Pneumatic Feeding

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Hesse Rationalization of Small workpiece feeding

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Hesse
Rationalization
of Small workpiece
feeding
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Orienting, sorting, checking and feeding
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Blue Digest
Blue Digest
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Hesse
Rationalisation of Small workpiece feeding

Orientating, sorting, checking and feeding
Handling
Pneumatics
Stefan Hesse
Rationalisation of
Small workpiece feeding
Orientating, sorting, checking and feeding
Blue Digest
on Automation
Blue Digest on Automation
© 2000 by Festo AG & Co.

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All rights reserved, including translation rights. No part of this publication may
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of Festo AG & Co.
Without order, modern production is impossible. The question always is “How
Foreword can workpieces be brought from a disorderly state into the required orientation
for a particular process?” This is also important from the economic point of view,
since the orientation process can be complicated and expensive. Attempts are,
of course, always made to retain the orientation achieved during component
production. In many cases, however, this is not particularly advantageous –
magazining costs may be high, the original orientation may in any case be lost in
the course of a process, or the parameters for post- production operations may
simply be different. Re-orientation is very often a better solution. But how can
we achieve this? How are workpieces orientated?
This book is concerned with equipment and methods that promote the
orientation of workpieces. These include, for example, vibratory feeders, which
are suitable for the feeding of over 80% of small bulk workpieces. Other hopper
feeding devices, however, also have their uses. Astonishing performances are
being achieved today using imaging systems. These are flexible in their
application, can “learn” from sample workpieces and can even be used for the
optical evaluation of quality features.
Everyone who is involved with factory rationalisation and planning and is sear-
ching for suitable technology requires an overview of the available possibilities.
The aim of this book is to help provide this. It is addressed at practical engineers
who do not wish to keep “re-inventing the wheel” but are glad to make use of
what is already available. And what is available is a wealth of both equipment
and experience.
Stefan Hesse
Foreword
Contents
1 Workpiece handling in component production and assembly ............................ 9
1.1 Development of feeding technologyk ............................................................... 9
1.2 Requirements and areas of application .......................................................... 12
1.3 Flexible orientating and feeding systems ........................................................ 14
2 Workpiece hopper feeding devices ............................................................................ 18

2.1 Vibratory feeders ................................................................................................... 18
2.1.1 Mode of operation ................................................................................................. 18
2.1.2 Types ......................................................................................................................... 23
2.1.3 Spiral drum .............................................................................................................. 25
2.2 Centrifugal feeders ................................................................................................ 30
2.2.1 Design and mode of operation .......................................................................... 30
2.2.2 Typical conveyed material and system performance .................................. 31
2.3 Multi-stage feeders ............................................................................................... 31
2.3.2 Range of applications ........................................................................................... 32
2.4 Segment feeders .................................................................................................... 32
2.5 Inclined and steep conveyors ............................................................................. 33
2.5.1 ADesign and mode of operation ........................................................................ 33
3 Orientation technology .................................................................................................. 35

3.1 Basic principles of orientation ........................................................................... 35
3.2 Orientation using mechanical devices ............................................................. 39
3.3 Orientation using pneumatic components ..................................................... 53
3.4 Orientation using electromagnetic effects ..................................................... 57
3.5 Orientation using optical detection technology ........................................... 59
3.5.1 Advantages and methods .................................................................................... 59
3.5.2 Detection device .................................................................................................... 62
3.5.3 Analysis of features ............................................................................................... 64
3.5.4 Programming of optical detection, orientation and sorting devices........ 66
3.6 Orientating and sorting mixed workpieces .................................................... 68
4 Checking and counting workpieces ........................................................................... 71

4.1 Important process-related workpiece parameters ....................................... 71
4.2 Counting .................................................................................................................... 72
5 Magazining orientated workpieces ........................................................................... 74

5.1 Outlet design of vibratory feeders .................................................................... 74
5.2 Magazine designs .................................................................................................. 77
6 Ancillary equipment ........................................................................................................ 81

6.1 Noise protection devices ...................................................................................... 81
6.2 Hopper top-up systems ........................................................................................ 81
6.3 Level monitoring ..................................................................................................... 84
7 Handling technology systems ..................................................................................... 86
7.1 Basic technological components ........................................................................ 86
7.2 Examples of applications ..................................................................................... 87
7.2.1 Vibratory feeders ................................................................................................... 87
7.2.2 System with contactless feature detection .................................................... 91
7.2.3 Orientation using the EMAGO method ............................................................ 92
7.2.4 Stepwise orientation using imaging systems ................................................ 94
7.2.5 Orientation using aerodynamic devices .......................................................... 94
8 Selection of workpiece feeding devices ................................................................... 96

8.1 Workpiece shape and degree of handling difficulty .................................... 96
8.2 Performance profile ............................................................................................... 97
8.3 Selection algorithm ............................................................................................. 100
8.4 Economic factors ................................................................................................. 102
9 Glossary ........................................................................................................................... 103
Further literature ............................................................................................ 107
Glossary of technical items ............................................................................................ 111

Modern production demands a high degree of automation in the feeding and
1 handling of individual components, modules and complete products. The auto-
Workpiece handling in mation of production equipment has allowed machining times to be reduced in
component production many processes. Feeding operations on the other hand, are frequently still
and assembly carried out manually, which means that handling now accounts for a greater
proportion of the overall working cycle time. Our task must be to exploit this
potential for rationalisation.
Another current trend is to link material or workpiece flow together with the flow
of information. Handling technology plays an important role within this wide
field, and one of the most costly and difficult handling operations is the auto-
matic orientation of small workpieces. These workpieces are the most common
type and in terms of size and weight have a length of around 200 mm, a dia-
meter of around 50 mm and a weight of around 0.5 kg.
The need to re-organise and rationalise the feeding of materials and components
1.1 emerged only with the development of the mass production of items such as
Development of light bulbs, needles, ammunition, buttons and screws. For example, a man called
feeding technology Spencer constructed an automatic lathe with automatic feeding of bar material
in the USA in 1873, whilst a scoop-arm feeding device was used as early as 1865
in an automatic machine for the production of wood screws. By the mid-1920s, it
had become standard practice to use scoop-segment hoppers to feed glass rods
and envelopes in the light-bulb manufacturing industry.
Vibratory conveyors, too, became popular. Vibrating devices were in use by the
end of the 19th century, particularly imbalanced vibratory conveyors for the
screening of bulk materials. When it was recognised that it was also possible to
convey individual workpieces by this method, linear vibratory conveyors were
also developed. Problems were, however, experienced, since smooth workpieces
can often “stick” together. The reason for this was the surface adhesion created
by the film of oil on the workpieces and the aerodynamic effect which at high
speeds produced a kind of suction effect with the workpieces instead of separat-
ing these.
The first patents for vibratory devices were granted as early as 1850. A patent
application was filed in the mid-1940’s by the Syntron Company of America for
the orientating, conveying and magazining of workpieces in a vibratory bowl
feeder. Other hopper feeding devices were, of course, also developed, for
example with scoop segments, pins and tubes. These are still in use today.
Magazine feeding devices have always been and remain the preferred choice for
use with machine tools. The magazines in question have generally been filled
manually. This operation included a visual inspection, often a vital part of the
process. Progressive companies soon recognised that vibration technology
provides relatively simple and inexpensive feeding systems or even assembly
systems. There is, for example, a description in an old book [1] of how watch
components were assembled using a “shaker box” or in other words a vibratory
device. How did this operate with these small workpieces (shafts)?
1 Workpiece handling in component production and assembly 9

“Here in the factory, the workpieces are placed into a round iron drum. The
shanks into which the shafts are to be fitted are positioned upright on a disk
which forms the base of the drum. Within the heap of workpieces, so small that
they can hardly be distinguished individually, are larger steel rollers. The electric
drive is switched on and vibrates the drum. The rollers, like pike in a carp pond,
churn up the tiny shafts, which gradually vibrate their way into the shank open-
ings, whose diameter appears about equal to the width of a fly’s foot!”
What this author was witnessing 60 years ago in Germany’s Black Forest was the
assembly of microscopic watch components in a vibrator.
Workpieces of many different shapes can be easily orientated in a vibrator. As

the workpieces move upwards within a spiral drum, they come into contact with
orientating devices (chicanes) which create uniform orientation, generally in
several stages (Fig. 1-1).
Fig. 1-1:
Principle of orientation in
a vibratory bowl feeder 4
1 Workpiece
2 Vibrating spiral drum
3 Desired lifting/rotary
vibration Ordnen durch
Orientation Gleichrichten
through correction
4 Orientating device of position
1 2 3 Ordnen durch
Orientation Auslesen
through selection
The following are examples of the throughput that can be achieved with this
conventional technology:
• Cylinder pressure springs 0.5 x 5 x 16.5 20 per minute
• Washers for spark plugs, diameter 16.9 mm 38 per minute
• Caps for spark plugs, diameter 14 mm 38 per minute
• Ceramic wafers 50 per minute
• Cable nuts 38 per minute
The orientation technology in the vibrator naturally becomes more complicated

as the number of workpiece features to be distinguished and thus the number of
different orientations (asymmetry) increase. Ways were therefore soon proposed
of replacing mechanical orientating devices with contactless checking devices.
Fig. 1-2 shows a solution in which a workpiece contour is detected in 2 planes
and evaluated. The image information from these two views is combined and fed
via fibre optic cables to a CCD line scanning camera. After evaluation, the work-
pieces are guided into appropriate sorting channels. This principle has now been
developed into a robust industrial solution and represents the present state of
the art in the feeding of small workpieces. We shall return to this subject and
discuss it in detail later.
10 1 Workpiece handling in component production and assembly

Fig. 1-2:
Imaging system with scan-
ning in 2 planes (according to 1 6
Cronshaw, 1980)
7
1 Parallel light source
2 Fibre optic cable
3 Combination of fibre
optic cables
4 CCD camera
5 Lens 1
6 Feed device
7 Rail
2
4
5
We must never consider feed technology in isolation. It is part of the overall

production process and must accordingly be considered holistically. From the
point of view of the production process, workpiece feeding is an auxiliary pro-
cess that occurs on various levels, as shown in Fig. 1-3 in schematic form. If, for
example, small workpieces are manufactured directly on the assembly conveyor
belt, this simplifies their handling considerably. The degree of flexibility which
can be achieved in this case is, however, low. It is also simple to feed compo-
nents in a belt, such as electronic components, since flowing or semi-flowing
materials are easier to handle in technical terms. Flexibility is certainly provided,
notwithstanding that the workpieces must first be placed into the belt at some
other point.
Fig. 1-3:
Workpiece feeding
A number of technological
variants for the feeding
of small workpieces for
component production,
Single magazine Bulk material Stack magazine Endless Integrated
assembly and checking
Top-up cassette magazine (belt) pre-production
M
V
M
Feeding Orientating Feeding Feeding Production

Distributing Magazining Destacking Distributing Feeding

This method also uses additional ancillary material, which subsequently be-
comes waste. In many cases, it is very practical to present workpieces in
magazines, particularly if they can be placed into magazines in preceding pro-
cesses without any great effort. If the magazining process takes place at another
location, the magazine costs may be a significant factor. In the case of short-
cycle working processes, however, the resulting frequent changing of magazines
may lead to a loss of productive time. In the case of magazine stacks, the local
feeding system must be able to resolve the three-dimensional arrangement of
workpieces on the workpiece-carrier magazines. It is, however, often the case
that workpieces are supplied randomly orientated in crates, sacks or other
containers. In this case, it is the recipient’s task to bring the workpieces from a
disorderly heap into an orientated state. This is generally the state of work-
pieces in a magazine [2 to 5].
Before a workpiece can be processed in any way, it must be brought to the place
1.2 at which processing is to be carried out, generally the working area of a
Requirements and machine. It must then be removed from this area again after processing (except
areas of application in the case of an assembly operation). There is generally a requirement that the
workpiece must be in a certain state (= orientation and position), usually with
no specification of how the workpiece is to reach the processing point. The
operation required to achieve this is referred to as “feeding”. This is shown in
general symbolic form in Fig. 1-4.
Fig. 1-4:
Feeding operation as a
black-box representation Input Feeding system Output
1 Workpieces in undefined U = Umax U = Umin = 0

(random) order (heap) w z
2 Feeding of workpieces Feeding
defined in terms of time operation
and physical arrangement v y
Umax – Umin
U Disorder S
u 0 x
1 2
In order to choose suitable orientating components, we need to know the

behaviour of the workpiece, for example on vibrating chutes. As Fig. 1-5 shows,
cylindrical workpieces with a longitudinal attitude rotate about their own axis at
the outlet of the vibrator. If the workpiece has lateral features, the rotating effect
can be used to achieve orientation. Under these special conditions, the motion
behaviour of the workpiece becomes the decisive operative principle. But what
do we mean by “workpiece behaviour”?

Workpiece behaviour is the totality of all the typical states of one or more
workpieces that are the result of the action of external forces, including
gravity.
We distinguish between 12 basic behavioural types according to their shape:

Tangle, flat, cylindrical, block-shaped, mushroom-shaped, conical, pyramidal,
hollow, spherical and long, together with complex workpieces made up of
differently shaped components and irregular solid workpieces.
Fig. 1-5:
Rotary motion during
conveying can be exploited
for orientation purposes
In order to automate feeding operations, we must possess adequate knowledge

of the workpiece to be handled. The important factors are:
• A description of the workpiece
• Its behaviour at rest
• Its motion behaviour.
A handling workpiece can be described by the following variables:

• Mass (reference mass, mass tolerances, mass after processing)
• Materials properties:
- Mechanical (elasticity, hardness, porosity, etc.)
- Electromagnetic (conductivity, permeability. etc.)
- Thermal (heat conductivity, absorption capacity, etc.)
- Chemical (corrosion resistance, hygroscopic tendency, etc.)
• Geometry
- Shape (internal shape, external shape, etc.)
- Dimensions (length, width. height, etc.)
- Dimensional ratios
• Surface properties
- State (temperature, humidity, presence of oil film, etc.)
• Special features relating to handling (position of centre of gravity, available
gripping points, etc.).

