tool Follow-up and Certification.
5. A first time complete shot of the tool/fixture must occur. If repairs are required during re-certification, it is the responsibility of the build source, and those discrepancies must be re-shot at their expense. Final documentation must show that the repairs were made. Show documentation on the first shot and highlight the discrepancies (unless otherwise authorized by AZ Automotive).
6. A brief statement explaining how the initial method of set-up was used to certify the tool/fixture.
To assure that the certification source has read the document thoroughly the following signatures show compliance:
1. Certification source__________________________________
Certification representative______________________________
Names of all operators____________________________
____________________________
____________________________
2. All originals go to AZ Automotive. This is the responsibility of the build source.
Tooling certification systems available for use, providing they meet accuracy and repeatability requirements and be approved by AZ Automotive.
Calibration checks, as recommended by the manufacturer, must be maintained. Before any certification commences, a copy of the calibration results must be provided to an AZ Automotive representative. All calibration systems, tools used must be traceable to NIST.
Control file/data file
1. Control/data file name = tool/fixture #CTL EX: 2FZJ-2960 - CTL
2. Point names
a. Scale names = E1, E2, E3...etc.
b. Benchmark names = BM1, BM2, BM3...etc
c. Control point names = CPBM1, CPBM2, CPBM33...etc.
d. Axis point names = X1, X2, X3,..41, 42, 43,..21, 22, 23
e. Extra point names = no requirements.
3. Three planes
a. Base plate
A.Minimum of 5 fixed points (on large base 10' x 20' 9 points min) on base for 1st axis.
B. Point names = X1 thru X5 = Y1 thru Y5 = Z1 thru Z5 (depending on axis)
b. Line
A. Minimum of 2 fixed points on the same cut line for 2nd axis
B. Point names = X1, X2 = Y2, Y2 = Z1, X1 (depending on axis)
c. Point
A. One fixed point for 3rd axis
B. Point names = X1, Y1 and Z1 (depending on axis)
4. Benchmark/Passpoints
The creation of a benchmark system allows us to move from the base as the generator for the coordinate system, (which may not be accessible to us), to a highly visible and repeatable coordinate system.
For the purpose of definition: a benchmark is a location, chosen at the tool certification operator's discretion for visibility and usability. The point is given value with body coordinates by the certification system. It is based on an existing coordinate system and the intent is that the point will be called upon at a later time to duplicate that coordinate system.
The benchmarks, once they are established and valued, will be used as the sole method of orientation to the object by the certification system. This allows any system or operator to enter the coordinate system and work in and around the object within acceptable accuracy parameters, barring operator blunders.
a . Benchmarks are CRS blocks 1" x 3/4" x 1" with a 1/4" reamed thru hole.
b. Minimum of 6 benchmarks per object orientation set-up.
c. There must be at least one benchmark in the general location of the details that are to be inspected.
d. Benchmark names = BM1, BM2...BM6.
e. Paint: all benchmarks shall be painted red and identified BM1, BM2...etc.
f. Benchmarks shall be shot in data capture after the original object orientation and put in the benchmark file.
g. Benchmarks can only be placed on units that are permanently doweled and or welded to the fixture bases.
h. To re-set into a fixture/tool, use local/default to object/transformation of tool.
i. Always use scale bar, never use object or tool for scaling.
j. Benchmarks must be protected from damage due to paint, weld splatter or the function of the tool.
6. Control/transformation points
a.Use only on initial setup and to be fixed or unknown
C. b.Go to local, to object orientation re-setup into tool
|
Type |
Name |
Num |
X |
X |
Y |
Y |
Z |
Z |
|
Scale |
E1 |
1 1 |
|
|
|
|
|
|
|
Scale |
E2 |
1 2 |
|
|
|
|
|
|
|
Point |
X1 |
|
900 |
FIX |
------ |
UNK |
------ |
UNK |
|
Point |
X2 |
|
900 |
FIX |
------ |
UNK |
------ |
UNK |
|
Point |
X3 |
|
900 |
FIX |
------ |
UNK |
------ |
UNK |
|
Point |
X4 |
|
900 |
FIX |
------ |
UNK |
------ |
UNK |
|
Point |
X5 |
|
900 |
FIX |
------ |
UNK |
------ |
UNK |
|
Point |
Y1 |
|
------ |
UNK |
-500 |
FIX |
------ |
UNK |
|
Point |
Y2 |
|
------ |
UNK |
-500 |
FIX |
------ |
UNK |
|
Point |
Z1 |
|
------ |
UNK |
------ |
FIX |
1200 |
FIX |
|
Point |
CPBM1 |
|
925 |
UNK |
260 |
UNK |
1900 |
UNK |
After control file requirements are met, any extra points (BM, extra points) may be placed into the raw file (data capture).
