INTERNATIONAL JOURNAL OF RESEARCH AND SCIENTIFIC INNOVATION (IJRSI)
ISSN No. 2321-2705 | DOI: 10.51244/IJRSI |Volume XII Issue IX September 2025
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Development of an Automated Screwing Machine: Design,
Production and Industrial Integration
TABOUBI Raja
1
, Hajji Olfa
2
and Khalil Hamdi
1
1
Industrial computing and automation engineer, university teacher at ISET Béja, Tunisia National
Higher School of Engineering of Tunis, Laboratory of Industrial Systems Engineering and Renewable
Energy (LR16ES03, Tunisia
2
University Teacher at Higher School of Engineering of Medjez-El Bab Route du Kef Km 5 University
of Jendouba, TUNISIA- Environmental Hydraulics Laboratory, Tunisia
DOI: https://doi.org/10.51244/IJRSI.2025.120800258
Received: 14 Aug 2025; Accepted: 20 Aug 2025; Published: 04 October 2025
SUMMARY
The transition to automated production processes is a strategic requirement in modern industrial environments,
particularly in the face of the intrinsic limitations of manual tasks in assembly lines.[1, 2]These limitations
include high cycle time variability, significant ergonomic constraints for operators, and a lack of traceability
and quality control over screwing operations.
In this context, this work is part of a technological innovation approach within the company Sagemcom
Tunisia, by developing an automated screwing machine integrating the guiding principles of Industry 4.0[3, 4].
The project offers a complete solution for the automation of a screwing station, initially carried out manually,
converting it into an intelligent, autonomous, traceable and secure system.
The designed machine is based on a robust and modular mechatronic architecture, integrating:
Multi-axis electric axes controlled by FESTO servo drives for spatial movement of the screwdriving
tool,
A Siemens S7-1200 programmable controller providing control logic and sequential control of
operations via structured programming in GRAFCET and Ladder,
A touch-sensitive human-machine interface (HMI) for supervision, real-time control and technical
alerts,
A DEPRAG industrial screwdriver equipped with a torque controller to guarantee the quality and
repeatability of tightening.
In compliance with the requirements of the 4.0 paradigm, the system offers integrated traceability of
production parameters, securing of operations through redundant devices (light barriers, safety relays), as well
as interoperability with industrial communication standards (PROFINET) [5].
The results obtained demonstrate a significant improvement in performance in terms of productivity, reliability
and safety, while preparing the ground for future integration into connected, predictive and intelligent
environments.
Keywords: Design, Production, Industrial Integration, Sagemcom Tunisia.
INTRODUCTION
The advent of Industry 4.0 represents a major shift in the industrial paradigm, combining digital intelligence,
advanced automation and real-time equipment connectivity [6, 7 and 8]. This technological revolution requires
INTERNATIONAL JOURNAL OF RESEARCH AND SCIENTIFIC INNOVATION (IJRSI)
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manufacturing companies to overhaul their processes, with the aim of optimizing productivity, ensuring fine-
grained traceability of operations and reducing risks associated with human intervention.
In electronics assembly lines, screwdriving remains an essential task, but has historically been relegated to
manual execution. Despite its apparent simplicity, this operation presents several challenges:
Tightening torque accuracy, directly affecting the reliability of assemblies
Cycle time variability, a source of inefficiency in production lines
Lack of traceability, making quality auditing difficult
Operator fatigue, linked to the repetitiveness and postural demands of the gesture
In order to overcome these limitations, the project proposed in this work aims to design and integrate an
automated screwing cell in accordance with the principles of Industry 4.0.
This cell is based on a mechatronic architecture controlled by an industrial programmable logic controller
(PLC), and includes:
Multi-axis electric axes for three-dimensional tool positioning
An intelligent torque controller guaranteeing the quality and conformity of screwing
A human-machine interface (HMI) ensuring supervision and control of cycles
A machine safety system with certified light barriers and relays
This project is part of an industrial retrofit approach, aiming to transform a manual workstation into a fully
automated, traceable and interconnected workstation. It thus contributes to improving productivity,
standardizing screwing operations, andto the integration of quality requirements into a proactive modernization
approach.