It will probably also be necessary to distinguish between prototype workpieces
and those from series production. Experiments and the selection of feeding
equipment should always be based on a large quantity of series-produced work-
pieces, preferably from different batches and produced using different tooling.
Plastic workpieces, for example, may occasionally be distorted or exhibit large
dimensional variations or differences in surface quality (peak-to-valley height,
gloss, fluid skin). These factors may have a major influence on the free move-
ment of workpieces in chutes.
Applications cover all areas of industry whereby which small-sized material is

used. The main areas are as follows:
• Metalworking industry (shafts, hardware fittings, drill bits, pins, etc.)
• Electrical engineering/electronics (terminal strips, ceramic wafers, switch
contacts, etc.)
• Woodworking industry (dowels, play bricks, fittings, screws, etc.)
• Electroplating (sensor housings, nuts, sockets, fittings, etc.)
• Manufacture of plastic workpieces (inserts, plastic housings, brush compo-
nents, etc.)
• Pharmaceutical and cosmetics industries (tablets, toothbrush components,
lipstick cases, etc.)
• Assembly and packaging (threaded pins, shafts, washers, nuts, etc)
• Jewellery industry (stampings, glass beads, watch housings, carton
components, etc.)
• Textile and clothing industries (buttons, zip-fastener components, needles, etc.)
• Precision engineering/optics (lenses, mounts, rings, stampings, etc.)
• Food industry (bottle caps, pressurised containers, spray-can valves, etc.)
• Medical technology (syringe components, glass ampoules, slip-on caps, seals,
etc.).
In view of the frequent need to deal with large numbers of workpiece types and
1.3 variants, together with the trend towards short-run production, workpiece fee-
Flexible orientating ding systems are required to offer high flexibility for changeovers from one work-
and feeding systems piece to another. Ideally, this facility should be programmable. It would other-
wise be necessary to have special feed systems for each workpiece type, which
would in most cases demand too much investment and destroy the overall
viability of an automation solution. Accordingly, the English company Bowl-
Feeders Automation produced vibratory conveyors in the 1960s that had inter-
changeable spiral sections including workpiece-specific orientating devices.
The output spiral section with an arc angle of 100° in each case reflected the
special feature of the workpiece concerned. Solutions of this kind, however,
did not gain widespread acceptance.

A special aspect of flexibility is the detection and separating-out of defective
workpieces that may be mixed in with the other workpieces. Automatic assemb-
ly, however, demands workpiece feeding that conforms 100% to specification.
In the case of bolts, for example, these may be defective due to the fact that
they have no threads or a false thread with no pitch. These workpieces must be
eliminated. Fig. 1-6 shows the defective workpieces that have been encountered
amongst stampings. These are produced at the extreme start and end of strip
material and if the side cutting edge of the tool does not work correctly. Similar
remnants will be encountered when working with bar material.
Fig. 1-6:
Defective workpieces and
remnants in the workpiece Gutteil
Good workpiece
flow can seriously disrupt
production
Defective workpieces
Falschteile
It is possible to list the following vital features for flexible feeding systems
[6 to 9]:
• Creation and maintenance of a defined workpiece state (position, orientation)
with a high degree of repetition accuracy
• Prevention of any mechanical damage or deformation of sensitive workpieces
• Reliable detection and elimination of workpieces which are unusable due to
the fact that they are the wrong type or damaged or do not conform to
dimensional or shape tolerances
• Short changeover times, perhaps even changeover at the press of a button,
and tolerance of minor interference (dirt, burrs, etc.)
• Large capacity achieved through compact storage of workpieces and easy
interchangeability of workpiece magazines
• Easy access of transfer position for automatic gripper devices (gripper space)
• Adequate feed delivery and high technical availability.
Of all the various flexible orientation systems, the one which has been widely
adopted is the vibratory bowl feeder (and in certain cases other hopper type
devices) in combination with automatic imaging detection and distributor
devices. A major advantage of this type of device is that it allows orientation and
sorting from a mixture of workpieces. Since these systems operate without
mechanical chicanes in most cases, we can speak of a programmable feed
system.

Another method involves the automatic filling of flat magazines. These are
equipped with workpiece-specific shaped nests. If workpieces are caused to
move across the magazines by linear vibration, they drop into the shaped nests
as they adopt correct orientation at random. Excess and incorrectly orientated
workpieces are fed back from the end of the magazines and are fed past these
again. Fig. 1-7 shows a system of this kind. Only the magazines need to be made
workpiece-specific [10].
Fig. 1-7:
Flexible magazining system
for small assembly work- 2
pieces 3
4 1
1 Assembly module
2 Magazine loading device
3 Vibratory bowl feede
4 Plate magazine
5 Linear vibrator
6 Assembly line
7 Workpiece carrier
8 Assembly robot
9 Feed position for
assembly workpieces
7
5 6
8
9
In electronics production, flat belt conveyors have been used for a considerable
time to fit components to printed circuit boards. The components are located on
flat bands or blister strips and are fed cyclically as flowing material. It is also
possible to produce sequence tapes, which contain all the various components
required for a particular assembly sequence. A typical feature of these systems
is that the overall feeding system does not need to be adapted for different
workpieces but need only be matched to the magazine belts or bands, which are
always the same. This provides a certain measure of flexibility.
A further method is to devise a system that imitates the way human beings “dip”
into a crate to pick up workpieces. Human beings find this easy – they see with
their eyes how the workpieces are lying in random order, pick up a workpiece
which is favourably positioned and feed this into a machine. The principles of
this operation can be transferred to a robot. Prototype solutions already exist
and will in time be developed for practical industrial use. For this purpose,
robots are equipped with 3D laser cameras that generate three-dimensional
images. Gripping points are then calculated on the basis of the detected work-
piece contours. The workpieces in question can lie in any random order but must
have gripping points which can be accessed by the jaws of the relevant gripper
without collisions. Systems of this kind are already working well on a laboratory
scale.

Things become somewhat simpler if workpieces are picked up from a table or
conveyor belt. The “table” can be a linear vibratory system like the one shown
in Fig. 1-8.
Fig. 1-8:
Orientating by picking up
from a table
1
1 Camera
2 Field of vision
3 Robot with gripper 2
4 Workpiece in correct
position
5 Screen of detection device
6 Table with tipping steps
7 Workpiece in incorrect
position
8 Vibrator
5 3
6
8
The principle is easy to explain. If enough workpieces are brought into the field
of vision of a camera, for example by means of a linear vibrator, there will almost
always be a workpiece in the right position for gripping. The workpieces pass
over tipping steps and are thus brought into a stable position; workpieces
standing on end fall over, while workpieces lying on top of others fall away. Once
the detection system has found a suitable workpiece, the relevant gripping coor-
dinates are output to the industrial robot. This picks up the workpiece by means
of a mandrel gripper. Excess workpieces run back into the hopper. It is of course
possible to use an intermittently running conveyor belt instead of the linear
vibrator.
The workpiece shape is programmable, which means that the solution is flexible
within certain limits. For many applications, camera-aided robotics represents
the current state of the art.

Hopper feeding devices accept bulk workpieces and are equipped with com-
2 ponents that are able to correctly orientate these workpieces. The workpieces
Workpiece hopper then leave the hopper feeders in an orderly fashion, generally in a string. The
feeding devices following operating principles are used to pick workpieces out of a randomly
ordered heap:
• Scooping with swivel segments, rams, wing rails or tubes

• Sliding along alignment edges which provide orientation
• Falling into profile apertures and travelling through shaped passages
• Application of vibration in combination with alignment components
• Exploitation of centrifugal force effects
• Removal of workpieces with the aid of magnetic forces.
Fig. 2-1 shows the principle of the design of devices of this kind. All the com-
ponents used to achieve the desired orientation operate in contact with the
workpieces. This may result in disadvantages, in particularly the following types
of workpiece damage:
• Roughness or loss of gloss due to friction

• Impact dents caused by falling workpieces
• Accumulations of dirt due to electrostatic effects, particularly with plastic
workpieces.
We will consider the most important types of hopper feeding devices in greater
detail below [11 to 13].
Electromagnetic vibratory feeders are especially important in conveying

2.1 technology for 4 reasons:
Vibratory feeders
• The drive of these feeders operates without the friction of components sliding
2.1.1 over each other and thus provides a trouble and maintenance-free conveying
Mode of operation device with a very low rate of wear.
• Open- and closed-loop control of these conveyors can be achieved by using
simple electrical-engineering components.
• The conveyors have low power consumption, since they operate in the area
close to natural resonance.
• They are robust and of simple design and are distinguished by their low
purchase costs.
Electromechanical vibratory feeders are spring/mass systems and obey the laws
of vibration mechanics. They can be produced in numerous variants.
18 2 Workpiece hopper feeding devices

Fig. 2-1:
Examples of hopper feeding
and orientating devices
1 Drum-type feeding device

2 Orientation with parallel
rollers
3 Vibratory bowl feeder
4 Vibrating dish hopper
5 Magnetic rotory hopper
6 Scoop segment hopper 1 2 3
7 Scoop tube hopper
8 Vibratory mat system
9 Centrifugal conveyor
10 Drum type with shaped
passage
11 Scoop wheel hopper
12 Step-type lifting feeder
13 Rotary hook hopper
14 Horizontal belt conveyor
15 Inclined conveyor
4 5 6
16 Disc hopper
17 Hook-wheel hopper
18 Conical-disc hopper
7 8 9
10 11 12
13 14 15
16 17 18
2 Workpiece hopper feeding devices 19

Depending on the type of workpiece motion on the conveyor spiral, we distin-
guish between micro-projection conveyance and friction conveyance [14 to 17].
In the case of micro-projection conveyance, the workpieces lift away from the
chute during the conveyance operation for brief periods, travel in free flight and
then impact onto the conveyor again. This impact phase creates a number of
problems. For one thing, the position of the workpieces is not precisely defined,
and for another, workpieces made of very brittle material may suffer damage.
There is also a not inconsiderable noise nuisance. It is, however, possible to
achieve very high conveyance speeds with this method of working. Fig. 2-2
shows the principle involved, The forward motion of the working material is in a
sense made up of a series of small ballet-like leaps. Due to the small size of
these “leaps”, however, a viewer has the impression of a continuous flow of
material.
Fig. 2-2:
Principle of micro-projection
conveyance 2 1
a) Vibratory system
b) Motion conditions
1 Workpiece
2 Guide 3
3 Spring mounting
4 Spring 4
5 Magnet
6 Motion of working material
7 Chute motion
F Flight time
K K Contact
t Time
a)
5
length
Hublänge
K
F
Stroke
0
t
b)

Under friction-conveyance conditions, the workpieces do not lift off the chute
but slide along this. This virtually eliminates the problem of uncontrolled work-
piece motion and significantly reduces the noise level but at the same time
involves a loss of speed. This type of conveyance is facilitated via single or dual-
mass oscillators coupled by leaf or rubber springs and excited by special elec-
tromagnets at a frequency close to their natural resonance. The acceleration
forces which act on workpieces during friction conveyance are less than 1 G
(1 G = 9.81 m/s2). In the case of micro-projection conveyance, on the other
hand, periodic acceleration forces occur of 9 to 16 G. Wear of the chute surface
is nonetheless low with micro-projection conveyance, since the workpieces
“jump”. Tests have shown that the wear on replaceable guide plates that have
been used to convey 300,000 tonnes of granite stone was less than 12 millime-
tres.
Conveyance behaviour depends on the relevant vibration characteristics, which

are governed principally by the following parameters:
• Relationship of working mass to counter-mass

• Relationship of workpiece mass to working mass
• Relationship of operating frequency to natural resonance
• Amplitude of exciter force
• Time curve of exciter force
• Mass moments of inertia
• Angle of introduction of force relative to working mass motion path
• Parallelism of working mass planes
• Centring of working mass and counter-mass relative to leaf-spring suspension
• Equal angles of incidence of leaf springs
• Spring stiffness.
By varying the voltage, it is possible to control the amplitude and thus the drive
force and the speed of travel of the fed workpieces.
For friction conveyance, sensor-guided spring/mass drives can be used. An

electronic closed-loop control system controls the two parameters of frequency
and amplitude. The reference variable is the distance/time signal, which is
converted within the computer into acceleration values. The controller keeps the
acceleration values constant to the preset desired values at all times,
irrespective of the instantaneous load state of the vibratory bowl feeder.
Frequencies of 5 to 20 Hz are used.

Vibrators should be installed on vibration insulators. They should nonetheless
not be installed in the immediate vicinity of precision machine tools. They must
also be aligned carefully on the horizontal plane. If vibratory bowl feeders are
installed at an angle, this will lead to variations in the angle of the spiral. As the
values of the chute rise angle and chute lateral inclination angle are small, an
inclination of the overall device may lead to malfunctions, such as the formation
of accumulations at certain points.
Of all the types of vibratory conveyors used in mechanical engineering, elec-

tromagnetic vibrators have proved to be the most popular. For the conveyance of
construction materials, for example, the preferred choice is vibratory chutes with
imbalanced drive. These vibratory systems are also significantly larger and very
robust.
We can distinguish between electromechanical vibratory systems on the basis of

their design features as follows:
• The number and orientation of the electromagnets fitted to conveyors with

vertical, horizontal or multiple tangentially arranged springs
• The nature of the elastic suspension of the conveyor drum with single or
multiple flat springs or round bar springs
• The way in which motion behaviour is controlled within the conveyor:
- By varying the voltage by means of a control transformer
- By varying the current and voltage drop across the electromagnet by means
of a resistor
- By varying the force by controlling the air gap of the electromagnet and
- By varying the number of electromagnetic coil windings that are fed with
current.
• The way in which the resonance setting is controlled:
- By varying the springs or spring assemblies in the case of multiple springs
- By varying the effective spring length and
- By varying the system mass by using mass trimmer pieces
• The shape and type of the workpiece-carrying component (chutes, cylindrical
and conical vessels, tubes and plates.
Vibratory feeders can be used for almost all kinds of workpieces (of small size),
provided that these do not have surfaces which are sticky, crumbling or generate
surface adhesion and that they do not lock together. Vibrators have even been
used for materials as hot as 900 °C and as cold as –50 °C. They can also be used
for conveyance in air-exclusion or vacuum environments. Conveyance speeds are
generally up to 7.5 m/min., but high-speed vibrators have already achieved
speeds of 100 m/min. [18 to 21]. On forging presses, vibrators are used to feed
workpieces with masses of, for example, 5 kg.

