Jigs and Fixtures

Helios knows too well the importance of tooling, jigs and fixtures design in manufacturing and that having a creative approach to a client’s manufacturing problem is essential, whilst at the same time making the solution as robust and simple as possible.

Case Study: Pipe Forming Fixture

Bending a 10mm diameter plastic pipe at a right angle was a problem for one of our clients. The pipe would distort at the bend, restricting the through-flow.
The problem was such that the process has to be out-sourced. Helios was commisioned to solve the problem, we did so by designing an uncomplicated fixture that an operator could insert the tube into, ensuring a clean even bend at the correct possition.

Case Study: Assembly Jigs.

A series of jigs and fixtures was required for a customer who has a contract for assembling parts for a leading manufacturer of power tools.
The jigs and fixtures were drawn up around the highly toleranced componant parts and designed to be used with ease and consistant accuracy.
Inter-changabillity of inserts was a key factor and detailed drawings were supplied to the customer so that wearing parts could be re-ordered.

Case Study: Steering Column Assembly Fixture.

The two component parts of a steering column are pressed together, and measurement is taken of the required force to do so. It is imperative that the two parts are in-line parallel.
As the fixture incorporates a load cell to gauge the downward force, it is not possible to have a sprung return on the floating middle plate; this would influence the load cell reading.
The problem was resolved by using die lift rods.
Spring clips are trapped between the two parts, creating an interference fit. These clips need to be located on the lower part before the press is actuated.
A method of clamping the clips in position had to be found which would retract automatically on ejection of the part, at the end of the sequence.
As it was the client’s preference that neither pneumatics nor hydraulics be used, spring loaded location blocks were used, doubling as a guide as the upper component makes contact with the lower.