Structure and production requirements of inspection tools

3.1 the structure of the inspection tool – the skeleton and the base part- The body part- Functional parts (including: quick collet, locating pin, detection pin, movable clearance slider, turning mechanism, measuring table, chuck, etc.). 3.2 basic principles 3.2.1.1 all bolt connections with the base plate must be equipped with spring washers of sufficient strength. The peripheral dimension of the base plate must be larger than the perimeter of the inspection tool, the opening state of the movable unit of the type body shall not exceed the contour of the base plate, and the excess area of the upper plane of the bottom plate shall be used for placing pins, measuring instruments, etc. 3.2.1.2 the structure design of inspection tools shall meet the requirements of quick and accessible product placement on the inspection tools; When the inspection equipment is opened, the inspection mechanism and clamp on the inspection tool will not affect the product taking and releasing, and the inspection operation will not be affected when the inspection is closed. 3.2.1.3 when the parts of the turning mechanism, push and pull mechanism and clamp are in open and closed state, they shall not interfere with each other, and shall not interfere with the parts of the inspection tool. 3.2.1.4 the inspection tool base plate assembly needs to eliminate the internal stress and process it to the tolerance range; The welding of skeleton and base plate must be firm without defects such as false welding and false welding. Under normal working conditions, cracks, deformation and damage are not allowed. The inspection tool shall be constructed with sufficient strength and shall not produce any warping deformation under normal use. 3.2.1.5 except for inspection tools less than 15kg, other inspection tools shall meet the requirements of fork and lifting; The structure of the inspection tool shall meet the requirements that the inspection tool will not be damaged or damaged in the process of forking or lifting; 3.2.2 framework structure requirements of inspection tools: 3.2.2.1 the requirements for inspection tool skeleton of all sizes and types refer to the following table: the classification of serial number inspection tools defines the thickness of the base plate of skeleton structure (after processing) material 1 the dimension of large inspection tools (length + width) ≥ 1800mm channel steel for outer frame, and the internal skeleton is I-beam, and the waist height shall not be less than 250mm, The thickness of the two type inspection tools is 1800mm (length + width) and 600mm double-layer square steel pipe welding structure with the thickness not less than 8mm ≥ 25mm45# the welding structure of double-layer square steel pipe with the size of 1800mm (length + width) and the specification is not less than 50 * 50 * 4. The height of the bottom plate surface to the ground is 430mm-450mm-25mm45 # the dimension of small inspection tools (length + width) of the 3 small inspection tools is less than 600mm plate structure. For convenience of inspection, movable trolley is required, The height meets the requirements of human-computer engineering ≥ 25mm6601 aviation aluminum (45 steel). After the stress treatment of materials is eliminated, the surface anodizing treatment is 3.2.2.2.2 large-scale inspection tools shall be equipped with horizontal regulators at the foot of the base. The quantity standard shall be set: the inspection tools for the outer side panel shall be set with not less than 6, and the door plate and top cover inspection tools shall be set with no less than 4. 3.2.2.3 if the height of the bottom plate assembly of a certain inspection tool needs to be changed due to special reasons, it needs to be approved by planton. 3.2.2.4 when the total weight of small single piece inspection tool is less than 15kg, manual handle shall be equipped. The handle material shall be aluminum, and the strength, structure and assembly of handle shall be firm and reliable. 3.2.2.5 the plate type inspection tool shall be equipped with four feet (hard rubber and plastic blocks can be directly used), and the foot shall be equipped with cushion pad. 3.2.5 the foot 3.2.5.1 the foot and base are bolted. Generally, the roller is four front and rear (two of them are universal wheels), the latter two have self-locking function to be used for the handling of inspection tools and also for storage; In order to facilitate the safety storage and protection of the inspection tools, the rigid rubber plastic block or supporting structure shall be considered when necessary to the anisotropic datum of the base plate. 