destaco.com
Automating Tomorrow™
WARNING: This is a controlled document. It is your responsibility to deliver this information to the end user of the
DESTACO product. Failure to deliver this could result in your liability for injury to the user or damage to the machine.
For copies of this manual, call your Customer Service Representative at 1-800-645-5207.
BodyBuilder Design Handbook
Mid Mount with GR1
Series Gripper
Mid Mounted Part Nest with
CPI-HTW Hold Table Weldment
and Nest Pad guides
Mid Mount with GR84
Series Mini-Clamps
End Mount with Venturi Cup
Mounts and Vacuum Cups
Mid Mount with 82M50
Enclosed Power Clamps
End Mount with GR84
Series Mini Clamp
Bodybuilder End Effector System
Product Overview
TABLE OF CONTENTS
1. Introduction .............................................................................................................. 4
2. Application Field BodyBuilder .................................................................................... 5
3. The BodyBuilder System ............................................................................................. 5
3.1 Octogonal Profiles .....................................................................................................5
3.2 Base Mounts ............................................................................................................. 6
3.3 Connectors ............................................................................................................... 7
3.4 Crash Management .................................................................................................. 8
3.5 Robot Adaptation for PSA Global Robots .................................................................... 9
3.5.1 PSA-PL-01 and PSA-PL-04 for 45mm/60mm BB profiles ........................................... 13
3.5.2 PSA-PL-02 for 60mm BB profiles (Parallel Arm Structure) ......................................... 13
3.5.3 PSA-PL-03 for 90mm BB profiles (Parallel Arm Structure ........................................... 14
3.6 Adaptors for OV Global Robots ............................................................................... 16
3.7 Adaptors for Single Arm Toolings ............................................................................. 19
3.8 Measuring References ............................................................................................21
3.9 Clamping of Metal Sheets ........................................................................................ 22
3.9.1 Clamping Solution .................................................................................................. 22
3.10 Centering of Componens ........................................................................................ 29
3.11 Part Presence / Sensing of Workpieces .................................................................... 33
3.12 Mounting Plates for Electrics Pneumatics ..................................................................34
4. Details Octogonal Profiles ......................................................................................35
4.1 Technical Data ........................................................................................................ 35
4.2 Free Cantilever Length of Profiles ............................................................................ 39
5. Details Transition Brackets ...................................................................................... 40
5.1 Technical Data Transition Brackets ........................................................................... 41
5.2 BodyBuilder T-Clamps.............................................................................................. 44
5.3 BodyBuilder TPMS-Clamps ....................................................................................... 46
6. Clamp blocks for connection of BB Profiles to Ø25mm round ..................................47
Technical Data ......................................................................................................... 47
7. Design Samples ..................................................................................................... 49
7.1 Clamping with Automation Clamps ........................................................................ 49
7.2 Vacuum Equipment / Interface to Vacuum Cups ...................................................... 50
7.3 Additional Possibilities ............................................................................................. 54
8. Design Procedure .................................................................................................... 55
3
Product Overview
Spidergrip Geometric End Effector System
1. INTRODUCTION
This Handbook shall submit Design Rules for the DESTACO BodyBuilder End Effector System to
end at optimal results in Design.
All components’ weights are available to summarize the total weight of the End Effector solution.
The calculation of deflection and torsion of the BodyBuilder System are according to the general
rules of Engineering Mechanics, which may be found in all corresponding Handbooks or please
do it with the help of your CAD system.
The BodyBuilder System Design Rules shall help to configure the needed components but does
not guarantee a design without any faults. This depends on the application and on the structure
of the workpieces.
In case of the design for the Automotive Industry it is obligatory to follow their specification and
find agreements with their head of Standardization if problems occur. A solution has to be found
with the detail project manager, to avoid faults in the beginning of design. The components
of the BodyBuilder shall be used in that way that the reachability of the screws is possible. The
components shall not be bundled together, a minimum distance between them shall be there for
adjustments of position and length.
4
Bodybuilder End Effector System
Design Handbook
2. APPLICATION FIELD BODYBUILDER
The DESTACO BodyBuilder System is designed especially for the rough usage at BIW
Applications. This system is applicable for Material Handling and Pedestal Welding Applications.
All Process Applications may be operated because of the rigid structure.
