AMS 7110 Resistance Weld Gun Specification

Resistance Weld Gun Specification Advance Manufacturing Engineering AMS 7110

Revision Date: 09/12/2005 Page 1 of 26 Revision: 02 File Name: AMS 7110 Resistance Weld Gun Specification PROPRIETARY

Advance Manufacturing Engineering

Resistance Weld Gun Specification



TABLE OF CONTENTS PAGE 1.0 GENERAL ................................................................................................................................................. 3

1.1 PURPOSE........................................................................................................................................... 3 1.2 SCOPE............................................................................................................................................... 3 1.3 TERMS AND DEFINITONS ..................................................................................................................... 3

2.0 DESIGN AND BUILD REQUIREMENTS.................................................................................................. 3 2.1 GENERAL ........................................................................................................................................... 3 2.2 MODULAR AND DIMENSIONAL REQUIREMENTS ..................................................................................... 5 2.3 CONSTRUCTION REQUIREMENTS......................................................................................................... 6 2.4 WELD GUN ACTUATORS..................................................................................................................... 8 2.5 WELD GUN EQUALIZER ...................................................................................................................... 9 2.6 ELECTRODE CAPS, CAP ADAPTORS AND SHANKS .............................................................................. 10 2.7 LAMINATED LEAF SHUNTS................................................................................................................. 10 2.8 TRANSFORMERS............................................................................................................................... 10

3.0 DESIGN PROCESS AND BUYOFF REQUIREMENTS ......................................................................... 11 3.1 DESIGN PROCESS ............................................................................................................................ 11 3.2 BUY-OFF PROCEDURE...................................................................................................................... 12

4.0 WELD GUN DESIGN DOCUMENTATION ............................................................................................. 12 4.1 DESIGN PROPOSAL PACKAGE ........................................................................................................... 12 4.2 DRAWING FORMAT ........................................................................................................................... 13 4.3 CAD DELIVERY ................................................................................................................................ 15

5.0 WELD GUN INTEGRATION REQUIREMENTS ..................................................................................... 16 5.1 GENERAL ........................................................................................................................................ 16 5.2 SERVO WELD GUNS .......................................................................................................................... 16

6.0 VALIDATION,RELIABILITY AND MAINTENANCE REQUIREMENTS................................................. 17 6.1 VALIDATION REQUIREMENTS ............................................................................................................ 17 6.2 RELIABILITY AND WARRANTY............................................................................................................. 18 6.3 MAINTENANCE AND SPARE PARTS..................................................................................................... 18 6.4 TRAINING ......................................................................................................................................... 19 6.5 SUPPLIER SERVICE........................................................................................................................... 19 6.6 SERVICE MANUAL............................................................................................................................. 19

7.0 SHIPPING................................................................................................................................................ 19 8.0 REFERENCE DOCUMENTS .................................................................................................................. 20 9.0 GLOSSARY............................................................................................................................................. 21 10.0 PUBLICATION, CONTACT LIST AND REVISION HISTORY ............................................................... 22 APPENDIX ........................................................................................................................................................ 23

A. AME WELD GUN COORIDNATION PROCEDURES .................................................................................... 23 B. CHRYSLER GROUP WELD GUN DESIGN REVIEW FORM.......................................................................... 25 C CHRYSLER GROUP WELD GUN BUILD BUY-OFF FORM ........................................................................... 26



1.0 GENERAL 1.1 PURPOSE

This specification provides the Chrysler Group standard requirements for all resistance weld guns. In conjunction with the current Quality Management System requirements, this specification is intended to promote safety, quality, delivery, low cost and standardization of weld guns.

1.2 SCOPE • This specification covers weld gun build and performance requirements for supplier designed weld

guns, while the Do’s and Don’ts, Section 6, covers Chrysler Group standard weld gun design and integration requirements. In case of conflict between this specification and the “Do’s and Don’ts”, this specification shall govern.

• This specification applies to all new, retooled and rebuilt equipment, which contain resistance weld guns. It applies to all parties involved with selection, design, construction and testing of resistance weld guns including weld gun suppliers, process, design sources and build sources.

• DaimlerChrysler encourages innovation, so it is not the intention of this specification to limit or inhibit the development of any improvement or new technology.

1.3 TERMS AND DEFINITIONS • May – defines a requirement that is condition dependent.

• Shall/Must – Mandatory requirements of this specification.

• Should – defines a recommendation.

• See 9.0 Glossary for additional definitions.

1.4 DEVIATIONS/REVISIONS 1.4.1 Request of deviations to the requirements of this specification shall be submitted to DCX/CG AME

Weld Gun Group and approved by the DCX/CG AME Core Group. 1.4.2 Revisions to this specification shall be forwarded to the AME Weld Gun Group for consideration.

2.0 DESIGN AND BUILD REQUIREMENTS 2.1 GENERAL

2.1.1 Non-Productive Material All equipment covered by this specification shall meet the requirements of AMS 0021 General Requirements for Non Productive Material.

2.1.2 DCX Weld Gun Process Weld Gun Source(s) and Process Integrator(s) must follow AME Weld Gun Group Coordination Procedures (Appendix A). The activities of weld gun model/concept review, design review and build buyoff must be completed based on the program timeline to fully support weld gun deliveries.

2.1.3 Weld Gun Library for Process Design The selected weld gun supplier must have a DCX approved weld gun library as described in Section 2.2 in order to limit the number of new weld gun designs. The library must consist of an assembly drawing and a solid model per design. The approved library shall be uploaded to a DCX Weld Gun Group designated database by the weld gun supplier prior to program start.

2.1.4 Weld Force Requirements and Cap Sizes Prior to the selection and/or design of weld guns, the equipment integrator and weld gun suppliers shall obtain the current DaimlerChrysler Process Standard PS-10947 to determine weld force requirements and cap sizes.

2.1.5 Tooling and Product Constraints The weld gun design and performance must be considered prior to tooling and product design.



2.1.6 Weld Gun Strength Requirements 2.1.6.1 Pneumatic Weld Guns

Plant Maximum Air Pressure PSI Size to PSI Stress to PSI 100 80 100 110 90 110 Pneumatic weld guns shall be sized per plant requirements. Weld guns shall not be designed to operate under 30 psi.

2.1.6.2 Servomotor Weld Gun The weld gun shall be designed to run 25% above the upper weld schedule, which is the minimum force requirement. In case of product or tooling constrains, a deviation must be approved by DCX Process Group.

2.1.7 Weld Gun Cap Displacement The Stationary cap displacement shall not exceed 4.6 mm (0.18 in) at maximum rated weld gun force (Fig. 1). The servo stroke times the transmission ratio minus the stationary cap movement shall not exceed 4.6mm. The measuring method of the deflection shall be approved by AME weld gun group prior to the program starting.

