Singulating Blade Component Feeder Jam Reduction
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Solution Overview
Problem
Conventional component feeding systems for cylindrical components often experience issues such as jamming, incorrect component selection, and increased downtime due to components with knurled or stamped ends, which disrupt manufacturing processes and increase costs and throughput time.
Innovation Solution
A component feeding system featuring a hopper with a singulating blade that slides between the hopper wall and a singulating wall, actuated to isolate and deposit individual cylindrical components into a component pocket, reducing friction and preventing jams, and allowing for continuous operation even if a component fails to reach the pocket.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional component feeders are used to separate cylindrical components from batches, then components can be fed to manufacturing equipment, but the system frequently jams or provides incorrect components due to knurled or stamped ends not laying flat
Solution Approach 1:
The singulating blade is designed to move dynamically between positions to interact with components. The blade moves into engagement with components that may be in various orientations, then withdraws to allow the next component to be singulated. This dynamic motion accommodates components with knurled or stamped ends that cannot lay flat, preventing jams while maintaining reliable singulation.
Solution Approach 2:
The singulating blade acts as an intermediary element between the batch of components and the component pocket. It selectively engages with individual components, transfers them to the pocket, and releases them for downstream processing. This intermediary mechanism ensures only one component is transferred at a time, preventing multiple components from being fed and maintaining manufacturing throughput.
2Productivity
If components with knurled or stamped ends are fed through conventional systems, then manufacturing can proceed, but the components do not lay flat causing increased delays and downtime
Solution Approach 1:
The singulating blade's dynamic motion allows it to engage with and move components that cannot lay flat. The blade pushes components into the pocket regardless of their orientation, then withdraws to reset for the next cycle. This continuous dynamic operation prevents downtime by accommodating various component end types without requiring system stops or adjustments.
Solution Approach 2:
The system maintains continuous operation through the singulating blade's repeated engagement and withdrawal cycles. The blade continuously singulates components from the batch and deposits them in the pocket, ensuring uninterrupted material flow to manufacturing equipment. This continuous action eliminates delays that would occur if the system had to stop for components that cannot lay flat.
3Ease of operation
If a batch of cylindrical components is held in a hopper, then components are available for feeding, but the feeder can become stuck or accidentally provide more than one component
Solution Approach 1:
The singulating blade serves as an intermediary that selectively transfers exactly one component from the batch to the pocket. The blade's geometry and motion are designed to engage with a single component at a time, preventing multiple components from being transferred. This intermediary mechanism ensures accurate singulation while maintaining ease of operation, as the blade automatically resets to its initial position after each transfer.
Solution Approach 2:
The singulating blade automatically performs the singulation function through its programmed motion cycle. After depositing a component in the pocket, the blade self-resets to its initial position, ready to singulate the next component. This self-service capability eliminates the need for manual intervention or complex control systems, maintaining ease of operation while ensuring reliable one-at-a-time component transfer.
Data Source
AI summary
A system for singulating a component comprises a hopper, a singulating blade, and an actuator. The hopper further comprises a back wall, a hopper wall, a singulating wall, and a feed surface, the back wall rigidly connected to both the hopper wall and the singulating wall. The singulating blade is configured to slide between the hopper wall and the singulating wall between a first position and a second position. An actuator is configured to move the singulating blade between the first position and the second position so as to selectively carry a component to a component pocket defined by the singulating wall.