3.2.5.2 roller size requirements: the diameter of medium-sized inspection roller is ≥ 125mm, the diameter of large inspection tool roller is ≥ 150 mm, and the diameter of side inspection tool roller is ≥ 200mm. The design countersign results shall prevail. 3.2.5.3 the roller shall adopt standard parts, and the caster with easy to force or higher standard shall be selected. 3.2.6 the forklift hole ensures that the forklift arm can be easily extended. The forklift hole is a double structure on the side. The maximum bearing capacity and the size and specification of the forklift must be considered in the design. The forklift hole position shall be painted with colored paint as safety mark, and the paint color shall be in csb05-1426-2001 y07 medium yellow. 3.2.7 lifting lug 3.2.7.1 the retractable or fixed lifting rod shall be preferred. The maximum bearing capacity shall be considered in the design, and the following factors shall be considered for the arrangement of lifting device: ensure that the sling will not affect the inspection body and function parts during the transportation of inspection tools, nor affect any measuring elements; If the weight of the inspection tool is ≥ 15kg, the lifting device must be set; When the base plate length is ≥ 3M, fixed lifting rod shall be used. When the base plate length is ≥ 1m, the telescopic lifting bar shall be used. If the base plate length is less than 1m, fixed lifting rod can be selected. The telescopic lifting seat is made by integral casting or finishing line cutting and surface rust prevention treatment. 3.2.7.2 installation specification of lifting lug: considering that it is convenient to lift and does not affect the position of inspection tool type and functional parts, it is placed on the surface of base plate, and the hoisting rod mechanism and base plate are connected by bolts. The specification of lifting mechanism and bolt shall meet the safety requirements and use requirements. 3.2.8 the manufacturing benchmark is to facilitate the inspection tool to be fixed on the machine table accurately when machining the inspection tool or using the inspection tool for three coordinate measurement. The lower part of the base of the inspection tool must be set with the X, y and Z reference plane at least in the triangle, with the dimension of 100mm × 100mm × 30mm, with no less than 4 pieces, the accuracy of the reference plane must be processed by grinding. The coordinate value of the reference plane directly intercepts the value of the body coordinate system. The perpendicularity of the reference plane X-and y-plane in the direction of length and width is: ± 0.05mm/1000mm, height direction reference plane: z-plane at the bottom of the bottom plate, its own flatness must be 0.05mm, and the parallelism with the upper plane of the bottom plate shall be 0.05mm/1000mm. 3.3 type part 3.3.1 type structure and material 3.3.1.1 cover resin material on the base, and then milling the physical examination surface directly in NC machine tool through cad/cam. Resin material and base are connected with plastic binder or bolt and locating pin. 3.3.1.2 inspection materials: 5166 made in China, 5166 resin of Dongquan and Haixu brands is preferred. Resin materials of the same performance and quality as Dongquan 5166 can be used. Party A shall agree before use. 3.3.1.3 expansion joint: expansion joint shall be made every 250-300mm of the length of the profile part, and the width of expansion joint shall not be greater than 2mm (expansion joint shall be reserved during the material preparation and bonding of the inspection tool body, and it shall not be cut manually in the later stage). 3.3.2 detection surface 3.3.2.1 the detection of the surrounding, flanging and part section of various types of parts can be realized by setting the detection surface. The detection content of the detection surface includes: the detection of 5mm clearance of the parts equal distance and the detection of the flatness of the surrounding. Therefore, 5mm clearance must be processed on the profile according to CAD data, and the inspection surface and the surrounding flatness detection surface shall be as shown in the following figure; When extension detection is adopted, the extended surface shall be ≥ 30mm, and a warning plate or mark shall be attached to the lower part of the corresponding detection surface. 3.3.2.2 the material of the test surface must be the specified resin material or aluminum alloy insert. 3.3.2.3 the equal distance gap detection 5mm and the surrounding flatness detection of edge cutting or flanging can be carried out manually. 3.3.2.4 the distance from the lowest point of the inspection surface to the base board shall be ≥ 100mm. According to the product inspection and placement status, final confirmation shall be made during design countersign. 