Vibratory feeders are produced in various forms. Fig. 2-3 shows a selection of
2.1.2 these. The spiral feeders with cylindrical or stepped drums will be familiar.
Types Feeders with an external spiral are used for vertical conveyance. These consist of
a support tube around which the conveyor path winds. The conveyance height is
theoretically unlimited. The path cross-section can be square or round. In the
case of tube feeders, the vibratory system is located on the tube. These feeders
can be used for both bulk materials and individual parts. Alternate driven and
non-driven tube sections can be connected up to form long pipelines.
Fig. 2-3:
Typical designs
1 Spiral feeder with

stepped drum
2 Vertical feeder with
external spiral
3 Vibrating tube
4 Vibrating tower
5 Linear vibrating chute
6 Spiral feeders with
1 2 3
multi-path outlet
4 5 6
Vibratory towers, which use one vibrator system to drive several drum type
conveyors, are required in assembly operations to provide a parallel feed of
small workpieces. They are not needed if feed systems are installed which are
able to separate and feed mixed workpieces from a random heap. Linear vibra-
ting chutes and spiral feeders with multiple outlet paths represent a modifica-
tion of the basic design principle. Fig. 2-4 shows the design of a circular spiral
conveyor. There are also versions with a single central magnet, with round bar
springs and with decoupled vessel bases (Fig. 2-4b).
Feed vibrators and storage vibrators are sometimes combined to form a single
unit. If the level of workpieces in a spiral conveyor falls, the storage vibrator tops
this up. A storage vibrator of this kind can be of very simple design, as shown in
Fig. 2-5. The angle at which the magnet is connected to the bin is chosen to
ensure that the vibration not only provides a conveyance function but also helps
to separate interlocked working material. This allows controlled dosing and fee-
ding to be achieved. The fed material can be nails, pins, screws or bolts, output
in batches for top-up purposes.

Fig. 2-4:
Design of a spiral vibratory
feeder
1
a) Micro-projection principle
1 11
b) Principle of friction
conveyance (Feldpausch) 3
12
1 Spiral drum 4
2 Hopper base 4
3 Leaf spring link 6
4 Electromagnet 7 4
5 Stand 5
8 13 14
6 Leaf spring
7 Base mounting
9 16
8 Base plate
9 Foot 2 15
10 Spiral outlet
11 Decoupled base
12 Intermediate mass
7
13 Counter-mass 10
14 Springs for vertical
1
motion
15 Springs for horizontal
motion
16 Rubber vibration dampers
a) b)
Fig. 2-5:
Storage vibrator
1 Hopper container
2 Spring
3 Table
4 Vibrator magnet 1
4
2

The actual workpiece hopper is referred to as a spiral drum, feeder drum or sim-
2.1.3 ply “drum”. The internal drum surface, and more rarely the external drum sur-
Spiral drum face, is equipped with a spiral feeder with an outlet at its upper end. Typical
drum types are shown in Fig. 2-6. Each type has its advantages and disadvan-
tages.
Fig. 2-6:
The most commonly used
a a
drum types
1 Cylindrical drum
2 Conical or funnel-shaped
drum
3 Stepped drum
4 External spiral drum
1 2 3 4
The cylindrical type is easier to manufacture but has the disadvantage that sepa-
rated-out workpieces fall down the full height of the drum. In the case of conical
and stepped drums, on the other hand, the workpieces fall only as far as the
next lowest spiral. There is also no possibility that they will jam against the
underside of the next highest spiral. In the case of a conical drum, the increment
“0a” of the spiral diameter is smaller than one spiral width. In the case of a step-
ped drum, the increment “a” is equal to the spiral width. Fig. 2-7 shows con-
veyor drums made of polyamide or aluminium into which a spiral has not yet
been cut. Standard spiral pitches “h” are 10, 15, 20, 25, 30 and 40 mm. The dia-
meter “D” ranges from 100 to 630 mm or even larger. Spiral drums are also
constructed from sheet brass, sheet steel, V2A and V4A materials and glass-
fibre-reinforced plastics (GRP).
Fig. 2-7:
Spiral designs
25 – D
40°
a) Standard spiral
b) Drum feeders
a
a Spiral width
h Spiral pitch
h
a) b)
With small workpieces, the diameter of the spiral drum should be approximately
8 to 12x the length of the workpieces to be conveyed. A slightly smaller diameter
will be obtained by using the graph in Fig. 2-8. This is also based on empirical
values.

Fig. 2-8:
Empirical values for drum
diameters as a function of
workpiece length (according
to Robertson)
160
length in mm
Werkstücklänge mm
120
Workpiece
80
40
0 200 400 600 800 1000
Drum diameterininmm
Aufsatzdurchmesser mm
Tumbling motions of the workpieces and contact between these may cause the
workpieces to move inwards during their upward motion and fall back into the
workpiece sump. To combat this, the spiral should be fitted with a low edge or
the channel should be given a lateral inclination a of up to 10 °.
The spiral pitch H must be selected so as to ensure that workpieces on 2 spiral

levels cannot obstruct each other. Allowance should be made for all possible
workpiece orientations (Fig. 2-9). The clearance should be 10 to 20% of the
pitch H.
Fig. 2-9:
Spiral pitch “H”
Clearance
Spiel
H

The base of the drum is shaped as a shallow cone; the angle of inclination of this
must be greater than the angle of friction between the base and workpiece. The
value chosen is usually around 10°. The coefficient of friction between the work-
piece and drum base should be as low as possible, while that between the work-
piece and spiral channel should be as high as possible. This allows higher
conveyance speeds. In certain cases, the conveyor spiral within the vibrator
drum is given a coating in order to improve conveyor or noise characteristics or
both. Various materials are used for this:
• Rubber: This improves operation and reduces operating noise. Ribbed sur-
faces improve the conveyance of small oily products.
• Polyurethane: This consists of PUR, which is approved for the pharmaceutical
and food industries. This material can be applied with a spray gun to give any
desired surface from the roughness of emery paper to mirror smoothness. The
thickness of the coating can be varied, and Shore A hardness values of 50, 80,
90 and 98 can be achieved. The coatings can have any desired colour. Coating
allows the noise level of conveyors to be reduced by as much as 20 dB(A).
• Brush lining: Vibrating channels can be covered with a brush lining. This
represents an elegant way of conveying workpieces while protecting their
surfaces.
Brush linings operate on a very interesting principle that is based on the de-
formation of inclined polyamide bristles which are under load and are then
subjected to vibration. Conveyance is virtually silent. Typical materials conveyed
in this way are bent-wire workpieces, sheet-metal workpieces, solid metal work-
pieces (including those with a relatively small contact surface), gearwheels, alloy
housings, light bulbs, lenses, etc. (Fig. 2-10). The bristle hardness must be
matched to the workpieces in each case.
Fig. 2-10:
Brush lining for workpiece
conveyance.
S Direction of vibration

Normally a horizontal vibratory system is used which generates micro-projection.
It is, however, also possible to generate a conveying motion with vertical
vibration. The motion is slower in this latter case and is generated by the in-
clination of the polypropylene bristles. Brush linings can also be used to create
orientating devices with a two-dimensional/linear mode of operation as shown
in Fig. 2-11. In the case of vertical vibration, it is the bristle alignment alone that
determines the direction in which the workpieces are conveyed. It is accordingly
possible to bring workpieces to a desired feed position by means of only a
suitable lining, without any further active guide components. This method at the
same time orientates or pre-orientates the workpieces. Depending on the work-
pieces concerned, gradients of up to 10° are possible.
Fig. 2-11:
Planar/linear ordered feeding
device (Ficon)
1 4
a) Brush-lining modules
for the creation of conveyor
systems 2 3
b) Plan view of a feed system
1 Workpiece
2 Brush lining
3 Lateral guide
4 Workpiece in feed position
3
a) b)
But let us return to spiral feeders: In the interests of better understanding, we

should note the following regarding directions of workpiece travel and outlet
connections. We generally refer to a feeder with clockwise motion as “right-
handed” (Fig. 2-12).
Fig. 2-12:
Directions of workpiece travel
and outlet connections
(plan views)
a) Left-handed outlet
b) Right-handed outlet
c) Lateral outlet
a) b) c)

Further conveyor devices and magazine chutes can be connected up in a number
of ways. Fig. 2-13 shows 6 examples of these. The chute for further conveyance
must not, however, be connected up rigidly (examples are shown in Fig. 5-2). In
certain cases, rubber tubing can be used.
Fig. 2-13:
Method of connecting up
gravity chutes, based on the
left-handed vibrator

A centrifugal feed device is a hopper feeder system with a central flat or conical
2.2 turntable which drives the working materials on this via a rotary action. The
Centrifugal feeders resulting centrifugal force causes workpieces to separate out of the heap and
move towards the edge of the drum. Here they meet the delivery ring and slide
2.2.1 onto the ramp. The speeds of the turntable and delivery ring can be adjusted
Design and mode of separately. Separated-out workpieces can be aligned by orientating devices and
operation thus proceed to the pick-up point correctly orientated. Incorrectly orientated
workpieces pass back into the hopper. Complex workpieces can be fed by means
of a conveyor belt, for example, in order to obtain the desired orientation for a
given process or to separate out all incorrectly orientated workpieces. Any
excess conveyed workpieces fall back into the heap in the hopper. In terms of
physics, the friction force FR and the internally-orientated force component “g”
resulting from the workpiece mass “m” must be somewhat smaller than the
centrifugal force FZ resulting from the rotation (Fig. 2-14). Incidentally,
centrifugal conveyors operate very quietly.
Fig. 2-14:
Centrifugal feeders [22]
1
a) Design
2
b) Forces
1 Adjustable hopper
suspension mounting
2 Workpiece already on 3
output channel
3 Rotating delivery ring
with drum lining
4 Continuously-rotating 4
turntable, e.g. with
10° angle of inclination
a)
FZ
FR
m·g
b)

The diameter of the drum of a centrifugal feeder can be 400 to 1200 mm, whilst
2.2.2 the conveyance speed can be 25 to 60 m/min. This allows workpiece through-
Typical conveyed puts to be achieved of 60 to 3000 units/min. This is very high, but despite this,
material and system the workpieces are handled very gently. Typical conveyed materials are small
performance items such as bolts, screws, rings, screw caps, cans, can lids, jar and bottle caps,
lamp sockets and socket sleeves (1200 units/min). It is also possible to feed
containers and bottles with capacities of up to 0.5 litres at high speed.
Workpieces should be of low weight. Centrifugal conveyors have accordingly
proved extremely valuable in the pharmaceutical and cosmetics industries and in
packaging applications. In comparison with vibratory bowl feeders, centrifugal
feeders are significantly larger and thus require more installation space.
In the case of stepped or lifting-plate feeders, small workpieces are conveyed

2.3 upwards in several steps by intermittently-moving plates. The plates are ar-
Multi-stage conveyors ranged in an ascending sequence, thus creating steps on which the workpieces
lie. The step thickness (which is equal to the plate thickness, e.g. 10 or 20 mm)
2.3.1 is matched to the workpiece dimensions. The plate mechanism is slightly in-
Design and mode of clined. Workpieces picked up by the lowest step assume a preferred orientation
operation and thus are at least pre-orientated by the time they exit from the feed device.
Further orientating devices will generally be installed at the outlet of the feed
device. The continuously rising and falling masses of the lifting plates demand a
good guide system and a high-quality crank drive mechanism, particularly as the
lifting steps can be up to 1400 mm wide.
Fig. 2-15 shows a special stepped feeder in which an additional pendulum

segment pushes the workpieces into the vicinity of the lifting plates.
Fig. 2-15:
Stepped feeders
a) Stepped feeders with

pendulum segment
(Köberlein)
b) Lifting-plate mechanism 2
1 Lifting step 1 5
2 Outlet or orientation zone
2
3 Hopper chute
4 Pendulum segment 3 1
5 Fixed step
6 Lifting drive
4
6
a) b)

Stepped feeders have a noise level below 78 dB(A). Another advantage is the
low top-up height of the hopper. Additional lifting devices for filling the hopper
with workpieces will generally not be required.
The hopper volume will often be 40 to 80 litres. Systems of this kind with inte-
2.3.2 grated top-up belt conveyors can offer a total of over 400 litres of storage space.
Range of applications This allows long periods of operation without human intervention. The average
throughput is up to 200 workpieces/min. Higher performance is possible but
depends on the workpiece shape. The workpieces to be conveyed may be made
of metal, glass, ceramics, wood or non-ferrous metal. Electronics components
are also possible. Typically, workpieces will be of low weight, such as bolts and
screws, washers, nuts, sleeves, pins, plastic mouldings and sheet-metal stam-
pings. Slightly oily or dirty workpieces will not cause malfunctions.
From as early as the 1920s, scoop segment hoppers have been used to feed
2.4 small workpieces, such as glass rods or tubes in electric lamp manufacture.
Segment feeders These hoppers operate quietly and without damaging workpieces and are well
able to feed machines with workpieces in a 2-second cycle. The principle of
2.4.1 these devices is shown in Fig. 2-16; there are numerous design variants.
Design and mode
of operation
Fig. 2-16:
Some design variants of
scoop segment hoppers
1 Arc-shaped slide
2 Hopper
3 Workpiece
4 Scoop segment 5
5 Outlet
6 Examples of
scoop-segment design 1
2
3
6
4

The scoop segment dips into the heap of workpieces and generally picks up
several workpieces at the same time, which then align themselves against the
edges of the segment. Twin-rail segments are used for workpieces that are
capable of being suspended. The segment is able to move in an arc or a straight
line. In the case of some solutions, the segment remains stationary and the
hopper rises and falls. Since the filling level of the hoppers has an influence on
the feed rate and, moreover, the orientation operation has a random quality, an
intermediate magazine is always installed between the scoop segment hopper
and the machine tool being fed. Segment feeders cannot tolerate chips or work-
piece fragments mixed in with the workpieces, since this debris becomes
jammed between the scoop segment and the segment guide [23].
Segment feeders are used for small and not excessively complicated workpieces.
2.4.2 In the case of cylindrical workpieces, the ratio of workpiece length to workpiece
Typical conveyed diameter should be 2:1 to 5:1 or greater. The workpieces should be unaffected
material and system by jolts, although glass workpieces can be conveyed at a rate of approximately
performance 25 double strokes/min., with a probable upper limit of 40 double strokes/min.
One design-related limiting factor is the time which the workpieces require to
slide or roll from the topmost point of the scoop segment into the magazine.
The scoop-segment length should be chosen as 5 to 8 x the workpiece length.
Typical conveyed material includes bolts and screws, washers, rollers, pins,
nails, hardware fittings, small tubes, welding studs, U-pieces and rivets.
Segment feeders will generally not be suitable for sensitive plastic workpieces or
workpieces with high-quality finishes. Feed rates are 80 to 300 workpieces/min.
Steep conveyors are of a very simple and robust design. As can be seen in
2.5 Fig. 2-17, a conveyor belt inclined at about 10 ° from the vertical is fitted with
Inclined and steep carrier vanes. These pick up workpieces which are by chance correctly orientated
conveyors and lift them out of the workpiece hopper. Shortly before they reach the top
guide roller, the workpieces slide or roll into the outlet channel at the side. The
2.5.1 lateral inclination of the carrier vanes must be matched to the rolling or friction
Design and mode characteristics (coefficient of friction) of the workpieces. An additional com-
of operation pressed air nozzle can be used to assist output. Instead of carrier vanes, slots
with a lateral inclination can also be used as active components. This design
principle facilitates quiet operation with a high level of reliability. The hopper is
close to the floor and can be filled easily. The output level is approximately 1.5m
higher. The hopper must be designed to ensure that there is always enough
working material in the scoop zone, since otherwise an unnecessary number of
workpiece carrier positions will remain empty. This is achieved by providing the
hopper floor with a suitable inclination (sometime adjustable). It can also be
advantageous for the hopper floor to take the form of a conveyor belt with an
intermittent action. The speed of the steep conveyor belt should also be
adjustable, since this allows it to be matched to the behaviour of the work-
pieces. For the conveyance of hollow workpieces, the carrier vanes can be re-
placed by hooks that engage in the openings in the workpieces. In this case,
a side outlet will no longer be possible. Instead, the workpiece must tip into a
channel or chute when they reach the uppermost point of the conveyor.

