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Custom Engineered Automatic Riveting & Sensor Assembly System

For automotive switch plate applications, structural integrity and electrical contact reliability are paramount. As the Original Equipment Manufacturer (OEM), Creative Automation Company engineered a high-performance, multi-component assembly workcell designed to integrate 12 individual pressure sensors with dual connector plates.

This purpose-built system utilizes a custom-engineered riveting architecture to achieve the extremely high degree of repeatability required for automotive safety components. By synchronizing complex material handling with precision mechanical fastening, this platform ensures 100% assembly verification and long-term durability in a high-throughput environment.

The Engineering Challenge: Scaling Throughput Under Strict Safety Protocols

For this automotive application, the primary hurdle was the intersection of mechanical force, operator safety, and high-volume output. The client’s internal safety mandates required a complete mechanical isolation of the riveting operation; no operator contact could occur during the high-pressure riveting cycle.

To meet these safety standards without sacrificing efficiency, our engineering team had to solve for:

Total Workcell Isolation

Designing a system where the riveting stations operate within a protected cycle, removed from human intervention.

High-Velocity Output

Achieving a sustained production rate of two complete, 14-component assemblies per minute.

Automated Synchronization

Moving beyond manual methods to a fully autonomous design that manages the complex timing of 12 sensors and two plates simultaneously.

Custom OEM Solution: Four-Station Two-Stage Automated Riveting

Creative Automation designed and manufactured a four-station system featuring dual riveting stations to accommodate two distinct rivet sizes. As the Original Equipment Manufacturer (OEM), we engineered this platform to bridge the gap between manual loading and fully autonomous, high-speed processing:

Secure Part Transfer: An operator loads the base assemblies onto fixtures; the system then automatically transfers the fixtures into a protected enclosure to begin the riveting cycle.
Precision Coordinate Positioning: A custom-engineered automatic riveting table maneuvers the fixture into the exact position required for each individual rivet placement.
Integrated Flaring Operation: A pneumatic mandrel located beneath the riveting head completes the flaring operation simultaneously as each rivet is inserted, ensuring a permanent bond.
Sequential Multi-Station Processing: Once the first set of rivets is installed, the fixture is automatically shuttled to a second station for the remaining rivets to be processed with identical repeatability.
Autonomous Cycle Management: Completed assemblies are automatically unloaded from the enclosure and presented for removal, while fixtures continuously cycle through the system to maintain maximum production capacity.

Custom Automation Systems for Today’s Automotive Manufacturers

Creative Automation provides modern automotive manufacturers and part makers with the automated tools they need to keep ahead of the market. From automated assembly and automatic forming systems for automotive parts to automatic testing/inspection systems, Creative provides today’s automotive industry with the state-of-the-art equipment solutions required for increased productivity and sustainability.