The DESTACO BodyBuilder System may be used for car body components with dimensions up
to 3 x2 m and to be handled weight of about 90 kg, which is approximately the weight of an
complete underbody. Also bigger Endeffectors may be build with the BodyBuilder structure, up to
4,5 m x 2 m. In case of these large dimensions a close cooperation of the design office and the
project manager is necessary. A double checking procedure about the robot payload has to be
made after the design is ready. In addition the system, may be used for build up of Hold Tables,
Pillars and Fixtures.
3. THE BODYBUILDER SYSTEM
3.1 Octogonal Profiles
The DESTACO BodyBuilder System is to be build
up with three structures: 30 mm, 45 mm und
60 mm. With these the designer may build up
the frames for the tooling. These structures are
to be characterized with highstrength Aluminium, low weight per meter and high rigidity. With
their help and the different components of our catalogue the designer may build up very flexible
Tooling Systems.
For large dimensions the structure B-90 may be used too.
Always closed framework have to be designed to reach best stability.
The strength of the system may only be assured 2 when the 2 parallel booms are connected with
cross booms.
5
Bodybuilder End Effector System
Design Handbook
3.2 Base Mounts
The interface to the Robot or Linear System are our Base Mounts.
They include the mounting pattern to the handling device and the main clamps for the build up
with the octagonal profiles.
Sample for a typical assembly (here you may see some examples with the DESTACO RM4-60):
Sample for a tooling mirrored:
6
Bodybuilder End Effector System
Design Handbook
For large dimension tooling, as Sidewall applications the B-90 mm profile may be used.
A standardized base mount is fixed. The connection B-90 shall be made with the profile
B-90 and clamps TPMS-90. For dimensions: 4,5 m x 2 m. Smaller dimensions please use
B-60 components.
The baseplate for attachment at the robot hand flange or the tool changer shall be made
according to the existing tooling dimensions with the help of special made base plates.
The dimensioning shall be made from the Integrators.
3.3 Connectors
The octogonal
profiles may be
connected with
Transition Brackets
M-XXB-XXB-M
If octagonal and
0 25 mm round
tubes shall be
connected please
use the M-XXB-
25M-M style
connectors
The clampblock
CL-25M-25M-A is
a block style clamp
block that may
connect two round
tubes Ø25 mm in a
rectangular position.
Made in high
strength aluminium
light weight solution.
TPMS Profilclamps,
TPMS-45 and
TPMS-60 are
connectors for
adaptation of
Automotive Clamps,
Adapter Plates, Pin
Packages fixed pins
and other special
made components.
The octogonal profiles may be connected
with Transition Brackets M-XXB-XXB-M
If octagonal and Ø25 mm round tubes shall
be connected please use the M-XXB-25M-M
style connectors
The clampblock CL-25M-25M-A is a block
style clamp block that may connect two round
tubes Ø25 mm in a rectangular position.
Made in high strength aluminium lightweight
solution.
TPMS Profilclamps, TPMS-45 and TPMS-60
are connectors for adaptation of Automotive
Clamps, Adapter Plates, Pin Packages fixed
pins and other special made components.
7
Bodybuilder End Effector System
Design Handbook
Torques for the used profiles:
B-30 => 25 Nm
B-60 => 40 Nm
B-45 => 25 Nm
B-90 => 54 Nm
In case of any screws M6 => use 10 Nm with 8.8 screw quality.
Please ensure the needed value with a torque wrench.
3.4 Crash Management
All connectors include our patented Crash Management. With a reference hole Ø6 H7 in the
base of our connectors you easily may find the position of the reference according to the index
groove block in the grove of the profile, as shown in the photos.
The index grove block is located in the grove with two screws and stays in position if the system
is crashed. With the help of a locating pin you may find the position easily.
This system also helps meanwhile the assembly of a BodyBuilder Tooling. All booms may be
equipped with index grove blocks before placing the connectors. These dimensions shall be
marked in the assembly drawing.
All dimensions for junctions shall be found on the assembly drawing.
8
Bodybuilder End Effector System
Design Handbook
3.5 Robot Adaptation
PSA-L-45-01-A for small dimensions (423x466) mm with 2 off TPMS-45 clamps and risers
for BB-45mm profiles and PSA-L-60-01-A 2 off TPMS-60 clamps and risers for BB-60mm
profiles for parallel main booms.