Fig. 2-17:
Steep conveyor as hopper
feed device
1 Workpiece
2 Hopper
4
3 Filling level 1
4 Output chute
5 Conveyor belt
6 Side wall
5
1
2 3 2
Steep conveyors can be used for medium-sized and also relatively heavy work-
2.5.2 pieces, and have a hopper capacity of 10 to 1000 litres, and a feed throughput
Typical conveyed of 10 to 1500 workpieces/min. These workpieces will be capable of being slid,
material and system rolled, suspended or poured and may be made of metal, plastic, rubber, wood,
performance etc., provided that they are not susceptible to jolts and do not have sensitive
surfaces. With certain workpieces, however, only partial orientation is possible.
In these cases, further orientation stages must follow.

The term “orientation technology” covers all the technical equipment and
3 methods used to bring workpieces into a desired state.
Orientation technology
Orientation means bringing a workpiece into a desired state in terms of positi-
on and attitude relative to a defined coordinate system (see also Fig. 1-4).
In the case of hopper feed devices, the task is reduced to the achievement of a
desired workpiece attitude. This involves turning workpieces about one or more
axes.
Orientation is a dynamic process. It involves the generation or application of

3.1 motion. During this process, the working material in a heap or group must never
Basic principles of be so constricted that it is totally unable to move. It is immaterial what forces
orientation (gravitation, vibration, air nozzles, positive actuation, magnetic fields) are used
to initiate the motion [13, 24 to 26].
The orientation process can be illustrated well by the example of a gaming dice
(Fig. 3-1). This is able to assume 24 different attitudes (orientations). In connec-
tion with workpieces, however, only one of these attitudes is useful.
Fig. 3-1:
Possible orientations illus-
trated by the example of a
cube with numerous features
(gaming dice)
a) Possible attitudes at 90°

intervals
b) Assignment of possible
attitudes to a 90°
rotational angle network
a) b)
3 Orientation technology 35
If, for example, the initial orientation is 1 and the desired orientation is 13, there
are various ways of achieving this through rotation:
1 - 24 -13 = –180° about y axis,

1 - 2 - 3 - 8 - 13 = +180° z, + 180° x or
1 - 6 - 23 - 20 - 13 = –90° x, -180° y, -90° x
etc.
The objective is now to achieve the desired orientation in as few steps as

possible and the shortest possible time.
If we take the opposite approach and separate out the incorrectly orientated
workpieces, we may have a problem dealing with the volumes concerned, since
of 24 orientations, it will always be necessary to separate out 23 orientations.
This brings us to the question of methods.
There are 3 methods that can be used to bring workpieces into a uniform ori-
entation (Fig. 3-2). These are as follows:
• Orientation by selection (selection principle), also described as passive ori-

entation. Incorrectly orientated workpieces are fed back to the hopper and
then pass through the orientation zone again.
• Orientation by correction (positive-actuation principle), also described as
active orientation. Each incorrectly orientated workpiece is acted on in such a
way that it assumes correct orientation.
• Orientation by division, also described as passive/active orientation.
Incorrectly orientated workpieces are collected separately and are also ori-
entated during this process. They are then fed to the processing station along
with the others.
36 3 Orientation technology
Fig. 3-2:
Orientation methods (symbols
in accordance with VDI 2860)
a) Orientation by selection
b) Orientation by correction,
c) Orientation by division,
1 Spiral, linear feeder

2 Workpiece
3 Chicane
a)
1 2 3
b)
c)
The use of auxiliary energy is not a criterion for classifying a method as “active
orientation”. Fig. 3-3 shows a number of typical workpieces and how these can
be orientated by “selection”. Chicanes (another word for “orientating devices”)
are relatively easy to produce.
Fig. 3-3:
Examples of orientation by
selection
1 1
a) Orientation of U-pieces
b) Orientation of conical
control knobs
c) Orientation of round 2
·
workpieces with a spigot 4
d) Orientation of sealing caps 3 3

2 Milled spiral zone
3 Workpiece a) b)
4 Inclined chute
5 Curved guide slot to
eliminate incorrectly-ori- 1 1
entated workpieces
6 Drop opening
6 3
c) d)
The behaviour of workpieces as these move against alignment edges (spiral

edges, chicanes, tipping edges, baffle plates) will vary from one type of work-
piece to another. It is, however, possible to identify the probability with which a
defined orientation will be achieved, for example if a workpiece free-falls onto a
table surface. This is known as the orientation probability factor [33 to 35].
The orientation probability factor is the ratio of the number of favourable ori-
entations for a given purpose to the overall number of possible orientations
(attitudes) of a workpiece.
This factor will vary in accordance with dimensional conditions. As an example

and demonstration, Fig. 3-4 shows the conditions and effects relating to a drum-
shaped workpiece. This graph is based on experiments in which the workpiece
was repeatedly allowed to fall onto a flat surface.
Fig. 3-4:
1.0
Graph for determination of A
orientation probability for
Orientation probability
centre-of-gravity distance S 0.8 y
and y = 0.282 L
A Open end downwards

D
0.6
B Closed end downwards
S L
C Lying on side
S Centre of gravity C
0.4
0.2
B
0
0.1 0.2 0.3 0.5 0.8 1.0 1.5 2.0 3.0
L/D ratio
The curves within the graph will of course shift if, for example, the workpiece
base is thicker than its walls, since this will result in a shift of the centre of gravi-
ty. In designing feed devices, we will attempt to take as a desired orientation
the workpiece orientation that has the highest orientation probability. If neces-
sary, we will accept that it will be necessary to re-orientate each workpiece as it
passes from the hopper to the point of processing on a machine. This can often
be achieved by simple means. A critical factor is, of course, the level of perform-
ance that the feed device in question is required to provide.
Orientating devices arranged along a conveyor zone, such as spiral vibrators, are
3.2 also referred to as chicanes. These operate in contact with the workpieces. Their
Orientation using task is to orientate workpieces by rotating or straightening these or turning
mechanical devices them over, making skilful use of geometrical details on the workpiece and also
centre-of-gravity distances. Incorrectly orientated workpieces are either brought
into the correct orientation or separated out. This is always achieved through the
use of several chicanes that create a kind of handling-technology sequence.
As a general principle, workpieces are always slowed down by orientating de-

vices, which reduces throughput. For example, the conveyance efficiency in the
feeding of cylindrical pins is approximately 0.5. The conveyance efficiency is cal-
culated as follows:
ËF = VP/Vth
where
VP Conveyance speed achieved in practice
Vth Conveyance speed theoretically possible.
The sequence shown in Fig. 3-5 gives a throughput of 32 workpieces/min. This is

a good guide value for many small workpieces when these are orientated in a
vibrator.
Fig. 3-5:
Typical sequence for
orientation in a vibrator
100 Stück
100 units
(according to Lotter)
1 Break-up of accumulation
2 Workpiece
30% 1
70 units
70 Stück
10%
50% 63
63units
Stück
32 units
Stück 10
The most importance types of chicanes will be described in brief below. Now just
as in the past, much depends on experience. Making chicanes work properly
demands the attention of mechanical-engineering specialists and also costs a
great deal of time. In recent times, simulation programs have been developed
which allow orientating chicanes to be tested out on the computer screen. The
animated 3D displays provided by these programs reflect the relevant physical
effects such as gravity forces, impact forces resulting from collision with other
objects, and frictional forces [27 to 30]. As we shall see, there are other ways
of achieving correct orientation. These involve the replacement of mechanical
components by software-supported device (imaging systems). We shall study
this in Chapter 3.5.
Let us briefly consider each of the most important types of chicanes. These are:
Top deflectors
This type of deflector (wiper) is installed at a defined height (Fig. 3-6). It is used
to separate out and push away workpieces which are lying on top of others
(“piggyback” position) or which are standing on end. The working height “h” is
the relevant workpiece height plus an allowance for the micro-projection effect
(“jump” height).
Fig. 3-6:
Top deflectors are simple
Clearance
metal wipers
Spiel
h
h
Top deflectors are, however, not suitable for use with flat workpieces, since
these workpieces are often not perfectly level and can then easily jam (Fig. 3-7).
It is better to allow “piggyback” workpieces to tip away to one side, either to the
inside or the outside. These workpieces will not be supported by the wiper edge
and will follow another path. If the workpieces are led away to the outside, they
can be guided to the spiral below (Fig. 3-8).
Fig. 3-7:
Flat workpieces jamming
against a deflector due
to a wedge effect
Fig. 3-8:
Workpiece feedback
1
1 Spiral drum
D
2 Workpiece
3 Feedback h
4 Inclined spiral
2
5 Spiral
3
“h” Height of wiper edge
D Drum diameter
4
Shaped deflectors
Incorrectly orientated workpieces can be separated out by appropriate mirror-
image components. Only correctly orientated workpieces are able to pass
through the shaped deflector (Fig. 3-9), while incorrectly orientated workpieces
are pushed further to the outside and tip back into the hopper. Shaped deflec-
tors can also be made adjustable.
Fig. 3-9:
Shaped deflectors have
a profile that is a mirror
image of the workpiece
contour
Notches
Notches are local constrictions (narrowings) of the conveyor spiral. They have
the task of separating out workpieces that are lying on top of each other or are
incorrectly orientated. This produces a uniform single row of workpieces.
Fig. 3-10 shows some typical forms of notch devices. A multiple notch (4) can,
for example, be used to separate out caps which arrive with their open side
facing downwards. They become unstable at this point and fall back into the
hopper.
Fig. 3-10:
Orientation based on tipping
at a notch 2 3
1 Spiral
2 Correctly orientated
workpiece
3 Incorrectly orientated
workpiece 4
4 Multiple notch
Notches can also be combined with local guide rails. Only correctly orientated
workpieces can pass through this chicane. Fig. 3-11 shows 2 examples of this.
In the case of the configuration shown in Fig. 3-11b, workpieces are able to pass
if they lie on the upper rails. The condition is a > b. Incorrectly orientated work-
pieces fall through.
Fig. 3-11:
Combination of notch and
upper rails 4
1
a) Orientation of a bracket
b) Orientation of a shoul-
2
dered cylindrical
component
3
1 Retaining rail
2 Inclined spiral track
b
3
with notch 3
a
3 Workpiece ·
4 Support rail, upper rail
a) b) m·g
Drop opening
Drop or profile openings can in principle provide very simple chicanes. They may,
however, also be an unwelcome source of trouble. Workpieces can pass over the
drop opening only if they are by chance orientated in a certain way, which may
be correct or incorrect. The openings always provide one orientating operation.
Fig. 3-12 shows a number of typical configurations. The best configuration
should be determined by practical tests to decide, for example, whether the
edges of the opening should be sharp or, as shown in Fig. 3-13, rounded-off.
Fig. 3-12:
Design examples of drop
openings
a) Openings for vee-shaped

