Flexible arm light Conduit Assembly Machine:
Here you see the familiar flexible arm flashlight...

How can you wrap this around pole, your arm, or other object and
it stays? Inside the corrugated black sleeve, is the secret! It is a
snap-together conduit that carries the wires from the power pack to the lamp,
and the tight fit allows it to be moved, but not easily. During the kick-off for
the 10 year anniversary of this light, Coastal Bend Tooling & Automation was
contracted to develop a machine that would assemble thousands of these conduits,
weekly. An automatically fed, dual station, cam operated assembly press was
built for the task...

To snap these together rapidly, the components are automatically fed to each of
the two stations by a vibratory bowl feeder. The components drop into the
assembly fixture, where a snap tool is attached to a cam wheel, operated by a
continuous motor. The snap tool reciprocates much like a sewing machine needle,
or a jigsaw blade. As it retracts, an opening is created to allow the next
conduit component to drop into position. During the forward stroke of the snap
tool, it forces a set of grip jaws to capture the next forward conduit component
and the snap tool drives the new component into the one being held by the jaws.
The Snap tool retracts, and the cycle is repeated, continuously.
Two shafts, attached to the snap tool, extend from the assembly fixture to
reach a mechanical ratchet device. When the stack up length of the conduit is
sufficient to reach the ratchet, it "grasps" the conduit and ratchets its way up
the conduit. Since the ratchet only allows the conduit components to pass
through in one direction, during the stroke of the snap tool, the conduit is
automatically extracted from the assembly fixture, ending the stack-up of
components. Back in the assembly fixture, the next string of components is
started, which pushes the previously completed conduit out the end of the
machine!