Hopper and Piston Feeder for Robotic Workcells
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Solution Overview
Problem
Existing methods for orienting and feeding loose components, such as vibratory feeders and tape-and-reel systems, are inefficient and costly, as they are often designed for single component types and require significant effort or expense, failing to provide a simple and adaptable solution for providing components in a known location and orientation.
Innovation Solution
A hopper and piston apparatus where the piston has a receptacle at its upper end to accept components in a determined orientation, allowing components to fall into the receptacle as the piston is lowered and raised, ensuring components are fed one at a time in a defined orientation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If vibratory feeders are used to accept loose components and provide them in a known orientation, then components are fed in a defined orientation, but the device becomes big, noisy, expensive to design, and designed for only a single size and type of component
Solution Approach 1:
The feeder is segmented into a hopper for storing multiple components and a single receptacle that processes one component at a time. The piston divides the feeding process into discrete steps, handling one component per cycle, which simplifies the overall device structure while maintaining orientation precision.
Solution Approach 2:
The receptacle is designed with a universal geometry that can accommodate different sizes and types of components. The same receptacle structure works for various component forms (e.g., cylindrical, rectangular, irregular shapes) by adjusting the piston motion and receptacle dimensions, eliminating the need for multiple specialized feeders.
2Ease of operation
If tape-and-reel is used to provide components, then components are supplied in a controlled manner, but significant effort is required to supply components in this configuration and it is not cost-effective for many parts
Solution Approach 1:
The system allows loose components to be freely deposited into the hopper without requiring pre-assembly onto tape substrates. The piston automatically performs the selection and orientation functions that would otherwise require manual preparation, making the system self-sufficient and eliminating costly pre-processing steps.
Solution Approach 2:
Multiple components are pre-loaded into the hopper in advance, and the piston retrieves them one at a time when needed. This preliminary loading eliminates the need for on-demand component preparation and reduces operational effort while maintaining controlled supply.
3Manufacturing precision
If loose components are accepted and oriented using traditional methods, then components are provided in a known orientation, but the process is expensive and time-consuming
Solution Approach 1:
The piston performs periodic reciprocating motions, retrieving one component at a time from the hopper and delivering it to the receptacle in rhythmic cycles. This periodic action maintains precise orientation control while enabling continuous high-speed operation, improving productivity compared to continuous vibratory methods.
Solution Approach 2:
The complex continuous vibratory mechanical system is replaced with a simpler reciprocating piston mechanism. The piston uses controlled linear motion and gravitational force to achieve component orientation and delivery, reducing mechanical complexity and operational costs while maintaining precision.
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
This solution provides a simple, adaptable, and cost-effective method for feeding components to a robot, ensuring they are presented in a known location and orientation, enhancing efficiency and reducing the need for expensive and bulky vibratory feeders.
Implementation Method 1
lowering a piston within a channel that passes through the bottom of the bin until a top of the piston is below the bottom of the bin, allowing one of the plurality of components to fall into the channel and then into a receptacle
Data Source
AI summary
Methods and apparatus for the acceptance of loose components and feeding of individual components in a known position and orientation are disclosed.