Overhead view of a complex automated assembly machine enclosed in a transparent safety cage. Inside, robotic arms and various mechanical components work in a circular arrangement on a large, rotating metallic table.

Hose Clamp Assembly Machine

High-torque Hose Clamp Assembly Machine

This machine was custom designed and built for our customer that specializes in after-market clamps and connectors supplied to industries like aerospace, military, marine, and more. Having recently built a similar machine for this customer, the project timeline was significantly shortened and cost-effective. With improvements and equipment updates, our automated solution was the perfect addition to their production line. This is a great example of how automation is shaping industrial and consumer product manufacturing.

Technical Components & Technologies

Durant Tool Company dual spindle uncoiler with variable proportional speed control
PA Industries 5300 Advantage Feeder with coil straightener
SEYI SN1-66 Mechanical Press
SDC Indexing Ring
Servo screwdriving and curling station with linear actuation
Allen-Bradley PLC & HMI
Two vibratory feeder bowls

The Machine Concept:

Built on our pre-engineered SDC Indexing Ring, this machine needed to accommodate 36 product nests and 72 assembly fixtures. Out of these fixtures, automated equipment like uncoilers, a punch stamp, a mechanical press, screwdriving, a product curling station, and testing and inspection needed to be included. The key challenges included:

  • Coil feeding and straightening for stamping and cutting to be performed before entering the machine
  • Housing and screw parts feeding for pick-and-place servos
  • Precision fastening systems, coil curling and screwdriving
  • Testing and inspection stations

The Solution:

SDC's automated assembly machine was built with the future in mind

On this assembly machine, the first component, referred to as the housing, is placed into a nest on the indexing dial by a custom mechanical gripper. At the next station, an uncoiler/decoiler feeds the metal band into a straightener, then a SEYI press. The strip is stamped, cut, and fed into the housing. Verifying correct placement, the part is moved through the machine.

A custom curling station utilizes a linear motor to curl the bands to varying diameters with no mechanical change-over necessary. Parameters are communicated by our programming software to achieve the proper curl of the band based on the specified part size.

The screw drive station uses multiple mechanisms in sequence to capture the free end of the band. Once the band is captured, it is guided into the housing. Simultaneously, a servo driven tool rotates the screw to engage the band and feed it through the housing, producing the finished part. There is an advanced feature where the camera will send data to the PLC to position the band based on operator input of required screw revolutions.

This flexible manufacturing system (FMS) utilizes a combination of quick-change tooling and programmable, soft change-over technologies, like servo driven part handling and curling to accommodate over 20 product sizes with minimal change-over.

Results & Business Impact:

This machine had a minimum efficiency of 98% for the different part sizes the machine was required to run.

Machine rate – 52 parts per minute

SDC Standard Product:

3D rendering of an SDC Indexing Ring with an SDC servo motor

SDC Indexing Ring

The SDC Indexing Ring is a custom-built, high-speed assembly machine platform designed to meet the unique specifications of each client. Built with an extremely flexible footprint, the open-ring design allows workstation modules to be placed both inside and outside the ring, enabling a wide range of assembly and processing configurations.

The SDC Ring Indexer’s heavy steel frame, precision components, and customized tooling are meticulously designed, assembled, and tested to meet or exceed required specifications. A robust, modular platform supports multiple process configurations, providing automation solutions for consumer goods manufacturing like this with high throughput and repeatability.

  • Smart Automation: SDC Ring Indexer’s Adaptable Tooling Suite: To enhance its capabilities, the SDC Ring Indexer can integrate a variety of tools, including vibratory and linear feeders, mechanical presses, custom conveyors, vision systems, and multi-part tooling. These components are selected and incorporated based on the specific needs of the application, ensuring precise handling, accurate assembly, and reliable processing.
  • Versatile Performance for Modern Manufacturing: The SDC Ring Indexer also excels in industries requiring fast changeovers and high-volume production. In this case, it facilitates quick tooling changes to accommodate different part sizes and assemblies, while its durable construction ensures long-lasting reliability with minimal maintenance.
  • Servo Pick-and-Place Arm: The servo-driven pick-and-place arms designed by SDC offer precise, repeatable motion at high speeds. It’s customizable, reliable, and fits well into operations where both accuracy and cycle time matter. With low cost and high repeatability, these systems provide a versatile, value-driven solution for optimized manufacturing.

Conclusion

This high-speed assembly machine showcases a specialized and efficient automation solution built upon SDC’s Indexing Ring platform. The machine’s design not only addressed the complexity of accommodating 36 product nests and 72 assembly fixtures but also integrated sophisticated processes including coil feeding, stamping, screwdriving, curling, and in-line inspection. Every stage, from the decoiler to the testing stations, was designed to work in seamless coordination, reflecting a strong emphasis on precision, speed, and flexibility.

What sets this solution apart is its ability to handle over 20 different product sizes with minimal mechanical changeover, thanks to smart automation features such as servo-driven motion systems, testing and inspection stations, and programmable parameters. These innovations allowed for greater control and customization, ensuring that each component was assembled with high accuracy while reducing downtime. The design exemplifies the system’s adaptability and forward-thinking engineering to accommodate an array of product sizes.

Ultimately, the successful implementation of this assembly machine underscores the value of SDC’s modular, high-performance Indexing Ring and smart tooling integration. By combining robust mechanical design with advanced automation technologies, SDC delivered a flexible manufacturing system capable of meeting evolving production demands with consistency and reliability. This case illustrates not only the power of custom automation in modern manufacturing but also the strategic importance of scalable, reconfigurable platforms in driving long-term operational efficiency.

FAQs (Frequently Asked Questions):

Q: What was the goal of this project?

A: The primary goal was to design and build a high-speed, high-torque hose clamp assembly machine tailored for a customer in the aftermarket clamp and connector industry, with a focus on flexibility, efficiency, and scalability.

Q: Why was the SDC Indexing Ring chosen as the machine platform?

A: The SDC Indexing Ring was selected for its modular, high-speed capabilities and flexibility. Its open-ring design allows for a versatile arrangement of tooling modules, making it ideal for complex assembly processes with high throughput.

Q: What industries benefit from this type of automation?

A: This type of automation solution can be applied to all different manufacturing industries like automotive, consumer products, electronics, aerospace, and more requiring precision-manufacturing with strict quality control.

Q: What automation technologies are integrated into the machine?

A: The system includes servo-driven screwdriving and curling stations, a mechanical press, pick-and-place arms, coil feeders, barcode labeling, vision inspection, and Allen-Bradley PLC/HMI for centralized control.

Q: What challenges did this machine help the customer overcome?

A: Key challenges included integrating multiple parts feeding systems, achieving precise screw engagement and band curling, and enabling automated handling of diverse part geometries—all solved with smart automation and innovative design.

Q: What was the business impact of this solution?

A: The machine significantly reduced production time and cost, increased reliability, and allowed for scalable growth by enabling rapid adaptation to new product lines, reinforcing the strategic value of custom automation.

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