2.1.8 Electrode Alignment and Weld Gun Skidding Electrodes or caps shall be concentric within a diametral tolerance of 1.0mm (0.04in) without tip force. Skidding of weld caps shall be concentric within a diametral tolerance of 1.6mm (0.06in) at maximum rated weld gun force (Fig. 2).

2.1.9 Non- Rotating ‘C’ Gun Requirements “C” type weld guns shall be designed with non-rotating moveable arm.

2.1.10 Symmetrical Design Weld gun design should be symmetrical. Right hand and left hand design should be avoided.

2.1.11 Weld Gun Mounting Application Weld gun frame shall be designed and incorporate three (3) common mounting positions.

2.1.12 Robot Adaptor Plate and Pedestal Weld Gun Mounting Plate Mounting hardware shall be designed and provided by the tooling integrator.

2.1.13 Castings Copper casting construction shall meet RWMA Class 2 or 3 copper specifications. Cast aluminum shall not be used for weld gun arms.

2.1.14 Electrical Contact Surfaces All machined electrical contact surfaces shall have a maximum roughness of 0.80 μm (32 μin).

2.1.15 Aluminum to Copper Surface Coating Requirement Aluminum alloy components that contact a copper surface must be silver or nickel-plated or equivalent.



2.2 MODULAR AND DIMENSIONAL REQUIREMENTS 2.2.1 Modular Weld Gun and Modularity

Weld guns shall be modular with as many common parts as possible to reduce the number of components and spares. A family of modular designs shall exist with pre-defined graduated dimensions prior to process design start. The pre-defined family of weld guns shall be documented in a DCX weld gun library.

2.2.2 Weld Gun Commonality Design and build cost of weld gun and component shall follow the blanket ordering system. The amount of design hours shall be determined based on the categories of blanket ordering set-up during Weld Gun Model and/or Design Review. Any unique weld gun design shall be a spot buy. MEDDS specifications and details shall be completed by AME weld gun group.

2.2.3 Weld Gun Dimensions (Fig. 3 & 4) “Lettered” dimensions of weld guns shall be reviewed by AME Weld Gun Design Group prior to program starts. The increments should be in multiples of 10mm and should be determined based on the characteristic of the designs of the selected weld gun supplier.

2.3 CONSTRUCTION REQUIREMENTS

2.3.1 Weld Gun Labeling 2.3.1.1 Weld Gun Body Labeling (Fig. 5)

A lamocoid tag shall be attached to the weld gun in a visible location. Lamocoid tag fasteners shall not interfere with weld gun performance. An additional lamocoid tag shall



be shipped to the plant or equipment integrator along with the weld gun. Lamocoid tags shall be white in color approximately 110mm/4.25in wide by 60mm/2.25in tall, with black letters 5mm/0.18in high, containing the following information. • DaimlerChrysler Weld Gun Assembly Number • Total Weight of Weld Gun (lbs/kg) • Maximum Rated Force (lbs/kg) @ xx psi for pneumatic weld guns • Maximum Rated Force (lbs/kg) for servomotor weld guns • Stationary Cap Displacement (in/mm) at maximum rated force (Fig 1.) • Maximum Tip Opening (in/mm)

Fig. 5– Lamocoid Tag

2.3.1.2 Weld Gun Component Labeling All weld gun components, including cap adaptors, weld and equalizer cylinders, servomotor, actuator and transformers etc., shall be stamped or permanently labeled with their assigned NPM code number. The NPM Code number shall be legible when the weld gun is assembled.

2.3.1.3 Air Cylinder Labeling Oil resistant labels shall be on both weld and equalizer cylinders. Labels shall contain the following information: • Manufacturing Company Name and Address • Service Telephone Number • Supplier Cylinder Number • Serial Number

2.3.1.4 Air Cylinder Port Identification The cylinder ports shall be clearly stamped on the housing showing the function of each port. Port Call out Stamped on Housing Weld Stroke Forward WF Weld Stroke Return WR Retract Forward RF Retract Returned RR Vent/Exhaust V Boost B

2.3.1.5 Servo Motor Labeling Oil resistant labels shall be mounted on the servomotor. • Manufacturer’s name.

W/GUN NPM XX-XXX-XXXX

WEIGHT XXX lbs / XX kg

MAX RATED FORCE XXXlbs/XX Kg

STA. CAP DISPLACEMENT XXX in/XX mm

MAX TIP OPENING XXX in / XX mm



• Manufacturer’s model. • Maximum voltage rating. • Maximum current rating. • Maximum peak stall force rating. • Maximum speed rating. • Maximum stroke. • Manufacturer date code.

2.3.1.6 Transformers Labeling It is the responsibility of weld gun supplier to attach the additional label onto the transformer at a visible location after the weld gun is assembled, if the original label is covered by brackets.

2.3.2 Weld Gun Cooling Weld gun shall be designed and manufactured to operate at the specified weld current and duty cycle without overheating. The temperature of weld gun surface excluding weld electrodes and shanks shall not exceed 54°C (130°F) under normal plant cooling conditions. 2.3.2.1 Robot Transguns, Portable, Manual and Remote Weld Guns

Three cooling circuits shall be considered as standard method. Weld gun transformer and each arm shall be cooled separately.

2.3.2.2 Machine Weld Guns A minimum of two cooling circuits is acceptable.

2.3.2.3 Water Flow Rate Requirements All weld guns shall be tested to meet the following minimum water flow rates. The testing shall be at a maximum water pressure differential (supply-to-return) of 30psi, circulating all cooling loops simultaneously. This test will be conducted prior to build buyoff. • 1.0 GPM for AC transformers • 2.0 GPM for 100 and 150 KVA MFDC transformers. Reference the manufacturer’s

recommendation and request for any other MFDC transformers that are utilized per process requirement.

• 1.5 GPM for each weld electrode of portable, robot and pedestal guns • 1.0 GPM for each weld electrode of machine and fixture guns. • Approval per Section 1.4 of this specification shall be required for any weld gun

which has lower water flow rate due to the special conditions, such as tight section, non standard caps, double and triple bend shanks, etc.

2.3.3 Water & Air Fittings 2.3.3.1 Fitting design Requirements

All water and air fittings threads are to be National Pipe Thread (NPT). All efforts should be made to reduce the number of fitting connections to eliminate potential leaks. No soldered water fittings to weld gun components.

2.3.3.2 Fitting Size Material on air and water fittings shall be brass and size shall be no larger than 3/4" for standard package.

2.3.4 Weld Gun Dense Packages Unless directed otherwise by AME, air manifolds, air valves, water manifolds and all controls for operation of the weld gun shall be mounted on the gun. The manifold blocks shall be designed to prevent air and water misapplication for plant maintenance personnel. Installation of all air, water and control devices is to be performed by weld gun supplier prior to shipment to OEM/Plant.