or triangular workpieces
b) Opening linked to
magazine for round
a)
workpieces with internal
contour feature
c) Drop opening for round
workpieces with external
feature
b) c)
Fig. 3-13:
Drop opening
with chamfered inlet
1 Workpiece
2 Spiral drum
3 Magazine
4 Drop opening
2
4
It can also be advantageous to provide a cover over the drop opening with a
small clearance relative to the workpiece as shown in Fig. 3-14. This prevents
the workpieces from tipping prematurely and becoming jammed in an inclined
position.
Fig. 3-14:
Profile opening with cover
1 Cover 1
2 Workpiece
3 Tube magazine 2
4 Inclined chute
5 Spiral
3 4 5
Profile openings can also be covered by a spring flap, as shown Fig. 3-15. The
flap opens only in the case of incorrectly orientated workpieces, due to the fact
that their centre of gravity is offset. Workpieces that are separated out in this
way pass to the next-lowest spiral and begin to circulate again. Chicanes of
this type with moving parts considerably reduce workpiece throughput speed
and are also susceptible to malfunctions. Today, better devices are used which
operate with optical detection, as we shall see.
Fig. 3-15:
Orientation using
a spring flap
1 Workpiece
2 Vibrator spiral
3 Flap
4 Torsion spring
1 2
3 4
Profile openings can also be placed at the side, in the drum wall. The workpieces
must, however, be upright for this purpose, as demonstrated by the example in
Fig. 3-16. In this case, the incorrectly orientated workpieces are separated out
and pass via a friction chute into the hopper or onto a downstream spiral zone.
The angle a of the wall inclination is approximately 70°. Multiple “drop aper-
tures” are arranged in series, each with contours matched to a certain workpiece
orientation.
Fig. 3-16:
Orientation with side profile
apertures
1 Top deflector 1
2 Ejected workpiece 3
· 2
3 Profile opening
4 Catch chute
5 Workpiece 4
6 Oscillatory motion
workpiece
8 Return track SchnittA-A
Section A-A Schnitt B-B
Section
1
4 A B 5 7
6
A B
Profile rail
Rails profiled in accordance with the outer contours of workpieces are highly
suitable for separation functions. Devices of this kind frequently exploit the
effect of the centre of gravity of the workpieces, as shown Fig. 3-17.
Fig. 3-17:
Separating-out of incorrectly I II I II I II
orientated workpieces using S
rails with various profiles
a) Round workpiece
with spigot
b) A sleeve is brought into
a longitudinal orientation
c) Rectangular-shaped work-
piece with longitudinal rib
I Correct orientatio
II Incorrect orientation
a) b) c)
S Centre of gravity
As the examples show, only workpieces with simple geometry can be orientated
in this way. On the other hand, these types of chicanes are relatively easy to pro-
duce and are also reliable. A completely different method is used to orientate
the workpiece shown in Fig. 3-18, which has a trapezoidal cross-section. The
workpieces are orientated gradually by the effect of gravity, and the profile spiral
then terminates in a rectangular channel. It is, however, costly to produce rails of
this kind.
Fig. 3-18:
Orientating via a shaped
channel
I 1 2 II III IV
1 Vibrator spiral
2 Workpiece
3 Alignment channel
By the way, it is also possible to use twisted profile rails or spirals to re-orien-
tate workpieces. The spiral zone in this case produces a “spin”, as shown in
Fig. 3-19. The workpieces in this case are turned through 90°. The actual orien-
tating operation is carried out before this.
Fig. 3-19:
Re-orientating using a spiral
twist groove
Profiled rails can also provide a useful way of orientating workpieces in linear
vibratory chutes. The device shown in Fig. 3-20 is used to orientate wire springs.
The springs are first allowed to fall onto a rail, from which they hang. They are
then transferred to the magazine rail during linear conveyance. This, however,
occurs only in the case of workpieces whose longer shank is on the right
(as seen in the illustration). Workpieces that do not succeed in transferring to
the magazine rail fall back into the hopper.
Fig. 3-20:
Orientating wire springs on B A
the basis of shank length
1 Magazine rai
2 Rail for separating-out
of incorrectly orientated 1 B A
workpieces
3 Workpiece 2
I II 2
I Correctly orientated
workpiece
II Workpiece is separated
out
Section A-A
Schnitt A-A
I II
3
Section B-B
Schnitt B-B
Fig. 3-21 shows the orientating of shaped dynamo plates. Once again, this
method exploits the difference in the length of the two shanks. Workpieces with
right and left-handed orientation are separated by purely mechanical means and
magazined separately. There is no return of workpieces to the hopper.
Fig. 3-21:
Orientation of dynamo plates
1
of non-symmetrical U-shape 3 4
using linear vibrator S
1 Workpiece
2 Linear vibrator system
3 Magazine rail
4 Feed rail
S Vibration
2
Inclined spiral with raised edge
Inclined spiral zones can be used to cause workpieces to fall back into a hopper
if their centre of gravity is located beyond the tipping edge. The shape and
inclination of the spiral must be matched to the position of the centre of gravity
of the workpieces concerned, just as in the case of the solutions using profile
rails. Fig. 3-22 shows some typical configurations. Orientation on the basis of
lateral position is made much easier if the workpiece has a chamfer. This is a
major factor in the design of workpieces that are compatible with automation
and handling-friendly design is one part of this [5].
Fig. 3-22:
Examples of applications
of chicanes of the “inclined
spiral with raised edge” type
m Mass
g Gravitational acceleration
S Centre of gravity S
m·g
Although many details of these chicanes are worked out empirically by testing, it
is also possible to work with calculations. It is, for example, possible to calculate
the required angle of inclination a of the spiral. We can demonstrate this with an
example.
Example: We wish to determine the maximum angle of inclination a for the

workpiece shown in Fig. 3-23 in order to ensure that workpieces with their
centre of gravity uppermost tip of their own accord.
arc tan (20/(2(21 – 5 – 0.3))) = arc tan (20/31.4) = 32.5°

arc tan (20/(2(35 – 21 – 5 – 0.3))) = arc tan (20/17.4) = 49°
The length of the spiral zone with a raised edge is selected as approximately
100 mm, while the track width is selected as 22 mm.
Fig. 3-23:
Sample workpiece
20
b Track width
S Centre of gravity
· Angle of inclination
21
b
35
S
Inclined spirals can also be combined with upper rails to create either a work-
piece guide or an ejector, as shown in Fig. 3-24. Workpieces that will not run in
the spiral slot fall away. The inclined discharge plane in the spiral is present only
in the vicinity of the chicane over a length of some 100 to 200 mm.
Fig. 3-24:
Inclined spiral combined
with an upper rail C
A
C
Section
Schnitt A-A Section
Schnitt B-B Section
Schnitt C-C
Spiral with longitudinal slot
This chicane is used to suspend workpieces with heads, such as bolts. If these
are required with a head-first orientation, this can be achieved by using a ramp
rail which inclines the workpiece shank as the workpieces pass through. This is
shown in Fig. 3-25a. There must of course be enough room below the spiral for
the workpieces to hang. Otherwise, the suspended workpieces are forwarded in
suspension, for example to a feed unit for a power wrench.
Fig. 3-25:
Design of longitudinal slot for D
suspendable workpieces with
heads
a) Re-orientating into
head-first attitude ·
b) Suspension of workpieces
s
for axis-parallel
magazining
m
h
1
b3
b1
b2
a)
m2
b3
b2
b)
The following guide values can be used for sizing:

b1 = 1.1 · D
b2 = 1.2 · D
b3 = 0.6 (D – d)
h = (l – s) 1.1
m1 = 1.5 · l
m2 = 2.5 · l
Overflow
For most orientation operations, workpieces are required to flow as a single-row
chain. This can be achieved by using an overflow device. Excess workpieces lying
adjacent to others are pushed off and fall back into the feeder drum. The over-
flow device (Fig. 3-26) is also able to clear workpiece jams to a certain extent by
ensuring that any excess conveyed workpieces are removed from the spiral. A
typical combination of several chicanes is shown in Fig. 3-27. First, upright work-
pieces are ejected. The overflow device then forces the workpieces into a single
row. Finally, to conclude the orientating operation, the screws are suspended to
create an axis-parallel order.
Fig. 3-26:
Example of design
of overflow device
Fig. 3-27:
Handling technology for
orientation of cheese-head
screws
1 Vibrator spiral 1 2 3
2 Overflow chicane
3 Top deflector
4 Spiral section with
longitudinal slot
5 Separating-out of work-
pieces moving in parallel
6 Separating-out of screws
standing on their heads
4
5 6
Tipping stage
Tipping stages are use to orientate or re-orientate workpieces. This allows, for
example, rotationally-symmetrical workpieces to be re-orientated from lying on
their sides to standing on end. One design of tipping stage is shown in Fig. 3-28.
An advantage of this design is that the workpiece is still guided at the side
during the tipping operation. Vee-shaped workpieces, too, can be stood on end
by using tipping stages. Tipping can also be carried out against support sur-
faces, thus creating a true orientation operation. The asymmetrical position of
the centre of gravity and the workpiece shape are used to achieve a certain
orientation.
Fig. 3-28:
Tipping stage for cylindrical
workpieces
1 Workpiece
2 Tipping edge for tipping
against external wall
3 Vibrator spiral
In the solution shown in Fig. 3-29, the only workpieces that come into contact
with the support surface are those travelling with their smaller diameter leading.
These catch against the support and are turned as they fall. Correctly orientated
workpieces tip away immediately, as soon as their smaller trailing diameter can
no longer be supported by the tube. A similar principle is used in the solution
shown in Fig. 3-30 to orientate L-shaped workpieces.
Fig. 3-29:
Tipping stage
with support surface
1 Tube with profile opening

in outlet
2 Support edge
workpiece 1
Fig. 3-30:
Orientation using a tipping
stage
1 Workpiece shapes
2 Tipping zone in vibrator
spiral
3 Support edge
1
workpiece 2 3 4
A somewhat difficult tipping operation is shown in Fig. 3-31. Workpieces arrive

pre-sorted into 4 different orientations. Only workpieces in orientation I can
engage with the tipping edge. Workpieces with orientations II to IV fall back into
the drum hopper. It undoubtedly requires some skill to make a chicane solution
of this kind operate reliably. Modern imaging systems offer a faster answer. We
shall discuss systems of this kind later.
Fig. 3-31:
Orientation of small levers
I II
by tipping
1 Workpiece
2 Tipping edge III IV 2
3 Friction surface
4
4 Magazine 1
I to IV 3
II III IV
Possible workpiece
orientations
A fine air jet can provide a useful separation function during the orientation of
3.3 workpieces. Hollow workpieces such as light-bulb sockets for example, that are
Orientation using lying with their open ends downwards of a spiral or a linear zone, can be ejected
pneumatic components highly effectively by means of an air jet (Fig. 3-32).
Fig. 3-32:
Orientation of a light bulb
socket
1 Workpiece 1
2 Vibrator spiral
3 Compressed-air nozzle
2
p Compressed-air jet
p 3 p
Air jets also provide a simple means of orientating the discs shown in Fig. 3-33
by their chamfered side.
Fig. 3-33:
Orientation in accordance
with an edge feature
1 Air jet 1
2 Workpiece (e.g. disc)
3 Vibrator spiral or channel
Another method is to use an air jet to eject profiled workpieces via a profile
opening through which only incorrectly orientated workpieces can pass. This is
illustrated in Fig. 3-34a. In order to be on the safe side, 2 profile openings and
air jets are provided in series. Workpieces lying with their slot uppermost are
ejected. Other incorrectly orientated workpieces are separated out before this
operation.
Fig. 3-34:
Orientation using com-
pressed-air nozzles 1 1
a) Orientation of U-shaped 2 p
workpieces p
b) Orientation of circuit
boards 5 p
1 Spiral 5
2 Air nozzle 2
3 Profile opening 4
4 Incorrectly orientated 3 4
workpiece a) b)
workpiece
p Compressed air
Fig. 3-34b shows a workpiece ejector consisting of a circular panel with three
riveted legs. Correctly orientated workpieces present too small an area to the air
jet to be ejected. This solution can be implemented very easily.
A combination of a sensor and air jet nozzle can be seen in Fig. 3-35. It is, howe-
ver, necessary to have gaps between the workpieces. The air jet is activated only
when an optical or inductive sensor below the spiral detects the leading edge of
a workpiece. Workpieces that arrive slot first can continue on their way, since
the brief air jet is not able to generate any ejector force in this case. A system
of this kind is costly, and a optical detection system would therefore probably be
a better choice.
Fig. 3-35:
Separating out incorrectly
3
orientated workpieces using
an air jet and presence 1 2
sensor
1 Air nozzle
workpiece
3 Incorrectly orientated
workpiece
4 Sensor (e.g. inductive
proximity sensor)
4
Compressed-air jets can, by the way, also be used to good effect to accelerate
workpieces in feed channels (Fig. 3-36). If the workpieces in question are lying
on a linear vibrator, the speeds of the vibrator and air jet are combined and it is
not necessary to incline the vibrator. With an appropriate arrangement of the air
jet it is also possible to eject excess workpieces from accumulation zones.
Fig. 3-36:
Accelerating workpieces 2 3
with an auxiliary air jet
a) Normal operation
b) Behaviour in accumulation
operation
c) Combination with vibration
conveyor 1
a)
1 Compressed air 1
2 Workpiece 4 3 2
3 Guide channel
4 Acceleration nozzle
5 Vibrator drive
b)
4
c)
A sophisticated form of fluidic orientation is hydrodynamic or aerodynamic
feed [36]. Fig. 3-37, for example, shows an oil-jet hopper in which pressurised
oil is used to force workpieces upwards in an eddy pattern. During this process,
the workpieces orient themselves according to the laws of fluid mechanics and
land in an orientated form in an output magazine. With an oil pressure of
69 x 103 N/m2, the achievable orientation throughput is less than 60 workpieces
per minute.
Fig. 3-37:
Oil-jet hopper [37]
1 Cover
1
2 Oil jet 2
3 Hopper
4 Workpiece filling level
3 10
5 Workpieces (e.g. made of
metal, glass, ceramics
6 Magazine tube
7 Pressurised-oil line 4
with nozzle 8
8 Oil overflow
9 Pump
10 Oil level 6
5
This orientating operation becomes neater from the technical point of view if air
jets are used. The workpieces remain dry and do not need after-treatment.
Orientation based on fluid mechanics exploits the following physical effects:
• Boundary-layer flows along the surfaces of bodies,
• The aerodynamic flow paradox (flow at a gap)
• The Coanda effect (lateral flow onto bodies)
• Separation of flow
• Turbulent free jets.
If these effects are exploited in the right way, they can produce jet impact forces
and force effects which are related to the drag form of the body in the air flow in
question. Drag form is expressed by the familiar coefficient of drag cw, which is
particularly important in the design of vehicles. This drag coefficient cw is pro-
portional to the turbulence behind the flow body. In view of the fact that bodies
which are to be orientated as part of a feed process also need to be guided
mechanically, there are a large number of reciprocal effects between the guide
geometry, the workpiece and the air flow. These effects can be controlled by the
chosen nozzle type and flow generation method and any air film gliding surfaces
deployed. Fig. 3-38 shows typical orientation effects in schematic form.
The requirements for the design of aerodynamic feeding systems are listed in
[36] as follows:
• Separation of transport (conveyance) and orientation functions
• Transport preferably by means of mechanical processes
• Orientation preferably by means of aerodynamic effects
• Exploitation of friction for stabilisation and damping
• Ensurance of “open” feeding devices.
“Open” here relates to the operating area for an orientation process within
which there is no possibility of workpieces jamming against any component of
the feeding device in question.
Fig. 3-38:
Orientation effects in a flow
field (according to Lorenz)
t t t t
a) Exploitation of global
cw factor
b) Exploitation of an
asymmetrical centre 2
of gravity S
c) Tipping operation
d) Swivelling
S S 5
1 Flow field 1
3 5 4
2 Double-inclination track
3 Gap nozzle
a b c d
4 Point nozzle
5 Workpiece
t Time
Workpieces can be detected via electronic means by measurements using

