检具设计通用标准书080107c

绪论检具是在汽车工装行业中，检测车身板件及塑料件的量具。其主要的检测内容为：形状，轮廓及位置度。检具有分总成与总成两大类。分总成检测单个零件；总成检测多个焊装在一起的总成件。后者结构较为复杂但他们的结构都是由支撑机构，定位机构，夹紧机构，检测机构及其他附件组成。国内外很多检具的结构大致相同，但也有区别，主要体现在支撑机构和部分检测机构的不同。我司也有自己的机构-《在天模具检具标准件》。它是我司检具结构设计的参考标准。分总成与总成设计流程与设计方法是一样的。检具设计流程如下：检具的一般设计步骤:检具设计一定要严格遵守〈〈检具开发技术协议〉〉，遵循客户的要求，并结合我厂的实际情况，进行正确，合理的设计。十堰在天模具有限公司2007-11-8存档备库审核与投产检具会签检具设计概念批准概念设计项目启动工程图设计其他附件设计检测机构设计定位结构设计支撑结构设计本体设计数模位置目录绪论························································································1第一章检具的概念设计·······················································3一，项目流程································································3二，项目的启动·····························································3三，概念的设计····························································3四，概念的批准·····························································3第二章检具结构·······························································41，本体机构····································································42，支撑机构····································································63，定位机构····································································94，夹紧机构····································································125，检测机构····································································126，其他附件····································································13第三章检具设计···································································13一，设计流程····································································13二，设计基础····································································131，数模位置的确定····························································132，检具设计方法·······························································13三，设计前的准备·······························································141，设计资料的准备·····························································142，文件的命名···································································143，数模的表示方法·····························································144，层的分布与命名·····························································14四，检具设计······································································151,分总成零件检测······························································152，总成件零件检测······························································18五，图纸设计·········································································20六，校对审核投产································································21第六章检具的数据管理·····························································22一，服务器的数据管理·························································22二，个人与项目负责人的数据管理·········································22三，数据交换管理·······························································23第一章检具的概念设计一、项目流程二、项目的启动当公司接下来一个项目的时候，首先向客户索取充分的技术资料其中包括检具开发技术协议，GD&T图，板件数模，以及其他书面要求。