Aerodynamic Feeding 4.0: A New Concept for Flexible Part Feeding

In modern production environments, the need for flexible handling systems constantly increases due to increasing uncertainties, shorter product life cycles and higher cost pressure. Part feeding systems are vital to modern handling systems, but conventional solutions are often characterized by low flexibility, high retooling times, and complex design. Therefore, in previous research, multiple approaches towards aerodynamic feeding technology were developed. Using air instead of mechanical chicanes to manipulate workpieces, aerodynamic feeding systems can achieve high feeding rates while at the same time being very flexible and reliable. Still, the complexity of the workpieces that can be oriented relies on the number of aerodynamic actuators used in the system. Previously developed systems either used one nozzle with a constant air jet or one nozzle and an air cushion, allowing a maximum of two orientation changes. This work presents a new concept for an aerodynamic feeding system with higher flexibility (with regard to the workpiece geometry) and drastically reduced retooling times compared to conventional feeding systems. In contrast to previous implementations of aerodynamic feeding systems, using only one air nozzle or an air cushion, the new concept uses multiple, individually controllable air nozzles. Using a simulation-based approach, the orientation process is divided into several basic rotations - from a random initial orientation to the desired end orientation - each performed by a distinct nozzle. An optimization algorithm is then used to determine an optimal layout of the air nozzles, enabling the feeding system to feed any desired workpiece, regardless of the initial orientation. With the proposed concept, high flexibility, low retooling times and relatively low costs are expected, setting up aerodynamic feeding as an enabler for changeable production environments

A Flexible and Robust Vision Trap for Automated Part Feeder Design

Fast, robust, and flexible part feeding is essential for enabling automation of low volume, high variance assembly tasks. An actuated vision-based solution on a traditional vibratory feeder, referred to here as a vision trap, should in principle be able to meet these demands for a wide range of parts. However, in practice, the flexibility of such a trap is limited as an expert is needed to both identify manageable tasks and to configure the vision system. We propose a novel approach to vision trap design in which the identification of manageable tasks is automatic and the configuration of these tasks can be delegated to an automated feeder design system. We show that the trap's capabilities can be formalized in such a way that it integrates seamlessly into the ecosystem of automated feeder design. Our results on six canonical parts show great promise for autonomous configuration of feeder systems.Comment: IEEE/RSJ International Conference on Intelligent Robots and Systems (IROS 2022

Flexible magazine operation and cellular techniques in automation systems

There is a strong current trend in automation towards These often systems that can handle small to medium batch sizes are also often associated with In prototyping situations. Batch numbers High complexity the application described Is for British Airways Heathrow Airport where the number of variations pattern of their meal trays Is large. The batch size the assembly variations Is also extremely variable. Catering at in assembly of each of This thesis describes the justification and design of anautomatic system to assemble these trays whilst retaining the flexibility Inherent In the current manual assembly arrangement.The work examines system layouts. Considering each possibility particularly from the flexibility and potential reliabilityaspects. This leads to the consideration of Industrial robots because of their Inherent flexibility. Consequently the variousconfigurations of robots are examined to assess the suitability of each In a cell arrangement the system which was chosen forIts potential reliability. The work continues by developing the Ideas and techniques of parts feeding to realise the maximumbenefits from a robotic cell system." The thesis describes novel magazining arrangements for handling each of the Items which make. up the tray assembly. Two major developments are described. one for the handling of stackable Items and the other for handling small discrete parts from bulk. Both systems are flexible to accomodate variations In part dimensions and possess ability to be quickly re-configured - to handle completely different parts. The equipment designed and constructed for British Airwaysuses Ideas that could also find use In many similar applications where the components have the same characteristics

Correlation between Geometric Component Properties and Physical Parameters of an Aerodynamic Feeding System

