Assembly line, enclosed in a transparent safety cage, features two yellow robotic arms. One arm is actively working on a component on a conveyor belt, while the other is staged nearby.

Automated Medical Tube Assembly

Custom Automated Solution for a Medical Equipment Manufacturer

A long-standing customer in the medical equipment manufacturing industry approached SDC to expand their production capabilities with an additional custom automated solution. The goal was to improve throughput, reduce manual labor, and automate a previously labor-intensive process involving medical tubing.

With extensive experience designing automated manufacturing machines for this customer—including prior systems for similar applications—SDC was able to streamline the development process. Only minor updates were needed to tailor the system to their current production goals, accelerating deployment and minimizing engineering risk for advanced medical tube assembly.

Technical Components & Technologies

Three FANUC LR Mate 200 iD robots
FANUC vision with Banner lighting
Two Performance Feeders vibratory bowl feeders
Custom Servo-driven tube dereeling and cutting system
Weighted dancer on tube dereeler
Allen Bradley PLC and HMI
Custom sky hook

The Machine Concept:

The advanced medical tube assembly system needed to meet several critical requirements to ensure reliable, high-throughput performance. It had to feed, cut, and assemble tubing components that are notoriously sticky and prone to tangling without operator intervention.

This automated medical tube assembly system needed to integrate robotic pick-and-place operations, precision tube feeding and cutting, dual solvent application, and vision-guided alignment for consistent, accurate assembly. It also needed to maintain a production rate of 240 assembled parts per hour with minimal operator oversight. Drawing from experience with similar automation challenges, our team was able to define and propose a robust machine concept quickly.

The Solution:

High-precision medical tube assembly graphic of key integrated technologies

SDC engineered an advanced, high-precision medical tube assembly with cleanroom compatibility built for the life sciences industry. The design addressed the unique challenges of medical tubing—tangling, sticking, and tight tolerances—through several key technologies:

  • Hose Dereeling & Tension Control System
    • Enclosed custom rotary dereeler
    • Weighted dancer, or weighted tension arm to maintain and measure slack
  • Tube Cutting & Inspection
    • Integrated servo cutter and vision system for real-time measurement feedback.
  • Solvent Dipping/Dispensing Station
    • Dual dipping stations with timing and position control.
  • Robotic Assembly Stations
    • Custom sky hook to grasp the slack portion of the tube during robotic handling to maintain location and orientation
    • Three FANUC LR Mate 200 iD robots with dedicated tasks:
        • Synchronous tube picking/dipping/placing
        • Y-port insertion
        • Final product transfer
  • Feeding Systems
    • Vibratory bowl for rigid components
    • Vertically oriented part separating/detangling infeed conveyor for difficult to feed y-ports
    • SDC Flex Feeding systems with integrated vision system for optimal robotic part picking
  • Vision Systems
    • Inline tube measurement
    • Part feeding accuracy
    • Y-port detection and part presence confirmation

Results & Business Impact:

The implementation of SDC’s automatic medical feed tube assembly machine delivered immediate and measurable benefits:

  • Consistent output of 240 assemblies per hour
  • Drastic reduction in manual labor and human error
  • Streamlined production flow with fewer quality control issues
  • Improved overall equipment effectiveness (OEE)
  • Increased capacity without expanding labor or facility space
  • Significant boost in production efficiency

This robust, fully automated system provided the client with a scalable, future-ready solution tailored to the challenges of medical tube assembly. Leveraging our library of proven designs, SDC delivered results faster and more cost-effectively, helping our customer meet growing product demand and position themselves for continued success in the competitive medical equipment manufacturing market.

Operational Workflow:

  • Tube Handling & Cutting
    • Input: Medical-grade flexible tubing on coiled spools (sticky surface, prone to tangling).
    • Action: Automatically dereel and straighten tubing with weighted tension.
    • Measurement: Use vision inspection to verify tube length and cut accuracy.
    • Output: Precisely cut tube segments ready for solvent dipping and assembly.
  • Solvent Application
    • Process: Dip both ends of the tube into a medical-grade primer/solvent using synchronized robotic arms.
    • Requirements: Ensure precise dip depth and contact time; eliminate contamination or overflow.
  • Feed Set Part Supply
    • Source: Two vibratory feeder bowls deliver the feed set components—each with a unique geometry—to dedicated pick stations.
    • Purpose: Provide accurate, continuous part orientation and supply for robotic insertion of the medical tube.
  • Assembly into Feed Set
    • Action: Insert solvent-treated tubing into feed set fittings using robotic placement.
    • Accuracy: Placement must be gentle yet firm enough to create a reliable seal.

