Progression of the Cylform Lockseamer System
The Cylform Lockseamer system has evolved with over a century of manufacturing advancement. What began as a mechanically driven solution to reduce production costs has become a fully servo-controlled, automation-ready platform designed for modern high-performance manufacturing environments.
Each generation reflects not only advancements in technology, but also a response to the changing needs of industry — from cost reduction and durability to flexibility, speed, and precision automation.
Generation 1 (1920): The First Patent
The original Lockseamer system was patented in 1920 as a central cam-driven, single-direction wrap-forming machine. Its primary purpose was to reduce the cost of billet radiator cores by enabling sheet-metal tubular production.
At the time, this was a major innovation. The mechanical cam-driven design provided reliable wrap-forming in a repeatable process, laying the foundation for cylindrical seam formation using sheet metal instead of more expensive solid materials.
This first generation established the core principle that still defines the Lockseamer today: precise, controlled wrap-forming to produce consistent tubular seams.
Generation 2 (1950s): Hydraulic Control & Independent Axis Movement
As manufacturing demands grew, so did the need for greater flexibility and operational control.
In the 1950s, the Lockseamer evolved into a hydraulically driven, hard-tooled wrap-forming system. The central cam was replaced with relay-controlled hydraulic and pneumatic axes, allowing independent axis control.
This advancement introduced two major benefits:
Greater operational flexibility
The ability to reverse motions to clear material jams
By moving away from a fixed mechanical cam, the system gained improved troubleshooting capability and reduced downtime — a significant step forward in industrial reliability.
Generation 3 (1970s): PLC Control & Quality Optimization
The 1970s brought programmable logic control (PLC) technology into the system. This generation introduced adjustable wrap forming and an articulated, spring-tensioned belt mechanism designed specifically to eliminate muffler layer rattle.
With PLC integration came:
Optimized sequencing
Speed control
Easier troubleshooting
The addition of programmable control marked the system’s transition from purely mechanical operation to intelligent automation, improving both seam quality and production efficiency.
Generation 4 (1990s): Quick-Change Flexibility
As production environments shifted toward smaller batch sizes and greater product variation, flexibility became critical.
In the 1990s, Cylform developed a quick-change Lockseamer system tailored for small-batch manufacturing. This generation featured:
A self-adjusting wrap-forming mechanism to reduce changeover steps
Drop-in tooling to simplify mechanical adjustments
The focus shifted from pure throughput to adaptability, reducing downtime between product runs and making the system more responsive to evolving production demands.
Generation 5 (2000s): High-Speed Automation Integration
With the expansion of fully automated manufacturing lines, speed and integration became the priority.
The 2000s generation introduced a high-speed hydraulic system designed specifically for automated lines. Capacity increased by 25% through the use of proportional valves and LVDT-controlled cylinders.
Key advancements included:
Rapid zero-scrap changeover with integrated fine-adjust tooling
Automated seam-oriented pipe delivery for consistent end forming quality
This generation emphasized precision, repeatability, and seamless integration into automated workflows — ensuring consistent downstream quality while increasing overall production capacity.
Generation 6 (2025): Fully Servo-Driven Precision
The current generation represents the most advanced Lockseamer platform to date.
The fully servo-driven system eliminates hydraulic pumps and associated leaks, significantly reducing maintenance and lowering operating noise to near office levels.
Using absolute encoder feedback, the system dynamically optimizes cycle time across both pipe diameter and length. This allows:
Greater process precision
Reduced energy consumption
Improved consistency across product variations
Quieter, cleaner operation
By replacing hydraulic motion with servo control, Cylform has modernized the Lockseamer for today’s efficiency-driven, data-informed manufacturing environment.