In previous research, an aerodynamic feeding system was developed, which autonomously adapts to different components by using a genetic algorithm that controls the physical parameters of the system (e.g. angle of inclination, nozzle pressure). The algorithm starts with two individuals with random values, generated within the boundaries of the parameters set by the user. Due to this, the setting time - the time that passes until a satisfactory orientation rate is reached - is hard to predict. The aim of this work is to identify basic interactions of geometric component properties with the physical parameters of the aerodynamic feeding system to determine in which areas of the workspace a satisfactory solution can be expected. By doing so, the initial population of the genetic algorithm can be generated based on certain geometric properties and would therefore no longer be random, presumably reducing setting time. To identify interactions of component properties and system parameters, exemplary components were developed. They represent relevant single properties that have significant impact on the aerodynamic orientation process. These components were then fed into the aerodynamic orientation process and their behavior was documented. To identify correlations between certain geometric properties and physical parameters of the feeding system, the tests were planned and carried out using Design of Experiments methods. The results of the tests were also used to determine the direct interrelations of said properties and the suitability for aerodynamic orientation

Design of an automated sorting and orienting machine for electronic pins

Thesis (M. Eng. in Manufacturing)--Massachusetts Institute of Technology, Dept. of Mechanical Engineering, 2012.Cataloged from PDF version of thesis.Includes bibliographical references (p. 93-94).At the power electronics manufacturer SynQor, the printed circuit board (PCB) assembly line is fully automated with the exception of the step which inserts electronic pins into the PCBs. Past attempts to automate this process have resulted in two unreliable machines that are not in use on the production line. Thus, electronic pin insertion is currently a manual process. The design proposed in this thesis for an automated pin insertion system separates the sorting and orienting of the pin from the insertion of the pin into a PCB. This system decoupling allows for more reliable pin delivery, which can in turn increase the insertion speed and reliability. This thesis focuses on sorting and orienting of the pin. The resulting design takes pins from a bulk state to an oriented state and inserts them in a pin holding magazine. Preliminary trials of the system show promise as an efficient way of preparing oriented pins for use by a pin insertion mechanism, but more experimentation is needed to test the robustness and speed of the sorting system.by Michelle Sueway Chang.M.Eng.in Manufacturin

Flexible Aerodynamic Part Feeding Using High-Speed Image Processing

In modern assembly systems, manufacturers expect a high level of flexibility and efficiency. As an interface between internal logistics and the actual assembly, part feeding technology plays a decisive role in the manufacturing process. Therefore, in this work, we propose a new way of flexible part feeding based on image processing and the proven principle of aerodynamic feeding technology. With a high-speed camera, we analyze the workpiece’s movement during the orientation process and automatically adjust the system parameters to ensure reliable and efficient feeding. Based on three parameters of the workpiece’s trajectory, we develop an algorithm that can systematically find suitable parameter combinations for efficient and reliable feeding. With the proposed concept, retooling for new workpieces can be achieved quickly, using only few components for the parameter setting. At the same time, no hardware changes are required for retooling when handling new components

Adaptive aerodynamic part feeding enabled by genetic algorithm

Aerodynamic feeding systems represent one possibility to meet the challenges of part feeding for automated production in terms of feeding performance and flexibility. The aerodynamic feeding system investigated in this article is already able to adapt itself to different workpieces using a genetic algorithm. However, due to the operating principle, the system is susceptible to changes in environmental conditions such as air pressure and pollution (e.g. dust). To minimise the effect of ambient influences, the system must be enabled to detect changes in the feeding rate and react autonomously by adapting the system’s adjustment parameters. In this work, based on pre-identified factors interfering with the aerodynamic orientation process, a new approach is developed to react to changes of the ambient conditions during operation. The presented approach makes us of an alternating sequence of monitoring and corrective algorithms. The monitoring algorithm measures the ratio of correctly oriented parts to the total number of fed parts of the process and triggers the corrective algorithm if necessary. Simulated and experimental results both show that an increased feeding rate can be achieved in varying conditions. Furthermore, it is shown that integrating both known process and parameter information can reduce the time for re-parametrisation of the feeding system