Cabinetmakers and manufacturers have been gluing up panels since the dawn of time, in fact it remains one of the oldest techniques used in the wood industry; gluing boards to make a panel! Does this explain why technological evolutions have been so slow in coming? I wonder! The fact is that my customers still expect to dedicate 2 to 3 operators to their new clamp carrier, even though this job has seen many technological advances in recent years.
Today, the stakes are different! The workforce dedicated to clamp carriers are getting older, and the new generations are not willing and physically able to handle the panels as their grandparents did.
As an engineer, I have been involved in the field of bonding clamps for over 35 years. I participated in the technological evolution by designing the very first clamping robots. Since then, I have become THE reference for clamp carriers at Doucet!
In this guide of the SRX Hydraulic Clamp Carrier, you'll find everything you need to know to guide you through the buying process. From technical specifications to advantages and disadvantages, to whom the SRX is made for, to costs and questions to ask yourself before making a purchase.
Welcome to the world of clamp carrier!
Tables of contents
Who is the clamp carrier made for?
Advantages and disadvantages of the different technologies
What are the different models of Doucet's "cold" clamp carrier?
Description and technical characteristics
How to automate a clamp carrier?
How do I select the right model of clamp carrier?
How much can a clamp carrier cost?
Who is the clamp carrier made for?
Although the clamp carrier is primarily intended for manufacturers who work with hardwoods, (casket industry, cabinets, furniture, railings, and stairs), some softwood customers (scaffolding floors and caskets) will also use equipment like the SRX.
To get a return on your investment, it takes volume! The SRX is not for the smaller woodworker. The latter is better off using manual clamps carrier with operators for the few panels they must glue occasionally.
Advantages and disadvantages of the different technologies
Cold technology (SRX) vs. high-frequency technology
While a "cold" clamp carrier such as the SRX requires 1 hour to dry, the "high frequency" clamp carrier requires about 5 minutes. In addition to being faster, they are smaller and therefore require less floor space.
On the other hand, it requires specialized labor for maintenance and servicing because of the many electronic components.
The quality of gluing can also be affected. The level of glue is not always completely adequate due to the technology that reacts to humidity levels.
Cold clamp carrier, such as the SRX, are robust, known for their reliability and quality of gluing, and require very little maintenance.
What are the different models of Doucet's "cold" clamp carrier?
Manual (NWR)
The entry-level model is the wall-mounted clamp. It is non-rotating, requires hand loading and clamping, and comes with a glue roller that is also applied by hand. It allows a small production of different lengths of panels.
Wall clamp do not compromise on quality or size.
Rotary (SRX)
The SRX models are available in several sections: 6, 8, 12, 20, 30, 40, 60 and 80 sections. A 6-section machine requires 10 minutes of loading/unloading time per section while a 60-section machine requires only 1 minute of work between each section.
The AGS and ALYX have a part width calculator, which calculates the width of the panels and is programmed to glue the right number of rods for each panel, resulting in an estimated saving of 20% to 30% in applied glue.
All these technological advances allow for increased production capacity, without physical effort. In fact, nearly 90% of-- clamp carrier projects (SRX) now include various options for workstation automation.
Also note that the option of fixed position clamps, which were only available on the ALYX, are now available on the SRX. There is no need to move the clamps, which removes a large physical burden from the operator and eliminates a non-value-added task to save up to 25% of production time. Plus, with the clamps already fixed, you'll be ready to automate your production when the time comes!
Description and technical characteristics of the SRX clamp carrier
The SRX clamp carrier is the most robust clamp on the market. Made of tubular steel with heavy duty clamps and a hydraulic unit for clamping and rotation, they are all very reliable elements that will last over time!
It allows a great production capacity depending on the options you choose.
Consult its technical specifications and options.
In this video, Simon demonstrates how the SRX works. 👇
How to automate a clamp carrier?
The following equipment are options to consider for automating your gluing process:
Addition of a clamping robot (RT100)
The RT100 clamping unit is the fastest and most technologically advanced on the market. It is designed to be added to an existing clamp or to be integrated into a new hydraulic clamp model SRX. It allows keeping control of the leveling and clamping of the panels, two critical steps to maintain the quality of the gluing process.
Addition of a loosening robot (RL100)
The RL100 loosening unit performs the loosening while the SRX is being loaded, which allows a productivity gain of up to 30%.
Adding a clamping and loosening robot (RLT100)
The RLT100 clamping, and loosening unit is designed for high-volume applications for clamping and releasing the material simultaneously while in the SRX.
Addition of an automatic loader (ALYX)
The automatic loader is an automated system for large productions. This option manages the application of glue, the formation of panels, as well as the loading and unloading of the clamp carrier.
Addition of a glue applicator (RC and GS2)
This technology is based on a roller partially immersed in a glue tank to soak and then receive the parts for glue application.
RC: Glue roller for manual and low-volume application.
GS-2: Glue applicator with infeed conveyor and accumulation conveyor. This conveyor requires operators for loading and unloading. It is controlled according to the length of the staves and the width of the clamp carrier. Depending on the number of operators, it can provide a large production volume.
