COOP-AMBULANCE MANUAL CYCLING BLUE WORKSHOP BIKE4CARE 2010-2011
INTRODUCTION
CONTENT
This manual describes the production of the CooP-Ambulance. The CooP-Ambulance consists of three items; a stretcher, a cart and a canopy. Every item is build from different parts. Step by step is explained how to produce these parts.
Tools needed
2
Production time
9
Manufacturing of the stretcher
10
Manufacturing of the cart
48
Manufacturing of the canopy
84
Manufacturing of the tire
94
End result
96
List of materials
98
Template 100ยบ
102
Lay out canvas (for sowing man)
103
This CooP-Ambulance manual has been set up in cooperation with Cycling out of Poverty, the Cycling Blue Workshop and four Industrial Design students of the TU Delft: Paul van Deelen Tamar Meijer Stephan van Meir Guido Molenaar
February 2011
2
3
TOOLS NEEDED
TOOLS NEEDED
Bench grinder
Spanners
Calliper
Chisel Compressor Cutting machine Drill ø 7 mm stretcher ø 9 mm stretcher ø 11 mm car tire + wheel ø 30 mm car tire Ear protector Gas Welder Hammer Hand drill Hand grinder Hand saw
10 Car tire 13 Stretcher backrest 15 wheels cart
Spray gun Steel wired brush Train rail Try square Tube vice Vice
MEASURING TAPE
COMPRESSOR
CUTTING MACHINE
TUBE VICE
BENCH GRINDER
HAND GRINDER
Welding machine Welding shield Other: Sowing man
Measuring tape Protractor Punch Safety goggles Sand paper
4
5
TOOLS NEEDED
6
TOOLS NEEDED
WELDING MACHINE
STEEL WIRE BRUSH
DRILLS 7,9,11,30
WELDING SHIELD
SAFETY GOGGLES
VICE
DRILL
HAND DRILL
SPRAY GUN
SPANNERS 10, 13, 15
TRY SQUARE
HAND SAW
7
TOOLS NEEDED
PRODUCTION TIME When all materials are in stock, 100 man hours are needed to produce one CooP-Ambulance. This is an estimation based on the production time of one CooPAmbulance at the Cycling Blue Workshop in Kisumu, Kenya.
GAS WELDER
CLAMP
TRAIN RAIL
8
CALLIPER
FILE
PROTRACTOR
HAMER & CHISEL
PUNCH
EAR PROTECTION
9
1
Steps 1. Stretcher frame 2. End supports 3. Cover circles 4. Middle supports and handles 5. Backrest joints 6. Backrest holder 7. Backrest 8. Backrest support joints 9. Backrest support stands 10. Backrest holder caps 11. Rubber straps 12. Canvas
10
Industrial Design Engineering
benaming
• Tube dimensions ø = 11/4 inch Thickness: 3 mm
FRAME thickness: 3 mm thickness: 2 mm
length: 2081/4 inch = 5290 mm length: 1693/5 inch = 4308 mm
Steps • Cut 2 x 81,1 inch
• Steel strip 21/2 X 21/2 inch thickness: 1,5 mm
• Cut 2 x 23 inch, make arches • Weld the frame
BACKREST SUPPORT • Tube ø = 1 inch ø = 1/2 inch
Tools needed • Compressor and spray gun • Saw/ cutting machine • Drill • Welding machine • Bench grinder • File • Gas welder
TU Delft
Material needed
Material needed
• Tube ø = 11/4 inch ø = 1 inch
thickness: 2 mm thickness: 1 mm
length: 905/7 inch = 2307 mm length: 601/8 inch = 1530 mm
• Steel strip 2 x 2,6 inch thickness: 3 mm 11/2 x 7/8 inch thickness: 2 mm • Canvas ± 50 x 80 inch • Rubber bands ± 10
datum
maateenheid
Stretcher complete 25 in - Copy drawing 3 schaal
groep
1:1
getekend
<<naam>>
15-2-2011
<<groep>>
formaat
A4
<<maateenheid>>
tekeningnummer
<<tekeningnummer>>
STRETCHER FRAME
11
COOP-AMBULANCE MANUAL STRETCHER
MANUFACTURING OF THE STRETCHER
1
STRETCHER FRAME - CUTTING & ARCHES • Make arches on both ends of the 23 inch tubes (using the bench grinder or a file) to fit the tube ø = 11/4 inch
• Be aware of the blade thickness when cutting
stretcher frame sides
stretcher frame ends
1,25
23,0
22,5
1 ,2
5
, R0
3mm
62
5
R0
,6 2
R0
5
, 62
5
3mm
81,125
0,25
0,25
MAKE THIS PART 2 TIMES
12
Make this part 2 times Name
Date
15-2-2011
Dimensions
INCHES
MAKE THIS PART 2 TIMES
13
Make this part 2 times Date
Name
TU Delft Stretcher bars Industrial Design Engineering
Scale
1:5
Drawn by
Group G.W. Molenaar
Dimensions
15-2-2011 21: Bike4Care
Size
A4
INCHES
Drawing number
Stretcher 2
COOP-AMBULANCE MANUAL STRETCHER
STRETCHER FRAME - CUTTING
1
STRETCHER FRAME- WELDING
1
STRETCHER FRAME
• Check the corners with a try square End result
• Finish the surface with a hand grinder, sand paper and/or a steel wired brush
2,0
23,75
°
90
90
° ° 90
°
1,875
77,25
77,25
90
14
TU Delft Industrial Design Engineering
Date
Name
Stretcher assembly 1
Scale
1:20
