Control systems + automation WRITE @ THE BACK
Ensuring precision in automotive ‘shrinker’ machines
Jendamark Automation’s innovative catalytic converter ‘shrinker’ machine, designed and built in South Africa for export worldwide, uses SEW-EURODRIVE’s advanced servo-geared units and motion control soware for its precision operation. The highly automated assembly cell integrates multiple machines, robots and laser measurement systems.
the segments close in, collapsing the can evenly around the monolith.”
Servo motor systems Driving that motion are two powerful SEW-EURODRIVE servo motor systems, each connected to precision roller screws that pull the ring from both sides. Synchronising the drives is critical. “If one side is pulled just a few millimetres more than the other, this will damage the very expensive roller screws,” Naidoo explains. “This is where we rely on SEW-EURODRIVE’s technology; the drives and controllers keep the two motors synchronised to within very fine tolerances, even at the high speeds we need to hit our 30-second cycle times.” The speed at which Jendamark Automation’s shrinker operates is one of its critical advantages, Naidoo emphasises, and this has been achieved through its innovative tool changer. He notes that flexibility is particularly important in converter production for commercial vehicles as variants change every few hours. Traditionally, each change required a lengthy manual tool change, which would mean two to three hours of downtime. “This is why we developed an automatic tool change system for the shrinker,” he says. “We have two cartridges outside the machine, one of which is preloaded with the next set of 16 segments. When the operator hits ‘tool change’ the machine ejects the old set, inserts the new one and locks everything down – all automatically – in about 45 seconds.” That innovation, also powered by SEW-EURODRIVE servo drives, has transformed productivity. “We have reduced tool changing times significantly, giving our customers more production time per shi£, allowing them to produce around 80 additional parts,” he says. “With two or three tool changes a day, the gains are massive.” The entire catalytic converter assembly cell can contain up to 30 SEW-EURODRIVE servo drives, powering and synchronising various machines – from laser measuring systems to robotic handlers. Behind the scenes, Jendamark’s proprietary Variant Manager so£ware orchestrates these movements. “Every part coming down the line is slightly dierent, so every 30 seconds a new set of parameters – such as diameters, spring loads and positions – is sent to the drives,” Naidoo says. “There are no fixed positions; it is completely dynamic, adapting in real time.” Parallel to this performance, he adds, is an equivalent focus on reliability as customers require minimal downtime to ensure their processes and products remain viable. He notes that a USA customer, Cummins (through its acquisition of Faurecia’s USA factory), has been running Jendamark’s shrinker for almost six years, during which time it has produced over three million catalytic converters.
SEW- EURODRIVE servo gear units and motion control software ensure dynamic
B ased in Gqeberha in the Eastern Cape, Jendamark Automation is a specialist in advanced automated assembly systems for powertrains, catalytic converters, hydrogen technologies and various automotive components. About 95% of Jendamark’s locally produced systems are exported to markets in Europe, India and the USA. Yanesh Naidoo, Executive Innovations Director at Jendamark Automation, explains the shrinking machine – or ‘shrinker’. “This is a core component within our catalytic converter assembly cell. The cell is a highly automated production environment in which machines, robots and laser measurement systems operate in coordination.” The process begins with the core of a catalytic converter – a ceramic ‘brick’ or monolith, coated with precious metals such as platinum and palladium, that converts exhaust gases into less harmful emissions. This brick is wrapped in a thick spring- like insulation mat and inserted into an outer casing (or can) of stainless steel. Naidoo says that in this process, there are many variable factors to consider. “Because the ceramic monolith is extruded and baked, its diameter can vary slightly – by two or three millimetres in a passenger vehicle converter and up to ten millimetres in a truck converter. This makes the size of every monolith slightly dierent.” To secure the monolith inside the casing with the right spring load, the casing itself has to be adapted. This is the key function of the shrinking machine – to reshape the stainless steel casing to the exact diameter required for each brick and mat combination. Shrinking stainless steel to tolerances of 50 microns requires enormous force and control, which the shrinker achieves by closing a set of heavy tapered segments around the can. “For a passenger vehicle converter, we use twelve segments, and for a commercial vehicle converter, which is larger, we use sixteen,” Naidoo says. “We pull a massive steel ring back over those segments and as the ring moves
precision in Jendamark Automation’s catalytic converter shrinker machine.
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4 Electricity + Control JUNE 2026
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