|
Point |
BM1 |
|
------ |
UNK |
------ |
UNK |
------ |
UNK |
|
Point |
BM2 |
|
------ |
UNK |
------ |
UNK |
------ |
UNK |
|
Point |
BM3 |
|
------ |
UNK |
------ |
UNK |
------ |
UNK |
|
Point |
BM4 |
|
------ |
UNK |
------ |
UNK |
------ |
UNK |
|
Point |
BM5 |
|
------ |
UNK |
------ |
UNK |
------ |
UNK |
|
Point |
BM6 |
|
------ |
UNK |
------ |
UNK |
------ |
UNK |
|
Point |
BM7 |
|
------ |
UNK |
------ |
UNK |
------ |
UNK |
Example: Control file in a local system (this is for re-entering into the tool using the local system.)
|
Type |
Name |
Num |
X |
X |
Y |
Y |
Z |
Z |
|
Cert. |
1 |
0 |
FIX |
0 |
FIX |
0 |
FIX |
|
|
Scale |
E2 |
1 .1 |
|
|
|
|
|
|
|
Scale |
E2 |
1 2 |
|
|
|
|
|
|
Shoot Benchmarks in the local system
A. Bundle Adjust:
1. Total RMS can't exceed .05 mm
2. Individual axis RMS can't exceed .05mm
(Using the local to object mode provides a comparison between the old and new benchmark file.)
Data
A. Prints
1. All prints must be available for the inspecting of the fixture.
2. All prints must be shipped with the fixture.
B. Project Definition
A copy of the project definition screens is to be part of the certification documentation.
C. Data and Control Files (Reference Only)
1. Hard copy of both files must be part of the certification documentation.
2. Floppy disk with both files must be shipped with the prints.
3. Data files are to have only block, pin, drill, and punch/die information. No benchmarks or three plane data.
4. Data files are to be arranged in detail number numerical order.
EX:
XYZ506_1
XYZ506_2
M506_1
M506_2
XYZ509_2
M509_1
M509_2
M509_3
PIN603
XYZ708_1
A sketch of the fixture with certification system positions relative to the fixture for each setup required to inspect the fixture must be part of the certification documentation. (See Illustration 13-5.0). Include the following:
Locating Pins
Check the pin center
1. Point name = PIN. detail #, R/L
Example: PIN504R = Pin, Detail 504, Right side
2. Enter design pin center dimensions in the comment area.
Drills
Check the drill center - (2) points minimum to check for axis orientation.
1. Point name = DRILL. Detail #, R/L
Example: DRILL1809L = Drill, Detail #1809, Left side
2. Enter design center dimensions in the comment area.
Punch/Die
Check punch/die with arc routine Point name - Punch/Die, Detail #, R/L
Example: IE1207L = Die, Detail #1207, Left side
Tolerances:
Level (When the base surface is leveled parallel to gravity)
Flatness
Fixture base is to be flat within +/-.125 mm for a 10 foot (3048mm) base and +/-.250 mm for base 18 foot (5486.4mm) or longer, when the base is not parallel to gravity.
Alignment
1.In a line of tools, alignment of grid lines is to be held parallel to +/- .250mm between multiples of three (3) bases where the last base of the previous multiple is to be the reference for the next multiple.
2.Station to station to be held to +/- .250 mm from o/line start hole to o/line start hole.
Locating the Blocks
1.The block itself is to be constructed within +/- .125 mm of the design dimensions.
2.The block in its assembled position is to be within +/- .25 mm from design location (controllable).
3.The block can be up to +/- 1.00 mm off design location in a non-controllable axis, when the mating surface is on a XY, XZ OR YZ slip plane.
Pins, Drills, Punch/Dies
Centerlines are to be within +/- .25mm from its design location.
Squareness
Blocks are to be square within .25 degree (.44mm/100mm)
Assembling PLP Block to "L" Block
1. Set-up Project Definition Screens
2. System Orientation
b. Locate benchmark blocks
Inspect fixture using the preceding specifications.
13.9.2
Build Shop Requirements for Certification of Tooling
In every case the certification is the supplier's responsibility. Certification documentation must be provided to AZ Automotive for final acceptance.
13.9.3
1. PLP blocks are dimensionally complete on the drawing, therefore, N.C machining of the blocks is not normally optional; however, it is not necessary to N.C. machine rest blocks, back-up blocks, and/or clamp fingers which have all contact surfaces that are both planar and parallel to the coordinate system. Precision dimensions of these contact surfaces can be derived from CATIA data. Cost savings for not N.C. machining the above PLP blocks must be reflected in the cost to AZ Automotive.
2. Final assembly position of the PLP block is to be held at +/- .010"(.250mm). The location of the "L" blocks and PLP blocks is shown as "0" line dimensions for interchangeability. The actual locating method used by the build source is left to their choice as long as the final certification dimensions are held and the block still has the ability to be interchangeable to accommodate replacement.
3. Build quality is the sole responsibility of the build source. When build errors occur, the build source will be responsible for repair and re-certification of tools.
4. All PLP blocks and fingers are designed with 5.00 mm grind spacers. Final certification of PLP blocks and fingers will have grind spacers of (See PLP block assembly 11.2.5) Re-machining of PLP blocks is not permissible.
5. Build source is responsible for mounting and identifying locations of all benchmarks blocks per fixture. Target locations are established by inspection source.
