The challenge
Manually assembling a corrugated tube with a rubber ring, a connector and four cable ties took ~80 s/part and required 4 operators. Fitting the ties at different angular orientations ruled out simple automation.
The outcome
We designed and commissioned an assembly machine made up of two stations linked by an automatic transport manipulator. The first station fits the rubber ring and the connector onto the corrugated tube using our own internal expansion system. At the second station, a three-position Weiss index table handles automatic forming, tightening and cutting of four cable ties at different angular orientations.
The first station fits a rubber ring and a plastic connector onto an automatically fed corrugated tube. The key element was the system we developed for expanding the tube from the inside, which gives it the right tension and stabilises it during assembly.
Once the first stage is complete, the part is moved automatically to the second station with a three-position Weiss index table. The operator places the cable ties in their seats - forming, routing, tightening, cutting and positioning happen entirely automatically. The tube is additionally rotated around its own axis, which allows ties to be fitted at various angles. The final stage is marking the part, quality control and automatic sorting into OK/NOK containers.
- automatic feeding and separation of corrugated tubes from a belt feeder
- in-house system for expanding the tube from the inside, stabilising it while the ring is fitted
- automatic assembly of subcomponents based on pneumatic actuators and a Festo servo drive
- Hiwin manipulator for moving parts between stations
- three-position Weiss index table allowing successive operations to run in parallel
- in-house unit for automatic cable tie forming - tightening and cutting
- repeated tube rotation allowing ties to be set at different angular orientations
- Baumer strain-gauge measurement of the tightening force of every tie
- Keyence vision systems checking assembly and marking correctness
- Hitachi inkjet printer for marking the finished product
- automatic sorting and packing of OK and NOK products
- safety curtains and working zones allowing safe operator interaction with the machine
What set this project apart?
Unlike typical assembly projects, the greatest challenge was not joining the components itself, but handling a flexible part that had to be repositioned and rotated repeatedly across successive operations.
A particularly demanding task was developing a system for automatically forming and tightening cable ties fitted at different angular orientations along the whole length of the tube, given the significant geometric variation and the lack of repeatability between components.
Designing the system for fitting the rubber ring onto the flexible corrugated tube was also a major engineering challenge. The internal expansion mechanism we used stabilised the part and created the right conditions for precise assembly despite the very high coefficient of friction.
The project stood out for its extensive quality control: measurement of tie tightening force, part length verification, print correctness control and automatic rejection of products that fail the requirements.
A few numbers that sum this project up:
- Manual assembly time
- 80 s/pc
- Assembly time on the machine
- 20 s/pc
- Cycle time reduction
- 72%
- Ties fitted automatically
- 4 pcs
- Index table stations
- 3
- Quality control
- 100% of production
Results of the implementation
- 1 operator replacing the work of 4
- Threefold increase in process throughput
- The most demanding manual assembly operations eliminated
- Repeatable tie assembly in multiple angular orientations
- Stable ring assembly thanks to the dedicated tube expansion system
- Tightening force controlled for every cable tie
- Automatic verification of product marking
- Full quality control with automatic rejection of NOK parts
- Greater repeatability and reliability of the production process
- Lower risk of operator error
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Industrial automation projects - ATIV technical documentation
We document how the automation projects we deliver for clients across industry actually ran. Each description covers the technical challenge, the hardware and software used, the stages of the work and the measurable results of the implementation - shorter cycle time, fewer rejects, higher output per shift or better process repeatability.
We deliver projects for the automotive (IATF 16949), FMCG, aerospace (AS9100), electronics and medical (ISO 13485) sectors. Experience with industry standards translates into machines that meet audit requirements and are straightforward for a client's quality department to validate.
Full project documentation - technical drawings, electrical diagrams, the PLC program, the operating manual and the validation report - is supplied as standard with every implementation. Get in touch to receive reference material matched to your industry.