2.3.5 Teflon Thread Sealant Non-hardening Teflon gels shall be used for thread sealant.

2.3.6 Component Color Codes 2.3.6.1 Air and Water Hosing

Reference: AME Tool Design Do’s & Don’ts Section 5 (Piping) 2.3.6.2 Weld Gun Hanger

Weld gun hanger shall be painted orange. Contact Chrysler Group Safety personnel for detailed information.

2.3.7 Fasteners 2.3.7.1 Accessibility

Fasteners shall be easily accessible for maintenance, particularly in the shunt, cylinder and servomotor areas.

2.3.7.2 Fasteners All fasteners, with the exception of the shunt/kickless cable fasteners, shall conform to the NAAMS metric fastener standards (Section F of the NAAMS Global Standards Components – Assembly). Additional locking mechanism, for example, lock washer and other type of locking elements, might be requested base on the components and work conditions. Weld Gun Supplier shall review with AME Weld Gun Group for all fasteners prior to program starting.

2.3.7.3 Non-Magnetic Fastener Shunt fasteners, which are inside the secondary field, shall be non-magnetic stainless steel. Proper torque must be applied during weld gun assembly for stainless steel bolts and nuts.

2.3.7.4 Supertanium Bolts All kickless and dry shunt cables shall be bolted to transformer lug adapters with the “Supertanium Kickless Cable Bolt Assembly” with proper torque value.

2.3.7.5 Heli-coil inserts Non-ferrous material components, with the exception of T7075-T6 aluminum alloy or higher grade material, shall require heli-coil inserts for threaded fasteners for locking and strength purpose.

2.4 WELD GUN ACTUATORS 2.4.1 Actuator Interchangeability

The weld gun shall be designed to allow interchangeability between the pneumatic cylinder and a servo motor drive unit. The mounting footprint and envelope size of the servomotor actuator shall be similar to the comparable stock pneumatic cylinder for interchangeability.

2.4.2 Force Repeatability The weld force shall be achieved and maintained within +/-5 % for pneumatic and servomotor weld guns.

2.4.3 Pneumatic Weld Cylinder Requirements 2.4.3.1 Type of Weld Cylinders

When a program requires limited amount of pneumatic weld guns, due to equipment reutilization, a 4-port cylinder shall be the first choice. 5-port cylinders shall require a deviation from AME process group and shall require a pressure restriction device installed by weld gun supplier. Weld cylinders shall be lubed for life. The type and design of cylinders must be approved by AME Weld Gun Group, Process and Plant representatives prior to the program starts.

2.4.3.2 Weld Cylinder Design Requirements All cylinder rebuild kits shall be common for same style and bore size cylinders for the program or user plant. It’s required to use the same rod diameter for piston rods per



program or user plant. Cylinder strokes shall provide a minimum of 0.75 inches of travel to compensate for tip wear. The time required for the movable component to move the first 25 mm shall require no more than 0.18 seconds (11cycles). The time required for each 25 mm segment of distance shall require no more than 0.12 seconds (7 cycles). This rule shall apply to both forward and return strokes.

2.4.4 Electrical Servo Actuator Assemblies and Servo Motors 2.4.4.1 Motors shall operate at 460VAC and minimum 6-pole. 2.4.4.2 Type and manufacturer shall be approved by DCX. 2.4.4.3 Servo motors and electrical servo actuators assemblies shall be design to be cooled by

ambient air; water cooling is prohibited. 2.4.4.4 Motors shall be equipped with a thermal sensing device, interfaced to the controller, for

monitoring motor over-temperature. A fault shall be issued if maximum motor temperature is exceeded.

2.4.4.5 In-line electrical servo actuator assemblies shall be used. 2.4.4.6 All external metal components shall have a non-corrosive protective finish. 2.4.4.7 Servo motor and servo actuator assemblies shall be capable of providing rated peak stall

force for no less than 5 seconds at 3 times per minute at the rated temperature. 2.4.4.8 A minimum number of servo actuator assemblies shall be available to cover a weld gun

tip force range from 300 lbs to 1900 lbs. 2.4.4.9 The actuator assembly shall have a manual override capability so the actuator and

connected gun component may be moved without power to the motor. 2.4.4.10 Servo actuator assemblies shall operate in any orientation without modification or

adjustment. 2.4.4.11 Servo actuator assemblies shall be engineered to provide lateral stability or rigidity

against side loading required for resistance welding. The actuator system shall allow for accurate, mechanical tip alignment.

2.4.4.12 Servo actuator assemblies shall be repairable. 2.4.4.13 Servo actuator assemblies shall be constructed such that damage will not occur if the

actuator is driven against a stop at full torque. 2.4.4.14 The driving mechanism of the actuator assembly shall be protected from contamination.

2.5 WELD GUN EQUALIZER

2.5.1 Weld Gun Equalizer 2.5.1.1 Weld Gun Equalization Methods for Servo Weld Guns

Robot compensation software for tip wear and gun deflection shall be considered prior to utilizing the mechanical equalizer for weld applications. Dual pedestal weld guns shall require a mechanical EQ Package. The robot manufacturer shall develop this software package and have approval by the DCX robot specialist and Weld Gun Group prior to program starts.

2.5.1.2 Equalizer Package Pneumatic weld guns shall include an equalizer package (air equalizer or air with spring assist) as a standard feature. The equalizer is an optional package for servo motor weld guns. Servo motor weld guns shall be designed with the capability to add an optional equalizer package in the field. The equalizer control devices shall be designed to be mounted on weld gun when an equalizer is utilized or needed based on program requirement or individual application. The EQ package must be approved prior to the program starts.



2.5.1.3 Equalizer Air Cylinder All equalizer air cylinders shall be sized and operated above 30 psi, and capable of running with unregulated air to 110 psi. All equalizer air cylinders shall be lubed for life.

2.6 ELECTRODE CAPS AND CAP ADAPTORS 2.6.1 Female Caps

Chrysler Group standard female electrode caps shall be used, reference DaimlerChrysler Process Standard PS-10947 for the detail information.

2.6.2 Male Caps Chrysler Group standard male electrode caps shall only be used when the tip angle is greater than 15 degrees.

2.6.3 Straight Shanks and Hex Adaptors Hex adaptors shall be used wherever possible. Conductive lubricant shall be used on threads during weld gun assembly.

2.6.4 Combo Holder Clamp All combo holders are required to be held in place by a clamp and screw arrangement, which prevents the combo holder (shank) from pulling out or/and rotating. The design shall be approved by AME Weld Gun Group during design review.

2.7 LAMINATED LEAF SHUNTS 2.7.1 Insulation

Leaf shunts shall be insulated or covered by resistance yarns both inner and outer. 2.7.2 Sizing

Leaf shunts shall be sized correctly for thermal loading (actual ECTC) and located at the optimum position so that no evidence of physical damage occurs when the weld gun closes or opens.

2.7.3 Installation and Removal Leaf shunts shall be designed for ease of installation and removal, without affecting the mechanical and electrical function.

