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.
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:
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.
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
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.
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.
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.
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.
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.
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.
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.
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.
