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2.8 TRANSFORMERS
2.8.1 Approved Source
Transformers shall be supplied by an approved Chrysler Group source.
2.8.2 RWMA Standards
Transformers shall comply with all the applicable RWMA standards.
2.8.3 Rating
All transformers (AC and DC) shall be rated at 50% duty cycle based on a one-minute integrating
period at the rated primary voltage, rated water flow and temperature as manufacturer
recommended.
2.8.4 Selection and Sizing
AME Process Group shall direct all parties for the type of transformer, AC or DC per program.
It’s the process integrator’s responsibility to size the weld gun transformers. The transformer
sizing program/formula shall be approved by AME Weld Gun Group prior to program starts.
Weld Gun supplier shall provide the information of weld gun dimensions and material
characteristic to process integrator.
Process integrator shall provide transformer size, weld schedules and other welding data to weld
gun supplier through the weld data sheet. A copy shall be delivered to AME Weld Gun Group
during weld gun model (concept) review.
B. Upon approval of the design proposal the Weld Gun Supplier shall submit two (2) copies
of the preliminary drawing, including all known detail part numbers, to the AME Weld
Gun Group. The Weld Gun Supplier shall indicate "NEW" on the drawing if new detail
components are required.
C. One preliminary drawing shall be returned to the Weld Gun Supplier with Chrysler NPM
code numbers added along with requests for modifications. AME Weld Gun Group
personnel shall assign new weld gun numbers and detail part numbers. The Weld Gun
Supplier shall update and verify the final weld gun drawing.
4.2 DRAWING FORMAT
4.2.1 Drawing Format
The AME Weld Gun Group must approve a new drawing format before the design begins.
4.2.2 Drawing Projection
Current drafting practices pertaining to multi view and sectional view drawings are defined
and illustrated in the current revision of ANSI Y 14.5M. All drawings should be drafted
using third angle projection on orthographic views.
4.2.3 Drawing Scale
For general design work, drawing scales shall be metric full size wherever possible.
4.2.4 Sheet Sizes
Drawings shall be drawn on A, D, E or 11 x 17 size sheet depending on the size of the
component. Excluding tabulations, only one detail shall be drawn per sheet. Chrysler Group
NPM code number shall be displayed in the Tool Number area of the title block. 11 x 17
drawings must be legible for assembly and build purposes.
4.2.5 Lettering
All text height shall be 3mm minimum on all drawings. Notes and descriptions shall be 5mm
minimum. View call-outs, section, and cylinder call-outs shall be 7mm minimum.
7.0 SHIPPING
All air, hydraulic and water connections and manifolds shall be thoroughly drained, blown out and plugged
prior to shipping.
A layout drawing of the weld gun assembly along with the entire gun test results, including calibration
information shall accompany the gun to its destination.
If any disassembly is required, all break points or areas must be identified.
9.0 GLOSSARY
9.1 ACRONYMS &TERMS
Acceptable Minimum criteria the product shall meet.
An alternate method may be used where specified. Approval of a product using an
Alternate
alternate method may be revoked at any time.
AME Advance Manufacturing Engineering
ASME Advance Stamping Manufacturing Engineering
CD Compact Disc
Configuration The electronic file contains the information of servo motor and servo weld gun setting
File parameters.
A part that gets used up as part of the manufacturing process. This part usually makes
Consumable direct contact with the body-in-white. (i.e. weld caps, adapters, cables, shunts, bushings,
etc.)
The complete series of motions performed by the weld gun during use, which originates
Cycle
at a starting position and ends at the same, starting position.
DCX DaimlerChrysler Corporation
DCX/CG DaimlerChrysler Corporation / Chrysler Group
Differential Water pressure difference between water inlet and outlet on a weld gun
ECTC Equivalent Continuous Thermal Current
The component of the resistance welding process that contacts the work piece and
Electrode Cap
carries current to affect the weld.
Electrode
Refers to the part that the electrode cap fits on.
Shank
Refers to equipment, old or new, that currently exists as referred to in the project
Existing
specification (i.e. the equipment is not supplied explicitly for this project’s use)
Any event, which requires skilled-trade intervention to correct (except for consumable
Failure
and perishable items).
Force Table The process of establishing a relationship between a range of servo motor torque
Setup commands and the resultant weld gun tip force.
GPP Global Project Procurement
The process of setting the basic servo motor and weld gun parameters to ensure weld
Initial Setup
gun delivering force and speed requirements.
JPH Jobs Per Hour
The first day in which the Plant produces 5% of the contracted daily volume of the new
Launch
model.
Life Cycle Expected time frame (or cycles) the component is to be designed to and utilized for.
MCBF Mean Cycles Between Failures
ME Manufacturing Engineer
MEDDS Manufacturing Equipment Development Description Systems
Appendix A
AME Weld Gun Group Coordination Procedures
Related Procedures
Documents & Responsibilities
Processes Notification of New Model
Launch and Carry-Over
programs and
AME & ASME Process Management
WDFM001 Weld Gun CWO Request Initiate CWO Request for
Welding CoC Manager
ASME New Launch Program
Tool Design Coordination Supervisor
Only
MEDDS Specification
Create MEDDS Specifications Weld Gun Design Coordinator,
APWI 257
Per Sub Assembly Systems AME & ASME Process Group
APFM 111
MEDDS Specification
Complete Weld Gun MEDDS
APWI 257 Weld Gun Design Coordinator
Information
APFM 111
--Blanket Order
--Spot Buy
Use of MCN MCN if Required Weld Gun Design Coordinator
APWI 114
Release Design and MEDDS for
Weld Gun Design Coordinator
Build
AME & ASME Process Group
Continued
Related Procedures
Documents & Responsibilities
Processes Continuation
Re-Install
Weld Gun Design Coordinator: Writes req'd
WDFM005 - Weld Gun Installation until
changes in Weld Gun Installation
Correction Log, installation Yes
Correction Log
Do's and Don'ts Section 6 meets
O.E.M: Makes the corrections.
Resistance Weld Gun Spefication Daimler
Tool Follow-up: Monitors that changes get made
AMS 7110 Chrysler
Stds.
Yes
For Reference Only: TFDP001 Buy-off @ Tier one Supplier Tool Follow-up
(Tool Follow-up Dept. Procedure)
END
Appendix B
Chrysler Group Weld Gun Design Review Form
C HRYSLER W ELD G UN G ROUP
Program: ________ Plant: ____________________ Major: _____________ Item: _____________
Area:
Assembly
Stamping Sub Major: ____________________
Pedestal / Robot No.: ___________________________________________________________
Qty: _____ ___________________________________________________________
___________________________________
Chrysler Weld Gun Group Representative/ Date
For current revision of this form reference AME MQAS Document WDFM002 Weld Gun Design (Revision D)
Appendix C
Chrysler Group Weld Gun Build Buy-Off Form
DaimlerChrysler