AES BIW Fixture Simulation

ADVANCED
ADVANCED ENGINEERING SOLUTION INC.

ENGINEERING
SOLUTION INC. Innovative Steps to Excellence..
Effective Automotive Engineering Solutions

Fixture Design & Robotic Simulation for BIW Manufacturing
www.aesglobalservices.com AES Property/Confidential

ADVANCED
ENGINEERING
Core Capability - Domains
Steam Turbine
Aerospace & Gas Turbine
Turbo machinery
Components Automotive
Industrial
Power
AES Generation
CAD/FEA/CFD
Energy
Oil & Gas
Valves/ Chemical &

Pumps/ Processing Electronics/
Pipes Semiconductor/ MEMS
Environmental/HVAC/
Building/Construction

ADVANCED
ENGINEERING
About Us
AES Automotive group is well trained with good understanding of

Automotive BIW Welding Fixture and Robotic simulation concepts,
and can work for different customer standards and requirements.
AES uses its proven methodology of onsite and offshore resources to

deliver value to its customers.
AES manages and executes various ongoing design and analysis

projects with onsite project coordinators and offshore engineering
staff located in India to provide better, faster and more cost-effective
solutions to its global customers.

ADVANCED
ENGINEERING
Departments
AES
AUTOMOTIVE DIVISION
BIW FIXTURE ROBOTIC

DESIGN SIMULATION

ADVANCED
ENGINEERING
Project Organisation
Rama Chandra Panda Govindarajan. V

Vice President Engineering Vice President Operations
Raghuram. S
Director Of Engineering
Hariharan. G
Delivery Head
Suresh Kumar. N
Saranya. S
Project Manager
Project Manager - Simulation
BIW Welding Fixture Design
Simulation Engineers Design Engineers

5 Members Team 15 Members Team

ADVANCED
ENGINEERING
TOOL & FIXTURE DESIGN
FOR
BIW MANUFACTURING

ADVANCED
ENGINEERING
Work Areas
BIW Welding Line

Welding Fixture Design & Detailing
1. Geo Station Design & Detailing
2. Respot Station Design & Detailing
End Effecter Design & Detailing
Pallet Tooling
Hold Buck Units

ADVANCED
ENGINEERING
Welding Fixture Units
Weld gun Units
Clamp Units
Base Units
Locating Pin Units

ADVANCED
ENGINEERING
Welding Fixture Design Process
Study of Clamping Plan

Understand the Sequence of operations
Application of NAMMS Standards
Selection of Various Commercial items
Apply Mechanical Design Standards
Verify the Feasibility with interacting tools
Verify the Design for Manufacturability
EOAT Design for Welding & Material Handling
Design Modifications of Welding Fixtures

ADVANCED
ENGINEERING
Welding Fixture Detailing
Detailing of Welding Fixtures and EOATs

Detailing as per various Standards like Gm/DC
Expertise on GM toolkit (KB tool)
Detailing to meet Customer Specifications and
Manufacturing Setup
NC Components Detailing
Part Detailing
Welded Construction Detailing (Construction Hole etc.)
Unit level Layout and BOM creation (Clamps, Locating
Pins & Bases)
Key sheet and BOM Creation for Weld Stations

ADVANCED
ENGINEERING
ROBOTIC SIMULATION

ADVANCED
ENGINEERING
Services
Providing various application services for Robotic Simulation of

Automotive Components.
Operations
Material Handling
Spot Welding
Arc Welding
Sealant Application
Stud Welding
Pedestal Applications

ADVANCED
ENGINEERING
Project Services
Feasibility Study
Process Simulation
Design Simulation
Design Validation
Process Optimization
Sequencing
Weld Spots Distribution
Offline Programming

ADVANCED
ENGINEERING
Process Flow
Input Data Intermediat Y
Feasibilit Y Stage-1
(UG File OR e Delivery-
y Study Sim
Para Solid File) 1
N N
Y Intermediat
Offline Stage-2
e Delivery-
Programming Sim
2
N
Final Y
QC Documentation Final Delivery
Check
Customer
Feed Back

ADVANCED
ENGINEERING
Feasibility Study
Reacheability study with the input tools
Placement of the tools and the robots
Feasibility study of spots

ADVANCED
ENGINEERING
Stage1 Simulation
Approval of Tooling and Facility Designs
Initial Path Creation
Swapping of the Spots if Needed
Initial Programming
Process under cycle.

ADVANCED
ENGINEERING
Stage2 Simulation
Robot Path Finalization
Collision free Workcell
Finalization of Robot and Tooling Placement
DXF out of the tool placement
Swept volume Creation
Payload Entry

ADVANCED
ENGINEERING
Offline Programming
Final Programming
Attributes entry according to customer standards
Fixture Programming
Sequence Creation
I/O Connection
Cycle time under Control

ADVANCED
ENGINEERING
Documentation
Weld Matrix Creation
Robot Data Sheet Creation
SIM Status Report Creation
Open Issues Report Creation
Cycle time Report Creation

ADVANCED
ENGINEERING
Case Study -1
Client : North American Client
Product Line :
Phase1, Phase2 & Phase3 Simulation of Rear Floor Body line
Objective :
Design Validation of Welding fixture, Holding Systems, Pallet Tooling, Weld
gun and EOAT has done and reported in the issue list with suggestion for
the Designers.
Weld gun Selection for all Welding station
Collision free path creation for the whole line
Offline programming for all the Robots
RDS and Weld Matrix Creation.