Problem And Objectives Of The Project
Limits of manual screwing
Manual screwdriving, although still common in many industries, has several technical, ergonomic and
organizational limitations [9, 10]. These constraints impact the quality of the final product, the performance of
the production line and the safety of operators.
a. Torque variability
The operator adjusts the tightening torque subjectively, often without measurement or digital
verification.
This variability compromises assembly reliability, particularly in electronic products where tightening
must be controlled to the nearest newton meter to avoid breakage or loosening.
Figure 1: Indicators of variability in manual assembly tasks
INTERNATIONAL JOURNAL OF RESEARCH AND SCIENTIFIC INNOVATION (IJRSI)
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b. Operator fatigue and ergonomic risks
Repetitive movements, awkward posture and screwing efforts are sources of MSDs (musculoskeletal
disorders).
Ergonomic risk increases with work rate and exposure time, negatively impacting performance and
quality.
c. Lack of traceability
Unable to associate each screw with a dataset (applied torque, position, timestamp).
In the event of a defect, quality monitoring is compromised, making retro-analysis difficult.
d. Low and uneven productivity
Cycle time varies depending on operator, fatigue status, or experience.
Lack of regularity slows down the flow and makes balancing positions impossible in an automated
chain.
Project objectives
In a process of continuous improvement and integration with Industry 4.0 standards, this project aims to
automate the screwing station in order to achieve the following objectives:
a. Fully automate the screwing process
Eliminate human intervention by integrating a multi-axis Cartesian robot controlled by PLC.
Allow constant cadence with high positioning accuracy.
b. Integrate digital torque control
Use a Deprag controller capable of measuring, recording and adjusting the torque at each cycle.
Ensure compliance with assembly standards and screwing repeatability.
Figure 2: Functional architecture of screw control
c. Guarantee the traceability of operations
Each operation is recorded: torque applied, cycle performed, result (OK/NOK), time stamp.
The HMI allows access to history for quality audits and predictive maintenance.
d. Ensure operator safety
Integration of safety light barriers (PILZ), certified relays, emergency stop, pressure switch.
Automatic cycle blocking in the event of intrusion or failure of the safety chain.
INTERNATIONAL JOURNAL OF RESEARCH AND SCIENTIFIC INNOVATION (IJRSI)
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Table 1: Visual summary of issues and solutions
Manual Limits
Automated Solutions
Variable tightening torque
Digital control by Deprag
Fatigue and awkward postures
Removal of manual position
No traceability
Cycle history and recorded measurements
Non-uniform cycle
Constant cadence via PLC and multi-axis motors
Operator risk
Safety chain + automated emergency stop
DESIGN METHODOLOGY
The adopted design methodology is based on a comparative approach between the initial state of the manual
station and the proposed automated solution. It relies on a functional analysis, a rigorous selection of
components, and software integration compliant with Industry 4.0 standards.
Study of the existing situation
The current manual workstation relies on a portable screwdriver combined with a simple installation. This
configuration has several major limitations [11, 12].On the one hand, the entire process is entirely operator-
dependent, leading to variability in quality and production rates. On the other hand, the lack of software
supervision prevents any traceability of operations, while quality control is non-existent: no sensor measures
the tightening torque, and no data is archived. Finally, the ergonomic risks associated with repetitive
movements and working posture are not negligible. These findings justify the transition to an automated
solution that is more reliable, traceable, and secure.
Design of the automated solution
The proposed solution is based on a modular mechatronic architecture integrating proven industrial
components.
a. Electric 4-axis Cartesian arm – Festo ELGC
The Festo ELGC Cartesian arm allows three-dimensional positioning of the screwdriver on the X, Y₁, Y₂ and
Z axes. It is powered by EMMS-ST servomotors and controlled via CMMT-ST drives with PROFINET
communication.
b. Deprag screwdriver with torque controller
The Deprag screwdriver incorporates a torque sensor for precise tightening control. It is capable of archiving
screwing data (torque, duration, OK/NOK status) and communicates with the PLC to validate each cycle.
c. Siemens S7-1214C PLC
The Siemens S7-1214C PLC manages safety functions, time delays, and logic transitions. It is programmed in
TIA Portal using Ladder, Grafcet, and function blocks, and communicates with other components via
PROFINET.
d. KTP400 Operator Interface
The KTP400 operator panel allows monitoring of machine states, display of faults and manual control. It is
configured under WinCC Basic for cycle and alarm logging.