2.7.4 Shunt Adaptor Solid shunt adaptors shall be used (soldered shunt adaptors are not allowed).

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.



2.8.4.1 Standard AC Transformers When applicable, the following AC transformers shall be used.

DCX/NPM Code KVA PRI V/ FREQ V/SEC Turns Ratio

91-901-1213 65 480/60 6.3 76:1

91-901-1214 93 480/60 10.9 88:2

91-901-1215 136 480/60 16.0 60:2

Table 1 - Standard AC Transformers

2.8.4.2 150 KVA Transformer When 2.7.4.1 can not satisfy the KVA requirement for machine weld guns, DCX standard 150KVA shall be used.

DCX/NPM Code KVA PRI V/ FREQ V/SEC

41-704-0222 150 480/60 Min 9.23, Max 15.00

Table 2 - 150 KVA Transformer

2.8.4.3 Standard DC Transformers When applicable, the following DC transformers shall be used.

DCX/NPM Code KVA PRI V/ FREQ V/SEC Turns Ratio

91-680-0515 100 650/1000 9.0 72:1

91-901-1217 150 650/1000 13.0 50:1

Table 3 - Standard DC Transformers

2.8.4.4 Standard transformers for Remote Weld Guns Remote (hip mount) weld guns shall use the following transformers.

DCX/NPM Code KVA PRI V/ FREQ

91-901-1218 200 480v/60Hz

91-901-1219 265 480v/60Hz

Table 4 - Standard Transformers for Remote Weld Guns

2.8.5 Weld Gun Secondary Grounding Secondary grounding strap shall be supplied with the transformer (AC and DC) by the welding transformer manufacturer(s). Utilizing secondary grounding strap to ground weld gun shall be the standard method except specified by DCX process group. It’s the responsibility of process integrator to remove the grounding strap in case a grounding reactor is required. All robotic and pedestal welding applications shall have the secondary circuit of the welding transformer connected directly to ground. This connection shall not be through the robot structure or other machine elements All manual welding applications shall utilize grounding reactors on the secondary of welding transformers.

2.8.6 AME/ASME Process Group shall be responsible for determining whether a hard wire or quick disconnect (Metric or English) is used for primary connection. All transgun drawings shall show the primary connector. It’s the responsibility of process integrator(s) to use proper size of cable(s).

2.8.7 Transformers Labeling Oil resistant labels shall be on the transformer and shall contain the following information: • Manufacturing Company Name and Address



• Service Telephone Number • Serial Number • KVA rating at 50% duty cycle • Primary voltage and frequency • Transformer turn ratio • Water Flow Rate An additional label shall be shipped to the weld gun supplier by the transformer manufacturing company for attachment at gun construction.

3.0 DESIGN PROCESS AND BUYOFF REQUIREMENTS

3.1 DESIGN PROCESS Reference Appendix B for the DCX Weld Gun Group Design Review Form. 3.1.1 Weld Gun Concept Review

The design of the weld gun shall be considered prior to the design of the tooling. AME Weld Gun Design coordinator shall participate in the weld gun concept review along with DCX BIW Process Engineer, Plant representatives, OEM and the weld gun supplier. The OEM is responsible to hold this activity at its location and with regular meeting schedules to ensure all weld gun concepts are completed and approved to meet program timeline. 3.1.1.1 Weld Gun Selection

Weld gun selection shall proceed as following guideline: • Weld gun design in the predefined process library; • Weld gun design with standard chassis from previous programs, but not the one in

the predefined process library; • Modification of cap adaptor(s), arm(s) from existing gun design with a standard

chassis; • A unique design from previous programs; • A new unique design.

3.1.2 Design Review The AME Weld Gun Group shall evaluate all new weld gun designs to ensure that they will meet the requirements of this specification, prior to release for build. The build supplier or weld gun manufacturer shall contact an AME Weld Gun Group Design Coordinator to arrange this review in a written notice (e.g. e-mail, fax etc.) at least two (2) business days in advance. Design reviews shall be completed within 3 weeks after the concept approval.

3.2 BUY-OFF PROCEDURE 3.2.1 Testing and Documentation

All weld guns shall complete a testing procedure before shipping from the weld gun supplier. Documentation shall be provided by the weld gun supplier to prove that the weld gun meets all requirements of this specification. The AME Weld Gun Build Buy-Off form shall be completed for each weld gun (Appendix C). The original form shall be given to the AME Weld Gun Group representative. A copy shall be retained by the weld gun supplier for the duration of the warranty period.

3.2.2 Build Buy-off All weld guns shall be checked by a member of the AME Weld Gun Group before the gun is shipped to the OEM or DCX plant. The weld gun manufacturer shall contact the AME Weld Gun Group Design Coordinator to arrange the build buy-off by a written notice (eg. e-mail, fax etc.) at least two business days prior to the event.



3.2.3 Requirements at System Build Supplier It is the responsibility of the AME Process and OEM to assure that the build buyoff procedure is followed. Any modifications on weld gun or components made during equipment integration requires notification of the AME Weld Gun Group and AME Process Engineering Group immediately. Major modifications may require another buy-off.

4.0 WELD GUN DESIGN DOCUMENTATION 4.1 DESIGN PROPOSAL PACKAGE

4.1.1 Design Approval Guidelines A. Weld gun design approval shall adhere to the following guidelines. Weld Gun supplier shall

submit a design proposal package for approval to the AME Weld Gun Group. The design proposal package shall include the layout drawing of the weld gun containing the following information:

• Welding Transformer Location • Composite Part Sections (screen dump) • Equalizer or locking device • IN/OUT Water Locations • Center of Gravity • Total Weight

• Total Opening

• Stress Calculations • Lube Location if required • Type of Lubricant if

required. • Weld Schedule(s) • Duty Cycle (spots per job) • Line Speed (jobs per hour) • Nugget size

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.



4.2.6 Reading Direction Unless otherwise specified, all dimensions and notes should be placed on the drawing using the unilateral method, so that they may be viewed from the bottom of the sheet.

4.2.7 Dimensioning and Tolerancing Dimensioning and tolerancing practices shall be as defined and illustrated in the current revision of ANSI Specification #Y14.3M. A zero before the decimal point shall be used for a number less than 1.0 Example 0.5 4.2.7.1 Assembly Drawing Dimensions

Weld gun assembly drawing dimensions shall consist of Jaw Depth, Jaw Throat, Total Tip Opening, Weld Opening, Movable Height and Stationary Height.

4.2.7.2 Assembly Drawing Notes Assembly drawing notes shall consist of Maximum Weld Tip Force (i.e. DO NOT EXCEED 800 lbs. WELD TIP FORCE), KVA Rating and Total Weld Gun Weight. Note the water flow "IN" or "OUT" at each water port.

