level 3 apprenticeship inertia definitiondefinition: an object at rest tends to remain at rest, and...
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Level 3 ApprenticeshipLevel 3 Apprenticeship
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InertiaInertia
• DefinitionDefinition: An object at rest tends to remain at rest, and an object in motion tends to continue in motion in a straight line unless acted upon by an outside force..
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Inertia ContinuedInertia Continued
• For example, passengers in an accelerating automobile feel the force of the seat against their backs overcoming their inertia so as to increase their velocity. As the car decelerates, the passengers tend to continue in motion and lurch forward. If the car turns a corner, then a package on the car seat will slide across the seat as the inertia of the package causes it to continue moving in a straight line
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External force is holding
Internal forces keepmoving
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Forces within the vehicle resist movement
External forces continue to move
Rear CollisionRear Collision
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Simple CollisionSimple Collision
Structure CollapsesUniformly
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Simple CollisionSimple Collision
Pull
Hold
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Strength and design of Body structure will dictate the deflection of collision forces acting upon it
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DeflectionDeflection
• a change of course after hitting somebody or something, or a changing of an objects course by being hit by it
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Deflection of ForcesDeflection of Forces
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Frame DesignFrame Design
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Deflection From Direction of Deflection From Direction of TravelTravel
Offset frontalOffset frontal
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Deflection From Direction of Deflection From Direction of TravelTravel
Side impactSide impact
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Another ExampleAnother Example
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Three Section PrincipleThree Section Principle
Front Centre RearFront Centre Rear
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Frontal Collision ForcesFrontal Collision Forces
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Frontal ImpactFrontal Impact
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1
Stage 1Stage 1
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Stage 2Stage 2
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Stage 3Stage 3
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4
Stage 4Stage 4
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Forces in a Rear CollisionForces in a Rear Collision
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Stage 1Stage 1
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Stage 2Stage 2
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Stage 3Stage 3
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Stage 4Stage 4
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Side ImpactSide Impact
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Side ImpactSide Impact
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Side ImpactSide Impact
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#2#2
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#3#3
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Forces Present in a RolloverForces Present in a Rollover
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Typical RolloverTypical Rollover
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#2#2
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#3#3
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MeasurementMeasurementReferenceReferenceSourcesSources
MeasurementMeasurementReferenceReferenceSourcesSources
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CENTRE LINECENTRE LINE
• IS AN IMAGINARY LINE THAT RUNS LENGTHWISE THROUGH THE VEHICLE AND IS A REFERENCE FOR DETERMINING LATERALALIGNMENT AND MEASUREMENT
LATERAL LATERAL MEASURMENTMEASURMENT
Centre Plane
Centre Line
CL
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CENTERLINECENTERLINE IS USED TO REFERENCE WIDTH THROUGHOUT THE VEHICLE. COMPONENTS MAY BE POSITIONED EQUALLYEQUALLY OFF OF CENTRE (SYMMETRICAL)OR UNEQUALLYUNEQUALLY OFF OF CENTRE (ASYMETRICAL)
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DATUM • IS AN IMAGINARY LINE WHICH IS USED TO ESTABLISH
THE HEIGHT OF THE VEHICLES COMPONENTS AND IS A REFERENCE FOR DETERMINING
VERTICAL MISALIGNMENT
DATUM PLANE
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DATUM PLANEDATUM PLANE