Drawn by
Group
G.W. Molenaar
Dimensions
15-2-2011 21: Bike4Care
Size
A4
INCHES
Drawing number
Stretcher assembly1
15
COOP-AMBULANCE MANUAL STRETCHER
1
END SUPPORTS
2
• Make arches on the ends of these tubes to fit the tubes of the frame (ø = 11/4 inch)
Material needed • Tube ø = 1 inch
END SUPPORTS - CUTTING & ARCHES
1,0
Thickness: 2 mm
2mm
Steps • Cut 4 x 5 inch, make arches on one side • Weld the 4 supports to the frame
25 6 , 0
4,5
4,5
1,0
MAKE THIS PART 4 TIMES
16
17
COOP-AMBULANCE MANUAL STRETCHER
2
END SUPPORTS - WELDING
• Weld the 4 end supports on the frame on the positions indicated below
° 90
90
0,5
3.25
23,75
°
9
90
0°
3,25
°
0,5
1,875
2,0
Date
Name
TU Delft Stretcher assembly 2
18
Industrial Design Engineering
Scale
1:20
Drawn by
Group
G.W. Molenaar
Dimensions
15-2-2011 21: Bike4Care
Size
A4
INCHES
Drawing number
Stretcher assembly 2
19
COOP-AMBULANCE MANUAL STRETCHER
2
COVER CIRCLES
3
• Close the open ends of the long side tubes with the 4 cover plates
Material needed
Steps
• Steel strip 21/2 X 21/2 inch Thickness: 1,5 mm
• Cut 4 pieces of 11/4 X 11/4 inch
1,5mm
COVER CIRCLES
• Make them round with a file
1,25
MAKE THIS PART 4 TIMES
20
21TU Delft
COOP-AMBULANCE MANUAL STRETCHER
3
Close the open ends of the long side tubes with the 4 round plates benaming
datum
maateenheid
Stretcher complete 25 in - Copy drawing 2 schaal
1:1
groep
15-2-2011
<<groep>>
formaat
<<maateenheid>>
tekeningnummer
MIDDLE SUPPORTS AND HANDLES
4
• Make arches on one side and cut 45º on the other side, be aware of the orientation.
Material needed
1,0
Thickness: 2 mm
0,25
• Tube ø = 1 inch
MIDDLE SUPPORTS AND HANDLES
Steps
5,0
• Cut 4 x 27,9 inch, cut 45º both sides • Weld on the frame
5,0
• Cut 8 x 5 inch, make arches on one side and cut 45º other side
45°
1,0 2mm MAKE THIS PART 8 TIMES
22
23
Make this part 8 times Name
Date
15-2-2011
Dimensions
INCHES
COOP-AMBULANCE MANUAL STRETCHER
4
4
MIDDLE SUPPORTS AND HANDLES • Weld the parts together, make sure the corners are 90º
• Cut both sides 45º, be aware of the orientation.
1,0
27,0
1,0 2mm
45°
1,0
2mm
45°
1,0
28,0
1,0 90
28,0
1,
90
°
°
0
1, MAKE THIS PART 4 TIMES Dimensions
Date
Name
24
1,0
1,0
27,0
TU Delft Stretcher support (b) Industrial Design Engineering
Scale
1:5
Drawn by
Group G.W. Molenaar
15-2-2011
21: Bike4Care
INCHES
Size
A4
Drawing number
Stretcher 3b
1, 0
0
Date
Name
25 TU Delft Stretcher support (b) Industrial Design Engineering
Scale
1:5
Drawn by
MAKE THIS PART 4 TIMES
Group G.W. Molenaar
Dimensions
15-2-2011 21: Bike4Care
Size
A4
INCHES
Drawing number
Stretcher 3b
COOP-AMBULANCE MANUAL STRETCHER
MIDDLE SUPPORTS AND HANDLES
5,0
4
MIDDLE SUPPORTS AND HANDLES
BACKREST
• Weld the middle supports and handles on the frame on the positions indicated below
The Backrest consists of: • Backrest joints • Backrest holders • Backrest
4,875
23,75
4,875
• Backrest support • Backrest support joints 0,5
• Backrest support stands
Place the tw
• Backrest holder caps
3,25
55,75 27,875
0,625
26 TU Delft
0,5
27,875
55,75 Date
Name
Stretcher assembly 3
Scale
1:20
Group
Dimensions
15-2-2011 21: Bike4Care
Size
INCHES
Drawing number
27
TU Delft
COOP-AMBULANCE MANUAL STRETCHER
4
benaming
datum
ma
Stretcher complete 25 in - Copy drawing schaal
1:1
groep
15-2-2011
<<groep>>
formaat
tek
BACKREST JOINTS
5
Material needed
BACKREST JOINTS
• Weld the joints on the frame on the positions indicated below
• Steel strip 2 x 2,6 inch
Thickness: 3 mm
Steps • Cut two pieces of 2 x 1,3 inch
0,5
1, R
1,0 0,3
0,3
1,0
9mm
29,25
1,0 2,0
28
0 0,5
• Drill a hole of ø 9 mm
32,5
3mm
• Make them round with a file
2,0
MAKE THIS PART 2 TIMES
Make this part 2 times
29
TU Delft Industrial Design Engineering
Date
Name
Stretcher assembly 4
Scale
1:20
Drawn by
Group
G.W. Molenaar
Dimensions
15-2-2011 21: Bike4Care
Size
A4
INCHES
Drawing number
Stretcher assembly 4
COOP-AMBULANCE MANUAL STRETCHER
5
BACKREST HOLDER
6
Material needed
BACKREST HOLDER
• Weld the backrest holders on the frame on the positions indicated below
• Tube ø = 1 inch Thickness: 2 mm Steps • Cut 2x 1,325 inch
2mm
1,0
1,25
0,75
°
1,25
1,325
60
0,75
1,0
23,75
• File as in indicated below SECOND TIME MIRRORED!
