Washer Dispensing System Vibration Motor Gravity Feed
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Solution Overview
Problem
The manual process of kitting fasteners, which involves coupling bolts and washers, is labor-intensive, costly, and prone to errors due to the small size and handling difficulties of washers, leading to repetitive motion injuries and high chances of incorrect coupling.
Innovation Solution
A washer dispensing system that uses a retaining bin with a vibration motor and a discharge chute to automatically dispense washers one at a time, utilizing gravity and resilient stops to align the washers correctly for easy coupling with bolts, allowing for one-handed operation and reducing errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual kitting process is used to couple bolts and washers, then flexibility in handling different fastener types is maintained, but labor intensity increases and error rate rises
Solution Approach 1:
A vibration motor is coupled to the retaining bin to vibrate at least a portion of the retaining bin, thereby moving the washers towards the bin outlet. This mechanical vibration automatically feeds washers to the discharge chute, eliminating manual handling while maintaining operational ease.
Solution Approach 2:
The system allows the washers to feed themselves through vibration and gravity to the discharge chute without requiring manual intervention. The bin outlet and chute are designed to automatically present washers one at a time to the operator.
2Reliability
If manual washer selection is performed, then correct washer-bolt matching can be achieved, but time consumption increases due to repetitive searching and handling
Solution Approach 1:
Washers are pre-sorted by size in different retaining bins, and the bin outlet is designed to present only one washer at a time in the correct orientation. This preliminary organization eliminates the need for operators to search through piles of washers, reducing time while maintaining matching accuracy.
Solution Approach 2:
The system segments washers by size into different retaining bins, with each bin dedicated to a specific washer type. This segmentation allows operators to work with one size at a time, improving both speed and accuracy of matching.
3Productivity
If washers are dispensed in bulk, then dispensing speed increases, but handling difficulty increases due to small size and stacking
Solution Approach 1:
The vibration motor operates periodically to advance washers one at a time toward the bin outlet, and the chute design ensures washers are presented individually rather than in bulk. This periodic dispensing maintains high productivity while improving handling ease by eliminating stacks of small washers.
4Reliability
If automated washer feeding system is implemented, then labor intensity decreases and error rate reduces, but device complexity increases
Solution Approach 1:
The system extracts only the essential function of washer feeding from the complex manual process, using a simple vibration motor and gravity-fed chute design. This extraction achieves automated feeding with minimal added complexity, maintaining high coupling accuracy.
Solution Approach 2:
The discharge chute acts as an intermediary between the retaining bin and the operator's hand, automatically orienting and presenting washers one at a time. This simple intermediary component achieves reliable coupling without requiring complex mechanical arms or robotic systems.
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 significantly reduces costs and improves accuracy and quality by ensuring correct washer selection and coupling, minimizing repetitive motion injuries and time consumption in the kitting process.
Implementation Method 1
A vibration motor is coupled to the retaining bin. The vibration motor is configured to vibrate at least a portion of the retaining bin to move the washers towards the bin outlet.
Implementation Method 2
a base of the retaining bin is downwardly angled towards the bin outlet to allow gravity to draw the washers towards the bin outlet
Data Source
AI summary
A washer dispensing system includes a retaining bin that is configured to receive washers within a washer-retaining chamber. The retaining bin includes a bin outlet connected to the washer-retaining chamber. A vibration motor is coupled to the retaining bin. The vibration motor is configured to vibrate at least a portion of the retaining bin to move the washers towards the bin outlet. A discharge chute is coupled to the retaining bin. The discharge chute includes a washer delivery channel connected to the bin outlet.