Sacma Group is well known for designing and manufacturing Combined Headers, which are able to produce fasteners from M4 to M24. So far, Sacma provided more than 4.000 combined headers worldwide.
Let’s remember how the Sacma combined header works.
All SACMA machines are fitted standard with hydraulic clamping of die side adjustments: threaded sleeves, kick out levers and trimming cam. The M version, with motorized DKO adjustment, is an important system to reduce the change over time and to speed up the fine setting. The set-up data of each product code are stored in the PLC. On operator’s demand from the control panel, the machine can adjust automatically the feed length, the stock gage position, and the DKO stroke. Hydraulic clamping of adjustments and tools is a great help when setting the machine and assures the best repeatability.
The transfer mechanism of SACMA combined machines is by far considered the world benchmark, so much that it has been subject of many unsuccessful imitation attempts. The precise movement of the transfer fingers, determined by a smooth oscillating mechanism, generated by perfect desmodromic cams, imparts to the whole system a perfect control of position, also at the maximal production speed. The multiple adjustments - timing of the transfer phase, variation of the clamping force, variation of the opening/closing speed of the fingers, together with the absence of springs - allow to transfer safely long and short parts at the highest speed.
Forming station
From the forming station the parts are directed to the pointing station by means of a fingers elevator which is easily adjusted in width according to the diameter of the shank. The adjustment is made by a micrometric system of easy access to the operator and simple to be implemented. The forged parts are then fed to the pointing unit where the extremity of the shank will be machined. It is possible to produce points with different geometries and angles including the typical 90° robot point widely used in the automotive industry. From the pointing station the blanks are then fed to the flat die thread rolling station.
Pointing station
The threading station carries a flat die, alternating motion, main slide. A stop gate and a single starter blade system fitted at the end of the rails guarantees a perfect introduction of the blanks between the roll dies. The match adjustment of the threaded profiles can be obtained either by means of the eccentric mechanism of the connecting rod which drives the slide or by means of a wedge that provides vertical adjustment of the fixed die. The fixed die can be adjusted in all 3 directions. Calibrated hardened spacers are quickly fit behind the fixed die according to the thread size for a quick changeover. The fixed die is looked by manual or hydraulic depending on the size of the machine.
Thread rolling station
In addition, The V version of the combined headers has been designed for the production of very short fasteners. A shutter elevator feeds the blanks from the heading station to the bowl of a vibratory feeder, where the parts are correctly orientated and delivered by rails to the pointing unit. The pointed blanks thereafter go to the rolling station to form the thread. By mean of dedicated devices the pointing operation or the rolling operation can be bypassed, according to the process the customer intends to apply.
SP18 combined header
In addition to the multi station combined headers, Sacma is re-introducing in its product line the 1D2B combined header to face an increasing request of small and self-tapping screws widely used in different industry fields : this combined header can produce fasteners and screws for the automotive, construction, electric/ electronic, white industry, starting from wire. That’s the best solution for high productivity requirements, consolidation of production methods, floor space utilization and work flow in the fasteners manufacturing process by having the forming and thread rolling all in one machine.
The combined Sacma headers offer many advantages to the fasteners manufacturers:
- The floor utilized by a combined header against a line of connected machines is normally 1 to 3, consequently, more parts produced per area make the overall plant more profitable and efficient.
- More often one operator manages two or three small combined headers.
- The combined machine is only one machine making more operations, therefore less maintenance is required.
- Production changeover is faster with the Sacma combined machine thanks to the fully motorized adjustments and the direct drive motor allowing the very easy set-up of the threading station.
- In the combined machine, with more operating units integrated in one soundproof enclosure, the cooling and lubricating oils are located in only one sealed area: no oil leakage, less pollution, clean and safe working place.
- All Sacma machines are recognized as “quick plug in” equipment. The combined header is ready for production just a few hours after the installation.
- High flexibility to define and modify the factory layout. Only one machine to be fixed to the floor and to be connected to the air plant and the power supply.
- Only one motor for all operations is more efficient than several motors. Combined headers consume less than two machines and the monitoring of power consumption becomes more simple and convenient.
- The forged parts still warm and oiled are delivered to the roller, so the flat dies last much longer, reducing the running costs and increasing the production efficiency.
1D2B combined header model KSP12-R
For the brand new Sacma combined header model KSP12-R, these undisputable advantages allow to run fasteners from M3 to M8 with a maximum shaft length of 60 mm in the best technical and economical way.
The KSP12-R combines typical SACMA solutions, proven by thousands of machines, with the most advanced mechatronic technology available in the market. The one-piece main frame, pearlitic cast iron, normalized, natural aged for at least 12 months, high precision machined, is a guarantee of rigidity and stability for all machine life. Main set-up adjustments are now motorized for a quick and friendly changeover: S-feed wire feeder driven by a torque motor, motorized wire stock gauge and DKO, threading starter driven by torque motor with self-learning function.
The quality management is facilitated by two gates interfaced with the load monitoring system and discharging NC parts, after the header and after the roller. An optional sophisticated load control system protects the machine against overloads and monitors the forming and rolling processes. Scraps separating grids in different sizes are available when producing self-tapping screws.
All the above features make the KSP12-R the best value for the customer, allowing a quick pay back of investment.
The legendary durability of SACMA machines, together with the everlasting availability of spares, are the guarantee of long-term success and profit.
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