INTERNATIONAL JOURNAL OF RESEARCH AND SCIENTIFIC INNOVATION (IJRSI)
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e. Safety light curtains – Pilz PSENopt II
Pilz PSENopt II light curtains protect the screwdriving area. Any intrusion interrupts the cycle via a safety
relay, in accordance with EN ISO 13855 and EN ISO 61496.
f. Programming under TIA Portal & Festo Automation Suite
Programming is carried out using TIA Portal for the PLC and HMI, and using Festo Automation Suite for the
axes. PROFINET telegrams are configured via GSDML, with initialization, production, and safety
GRAFCETS.
Functional modeling
Functional modeling aims to decompose the automated system into elementary functions in order to clarify the
interactions between the components and to guarantee the consistency of the screwdriving cycle.[13]It is based
on a top-down approach, identifying the main functions such as presence detection, positioning, face, quality
control and supervision. A simplified functional diagram allows this logic to be visualized (figure 3).
Figure 3: Simplified process flow of an automated assembly system
This model highlights the information flows between the sensors, the PLC, the screwdriver, and the operator
interface. It facilitates the programming of GRAFCETS and the management of machine states.
Mechatronic flow diagrams
Mechatronic flow diagrams represent the exchanges of energy, information and material between the
subsystems of the automated station. They are essential for validating the overall architecture and anticipating
critical interactions [14, 15].
a. Energy view
The system relies on a centralized power supply that distributes energy to the Cartesian arm motors, the PLC,
the screwdriver, and the safety sensors. Each subsystem consumes a specific amount of energy depending on
its function.
b. Information flow
The sensor signals (presence, safety) are processed by the Siemens PLC, which controls the Cartesian arm and
the screwdriver. The screwdriving data is then transmitted to the HMI for display and archiving.
Figure 4: Logic flow of the S7-1214C automated system
INTERNATIONAL JOURNAL OF RESEARCH AND SCIENTIFIC INNOVATION (IJRSI)
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The design methodology presented allows for the transition from a manual workstation to a high-performance
automated cell, compliant with the requirements of Industry 4.0. The analysis of the existing system
highlighted the ergonomic, qualitative and safety limitations of the initial system. The proposed solution
integrates robust industrial components, a coherent mechatronic architecture, and advanced software
supervision.
Functional modeling and flow diagrams helped structure the interactions between subsystems, facilitating
programming and validation. Performance analysis shows significant improvements in cycle time, traceability,
and safety.
System Architecture
The architecture of the automated system is based on a coherent integration between the mechanical structure,
the control components and the communication network [16, 17 and 18].. This configuration aims to guarantee
the precision, flexibility and traceability of the industrial screwing process.
Mechanical structure
The mechanical structure constitutes the physical foundation of the system. It is designed to offer robustness,
modularity and adaptability to different part formats.
Aluminum chassis: The main frame is made of extruded aluminum profiles, ensuring sufficient
rigidity while facilitating the assembly of components. This material is chosen for its lightness, its
resistance to corrosion and its compatibility with industrial environments.
Adjustable multi-product installation: The part holding device is designed to adapt to several
product geometries. It integrates adjustable elements (slides, jacks, modular wedges) allowing rapid
repositioning without specific tools, thus promoting production flexibility.
XYZ + rotation axis modules: The Cartesian arm is equipped with translation modules on the X, Y
and Z axes, as well as a rotation axis for tool orientation. These modules are motorized and controlled
by digital drives, ensuring precise and repeatable positioning. The kinematics allows the entire
screwing area to be covered with a tolerance of less than 0.1 mm.