以上资料预备好后，由项目负责人主持召开概念设计预备会，技术部长，全体技术人员，商务方参加。此会议主要是分配任务，移交资料，说明设计要求，申明客户要求，讨论并预定大概结构。待以上会议内容全部确定完成后，项目正式启动，开始概念设计。三、概念设计概念设计应包括详细的检具草图和书面描述以便能依此进行检具设计。其应具备以下信息：1、被测零件与检具底板的位置关系。即板件的放置方向。一般根据板件的形状，综合考虑板件的通常变形形式，板件的检测位置，检测方法，检具的操作性能来确定方向。不过最好使用装车位置，如果相对装车位置有偏离，应以90°增量进行偏转，若偏转非90°能更有利于零件的检测，则需客户的同意。2、零件的定位方案。定位方案与几何尺寸及GD&tT一致。3、夹紧方案。与GD&T一致。4、支撑与升举机构的机构形式。按客户要求或我方设计需来确定。5、用于检测下列特性的检具零件和装置：a、关键产品特性b、特性线c、功能孔d、过去经常发生过程变差较大的区域6、检具各结构所使用的材料。所用的材料依据检具的使用和环境确保在零件现行生产有效期内的功能性、重复性和在现性。概念设计还应考虑操作者的使用习惯，被测零件装卸的容易度、三坐标检查和SPC的数据采集的可行性。当检具用于全球性的整车项目时，应考虑操作者的习惯。四、概念的批准概念设计完毕后，发往客户会签。然后，按照客户反馈的信息修改方案，直到确认为止。待方案确定后，将最终设计概念存档备份，作为以后客户提出大的方案变动时，索要整改费用的依据。最终设计概念（检具草图，书面描述）移交设计者，开始检具设计。存档备库审核与投产检具会签检具设计概念批准概念设计项目启动第二章检具结构1，本体机构检具本体包括以下结构面：Ⅰ,三毫米面轮廓划线检测面按偏置后的数模面沿切向方向延伸10-15MM。Ⅱ,一毫米检测面一毫米检测面一般用来做孔划线。按零件孔大少单边加3MM做2MM台。如果一毫米面相邻比较近可以把两个台融合在一起，做成一个。Ⅲ,零位面零位面，与板件距离为0MM.有两种形式见下图。还有一种零位支撑。图1（法向面）图2（延伸面）一般大检具零位面宽40MM，小检具宽30MM.Ⅳ，检测线检测线，包括0，3MM划线和中心线。划线要把数模串起来。0，3MM检测线用双点画线表示；0线用白色表示，3线用黑线表示。中心线用点画线，用黑色表示。本体设计完成后要用检测几何体检测本体是否有问题。最后，所有结构面根据客户要求着色。注意：※本体设计尽量减少边界的小R角，尖角；避免出现高而且薄的本体。※在分检具本体设计中，设计出来的本体一般体积较大，重量重，为了减轻重量，节省材料，可以在保证检测功能和保留零件原有基本形状下，做适当的掏空。下面以顶盖为例说明。※一些负角处理。本体设计完成后，为了降低加工难度，方便板件的取放，在不影响板件检测的条件下，对一些负角的地方做适当的处理。※总成检具的本体较为简单，一般都为条状结构。用来检测轮廓和型面。2，支撑机构由于检具精度非常高，所以要求支撑机构足够的强度，刚度，变形少；（1）分总成检具支撑机构分总成检具支撑机构主要有两大部分组成：底板和二层架子。◎检具底板上有三大功能机构：○1搬运装置，包括叉车槽，起吊环，起重棒，防撞吊耳，把手。叉车槽是直接焊接在底板上的。起吊环起重棒防撞吊耳把手○2检测装置，基准套，基准块，基准球，基准孔，基准面。其中基准孔和基准面是直接加工在底板上的。基准球基准套基准块○3支撑装置，底板基准，底板◎检具底板有三种:a,槽钢结构槽钢底板有两种规格H120和H200。H200的强度比H120强。根据底板所承载重量的大小和检具面积的大小来选择底板。重量重，面积大选用的H200，其他选H120。底板的钢板厚度T一般取10～20MM.如下图为了保证强度，减少底板变形，要求底板按米字形搭接,如果底板较长可以搭成双米形。底板中间的拉板（B1）要设计得足够大，把所有连接此处的槽钢的焊缝盖住。底板基准板B2=120×120×15,脚轮安装板B3=120×120×10.底板的起吊装置有吊耳和防撞吊耳两种,根据检具具体情况来确定起吊装置..B1中央拉板B2底板基准块B3脚轮安装板详细结构见《在天模具标准件》b,方钢结构方钢底板有H200和H250两种规格。根据底板所承载重量，可选50*50*5或60*60*5的方钢；板厚可以选8-15MM；底板方钢之间的距离为300MM—400MM。叉车槽的中心距取500MM—700MM。c,铝板结构铝板底板,由底板跟跟底板支撑构成.零件长+宽在600MM以内的用20MM铝板,大于600MM用30MM铝板.方钢底板A1底板基准块A2脚轮安装板详细结构见《在天模具标准件》方钢底板结构搭接示意图铝板底板定位机构A、主次定位销主次定位销有两种结构，○1直柱定位销，定位部分是圆柱形的。○2锥型定位销，定位部分为圆锥形。直柱定位销制造简单，长期使用受磨损影响，定位精度会降低；锥型定位销大，但定位精度高。使用锥型定位销使要在本体上5MM开槽让开销3、定位机构包括主次定位销和边定位。主次定位销是主要的定位机构.它的定位原理如下图,主定位销限制四个方向的自由度，次定位销限制旋转的自由度。主次定位销定位示意图主次定位销定位原理图加工难度稍