Hibachi Project
Building a Prototype
The hibachi is now nearing the stage where the design is becoming final. A prototype was made using aluminum flashing.
Before Prototyping
Focus Group Input
A focus group met to discuss the current design.
Changes after prototyping:
1) Lower the grill to prevent food from rolling off the sides. Lower grate to compensate for new height of grill.
2) Move grate stops to the ends rather than sides. Eases manufacturability.
3) Need to add grate stops to flat pattern.
Hibachi 12-08-2012
Fixtures & Jigs to Consider
The following fixtures are recommended:
1) Shear length fixture. Since the ideal lot size is one unit, it is necessary to have quick-change shear backstops. Shearing will be done on CTS Ironworker.
2) 5S Layout for grill components - To help avoid confusion over which component is which.
3) Jig for cutting arcs with torch
4) Fixture for welding grate stop and grill stop to ends.
Fixtures & Jigs to Consider
5) Fixture (setup aid) for bend locations.
6) Fixture for welding ends to barrel.
7) Fixture for welding grill together.
8) Fixture for welding feet to barrel.
9) Fixture for hole punch location on grate.
Grill Prototype
Revised Grate Stop Location
Prototype of Final Design
Sheet Metal Bend Allowance
Based on material thickness and internal bend radius.
Sheet Metal Bend Allowance
Revised Flat Pattern (see AutoCAD file) 2-13-2012
What to do with drop?
Grate lifter?, etc.
Need focus group
2-21-2012 Made Shear Fixture
Fixture Characteristics
Has two alignment lugs mounted on the back, for 3-2-1 locating.
Divided into two sections:
Lettered Marks (for second shear)
Sheared Blanks
Sheared Blanks
Punch Template
Rolling Grill Body
Grill Body Profile Template
First Article of Two Components
Grill End Welding Fixture (idea)
Jig for Plasma Cutting Legs
Grill End Welding
Fixture
Incorrectly positioned end plate reveals red paint (semi-poke-yoke)
Body to End Fixture
Grill Rail Fixture
Grill Assembly, without Legs
Leg Fixture (in progress)
Grill Leg Fixture
Testing with Focus Group
High Temp Paint Sourced
First production run 4-24-2012
36 minutes per unit
Drop
Utilization...
Second run 4-10-13 20 mins cycle time
2016 Version
Eliminated fixtures for: