Multiple Position Welding Ladder The Magic Carpet

The Rockland Manufacturing Company

Fabricates custom construction

equipment

Front End Loader Buckets Bulldozer Blades

Design a Welding Apparatus with the following characteristics

Allows welders to access

Low Production/High Variability

Among Products

No more than 6 Replications of Products

work pieces where needed with fall protection Easily moved and set up by 1 worker Cost effective build (<$5000) Can be configured to most work-piece shapes

http://www.forconstructionpros.com

An analysis of the problem and possible options considered by the team. A working prototype. A successful test in our factory.

A solution and how the solution meets all of the projects goals. A design of the safety ladder.

Sixty by twenty four inch platform

Full railing Reach height of five feet Storable Mobile Under 5 minute set up time
One person able to set up With sliders extended

Safety is a priority.

Accessible by stairs Less than four feet in depth (limited space)

No more than 70o incline

alone

Stepladder
Can serve as an access

method to the top of the work piece Can serve as a platform to stand on while welding

Movable Scaffolding
Serves as a platform to

stand on while welding at medium heights (5-6 ft.)

High Heights Fall Protection Required Above 4 ft.

No fall protection when

Current Access Equipment

Ladder makes

working on top of the work piece

positioning difficult, has limited horizontal reach, and requires constant adjustment Scaffolding has limited horizontal reach and limited vertical reach

High heights
Attaching rails around the platforms perimeter at the OSHA

required 40 Using a platform which conforms to the shape of the work piece reduces the risk of gaps which the worker can fall through

Access to Equipment
By allowing the platform to conform to the shape of the work

piece the worker is able to get in closer, without leaning A 60 wide platform give the worker access to a wider work area without the need for readjustment

Chair Lift Powered Winch Platform Hand Crank

Requires worker to be harnessed General chair lift concept dismissed Concerns about dirt and grime

Platform Pneumatic Pump

inhibiting crank operation Potential problems with resistance from lifting heavy loads
90 psi air lines currently at each weld

Platform Hydraulic Pump

station Concerns regarding pneumatic spring effect

No plant resources available for

automated use More stable hold no spring effect Common in standalone lift units
Foot pump Electric Hydraulic Pump

Chair Lift Harness w/ Winch Platform Single Center Actuator w/ 4 Support Legs on Rectangular Platform
Chair lift design dismissed

Platform Actuators on Each of 4 Support Legs on Rectangular platform

Vertical collapsibility concerns with vertical actuator Requires considerable floor space Custom fabrication and installation of actuator 4 sliding legs leaves room for error in alignment Limited space for adjustable planks

Vertical collapsibility concerns with vertical actuators Requires considerable floor space Custom fabrication of 4 actuators Actuators must be maintained to raise and lower at the same rate Spreading air or hydraulic power to each actuator

Platform Scissor Lift for Rectangular Platform

Great vertical collapsibility Requires considerable floor space Limited or no space for adjustable

Platform Attachment to Pallet Stacker Tines

No height collapsibility Consumes smaller horizontal area

planks High weight concerns Serious tipping problems in multiple directions

than other options Tipping protection integrated into design

Problem side supports run into work pieces

Wire Rope Clamp Down

Complicated, time

consuming setup Difficulties with differently size products and set positions of clamp hooks

Magnets
Problems related to

resulting arc blow May require electricity (electromagnets)

More Tipping Protection

Extending support legs Run into work piece If fold out legs, weight depends on folding hinge Side Support Frame w/

Leveling Pads
Longer setup time Adds weight to platform In conjunction with extending legs can provide great stability

The Need for Variable Platform Extension

A fixed length

platform will not provide falling protection between the ribs on buckets. Our system eliminates all gaps between the ribs of the bucket eliminating the falling hazard.

Fully Adjustable Platform Extension

Made from Unistrut

steel telescoping square tubing Each slider extends to any length under 15.6 inches Sliders lock into place automatically once loaded

Platform Dimensions
Platform depth minimum for required extension.

All sliding extenders slide into place

Slider is free to move

Once loaded the sliding extender locks into place

The Unistrut lock is now restricting the slider from moving

 Sliders mold to any

work surface shape and lock into place Diamond plate Aluminum surface prevents slipping and dirt from entering the track Railings wrap around the back and sides of the platform Platform can be removed from lift

The first design used a set of stairs which would slide out from under the platform. This type of design would allow the stairs to be completely out of the way when not in use, and only the length of stairs needed would be used. This design was later determined to be too heavy, and not cost effective

The next design used a vertical ladder, similar to one used to climb onto a boat. The advantage being that it is light weight, and it also does not take up much room horizontally. It was later decided that this design made it too difficult to mount the platform, while becoming even more difficult when carrying tools.

http://www.gmtcomposites.com/boarding

The final design required the modification of a step ladder. The ladder is removable so when not in use it does not make the platform wider. By using an existing product fabrication time was greatly reduced. It was extremely cost effective. It is light weight The angle and added railing makes mounting the platform extremely easy.

Ladder Mounting Bracket

Ladder in Place

Item Platform Sliding components Rails and Frame Lift Step ladder Total

Price $125.00 $458.43 $183.00 $1919.28 $105.00 $2790.71

With an estimate of fifty hours of labor at 30 dollars per hour total cost is about 4290

Lift
Extending legs for tipping resistance Cut tines for fitting platform

Welding brackets for ladder

Platform
Assembling unistrut
Welding toe kicks Fitting and locating unistrut Locating nuts and brackets as necessary Cutting and welding stoppers for individual sliders

Welding brackets for unistrut and for tines of lift

Cutting and welding frame

Cutting and fitting diamond plate aluminum sheet
Drilling holes for bolting

Initial unistrut layout

Unistrut attached to Frame Toe Kicks and Diamond Plate Added

Final Design

Locking Mechanism and stopper

Railings
Degreasing and cutting metal tubing Welding tubing together and to platform

Welding rails to outermost unistrut sliders

Chain Welding chain brackets to railings Cutting and locating chain to outer most sliders Adding carabineers to opening for ladder

Ladder
Cutting ladder to be fitted to lift Drilling holes for pinning to bracket to allow for

detachability Cutting and welding support beam to bracket

1.
2. 3. 4. 5. 6.

Hand pump or foot pump hydraulic lift to desired height Push lift up to work piece Lock castor wheels Pin ladder into place Climb ladder onto platform and unhook chain (re-chain once on platform) Kick out sliders so that it fits shape of work piece (including outermost rails)
Approximately 3 Minutes to Setup

Fully Functional Prototype

Adjustable height 10 inches

to 63 inches Fully adjustable platform extensions spanning 62 inches Detachable ladder Full railing coverage where fall protection is needed Locking casters