In many modern assembly environments, engineering teams are challenged with designing products that vary in geometry, component stack-ups, and rivet or stake locations, yet still need to be produced efficiently using the same machine. To support this demand for both precision and flexibility, Orbitform developed the Servo-Z Programmable Hard Stop Mechanism.
What is the Servo-Z Mechanism?
Orbitform’s Servo-Z is a servo-controlled, programmable stroke adjustment system integrated into our orbital, radial, or roller forming powerheads. It replaces traditional manual stroke adjustments by automatically setting the hard stop position via a servo motor. This allows for precise, repeatable control over the final form height without requiring manual mechanical changes between parts or forming locations.
The Servo-Z is often integrated with process monitoring, pressure pads, and LVDT part sensing to maintain consistent rivet head height by adjusting to slight variations in part thickness or rivet length. This closed-loop control enables engineers to design assemblies with tight tolerances while ensuring the machine can compensate for normal part-to-part variation during production.
Why Use a Servo-Adjustable Hard Stop?
For engineers designing components with multiple form heights or variable part versions, the Servo-Z offers several key advantages:
• Precision control of stroke depth for each operation
• Automated adjustment between cycles for multi-part or multi-location forming
• Elimination of manual setup, reducing the chance for human error
• Support for high-mix production, enabling one machine to process multiple part types
• Improved repeatability, which is essential for safety-critical or assemblies with tight tolerances
The Servo-Z becomes particularly valuable in environments where engineers want to maintain part design flexibility without introducing complexity into the manufacturing process.
Application 1: Multiple Form Heights Within a Single Part
One application involved a hinge manufacturer whose product required orbital forming at three different locations, each on a separate plane. Instead of designing and building multiple forming stations, we developed a machine with:
• A 3-position slide to move the part between rivet locations
• The Servo-Z mechanism to adjust the form height for each position
The operator only needed to load the components. The machine automatically moved the part into each position, and the Servo-Z adjusted the powerhead stroke to match the required forming height. This solution eliminated the need for manual stroke adjustments or separate tooling setups, improving efficiency while maintaining forming accuracy.
Application 2: Multiple Part Versions with Variable Stack-Ups
A second example came from an aerospace manufacturer producing several versions of a part family. Each version had slight differences in thickness and required a unique forming height. To streamline production, we implemented a Servo-Z solution combined with part-specific programs saved in the HMI.
The operator could select the appropriate part number on the touchscreen, and the Servo-Z would automatically adjust the stroke depth for that configuration. This allowed the same machine to process different assemblies with no mechanical changeover, enabling faster cycle times and improved traceability.
Integrating Servo-Z Into the Design Process
For engineers considering long-term production scalability, the Servo-Z mechanism is a valuable design consideration. It can reduce the number of machines required for low-to-medium volume product families, support quick transitions between prototypes and production, and future-proof the assembly line for revisions or product evolution.
By including the Servo-Z in initial design discussions, engineering teams can build flexibility into their assembly equipment that supports product iteration and expansion, without sacrificing performance.
Looking for support in determining whether a Servo-Z solution is right for your application? Orbitform’s team of engineers can evaluate your assembly requirements and recommend the appropriate forming and control technologies to meet your production goals. Contact us today.