Switch Assembly Automation: A Hybrid Solution

Flexible Automated Systems for High-Speed Production

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.

Technology Used

• Yaskawa Motoman 6-axis robot with SDC Flex Feeding technology
• Yaskawa Motoman SG400 SCARA robot
• 3 SDC servo-driven pick-and-place units
• SDC Indexing Ring
• Deprag screwdrivers, nutrunners
• Bellco Feeders vibratory bowl feeders
• Keyence vision system – overhead bin picking, flex feeder, & final inspection
• Modicon Megelis HMI and Modicon M580 PLC

The Machine Concept:

Our customer needed a machine to perform the tedious and rigorous task of assembling an electrical safety switch. The key challenges included:

• Custom parts feeding solutions for 5+ different components on a complex assembly
• Automated grease dispensing
• Operator loading station with safety light curtains and pressure switches
• Automated screw driving and nut runners
• Testing and inspection stations

Solution: Adaptive Production Workflows Meet Cutting-Edge Technology

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:

• Robotic Integration: A Yaskawa Motoman 6-axis robot performs a hybrid function of bin-picking and flex feeding parts and placing them into the same nest on an SDC Indexing Ring. A Yaskawa Motoman SCARA robot performs a pick-and-place function, forming synchronous precision robotic integration.
• SDC Flex Feeding: This intelligent flex feeding system provides continuous, automated material handling and processing by guiding parts using integrated vision-guided robotic systems. This ensures optimal pickability, even for complex-shaped components.
• SDC Indexing Ring: SDC’s pre-engineered indexing ring enables streamlined machine operation throughout each station.
• Robotic Bin Picking and Vision Systems: Utilizing a KEYENCE vision-guided robotic system, the robot can perform accurate bin picking, recognizing part orientation and ensuring efficient part handling throughout the cycle.
• SDC Pick-and-Place: Multiple components are introduced to the machine via vibratory feeder bowls and linear tracks to a SCARA robot and multiple servo drives.
• Automated Screwdriving and Nut Running: Integrated Deprag screwdrivers and nutrunners to perform essential assembly processes.
• Testing & Inspection: The system includes 10kV hipot testing and multiple electrical and mechanical verification zones to ensure safety and compliance in every assembled part.

Operational Workflow:

SDC Flex Feeding with Hybrid Bin-picking: High-speed delivery of accurately oriented parts to the assembly zone. One robot is used to perform both flex feeding and bin picking of two different components at the same station. This optimizes the machine footprint, reduces cost, and improves efficiency.

Grease Dispensing: Precisely dosed and applied to designated components

Component Loading, Screwdriving, and Nutrunning: Fully automated for speed and consistency

Inspection and Testing: Integrated at multiple checkpoints for maximum quality assurance

SDC Standard Products: Eliminating Engineering Risk with Proven Solutions

SDC Flex Feeding

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 many applications.

Key Features:

• High-Speed, Precise Motion: Servo-driven technology ensures fast and accurate part handling. This unit moves with pinpoint accuracy and incredible speed. No more waiting around – your parts will be handled in record time, with zero compromise on precision.

• Cost-Effective Solution: The proven, pre-engineered design delivers high performance at a low cost, maximizing value. Thanks to its proven, pre-engineered design, the SDC pick-and-place provides exceptional value by maximizing output and boosting efficiency without burning a hole in the project budget.

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• Seamless Integration: This system isn’t just a standalone champion; it plays perfectly alongside other equipment, like the SDC Tray Handler and FANUC SCARA robot, working in perfect harmony to transfer parts smoothly with minimal downtime.

SDC Pick-and-Place:

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.

Key Features:

• High-Speed, Precise Motion: Servo-driven technology ensures fast and accurate part handling. This unit moves with pinpoint accuracy and incredible speed. No more waiting around – your parts will be handled in record time, with zero compromise on precision.
• Cost-Effective Solution: The proven, pre-engineered design delivers high performance at a low cost, maximizing value. Thanks to its proven, pre-engineered design, the SDC pick-and-place provides exceptional value by maximizing output and boosting efficiency without burning a hole in the project budget.
• Seamless Integration: This system isn’t just a standalone champion; it plays perfectly alongside other equipment, like the SDC Tray Handler and FANUC SCARA robot, working in perfect harmony to transfer parts smoothly with minimal downtime.

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 that supports multiple process configurations, enabling automated electrical device assembly with high throughput and repeatability.

Key Features:

• Smart Automation: SDC Ring Indexer’s Adaptable Tooling Suite: To enhance its capabilities, the SDC Ring Indexer integrates a variety of optional tools, including vibratory feeders, high-speed robotics, custom flex feeders, 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. It facilitates quick tooling changes to accommodate different parts and assemblies, while its durable construction ensures long-lasting reliability with minimal maintenance.
• Servo Pick-and-Place Arm: Our SDC-designed servo-driven pick-and-place systems offer high-speed, precise motion in a customizable design. With low cost and high repeatability, these systems provide a versatile, value-driven solution for optimized manufacturing.

Results & Business Impact

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:

• Improvement in Production: 3,000 parts per day with 94% efficiency rate.
• Enhanced Scalability: Built to meet final assembly line demand without requiring overtime.
• Increased Digital Connectivity: Seamless integration into our customer’s IIoT ecosystem to track efficiency and monitor machine performance.
• Significant Cost Savings: Standard components and proven systems reduced engineering risk and time-to-deployment.

Conclusion

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.

Check out a video and pictures of this machine in action with our case study - Switch Assembly Automation: A Hybrid Solution