Abstract
Welding of sheet metals is the most desired and widely used process in automobile body shop. The use of new welding technologies becomes necessary as the automobile designs evolve to be light and strong. Technologies like Resistance Projection Welding, Remote Laser Welding help reduce Material usage, increase the welded area in the body panels, eliminate weld marks in the A class panels and flanges that are visible in a Car Body. Even though these technologies are promising, the need for robots and automation to aid welding makes the design costly. This paper presents low cost design concept for using RPW and RLW technologies in low JPH plants. The design has to be simple and manually operated, use minimum automation, and allow more than one welding method in the same station. From a Fixture design and Manufacturing stand point a simple manual operated design that uses manual clamps, provides removable gun guides to position RPW guns, uses blocks that are assembled into fixtures using screws is required.