On the whole, there are a number of desirable places in the carburetor department which are well suited for handicapped men. The working conditions in these factories are good and the wages paid are about the same as those paid by any general assembly or manufacturing plant.
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.