One of SDC’s long-term customers that manufactures corrugated tubing for appliances needed a machine to assemble, print mark, and perform testing on their product. Having already built similar systems for this customer, we approached this project with a deep understanding of product specifications and the requirements of this custom hose assembly and testing machine.
This fully automated assembly machine had two main tasks – to assemble and test. Due to the nature of the parts being assembled, spin welding was the best option to join the two together. Two different tests to be performed were compression and leak testing. Additional stations included print marking and sortation of the assembled product.
The SDC team developed a comprehensive assembly and test machine with five process stations. Fed by the customer’s extruder line which makes the drain tubes out of corrugated rubber, the tubes enter the machine by a belt conveyor. While on the conveyor, a Cognex camera takes a picture of the front and back of the tube to determine orientation and verify cut length. A FANUC SCARA robot picks good parts off the conveyor belt and places them onto the servo indexing conveyor.
A compression test measures the deflection of the top of the part under low and high pressure by using Keyence high accuracy touch probes. Another station with two mounted spin welders join the drain connector to the tube. This is accomplished by a multi axis servo system spinning the fitting at a high speed while inserting into the tube. The tube is then marked by an ink jet mark application and verified by two Cognex cameras. A servo pick-and-place transfers the parts into a 6-up air leak test where part presence is verified using photoelectric sensors. The process station locates the tubes by using a 2-axis pneumatic pusher. Parts are then sorted accordingly.
Rather than having multiple units of equipment taking up room on the manufacturing floor, this single automated machine includes all the necessary steps post-extrusion to ensure quality parts with high-speed production.
Key benefits:
✅ Smaller footprint — replaces multiple machines, saving floor space
✅ Upskills labor — operators manage smarter systems instead of manual tasks
✅ More powerful PLC — improved control and system performance
✅ Easy sortation — automatic sorting of pass/fail parts
✅ Less part handling — reduced manual labor increases part quality
✅ High-speed production — consistent, reliable output at scale
Compression test – Touch probes measure applied pressure to the corrugated rubber tubing.
Parts feeding system – Vibratory Feeder Bowl with proper part orientation and inline feed track. There is a singulating mechanism and shuttle to load the spin weld station.
Spin weld station – Spin weld assembly where the hose is gripped on the indexing conveyor for the process.
Orientation line mark station – Two Keyence inkjet printers apply a line and customer-specific data.
Low friction crossed-roller slide with pneumatic clamps – a two-stage process to load parts from the spin welding station to the air leak test, then to the sortation area.
6-up CTS (Cincinnati Test Systems) air leak test – Each unit is individually mounted with compliance to linear slides and is tooled to plug the inside diameter on both ends of the hose. This hose is tested to max 15 PSI.
Part sorting – The transfer removes the completed product from the air test nests and drops them in designated “pass/fail” locations. Individual parts can be sorted based on the programmable motion of the slide and individual gripper control.
This custom automated assembly machine helps our appliance manufacturing customer save space, time, and labor. By combining important steps like spin welding, part marking, and leak testing into one machine, the SDC team made sure every hose assembly was strong, airtight, and ready to use. The machine checks that parts do not burst under pressure and stay connected tightly, which is key for making safe and reliable products.
With automated testing and part sorting built into the system, the customer can now produce 24 parts every minute with fewer errors and higher quality. Instead of needing several machines, they now use one smart solution that does it all. This helps workers focus on skilled tasks while the machine handles the tough job. The result is a faster, cleaner, and smarter way to build hose assemblies for appliance use.
A: This custom automation solution was designed specifically for home appliance manufacturing. It assembles hose assemblies using spin welding, performs part marking, and runs automated testing like compression and leak tests. Finally, it sorts the parts into pass or fail categories—all in one streamlined system.
A: Spin welding is used because it creates a strong, airtight seal between the drain connector and the corrugated hose. This method is ideal for rubber parts in hose assemblies, especially in applications that require reliable connections for appliances.
A: The machine uses custom automation to perform compression tests and leak tests on every hose assembly. Touch probes measure how much the part bends under pressure, and cameras confirm correct part marking and orientation. It seals both ends of the tube and applies air pressure to check for leaks and burst resistance.
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A: The automated assembly machine operates at 24 parts per minute, with a fast 2.5-second cycle time. This high-speed output helps appliance manufacturers keep up with production demands while ensuring every hose assembly meets strict quality standards.
A: Instead of relying on several individual machines, a custom automation solution brought post-extrusion steps—assembly, testing, and part sorting—into one streamlined system. This improved efficiency, reduced part handling, and freed up valuable floor space in the manufacturing environment.