•The reference line for all vertical body dimensions
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ZERO PLANESZERO PLANES
CENTREFRONT REAR
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From the ‘Zero’ Plane we can establish length measurement
0
0
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From the ‘Centre’ Plane we can establish width
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The ‘Datum’ Plane establishes Height dimensions
With these dimensions we can reference all known control points
L
W
H
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Measuring ToolsMeasuring Tools
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Datum Length Vs. Point to Point
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TYPES OF MEASURING SYSTEMSTYPES OF MEASURING SYSTEMS
1. UNIVERSAL1. UNIVERSAL -Mechanical -Laser -Sonic
2. DEDICATED BENCH AND FIXTURE MEASURING2. DEDICATED BENCH AND FIXTURE MEASURING -Mechanical-Mechanical -Laser-Laser
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SELF CENTERING GAUGE
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Strut Tower GaugeStrut Tower Gauge
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Cross member Pin
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Digital Tram GaugeDigital Tram Gauge
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Most Mitchell, Chief, & Hein-Werner specificationscan be measured using a tram gauge set at equallengths. Measurements can be read directly fromthe tram gauge bar scale or by measuring the distance from pointer to pointer
Tram GaugeTram Gauge
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Tape MeasureTape Measure
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TermsTerms
• perpendicular
1. at right angles: at right angles to a line or plane2. vertical: perfectly vertical
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Laser SystemsLaser Systems
- Single target- Mirrored / Beam splitter / 3d- Multi laser 3d- Reflective pulse laser
Basic theory behind Genesis style systems
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Multi TargetLaser
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Universal System
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Fixed Universal systemFixed Universal system
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Universal Bench
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Dedicated Bench
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Laser Measuring
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DatalinerDatalinerLaser measuringLaser measuringsystemsystem
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Dedicated Bench and Fixture System
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Measuring Systems on the Measuring Systems on the InternetInternet
• http://www.car-o-liner.se/us/• http://www.dataliner.se/• http://www.hein-werner.com/• http://www.chiefautomotive.com/• http://www.lasermateusa.com/• http://www.celette.com/
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CRITICAL MEASUREMENTCRITICAL MEASUREMENT
REFERS TO ANY DISTANCE FROM ONE POINT TO ANOTHER THAT MUST BE MEASURED ACCURATELY
TO DIAGNOSE STRUCTURAL DAMAGE
THESE AREAS INCLUDE: • TORQUE BOX WIDTH AND LENGTH• FRAME HORN WIDTH AND LENGTH
• BALL JOINT POSITION• SRUT TOWER POSITION
• SUSPENSION MOUNTING POINTS ETC.
WHILE MOST MEASUREMENTS REQUIRE A DIMENSIONSHEET, QUITE OFTEN CHECKING ONE SIDE TO
ANOTHER WILL SUFFICE IF NO DIMENSION EXSISTS
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BASIC STRUCTURAL ALIGNMENT
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Body Centre MarkingsBody Centre Markings
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Picture the Vehicle as a Box
The Box is Divided Into 3 Sections
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BY HANGING GAUGES ON THE UNEVEN BODY OF THEVEHICLE ALLOWS US TO LOOK AT THE UNDERBODY
AS A FLAT LEVEL PLANE. THE GAUGES ALSO DIVIDE THE PLANE INTO THREE SECTIONS
Front Centre RearFront Centre Rear
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THIS ALLOWS US TO VIEW THE GAUGES TO DETERMINE
IF THE PLANE HAS BEEN DISTORTED BY THE COLLISION
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EXAMPLES OF LATERAL AND VERTICAL MISALIGNMENT
INCORRECT DATUM
While level and datum both relate to vertical While level and datum both relate to vertical (up/down) alignment all three sections are still(up/down) alignment all three sections are still
Level or parallel with each otherLevel or parallel with each other
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TWISTTWIST
This structure is out of parallel (twist)This structure is out of parallel (twist)this type of damage is not considered athis type of damage is not considered adatum misalignment as the front and datum misalignment as the front and
rear sections are not up or down relativerear sections are not up or down relativeto the centre sectionto the centre section