4.2.7.3 Detail Drawing Dimensions Detail drawing dimensions shall be displayed in metric with inches in parentheses. Example: 10.0 (0.39)

4.2.8 Dimension Arrangement Dimensions should be shown in true views and should not be taken from hidden lines. 4.2.8.1 Location

Dimensions should be located outside the outline of the detail wherever possible. 4.2.8.2 Screws and Dowels

Screw and dowel sizes shall be written along the centerline, of the fastener in its profile on assembly drawings

4.2.9 Holes and Slots All tapped, dowel and clearance holes on details are assumed to be through. It is not necessary to specify on a drawing that the hole is “THRU”. 4.2.9.1 Depth

When a hole requires that a depth be specified, the depth shall be incorporated into the hole callout.

4.2.9.2 Construction Hole Construction holes are assumed to be through or to a cross-hole if applicable.

4.2.9.3 Counterbore Depth Depths for counterbore holes shall not be specified unless they are non-standard, in which case “AS SHOWN” should be noted on the drawing.

4.2.9.4 Tapped Hole All tapped holes should be Unified National Coarse threads.

4.2.9.5 Tabulation On detail drawings with three or more hole sizes, holes shall be tabulated using the label shown (Fig. 6).



Fig. 6-Detail Drawing Tabulated Label

4.2.9.6 Call Outs For slots, call-outs for “CENT.”, “TYP.”, and “RADIUS” or “R” are assumed, and are not required.

4.2.10 Details of the Weld Gun If a detail is shown & opposite on a particular weld gun, separate consecutive numbers shall be allocated with “SHN.” and “OPP.” written alongside the balloon.

4.2.11 Out of Scale Dimensions out of scale should be avoided, but when a dimension cannot be made to scale (because of a drawing revision), then the dimension should be underlined. Example: 5.62 DIA

4.2.12 Revision Level The information recorded in the change column should be brief and accurate, but complete to the extent that the drawing could be reverted to its original form. 4.2.12.1 Affected Sheets

A change letter used when recording a change should continue to be used on all of the affected sheets (assembly, B.O.M., etc.) pertaining to that change.

4.2.12.2 Change Balloon A change letter (upper case) should be enclosed in a 6mm-diameter balloon.

4.2.12.3 Recorded All changes should be recorded in the change column on the affected sheet or sheets after 40% design review. Change letters should be placed in a vertical row in the change column.

4.2.12.4 Placement A change letter and balloon should be placed near the revision on the affected sheet.

4.2.13 Controls Documentation All controls requirements and documentation shall be on shown on WD’s, but not on weld gun mechanical drawings. Weld gun supplier shall contact AME Control Design Coordination Group for any additional information.

4.2.14 NPM Code Numbers New NPM code numbers shall be assigned to all weld guns and their components, by an AME Weld Gun Group Design Coordinator after the design review is completed. Weld gun suppliers are responsible to show existing NPM codes on drawings.



4.3 CAD DELIVERY

4.3.1 Hard Copy Print Requirement A copy of the weld gun assembly shall be shipped to the user plant with the weld gun. The minimum size shall be 11x17 inches and must meet text size requirements. It’s the responsibility of the process integrator to ensure the weld gun drawings are shipped to the DCX plant with the equipment for a new program. New prints shall be furnished to the user plant if changes occur during launch by the weld gun supplier.

4.3.2 Preliminary weld gun drawing delivery Ten business days following weld gun approval, weld gun suppliers shall supply an assembly drawing and model to the AME Weld Gun Group CAD Coordinator. The drawings shall be in the format of Catia or AutoCAD 2000 or other approved software. The file name must contain the Chrysler NPM code or in the case of a Chrysler weld gun, the Chrysler number. File name example: NPM code: 91-814-1712.DWG or Chrysler Gun #: CHR116-1C-1F.DWG Twenty business days following weld gun approval, weld gun suppliers shall supply a detail drawing for each new detail that was created for the assembly. The drawings shall be in the format of Catia or AutoCAD 2000 or other approved software. The file name must contain the Chrysler NPM code. Drawings attached through Email must not exceed 20 megabytes per business day.

4.3.3 Final Weld Gun Drawing Delivery All new weld gun drawings shall be delivered to the AME Weld Gun Group in CATIA format no later than 60 days following the official vehicle launch date. The drawings shall meet the following requirements: 4.3.3.1 CATIA

All new assembly and detail drawings to be supplied in CATIA by the weld gun supplier. One (1) complete drawing shall reside in one (1) model.

4.3.3.2 Vector Elements Models may consist of "draw" or "space" vector elements. No scanned data.

4.3.3.3 Translations Models may be translated from other CAD systems, provided no data is lost or altered due to the translation process.

4.3.3.4 Storing Models Model shall be stored with a draw window, displaying the complete drawing.

4.3.3.5 Electronic Data Transfer All models shall be shipped via electronic data transfer per platform requirement.

4.3.4 Solid Model Weld Guns Any new weld gun designs, which are solid modeled in CATIA per platform requirement, shall be delivered to the AME Weld Gun Group no later than 60 days following the official vehicle launch date. The solid model shall be drawn to the latest revision level of the assembly drawing with the following requirements. • Solid model to be supplied by the weld gun supplier. • Model to show the entire outline of the weld gun as shown on the assembly drawing,

including water fittings. Internal components are not required. • Show mounting holes on the weld gun frame/cradle. • The weld point of the weld gun shall be located on the origin (axis1) of the CATIA

model. Align the weld gun to X-direction and Z-direction of axis 1 as follows: "X" - positive direction towards the fulcrum "Z" - "normal" to weld spot, with the positive direction toward the movable gun body.



• Show open and retract position of weld tips, gun bodies, and servo actuator/cylinder in phantom.

• Store model with default isometric window displayed with the weld gun being in the weld position.

• All models shall be shipped via electronic data transfer.

5.0 WELD GUN INTEGRATION 5.1 GENERAL

AME Weld gun group will make every effort to ensure each weld gun is designed and built according to the specification contained herein, prior to shipping to process integrator’s location. The integrator has the responsibility to pipe and wire properly as specified by the approved WD’s from AME Control Design Coordination Group. If any other weld gun performance or quality issue arises, contact AME Weld Gun Design Group to coordinate with the weld gun supplier for a resolution.

5.2 SERVO WELD GUNS Weld gun supplier, Servo Control System and/or Robot Manufacturer and Process Integrator shall understand their responsibilities to deliver the best results of servo weld guns. 5.2.1 Weld Gun Supplier Responsibilities

Initial set-up shall be completed at weld gun supplier location. The configuration file shall be delivered to process integrator or DCX plant along with the weld gun through electronic media. • Servo motor parameters shall be configured to include the following:

--Maximum speed --Maximum current --Maximum torque --Number of poles pairs --Resistance --Inductance

• Weld Gun Parameters --Maximum opening --Tip displacement (transmission) ratio -- Stationary Cap Displacement at maximum rated gun force, if the force vs. deflection is

nonlinear relationship, then two or more points shall be required. --Maximum weld gun tip force

• Force Table set-up. 5.2.2 Servo Control System and/or Robot Manufacturer’s Responsibilities

● Servo control system and/or Robot manufacturer shall provide the proper software and information to weld gun supplier for the initial set-up prior to the program start. Contact AME Robot/Control group for further detail requirements on servo motor control system. Servo parameters and variables that characterize the weld gun dynamics shall be calibrated automatically and without the aid of an oscilloscope or other special instrumentation.

