The challenge:
In automotive component assembly, clip fitting is a repetitive, high-volume task that is prone to human error. Missing or incorrectly seated clips can result in quality escapes, warranty claims, and costly rework. The client required a solution that could:
● Accurately apply multiple clips to automotive components
● Ensure correct clip presence and placement
● Maintain traceability through barcode integration
● Minimise manual intervention
Consistency, verification, and throughput were critical factors.
Key features:
● Fully automatic clipping process
● Dual bowl feeding system for continuous supply
● Controlled escapement for accurate presentation
● Multi-stage clip verification
● Integrated barcode scanning and MES communication
● Operator-friendly HMI with alarms and status feedback
● Safety-focused design with guarded robot area
Key benefits:
● High repeatability and precision in clip placement
● Reduced risk of missing or incorrectly fitted clips
● Improved production efficiency with minimal operator input
● Scalable solution for high-volume automotive manufacturing
Dual bowl feeders with linear tracks and escapements
6-axis robot for pick, place, and verification
Overview
A fully automatic robotic clipping machine was developed and deployed to streamline the process of fitting clips to automotive components. The stand-alone system replaces manual clip insertion with a precise, repeatable, and verifiable automated process — reducing operator involvement, improving cycle consistency, and enabling full production traceability through MES integration.
Solution
A stand-alone automatic clipping machine was designed and built to meet the client’s requirements. The system is fully enclosed within guarding and operates with minimal operator interaction, requiring only component load/unload and periodic clip replenishment.
Clip Loading & Feed System
Each robot is served by a dedicated bowl feeder, linear track, and walk-forward escapement. This arrangement ensures a continuous and consistent supply of correctly orientated clips, presented at a fixed pick point ready for the robot.
Operators are responsible for maintaining correct clip levels and ensuring the correct variant is loaded for the current production run. Low-level and variant alarms are displayed on the HMI to prompt operator action when required.
Robotic Clip Application
The heart of the system is 6-axis industrial robots equipped with custom-designed End of Arm Tool (EOAT). The robots follow a precise, repeatable cycle for each clip:
1. Pick: Retrieve a clip from the escapement.
2. Sense: Confirm clip presence within the gripper jaws.
3. Insert: Apply the clip into the designated location at the component.
4. Verify: Retracts and checks that the clip is no longer present in the jaws, confirming a successful release.
5. Seat Confirmation: A secondary check confirms the clip is correctly seated on the component.
Repeat — The robot proceeds to the next clip location and repeats the cycle until all clips are fitted.
Inspection & Traceability
Fixed barcode scanners read component barcodes at the end of the cycle. Data is transmitted to the MES system to ensure full traceability and validation.
This automated clipping system delivers a robust, repeatable solution for automotive component assembly. By combining proven bowl feeder technology, precision escapement systems, robotic handling, and integrated verification, the system delivers a reliable, traceable, and efficient clip fitting solution that meets the demanding quality and productivity requirements of modern automotive manufacturing.
Watch
How RNA clipping machine applies clips to automotive components with high precision and repeatability
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