Flexible Discrete-Part Feeding With Rotating Holders for High Output
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Solution Overview
Problem
Conventional feeding systems for discrete parts are limited in output rate, require customization for specific parts, are sensitive to part imperfections, and often need additional orientation mechanisms, making them unsuitable for high-volume industries.
Innovation Solution
A flexible feeding system that includes a part-retaining device with agitators and grippers to orient and transfer parts efficiently, using a pick-and-placer mechanism to handle parts of varying shapes and dimensions, and a transporter system to deliver parts to downstream processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional vibratory or centrifugal feeding systems are used, then parts can be fed in a directed motion, but the output rate is limited and the system is highly customized for specific parts
Solution Approach 1:
The patent implements a universal feeding system using a rotating table with multiple stations that can handle various part types through standardized holders and grippers. The system can accommodate different part geometries by changing the holder configuration rather than requiring custom-built systems for each part type, thereby achieving both high productivity and versatility.
Solution Approach 2:
The feeding system is divided into multiple independent stations around a rotating table, with each station capable of holding and releasing parts independently. This segmentation allows the system to process multiple parts simultaneously at different stations, increasing output rate while maintaining flexibility to handle diverse part types through modular station configuration.
2Productivity
If conventional feeding systems are used, then parts can be fed efficiently, but they are sensitive to changes in part materials, colors, and surface characteristics
Solution Approach 1:
The system uses passive gravitational feeding where parts are fed onto the rotating table and distributed to holders through gravity and controlled agitation, rather than relying on active sensing and adjustment mechanisms. This self-service approach reduces sensitivity to part variations in material, color, and surface characteristics while maintaining consistent feeding efficiency.
Solution Approach 2:
The patent replaces complex mechanical adjustment mechanisms with a simpler gravitational and inertial-based feeding system. By using the rotating table's centrifugal force and gravity to distribute parts, the system avoids the need for sensors and active control mechanisms that would be sensitive to part variations, thereby improving reliability while maintaining productivity.
3Productivity
If conventional feeding systems are used, then parts can be fed in directed motion, but they are large, noisy, and energy-intensive
Solution Approach 1:
The system uses periodic rotation of the table to distribute parts to holders, replacing continuous high-energy agitation mechanisms with intermittent rotational motion. This periodic action maintains the ability to feed parts in directed motion while significantly reducing overall energy consumption compared to continuous vibratory or centrifugal systems.
4Ease of operation
If parts must be oriented in a particular attitude before assembly, then conventional feeding systems can place parts in required orientation, but this requires supplemental orientation mechanisms or special tooling
Solution Approach 1:
The rotating table system serves multiple functions simultaneously: it feeds parts, orients them through controlled rotation, and positions them in holders. This multi-functionality eliminates the need for separate supplemental orientation mechanisms or special tooling, as the same system that feeds the parts also handles their orientation and positioning.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system achieves higher output rates and versatility in handling diverse parts, reducing the need for customization and maintaining efficiency across varying part materials and orientations.
Implementation Method 1
agitating the part-retaining device... causes some of the part holders to receive and hold individual parts
Data Source
AI summary
There is provided a device, system, and method for flexible feeding capable of being integrated into an assembly system. The device includes a disperser, a part retainer, a vibrator, an excess part removal device, a pick-and-placer, carriers, a transporter, a carrier inspection disc, a part remover, a gate, a transfer station, and re-entry tracks. The method includes dispersing parts, agitating parts, removing excess parts, picking captured parts, placing the captured parts into carriers, inspecting the carriers, positioning the carriers at a transfer station, and transferring the parts to a downstream processor. The system includes a flexible feeding device configured to perform flexible feeding operations, a data processor, and a medium having machine-readable instructions executable by the data processor and configured to cause the data processor to generate signals useful in the synchronization of two or more flexible feeding operations.