0,5
30
TU Delft Industrial Design Engineering
Name
Weld it AGAINST the ha
Make this part a second - MIRRORED MAKE THIS PART A SECOND TIME -time MIRRORED
Stretcher backrest holder right
Date
Scale
1:1
Drawn by
Group G.W. Molenaar
Dimensions
15-2-2011 21: Bike4Care
Size
A4
INCHES
Drawing number
Stretcher 7
COOP-AMBULANCE MANUAL STRETCHER
6
Date
Name
31
TU Delft Stretcher assembly 5 Industrial Design Engineering
Scale
1:10
Drawn by
Group
G.W. Molenaar
Dimensions
15-2-2011 21: Bike4Care
Size
A4
INCHES
Drawing number
Stretcher assem
5
BACKREST
7
• Cut 2x 31,5 inch with one side 45º
Material needed • Tube ø = 1 inch
BACKREST
• Flatten one end by using a gas welder (to heat the metal) and a hammer, be aware of the orientation!
Thickness: 2 mm
• Drill ø 9 mm holes on this side • Round the corners on this side
Steps • Cut straight and 45º
°
• Flatten ends 31,5
• Drill holes
1,0
90
1,75 45°
1,75 m
2mm
0,5
,5
9m
1,0
R0
0,5
MAKE THIS PART 2 TIMES
32
33
Make this part 2 times Date
Name
TU Delft Stretcher backrest (a) Industrial Design Engineering
Scale
1:5
Drawn by
Group
Dimensions
15-2-2011 21: Bike4Care
Size
INCHES
Drawing number
Stretcher 6a
COOP-AMBULANCE MANUAL STRETCHER
7
23,75
7
BACKREST
7
• Cut 243/4 inch with both °sides 45º, be90aware of the orientation! ° 90 9 0° ° 90
BACKREST • Weld the parts together, make sure the corners are 90º
23,75
9
23,8 23,75 24,75 23,75 24,75 24,8 45°
Name
45°
1,0 Delft Stretcher backrest (c) TU 2mm Delft Stretcher backrest (c) TU Industrial Design Engineering
Scale
Date
1,0 2mm
Group 1:10 Date 21: Bike4Care 15-2-2011 Drawn by G.W. Molenaar Scale Group 1:10 21: Bike4Care Drawn by
Dimensions
15-2-2011
G.W. Molenaar
1,0
Industrial Design Engineering
1,0
Name
°
INCHES
Size
Drawing number Dimensions INCHES
Size
Drawing number
A4 A4
90
0°
Stretcher 6c Stretcher 6c
23,75 24,75
34TU Delft Industrial Design Engineering
Date
Name
Stretcher backrest (b)
Scale
1:5
Dranwn by
Group G.W. Molenaar
Dimensions
15-2-2011 21: Bike4Care
Size
A4
INCHES
Drawing number
Stretcher 6b
35
Date
Name
TU Delft Stretcher backrest (c)
Scale
1:10
Group
Dimensions
15-2-2011 21: Bike4Care
Size
INCHES
Drawing number
COOP-AMBULANCE MANUAL STRETCHER
23,75
BACKREST SUPPORT JOINTS
8
BACKREST SUPPORT JOINTS
• Weld the joints on the outside of the centre line
Material needed
Steps
• Steel strip 11/2 x 7/8 inch Thickness: 2 mm
• Cut two pieces of 3/4 x 7/8 inch 2mm
• Make the top round with a file
90
°
°
23,75
90
2mm
3,0
3,0
• Drill a hole of ø 7 mm
2mm
0,75
0,5
0,5
7mm
0,375 0,5
0,875
0,5
2mm
0,875
2mm
0,75
23,75
0,75
0,375 0,75
Delft 36
sign Engineering
Make this part 2 times benaming
datum
Stretcher backrest support joint schaal
1:1
groep
15-2-2011 <<groep>>
23,75
MAKE THIS PART 2 TIMES
Make getekend this part 2 times <<naam>>
maateenheid
formaat
A4
<<maateenheid>>
tekeningnummer
<<tekeningnummer>>
37 TU Delft Industrial Design Engineering
benaming
Place the plates on the outside of the centre line datum
maateenheid
Stretcher complete backrest drawing file schaal
groep
1:1
getekend
<<naam>>
15-2-2011
<<groep>>
formaat
A4
COOP-AMBULANCE MANUAL STRETCHER
8
<<maateenheid>>
tekeningnummer
<<tekeningnummer>>
9
BACKREST SUPPORT STAND
Material needed
• Cut 2x 20 inch
• Tube ø = 1/2 inch
• Flatten one end
Steps • Cut parts
Thickness: 1 mm
• Drill ø 7 mm holes 0,5 0,25
• File round
7m m
• Flatten ends
20,0 19,5
• Drill holes
3,0
End result
0,5 0,5
1mm
A
38
39 TU Delft Industrial Design Engineering
Date
Name
Backrest support stands
MAKE THIS PART 2 TIMES
A
Scale
1:5
Drawn by
Group G.W. Molenaar
Dimensions
15-2-2011 21: Bike4Care
Size
A4
INCHES
Drawing number
Backrest Support 1
COOP-AMBULANCE MANUAL STRETCHER
BACKREST SUPPORT STAND
1,0
9
9
BACKREST SUPPORT STAND • Weld the parts together as indicated below, make sure the corners are 90º
• Cut 23,5 inch
0,5
3,0
23,5
R0
40
, 25
0,
25
TU Delft
90
°
90
23,5
R
0,5
R
3,0
• Make arches on both ends, be aware of the orientation!