SDC Standard Products: Eliminating Engineering Risk with Proven Solutions

SDC Flex Feeding:

Our SDC Flex Feeding systems are engineered to provide a continuous, uninterrupted supply of pickable parts, eliminating robotic wait times and maximizing robotic pick rates. Designed to seamlessly integrate with automated manufacturing solutions, our systems enhance efficiency, ensure minimal downtime, and boost overall productivity for life sciences and medical equipment manufacturing.

The SDC Flex Feeder is built to handle a wide variety of part shapes and sizes with precision. Leveraging decades of expertise, we deliver a proven parts feeding solution that optimizes the flow of small to medium-sized parts through the production process. Whether working with complex geometries or varying part orientations, our flex feeding systems are engineered to keep parts moving smoothly, ensuring peak performance in advanced automated assembly and packaging applications.

Key Features of the SDC Flex Feeding System:
  1. Continuous and Uninterrupted Part Supply
    • The SDC Flex Feeder ensures a steady flow of pickable parts, maximizing robotic pick rates and preventing costly downtime. This automated parts feeding system keeps production moving efficiently, optimizing throughput.
  2. Handles Complex Part Shapes with Vision Guidance
    • Our system is equipped with vision guidance technology that helps robots accurately pick parts with complex shapes, sizes, or orientations. This feature is crucial for life sciences and medical equipment manufacturing automation, where part variability can be a challenge.
  3. Smart Conveyor Technology with Automated Part Re-orientation
    • The integrated smart conveyor system with the SDC Flex Feeder automatically cycles parts to improve pickability through repositioning. By ensuring that parts are consistently presented in the optimal orientation, this technology reduces errors and improves efficiency in both industrial and consumer product manufacturing.
  4. Seamless Robotic Integration and High-Speed Performance
    • Designed for high-speed performance, the SDC Flex Feeder integrates seamlessly with various robotic systems. With built-in accumulation and buffering, it supports high-speed pick-and-place applications, boosting production flow and maximizing throughput in consumer goods manufacturing.

Whether streamlining an automated production line or enhancing part feeding, the SDC Flex Feeder provides the reliability and efficiency needed for optimal productivity in our automated manufacturing machines.

Conclusion:

From a business standpoint, the machine enabled the client to scale production capacity without increasing labor costs or expanding floor space. The reliable, repeatable nature of the automation system improved overall equipment effectiveness (OEE) and allowed for better resource planning and uptime.

The integration of three FANUC robots, SDC Flex Feeding, precision tube cutting with real-time vision feedback, and unique automated parts feeding allowed the customer to maintain high product quality while reducing operator involvement and minimizing error rates. As a result, a more predictable and streamlined production workflow was achieved with fewer quality control issues and reduced rework.

Additionally, SDC’s ability to leverage prior machine designs meant faster project deployment and reduced engineering costs. By automating a once challenging and labor-intensive process, our customer not only met rising product demand but also positioned themselves for long-term growth in the competitive medical equipment manufacturing industry.

FAQ’s (Frequently Asked Questions)

Q: What challenges does this automated medical tube assembly system solve?

A: This system addresses the common issues of handling sticky, flexible tubing that tends to tangle and cause assembly delays. It automates tube feeding, cutting, solvent application, and insertion with robotic precision. As a result, it improves consistency, eliminates bottlenecks, and significantly reduces labor costs.

 

Q: How does the Flex Feeding system improve part handling?

A: The SDC Flex Feeding system uses smart conveyor technology and integrated vision to automatically orient and present parts for robotic picking. It ensures a continuous, high-speed supply of components, even those with complex geometries. This eliminates robotic wait time and boosts overall machine throughput.

 

Q: What production rate can be achieved with this automated system?

A: The machine is designed to maintain a steady output of 240 assembled parts per hour with minimal operator oversight. This high throughput allows manufacturers to scale operations without increasing labor or floor space. It’s ideal for fast-paced medical equipment manufacturing environments.

 

Q: Is this solution customizable for different tube assembly applications?

A: Absolutely! SDC specializes in custom automated solutions tailored to unique production needs. Whether it’s different tube materials, sizes, or assembly configurations, the system can be modified to fit a variety of medical or life sciences applications and more. Our modular approach also supports future upgrades and expansion.

 

Q: What is the business impact of implementing automated manufacturing machines like this?

A: Automation improves efficiency, reduces operational costs, and enhances product quality by minimizing human error. With repeatable processes and real-time quality checks, manufacturers gain better control over production outcomes. Long term, this leads to improved OEE (Overall Equipment Effectiveness) and faster ROI.

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