● Servo control system and/or Robot manufacturer shall provide the proper software and information to process integrator(s) to fine tune individual weld guns to achieve the maximum performance. Auto tuning procedure shall be requested and approved by AME Robot and Weld Gun Group prior to program starts.

● Servo control system or Robot manufacturer shall provide the proper software and information of tip wear and gun deflection to process integrator(s) prior to program start.



● Servo control system shall have software stroke limit settings to protect the gun from damage during opening and closing in automatic or jog modes.

● Zero position setting shall be set without the aid of alignment tools or instrumentation. The servo control system shall be accurate and simple enough to allow plant maintenance personal to perform the tip force check with a regular force gauge.

● Servo control system and/or Robot manufacturer shall provide servo motor weld gun operation setting definitions and instruction to DCX, weld gun supplier and process integrator prior to program start.

5.2.3 Process Integrator’s Responsibilities ● Install, dress and program servo weld gun to program requirements to achieve weld

quality, product quality and production rate.

6.0 VALIDATION, RELIABILTY AND MAINTENANCE REQUIREMENTS 6.1 VALIDATION REQUIREMENTS

All new weld gun concepts shall require validation tests by the weld gun supplier. A design concept shall be considered as new if one or more of following items occur: • New construction methods (e.g. bar stock);

• Change in material for weld gun body and components;

• Change in the supplier of servomotor, actuator or pneumatic cylinder;

• Change in equalizer package;

• Change in pivot design;

• Change in water circuit.

6.1.1 Test Plan Supplier will submit a test plan to the AME Weld Gun Group prior to validation tests. At a minimum, the testing shall consist of following requirements: 6.1.1.1 Test Set Up

• Air pressure per this specification or servo motor weld gun per design force. • Water cooling circuits and differential pressure per this specification. • Accelerated validation test of 10 million weld strokes for durability test. • One-hour thermal capability test to demonstrate that weld gun is designed to

operate at specified weld current and duty cycle without overheating. 6.1.1.2 Measurement Items

• All items, which have potential to be worn out during operation, shall be measured per this specification prior to and post of test, including weld gun and key component design tolerances, structural integrity and performance requirements. Components shall be inspected at 5 million and 10 million strokes. AME Weld Gun Group representative(s) must be notified.

• Weld gun tip force repeatability per this specification (2.4.2). • Weld gun cycle time per this specification (2.4.3.2).

6.1.2 Validation Testing Summary Weld gun supplier shall submit a validation test summary to the AME Weld Gun Group and AME Process Engineering Group (if applicable) for review and approval. The test summary must demonstrate that the requirements of this specification are met.

6.1.3 Approval Approval for a new weld gun design must be granted by the AME Weld Gun Group in writing.



6.1.4 Machine FMEA A machine FMEA shall be required per Chrysler Group Supplier Quality requirements.

6.2 RELIABILITY AND WARRANTY All components, except perishable items, shall have a minimum mean time between failures (MTBF) of 30 million weld stokes or 3 years of production, which ever comes first. Warranty shall meet the requirements of DaimlerChrysler program specifications.

6.3 MAINTENANCE AND SPARE PARTS 6.3.1 Mean Time to Repair (MTTR)

Mean time to repair or replace major components, for example, actuator, slide, transformer, arms and mounting brackets, etc, shall not exceed 45 minutes during production. Time to replace shunts, jumper cables, and cap adaptors shall be less than 15 minutes for common weld gun designs. The above tasks and repair times are for ordinary maintenance personnel from the user plant.

6.3.2 Maintenance Manual Weld gun supplier shall provide maintenance manual to DCX user plant and AME weld gun group.

6.3.3 Manual Contents Maintenance manual shall be reviewed and approved by DCX user plant and weld gun group prior to program production start. Minimum contends shall include: • Weld gun and components replacement procedure. • Adjustment procedure for any components if required. • Basic mechanical and electrical troubleshooting. • Pneumatic schematic and components listing • Schematic of proprietary items detailing manufacture’s part numbers • Lubrication schematic showing lube points, type of lubricant and component listing • Locations of insulation • Servo motor and gun operation instructions and troubleshooting techniques.

6.3.4 Preventative Maintenance The maintenance manual shall contain the required PM activities as well as the activity frequency. The manual shall contain recommended spares as well as all replacement part information.

6.3.5 Spare Parts Weld Gun Supplier shall provide a spare part list to DCX user plant and AME Weld Gun Group with the appropriate manufacturer and part numbers, both NPM and supplier’s number. The spare list shall be delivered to DCX as the progressive of the program and assembly areas within 30days or 90% weld gun design completion, which ever comes first. In the event that a supplier cannot furnish replacement parts and assemblies to meet DCX plant needs, the supplier shall be required to surrender any specific details, including any “proprietary” design and components, to AME weld gun group and DCX plant.

6.4 TRAINING Weld gun supplier shall provide onsite and offsite training.

Training shall utilize the maintenance manual supplied by weld gun supplier.

6.5 SUPPLIER SERVICE 24 hours emergency assistance from supplier shall be available to the user plant maintenance manager.



The supplier shall have a permanent office or representative company in the United States, through which contacts shall be made. This arrangement shall last for the life of the vehicle program to address orders, components issues, replacement parts, service and warranty issues.

A supplier repair person or crew shall be on site within 24 hours of notification from a DCX representative.

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.

8.0 REFERENCE DOCUMENTS The design, construction and shipment of all weld guns shall conform to the latest version of all applicable DaimlerChrysler Standards. These shall include but are not limited to the following:

Doc. No. Title

WDFM003 Weld Gun Build Buy-Off Form

WDFM002 Weld Gun Design Form

PS-10947 Resistance Spot Welding Automotive Components

AME Do’s and Don’ts

AMS0021 General Requirements for Non-Production Material Used in Industrial Machinery



9.0 GLOSSARY 9.1 ACRONYMS &TERMS

Acceptable Minimum criteria the product shall meet.

Alternate An alternate method may be used where specified. Approval of a product using an alternate method may be revoked at any time.

AME Advance Manufacturing Engineering

ASME Advance Stamping Manufacturing Engineering

CD Compact Disc

Configuration File

The electronic file contains the information of servo motor and servo weld gun setting parameters.

Consumable A part that gets used up as part of the manufacturing process. This part usually makes direct contact with the body-in-white. (i.e. weld caps, adapters, cables, shunts, bushings, etc.)