3.4 a high-frequency magnetic field. Workpieces are passed through this field
Orientation using (Fig. 3-39) and continuous measurements are taken. The workpieces must be
electromagnetic effects fed singly. The guides used can take the form of tubes, channels, gravity chutes
and also conveyor belts. There are, however, limits to the precision of detection
that can be achieved.
This is how it works: The workpiece to be detected can, for example, be divided
into 4 measurement zones. The system is pre-programmed as to which zone is
to be checked for asymmetry against which other zone. The detection operation
generates switching signals that can be used, for example, to control down-
stream sorting channels. In the case of the example below, the values for the
zones b and c are checked against each other for asymmetry.
Fig. 3-39:
Orientation detection with 1
the aid of high-frequency
2 3
magnetic fields
4
a) Sensor configuration
b) Sample workpiece for
checking
1 Measurement zone
2 Feed tube
3 Workpiece
4 Electronics
a)
a b c d
b)
The workpieces must all exhibit clear symmetrical differences. In the case of
composite workpieces, symmetry can also be the criterion for a complete assem-
bly operation. To a certain degree, internal features can also be detected, for
example in the case of workpieces that are externally symmetrical with press-
fitted components of a different material (Fig. 3-40). Other detection methods
cannot do this. Preliminary testing should be carried out in all cases before a
decision is taken in favour of one method or another.
Fig. 3-40:
Examples of workpieces
for which electromagnetic
orientation or detection can
be used
It is, by the way, also possible to identify workpieces by “enveloping” them with
sound. This is a particularly interesting method for small workpieces and detects
workpieces by measuring reflected ultrasound. In contrast to camera and laser
systems, which detect only the periphery or shadow of workpieces, ultrasound
measurements permit a three-dimensional checking operation. The sound waves
surround the entire workpiece and can even penetrate into internal contours
such as drilled holes, internal hexagons, etc. This is what gives the process its
comprehensive detection capability. It can be used for all workpieces made of
sound-reflecting material, such as ferrous or non-ferrous metals, plastics, cera-
mics or glass, and also for pre-assembled modules of virtually any configuration.
As the workpieces travel through the system, they pass several sound meas-
uring heads whose signals are used to create an acoustic “map”. The system
“learns” from good workpieces and uses these to derive the desired sound
reflection pattern with which every workpiece is compared.
The simplest method of visual contour detection is to compare a workpiece

3.5 contour with a number of contour templates, each of which represents a partic-
Orientation using ular orientation or workpiece shape. If the contours coincide, this provides an
optical detection indication of the identity of the contours or of the current orientation of the
technology workpiece in question. This was “Mark I” imaging, as actually practised 25 years
ago with rotating template discs. Today, workpieces maps are acquired and
stored electronically and are also compared with reference patterns by electronic
means.
Orientation by means of imaging systems has the following major advantages:

3.5.1 • The only workpiece pre-orientation required is a few simple chicanes in a
Advantages and hopper feed device. These chicanes can generally be set up very quickly.
methods • Imaging systems can detect not only incorrectly orientated workpieces but
also defective workpieces which should not be in the system at all.
• Imaging systems can generally be reset for a different workpiece without
any physical conversion work, particularly if the old and new workpieces are
members of the same workpiece family.
• Different workpieces from a single hopper feed device can be detected
simultaneously, divided into types and fed separately. This saves space in the
vicinity of an assembly station.
• In addition to orientation, various software characteristics can also be
checked and documented via software.
• The data material which is generated can also be used for counter functions.
These can count not only good and bad workpieces but also predetermined
quantities. The resulting data can be processed for statistical processes.
• Certain mechanical chicanes react acutely to small physical changes (voltage,
mains frequency) in the drive system. Optical detection does not place
stringent and expensive demands on feed technology.
• In view of the fact that workpiece features are stored as data, more sorting
steps can be utilised than in the case of mechanical selection devices.
• The latest imaging systems today (for example, Festo’s Checkbox) are
designed to be set up using the teach-in method, which does not require any
special knowledge.
One approach that is being pursued with great success at the present time is
to combine classic feeding systems with optoelectronic detection systems. A
system of this kind could, for example, consist of a vibratory feeding system,
a top-up hopper, a CCD camera with lighting, a controller, display devices and
software for programming (generally using the teach-in method) and for algo-
rithms for orientation detection or quality-assurance and checking tasks. Test
algorithms can, for example, be developed for the following kinds of tasks:
• Detection of workpiece features in order to derive an indication of workpiece
type and orientation. The software used must be able to compare workpiece
maps with reference data records.
• Measurement of workpieces or selected areas of these as part of the quality-
assurance process. For this purpose, edges are located in the workpiece map
by software means and the distances between these are measured. In order to
enhance accuracy, subpixeling methods are used in certain cases. These are
an electronic means of increasing resolution.
The tasks described above are almost always carried out with workpieces which
are in motion on a non-stop continuous-throughput basis at remarkably high
speeds. It is possible with today’s line cameras to achieve resolutions ranging
from 0.1 mm per pixel, down to 0.01 (0.001) mm at conveyance speeds of over
1 metre per second. Special cameras can achieve a multiple of this speed.
If mechanical orientating components are used, these will generally operate

reliably if workpieces are fed singly. This also applies as a general principle to
the optical detection of workpieces. Workpieces in multiple rows must be se-
parated out. This can be achieved in a vibrator by, for example, providing a kink
in the pitch of the spiral (Fig. 3-41a). This produces a change in the speed of the
workpieces from v1 to v2, where v2 > v1. A mechanical trick of this kind is not
necessary when working with a detection unit such as the Festo Checkbox,
which has an integrated conveyor belt and whose speed can be adjusted easily.
Fig. 3-41:
Differential separation
V2 V1
of working material
a) With a kink in the pitch

of the conveyor spiral
b) With an external
variable-speed conveyor
belt
a)
1 Detection device
V2 > V1 V2
V2
1 2
b)
How can we produce a map of our workpieces?
There are two ways of recording workpiece images as silhouettes:

• A two-dimensional image can be recorded with a large-area CCD camera as a
kind of “snapshot”
• An image can be recorded with a CCD line camera and continuously moving
workpieces on a “slice by slice” basis. An image is produced only when there
is relative motion between the line camera and the workpiece.
The latter variant is suitable for conveying operations and is also simpler in tech-
nical terms. The principle of this method is shown in Fig. 3-42. A prerequisite is
that workpieces must not overlap or touch other workpieces, since this will lead
to misinterpretation of the image data.
Fig. 3-42:
Generation of a mono-
Werkstück
Workpiece 1 2 3
chrome contour image on a
continuous-throughput basis
using a line camera
1 Recording of a greyscale
image in slices
2 Conversion of strip images
into monochrome contours
v,t
3 Generation of a complete
digital image and checking
of this for features
t Time
v Conveyance speed
The workpiece is fed past the line camera and scanned step by step. The image
data is then digitised into a binary contour image, which is then used as the
basis for all feature-analysis operations. The resolution in the direction of
conveyance is equal to the “slice” width as follows:
v · tc = b 1 BE
v Speed of conveyance
tc Camera exposure time
b “Slice” width
BE Pixel.
Example: Let us assume a speed of conveyance of v = 300 mm/s and an expo-

sure time tc = 256 microseconds. 1 pixel thus represents 300 x 256 x 10–6
0.0768 millimetres on the workpiece in the horizontal direction. The vertical
resolution of the selected line camera is fixed at, for example, 512 pixels.
The principle of a workpiece detection system is shown in Fig. 3-43 by the ex-
3.5.2 ample of a Festo Checkbox. This is available in several sizes for different classes
Detection device of workpiece size and has a maximum throughput window size of 80 x 80 milli-
metres. Scanning is by transmitted light, which has the following advantages:
• The system is robust and unaffected by external light and variations in light
levels
• There is high contrast between the workpiece and the background
• Colours and surface patterns are not recorded and do not affect the
evaluation.
Fig. 3-43:
Principle of a workpiece
detection system 6
(Festo Checkbox family) 7 D
1
2 5
a) Scanning principle
b) Overall view of “Sortbox” 2
device C
9 B
A
1 Viewing angles and 8
10
throughput windows
of the various sizes 3
2 Line camera 4
3 High-intensity 5
LED lighting b)
a)
4 Workpiece
5 Conveyor belt
6 Lateral guide
7 Ejector nozzle
8 Input zone In order to obtain high-precision workpiece maps, the camera is equipped with
9 Sorting channel telecentric lenses. These are lenses with which all light rays travel through the
10 Control unit subject field parallel to the optical axis. These are used in cases where the
A to D distance between the test subject and the lens is not precisely defined or where
Workpiece sorting channels the length of the optical path varies during the evaluation of different features
and a precise mapping scale is required (Fig. 3-44). Normal lenses cannot achie-
ve this. The choice of lenses is thus a question of the accuracy required.
Fig. 3-44:
Light beam path with
telecentric imaging 2 3 4
1 Subject
2 Lens or lens group
1
3 Aperture
4 CCD chip
Once a workpiece or workpiece orientation has been detected, the actuator

signal which is generated by this is fed down parallel to the direction of travel to
the appropriate ejection position for the scanned workpiece. An ejector nozzle is
activated at this point and the workpiece is propelled into the relevant sorting
channel. If the conveyance speed is changed, the signal transit times for the
ejection operation also change automatically without the need for intervention
by the operator. The ejection of “normal” workpieces such as those shown in
Fig. 3-45a presents no problems. Some workpieces, however, are very streamli-
ned and also have very smooth surfaces. In these cases, the air ejector pulse
may not prove to be strong enough, and it will be necessary to change the nozz-
le geometry and possibly also the timing of the ejector pulse. Tests are also
advisable with very light workpieces.
It is, however, possible with optical devices to detect the workpieces shown in
Fig. 3-45b, which frequently have only fine features of the order of magnitude of
tenths of a millimetre. Generally speaking, mechanical orientation devices are
unable to achieve this.
Fig. 3-45:
Workpieces suitable R 0,5
for optical detection
Ø 17
a) Typical very easily

recognisable turned
workpieces 36
b) More difficult workpieces
0,1
0,1 deep
tief
which have nonetheless
Ø 0,8
been detected success-

fully
a b
In comparison with mechanical orientation components, it is only necessary with
imaging systems to press a button in order to change the system over to another
workpiece (for which data has been stored previously) or to another test algo-
rithm. The replacement of workpiece-specific hardware components by software
is the most important advance that has been made to date in the automatic fee-
ding of workpieces for orientation.
In order to make it possible to analyse a digital image (and in principle other

3.5.3 types of images as well) for various features even at high conveyance speeds,
Analysis of features we need high-speed imaging computers, equipped for example with digital sig-
nal processors. Typical features that are capable of analysis are illustrated in
Fig. 3-46 by an imaginary workpiece. This shows how the height and length of
an image can be measured. The line sensor measures a distance by counting
the number of pixels. The values H and L can be used to determine the area and
the aspect ratio H/L. The precise contents of an area can be determined by
simply counting the pixels. The contour image can be used to determine the cir-
cumference, the surface centre of gravity and the contour centre of gravity.
The distances S and K can be used for detection purposes, as can the polar
distances that result if circles are plotted based on the centre of gravity and
allowed to intersect with the contour line.
Fig. 3-46:
1
Selected features for the y y y
y/2
investigation of digital
contour images
H
a) Dimensions, counting
of area pixels
L x x/2 x x
b) Area X/2
c) Area Y/2
a) b) c)
d) Area centre of gravity S 2
y y y
e) Radius of inscribed
maximum circle (R2) S R1
and minimum circle (R1) R2
f ) Window investigation
y1
g) Investigation of vertical
strips x1 x x x
h) Investigation of selected e) f)
d)
edge zone 4
3
y y
1 Contour image
2 Window
3 Strip (vee strip)
4 Upper external contour
x x
g) h)
It is also possible to determine the moments of inertia of a surface about the

axes x-x and y-y and use these to determine the surface’s orientation. With
certain workpieces, it is sufficient to analyse only a selected (programmable)
window (a contour zone or digital image strip). This is of particular interest in
connection with quality assurance. The relevant window (region of interest or
ROI) may be a threaded part of the workpiece or a recess.
If we are concerned only with detecting the orientation of a workpiece, relative
comparisons are sufficient, which means that absolute measurements are not
required. In quality assurance work, absolute measurements can be taken and
compared with absolute reference dimensions. It is often, however, enough in
these applications also to carry out relative comparisons with good workpieces.
In most cases, the system will require only a correctly dimensioned workpiece in
order to “learn” data for comparative measurements.
With certain workpiece shapes or topologies, a particular method may fail,

which will mean switching to other workpiece features or evaluation algorithms.
It is of course not possible to read an infinite amount of data from an optical

contour image in the form of a silhouette. There are process-specific limitations.
Features that are not optically visible are lost for detection purposes. These
features fall into the following groups:
• Workpieces with features which remain externally invisible in contour images,
such as:
- Internal contours,
- Symmetrical workpieces made of more than one material
- Symmetrical workpieces with varying surfaces or colours.
• Workpieces which cannot be separated reliably, such as:
- Sticky workpieces or those sticking together
- Workpieces which tend to lock together
• Workpieces which are larger than the evaluatable image window and those
which do not assume a stable position on the conveyor belt and, for example,
roll backwards and forwards during scanning.
• Workpieces which are very dirty, have burrs which do not show in the scan or
remaining cutting residues will either be incorrectly rejected or passed as
good, despite the fact that rework is required. Highly reflective workpieces will
also often be rejected. Practical testing is vital.
• Very thin flat workpieces that offer hardly any cross-section. Workpieces of
this kind can sometimes be scanned better at an oblique angle. Flat work-
pieces can also be detected by using translucent conveyor belts. The principle
of a detection device of this kind is shown in Fig. 3-47. It will also not be
possible to detect features which are very fine (small) in relation to the overall
workpiece. In the case of dimensional checks, it will not be possible to detect
fine details of the order of magnitude of the system resolution.
Fig. 3-47:
Silhouette detection with a 7
transmitted-light system
1 Sichtfeld 5
Area of view
1 Feed hopper
2 Speed sensor
3 Translucent conveyor belt
4 CCD camera
5 Multiple gripper
6 Mirror
7 Lighting 2
6
3
4
The Festo Checkbox is prepared for use by means of the teach-in method. This
3.5.4 involves allowing a number of sample workpieces to pass through the device
Programming of optical correctly orientated. A contour map is recorded in each case. It is also necessary
detection, orientation to “teach” the system all the other incorrect orientations that may occur.
and sorting devices Fig. 3-48 shows an example of this. All orientations other than those shown are
eliminated beforehand in the hopper feeding device. The number of teach-in
workpieces required will vary from one workpiece to another. In the case, for
example, of semi-transparent workpieces, more will be required for statistical
reasons.
Fig. 3-48:
One orientation must be
declared as the desired 1 3
orientation 4
2
1 Support surface
2 Conveyor belt
3 Direction of view
4 Workpiece
5 Direction of conveyance 5
S F
F Incorrectly orientated
workpieces
S Desired orientation
F F
The sample teach-in workpieces must have all the features of good workpieces.
The sample workpieces will, of course, also exhibit shape and dimensional var-
iations. These variations will also be incorporated into the reference data list and
represent a distribution. The following rule applies:
The greater the deviations between the sample workpieces, the greater the
permissible deviations among subsequent workpieces evaluated as “good”.
This is of course not a disadvantage. Even with manually inspected workpieces,

items are accepted as “good” provided that they fall within defined tolerances.
As shown in Fig. 3-49, the teach-in mode stores the workpiece data that will
later be used in the automatic mode as reference data to correlate the workpie-
ces to certain types or orientations.
Fig. 3-49:
Sequence diagram showing
the generation of switching Comparison with
Automatic
signals for actuators Threshold value reference data
mode
for digitisation
Digital Digital Work- Decision, Signals to Deflector,

