Had a small production run of 15 carts over the past couple days. It had been some time since I built a batch but a few years ago we where crancking out 300-350 units per year for several years. Normally, a production run would be 60 units at a time but homeland security funding has dried up resulting in slow sales. Anyway, our inventory was depleted and another batch was started.
The dedicated jig table is used for building four out of five components in three different models we offer. The cool part is the compact overall size of the rolling jig table and the fact that all the individual pieces to be welded are pulled from said table in the correct position from support brackets and shelving. The main top plate is 3/4" and to simply look at the table , one would think its scrap.
This is the main frame jigged up for welding. The two long 1"x1" has to be loaded a certain way with seams down and the left rail has two extra holes for the indexing pin on the telescoping feature of the cart. Every thing is pulled from the cart itself for welding, so no wasted movement grabbing parts. The end piece is 3/8" x 1" flat bar welded to 14 ga.
The top cross members are 1/4" x 1" flat bar and keep the spine board centered when loading a patient. This is repeated until all main frames are complete.
The other end of the table is the axel jig and can be adapted for larger axels via threaded holes allowing bolting of secondary jigs. In this demonstration, we are building axels for 10" wheels (urban model). Axels are 5/8" CR welded to 3/4"x 3" sleeves welded to pre-bent 1/4"x1" flat bar.
This part of the jig table is used to weld up the support feet (components only). This shares the same area of the jig used for the main frame with added stops for the 3/8"x 1" flat bar.
Main frames cleaned up and ready for the individual components (axels and support feet).
Individual jigs are used to index the feet and axel and are used at the same time to complete the main frame.
The finished frames are then loaded onto a transport fixture that can carry 40 frames to the powder coaters for sand blasting and finish. Making unloading with a fork lift a breeze.
The handle bars require fairly close bending to fit into a dedicated jig for welding a cross member and drilling 5/16" holes for the rotating feature of the bars.
My son has returned from the military and has been by my side for the entire batch. I cut him loose on the bandsaw, de-burring station, and bender.
A small level is used when flipping the 12 ga. x 1" round tubbing for secondary bending.
The handel bar jig allows for clamping these awkward pieces for welding and drilling. Drill bushings are used for all seven required holes per cart. No measuring required for any holes. A secondary de-burring operation is required when drilling all holes except the handle bars. A s/s push pin is used for the telescoping feature of the cart so no burrs can exist in the inside of the tubing. A Burr-Zit cutter is used for this after drilling all holes eliminating the small outside and inside burrs that drilling leaves behind.
The double drill bushing ensure a straight and centered hole and is the only holes drilled by hand.
