A returning SDC customer in the thermal heating industry needed a fully automated production line to improve a time-consuming manual process. The system was developed to streamline the manufacturing of a thermal heating component (burner) and increase throughput to meet rising demand. Due to its difficult and complex nature, the process had not been automated before.
With a wide variety of product sizes and challenging assembly steps, SDC developed a custom flexible manufacturing system featuring easy mechanical changeover. This approach enabled the machine to produce more than 20 different burner sizes with minimal operator input.
To simplify the complexity, the machine was designed as three individual cells—two for subassembly and one for final assembly. Each cell supports standalone operation or can run as part of the complete robotic automation system, forming a seamless fully automated production line. Integrated conveyors move parts between cells, while manual load/unload stations give operators hands-on access when needed.
SDC found an effective solution including multiple assembly cells utilizing robotic integration. Our team engineered, designed, and built a fully automated assembly system to produce a thermal heating component, commonly known as a burner. The total machine footprint came to 40’ x 28’ and was built in an “L” shape to suit the space requirements of the customer’s facility.
The machine supports a flexible manufacturing system with quick tooling changeover for over 20 burner sizes. Operators use a simple pin-and-hole method to adjust tooling based on pan sizes ranging from 7.5″ to 11.5″. Each station was customized for metal manipulation, including crimping, forming, and staking, depending on the subassembly. Advanced automated welding and inspection processes were integrated to ensure high product consistency and safety.
The overall machine consisted of two subassembly cells and a final assembly cell with a series of conveyors moving parts between cells. Using a three-system approach allows the machine to run in a fully automatic mode and is equipped with the necessary communication to manage a queue of parts between the cells. This also allows the system to run in a semi-automated mode, enabling each cell to operate individually to produce their respective subassemblies.
Key Solutions:
The fully automated production line successfully replaced a labor-intensive manual process, significantly improving throughput for an essential product line in the thermal heating industry. Designed as a flexible manufacturing system, the machine allows simple mechanical changeover to produce over 20 burner sizes with minimal downtime, offering both full automation and semi-automated flexibility based on production needs.
Key Results:
Cell 1: Robotic Tube Processing
Cell 2: Robotic Pan Sub-assembly
Cell 3: Final Assembly
Capacity to tie in a future automation cell for additional riveting to another series of burner. This project demonstrated how robotic automation systems can transform a previously manual, complex process into a streamlined, high-throughput solution. By integrating automated welding, precision tooling, and automated inspection into a fully automated production line, the customer achieved significant improvements in efficiency, safety, and product consistency.
With its flexible manufacturing system, the machine can quickly adapt to over 20 burner sizes, allowing the customer to meet shifting production demands without extensive downtime. Designed for scalability, the system also has the capacity to integrate future automation cells, ensuring long-term value and adaptability in a rapidly evolving manufacturing environment.
A: Very flexible. The custom tooling allows quick changeovers to accommodate over 20 burner sizes ranging from 7.5″ to 11.5″, making it a highly adaptable flexible manufacturing system.
A: The system uses five FANUC 6-axis robotic arms for various tasks like material handling, automated welding, and robotic assembly, ensuring high-speed and consistent operation across all stations.
A: Yes. Each cell can function independently or together as a fully automated production line. Manual load/unload stations are built in, allowing for semi-automated operation when needed.
A: Key benefits include faster production (1 part every 18 seconds), reduced labor demands, enhanced safety, space efficiency, and the ability to scale or integrate additional automation cells in the future.
A: Yes. The modular design supports expansion, such as adding future automation cells for additional processes like riveting. This makes it a smart long-term investment in manufacturing automation.