Work- piece update, ejector
greyscale contour control work-
piece featu- counting, nozzle,
image image piece flow
res classifier other
actuators
Workpiece motion Algorithms Generation Storage

Exposure time for contour Teach-in
of teach-in and loading
Analogue/digital detection mode
data of teach-in
converter data
Teach-in data
Digital images form the basis for all necessary operations. For this purpose, the
image captured by the camera in 256 shades of grey is analysed into black-and-
white values using a threshold value (binary level). The function of this threshold
value is shown in Fig. 3-50. A change results in a different relative ratio of pixels
with white and black declarations. If the binary level is raised in our example,
the number of pixels detected as black will rise. The definition of the binary level
will depend on the optical properties of the scanned material and the backgro-
und and thus on the lighting. The advantage of digitisation are the high signal
processing speed which this allows, due to the fact that the volume of data is
considerably reduced in comparison with a greyscale image.
Fig. 3-50:
Digitisation of analogue
signals
1
a) Binary level
b) Number of pixels 2
1 Analogue signal
2 Binary level
w w
s Black,
w White
s s
a)
b)
If the system is used with a workpiece mix, the complete teach-in process must
be repeated several times. In the automatic mode, all contour images will then
be compared with all correct and incorrect orientations of each workpiece type.
In rare cases, incorrect sorting may occur during air ejection due to projecting
burr edges on workpieces and, for example, suction effects. At high throughput
speeds, these errors can be detected by monitoring with a video camera. This
applies to an even greater degree to orientation in a vibrator, where sorting and
orientation errors of this kind occur far more frequently. We must always bear
the consequences in mind - any incorrectly sorted workpiece or overlooked
reject may bring the operation of a downstream assembly station to a halt.
Every assembly operation involves the feeding of several workpieces. This re-
3.6 quires an appropriate number of feeding devices. In order to save space in the
Orientating and sorting vicinity of assembly stations, occasional use has been made of tower vibrators.
mixed workpieces These are a series of vibrators, each matched to a particular workpiece and
installed in tiers on a single vibratory system. A tower vibrator is thus a dedi-
cated solution that cannot be used for other workpieces (Fig. 3-51a).
Fig. 3-51:
Orientated feeding of several
types of small workpieces 2
a) Workpiece types stored

5 4 2
separately in the hopper 3
b) Workpiece mix in vibratory

feeder
1 Tower vibrator 6
2 Vibratory feeder
3 Outlet
4 Conveyor belt 7
5 Sorting and checking 1
device (Festo Sortbox)

6 Ejector nozzle
7 Separated workpiece A B C D ABCD
magazine
a) b)
A to D
Workpiece types
Modern checking and sorting devices allows workpiece mixes to be stored

unsorted, with orientation and sorting then taking place in the course of the
feeding process. The principle of this is shown in Fig. 3-51b. Since the system
intelligence is primarily located in the imaging unit, while the hopper feeding
system (centrifugal conveyor, vibrator, inclined conveyor, etc.) can be largely
non-workpiece-specific, systems of this kind offer enhanced flexibility, at least
within the limits of their size. The space saving due to the reduction in the num-
ber of feed systems required is a decisive advantage, particularly in the assem-
bly of small workpieces. The required investment is also lower. The “sorting”
process can be defined as follows:
Sorting is the automatic separation of mixed workpieces. A volume of different

articles is arranged into groups on the basis of certain classes of features
(type, properties).
The golden rule in production operations is not to discard correct orientation

once this has been achieved. For certain processes, such as heat treatment and
electroplating, a different approach must often be taken. In the interests of
achieving the maximum degree of utilisation of electroplating lines, different
workpieces are often temporarily mixed. The resulting complex mixture of work-
pieces must then be separated again. The difference between the workpieces is
frequently a matter of a few millimetres. Manual sorting after production can
virtually never be justified in economic terms.
An example of a solution for tasks of this kind is shown in Fig. 3-52. Various
workpieces are fed from a spiral conveyor. The workpieces have different shapes
and arrive at the output belts or rails in a chaotic order. Each workpiece is re-
corded by a CCD camera. If the orientation of the workpiece is acceptable, it
is able to pass the ejector nozzle and continue to the deflector, which has now
been set to the appropriate magazine channel, allowing the workpieces to
proceed to the pick-up point. Incorrectly orientated workpieces are returned to
the bowl feeder by the ejector nozzle.
Fig. 3-52:
Vibratory bowl feeders
with parallel output rails
for different workpieces 1 3 8
(according to Schmid) 2
9
1 CCD camera
2 Conveyor belt
3 Return ejector nozzle
4 Gravity chute
5 Belt drive
4 5 7
7 3-position pneumatic drive
8 Magazine belt drive 10 11 12
6
9 Deflector
10 Magazine channel
11 Motor for automatic track
width adjustment
12 Side edge guide
The deflector adjustment is static, i.e. it is adjusted before each workpiece ar-
rives. For this purpose, it is necessary for the workpieces to be fed singly and
not in a continuous stream. The example also indicates that it is possible to
adjust the channel widths for the various workpieces to ensure that these main-
tain their orientation. Servo motors allow programmable width adjustment at the
time of a workpiece changeover.
Fig. 3-53 shows a 25-year-old idea for the sorting of workpieces. This is a contin-
uous-throughput method in which the electrophysical properties of the 2 work-
piece types are investigated by proximity means in a magnetic field. Based on
the results of this, the workpieces are then transferred by an ejector nozzle to a
parallel conveyor track or left on the same track. The sorted workpieces exit from
the system via separate feed channels. Pre-orientated workpieces can be fed to
this device, for example, from a vibratory bowl feeder.
Fig. 3-53:
Sorting 2 workpiece types
(according to Kanaew)
1 Electromagnet
1
2 Ejector nozzle
3 Workpiece in feed channel
4 Output chute with separate 2
channels for each 4
workpiece type
5 Conveyor rotor 5
p Compressed air
p 3
A special kind of workpiece mix is involved when we are sorting natural prod-
ucts, such as nuts. The workpieces are all of the same type, but differ in size
and details. Fig. 3-54 shows a sorting method using a Festo Checkbox. The nuts
are scanned in free fall from 2 angles of view at a 90° interval and their volume
is calculated from the resulting measured values. Images from the two view-
points are fed via a mirror and prism to a line camera in a way similar to the
solution shown in Fig. 1-2. This is a difficult task, since the nuts rotate about
their own axis during their free fall, resulting in motion blur. After the measure-
ment operation, air nozzles are activated and blow the workpieces as they fall
into the appropriate sorting channel K1, K2 or K3. It is a tribute to the high level
of performance of the Festo Checkbox that it is also able to provide a solution for
an application of this kind.
Fig. 3-54:
Sorting nuts in free fall
(Festo) 1
a) Drop system
5
b) Beam path of measuring
system
c) Angles of view
of workpieces
1 Feed channel 6 8 7 5
2 Nozzle ring
b
3 Pulsed air jet 2
4 Sorting channel
5 Line camera
3 9
6 Lighting
7 Mirror 4
8 Sorting workpiece K1 1
9 Angles of view 8
K2 K3
a c
Automatic production with fast cycle rates demands workpieces which are 100%
4 checked, since otherwise malfunctions will occur and production or assembly
Checking and counting machines will be effectively operating additionally as checking machines,
workpieces leading to a drastic fall in throughput. The use of imaging systems means that it
is possible to record data that provides an indication of major workpiece quality
parameters.
Screws provide a standard example of quality parameters. Before these leave

4.1 the manufacturer’s, they are checked and sorted according to the following
Important process- criteria:
related workpiece • Bent shanks
parameters • Squashed heads
• Damaged, short or absent threads
• Length, head height
• Excess material on tips
• Sorting to exclude incorrect workpieces
• Check for presence of single slot or cross-slot.
The aim is to achieve workpieces of zero-defect which are 100% correct. In the
case of screws, there is generally a facility for counting off a preselected quantity
for a given pack size.
Further checks may include the following:

• Measurement of contour segments
• Relative comparison of distances
• Absolute comparison with reference values
• Measurements of length and height
• Detection of features e.g. 0.1 mm and larger
• Detection of fluidic skins, burrs and chips
• Number of contour features.
It would seem appropriate to make statistical use of the large volume of data
generated during checking operations. In this way, quality features can be docu-
mented, trends can be spotlighted and long-term developments affecting com-
ponent quality or individual features can be traced. The Festo statistical software
“CheckStat”, for example, allows quality data to be recorded over any desired
period and evaluated in any application in which a Festo Checkbox is installed.
The results are shown in a screen graphic. Fig. 4-1 shows an example of this
visualisation.
4 Checking and counting workpieces 71

Fig. 4-1:
Statistical software helps
visualise test results with the
Height
Festo Checkbox system
Pol. min.
Length
Base
Counting is an essential operation, particularly during packing and order picking,

4.2 but also in order to obtain data on workpiece throughput for use in modern
Counting production control systems. Data of this kind allows conclusions to be drawn
regarding the condition of the tools of preceding machines. Counting operations
can thus help monitor tool service life and initiate maintenance work. Counting
itself is relatively simple to accomplish if optical, acoustic or inductive sensors
are installed in the workpiece flow.
Counters are digital circuits that add and store the pulses with which they are
fed (incremental counters) or subtract and store these (decremental counters)
and display the number of pulses which they have counted.
A typical application of incremental counters is for the continuous recording of

the number of good workpieces produced for production control purposes.
Decremental counters are used in the main as predetermining counters. A de-
sired quantity is preset, and when the counter reaches zero a signal is output
to the next machine on the production line. After this has been acknowledged,
a new counting cycle is started.
To allow counting, however, there must be gaps between the moving workpie-
ces. Gaps can be introduced into a chain of workpieces by transferring them
to a faster-running conveyor or by reducing the spiral pitch at the outlet of a
vibratory bowl feeder. Counting is more difficult if the workpieces travel in a
chain without gaps. Fig. 4-2 shows a solution in which the workpieces tip away,
aided by an air jet. This tipping operation can be reliably detected by a sensor
which supplies a counting pulse.
72 4 Checking and counting workpieces

Fig. 4-2:
Counting a continuous stream
of workpieces without gaps
1 Compressed air tube

with ejector nozzle
1
2 Diffuse sensor
3 Workpiece chain
4 Vibratory feeder
2
A special form of counting is represented by order picking of workpieces and

components, for which sorting systems supported by imaging devices can also
be used, provided that the workpieces are not too large.
Order picking is the process of collecting together particular quantities of dif-

ferent workpieces from larger stored quantities in response to the demands of
a consuming system.
A typical example of order picking is the compilation of particular quantities of

fixing materials (bolts, washers and nuts) for manual assembly systems. Order
picking tasks are also frequently encountered in packing systems. In the past,
only one type of workpiece was usually fed to each packing station. If several
types of workpiece are fed from a single hopper feed system, the packing line
can be made considerably shorter, thus saving space in the production work-
shop and the investment cost of hopper feeding devices.
4 Checking and counting workpieces 73

The orientation of workpieces is meaningful only if this orientation can be main-
5 tained in a magazine. There are various ways of achieving this, with shaft maga-
Magazining orientated zines being the most common type used. They may be stationary or also mobile.
workpieces We will study a few possibilities below.
Orientated workpieces (often they are only pre-orientated) must be fed into a
5.1 magazine when they exit from a hopper feeding device. The transfer from one
Outlet design of vi- sub-system to another may result in technical problems. This applies particularly
bratory conveyors to spiral vibratory conveyors. The connection of a magazine rail forms a transiti-
on from a vibratory system to a static system and is a critical point. The points
of transition from a vibratory system to another moving system (conveyor belt,
linear vibrator chute) also requires careful thought. The reason can be seen in
Fig. 5-1. The further the channel is extended, the more unfavourable the effect
of the force component which moves the workpieces forward. The outlet channel
should therefore never project by more than the drum radius D/2. This also
means that it is not permissible to have fixed links to further magazine channels.
Fig. 5-1:
Extended vibratory channels
oscillate simultaneously in
curvilinear form
D
D/2
The channels must therefore be separated. A number of examples are shown

in Fig. 5-2. A right-angle transitional gap is generally used when the workpiece
length L is > 4b (b = channel width). If the workpieces are shorter than this, an
angle transition is better.
If a fixed connection of the magazine rails is made, it must be made in such a

way that the lateral motion components are kept away from the coupled maga-
zine rail. This can be achieved, for example, by using a ball and vee or leaf spring
connection.
74 5 Magazining orientated workpieces

