One Thousand Ways to Make a Living; or, An Encyclopædia of Plans to Make Money

by Harold Morse Dunphy

PLAN No. 1132. IGNITION

A number of factories make a specialty of building ignition apparatus for automobiles. In them we find the usual organization found in other similar factories. Some of these factories build ignition systems on a large scale, in which case the organization is elaborate.

One of the most important factors of the ignition system is the insulation. A compound has been discovered, known as “bakelite,” which has a very high resistance to electricity. This substance usually comes to the manufacturer in powdered form and the manufacturer puts it through his mixing process.

The bakelite for parts to be made is carefully weighed for each piece. It is then placed in jigs which hold contacts, segments, etc. The jigs or molds are then placed in a molding machine to which is applied considerable pressure and heat. The heat causes the bakelite to run together, forming one solid piece of material when it is properly cured. After the standard heat has been applied to the bakelite for the proper length of time the mold is placed in another press and cold water is run around it to chill or set the bakelite. The molded part is then removed from the press and is ready for inspection.

When the part comes from the mold it is very shiny and smooth in appearance. The inspection of this part is to determine whether or not the contacts have stayed in proper position and whether or not there are any flaws in the bakelite. Bakelite parts are used in many places in the ignition system. There are a number of places in the bakelite section of the ignition factory where disabled men might well find employment.

Men with one leg could weigh out the bakelite, and a man with one leg and one arm could possibly run the presses around the bakelite for curing. This work is done in a dry department; the conditions are very good and the wages are reasonable.

In the coil department of the ignition factories we find various types of work going on. Here are machines for winding the primary and secondary coils, testing machines, etc. The ignition coil is made up of an iron core, an insulator around the iron core, a primary winding, a secondary winding, and a condenser. Some coils have vibrators attached, in which case the vibrators are mounted on the outside of the coil windings.

The core of the coil is made up of a bundle of soft iron wires. The fiber tube is commonly used as insulating material. This tube is filled with the soft iron wire. The primary winding, of which there are about two layers, is wound on the outside of the fiber tube. This operation takes but a few seconds, the tube being placed between a pair of centers on a small motor driven machine similar to a small lathe. The wire is guided on to this tube while it is revolving. This work is done sitting, and could very well be done by men who have received injuries to their legs, or by men who have received injuries to their spine. The main requirements are that the operator shall have the free use of both hands, and be able to see properly the work that is going on.

The secondary or high-tension winding of the coil is similar to the low-tension winding. The high-tension winding, however, has many turns of very fine wire no larger than the ordinary thread used on sewing machines. This wire is insulated, and care must be exercised that the insulation is not broken. The secondary winding also is wound on a fiber tube on a machine similar to that on which the primary coil is wound. Between each layer of wire in these windings a small strip of insulation is placed. This, of course, is done at the end of each layer of wire. In carrying out this operation the operator must be very careful that the insulation is not broken; that the insulation is properly placed, and that the layers of wire are smooth and uniform.

The condenser of the ignition coil is made of two layers of tin foil and several layers of insulation, such as paraffin paper. This operation requires a person who is very careful, since if this particular part is not carefully constructed it will not function properly. The condenser is also machine wound in a number of cases, and skill comes with practice in this work.

Requirements for this job are about the same as found in the coil winding, viz., that the operator must have the free use of both hands, and be able to watch his work carefully.

After these various parts have been made in their respective departments they are ready for the industrial tests. This is done with meters to determine the amount of resistance that each coil has. If the resistance is not the same as found in other coils, the insulation is broken or the coil is shorted, in which case the coil is rejected. The condenser test is somewhat different. Here we find that special meters are used for determining the capacity. These testing operations require a man who has been trained for this particular job. The work is usually done sitting down.

After these various parts have passed inspection they are sent to the coil assembly, where they are put together in their proper relation. Where the coil is a box coil, the windings and condenser are placed in a box and hot paraffin or an insulating compound is poured into the box. After it has cooled all the ignition parts are held securely in place. The coil is then finished and is ready for the final test. This work is all light work, and there are a number of positions in which handicapped men could be employed.

In another part of the ignition factory, we find the breaker mechanism and other ignition apparatus being manufactured. This mechanism requires considerable machine work, which is done on special machines in the machine-shop department. After these parts have been machined and inspected they come through the assembly department, where the ignition apparatus is assembled. Here we find the workers at benches assembling the very fine delicate parts of the apparatus. The small springs, platinum points, screws, etc., must be placed in their proper places and with proper tension. After the ignition apparatus has been properly assembled it is inspected, and then goes to the testing department, where apparatus is tested as to its efficiency, etc.

In another department, wires are cut and made into proper lengths for certain ignition jobs. Here the terminals are soldered to the ends of the wires. Sometimes these operations are done on a conveyer system. This work is done sitting, and is well adapted to disabled men.

In the ignition, assembly, inspection, and testing departments, there are a number of operations that could be done by men with one arm and no legs, one leg and two arms, one eye, one arm and one leg, by men who have lost their hearing, and even by men who have been blinded. The work as found in the ignition department is light, working conditions are good, and the pay is average.

Where the ignition manufacturer manufactures magnetos, we find a little different class of work going on. Armatures are wound with primary and secondary windings, and this is done on a somewhat specialized machine. Insulation, also, is somewhat specialized, and assembly work differs somewhat from other assembly work. Magnetos must be made, charged, and tested. Condensers are of a special design. As a whole, however, the work in the magneto department requires about the same class of workmen as are found in the ignition department.