Project Brief
Project ID Project Title* : Changing Welding Rods with Zero Hand Function
Brief Description of the Project : A way for a quadriplegic with zero hand function to change welding rods for an electric arc welder.
Reason for Proposing the Project: I do a lot of welding and struggle to
change rods
Hopes for the Project: A simple hand piece to allows to change welding rods
Relevant Videos: https://www.facebook.com/sculpturesbype terworsley/
https://www.youtube.com/watch?v=0n6L WciMlsQ&fbclid=IwAR2UmDXoYFFqK_A5VF 0IW8Cm9x7hNlN- nzZsCD5gdCVAneOrIzoluxmRfLI
https://www.youtube.com/watch?v=E7zKH BN1kPA&fbclid=IwAR3DbzOutxkS1grSwbvv wbjx1F01uwhD0YOWq5OWhUX_pgdkVww V76pKwrY
https://www.youtube.com/watch?v=i7ZLoE D5AGo&fbclid=IwAR1RpBrhl7vpDqO9LoQn YWazRNO0IboCMdA6hTYWfJVz0QpgQvW3 _dpF_jU
Design Requirements:
- To assist our partner to change welding rods without grabbing motion, the design of project aims to be less than 1kg in weight which allows our partner to wear and operate in a comfortable way.
- The connection between design and welding rods should not only provide friction to stabilize the rod during the welding but also not to be restricted to change the different rods or various operating angles easily.
- Based on size of welded object, the design should normally match 2.5mm and 3.2mm welding rods; might not be suitable for over 4mm rods because partner never operate under this standard.
- The design should be located on partner’s current welding device, a standard electrode holder duct taped to a 150mm diameter PVC pipe. And the design should be removable to allow later reformation on welding device.
- Since reduction on stiff connection could cause possibility of short circuit during the welding by generating extra movement of welding rods, the short-cut protection should be considered in this project for safety.
- Due to the limited body motion, the deigned system should be controlled by switches with large colorful surface where the device could be activated comfortably.
Design Requirements:
- Lightweight – Needs to weigh less than 1kg as it is attached to the end of arm and he will have to lift it and keep it steady for extended periods of time to create good welds.
- Highly mobile – Needs to be easy to reposition. His workshop is designed to suit his motorised wheelchair and he has designed a boom arm to lift his larger pieces but the cable leads that connect to the hand piece often cause mobility issues.
- Suitable force – The handpiece needs to clamp onto rods with enough force such that they will not short out.
- Attached to arm piece that can fit around his arm and protect him from burns. He currently uses a PVC pipe fitting, but this is loose around his arm meaning that any weight attached to the end rotates to the bottom.
- Conductive jaws – The jaws of the handpiece that hold the electrode must be conductive.
- Switches – If automated, any switches used need to be large enough to operate (either large jellybean switches or long lever rocker switches).
- He has asked that the design is based on the clamp electrode holders rather than the twistlock variety
Consolidated Design Requirements for Handpiece (Changing welding rods)
• Less than 1 kg
• Highly mobile
• To suit both 2.5mm and 3.2mm rods
• Needs to hold rod tight enough to fix it in place and prevent it from shorting out but also need to be able to be released and replaced
• Need to use easy access switches (e.g. jellybean switches or homemade ones as seen in videos above)
• Conductive jaws
• To suit current connection leads that he already owns.
• Attached to an arm piece (currently PVC pipe) that fits around arm
• Handpiece will be made from a material that is lightweight, heat resistant and strong enough to support clamping of rods.
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