25
0,
1mm
benaming
datum
23,75
Stretcher backrest support connector schaal
°
groep
15-2-2011
formaat
maateenheid
<<maateenheid>>
tekeningnummer
41 TU Delft
benaming
datum
maateenheid
Stretcher complete 25 in - Copy Drawing schaal
1:1
groep
15-2-2011
<<groep>>
formaat
COOP-AMBULANCE MANUAL STRETCHER
BACKREST SUPPORT STAND
9
<<maateenheid>>
tekeningnummer
10
BACKREST HOLDER CAPS
• This rubber part should be purchased or handmade
• Spray paint all the parts before assembling • Connect the support stand to the backrest • Connect the backrest to the frame M6 connection (2 bolts, 6 washers & 2 nuts)
0,5
M8 connection (2 bolts, 6 washers & 2 nuts)
0,625
1,0
42
TU Delft Industrial Design Engineering
benaming
datum
maateenheid
Stretcher complete 25 in - Copy drawing 2 schaal
groep
1:1
getekend
<<naam>>
15-2-2011
<<groep>>
formaat
A4
USE THIS PART 2 TIMES
<<maateenheid>>
tekeningnummer
<<tekeningnummer>>
43
COOP-AMBULANCE MANUAL STRETCHER
BACKREST
Make this part 2 time
TU Delft
Name
Date
15-2-2011
Dimensions
INCHES
BACKREST HOLDER CAPS
11
RUBBER STRAPS • Wrap ± 6 rubber straps around the main frame and the backrest
• Place the two caps as indicated below
• Fasten them by making nuts and wrapping around the tubes
Place the two caps
Wrap rubber straps around the main frame and the backrest. Fasten them by making nuts and wrapping around the tubes
44 TU Delft
benaming
datum
maateenheid
Stretcher complete 25 in - Copy drawing 3 schaal
1:1
groep
15-2-2011
<<groep>>
formaat
<<maateenheid>>
tekeningnummer
45 TU Delft
benaming
datum
maateenheid
Stretcher complete 25 in - Copy drawing 3 schaal
1:1
groep
15-2-2011
<<groep>>
formaat
<<maateenheid>>
tekeningnummer
COOP-AMBULANCE MANUAL STRETCHER
10
CANVAS Material needed
Steps
• Canvas ± 50 x 80 inch
• Ask a sowing man to make the following lay outs
• Easy to clean, strong, preferably orange
Backrest
46
12
CANVAS • Attach the two parts of canvas to the stretcher using rubber bands
• The grey rectangles indicate the location where the ‘tunnels’ should be placed (on the inside!), these tunnels should be big enough to fit a rubber band. This rubber band can be wrapped around the frame of the stretcher to attach the canvas.
Stretcher
TU Delft
47
Industrial Design Engineering
benaming
datum benaming 15-2-2011
maateenheid
COOP-AMBULANCE MANUAL STRETCHER
12
Stretcher complete in - CopyStretcher drawing complete 3 25 in - Copy drawing 3 TU25Delft schaal
1:1
getekend
Industrial Design Engineering <<naam>>
groep
<<groep>>
formaat
A4
datum
<<maateenheid>>
tekeningnummer
schaal
groep
1:1
<<tekeningnummer>> getekend
<<naam>>
15-2-2011
<<groep>>
maate
formaat
A4
teken
<<te
1
BACK- SIDES - CART FENDER TUBE A • Cut two pieces of 41/2 inch
WHEEL FENDERS 11. Wheel fenders 12. Complete assembly 13. Extra options
• Make arches on one side and cut 45º on the other side, be aware of the orientation.
1,0 R0 ,5
Material needed • Tube ø = 1 inch
thickness: 2 mm
• Steel strip/plate 8 x 2 inch 2 x 1 inch 29 X 29 inch 413/4 x 8 inch
thickness: 3 mm thickness: 1,5 mm thickness: 1,5 mm thickness: 1,5 mm
4,5
length: 4351/2inch = 11062 mm
1,0 2mm
R0 ,5
1,0
CART FRONT 6. Front sides 7. Crossbars 8. Handles 9. Front and back assembly 10. Front connector
Tools needed • Saw • Welding machine • Bench grinder • File • Hand grinder • Hammer and chisel • Compressor and spray gun
45 °
Steps CART BACK 1. Sides 2. Crossbars 3. Wheel mountings 4. Canopy holders 5. Cover circle
MAKE THIS PART 2 TIMES
48
49 TU Delft
Make this part 2 times benaming
datum
Cart fender tube left - drawing a schaal
1:1
groep
maateenheid
23-2-2011 <<groep>>
formaat
<<maateenheid>>
tekeningnummer
COOP-AMBULANCE MANUAL CART
MANUFACTURING OF THE CART
BACK - SIDES - CART FENDER TUBE B
1
BACK - SIDES - CART FENDER TUBE C
• Cut two pieces of 71/4 inch. Make arches on one side and cut 45º on the other side, be aware of the orientation.
• Cut two pieces of 30 inch with both sides 45º, be aware of the orientation!
