Our established customer in global industrial technology needed an addition to their line of automated machines in the United States. This semi-automated machine that is focused on digital transformation of energy management is one of many machines supporting their smart factory initiative, meaning this machine needed to have IIoT (Industrial Internet of Things) capabilities.
This customer required a company who was experienced with Yaskawa Motoman robotics. Our team was a good fit due to working with these robots in the past and recently reestablishing our integrator status in their Yaskawa Motoman Partner Program.
Our customer needed a machine to perform the tedious and rigorous task of assembling an electrical safety switch. The key challenges included:
With years of experience building and optimizing our own technology, several of our highly beneficial pre-engineered solutions were the perfect integration for this project, among others. We incorporated the following key technologies:
SDC Flex Feeding with Hybrid Bin-picking:
Grease Dispensing:
Component Loading, Screwdriving, and Nutrunning:
Inspection and Testing:
Our SDC Flex Feeding systems are engineered to deliver a continuous supply of pickable parts, eliminating robotic wait times and maximizing pick rates for unmatched efficiency. Designed to keep parts moving seamlessly through your production process, our systems ensure that robots operate at peak performance with minimal downtime, significantly improving overall productivity.
These systems are constructed with carefully selected components that gently process small to medium-sized parts, regardless of shape or size. Leveraging decades of expertise, we’ve created a proven system that handles a wide variety of parts, ensuring smooth and reliable part delivery for your applications.
The SDC two-axis, servo-driven pick-and-place is engineered for peak performance while keeping costs down, making it the ideal solution for high-speed operations. Operating in parallel with an SDC Tray Handler and Fanuc SCARA robot, each unit delivers efficient part transfer with minimal downtime.
he 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 that supports multiple process configurations, enabling automated electrical device assembly with high throughput and repeatability.
This is operational efficiency optimization in action. The implementation of SDC’s automated solution resulted in significant operational improvements. By integrating advanced technologies, we’ve created a system that offers:
The successful delivery of this semi-automated assembly machine showcases how SDC’s standard platforms, integrated automated technology, and automation expertise come together to solve modern manufacturing challenges. By combining advanced robotics, precision parts feeding, and high-speed indexing with IIoT-ready architecture, we not only met the demanding requirements of our customer’s smart factory initiative but set a new benchmark for what adaptive automation can achieve.
Through seamless collaboration, strategic use of proven technologies, and an unwavering focus on efficiency, this system now produces 3,000 parts per day at an impressive 94% efficiency rate – all without the need for overtime labor. SDC’s modular and scalable approach ensured minimized engineering risk, accelerated deployment, and long-term value, helping our customer take another confident step forward in their digital transformation journey.
This project demonstrates how future-ready automation is about smart solutions, strategic partnerships, and engineering excellence built to last.
A: This machine was one of several SDC built for this customer that all serve a different purpose in their manufacturing facility. With the goal of automating and optimizing their facility, our highly successful machines exceed customer expectations, leading to additional automation projects and a long-term partnership.
A: The main challenges included:
A: The system integrated a Yaskawa Motoman 6-axis and SCARA robot, automated grease dispenser, Bellco vibratory feeder bowls with linear tracks, Deprag screwdrivers and nutrunners with part feeding systems, hipot testing, inspection stations, and Modicon Megelis HMI and PLC.
A: By leveraging our pre-engineered flex feeding systems, servo-driven pick-and-place solutions, and indexing ring, we minimized custom engineering work, ensuring a cost-effective, streamlined, and reliable solution. These proven technologies eliminated major design risks and accelerated implementation.
A: Production rate is now 3,000 parts per day with 94% efficiency rate with improved connectivity from the manufacturing floor to our customer’s IIoT ecosystem. This machine replaces a legacy system that was in operation for over 40 years, offering at least twice the throughput and close to double the efficiency of the previous equipment.
A: This machine is a standalone unit designed to produce disconnect switches, which are later integrated into the final disconnect assemblies within metal housings. It operates independently and does not directly interface with any other systems in the current production line.
A: Yes! Our automation expertise spans multiple industries, including medical devices, consumer goods, electronics, and more. We specialize in tailored automated solutions for high-speed, precision manufacturing needs.