ADVANCED
ENGINEERING
Challenges:
Weld gun Selection is the main challenge in this project. AES
Engineers has done a great job in this area and given very good
suggestions to our customer to make the system work.
Tool Used : USPOT

ADVANCED
ENGINEERING
Case Study -2
Client : North American Client
Product Line :
Phase1,Phase2 & Phase3 Simulation of Front Floor Body line
Objective :
Design Validation of Welding fixture, Holding Systems, Pallet Tooling,
Weld gun and EOAT has done and reported in the issue list with
suggestion for the Designers.

ADVANCED
ENGINEERING
Challenges :
Cycle time is the major challenge in this project. AES Engineers has to
work out in the paths to make the system under cycle.
Tool Used : USPOT

ADVANCED
ENGINEERING
Case Study -3
Client : Indian Client
End User : European Major OEM
Product Line :
Phase1,Phase2 & Phase3 Simulation of Hood line
Objective :
Design Validation of Welding fixture, Holding Systems, Pallet Tooling, Weld
gun and EOAT has done and reported in the issue list with suggestion for
the Designers.

ADVANCED
ENGINEERING
Challenges :
Cycle time & gun selection are the major challenges in this project.
AES Engineers has to work out in the paths to make the system under
cycle.
Tool Used : ROBCAD

ADVANCED
ENGINEERING
Simulation Software CAD Software

UltraSpot Pro E
Robcad Unigraphics
Catia V5
Igrip
Solid Works
Inventor
Autocad

ADVANCED
ENGINEERING
OUR OFFICES
Development Centers In India
Registered Office
# 303, Golden Heights
Sector 12, Pocket 8
Dwaraka, New Delhi - 110 075
Tel: +91 11 4281 5274
Chennai
# 15, Goutham Towers, 1st Floor
General Patters Road,
Chennai - 600 002
Tel: +91 44 4322 7171 / 72
Bangalore
# 335/1, Gokul Complex Corporate Office Proposed Offices
3rd Floor, Sampige Road, # 253 Lychee Ct.
13th Cross, Malleshwaram Europe : Germany
San Jose, CA 95111, USA Asia-Pacific: Japan / South Korea
Bangalore - 560 003
Mobile : +1 408 386 3278
Tel: +91 80 4168 9581
Tel : +1 408 226 6918

ADVANCED
ENGINEERING

AES BIW Fixture Simulation

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ADVANCED

ADVANCED ENGINEERING SOLUTION INC.

Effective Automotive Engineering Solutions

www.aesglobalservices.com AES Property/Confidential

Valves/ Chemical &

www.aesglobalservices.com AES Property/Confidential

AES Automotive group is well trained with good understanding of

AES uses its proven methodology of onsite and offshore resources to

AES manages and executes various ongoing design and analysis

www.aesglobalservices.com AES Property/Confidential

BIW FIXTURE ROBOTIC

www.aesglobalservices.com AES Property/Confidential

Rama Chandra Panda Govindarajan. V

Simulation Engineers Design Engineers

www.aesglobalservices.com AES Property/Confidential

www.aesglobalservices.com AES Property/Confidential

BIW Welding Line

www.aesglobalservices.com AES Property/Confidential

www.aesglobalservices.com AES Property/Confidential

Welding Fixture Design Process

Study of Clamping Plan

www.aesglobalservices.com AES Property/Confidential

Welding Fixture Detailing

Detailing of Welding Fixtures and EOATs

www.aesglobalservices.com AES Property/Confidential

www.aesglobalservices.com AES Property/Confidential

Providing various application services for Robotic Simulation of

www.aesglobalservices.com AES Property/Confidential

www.aesglobalservices.com AES Property/Confidential

www.aesglobalservices.com AES Property/Confidential

Reacheability study with the input tools

Placement of the tools and the robots

Feasibility study of spots

www.aesglobalservices.com AES Property/Confidential

Approval of Tooling and Facility Designs

Initial Path Creation

Swapping of the Spots if Needed

Process under cycle.

www.aesglobalservices.com AES Property/Confidential

Robot Path Finalization

Collision free Workcell

Finalization of Robot and Tooling Placement

DXF out of the tool placement

Swept volume Creation

www.aesglobalservices.com AES Property/Confidential

Attributes entry according to customer standards

Cycle time under Control

www.aesglobalservices.com AES Property/Confidential

Weld Matrix Creation

Robot Data Sheet Creation

SIM Status Report Creation

Open Issues Report Creation

Cycle time Report Creation

www.aesglobalservices.com AES Property/Confidential

www.aesglobalservices.com AES Property/Confidential

www.aesglobalservices.com AES Property/Confidential

www.aesglobalservices.com AES Property/Confidential

www.aesglobalservices.com AES Property/Confidential

www.aesglobalservices.com AES Property/Confidential

www.aesglobalservices.com AES Property/Confidential

Simulation Software CAD Software

www.aesglobalservices.com AES Property/Confidential

www.aesglobalservices.com AES Property/Confidential

www.aesglobalservices.com AES Property/Confidential