Assembling structures for experimental vehicle engineering using mechanical fasteners
Overview
This standard identifies the competences you need to assemble fabricated items and other components, into structures used for experimental vehicle development activities, in accordance with approved procedures. The structures to be assembled will typically be test rigs, jigs and formers, and other equipment used for the testing of vehicle components. You will be required to produce suitable and appropriate joints, using appropriate methods for the materials to be joined, that meet the specified conditions and subsequent operating conditions to be demanded of the joint.
Particular attention will be needed in the preparation and finishing of the materials, so that the finished component is fit for purpose and meets the level of accuracy required. The mechanical fastenings used will include rivets, screws, nuts, bolts, screwed fittings, anchor nuts and proprietary fasteners, as appropriate to the application and/or specification. The joint will be of two or more materials, and may include non-metallic materials and joints of dissimilar metals.
Your responsibilities will require you to comply with organisational policy and procedures, or those of the fastener manufacturers. You will be expected to report any problems with the mechanical fasteners, or the joining activities that you cannot resolve, or that are outside your permitted authority, to the relevant people. You will be expected to work with a minimum of supervision, taking personal responsibility for your own actions and for the quality and accuracy of the work that you carry out.
Your underpinning knowledge will be sufficient to provide a good understanding of your work, and will provide an informed approach to the mechanical joining activities carried out. You will understand the basic characteristics of the materials to be joined, the various processes used, and the appropriate procedures that go with them, in adequate depth to provide a sound basis for achieving a sound and cohesive joint that is fit for purpose.
You will understand the safety precautions required when working with the tools and equipment. You will be required to demonstrate safe working practices throughout, and will understand the responsibilities you owe to yourself and others in the workplace.
Performance criteria
You must be able to:
- work safely at all times, complying with health and safety and other relevant regulations, directives and guidelines
- follow the relevant instructions, assembly drawings and any other specifications
- ensure that the specified components are available and that they are in a usable condition
- assemble the components in their correct positions using appropriate methods and techniques
- secure the components using the specified connectors and securing devices
- check the completed assembly to ensure that all operations have been completed and the finished assembly meets the required specification
- deal promptly and effectively with problems within your control and report those that cannot be solved
- ensure that work records are completed, stored securely and available to others as per organisational requirements
- leave the work area in a safe condition on completion of the activities, as per organisational and legal requirements
Knowledge and Understanding
You need to know and understand:
- the specific safety precautions to be taken whilst carrying out the activities (including any specific legislation, regulations or codes of practice relating to the activities, equipment or materials)
- the health and safety requirements of the work area and the activities, and the responsibility these requirements place on you
- the hazards associated with the activities, and how to minimise them and reduce risks
- the personal protective equipment and clothing (PPE) to be worn during the activities
- how to obtain the necessary drawings and joining procedure specifications
- how to extract and use information from engineering drawings and related specifications (to include symbols and conventions, current industry standards and codes of practice) in relation to work undertaken
- the use of manufacturers' specifications for the types of fastener used
- the various joining processes that are used, and the tools and equipment required
- the preparations to be carried out on the materials/components prior to joining them (such as materials to be degreased, dry and clean, with holes and flanges de-burred)
- how to set up and align the joints prior to fixing, and the tools and methods that can be used (clamps, rivet gripping tools, temporary fixings, jacking and supporting devices)
- how to produce a secure joint using blind rivets, and the type of riveting tools that are available
- how to produce a good riveted joint and the use of the various riveting tools
- how to determine the correct length of the rivets to give a properly formed rivet head
- the range of bolts and screwed fasteners that are to be used; why it is important to use the correct type of washer; sequence of tightening bolts on flanged joints; and the tools and equipment used to ensure they are tightened to the required torque
- the checks to be carried out on the tools and equipment prior to use, to ensure that they are in a safe, tested and usable condition (condition of plugs and leads on power tools, condition of striking faces on hammers, condition of riveting tools and rivet snaps)
- equipment setting, operating and care procedures; why equipment and tools need to be correctly set up and in good condition
- the importance of using the tools only for the purpose intended; the care that is required when using the equipment and tools; the proper way of preserving and storing tools and equipment between operations
- the problems that can occur with the joining operations and how these can be avoided
the extent of your own responsibility and to whom you should report if you have problems that you cannot resolve
how to access, use and maintain information to comply with organisational requirements and legislation
Scope/range
Scope Performance
Carry out all of the following during the assembly of the vehicle components:
- obtain and use the appropriate documentation (such as job instructions, assembly drawings, quality control documentation)
- adhere to procedures or systems in place for risk assessment, hazardous substances, personal protective equipment and other relevant safety regulations and procedures to realise a safe system of work
- check that all cables, extension leads or air supply hoses are in a safe, tested and serviceable condition
- check that all tools and equipment to be used are within current calibration/certification dates
- correctly prepare the faces of the materials to be joined
- select the appropriate/specified fixings
- correctly align the materials and faces to be joined
- assemble the components in the correct order or manner
- use safe and appropriate assembly methods and techniques at all times
- return all tools and equipment to the correct location on completion of the activities
- leave the work area in a safe and appropriate condition on completion of the activities
- produce joints that meet the requirements of the specification
Produce assemblies which include four of the following:
- flat and flanged joints on flat or curved surfaces
- structural components
- joints with gasket or sealant
- long or critical alignments
- pipes
- permanent and temporary assemblies
Use four of the following assembly methods and techniques:
- assembling using bolt fittings
- riveting using solid rivets
- riveting using pop/blind rivets
self-tapping screws
use of proprietary fasteners structural components long or critical alignments permanent and temporary assemblies
- using screw fittings to tapped components
- nuts and (spot welded) screw studs
- locking devices
- clinching (self securing)
Join the components in three of the following jointing positions:
- flat
- vertical
- overhead
- horizontal
Check that joints in assemblies meet all of the following quality and accuracy standards:
- assembled and aligned, in accordance with the specifications
- joints are secure and firm
- bolted and screwed joints are tightened to the correct torque
- riveted joints are free from excessive material deformation and hammer marks
- pitches of holes meet the specification
- completed joints are clean and free from burrs