DESTACO BodyBuilder User manual

Brand: DESTACO

Model: BodyBuilder

Type: User manual

destaco.com

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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

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.

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.

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:

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.

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.

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.

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

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

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.

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

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

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.

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

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°

Ø13.0

THRU (4)

[.51]

Ø14.0

THRU (8)

[.55]

Ø160.0

[6.30]

30°

Ø10.0

S.F. (4)

[.39]

Ø11.0

THRU (8)

[.43]

Ø160.0

[6.30]

30°

Ø13.0

THRU (12)

[.51]

Ø125.0

[4.92]

30°

10.0

S.F. (2)

[.39]

Ø12.5

THRU (8)

[.49]

Ø125.0

[4.92]

Ø160.0

[6.30]

30°

60°

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°

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°

Ø13.0

THRU (4)

[.51]

Ø14.0

THRU (8)

[.55]

Ø160.0

[6.30]

30°

Ø10.0

S.F. (4)

[.39]

Ø11.0

THRU (8)

[.43]

Ø160.0

[6.30]

30°

Ø13.0

THRU (12)

[.51]

Ø125.0

[4.92]

30°

10.0

S.F. (2)

[.39]

Ø12.5

THRU (8)

[.49]

Ø125.0

[4.92]

Ø160.0

[6.30]

30°

60°

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°

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

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.

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.

[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

Bodybuilder End Effector System

Design Handbook

Features:

• Can be used as direct robot

interface.

[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.

Bodybuilder End Effector System

Design Handbook

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DESTACO BodyBuilder User manual

Brand: DESTACO

Model: BodyBuilder

Type: User manual

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DESTACO BodyBuilder User manual

DESTACO BodyBuilder User manual

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