7,25
45°
1,0 1,0
1,0
2mm
1,0 2mm
45 °
45 °
4 5°
30,0
50TU Delft
Industrial Design Engineering
2mm
45 °
1,0
1,0
benaming
datum
Cart fender tube left - drawing b schaal
groep
1:1
getekend
<<naam>>
MAKE THIS PART 2 TIMES maateenheid
23-2-2011 <<groep>>
formaat
A4
<<maateenheid>>
tekeningnummer
<<tekeningnummer>>
MAKE THIS PART A SECOND TIME MIRRORED Make this part one more time but -then MIRRORED
TU Delft 51 Industrial Design Engineering
benaming
datum
Cart fender tube left - drawing c schaal
1:1
getekend
groep
maateenheid
23-2-2011 <<groep>>
formaat
<<maateenheid>>
tekeningnummer
<<tekeningnummer>>
COOP-AMBULANCE MANUAL CART
1
BACK - SIDES - SUBASSEMBLY
1
BACK - SIDES- SIDES
• Cut two pieces of 59 inch and make arches on one end.
• Weld the parts together as indicated below, make sure the corners are 90º
30,0
90
° 90
°
,5 R0
29,0
7,25
1,0
59,0
90
7,25 °
°
90
4,5
7,25
4,5
R0
1,0
,5
2mm 59,0
Make this subassembly 2 times. Whereby the second will be mirrored (because of mirrored piece of 7,25in) datum
benaming
THIS SUBASSEMBLY 2 TIMES. THE SECOND WILL BE MIRRORED Cart fender tubeWHEREBY left Delft TUMAKE A4 <<tekeningnummer>> schaal
52
maateenheid
Industrial Design Engineering
groep
1:1
getekend
<<naam>>
23-2-2011
<<groep>>
formaat
<<maateenheid>>
tekeningnummer
53
TU Delft Industrial Design Engineering
benaming
Cart side
Make this part 2 times datum schaal
groep
1:1
getekend
<<naam>>
maateenheid MAKE THIS PART 2<<maateenheid>> TIMES
23-2-2011
<<groep>>
formaat
A4
tekeningnummer
<<tekeningnummer>>
COOP-AMBULANCE MANUAL CART
1
BACK - SIDES - ASSEMBLY
2
• Weld the two mirrored subassemblies on the long tubes, make sure that the tubes are parallel
COOP-AMBULANCE MANUAL CART
1
BACK - CROSSBARS - REAR A
• Cut two pieces of 41/4 inch with both sides 45º, be aware of the orientation!
7,25
4,5
1,0
30,0
2mm 1,0
°
1,0
90
59,0 1,0
4 5°
90
4 5°
1,0
°
90
4,25
4,25
59,0
°
1,0
MAKEWeld THIS 2 TIMES. WHEREBY THE SECOND WILL MIRRORED theASSEMBLY two mirrored sub assemblies on to the long tubes, make sure thatBE the tubes are parallel
54 TU Delft
benaming
datum
Cart complete Redesign - Drawing 1 schaal
1:1
getekend
groep
23-2-2011
<<groep>>
formaat
maateenheid
<<maateenheid>>
tekeningnummer
<<tekeningnummer>>
MAKE THIS PART TIMES Make2this part 2 times
55TU Delft
benaming
datum
Cart cross bar rear drawing 1 schaal
1:1
groep
maateenheid
23-2-2011 <<groep>>
formaat
<<maateenheid>>
tekeningnummer
BACK - CROSSBARS - REAR B
COOP-AMBULANCE MANUAL CART
2
BACK - CROSSBARS - REAR SUBASSEMBLY
2
• Weld the parts together as indicated below, make sure the corners are 90º
1,0
• Cut 23 inch with both sides 45º, be aware of the orientation!
1,0
22,0
45 °
2mm
90
1,0
4,25
23,0 1,0
°
90
°
3,75
4 5°
1,0
23,0
56
TU Delft Industrial Design Engineering
benaming
datum
Cart cross bar rear drawing 2 schaal
groep
1:1
getekend
<<naam>>
maateenheid
23-2-2011 <<groep>>
formaat
A4
<<maateenheid>>
tekeningnummer
<<tekeningnummer>>
57 TU Delft
Industrial Design Engineering
benaming
Cart cross bar rear
datum schaal
groep
1:1
getekend
<<naam>>
maateenheid
23-2-2011 <<groep>>
formaat
A4
<<maateenheid>>
tekeningnummer
<<tekeningnummer>>
BACK - CROSSBARS - ASSEMBLY
2
• Weld the parts together as indicated below, make sure the corners are 90º
• Cut 251/2 inch with arches on both sides, be aware of the orientation!
