Aluminium frame structures, easy ways to improve your assembly process

There is much that can be done to streamline the construction of aluminium profiles. Good technical drawings of the right quality is an important factor for subsequent steps in production. Smart accessories that simplify assembly are another. Our colleague Niclas tells us more.

Niclas Hellgren has been working at Rollco for several years, first as a fitter and now at technical support. He comes into contact daily with aluminium constructions that Rollco manufactures for its customers. We took the opportunity to speak with him and tap into his expertise in the field. We asked if he had any tips to share on the assembly and construction of aluminium frame structures.

Niclas 3 tips for design engineers (and fitters...)

• Always use a footplate when mounting a foot
  So, what is a footplate? A foot plate is used when mounting a foot on an aluminium stand, especially if there is a long thread on the foot. It makes the assembly itself easier and it also becomes easier to adjust the foot afterwards. 
  – When you use a foot plate, you avoid threading the profile, says Niclas. Note that it adds some extra millimetres in height. You therefore need to include it in your drawing right from the start, otherwise you will be forced to redesign your construction when it is time to assemble. The footplate is available in three different profile sizes, 40x40, 40x80 and 80x80.
  
  
• Draw profile by profile - save time and minimize the risk of errors
  Often, you come across drawings that show a complete aluminium stand, known as an overview drawing. These drawings have small annotations that describe each part to be made, placed next to the relevant component. The more parts and elements the drawing includes, the higher the risk of errors when reading it in the workshop.
  A better approach is to have a drawing that shows each profile individually, i.e. a separate drawing for each part of the construction that requires processing. This minimizes the risk of the operator, for example, drilling into the wrong profile or making another mistake that could lead to a part being discarded.
  – It places higher demands on the designer who draws, but it pays off, says Niclas. It improves the quality at all subsequent stages. An error, such as drilling incorrectly, might not be noticed until the final assembly, which can be costly in terms of new materials and delayed delivery. Aim to get it right from the beginning, Niclas advises.
  
  
• Assemble according to a CAD model instead of paper drawing
  – It may sound like an obvious thing, but a paper drawing only has two dimensions, you cannot spin the stand on a paper outline no matter how hard you try. Nevertheless, you often still see 2D, paper drawings. So why are 2D drawings on paper still used in many manufacturing processes? Old habits, tradition and resistance to change are probably some of the reasons, Niclas believes. It takes time to adapt to new ways of working. 
  
  Especially when it comes to larger, more complicated structures, a 3D model on a computer can help the fitter enormously. A 3D drawing can be inspected from all sides and angles. All fitters at Rollco have been trained in reading drawings and have a good ability to interpret even digital 3D drawings, says Niclas.