3.3.2.5 the clearance detection and processing of piece inspection tools without special requirements is 3mm. 3.4 functional parts 3.4.1 positioning surface 3.4.1.1 the positioning surface shall be set in accordance with the RPS of the product. If there is a need for fine adjustment under special conditions, it must only be transferred on the same functional surface, and the fine adjustment position shall not exceed 50mm, and it can be implemented only after being approved by the panilongton inspection engineer. 3.4.1.2 the reference plane is made of stainless steel, Rockwell hardness C 58-60, and the surface roughness of contact surface with the part is ra=0.8（ μ m) , non-contact surface roughness ra=1.6（ μ m)。 3.4.1.3 positioning surface is preferred 10 × ten × 5mm； The manufacturing tolerance of positioning surface is +0 / – 0.05mm. 3.4.1.4 the positioning surface shall be fastened with flat head screw, and the screw surface shall be lower than the zero position surface. The threaded hole shall be equipped with thread bush. 3.4.1.5 the assembly position of positioning surface shall be at least 3mm away from the r part of product. In special cases, it can be implemented after being approved by planton. 3.4.2 locating pin and inspection pin 3.4.2.1 before the part clamping and inspection start, the part must be positioned first. Therefore, the locating pin is used to accurately locate the parts on the inspection tool, and the locating pin is divided into the disassembly type positioning pin and the fixed positioning pin; In general, the main positioning uses fixed positioning pin, and the auxiliary positioning uses the disassembly type positioning pin; The positioning position of the locating pin shall be 5mm beyond the surface of the part, and the length of the guide part of the fixed positioning pin shall be 5-10 mm. 3.4.2.2 according to the positioning needs, the main positioning pin is divided into the main and secondary positioning pin, which is cylindrical, and the secondary positioning pin decides to adopt round pin or diamond pin according to the shape of the product auxiliary positioning hole. The diamond pin guide pin sleeve must be set as anti rotation structure. Diameter of main and auxiliary locating pin is: hole size position tolerance, manufacturing tolerance is 0 / – 0.02mm. 3.4.2.3 inspection pin is used to detect the position of the inspection hole, and it can be divided into two types, cylinder pin and scribe pin according to the different detection position. 3.4.2.4 inspection pin: diameter of position through pin end is: aperture dimension – (absolute value of deviation under aperture + tolerance of position), manufacturing tolerance is 0 / – 0.02mm; Diameter of pin of marking pin = diameter of inspection hole of parts + 4mm; Check the actual diameter of the pin with cylindrical through pin and scribed pin on both ends of handle. 3.4.2.5 there are many (>2) holes to be tested with the same diameter and tolerance requirements of the same position in the adjacent area of the parts, and these holes must be inspected by inspection pins. If the holes are usually set with one inspection pin within 200mm-300mm. 3.4.2.6 all detachable pins need to be engraved with the actual diameter of the pin at the handle. Each removable locating pin is equipped with a telescopic rope to fix it at a suitable position on the inspection tool base plate. 3.4.2.7 the radial fit of inspection pin is h7/g6, and the surface roughness of inspection pin fit is ra= 0.8（ μ m)。 3.4.2.8 the positioning pin and inspection pin can be made of Cr12MoV or equivalent material. The surface of pin shall be hardened, and Rockwell hardness C 58-60. 3.4.2.9 guide of the pin on the inspection tool shall be matched with the bushing, and the bushing on the inspection tool shall be provided with exhaust hole or the pin shall be degassed. The bushing can be made of Cr12MoV or equivalent, and the surface shall be hardened, and Rockwell hardness C 58-60. The surface roughness of Bush fit is ra= 0.8（ μ m)。 3.4.2.10 the positioning / testing part of pin shall be at least 5mm higher than the surface of the part. 3.4.2.11 the color of the handle or storage pin seat of the main and auxiliary positioning pin shall be distinguished from the inspection pin. The main positioning pin shall be red, the auxiliary positioning pin shall be blue, and the inspection pin shall be green or material color; When the assembly type is adopted between pin handle and testing part, the connection between the test part and handle is not easy to fall off. When the whole processing is adopted, the handle shall be knurled, and the knurled depth shall be ≥ 0.5mm. 3.4.2.12 placement of pin box: after the positioning pin and the inspection pin are used, they shall be placed in the pin box horizontally. The pin box shall be placed in the proper position on the upper part of the inspection tool base plate and the corresponding mark shall be marked on the bottom plate. If there are more than one inspection pin, the identification shall be distinguished in the proper position of the inspection tool to show the difference. Plastic is recommended for pin boxes. 