Control Components
The system's intelligence is based on a distributed command chain, integrating interconnected industrial
components (Table 2).
Table 2: Automated system configuration: references and functions
Component
Reference
Role
Automaton
Siemens S7-1214C DC/DC/DC
Global order
Variators
Festo CMMT-ST-C8-1C-MP-S0
Engine control
Engines
EMMS-ST-57-S-SE-G2
Axle drive
HMI
Siemens KTP400
Operator interface
Screwdriver
Deprag 330 OS BASIC
Torque-controlled screwing
Each component is selected based on compatibility, reliability, and CE compliance. The Siemens PLC ensures
synchronization of actions, while Festo drives control the motors in a closed loop with feedback [18, 19].
INTERNATIONAL JOURNAL OF RESEARCH AND SCIENTIFIC INNOVATION (IJRSI)
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Communication network
The system is based on an industrial communication architecture based on the PROFINET protocol,
guaranteeing rapid, secure and deterministic exchanges between equipment.
Star topology: The S7-1214C controller acts as the PROFINET master, while the drives, HMI, and
screwdriver are configured as slaves. Each device has a fixed IP address and a GSDML file for
integration into the TIA Portal project.
Real-time synchronization: The PROFINET IRT (Isochronous Real Time) protocol enables
movement synchronization with a latency of less than 1 ms, essential for controlled screwdriving
applications.
Diagnosis and supervision: PROFINET frames also carry diagnostic data, facilitating predictive
maintenance and network anomaly detection.
This infrastructure ensures complete interoperability between components, system scalability and compliance
with Industry 4.0 standards.
Machine Safety
Functional safety in automated systems is a major issue in industrial engineering. It aims to prevent risks
associated with mechanical movements and motorized tools, in accordance with ISO 13849-1, IEC 62061 and
ISO 12100 standards. In this screwdriving cell, the safety strategy is based on a redundant and reactive
architecture (Table 3).
Table 3: Implemented security architecture
Reference
Main function
Light curtain type
Intrusion detection by interruption of optical beams
Pilz PNOZ s4
Interpreting signals and triggering emergency stops
Festo CMMT-ST
Release of Cartesian axes in case of alert
Siemens KTP400
Manual reset after crash
Programming And Automation
The system is programmed using a modular logic architecture, compliant with the IEC 61131-3 standard,
enabling efficient management of sequences, safety features and supervision. It is carried out using TIA Portal
for the Siemens S7-1214C PLC and the KTP400 HMI, and using Festo Automation Suite for the Cartesian
axes.
Automation
The control logic is structured around two main GRAFCETs, supplemented by custom functional blocks and
safety logic diagrams [18, 20].
Initialization GRAFCETThis GRAFCET ensures the safe commissioning of the system. It includes
sensor verification, axis zeroing, activation of light curtains, and waiting for operator validation. This
sequence ensures that the system starts in a stable state and complies with safety conditions.
Production GRAFCETThis GRAFCET controls the automated screwdriving cycle. It combines the
steps of loading the part, positioning the Cartesian arm, activating the Deprag screwdriver, torque
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control, OK/NOK validation, and data archiving. It is optimized to reduce cycle time while ensuring
screwdriving quality.
Custom Functions (FC/FB) Each axis is controlled by function blocks (FB) or functions (FC) coded
in Structured Text (ST) or Ladder Diagram (LD). These blocks encapsulate the position, velocity,
acceleration, and sensor feedback parameters. For example:
FC_AxeX: management of horizontal movement.
FB_Screwing: torque control and screwing validation.
FB_Security: monitoring of barriers and PNOZ relays.
Safety flowchartsThe logic diagrams define the emergency stop conditions and the system's reactions in the
event of an intrusion or fault. They are integrated into the PLC logic and interact with the safety relays to cut
power to the motors and disengage the axes. Any recovery requires a manual reset via the HMI.
Supervision
Supervision is provided by the Siemens KTP400 operator panel, configured under WinCC Basic, offering an
intuitive and functional interface (figures 5, 6 and 7) [1, 8].
