Servo-Z for Automatic Adjustment

Part variation and high tolerances are troublesome when manufacturing an assembly.  When the challenge of maintaining tight specs arises, what are your options?

 Each Individual

At Orbitform, each assembly is treated individually.  We ask many questions to fully understand the joint.  Questions may include material used, hardness of the material, finished form dimensions, functional requirements, aesthetics and production volume to determine the best process for the application.  At times, one machine may be required to form two or more parts, which adds yet another dimension to the requirements.  With many core options, Orbitform has the right solution for your assembly every time.

Multiple Assemblies, Multiple Forms

When one manufacturer contacted Orbitform for help in forming multiple sizes of their air bag assembly, consistency and functionality were key in producing exceptional parts.  This project included two sizes of assemblies, each with two forms that needed to be completed.  One form was to seal an ignitor cap to the part, and another created a retention groove on the side of the part.

Two Separate Forms

Upon review of the parts, it was clear that articulating roller forming was required to form the retention groove on the side of the part. However, forming two components together to seal the ignitor cap required static roller forming.  Typically, these two processes are independent of one-another, but the customer asked to have both forms completed in one machine.  Orbitform’s engineers were up for the challenge and designed an articulating roller form machine that could also create the static forming required with a quick tooling change-over.

Part Variation

Due to varying part lengths, the customer and Orbitform began to question annual volumes and the time required to change over tooling between parts.  With the required annual volume, a short cycle time was required.  Manually adjusting the stroke of the machine was a timely changeover that limited production. Orbitform suggested adding a servo-z programmable hard stop mechanism to automatically adjust the powerhead for each application directly through the HMI.  This addition produced a quick, repeatable change-over and greatly reduced opportunities for human error in manually adjusting the stroke for each application.    

End Result

In partnering with the experts at Orbitform, this customer received the best solution for their assembly – an adjustable powerhead that could perform both static and articulating roller forming on multiple parts.  The bench machine included a through spindle pressure pad to hold components tightly while forming, process monitoring to prove great parts were being formed, and servo control of the stroke that could be adjusted by a touch of the button on the HMI screen.  These options combined to create a repeatable process for consistent parts.

Your Turn

The experts at Orbitform have decades of experience in finding the best assembly process.  We stand ready to partner with you to determine the right forming process and options to create your own system of repeatability for consistent parts.  Contact us today for your unique solution.