3.4.2.13 when the test pin is not used, it shall be stored horizontally. 3.4.3 the overturning mechanism and push pull mechanism 3.4.3.1 the structure strength is enough and the operation is simple; Material requirements: 45 # and above grade steel, tempering treatment, surface electroless nickel plating phosphorus. If the weight reduction is required due to the small inspection tools, the material of 6061 aviation aluminum and the surface of the device is made of hard anodizing material to make the turning mechanism. The structure and quality of the turning mechanism can only be used after being approved by the planton inspection tool engineer. 3.4.3.2 when the turning mechanism of section gauge is inserted into the locating pin but not fastened, it is required that the cross-section gauge is firm and free from shaking. 3.4.3.3 two overturning mechanism and push pull mechanism shall be used for installation Φ 8. Assembly method of locating pin and ≥ 4 bolts. 3.4.3.4 RA = 0.8 of mechanism positioning surface（ μ m) , RA = 1.6 for the rest（ μ m)。 3.4.4 section gauge 3.4.4.1 material: stainless steel plate or aluminum plate with pin sleeve, surface roughness ra=1.6（ μ m) When aluminum is selected, the surface of section gauge shall be anodized with its own color. 3.4.4.2 width of section gauge: 10-12mm, and the width of detection function part is usually 2mm. 3.4.4.3 the insertion direction of the locating pin shall be marked on the section gauge. 3.4.4.4 clearance detection points and detection direction shall be clearly marked on the section gauge. 3.4.5 clamping 3.4.5.1 in order to fix parts, quick collet or magnet must be equipped in the positioning surface and support surface area. 3.4.5.2 the collet device is usually directly fixed to the proper position of the upper surface of the inspection tool base by bolts or connected by welding beam or cast beam. The diagonal two bolts set on the collet connecting plate meet the process requirements in principle. The location of the collet device reflects the RPS position and quantity of the parts. 3.4.5.3 in the arrangement and arrangement of collet device, it is necessary to note that: 1) when the collet is loosened and restored to the starting position, there must be enough space to ensure that the parts are placed and removed without interference. 2) there is enough space to provide enough space for the collet to realize the space free interference curve movement on the inspection tool. 3.4.5.4 the contact between the chuck and the workpiece surface shall ensure that the chuck only plays a fixed role on the workpiece, not clamping deformation (in principle, the clamping force is not greater than 5N). 3.4.5.5 the claw head is facing the center of the reference plane, and the claw surface shall be parallel to the plane of the reference block. 3.4.5.6 the clamping sequence shall be marked on the pressing claw, such as S1, S2 and S3; In principle, the clamping sequence shall be symmetrical, and the specific clamping sequence shall be approved during design countersign. 3.4.5.7 the quick clamp shall be of Jiagang or Jiashou brand or the same quality as Jiagang. 3.4.6 reference block: the measuring datum 3.4.6.1 the reference block of the inspection tool is used to establish the coordinate system of the inspection tool, used for the manufacturing and calibration of the inspection tool, and the coordinate system established by the inspection tool reference block is used to measure the parts during the CMM inspection of the parts. 3.4.6.2 at least 3 measurement benchmarks are used Φ 8h7 hole is used as the reference, and its actual coordinate value shall be marked next to the reference block. The hole provides the coordinates of two directions, and the surface of the reference block provides the coordinate of the third direction. 3.4.6.3 the reference block must be protected separately. 3.4.6.4 reference block material: Cr12MoV or equivalent material shall be used. 3.4.6.5 the design and assembly position of the measurement reference block shall be at the intersection of the 100 position line in two directions. If the size of the base plate or the influence of lifting lug are avoided, the design assembly position of the reference block can be moved to the intersection of 50mm integer value in both directions of the 100 position line. Use at least 2 locating pins and 2 bolts to lock the assembly method. 3.4.6.6 reference block hole and reference