9
Bodybuilder End Effector System
Design Handbook
PSA-L-45-04-A for small dimensions (400x420)mm: The 2 off TPMS-45 rotated by 90°
And PSA-L-60-04-A for small dimensions (400x420)mm: The 2 off TPMS-60 rotated by 90°
for one main boom
10
Bodybuilder End Effector System
Design Handbook
PSA-L-60-02-A for medium dimensions plate (560x600)mm with 4 off TPMS-60-BM2-01
clamps and risers for BB-60mm profiles
PSA-L-60-04-A for medium small dimensions plate with 4 off TPMS-60-BM2-01 clamps
and risers for BB-60mm profiles
11
Bodybuilder End Effector System
Design Handbook
PSA-L-90-03-A for large dimensions (750x800) mm and 6 off TPMS-90 clamps and risers
for BB 90mm profiles, 2 parallel main booms
DESTACO proposes these Base Mounts according to customer specification. The Base mount may
be assembled directly to the hand flange of the system.
12
Bodybuilder End Effector System
Design Handbook
These variants are standardized:
3.5.1 PSA-L-45-01-A and PSA-L-60-01-A for 45mm/60mm BB profiles
(Parallel and Inline Arm Structure)
Consisting of a Base Mount plate with two connectors that carry one boom with adapted Cross
Booms, or if the TPMS-45 is rotated by 90° the plate may carry to parallel booms of 45mm
BodyBuilder structure. Used for small and medium parts with good reachability at the Spot
welding guns due to small break down lines.
Examples may be doors or hoods.
Weight for 45mm Version PSA-L-45-01-A: 12,71 kg including risers parallel arms.
Weight for 60mm Version PSA-L-60-01-A: 13,43 kg including risers parallel arms.
Dimensions: (423x466) mm
Weight for 45mm Version PSA-L-45-04-A: 11,13 kg including risers inline arms.
Weight for 60mm Version PSA-L-60-04-A: 11,85 kg including risers inline arms.
Dimensions: (400x420) mm
13
Bodybuilder End Effector System
Design Handbook
3.5.2 PSA-L-60-02-A for 60mm BB profiles
(Parallel Arm Structure)
Consisting of a Base Mount plate with 4 connectors that allow to adapt 2 parallel booms.
Those arms carry the adapted Cross Booms.
This structure allows to handle medium to large parts also with good reac welding guns
due to small break down lines. Examples may be sidewalls or underbody structures.
Dimensions: (560x600) mm
Weight: 20,55 kg
Medium Small size for 60mm profiles: PSA-L-60-05-A has the same function
as PSA-L-60-02-A but with smaller dimensions.
Dimensions: (400x450) mm
Weight: 14,52 kg
14
Bodybuilder End Effector System
Design Handbook
3.5.3 PSA-L-90-03 for 90mm BB profiles (Parallel Arm Structure)
Consisting of a Base Mount plate with 6 connectors that allow to adapt 2 parallel booms.
Those arms carry the adapted Cross Booms 90mm BodyBuilder style.
This structure allows to handle large parts also with good reachability at the Spot welding guns
due to small break down lines. Examples may be large sidewalls or Underbody structures.
Weight: 51,81 kg.
Dimensions: (750x800) mm
Speciality: Extra Large Tooling
A standardized Base Mount is not fixed. The base mount shall be built using TPMS-90 and a
special made Base Plate.
The dimensions of this Base Plate shall be adopted to the robot hand flange or tool changer
and the needed dimensions according to the tooling itself.
The dimensioning shall be made from the Engineering of the tooling. Either Steel or Aluminium
may be used depending on the stress and forces that are existing. 2 parallel B-90 structures
shall be attached to the base plate with 2 x 3 TPMS-90 profile clamps similar as the PSA-PL-03.
The delivered length of the B-90 profile is fixed at a length of 4,0 m each boom.
Each boom has to be attached by 3 profile clamps TPMS-90 and additionally B-60 or B-45
T-booms for better strength.
15
Bodybuilder End Effector System
Design Handbook
3.6 Standard Catalog Adaptors
Robot Adaptation with RM4-60-R22
DESTACO proposes a standard Base Mounts out of the DESTACO BodyBuilder catalog.
The Base Mount may be assembled directly to the hand flange of the system.
