Manufacturing Technology

Well known as a leader in the design and manufacture of combined headers for the production of M3 to M24 fasteners, SACMA Group’s thousands of combined headers are responsible for the manufacture (by its global client base) of a wide range of bolts and special screws, directly from wire, across many industry sectors. 

SACMA Group states that its machines are the best solution for high productivity requirements; production method consolidation; floorspace usage optimisation; and workflow streamlining in the manufacturing process – all because they have forming, pointing and thread rolling operations all in one machine. 

In the mid-1980s, the first KSP, one die two blow combined header with roller, left the SACMA factory for delivery to a French customer. Since then, the company has built and delivered more than 200 of those KSPs, most of which are still producing small screws all over the world and are still well supported by the company’s network of service and spare parts agents.

As a design, the KSP is a SACMA original, which, for a long time, has been the only one of its kind on the market. However, iconic products are always copied and, in this instance, it’s SACMA itself doing the copying. At wire® Düsseldorf 2022, the company introduced its new KSP12-R, in response to requests from faithful customers, who wanted SACMA to repeat the success of the previous model with a state of the art machine. Able to run fasteners from M3 to M8, with maximum shaft length 60mm, the new KSP12-R fits the bill and is a double blow header with an integrated threading station – representing the new generation of the world renowned KSP11-R. This latest machine combines typical SACMA features with the most advanced mechatronic technology available in the market. The one piece mainframe, cast from pearlitic iron, which has been left to ‘age’ for at least 12 months, results in a highly precision-machined end product that has its rigidity and stability guaranteed for the life of the machine. 

One new feature of the KSP12-R is its brand new drive system, with the clutch brake unit pneumatically operated and installed on the gear transmission’s fast shaft, which enables it to drive the heading station and the threading station with only one motor. A new generation inverter also allows energy from the motor to be recycled once the machine has stopped. This makes the header more efficient and environmentally friendly.

To complete its bed frame design, SACMA’s R&D department came up with a new slide body to improve precision positioning of the two strokes; increase longevity of the structure; and to guarantee 24/7 use; which SACMA points out is one of the most important qualities for which its headers are recognised.

The machine is also equipped with the latest release of S-Feed 2.0, which consists of the mechatronic solution with a direct drive motor, combined with the motorised wire stop, allowing for a very precise cut-off length and volume. The system, from its motorised wire introduction, the rewind, and pull back function, is easy to set-up. The DKO of the machine is adjusted through an innovative device for an easy and reliable screw length set-up, from 6mm to 60mm. 

As for the loading conveyor, the use of new generation motors allows the fine tuning of the conveyor’s speed, so parts from the heading station can be transferred to the feeding rolls, which ensure the right orientation, with the right speed – according to the length of the headed blanks – before their introduction into the threading station. For product that’s difficult to orientate, it is possible to set the feeding rolls so they rotate in opposite directions. To support orientation of blanks, there is also a rotating wheel over the rolls to remove any parts displaying incorrect orientation. 

After the feeding rolls, rails convey blanks for introduction into the threading station. The starter unit is driven by a torque motor, so that the introduction of the parts is accurate, with adjustable loads applied to the blank, if necessary, during the introduction. This function is useful, especially when producing self-tapping screws. Another feature of the machine is its starter-unit-stroke self-learning adjustment function, which makes the set-up of the roller extremely user-friendly and accurate.

The machine’s complete set-up parameters are stored on the PLC and can be recalled when producing the same part code. This new feature of the latest KSP machine enables a rapid production changeover, not possible using the older model. Depending on the parts to be produced, customers can also install a scrap separator device, as well as a dedicated, finished parts conveyor. Plus, coolant can also be collected, which is then recirculated to the machine tank.

As quality management is a key factor on any production line, the machine can be equipped with n.2 quality sorting flaps in order to select any NC (non-compliant) parts detected, thanks to the SACMA K-Loadmatic, which monitors heading and threading operations. In addition, the motorised wheel over the feeding rolls rejects any parts with a defective head. The K-Loadmatic also protects the machine against overload, measuring the forming load at the start of production by means of a piezoelectric sensor inside the frame.

SACMA Group is very careful about the ergonomics of its machines, as well as the working conditions in which the technicians using them will operate. With its new KSP, manual operation is guided by a tutorial and a crowning achievement of this new machine is that its noise output does not exceed 78dB, making it a very quiet one die two blow header.

All the mechanical parts for the new KSP12-R are manufactured in SACMA’s factories in Limbiate and Vimercate, Italy, a factor that ensures 100% spare parts availability, at any time. Electrical, electronic, pneumatic and hydraulic components also come from leading European suppliers, as well as other sources, worldwide, to ensure uninterrupted production for the company’s global customer base.

With all these factors considered, SACMA believes its new KSP12-R is the highest performing one die two blow combined header on the market.