1.1 It is the intention of Van-Rob Inc. to ensure that checking fixture vendors are adhering to this standard.

Transcription

1 PROCEDURE # E233 Page 1 of Purpose: 1.1 It is the intention of Van-Rob Inc. to ensure that checking fixture vendors are adhering to this standard. 1.2 Fixture sources shall refer to this rider for quote, design and build of all fixtures, and shall meet all criteria as specified unless otherwise approved by the responsible Van-Rob Inc. Engineering representative. 2.0 Build and design requirements 2.1 This section should be utilized as a checklist to build and design a check fixture and subsequently as a verification checklist for design review and acceptance. BUILD AND DESIGN REQUIREMENTS 1 The base plate to be made of aluminium 25mm thick; length and width to be a minimum, to ensure all details open or close within its limits. Over 600mm x 600mm base plates to be castings and must be stress relieved. Size requires approval at time of design approval. 2 Base plate:- 1.) Overall squareness relationship of machine edges, length, and width shall be ±0.08 mm. 2.) Overall, parallelism between top and bottom surfaces shall be ± 0.08 mm bases shall be flat within ± 0.13mm per 250 square mm of area with a maximum of ±0.10 mm total in any length. 3.) Base surface shall not exceed 2.03 microns RMS roughness. 3 The base must have visible bodylines at every 100mm identified in three planes. 4 The base-starting corner is to be identified and its co-ordinates (in three planes) to be stamped in appropriate places, and stamped reference. 5 The base-plane shall have 3 circled locations identified as fixed location for CMM probe pick-ups if fixture is under 300mm on any axis and one (1) tooling ball is provided. 6 Fixtures larger than 300mm on any axis require three tooling balls. They are to be securely capped and identified with their co-ordinates (3 decimal places) and as per the fixture certification. If fixture is 3 rd party certified, the tooling ball coordinates shall match the 3 rd party certification results. 7 All gauges shall have jig feet. Optional jig feet ref.: Carr Lane 12L14 Steel, Carburised, Hardened, Bulk. oxide finish Jig rest buttons Part No. CL-1 through 20-SRB

2 PROCEDURE # E233 Page 2 of 5 8 Fixture over 45kg (100 lbs.) shall require a suitable cart with the Van-Rob part number clearly identified and built to a working height of 36 inches. The cost of the cart shall be quoted. 9 No shims allowed on checking fixtures. 10 All features must meet the GD&T requirement prescribed in the part drawing and all virtual condition of pins and feeler gauges are to be correctly detailed in the gauge design and build. 11 Correct blueprint and CAD engineering level and date and design date must be clearly identified on a revision record plate mounted on the base of the fixture. Follow customer specific procedures (ie. GM1925, DC Gage Standards) when applicable. Ownership identification (i.e. PROPERTY OF FORD, GM, CHRYLSER, HONDA, etc.) and Tooling identification number (i.e. GM - VTAM #, FORD ASSET #, etc.) MUST be clearly identified on the gauge base. 12 All sliding surfaces to be hardened and ground. 13 All details must be mounted with a minimum of 2 screws at a minimum size of ¼ and doweled to the base plate of the fixture. 14 Where possible, blocks are to be made of aluminium. Other material used must be approved by Van-Rob Inc. Engineering. 15 Where possible, captive pins should be used for attribute checks. Pin shall not extend past the gauge clearance surface when retracted. If stab pins are used, different bushing sizes shall be used for unique hole sizes and positional tolerances. All captive pins must retract back into blocks to avoid damages 16 Location pins (GO/NO GO) and feelers to be identified with a numbering system, Pin to be stamped with their size, location, VRS code (not including letter suffix) and GO or NO GO accordingly. A standard holder type GO/NO GO pin is preferred. All GO/NOGO size checks to be attached to base (soldier pins) if part geometry allows. 17 Slot size shall be checked using 2 separate pins to check each width and length. Location pin shall be made as per GD&T callout. The width of the length check feature to be cut to at least 10% below the minimum width tolerance. 18 Van-Rob Inc. may also request that in certain instances (ie. Positional checks under Ø 2.00 mm), spring loaded retractable pins be used on multiple hole checks. This will be discussed at design / quote review stage. 19 All gauges are to be painted on non-functional surfaces only. NOTE: Edges of gauge base are not considered nonfunctional surfaces. Colours used must be as per the Automotive Manufacturers Specifications. 20 Surfaces for flush or trim checks to be stamped FLUSH (or MIN FLUSH/TRIM or MAX FLUSH/TRIM based on design requirements) and must be visible when part is in fixture. 21 For external features, trim-line checks are machined to the maximum trim-line tolerance limit. For Internal features, minimum trim-line tolerance limits. Features requiring variable data shall be identified at fixture concept review. Scribed trim lines MUST be checked and reported during gauge certification. Trim tolerances under 1.5 mm require feeler or step block check. 22 Standard check clearance shall be 5.0 mm from part design nominal of surface and periphery and provides CMM probe accessibility. Deviation shall be requested or approved by a responsible Van-Rob Engineering representative. Supplier MUST ensure all dimensional checks can be performed correctly.

3 PROCEDURE # E233 Page 3 of 5 23 All net pads and key feeler check areas to be tool steel hardened to 44/50 RC. Net pads size and location MUST match blueprints. Net pads should be designed to not allow for compression into gauge under pressure (i.e. Shouldered net at CNC surface) 24 All pins to be case hardened 0.75mm (0.030 ) deep. 25 All pins, hand-apply gauges and other details gauges that are to be fastened to the base by retractable-coated wire (key backs) or reinforced coiled cable and container/retainer must be attached at a close proximity to the detail being checked. 26 All checking fixtures must be R&R capable as referenced to guideline in AIAG- MSA (Measurement Systems Analysis). Guidelines for average & range Gauge R&R: 1.) Under 10% of error - Acceptable. 2.) 10% - 30% error May be acceptable based on application, cost, cost of repair, etc., Acceptance by customer SQE is required. 3.) Over 30% of error unacceptable. 27 Checking pins to be a sliding fit in standard hardened bushings and designed to be retained in the bushings. Air vent holes to be provided on any sliding fit pins. 28 Probe surface contact shall be 40mm, or 31mm nominal from part surface in VDP check areas. Include the standard set block on each VDP fixture with a 40mm, or 31mm set distance accordingly. Digital indicator is not to be quoted into the cost of gauge unless it is requested in the RFQ. Optional LMI data collector hardware to be quoted as per RFQ. 29 Variable data collection points (VDP) may be required in the gauge design. VR will specify the placement of the VDP gauging where it is critical to control the process to meet design requirement. All VDP points are to be clearly identified on the fixture design. 30 Hold down clamps are preferred to have steel swivel cup ends or rubber tips with a minimal force and must be over top of a net pad, and normal to net pad surface, and must cover at least 75% of net pad surface. The exception is when a horseshoe style clamp is required. 31 Clamping sequence shall be correctly and clearly identified. The identification marking shall be permanent. 32 All RFS 2 & 4 way locating pins must be tapered with a 5-10 angle and be dimensionally capable of locating parts, which may be running at 10% undersize to 10% oversize relative to print hole size and tolerance. MMC locators may be required in certain circumstances and will be determined during design review. 33 All 2 way tapered location pins must have a lock down feature for layout purposes. 34 When a fixture has heavy swing details or flip templates, an automatic locking feature, counter balance system or shock absorber must be incorporated to protect anyone operating the fixture. 35 Loading and unloading instruction shall be required for larger fixture and the instruction shall be adhered to the fixture base. Fixture base shall be designed for access of lifting equipment for this purpose. 36 Fixture shall be designed to check part in car position. Deviation should only be considered to maximize fixture / gauge use or reduce cost. Deviation shall only be granted in 90-degree increment from car position.

4 PROCEDURE # E233 Page 4 of 5 37 Upon completion of gauge build, final CAD design of each gauge will be provided (on CD) to Van-Rob at time of delivery. 3.0 Build Tolerances 3.1 All features shall meet the dimensional tolerances as prescribed herein and are reportable upon delivery. 3.2 Part feature dictates deviation from the build tolerance as specified here, the 1/10 th rule can be used with written approval by Van Rob Engineering. 10% of tolerance should be used with the following as limits. Feature Location Size Surface Boundary Location or non-working axis Locating Pins / Bushing ± 0.05 mm ± 0.02 mm Net Surface ± 0.05 mm ± 1.0 mm Flush Check (trim or surface) ±0.15 mm Flush Check 3.0 mm Tol. or less ± 0.12 mm Flush Check (not checked areas) N/A ± 0.20 mm Flush Check 1.0 mm Tol. or less ± 0.10 mm Flush Check 0.5 mm Tol. or less ± 0.05 mm Pin Check ± 0.10 mm ± mm GO Pin /0.0 mm NO GO Pin + 0.0/-0.02 mm Sight Check ± 0.2 mm ± 0.04 mm SPC Transducer Bushing ± 0.05 mm Nom. To Surface ± 0.25 mm SPC Flush and Feeler Block ± 0.05 mm Nom. To Surface ± 0.25 mm Dowel Holes (items mounted ± mm to fixture base Units or sub-base to be held ± 0.05 mm from start Templates ± 0.25 mm ± 0.12 mm Scribed Trim Lines ± 0.20 mm 4.0 General Notes 4.1 Once the contract has been awarded, the supplier is expected to submit a concept drawing clearly showing design intent of the fixture to be evaluated by the APQP team. The customer and VR part numbers, revision level and date, and CAD file used should be included in the design. 4.2 The vendor is required to complete the design and submit to VR for approval. A PDF version of the design is recommended. Final approval must be obtained from VR Engineering prior to commencement of construction of the fixture.

5 PROCEDURE # E233 Page 5 of An updated drawing and a CMM certification must accompany the fixture when it is delivered to Van-Rob. 4.4 Vendor is to verify and warrant that the fixture build and construction are correct and accurate. A third party fixture certification is required only if it is specified so by the VR customer and the requirement will be specified in the purchase order. The third party certification source contracted must be agreed by Van-Rob and MUST be either certified to A2LA ISO/IEC or CSA. A third party source on the Van-Rob ASL (Approved Suppliers List) is preferred. 4.5 All fixture certifications should identify which CAD file is used, revision level and revision date. CAD file used by the certification source shall not be modified in anyway. Tooling ball co-ordinates will be reported. Request for all CAD by the certification party must be made directly through the VR Design Department. All customers requested measurement points shall be reported in the certifications using the customer dimensional co-ordinates as nominal targets. 4.6 Unless otherwise specified, the fixture shall comply with the applicable OEM customer standard. 4.7 The ownership of the OEM and the tooling identification number e.g. GM VTAM must be clearly and permanently inscribed onto the base of the check fixture 4.8 Other purchase agreement, term and condition are as stated in Supplier Development Manual. 5.0 References Supplier Development Manual Measurement System Analysis Manual AIAG Gauge Development C3-07 Control of Inspection, Measure and Test Equipment QA017 Fixture Check List QA0213 Purchasing Process P002 PR, PO Intranet / SAP RFQ Fixture Cost and Timing P0008 Program Cost and Spending Tracking E0070 Tooling Invoices and Approvals F169