The problem
Frames welded freehand drift out of square, and every one comes out a little different. A shop building them in batches needs a fixture that's quick to load, holds the parts against heat distortion, and lets the welder reach every joint.
How I approached it
- Built the frame as a weldment from standard tube profiles so the cut list and lengths come straight off the model.
- Designed the fixture on a slotted base with modular locators and toggle clamps, so it can be adjusted for other frame sizes.
- Placed the clamps clear of the weld joints and sequenced the welds to balance distortion.
Checks
Frame deflection under a [X] lb distributed load, caster load rating with margin, and a clamp force check against weld pull. [Add your hand calcs or simulation plot.]
What was delivered
- Weldment drawing with cut list and weld callouts
- Fixture assembly and detail drawings
- BOM with purchased clamps and locators
- Load and deflection calcs