Home page with cycle visualization: The HMI displays in real time the system status, GRAFCET steps,
performance indicators (cycle time, OK/NOK rate), and motion animations. This visualization facilitates
process understanding and production monitoring.
Alarm management: Alarms are classified by criticality level (information, warning, critical). Each alarm is
time-stamped, described, and requires operational validation.
Manual mode for maintenance: This mode allows the operator to individually control axes, test the
screwdriver, and check sensors without running the full cycle. It is secured by access conditions and software
limitations to prevent accidental activation.
History of screwing cycles and torques: Each cycle is recorded with the part ID, date, torque applied,
tightening time, and final status (OK/NOK). This data is archived locally and exportable for quality audits,
traceability, and statistical analysis.
Figure 5: Screwing technology | WEBER Automatic Assemblies (www.weber-online.com)
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Figure 6: Analysis of the screwing curve (www.celofasteners.com)
Figure 7: Tightening process in screwdriving technology: solutions & methods (www.deprag.com).
EXPERIMENTAL RESULTS
The comparative evaluation between the initial manual workstation and the automated solution was carried out
using a series of tests under industrial conditions. These tests made it possible to analyze the performance of
the automated system according to several key criteria: productivity, assembly quality, traceability and
ergonomics [18].
The following data summarize the observed results:
Table 4: Evaluation criteria
Evaluation criteria
Front (manual)
After (automated)
Average time per part
14 s
6.5 s
Error rate
4%
< 0.5%
Tightening torque accuracy
Uncontrolled
±5% of nominal value
Traceability of operations
Absent
Total (cycle + torque)
Ergonomics for the operator
Weak
Excellent
These results demonstrate the effectiveness of the proposed solution, both in terms of throughput and quality.
INTERNATIONAL JOURNAL OF RESEARCH AND SCIENTIFIC INNOVATION (IJRSI)
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Productivity
The average screwdriving time per part was reduced from 14 seconds to 6.5 seconds, a gain of more than 50%.
This reduction is explained by the optimization of movements via Cartesian axes, cycle synchronization, and
the integration of the Deprag torque controller.
Error Reduction
The error rate has dropped from 4% to less than 0.5%, representing a significant reduction in facial defects.
This improvement results from the automatic application of a controlled and reproducible torque, avoiding
under-tightening or over-tightening.
Quality Control
The manual system did not allow any direct control of the tightening torque. In contrast, the automated
screwdriver allows controlled tightening with a tolerance of ±5% around the nominal value. This precision
guarantees that the assemblies comply with mechanical specifications.
Traceability and supervision
Automation introduces complete traceability. Each cycle is recorded, along with torque, duration, OK/NOK
status, and product ID data. This information is accessible via the KTP400 HMI and archived locally. This
facilitates quality audits, statistical analyses, and feedback in the event of non-conformity.
Ergonomic improvement
The automated machine eliminates the physical effort and repetitive movements associated with using a
manual screwdriver. The operator is only required to intervene during the initial loading or maintenance phase.
This reduction in ergonomic constraints helps improve working conditions and prevent musculoskeletal
disorders.
Conclusion of the tests
These results convincingly demonstrate the added value of the automated solution. It enables a simultaneous
improvement in throughput, quality, traceability, and operator comfort. This project thus represents a concrete
step forward towards a connected and efficient industry, in line with the requirements of Industry 4.0.
DISCUSSION – INTEGRATION, DATA EXPLOITATION AND
STANDARDIZATION PROSPECTS
The integration of the automated screwdriving machine is fully in line with an industrial digital transformation
approach in line with the paradigms of Industry 4.0. This project goes beyond simple functional automation: it
provides systemic optimization levers that affect production, quality, maintenance and information flow
management.
Connectivity and Industry 4.0 approach
The automated cell is designed to be interoperable with existing digital infrastructures thanks to its PROFINET
communication and integrated HMI. Components such as the Siemens S7-1214C PLC, the Deprag controller
and Festo drives ensure distributed processing of technical data, facilitating their consolidation in local
databases or in cloud environments.
