Aerospace Micro-Screw Feeding
A Lesson in Micro-Feeding
A manufacturing plant was struggling with its complex assembly line due to delays caused by feeding tiny adhesive-coated screws at high speed. To solve this, they partnered with SEYMOUR Advanced Technologies, which developed a customized high-speed screw feeder. This included a vibration-isolated rail, a precise pick-and-place mechanism, specialized rails for the screws, and a user-friendly HMI for remote monitoring. This solution streamlined the assembly process, reducing delays and improving product quality.
The Challenge
The automation industry is constantly seeking innovative solutions to improve efficiency and productivity. One critical challenge in assembly automation is the reliable and efficient feeding of small, delicate screws, especially those with varying head types and pre-applied Loctite. These screws are commonly used in various industries, including electronics, automotive, and medical device manufacturing.
Traditional screw feeders often struggle to meet the demands of high-speed, precision assembly. They may lack the accuracy to handle small, delicate screws, or they may not be able to handle the varying head types and pre-applied Loctite. Additionally, traditional feeders may not be compact enough to fit into the limited space available in many automated assembly lines.
The Solutions
To address these challenges, a customized, miniaturized screw feeder system is proposed. This system incorporates several key components:
One of a Vibration-Isolated Feeding Rail:
A precisely machined, low-friction feeding rail is installed on a vibration-isolated platform. This platform is equipped with a tuned mass damper, a mechanical device designed to absorb vibrational energy at a specific frequency. By carefully tuning the mass and stiffness of the damper, it effectively mitigates vibrations transmitted from the baseplate to the feeding rail. This ensures smooth and reliable screw transport, even in environments with significant vibration.
High-Speed Pick-and-Place Escapement:
A high-speed, servo-driven pick-and-place mechanism is crucial for accurately picking individual screws from the feed bowl. Servo-driven actuators provide precise and rapid motion control, ensuring accurate placement. To further enhance accuracy, a vision system can be integrated to inspect screws for defects, orientation, and correct placement in the feed bowl. The gripper, a critical component of the pick-and-place mechanism, is designed to minimize contact pressure and ensure a secure grip on screws with varying head types.
Loctite-Compatible:
Handling screws with pre-applied Loctite requires a specialized gripper. To prevent adhesion, the gripper can be coated with a non-stick material. Additionally, the gripper must exert sufficient force to securely hold the screw without damaging it or causing the Loctite to spread.
Sensor-Based Monitoring:
Sensor-based monitoring is essential for ensuring reliable operation and early detection of potential issues. Capacitive sensors can be used to detect the presence of screws in the feed bowl and trigger a low-level alert. Optical sensors can be used to monitor the position of the pick-and-place mechanism and ensure accurate screw placement. These sensors provide real-time data on the feeder's performance, enabling proactive maintenance and troubleshooting.
HMI Integration:
The feeder is integrated with a user-friendly HMI to allow for remote control and monitoring. The HMI provides a clear and intuitive interface for operators to monitor and control the feeder, displaying real-time data on screw feed rate, vibration levels, and sensor readings. Remote access capabilities can be implemented to allow for remote troubleshooting and maintenance, reducing downtime and increasing productivity.
By combining these components and addressing the specific challenges, this solution offers a reliable, efficient, and flexible screw feeding system for the manufacturing facility. This system can significantly improve production efficiency, reduce downtime, and enhance product quality.