6. AZ Automotive shall provide a selection list and monitor jointly with the build shop the tool certification system and CMM inspection source. Any problems that may develop shall be immediately referred to AZ Automotive Certification and Follow-up for clarification.
7. All PLP blocks are to be black oxided and hardened steel (Rc 52-60) unless NMSS. (See Illustration 13-5.0) Certification set-up.
8. All PLP blocks and pins are required to meet a design specified hardness. The build source is responsible for testing and documentation of the hardness checks/results (including source, equipment, etc. used for the testing). Copies of the hardness results must accompany all certification documentation.
9. The build source shall provide to the assembly plant, an extra set of locator pin design prints for all tools that are not NAAMS standard.
13.10.1
Re-Certification at Assembly Plant
The following procedure is to be strictly adhered to "re-verify" the location of the locating blocks and locating pins after tooling installation in the assembly plant.
1.Certification Set-up
The certification systems are to be positioned in the same locations relative to the tool as shown on the final certification sketch.
2. If the final certification sketch is unavailable, the positioning of the system must be such that at least six passpoints shall be visible for the use of orientation and that any and all locating blocks as certified from the set-up shall provide accurate and repeatable results.
3. System Orientation
a) A minimum of six (6) passpoints shall be used on "small" fixture/tools and ten (10) passpoints on large fixture/tools. If insufficient passpoints are available to perform an orientation, the operators must establish more passpoint locations using the guidelines set forth in 13.5 Section C.5 passpoint creation.
b) Level fixture within .125 mm over all leveling jacks.
c) To re-set the tool, use benchmarks to get into the system through the local to object orientation. Spot check a minimum of six (6) points on different locator blocks or pins to make sure that the coordinate system is accurate.
d) Re-set the whole fixture if coordinate system was not accurate. Follow the procedures as outlined in 13.5 Section C.
4. Assembly plant re-certification
Tools/Fixtures being re-certified at the assembly plant require 100% re-certification of locator pins a minimum of 10% verification check for PLP blocks. This percentage will determine the overall condition of the tool/fixture. The build source should be present for verification checks.
In the event that (1) of the points during the minimum 10% re-certification fail, the entire tool must be re-certified at the build source's cost.
5. Tool/Fixture Responsibility
For warranty purposes, if a tool is found to not meet certification levels previously attained during assembly plant re-certification, the build source is responsible for any rework necessary.
Tool/Fixture re-certification will then require a 100% re-shoot to verify all locations.
Setup system and align to body coordinates:
1. Scribe lines on base
2. Tooling holes on base
3. Bench marks
Verify the setup accuracy: LEP sdev < 0.03mm.
Verify that the change level stamped on each detail part agrees with build plan. (tool part matrix sheet)
Load each detail part into fixture.
Verify there is no part to locator interference.
Load all parts and close clamps per AMPS, check that all clamp fingers are set correctly.
Attach Measurement Targets to each part, more on larger parts.
It is the responsibility of the Measurement Team to perform a "System Repeatability" test. The test requirements are as follows:
System repeatability - Close clamps and cycle system 30 times for static repeatability. If measurements exceed 0.043mm re-setup system.
It is the responsibility of the Measurement Team to perform a "Clamping Repeatability" test. The test requirements and procedure are as follows:
Clamp repeatability – Close clamps as identified in AMPS, cycle system, open & close clamps, cycle system, repeat 10 times without removing parts. Check data, make corrections and restart test, print report. Source of problem:
1.Clamps / dumps close with to much pressure – adjust soft stops (production tooling).
2.Clamping sequence – document any changes.
3.Parts - measure parts in tool, clamped and unclamped position.
4.Tool - remove parts and measure tool at the areas of movement.
5.Product design – cut sections at the areas of concern in CATIA to verify design.
Tool repeatability – load parts, clamp and cycle system, repeat 30 times, 10 times for parts that demonstrate wear over repeated use (i.e. Panel Line parts, torque items, etc..). Check data after 10 cycles and continue if data is OK. If data is not to 0.25mm, print report to show before and after conditions. Maximum range not to exceed 0.25mm.
Source of problems:
1.Clamping sequence – slip fit clamp fingers (production tools).
2.Inside corner net block interference
3.Locating holes / slots oversized – use digital calipers to measure diameter.
4.Undersize PLP holes / slots
5.Locating pins not normal to its hole / slot with incorrect diameter.
6.Modify GD&T – add / relocate.
Weld repeatability – Load parts in tool, close clamps, mark locations to measure, measure points, open clamps measure points, close clamps weld sub-assembly measure points.
14 Tool repeatability Report requirements:
1.LED locations must be displayed / reported graphically using a CAD wire-frame of each part of the related sub-assembly. All graphics must be reported in large scale mode.
2.All repeatability data must be displayed / reported using a vertical bar graph.
3.Each measurement Axis (X,Y &Z) must be represented with a separate bar.
4.Report must include a horizontal line representing (0.25 mm range) tolerance.
5.Reports must be printed in large-scale mode.