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Incorrect datumIncorrect datum
On the other hand, a vehicles front or rear On the other hand, a vehicles front or rear section can be vertically misaligned (datum)section can be vertically misaligned (datum)and still remain parallel (level) to the centreand still remain parallel (level) to the centre
sectionsection
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Datum and Level MisalignmentDatum and Level Misalignment
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THREE STEPS FOR GAUGING:
1. DIVIDE THE VEHICLE INTO THREE SECTIONS2. LOCATE ITS CONTROL POINTS3. ESTABLISH A BASE FOR THE GAUGING PROCESS
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CONTROL POINTS:CONTROL POINTS:
• A POINT ON WHICH ANY STRUCTURAL ALIGNMENT IS DEPENDENT• POINTS UPON WHICH ALL MEASURING MUST BE TAKEN TO DETECT COLLISION DAMAGE
BASIC CONTROL POINTS
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MANUFACTURERS USECONTROL POINTS FORPOSITIONING OF STRUCTUREDURING MANUFACTURE
TECHNICIANS USE THEM AS GUIDES DURING THE REPAIR PROCESS
COMMON REFERENCE AREAS:- HOLES- BOLTS- STUDS- SUSPENSION MOUNTING POINTS- RIVETS
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ESTABLISHING A BASE
FIRST ESTABLISH THE CENTRE SECTION
22
33
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BY INSTALL GAUGES AT THE EXTREME FRONT ANDREAR OF THE STRUCTURE, WE DIVIDE THE VEHICLE INTO
THREE BASIC SECTIONS FOR GAUGING PURPOSES
• WITH THESE GAUGES INSTALLED, YOU CAN NOW COMPARE THE TWO BASE GAUGES TO EACH OTHER TO CHECK THE
CONDITION OF THE CENTRE SECTION.• YOU CAN THEN SIGHT THE FRONT AND REAR SECTIONS
FROM THE BASE SECTION TO DETERMINE COMPLETEAND OVERALL STRUCTURAL CONDITION
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ADDITIONAL CONTROL POINTS
- LOWER SUSPENSION IF IN THE AREA OF IMPACT
- STRUT TOWERS IF UNITIZED
- STEERING ATTACHMENT POINTS
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CONTROL AREAS
- MAY REQUIRE REMOVAL OF MECHANICAL COMPONENTS TO FACILITATE MOUNTING
- MAY REQUIRE ADAPTERS TO FACILITATE MOUNTING
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USING DATUM
- WHAT IS THE PURPOSE OF DATUM IN TERMS OF COLLISION DAMAGE ANALYSIS AND REPAIR?
- WHEN SHOULD DATUM BE USED?
PURPOSE
- PROPER SHEETMETAL ALIGNMENT- PROPER HEIGHT OF SUSPENSION MOUNTING AREAS
USAGE
- ANYTIME THE BODY STRUCTURE HAS BEEN COMPROMISED AND STRUCTURAL COMPONENTS ARE INVOLVED
...DIFFERENCES. SHEET METAL VS DIMENSION
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Setting DatumSetting Datum
• Datum – 1. point of reference: a point, line, or surface
used as a basis for measurement or calculation in mapping, surveying or measuring
– Datum is used for all vertical alignment measurements
– Used to restore and check correct positioning of both sheet metal and major control points
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Areas of givenMeasurement reference
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Measurement ReferencePoints to Observe
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Setting DatumSetting DatumControl Points
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Datum Length Vs. Point to Point
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WHEN READING GAUGES, USE THE CENTRESECTION AS YOUR BASE REFERENCE POINT
TAKE NOTE OF LOADED ANDTAKE NOTE OF LOADED AND UNLOADED SPECIFICATIONS!UNLOADED SPECIFICATIONS!
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OPTIONAL MOUNTING PRACTICESOPTIONAL MOUNTING PRACTICES
The location of thecorrect datum willbe shown in thedimension manual
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OVERCOMING OBSTACLES BY REVISING DATUM
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Datum Revision SheetDatum Revision Sheet
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SWAY: LATERAL MISALIGNMENT OF THE VEHICLE CENTRELINE (FRONT OR REAR)
DAMAGE RELATING TO CENTRELINE
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DAMAGE RELATING TO LEVEL
• THE TERM “LEVEL” REFERS TO ALL AREAS OF THE VEHICLE BEING PARALLEL TO ONE ANOTHER
• HAS NOTHING TO DO WITH THE WAY THE VEHICLE SITS
• CAN REFER TO THE FRONT, CENTRE OR REAR SECTIONS BEING OUT OF ALIGNMENT
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• SLANG TERMINOLOGY FOR THIS CONDITION WOULD BE “DOWN AT THE COWL” WHEN IN FACT THE VEHICLES LEFT FRONT RAIL IS ACTUALLY “UP”.
• AS THE VEHICLE RESTS ON ITS SUSPENSION, IT WILLAPPEAR TO SAG AT THE LEFT COWL AREA
VERTICAL MISALIGNMENT
HIGH OR LOWRAIL IS THECORRECT TERM
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• THIS TERMINOLOGY LEADS YOU TO BELIEVE THAT THE VEHICLE NEEDS JACKING AT THE LEFT FRONT TORQUE BOX
• WHAT IS REQUIRED IS BLOCKING AT THIS AREA, AND A DOWN PULL ON THE LEFT FRONT RAIL
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TWISTTWIST
THE EXCEPTION TO THE RULE IS “ TWIST ”.