Cycle The complete series of motions performed by the weld gun during use, which originates 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

Electrode Cap The component of the resistance welding process that contacts the work piece and carries current to affect the weld.

Electrode Shank Refers to the part that the electrode cap fits on.

Existing Refers to equipment, old or new, that currently exists as referred to in the project specification (i.e. the equipment is not supplied explicitly for this project’s use)

Failure Any event, which requires skilled-trade intervention to correct (except for consumable and perishable items).

Force Table Setup

The process of establishing a relationship between a range of servo motor torque commands and the resultant weld gun tip force.

GPP Global Project Procurement

Initial Setup The process of setting the basic servo motor and weld gun parameters to ensure weld gun delivering force and speed requirements.

JPH Jobs Per Hour

Launch The first day in which the Plant produces 5% of the contracted daily volume of the new 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



MQAS Manufacturing Quality Assurance System

MSDS Material Safety Data Sheet

MTTR Mean Time To Repair

N/A Not Applicable

Operator The term operator is used generically to describe a support person. An operator may be production, maintenance or engineering personnel depending on the specific application.

Perishable A part that degrades, deteriorates, or wears out over time, and is not expected to last per reliability requirements (i.e. shanks and shunts).

PM Preventive Maintenance

Tuning Setting servo parameters to optimize the performance of servo motor.

WD Wiring Diagram

10.0 PUBLICATION INFORMATION AND REVISION HISTORY 10.1 PUBLICATION INFORMATION

Contact/Phone No: Feng Cao, 248.944.6144 Alternate Contact/Phone No: Mark Garnett , 248.944.6223 Dept. Name & No: AME BIW Core Group, Dept. 8410/8402

10.2 AME WELD GUN GROUP CONTACT LIST Name Job Function Telephone Email

Mark Garnett Welding COC Manager 248-944-6223 [email protected] Feng Cao Tool Design Supervisor 248-944-6144 [email protected] James Clancy Weld Gun Coordinator 248-944-6168 [email protected] Mihal Dukhan Weld Gun Coordinator 248-944-6178 [email protected] Ron Klonowski Weld Gun Coordinator 248-944-6153 [email protected] John Rudnicki CAD Coordinator 248-944-6134 [email protected] Mark Carlson Weld Gun Coordinator 248-944-6117 [email protected]

10.3 REVISION HISTORY

Date Revision Number* NAME Description (include pages affected)

11/30/04 01 F. Cao Initial Full Release

8/1/06 02 F. Cao Revised by AME Weld Gun Design Coordination Group



Appendix A AME Weld Gun Group Coordination Procedures

ResponsibilitiesRelated

Documents &Processes

Procedures

Notification of New ModelLaunch and Carry-Over

programs andInitiate CWO Request for

ASME New Launch ProgramOnly

Attend Program Kickoff Meeting:Review weld gun requirementswith DCX Process and/or plant

and/or OEM

Complete Weld Gun MEDDSInformation

--Blanket Order--Spot Buy

Modify an existinggun or Design a new

weld gun

Issue NPM Codes for new weldguns and components enter into

ODIMS

Weld Gun Design Coordinator:Return marked up dwgs. toDesign Source. File copy.Weld Gun Design Source:

Finalizes design upon receipt ofdwgs.

Continued

AME & ASME Process ManagementWelding CoC Manager

Tool Design Coordination Supervisor

Weld Gun Design Coordinator

AME & ASME Process GroupWeld Gun Design CoordinationGroup

Weld Gun Design Coordinator,AME & ASME Process Group

Weld Gun Design Coordinator,AME Process Group

Weld Gun Design Source& O.E.M

Weld Gun DesignCoordinator,

AME Process Group,Weld Gun Design Source

& O.E.M

Weld Gun Design Coordinator

WDFM002 - WeldGun Design Form

Weld Gun Model ReviewUse Process Library gun or an existing weld gun design?

MEDDS SpecificationAPWI 257APFM 111

Release Design and MEDDS forBuild Weld Gun Design Coordinator

AME & ASME Process Group

No

WDFM001 Weld Gun CWO Request

Meeting Minutes - platform quality recordDo's & Dont's Section 6

Resistance Weld Gun Specification AMS 7110Program Weld Gun Tracking Form

WDFM00408

Weld Gun Design FormWDFM002

Platform Specification

Weld GunDesign Stds

Marked -upDrawingFile

Weld Gun DesignReview

Create MEDDS SpecificationsPer Sub Assembly Systems

StandardWeld Gun Body

Assemly?

MCN if Required

Weld Gun Design Coordinator,

Weld Gun Design Source

Weld Gun Design Source SubmitsSpot Buy Quote to DCX Purchasing,AME Process and Weld Gun Group

No

Yes

Yes

DCX PurchasingAME & ASME Process Group

Weld Gun Design CoordinationGroup


Use of MCNAPWI 114

Approved ByDCX



ResponsibilitiesRelated

Documents &Processes

Procedures

Continuation

Weld GunBuild Source: Does the

Weld Gun (As-built)conform to Design Review?

Build shop to rebuildgun to conform to

Design Review

Has theWeld Gun been installed

per DaimlerChryslerstandards for 20hr. Run?

Re-Installuntil

installationmeets

DaimlerChrysler

Stds.

Buy-off @ Tier one Supplier

Archive design documentation

END

No

No

Yes

Weld Gun Design Coordinator,Weld Gun Build Source

Weld Gun Build Source

Weld Gun Design Coordinator, O.E.M

Weld Gun Design Coordinator: Writes req'd changes in Weld Gun Installation

Correction LogO.E.M: Makes the corrections.

Tool Follow-up: Monitors that changes get made

Tool Follow-up

Weld Gun CAD Coordinator

WDFM003 - Weld GunBuy-off Form,

WDFM005 - Weld Gun Installation Correction Log,Do's and Don'ts Section 6

Resistance Weld Gun Spefication AMS7110

For Reference Only: TFDP001 (Tool Follow-up Dept. Procedure)

For Reference Only: WDOP005Control of weld gun design master

drawing

WDFM003 - Weld Gun Buy-off Form

WDFM005 - Weld Gun Installation Correction Log,Do's and Don'ts Section 6

Resistance Weld Gun SpeficationAMS 7110

Complete Spare listRecommendation

Complete MEDDS andRelease if Required byUser Plant and AME &ASME Process Group

Weld Gun Build Source

Weld Gun DesignCoordinator


Yes



Appendix B Chrysler Group Weld Gun Design Review Form

Program: ________ Plant: ____________________ Major: _____________ Item: _____________ Area: Assembly Stamping Sub Major: ____________________ Pedestal / Robot No.: ___________________________________________________________ Qty: _____ ___________________________________________________________

WELD GUN CONCEPT / MODEL Target Completion Date: ____________ Chrysler Weld Gun NPM: ____________________ Supplier Weld Gun No.: ____________________