90
26,0
1,0
° 90 90
25,5 ,5
4,0
55,25
25,5
R0
R0 ,5
COOP-AMBULANCE MANUAL CART
BACK - CROSSBARS - STRETCHER BAR
2
°
°
°
90
1,0 2mm 3,25
26,0
26,0
58
TU Delft Industrial Design Engineering
benaming
Stretcher cross bar
datum schaal
groep
1:1
getekend
<<naam>>
maateenheid
23-2-2011 <<groep>>
formaat
A4
<<maateenheid>>
tekeningnummer
<<tekeningnummer>>
59
90
°
90
°
TU Delft Industrial Design Engineering
benaming
°
90
22,0
datum
Cart complete Redesign - Drawing 2 schaal
1:1
getekend
groep
23-2-2011
<<groep>>
formaat
maateenheid
<<maateenheid>>
tekeningnummer
<<tekeningnummer>>
3
Material needed
Steps
• Fix the plates to the 2 rims, tighten the nuts
• Steel strip 8 X 2 inch
• Cut 4 pieces of 2 X 2 inch
• Place them onto the frame like shown
• Drill ø 11 mm holes in the middle of the plate
• Tag the plates to the frame while wheels are aligned with each other and the frame itself
Thickness: 3 mm 2,0
• Remove the rims and weld the four plates to the frame properly
• File a slot to one corner of the plate
• Try to fit the rims again, align them again if necessary
• Soften all sharp edges to prevent injuries
Width of wheel axle Width of wheel axle
45 °
3mm
mm 2,0
1,0
4 5°
11
2,0
14,5
• Make sure all 4 parts are identical
3mm
3mm
1,0
11
2,0
TU Delft
benaming
mm
m 11
4 5°
m
1,0
60
BACK - WHEEL MOUNTINGS - ASSEMBLY
Cart wheel mountings
13,5
13,5
1) Fix the plates to the 2 rims, tighten the nuts 2) Place them onto the frame like shown 3) Tagg the plates to the frame while wheels are alligned with each other and the frame itself 4) Remove the rims and weld the four plates to the frame properly 5) Try to fit the rims again, allign them better if necessary
Soften all sharp edges to prevent injuries! MAKE THIS PART 4 TIMES Make this part 4 times (EXACTLY the same) datum
23-2-2011
maateenheid
<<maateenheid>>
61
TU Delft
COOP-AMBULANCE MANUAL CART
BACK - WHEEL MOUNTINGS
3mm
3
benaming
datum
Cart complete Redesign - Drawing 3 schaal
1:1
groep
23-2-2011
<<groep>>
formaat
maateenheid
<<maateenheid>>
tekeningnummer
BACK - CANOPY HOLDERS
4
BACK - CANOPY HOLDERS - ASSEMBLY • Weld the canopy fasteners on the cart as indicated below, make sure the corners are 90º
• Cut two pieces of 33/4 inch and make arches on one end. 1,0 2mm Remove sharp edges
4,0
3,75
1,0
R
5
0,
0,5
90
°
90
62
MAKE THIS PART 2 TIMES Make this part 2 times benaming
datum
23-2-2011
63 TU Delft maateenheid <<maateenheid>> Industrial Design Engineering
benaming
datum
26,0 °
°
90
Cart complete Redesign - Drawing 4 schaal
groep
1:1
getekend
<<naam>>
23-2-2011
<<groep>>
formaat
A4
maateenheid
<<maateenheid>>
tekeningnummer
<<tekeningnummer>>
COOP-AMBULANCE MANUAL CART
4
BACK - COVER CIRCLES
5
• Close the open ends of the long side tubes with the 2 cover plates
Material needed
Steps
• Steel strip 2 X 1 inch
• Cut two pieces of 1 X 1 inch
1,5mm
Thickness: 1,5 mm
BACK - COVER CIRCLES - SUBASSEMBLY
• Make them round with a file
1,0
Close the gaps
MAKE THIS PART 2 TIMES
64
Make this part 2 times
65
COOP-AMBULANCE MANUAL CART
5
Remove any sharp edges to prevent injuries
FRONT - SIDES A
6
COOP-AMBULANCE MANUAL CART
6
FRONT - SIDES B
• Cut two pieces of 241/2 inch with both sides 45º, be aware of the orientation!
• Cut two pieces of 31/4 inch
1,0
• Make arches on one side and cut 45º on the other side, be aware of the orientation.
2mm
1,0
1,0
1,0
4 5°
,5
50 °
R0
1,0
24,5
3,25
2mm
3,5
1,0
5 0°
MAKE THIS PART 2 TIMES
66
Make this part 2 times
TU Delft
benaming
Assem2
datum schaal
groep
maateenheid
23-2-2011 formaat
<<maateenheid>>
tekeningnummer
Make this part 2 times MAKE THIS PART 2 TIMES
67 TU Delft Industrial Design Engineering
benaming
datum
Cart side front right - drawing b schaal
1:1
getekend
groep
maateenheid
23-2-2011 <<groep>>
formaat
<<maateenheid>>
tekeningnummer
<<tekeningnummer>>
FRONT - SIDES C
6
FRONT- SIDES ASSEMBLY • Weld the parts together as indicated below, make sure one corner is 90º and one 100º. Use a protractor or the template on page 100
45 °
• Cut two pieces of 301/2 inch with both sides 45º, be aware of the orientation!
30,5
°
90
1,0
1,0
45 °
1,0
1,0
30,5
10
0°
45 °
24,5
2mm
1,0 45°
Make this part another time but then MIRRORED
68
TU Delft Industrial Design Engineering
benaming
MAKE THIS PART A SECOND TIME, MIRRORED datum maateenheid
Cart side front right - drawing c
23-2-2011
schaal
groep
1:1
getekend
<<naam>>
<<groep>>
3, 2 5
<<maateenheid>>
formaat
A4
tekeningnummer
<<tekeningnummer>>
69TU Delft
benaming
COOP-AMBULANCE MANUAL CART
6
MAKE ASSEMBLY A SECOND - MIRRORED Make this assembly twice,THIS whereof one mirrored (because ofTIME the mirrored part of 30,5in)
Cart side front right
datum schaal
1:1
groep
maateenheid
23-2-2011 <<groep>>
formaat
<<maateenheid>>
tekeningnummer
FRONT - CROSSBARS - MIDDLE
7
COOP-AMBULANCE MANUAL CART
7
FRONT - CROSSBAR - FRONT
• Cut two pieces of 61/2 inch with both sides 45º, be aware of the orientation!