- TWIST REFERS TO AN OUT OF LEVEL CONDITION INTHE CENTRE SECTION
- TWIST WILL HAVE (2) HIGH AND (2) LOW AREAS PRESENT
- THE HIGH AND LOW AREAS WILL BE DIAGONAL OF EACH OTHER
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LEVEL ONLY REFERS TO PARALLEL WITHIN THE VEHICLESSTRUCTURE, AND HAS NOTHING AT ALL TO DO WITH HOW THE VEHICLE SITS IN RELATION TO THE FRAME
MACHINE OR THE FLOOR
LevelLevel
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PERSPECTIVE VIEW AND TOP VIEW
TWIST
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DAMAGE RELATING TO DATUM
INCORRECT DATUMONLY
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DIFFERENCES
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DIAMOND
DIAMOND
- THIS CONDITION ARISES WHEN ONE FRAME RAIL ISMISLOCATED FORWARD OR REARWARD OF THE OTHER
- THIS CONDITION IS APPARENT WHEN MEASURING THECENTER SECTION DIAGONALLY (“ X ”)
- NOT GENERALLY DIAGNOSED BY SELF CENTERINGGAUGES
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COLLAPSED RAIL
- RAIL LENGTH IS COMPROMISED
- DETECTED BY LENGTH MEASUREMENT USING A TRAMBAR
CHECK LENGTH, WIDTH AND CROSS MEASURMENTS
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COLLAPSED CROSSMEMBER
WIDTH MEASURMENTWIDTH MEASURMENT
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STRUT TOWER AND LOWER BALL JOINT WIDTH
AFFECTS CAMBER AND SAI
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BALL JOINT LENGTH
AFFECTS CASTER
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STRUT TOWER AND LOWER BALL JOINT LENGTH
AFFECTS CASTER
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READING SELF CENTERING GAUGES
THESE GAUGES SHOW CORRECT FRAME OR BODYALIGNMENT
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Out of LevelOut of Level
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SagSag
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SideswaySidesway
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Sequencing for DiagnosisSequencing for Diagnosis
• Twist (centre section only)• Diamond (affects centreline front and rear)
• Level (parallel readings front and rear)
• Mash (length)
• Sidesway (centreline)
• Measurements (taken constantly)
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Perfect AlignmentPerfect Alignment
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Sway
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Out of Level Out of Level
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Diamond? Diamond?
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POSITION YOURSELF CORRECTLY TO VIEWTHE GAUGES
Incorrect
Correct
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CORRECT DISTANCE6’-10’ AWAY
POSITIONING
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TOO CLOSE
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CORRECT
- THE TECHNICIAN MUST ALWAYS POSITION HIM ORHERSELF IN A CENTRAL LOCATION AS WELL AS BEING
THE CORRECT DISTANCE AWAY
WHEN GAUGING FOR PARALLEL (LEVEL), YOU MUSTSIGHT THE GAUGES WITH BOTH EYES OPEN
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WHEN GAUGING FOR CENTRELINE (LATERAL MISALIGNMENT)SIGHT WITH ONE EYE ONLY
ALWAYS USE THE CENTRE (BASE) GAUGESAS YOUR REFERENCE POINT IN DETECTING
ANY MISALIGNMENT
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SOMETIMES SIGHTING FROM THE OPPOSITE END
AIDS THE TECHNICIAN WITH A CLEARER VIEW
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VIEWING FROM THE OPPOSITE END OF THE VEHICLE
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CHECKING THE CENTRE SECTION
IF NO DIMENSIONS ARE AVAILABLE FOR DIAGONALMEASUREMENT, THE FOLLOWING WILL APPLY:
- IN THE CENTRE SECTION, CHECK THE LENGTH ANDWIDTH OF REFERENCE POINTS AVAILABLE
- ONCE VERIFIED EQUAL, SIDE TO SIDE AND END TO END, A CROSS MEASUREMENT CAN BE ACCOMPLISHED
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THIS IS AN EXAMPLE OF INCORRECT WIDTHTHAT WOULD CAUSE A PROBLEM WITH A “X”
MEASUREMENT
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IT IS POSSIBLE TO USE A STEEL MEASURING TAPETO ACCOMPLISH A CROSS MEASUREMENT,PROVIDING THERE ARE NO OBSTRUCTIONSWHATSOEVER
USE A TRAM BAR WHENEVER POSSIBLE
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ON PICKUP TRUCKS THE CENTRE SECTION ISRELATIVELY SMALL
EXTRA PRECAUTIONS SHOULD BE MADE SO AS NOTTO MEASURE OUTSIDE OF THE CENTRE SECTIONOR INACCURATE READINGS WILL OCCUR
CORRECT PROCEDURE
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INCORRECT MEASURING
DO NOT USE CAB MOUNTS AS A REFERENCE POINT
DIAMOND FRAME
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CENTRELINE MISALIGNMENT RESULTING FROMDIAMOND
TYPICAL
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NON-TYPICAL
DIAMOND AND SWAY
THIS SITUATION IS PRECISELY WHY WE CHECKFOR DIAMOND FIRST
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- ONCE CHECK FOR DIAMOND IS COMPLETE, INSTALLTHE TWO BASE GAUGES, #2 & #3.- COMPARE THEM FOR PARELLEL TO DETERMINEIF A TWIST CONDITION EXISTS
- IF THE GAUGES ARE NOT PARALLEL, A TWIST EXISTS
CORRECTALIGNMENT
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TWISTEDSTRUCTURE
- ALTHOUGH TWIST CAN ONLY EXIST IN THE CENTERSECTION, THE TECHNICIAN CAN ASSUME IT WILLAFFECT THE LEVEL CONDITION OF THE END SECTIONS
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REMEMBER, TWIST ONLY EXISTS IN THE CENTRESECTION, ERRORS IN DIAGNOSIS WILL OCCUR
IF THIS THOUGHT PLAN IS NOT FOLLOWED!
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DETERMINING DAMAGE IN THE FRONT OR REARSECTIONS
Out of Level
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PREDICTABLE AREAS OF DAMAGE
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KEY AREAS OF GAUGE PLACEMENT
DO NOT OMIT THIS GAUGEIF FRONTAL IMPACT IS SUSPECT
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DO NOT OMIT CROSSMEMBER GAUGE!
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This is the correct method
READ # 1B GAUGE TO THE #2 BASE GAUGE,
Correct method ofreading the main cross member to the base gauge
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THEN READ THE 1A GAUGE TO THE 1B GAUGE
THIS IS THE CORRECT PROCEDURE
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TRUE SWAY: NO OTHER DAMAGE AFFECTS CENTRELINE
NOTICE THE FRONT SECTION IS OUT OF SQUAREAND DAMAGE CAN ONLY BE CORRECTED BY PULLING
LATERALLY
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DIAMOND CONDITION WILL AFFECT CENTRELINE ON BOTH ENDS OF THE VEHICLE, HOWEVER THIS IS NOTA SWAY CONDITION SINCE PULLING THE DIAMOND-
WILL CORRECT CENTRELINE. NO CORRECTION FORSWAY WILL BE NECESSARY
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RAIL LENGTH / SHORT RAIL• AS ONE SIDE IS SHORTENED BY THE FORCE OF THE COLLISION, IT DISTORTS THE CENTRELINE READINGTOWARD THAT SIDE OF THE VEHICLE.
• AGAIN, THIS IS NOT A TRUE SWAY SINCE PULLINGSTRAIGHT FORWARD TO RESTORE THE RAIL LENGTHWILL CORRECT THE CENTRELINE
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OTHER ISSUES THAT CAN CAUSE CENTRELINEMISALIGNMENT
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SHORT RAIL, CENTRELINE CORRECTION PROCEDURE
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Note Gauge Position
Correct DatumCorrect Datum
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NOTE GAUGE POSITION ON FIRST GAUGE
Incorrect datumIncorrect datum
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SUSPENSION / CROSSMEMBER / CRADLE MUST BEGAUGED AND BE LEVEL WITH THE BASE OF THE
VEHICLE
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ANOTHER CRITICAL AREA TO BE GAUGED ISAT THE LOWER CONTROL ARM MOUNTING POINTS
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MANY NEW VEHICLES HAVE A SUB-FRAME ASSEMBLYTHAT CAN SUSTAIN DAMAGE OR MOVEMENT DURING
A FRONTAL IMPACT
THIS REQUIRES GAUGING AND MEASURING PROCEDURES BE PERFORMED TO ENSURE CORRECT
ALIGNMENT OF THESE MEMBERS TO THE UNIBODYSTRUCTURE
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IF A VEHICLE UTILIZES STRUT TYPE SUSPENSION,GAUGING OF THE STRUT TOWERS IS NECESSARY
CENTRELINE AND LEVEL ARE CRITICAL
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CENTRELINE AND LEVEL ARE VERY IMPORTANT
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THE CROSSMEMBER PIN, ONCE INSTALLED, WILL ACT AS A GUIDE FOR COMPARING CENTRELINE TO THE
SELF CENTERING GAUGES
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IT IS IMPORTANT FOR THE SUSPENSION MOUNTING POINTS TO BE IN THE RIGHT LOCATION IN REGARDS TO DATUM
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WIDTH AT THE SUSPENSION MOUNTING POINTS ISANOTHER IMPORTANT AREA OF MEASURMENT
THIS CAN BE A DIFFICULT AREA TO DIAGNOSE, ANDA TRAM GAUGE WITH LONG POINTERS MAY BE THE
RIGHT TOOL
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USING THE STRUT TOWER GAUGE AS A TOOL FORMEASURING LOWER BALL JOINTS ON A STRUT TYPE
SUSPENSION.