These variants may be used for 125mm and 200mm mounting pattern:
BM1-80-SE-R22
Basisträger BM1 mit 1258200 mm
Anbindung, keine Isolierung
Mid mount assembly BM1 with
125&200mm pattern, no insulation
RM4-80-R22
Basisträger RM4 mit 1258200mm
Anbindung, keine Isolierung
Mid mount assembly RM4 with
125&200mm pattern, no insulation
Applicable at robots with diameter 125 mm / 200 mm mount:
RM4-60-R22 without insulation:
Technical Data BM1-60-SE-R22
16
Bodybuilder End Effector System
Design Handbook
Mounting pattern is combined on one flange.
Please check if there will be used STÄUBLI tool changers.
In case of such tool changers please make sure that a
minimum Ø8 mm hole per screw is needed through the
base plate to reach the screw head of the fixation screws
of the center bolt in the STÄUBLI changer. A complete
big hole to reach all these screws at once is not possible
because of the base will not be able to be strong enough
with such big hole. See this sketch:
Features:
• Can be used as a direct robot
interface.
• Provide robust clamping of each
extrusion for maximum stability.
• Standard robot interface patterns
provided. Plate can also be left
blank.
Specifications:
Max. Static Product Load:
453.6 kg [1000 lb]
Material:
Mid Mount:
Cast Aluminum
Clamps: Steel
RM4-60 60mm Heavy Duty Mid Mount Assembly - Dimensions
R02 (Ø125mm Bolt Circle)
R01 (Ø200mm Bolt Circle)
Ø12.0
P.F. (2)
[.47]
Ø12.5
THRU (6)
[.49]
Ø200.0
[7.87]
30°
60°
Ø10.0
P.F. (2)
[.39]
Ø11.0
THRU (10)
[.43]
Ø125.0
[4.92]
30°
30°
Ø13.0
THRU (4)
[.51]
Ø14.0
THRU (8)
[.55]
Ø160.0
[6.30]
30°
30°
Ø10.0
S.F. (4)
[.39]
Ø11.0
THRU (8)
[.43]
Ø160.0
[6.30]
30°
30°
Ø13.0
THRU (12)
[.51]
Ø125.0
[4.92]
30°
30°
10.0
S.F. (2)
[.39]
Ø12.5
THRU (8)
[.49]
Ø125.0
[4.92]
Ø160.0
[6.30]
30°
60°
30°
30°
Ø12.0
P.F. (2)
[.47]
Ø13.0
THRU (6)
[.51]
Ø200.0
[7.87]
30°
45°
Ø16.0
THRU (8)
[.63]
Ø13.0
THRU (2)
[.51]
Ø160.0
[6.30]
Ø125.0
[4.92]
30°
30°
30°
Ø15.0
THRU (2)
[.59]
Ø20.0
THRU (6)
[.79]
Ø200.0
[7.87]
45°
30°
Ø12.5
THRU (6)
[.49]
Ø12.0
P.F. (2)
[.47]
200.0
[7.87]
30°
60°
Ø16.0
THRU (6)
[.63]
Ø15.0
THRU (2)
[.59]
Ø200.0
[7.87]
30°
60°
Ø13.0
THRU (12)
[.51]
Ø160.0
[6.30]
60°
30°
Ø11.0
THRU (6)
QC1200 R01 R02 R03
R04R05 R06 R07
R08R09 R10 R11 R12
[.43]
Ø10.0 (2)
P.F. (2)
[.39]
Ø125.0
[4.92]
30°
60°
Ø10.0
P.F. (4)
[.39]
Ø11.0
THRU (8)
[.43]
Ø160.0
[6.30]
30°
R17
Ø12.0
P.F. (2)
[.47]
Ø12.5
THRU (6)
[.49]
Ø200.0
[7.87]
30°
60°
Ø10.0
P.F. (2)
[.39]
Ø11.0
THRU (10)
[.43]
Ø125.0
[4.92]
30°
30°
Ø13.0
THRU (4)
[.51]
Ø14.0
THRU (8)
[.55]
Ø160.0
[6.30]
30°
30°
Ø10.0
S.F. (4)
[.39]
Ø11.0
THRU (8)
[.43]
Ø160.0
[6.30]
30°
30°
Ø13.0
THRU (12)
[.51]
Ø125.0
[4.92]
30°
30°
10.0
S.F. (2)
[.39]
Ø12.5
THRU (8)
[.49]
Ø125.0
[4.92]
Ø160.0
[6.30]
30°
60°
30°
30°
Ø12.0
P.F. (2)
[.47]
Ø13.0
THRU (6)
[.51]
Ø200.0
[7.87]
30°
45°
Ø16.0
THRU (8)
[.63]