• Cut two pieces of 5 inch and make arches on both ends, be aware of the orientation 5,0
1,0
1,0
1,0
R0,5
2mm
R0,5
45 °
1,0 4 5°
1,0
5,5
2mm
6,5
5,0
70
TU Delft Industrial Design Engineering
benaming
Make this part 2 times
Cart cross bar front middle schaal
1:1
getekend
<<naam>>
datum groep
MAKE THIS maateenheid PART 2<<maateenheid>> TIMES
23-2-2011
<<groep>>
formaat
A4
tekeningnummer
<<tekeningnummer>>
71
benaming
Cart cross bar front
datum
23-2-2011
maateenheid
<<maateenheid>>
FRONT - CROSSBARS - ASSEMBLY
FRONT- HANDLES
8
• Cut two pieces of 41/4 inch and make arches on one end.
• Weld the middle crossbars and the front crossbar to the frame as indicated below, make sure the corners are 90º
4,25
1,0
• Align the sides correctly, then it will be easier to weld it to the main frame of the cart later
90
°
°
6,5
5,5
90
1,0
4,5
°
90 2 ,0
° 90
90
°
90
2mm
6,5 5,0
1,0
°
°
2,0
90
5,0
72
TU Delft Industrial Design Engineering
benaming
Cart Front end Drawing schaal
1:1
getekend
<<naam>>
datum groep
Make sure the sides are alligned correctly, then it will be easier to weld it to the main frame of the cart. maateenheid
23-2-2011 <<groep>>
formaat
A4
<<maateenheid>>
tekeningnummer
<<tekeningnummer>>
Make this part 2 times
73
TU Delft Industrial Design Engineering
benaming
Cart handle
datum schaal
groep
1:1
getekend
<<naam>>
MAKE THISmaateenheid PART <<maateenheid>> 2 TIMES
23-2-2011
<<groep>>
formaat
A4
tekeningnummer
<<tekeningnummer>>
COOP-AMBULANCE MANUAL CART
7
FRONT - HANDLESS - ASSEMBLY
9
FRONT AND BACK ASSEMBLY • Weld the front assembly to the back assembly on the frame as indicated below, make sure the corners are correct
• Weld the handles on the frame as indicated below, make sure the corners are 90º °
10,25
90
90
°
90
° °
10,25
90
2, 5 10,25 0 10
74
benaming
datum
23-2-2011
maateenheid
75 TU Delft <<maateenheid>>
Industrial Design Engineering
benaming
°
10,25 90
°
90
datum
Cart complete Redesign - Drawing 6 schaal
groep
1:1
getekend
<<naam>>
°
23-2-2011
<<groep>>
formaat
A4
maateenheid
<<maateenheid>>
tekeningnummer
<<tekeningnummer>>
COOP-AMBULANCE MANUAL CART
8
FRONT CONNECTOR
10
COOP-AMBULANCE MANUAL CART
10
FRONT CONNECTOR ASSEMBLY
• Adjust the tubes if necessary, try to keep them at the same height
• Cut two pieces of 14 inch with 45º angles, make arches on the ends and adjust them so they will fit the assembly properly
• Weld the parts together as indicated below, make sure the corners are 45º
15
45
45°
1,0 2mm
same height
14,0
Make another just like this one, only MIRRORED Adjust them to fit properly!
TU Delft
76
Industrial Design Engineering
benaming
datum
maateenheid
Adjust the tubes if necessary, try to keep them at the same height
Cart canopy holder front connector right MAKE THIS PART A SECOND TIME, MIRRORED schaal
groep
1:1
getekend
<<naam>>
23-2-2011
<<groep>>
formaat
A4
45
45
Fix the two tubes to connect the front end and the canopy holders
<<maateenheid>>
tekeningnummer
<<tekeningnummer>>
77
TU Delft Industrial Design Engineering
benaming
datum
Cart complete Redesign - Drawing 7 schaal
groep
1:1
getekend
<<naam>>
23-2-2011
<<groep>>
formaat
A4
maateenheid
<<maateenheid>>
tekeningnummer
<<tekeningnummer>>
WHEEL FENDERS
11
WHEEL FENDERS - STRAIGHT PLATE • Draw a circle of 141/2 inch on the steel plate
Material needed • Steel plate 413/4 x 8 inch
• Use a hammer and chisel to cut out the parts , be aware that the parts are not a complete half circle but only 121/2 inch high Thickness: 1,5 mm
Tools needed
Remove sharp edges toand prevent injuries • Hammer chisel
1,5mm
28,75
• Hand grinder
R1 4
,5
Weld the two plates together on the in- and outside
• Welding machine
2,0
12,5
4,0
• File
4,0 R1 5
1,5mm
4,
this part 2 times MAKE THISMake PART 2 TIMES
28,75
78
79
TU Delft Industrial Design Engineering
benaming
Cart fender plate straight schaal
1:1
getekend
<<naam>>
datum groep
maateenheid
23-2-2011 <<groep>>
formaat
A4
<<maateenheid>>
tekeningnummer
<<tekeningnummer>>
COOP-AMBULANCE MANUAL CART
11
WHEEL FENDERS - CURVED PLATE
11
• Cut two pieces of 413/4 inch x 4 inch
WHEEL FENDERS - ASSEMBLY • Weld the two plates together on the in- and outside
Dimensions of the plate needed: 41,75 inch x 4,0 inch x 1,5mm
• Remove sharp edges with a grinder and file to prevent injuries
Weld the two plates together on the in- and outside
4,0
Remove sharp edges to prevent injuries
4,0
4,0
5m
R
,5
4,0 4,
m
14
R1
1,
2,0
5
Make this part 2 times
TU Delft Industrial Design Engineering
80
benaming
Cart fender plate curved schaal
1:1
getekend
<<naam>>
datum groep
maateenheid
23-2-2011 <<groep>>
formaat
<<maateenheid>>
tekeningnummer
A4 THIS PART 2 TIMES MAKE <<tekeningnummer>>
MAKE THIS ASSEMBLY TIMES Make this2part 2 times
81 TU Delft Industrial Design Engineering
benaming
Assem1
datum schaal
groep
1:1
getekend
<<naam>>
maateenheid
23-2-2011 <<groep>>
formaat
A4
<<maateenheid>>
tekeningnummer
<<tekeningnummer>>
COOP-AMBULANCE MANUAL CART
11
COMPLETE ASSEMBLY CART
EXTRA OPTIONS
13
• Weld the fenders on the centre lines of the tubes
1. Add (orange) hand grips to the handles
• Paint the whole cart white
2. Add a kick stand to the cart
• Place two 26 inch, heavy duty bicycle wheels
3. Indicate where the canopy should be placed by using orange tape on the canopy stand and the canopy holder (on the cart)
• Place rubber circles in the canopy holders and around the frame (as indicated below) to prevent noises
4. Place stickers on the frame
0,5
5. Add a security belt 6. For extra comfort a head cushion can be made by a sowing man
0,5
Canopy stand Canopy holder 3
1
14,5
82
Weld the fenders onto the centre lines of the tubes.