CARRY-OVER WELD GUN Application Sections (Screen Dump) STANDARD WELD GUN Weld Schedule Sheets NEW WELD GUN with STD. B.G.A. UNIQUE (SPOT BUY) WELD GUN

- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - MEDDS (PURCHASING) NPM CODES - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - BODY GUN ASM .........._____________________ ACTUATOR........................_________________________ TRANSFORMER .........._____________________ CONNECTOR ...................._________________________ EQUALIZER N/A _________________________ DESIGN COSTS BUILD COSTS FOR ARM ASSEMBLY

DESIGN CHARGE - 5 HOURS ......48-225-0003 STANDARD ARM ASM......................................... n/a DESIGN CHARGE - 15 HOURS ....48-225-0004 ONE SPECIAL ARM ASM............................ 91-689-1000 DESIGN CHARGE - 28 HOURS ....48-225-0001 TWO SPECIAL ARM ASM ........................... 91-689-2000 DESIGN CHARGE - 33 HOURS ....48-225-0002 TWO ALUMINUM ARM ASM ....................... 91-689-3000

Remarks: _________________________________________________________________________________

_____________________________ ____________________________ ______________________________ Chrysler Weld Gun Group Representative/ Date Chrysler Process Representative / Date O.E.M. Representative / Date

DESIGN REVIEW shall be completed within 3 weeks from WELD GUN CONCEPT/MODEL approval date.

DESIGN REVIEW Target Completion Date: ____________ Chrysler Weld Gun NPM: ____________________ Supplier Weld Gun No.: ____________________

Est. Weight: _________ lbs. (_______kg) Max. Tip Opening: _______in. (_______mm) Max. W/Gun Rated Force: _____lbs. (_____kg) and Estimated Total Deflection: ______in. (____mm)

Description NPM Code Description NPM Code

____________________............___________________ ____________________ .........____________________ ____________________............___________________ ____________________ .........____________________ ____________________............___________________ ____________________ .........____________________ ____________________............___________________ ____________________ .........____________________ ____________________............___________________ ____________________ .........____________________ ____________________............___________________ ____________________ .........____________________

Remarks: _________________________________________________________________________________ _____________________________ _____________________________ _____________________________ Chrysler Weld Gun Group Representative/ Date Chrysler Process Representative / Date Supplier Representative / Date

BUILD BUY-OFF Target Completion Date: ____________

Remarks: ________________________________________________________________________________

NEW DESIGN CATIA DELIVERABLE Target Completion Date: ____________ Assembly Model (3D Solid) Assembly Model (2D Drawing) Detail Models (2D Drawings)

Remarks: _____________________________________________________________________________

___________________________________ Chrysler Weld Gun Group Representative/ Date

CHRYSLER WELD GUN GROUP

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

ITEM Weld Gun Supplier Rep.

DC Weld Gun Rep.

LAMACOID IDENTIFICATION TAGS (2) ACCEPTABLE NON-CONDUCTIVE FULCRUM COVER (with snaps - no screws)ACCEPTABLE SHUNT COVERS BEND RADII FOR SHUNTS PER DESIGN DWGACCEPTABLE FULCRUM TOLERANCE (IF LOOSE - TIGHTEN) ANTI-ROTATION DEVICES ON ELECTRODES (KEYS)COMPONENTS IDENTIFIED WITH DAIMLERCHRYSLER NPM CODES PER ASM7110 or DO'S&DON'TS ACCEPTABLE WATER FITTING CLEARANCETIP ALIGNMENT WITHIN 0.5MM (0.020”) TOTAL DEFLECTION WITHIN 4.6MM (0.180") AT MAXIMUM RATED FORCEMECHANICAL EQUILIZER PERFORMS AS REQUIRED1/4" CLEARANCE TO PREVENT ELECTRICAL SHORTS ( OR INSULATE )MOUNTING / ATTACHING SCREWS / NUTS SELF-LOCKING WHERE APPLICABLEDOCUMENTAION AND NO VISIBLE EVIDENCE OF WATER AND/OR AIR LEAKS BURRS AND SHARP EDGES REMOVED ACCESS FOR MAINT. (FITTINGS, FSTNRS., SHUNTS, TRANSFS.)WELD GUN PORTS LABELED IN & OUT FOR WATERGUN BODY AND COMPONENTS FREE OF VISIBLE CRACKS AND VISIBLE SURFACE POROSITYNO INTERFERENCE BETWEEN MOVABLE COMPONENTSADAPTOR OR HOLDER STICKOUT LIMITED TO SIX INCHES OR PER DESIGN DWGPINCH POINTS COVERED (MANUAL WELDGUNS ONLY) PER DO'S & DON’T'SSOFTWARE LIMITS ( MAXIMUM TIP OPENING LIMITS)BIAS SETTING SCRIBED (CENTERLINE GUNS ONLY)PLASTIC PLUGS IN ALL PORTS IF NEEDED MINIMUM WATER FLOW OF GUN ASSEMBLY @30PSI D IFFERENTIAL: 1.50 GAL/MIN EACH ARM ASSEMBLY FOR ROBOT/PORTABLE & PED WELDERS 1.00 GAL/MIN EACH ARM ASSEMBLY FOR MACHINE/FIXTURE WELDERS 1.00 GAL/MIN TRANSFORMER (AC) 2.00 GAL/MIN TRANSFORMER (MFDC) ____GAL/MIN FOR OTHER TRANSFORMER PER MANUFACTURER'S REQUEST"O" SETTING TOOL (SERVO GUN ONLY) WITH MANUAL OPENING TOOL (SERVO GUN ONLY)VERIFY VENDOR'S DOCUMENTATION OF SERVO GUN SET-UP PER ASM7110 REQUIREMENTS GUN CHECKED TO DESIGN DWG.: REV LEVEL / DATE: ______

For current revision of this form Ref: AME MQAS Document WDFM003 Weld Gun Build Buy-off Rev. DACCEPTANCE DOES NOT RELIEVE WELD GUN SUPPLIER'S RESPONSIBILITY.

DaimlerChrysler Weld Gun Coordinator Signature: _________________________Date: ______________

SERIAL NUMBERS INCLUDED IN THIS REVIEW (ATTACH ADDTL SHEETS IF NECESSARY):

DaimlerChrysler

DaimlerChrysler WELD GUN NO. DATE:

(FOR BUY-OFF @ WELD GUN SUPPLIER OR OEM)

CHRYSLER GROUP WELD GUN BUILD BUY-OFF FORM

PROJECT ID (Program year and Program ID):

Weld Gun Build Source Signature: _________________________ Date: ______________

ADDITIONAL COMMENTS:

OEM: WELD GUN SUPPLIER: SPARE: Y__ N__

ROBOT_____ PORTABLE_____ PEDESTAL_____ PNEUMATIC_____ SERVO_____