Addition of an automated glue applicator (AGS)
this is a semi-automated glue application system that includes a glue extruder. As fast as a glue conveyor but giving the exact amount of glue to each stave. Among its benefits is a reduction in the amount of glue used, as well as resulting in cleaner machines that require less cleanup after shifts. A task that has no added value added and physically very demanding.
While roller technology sometimes leaves glue-free areas on the material, extrusion technology offers a glue detection sensor. The principle is simple, a UV marker is added to the glue, which allows the UV sensor to detect the presence or of glue not.
How do I select the right model of clamp carrier?
Determine your needs for the size of the panels to be glued
First, you need to choose the clamps according to the size of the panels to be glued. Know your largest panel width then add about 1 or 2 inches larger. Knowing that they are produced from 32'' and in 2'' increments up to about 52''. So, if your panel is 36” then you would need to add 2“ to get to the next size. That would be 38”. If you panel was 35” then you would only add 1” to get to the next size.
Once the opening of the clamp carrier has been determined, it is necessary to choose between 2.5" or 3.5" stops. The 2.5'' can accommodate panels from about ¾'' up to 4", while the 3.5" clamps carrier can accommodate up to 6'' of panel thickness. For face gluing, it is recommended to use 4" or 6" risers.
Historically, the clamps had a 5" wide compression plate and were placed according to the panel to be glued. For example, for a 36'' to 40'' long panel, we could have 4 clamps to position so that the clamping force would be well distributed. Today, there are clamps with 8" wide compression plates that are distributed at 10" intervals. These new clamps have a fixed position, so there is no need to move the clamps according to the length of the panel.
Determine your needs in terms of number of sections
Next, you need to determine the number of sections you will need so that the glue on the panels has time to set. Usually, it takes about 60 minutes for the glue to set before you can loosen the clamps and remove the parts.
The machine is available with the following sections: 6, 8, 12, 20, 30, 40, 60 and 80. While a 6-section gluer gives 10 minutes of work time per section, a 60-section gluer requires only 3 minutes of work between sections.
The number of sections needed depends on the volume of panels to glue up and if you want to operate continuously or not.
The work between each section depends on several factors, e.g., the number of operators, the degree of automation, the size and quantity of the staves to be glued. At its simplest, there are manual hydraulic clamping and turning tools in addition to a glue conveyor. The most popular combination is the RT-100 clamping robot with a glue conveyor, and this will change with the arrival of the new extrusion glue applicators like the AGS model. Finally, it is possible to take automation to another level with the addition of an ALYX.
You may want to speak with a representative to determine the time required for each section.
What pressure should be applied to the glue?
Once installed, you will need to determine the correct clamping pressure to achieve the level of glue required by your manufacturer. This pressure is determined from a calculator available in the machine's instructions or on our website, in the SRX product sheet.
What factors affect the pressure?
- The thickness of the wood to be glued
- The distance between each clamp
- The clamping force recommended by the glue manufacturer
The pressure calculator is designed to determine the pressure according to these factors
**The clamps are designed to apply a pressure up to 5000lbs
The SRX vs. Taylor clamp carrier
For many years, Taylor clamp carriers were so well known that customers named the brand instead of the product. Like a Kleenex instead of a tissue!
Since then, Doucet has greatly contributed to the evolution of clamp carriers’ and especially its automation. Our clientele is mainly composed of high-volume manufacturers.
Today, a customer who takes the liberty of comparing will notice several advantages to the Doucet's SRX. The robustness, the reduced number of parts, the hydraulic vs. pneumatic components and therefore lower maintenance costs. Finally, the technological advances of the last few years with the "ALYX" for example, leave a considerable gap between the two companies.
Previously, Taylor offered pneumatic clamping and rotation only, a technology that is less expensive than hydraulics, but also less durable. With a pure pneumatic system, a high volume of compressed air supply is required. So, it could be necessary to upgrade your air compressor to accommodate this need. For the last few years, they have been manufacturing hydraulic clamp carrier in addition to pneumatic ones, so be careful to compare apples to apples when evaluating!
How much can a clamp carrier cost?
What factors impact the total price?
The range of prices can vary considerably for your personalised clamp carrier, unlike other types of machinery, it is necessary to talk to a representative, here are the factors that impact the price.
- The number of clamps
- Level of automation
- Number of sections
- Mobile clamp carrier vs fixed clamp carrier
In this era where the lack of manpower too often dictates the pace of production, it becomes imperative to turn to technology to reduce dependence on manual labour and ensure the growth of the company. Currently, it is unthinkable to dedicate 2 to 3 operators for a clamp carrier, you must think differently!
After having demystified the clamp carrier and its technological advances, and you have continued reading until now, it is probably because you are considering adding such a piece of equipment to your production cell, right? Your next step will be to discuss your project with one of our representatives to specify your needs and obtain a quote.
All our products are designed around fit and function by our team of technical experts. Contact us now! You have three choices: fill out our quote request form, contact us by email at info@doucetinc.com or call us at 1-866-673-8876