This data, made available in real time, allows:
Production monitoring: continuous control of the number of parts produced, cycle status and
performance indicators (cycle time, OK/NOK rate).
INTERNATIONAL JOURNAL OF RESEARCH AND SCIENTIFIC INNOVATION (IJRSI)
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Online quality control: systematic measurement and recording of the screwing torque, associated with
each product ID.
Digital traceability: complete history of events and structured archiving, facilitating quality audits and
traceability of defects.
Predictive maintenance and reliability
Continuous recording of operating states and warning signals (faults, interruptions, sensor anomalies) opens
the way to predictive maintenance. By integrating trend analysis algorithms on critical parameters (screwing
torque, power consumption, error frequency), it becomes possible to anticipate failures before they impact
production.
Festo mechatronic axes, thanks to their integrated status feedback, can measure motor forces, actual positions,
and load cycles. This data can be used to establish aging curves, calculate the MTBF (Mean Time Between
Failures) and plan preventive interventions.
Prospects for industrial standardization
Beyond its immediate use, this project constitutes a reproducible technological building block. Its modular
design and comprehensive documentation (electrical diagrams, PLC programs, GRAFCETs, HMI interfaces)
facilitate duplication on other similar screwdriving or assembly stations.
This standardization could extend to:
With several production lines within the same site,
At multi-reference screwing stations (various products),
To other assembly operations such as clipping or functional testing,
And even the establishment of collaborative cells with operators.
Reusing functional blocks (FC/FB), safety routines and user interfaces would reduce development costs and
accelerate commissioning time.
The machine developed is not a simple technical response to a specific problem, but a prototype of intelligent
integration, capitalizable in a logic of industrial scalability. Its capacity to generate, exploit and structure data
makes it compatible with scalable, demanding production environments oriented towards sustainable
performance.
Figure 8: Modular architecture of the automated fastening system
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GENERAL CONCLUSION – MECHATRONIC CONTRIBUTIONS, INDUSTRIAL
PERFORMANCE AND EVOLUTIVE MODULARITY
The project presented illustrates a major step forward in the digital transformation of manual workstations in
industrial environments. By replacing a critical manual screwdriving process with an automated cell, the
implemented system now ensures operational robustness, functional precision, and enhanced traceability,
meeting the sector's quality and productivity requirements.
The success of this transformation is based on a coherent integration of three fundamental disciplines:
Control via the Siemens S7-1214C PLC, allowing fine cycle management and real-time monitoring.
Intelligent mechanics, represented by Festo electromechanical axes and the Deprag controller, ensuring
precision, repeatability and adaptability to different configurations.
The structured scheduling logic, embodied by GRAFCETs, guarantees the clarity and reliability of
operating sequences.
This unified mechatronic architecture, interconnected by the PROFINET bus, promotes smooth data flow and
efficient synchronization of actions, while pThe system allows complete supervision of key variables:
Screwing torque: guarantees consistent assembly quality.
Angular position: essential for reproducibility and compliance with mechanical tolerances.
Product identification: facilitating traceability and structured archiving.
The integration of safety devices, inspired by Pilz recommendations (2024), ensures compliance with current
standards (ISO 13849, IEC 62061), while protecting operators and equipment.
One of the essential added values of the project lies in the flexibility of the architecture, which allows:
Adaptation to multiple product ranges, thanks to intelligent parameterization of sequences.
Rapid modification in the event of changes to the specifications, without major overhaul of software or
hardware infrastructures.
A reassignment of the position to other assembly lines, retaining the functional blocks and safety
routines.
This degree of modularity and reusability positions the cell as an internal technological standard, capable of
being deployed on several stations and lines, with substantial gains in engineering time and deployment
reliability.
The project thus goes beyond a simple one-off need. It constitutes a technological building block that can be
capitalized on in a global industrial transformation process:
Promoting the scalability of automation solutions.
Enabling seamless integration with MES, ERP systems and cloud platforms.
Providing a reproducible example in the context of inter-line standardization, with a reinforced return
on investment.
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