USING THE CENTER PIN, MEASURE LEFT AND RIGHT BALL JOINT LOCATIONS OFF OF THE PIN, THIS WILLHELP ESTABLISH SAI (STEERING AXIS INCLINATION)BETWEEN THE UPPER AND LOWER STEERING AXIS
POINTS
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MEASURING LOWER BALL JOINT LOCATIONSHOULD ALWAYS BE PERFORMED IN ANY FRONTALCOLLISION.
ONCE CHECKED FOR LENGTH, CROSS MEASURE.
FULL FRAME
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THE SAME PROCEDURE GOES FOR SUB FRAMEMOUNTED SUSPENSION, CHECK LOCATION OFBALL JOINTS, LENGTH AND CROSS.
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SEVERE IMPACT TO ONE SIDE OF THE VEHICLECAN RESULT IN A TWISTED CROSSMEMBER
AGAIN, THIS IS WHY INSTALLATION OF GAUGESIN THE CROSS MEMBER AREA IS IMPORTANT TO A PROPER REPAIR PROCEDURE
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PROPER INSTALLATION OF GAUGES TO DETECTCROSSMEMBER DAMAGE
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EFFECTS OF
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REAR IMPACT HAS CAUSED DATUM MISALIGNMENT•REAR SECTION IS BELOW DATUM HEIGHT AND THEWHEELHOUSE ARCH IS ABOVE
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INERTIAL FORCES DEFLECTION THROUGHOUT VEHICLE, RESULTING IN DIRECT AND INDIRECT
DAMAGE
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RESULTING DAMAGE IS EVIDENT AFTER THOROUGHGAUGING
IN THIS CASE, THE REAR IMPACT IS TYPICAL WHILETHE FRONT SECTION SUSTAINED VERTICALDEFLECTION RESULTING IN DATUM MISALIGNMENT
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TYPICAL DEFLECTION IN A REAR COLLISION
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TYPICAL CROSS MEASURING AREAS WHEN CHECKINGUPPER BODY DIMENSIONS
UPPER BODY DIMENSIONS CAN COME FROM SOURCESSUCH AS REPAIR MANUALS, OR BE REFERENCED FROMKNOWN STRUCTURAL AREAS OF THE VEHICLE SUCH AS
SEAT BELT MOUNTING POINTS ETC.
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Upper Body Dimension ChartUpper Body Dimension Chart
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STRUT TOWER MOUNTING GAUGE CAN BE USEFUL IN MANY LOCATIONS OF THE VEHICLE
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EXAMPLE OF DAMAGE ANALYSIS SHEET
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Measurement Measurement TrackingTracking
• Benefits– Completely assess
damage – Ability to monitor
progress– Determine pulling
direction– Results in a more
accurate repair
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Mitchell System Damage Report
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Mitchell System Tram Dimensions Chart
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Wedge Clamp Diagnostic SheetWedge Clamp Diagnostic Sheet
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By Using a DiagnosticSheet, You canEstablish a RepairPlan
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Hein WernerHein WernerDimension SheetDimension Sheet
DingerDinger HoopedHooped
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Mitchell System Upper Body Dimensions Chart
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MitchellMitchellCD systemCD system
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