TU Delft
benaming
83 Backup of Cart complete Redesign - Drawing 8 datum
schaal
1:1
groep
maateenheid
23-2-2011
<<groep>>
formaat
<<maateenheid>>
tekeningnummer
4
5
4
COOP-AMBULANCE MANUAL CART
12
1
SIDES • Cut two pieces of 40 inch with one side 45º cut.
Steps 1. Sides 2. Connection bars 3. Front verticals 4. Canvas
Material needed • Tube ø = 3/4 inch
• File the other sides (one mirrored) as indicated below, be aware of the orientation! thickness: 1,5 mm length: 2171/7 inch = 5517 mm
• Canvas ± 110 x 100 inch • Rubber bands: 4
Tools needed • Saw/ cutting machine • Welding machine • Bench grinder • File • Compressor and spray gun
MAKE THIS PART A SECOND TIME - MIRRORED
84
85
COOP-AMBULANCE MANUAL CANOPY
MANUFACTURING OF THE CANOPY
SIDES
1
• Weld the parts together as indicated below, make sure the corners are 90º
• Cut two pieces of 3413/40 inch with one side 45º cut.
MAKE THIS PART 2 TIMES
86
SIDES ASSEMBLY
MAKE THIS ASSEMBLY TWICE - MIRRORED
87
COOP-AMBULANCE MANUAL CANOPY
1
CONNECTION BARS
2
• Weld the parts together as indicated below, make sure the corners are 90º
• Cut two pieces of 26 inch and make arches on both ends.
MAKE THIS PART 2 TIMES
88
ASSEMBLY WITH CONNECTION BARS
89
COOP-AMBULANCE MANUAL CANOPY
2
FRONT VERTICALS
3
ASSEMBLY • Weld the front verticals to the canopy as indicated below, make sure the corners are 90º
• Cut two pieces of 81/4 inch and make arches on one end.
• Spray paint the canopy white
MAKE THIS PART 2 TIMES
90
91
COOP-AMBULANCE MANUAL CANOPY
3
4
CANVAS Material needed
Steps
• Canvas ± 110 x 100 inch
• Ask a sowing man to make the following lay out
• Rubber bands: 4 • Easy to clean, strong, preferably white
10 inch
9 inch
92
9 inch
CANVAS • Attach the canvas to the canopy using rubber bands
• The grey rectangles indicate the location where the ‘tunnels’ should be placed (on the inside!), these tunnels should be big enough to fit a rubber band. This rubber band can be wrapped around the frame of the canopy to attach the canvas.
Canopy rolled up
• The orange parts are ropes and loops to role up the canvas
10 inch
93
Canopy full cover
COOP-AMBULANCE MANUAL CANOPY
4
1
TIRE CONNECTION PIECE
2
CAR TIRE
Material needed
Steps
1. Cut a piece of ± 4 inch out of a care tire
• Steel strip 23/4 X 11/4 inch
• Make a plate of 2,75 x 1,25 inch
2. Make a hole of ø 30 mm for the saddle pin
• Drill 2 holes of ø 11 mm on the sides
3. Make two holes ø 11 mm next to this slot to attach the tire connection piece
Thickness: 3 mm
4. Drill another hole to keep the bar of the cart in its place in the car tire 5. Use bolts and nuts to connect everything
94
95
2
4
3
COOP-AMBULANCE MANUAL TIRE
MANUFACTURING OF THE TIRE
END RESULT • The CooP-Ambulance can now be connected to every bicycle • Make a test ride with the CooP-Ambulance • Check all connections, bolts and nuts
96
97
#
LIST OF MATERIALS
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LAY OUT CANVAS CANOPY (FOR SOWING MAN) • The grey rectangles indicate the location where the ‘tunnels’ should be placed (on the inside!), these tunnels should be big enough to fit a rubber band (±4 inch).
10
0°
TEMPLATE 100º
10 inch
9 inch
102
9 inch
10 inch
• The orange parts are ropes and loops to role up the canvas
LAY OUT CANVAS STRETCHER(FOR SOWING MAN) • The grey rectangles indicate the location where the ‘tunnels’ should be placed (on the inside!), these tunnels should be big enough to fit a rubber band (±4 inch).
Backrest
Stretcher