Ø13.0
THRU (2)
[.51]
Ø160.0
[6.30]
Ø125.0
[4.92]
30°
30°
30°
Ø15.0
THRU (2)
[.59]
Ø20.0
THRU (6)
[.79]
Ø200.0
[7.87]
45°
30°
Ø12.5
THRU (6)
[.49]
Ø12.0
P.F. (2)
[.47]
200.0
[7.87]
30°
60°
Ø16.0
THRU (6)
[.63]
Ø15.0
THRU (2)
[.59]
Ø200.0
[7.87]
30°
60°
Ø13.0
THRU (12)
[.51]
Ø160.0
[6.30]
60°
30°
Ø11.0
THRU (6)
QC1200 R01 R02 R03
R04R05 R06 R07
R08R09 R10 R11 R12
[.43]
Ø10.0 (2)
P.F. (2)
[.39]
Ø125.0
[4.92]
30°
60°
Ø10.0
P.F. (4)
[.39]
Ø11.0
THRU (8)
[.43]
Ø160.0
[6.30]
30°
R17
17
Bodybuilder End Effector System
Design Handbook
3.6.1 BM1-60 (Parallel Arm Structure)
Consisting of a Base Mount plate with two connectors that carry one boom with adapted Cross
Booms. Also used for small and medium parts with good reachability at the spot welding guns
due to small break down lines.
Examples may be doors or hoods.
BM1-60-SE-R22
Basisträger BM1 mi 1258200mm
Anbindung, keine Isolierung
Mid mount assembly BM1 with
1258200mm pattern, no insulation
3.6.2 RM4-60 (Parallel Arm Structure)
Consisting of a Base Mount RM4 with 4 connectors that allow to adapt 2 parallel booms.
Those arms carry the adapted Cross Booms.
This structure allows to handle medium to large parts also with good reachability
at the spot welding guns due to small break down lines. Examples may be sidewalls
or underbody structures.
18
Bodybuilder End Effector System
Design Handbook
3.7 Adaptors for single arm toolings
60mm BodyBuilder and 90mm BodyBuilder
Flange Mount for 60mm BodyBuilder profiles
Model Number Weight
BECC-60-00 1.21 kg [2.67 lb]
Features:
• Mounts 60mm extrusion 90° to
the mounting surface.
• Can be used as robot interface
when quick-change connector is
not required.
• Cross-key design provides added
strength for high-torque applications
when used in conjunction with a slot
and key mechanism.
60
[2.36]
107.1
[4.22] 19.1
[.75]
79.4
[3.13]
79.4
[3.13]
82.6
[3.25]
100
[3.94]
3.3
[.13]
107.9
[4.25]
Ø11
THRU (4)
[.43]
M10 FASTENERS
W/PATCHLOCK (4)
Specifications:
Max. Static Clamp Load:
746 Nm [550 ft-lb]
Material: Cast Aluminum
Cross Key sold separately: (2) x 540-25388
BECC-60 60mm End Flange Clamp Mount
ALIGNMENT NUT
INCLUDED
19
Bodybuilder End Effector System
Design Handbook
Features:
• Can be used as direct robot
interface.
90
[3.56]
M10 FASTENERS (6)
177.8
[7.00]
152.4
[6.00]
190.5
[7.50]
25.4
[1.00]
11.5
THRU (6)
[.45]
60°
Ø160
[6.30]
W/PATCHLOCK
TYP.
Specifications:
Max. Static Clamp Load:
746 Nm [550 ft-lb]
Material: Aluminum
Model Number Weight
CPI-CL-90B-160F 5.91 kg [13.04 lb]
CL-90B-160F 90mm End Mount
Flange Mount for 60mm BodyBuilder profiles
Please take care that the max. payload and the free cantilever length will always be ensured
and no overload will be applied.
20
Bodybuilder End Effector System
Design Handbook
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
/
