Manufacturing of a clamping fixture for electric motor housings

The thesis deals with the design, implementation, and optimization of clamping fixtures within the production processes of the company Mega-Metal d.o.o. The introductory part includes the definition of the research area, objectives, and fundamental hypotheses, along with key assumptions and limitations. This is followed by a presentation of the company, including its organizational structure and the technological equipment of its machining park dedicated to metal machining.

The theoretical part of the research provides a detailed analysis of the development of clamping fixtures through various historical periods, from early mechanical solutions to modern high-tech systems. A classification of clamping devices is presented, including manual, machine, hydraulic, pneumatic, magnetic, vacuum, modular, and quick-change systems. An analysis of the current state has been carried out, technical limitations have been identified, and concrete proposals for improvements have been made based on the identified shortcomings.

The practical part of the thesis involves the development, design, and manufacturing of an optimized clamping fixture using SolidWorks and Mastercam software. The technological manufacturing process is described in detail, including welding, vertical turning, milling, drilling, as well as thermal and chemical treatments aimed at improving the mechanical properties and durability of the clamping fixture.

The results of the implementation of the new clamping fixture show significant time savings. The clamping time has been reduced from 30 to 20 minutes, representing a 33.3% reduction, while the machining time has decreased from 3 hours to 2 hours and 40 minutes, resulting in an 11.1% reduction. Considering the weekly production of four pieces, this translates to annual savings of 75 hours, equivalent to almost 10 working days.

The final part of the thesis discusses long-term maintenance and potential future system upgrades that could further enhance efficiency. The approach to optimizing clamping systems enables greater competitiveness, lower production costs, and improved final product quality, which is of crucial importance in modern industry.

In addition to the analysis of the development and classification of clamping devices, the thesis also includes four confirmed hypotheses emphasizing the importance of analysis in reducing errors, optimization for faster clamping, adaptability of fixtures for use on different machines, and regular maintenance to ensure durability.