Fig. 5-2:
Connection of magazine
channels
a) Right-angle transitional
gap
b) Comb-like transition
c) Angle transition
b
a) b) c)
In addition to magazine channels, small conveyor belts or linear vibrator chutes

can also be used to forward orientated workpieces. The different theoretically
possible variants are shown in Fig. 5-3.
Fig. 5-3:
Forwarding orientated
workpieces
a) Small conveyor belt

b) Linear vibrator chute
c) Shaft magazine 1 2 3
d) Drop transfer device
a) b)
5
4
c) d)
A small conveyor belt can also be placed at 90° to the position shown in
Fig. 5-3a. Especially for feeding bulk materials in random order, outlet channels
are cut at an angle at their end points at which the material in question is trans-
ferred to a conveyor belt. This results in optimum distribution across the full
width of the channel. Fig. 5-4 shows a configuration of this kind.
5 Magazining orientated workpieces 75

Fig. 5-4:
Transfer point
to a conveyor belt
1 Side edges
2 Outlet channel of vibrator 2
3 Small conveyor belt
Workpieces that travel into a magazine by gravity (Fig. 5-3c) must not jam whilst
doing so. Conversely, it must be possible for a single workpiece to travel down
the magazine channel without turning over. Workpieces that have a tendency to
do this should be brought to their pick-up point by a conveyor belt or linear
vibrator chute. Magazine rails and channels should have openings which allow a
visual inspection and, if necessary, manual interventions to correct malfunctions.
They must also not be affected by dirt.
In modern hopper feeding and orientating devices, the outlet conveyor belt is
equipped with imaging devices. In cases of this kind, we must consider how
separated-out workpieces can be returned to the hopper. Return channels can
be used for this purpose, as shown in Fig. 5-4. Other solutions included parallel
return conveyor belts or collecting the workpieces in bins and emptying these
back into the hopper (probably the simplest variant).
Fig. 5-5:
Incorrectly orientated
workpieces are returned
to the hopper drum (Festo)

Magazines are always placed between hopper feeding devices and workstations,
5.2 due to the fact that feeding directly from a disorderly body of workpieces is ran-
Magazine designs dom to a certain degree, while workstations operate in a fixed cycle. The stan-
dard solution is magazines that match the contours of the workpieces. The main
problem is that it must also be possible for individual workpieces to pass
through the magazine without turning over or otherwise losing their orientation.
A typical magazine solution is shown in Fig. 5-6.
Fig. 5-6:
Shaft magazine
with gravity operation
5 5
a) Horizontal pick-up
b) Vertical feed
3 3
1 Magazine guide wire 2 1
2 Workpiece 3
2
3 Wire securing ring
4 Distributor
1
4
5 Infeed from hopper feeding 2
device
a) b)
All kinds of profiles are used to create magazines, including tubing and spiral
wire sleeves. A number of examples are shown in Fig. 5-7. It should be ensured
that magazines remain accessible, for example to allow jammed workpieces to
be freed quickly. Dirt grooves are also important, in order to ensure that the
workpiece contact surfaces do not collect dirt and gradually develop encrustati-
ons.
Fig. 5-7:
Examples of outlet
or magazine rails
1 Open channel
2 Fully covered channel
3 Partial cover 1 2 3 4
4 Suspension rail
5 Workpiece
6 Channel with cover rails 5
7 Wire rail cover
8 Spiral wire sleeve 6 7
9 Wire rail magazines
10 Open tube 8
11 Tube magazine with 12
internal profile 13
12 Drop funnel
13 Magazine tube
9 10 11

If channel magazines are required with only a slight inclination, we can consider
air cushion channels. With these devices, workpieces glide on a virtually fric-
tionless film of air (Fig. 5-8). The devices can thus operate with angle of inclina-
tion a of only 1° to 3 °.
Fig. 5-8:
Design of air cushion
3
magazines
5 2
1 Compressed air channel
2 Workpiece
1
3 Nozzle bore
4 Lateral guide ·
5 Air film
1 m·g
· Angle of inclination 2
4
3 3
1
There is occasionally a requirement to output orientated workpieces to mobile

magazines, for example panel magazines, which are then transferred to an
automatic assembly machine or workstation. The principle of this is shown in
Fig. 5-9. In order to fill all the magazine positions, the magazine must be indexed
one longitudinal row at a time, while the end of the tube is indexed in each case
by one lateral row. This requires positioning axes or other mechanical devices
with either a fixed step width or a mechanically adjustable width. It may be
necessary to stop the workpiece feed for a short time to allow magazine
changing.
Fig. 5-9:
Magazine filling device
1 Feeding conveyor
2 Infeed funnel
3 Flexible tubing 1
4 Workpiece
5 Positioning axis 2
6 Magazine guide
7 Panel magazine
3

If different types of workpieces are fed and orientated at the same time, each
type must be magazined or accumulated separately. Random-order accumu-
lation is used, for example, to count out packaging quantities. In this case,
the packaging material or bulk material container is fed automatically.
Orientated storage in channel magazines requires controlled magazine inlets.

The relevant control signal must accompany the workpiece up to the magazine
inlet.
For multiple magazines, various organisational variants have been devised to

ensure that each type of workpiece is fed to the right magazine. These are
shown in Fig. 5-10. The positioning motions are provided by pneumatic multi-
position cylinders. The critical factor is whether there is one or more pick-up
positions for the handling device. If there is only one, this means that pick-and-
place devices can be used for handling, while multiple pick-up positions will
generally demand programmable handling systems. In the solution shown in
Fig. 5-10b, a distributor in each case releases the next workpiece to arrive at the
pick-up point by gravity. The filling and emptying of the magazine channels are
independent of each other.

Fig. 5-10:
Multiple magazining
a) Variable pick-up position

and variable infeed
position 4
b) Fixed pick-up position and
variable infeed position
c) Fixed pick-up position and
fixed infeed position
G3
1 G1 G2
1 Feed belt 2
2 Multi-row magazine
3 Multi-position cylinder 3
4 Linear guide
5 Assorted workpieces
a)
6 Distributor
7 Lateral guide
8 Trunnion pin mounting
9 Conveyor belt
10 Outfeed position 5
11 Deflector
G Pick-up position
1
2
3
G
b)
8
1 7
11
9
3
c) 10

There has long been a demand for quiet technologies and devices. Certain
6 hopper feeding devices and particular vibratory units, are notorious for their
Ancillary equipment noisy operation, due to their design principle. Sheet-metal spirals in combina-
tion with sheet-metal workpieces generate a noise level of 90 to 100 dB(A) if
they operate on the micro-projection principle. Friction conveyor systems ope-
6.1 rate with frequencies of 5 to 20 Hz and a noise level of less than 78 dB(A).
Noise protection The following noise-reduction methods are available:
devices • Lining the feeder drum with, for example, polyurethane 1 mm thick, or ap-
plying other coatings by spraying. It is also possible to apply a lining of brush
material.
• Encapsulating the vibrators in a sound-absorbing hood. Depending on the
workpieces in question, a reduction of noise level of 20...25 dB(A) can be
achieved. This measure in combination with sound-absorbing drum coatings
makes it possible to achieve an operating noise level of 60 dB(A).
• Complete enclosure of feed system. This may, however, restrict accessibility.
Enclosures should always be designed in such a way that a view of the con-
veyor is retained. It must be possible to rectify malfunctions quickly.
In order to ensure continuity of workpiece feed, the supply of workpieces in the

6.2 hopper feed device must not be completely used up. Top-up devices installed
Hopper top-up systems upstream of the hoppers are therefore activated when sensors signal that the
workpiece level has fallen below a defined minimum. Topping-up is particularly
important with vibratory bowl feeders, which must not under any circumstance
be completely filled, since this will excessively restrict the movement of the
workpieces and prevent the feeder from operating correctly. Typical top-up
devices are vibratory conveyors, linear vibratory hoppers and hopper conveyors.
Fig. 6-1 shows a solution with a hopper conveyor.
Fig. 6-1:
Hopper conveyor
for workpiece top-up (Intec)
1
1 Hopper conveyor
2 Controller
3 Stand
4 Gravity chute
5 Level sensor
6 2
4
6 Ancillary equipment 81
This allows periods of operator-free working to be created of greater or lesser
length, depending on the hopper volume, workpiece size and the required feed
throughput. The hopper conveyor itself of course also needs periodic refilling.
As its filling height is approximately 1.80 m, hopper conveyors are also produced
with a built-in lifting axis, as shown in Fig. 6-2, which allows them to be brought
close to the floor for refilling.
Fig. 6-2:
Topping-up using a hopper
conveyor with lowering 3
facility

2 Telescopic cylinder
3 Hopper conveyor 1
1600 mm
2
If the fed workpieces are ferromagnetic, they can also be topped up using a
handling device equipped with a magnetic gripper. This is shown in Fig. 6-3.
It may be possible to take workpieces directly from a box pallet. The magnet
gripper is a simple bell-shaped electromagnet with suspension mounting.
Fig. 6-3:
Topping-up using a handling 3
device
1 Magnetic gripper
3 Handling device
4 Box pallet
1 4
82 6 Ancillary equipment
Topping-up can also be carried out relatively easily using an inclined conveyor.
This type of conveyor is commercially available in numerous forms and activates
itself automatically only when required.
Solutions using auxiliary vibratory hoppers are also possible, as shown in

Fig. 6-4. The auxiliary hopper supplies 2 vibratory bowl feeders. A deflector
switches the top-up flow to the vibrator requiring this at any given time.
Fig. 6-4:
Topping-up using an auxiliary
vibratory hopper
1 Hopper drum
2 Vibrator for workpiece feed
3 Deflector
4 Outlet channel, 1
3 4 5
A further interesting way of providing a topping-up function with bulk materials

is a pneumatic workpiece conveyor system. Fig. 6-5 shows a system of this kind
in schematic form, which allows workpieces to be conveyed over distance of up
to 50 m entirely without damage. A separator halts the conveyed material and
guides it to the relevant hopper feed unit. Workpieces for use with systems of
this kind should be light in weight, such as plastic articles of all shapes up to
a size of around 80 mm or small light metal workpieces. Workpieces that have a
tendency to lock together are not suitable.
Fig. 6-5:
Pneumatic top-up system
a) Conveyor system
b) Examples of workpieces 4
1 5
which can be conveyed
by pneumatic means 2
3
1 Distributor with up
to 7 branche
2 Tubing
3 Pneumatic elevator
with hopper e.g.
400 litre capacity
5 Separator with output tube
a) b)
With hopper feeding devices, it is necessary to monitor the instantaneous filling
6.3 level to ensure that topping-up – automatic or manual – can be initiated in good
Level monitoring time. Depending on the type of hopper design, it is possible to use optical,
acoustic (ultrasound), inductive or tactile sensor; binary-type sensors, which is
to say those which supply only yes/no information, are fully adequate. Optical
and inductive sensors are fitted to the outside of the hopper at the desired
minimum filling level. In the case of vibratory bowl feeders, we can use a
“finger” directly over the centre of the drum to scan the workpiece surface.
Fig. 6-6 shows an example of this. We can see that it is also possible to fit the
level sensor directly to the top-up hopper. It is particularly important to re-fill
vibratory bowl feeders frequently, since in order to ensure correct operation the
bowl must not be more than one third full.
Fig. 6-6:
Level sensor (Intec)
and top-up hopper
1
a) Top-up hopper with level 5
6 7
sensor for vibrator
underneath 2
b) Example of a level sensor 9 10
8
1 Hopper
3
2 Controller
3 Stand
4 Level sensor
4
5 Conveyor belt
6 Mounting
7 Adjustable arm
8 Sensor lever
9 Sensor It is of course also necessary to monitor the filling level of the magazines that
follow the orientating device. It is thus useful if an orientation module is able to
process the signals from buffer-zone sensors. Fig. 6-7 shows an example of a
typical configuration with monitoring of the minimum and maximum filling
levels. When the upper limit is reached, any further working material must be
returned to the hopper and the hopper feeder switched off. In the example
shown, the sensors cover 3 magazine zones (A, B and C).
Fig. 6-7:
Example of buffer-zone
sensors
1
1 Top-up hopper 5
2 Orientation device 2
3 Conveyor belt 4
4 Handling device
3
with gripper
B A
6 Controller
7 Workpiece bin
8 Sensor
9 Pick-up position
7 6
C
A to C
Magazine zones
8
84 6 Ancillary equipment
• Magazine zone A: This zone must have sufficient capacity to hold all the
already-checked workpieces which are still on the conveyor belt at the
moment the feed unit is switched off.
• Magazine zone B: This zone is the actual magazine whose contents may
fluctuate between maximum and minimum limits. The bigger the capacity
of this zone, the less frequently it will be necessary to switch off upstream
feeding devices.
• Magazine zone C: This zone has the task of holding enough workpieces to
bridge the time until the first newly-conveyed workpiece is received when the
conveyor is switched back on. This is intended to prevent unnecessary down-
time at the workstation due to a shortage of workpieces.
The reasons for the fluctuations of quantity in the magazine are as follows:
• The stochastic process of orientation

• Interruptions in the delivery of workpieces by the hopper feeding device
• Interruptions in workpiece pick-up due to brief standstill periods at the
workstation
• The proportion of correct workpieces. A large proportion of incorrect work-
pieces will reduce the feed throughput.
We can define a “handling technology system” as a sequence of sub-functions
7 that are used to bring a workpiece from a random orientation into a desired
Handling technology orientation. It is not easy to develop a practical handling system, and there will
system generally be a choice of devices as potential function providers. We will also
need reliable knowledge of the static and dynamic behaviour of the workpieces,
their centre of gravity, their frictional and rolling properties and factors relating
to their contours. The successful operation of an orientating device is often a
matter of small adjustments of feed channels, chicanes and workpiece contact
surfaces.
A “handling technology system” describes the type, sequence and configuration

7.1 of the equipment items (chicanes, motion units, grippers) which can be used to
Basic technological achieve a desired orientation and target position. In a more general sense, we
components can use the term to cover the overall feed process. Fig. 7-1 shows sketches of
examples of handling technology systems. Vibratory bowl feeders are featured
here only as representatives of feeding devices in general. We will always carry
out technological planning on the basis of overall processes, by considering how
a workpiece can be brought quickly and inexpensively from a random heap to
meet up with a basic assembly component or to another target position. Basic
technological components provide the functions such as storage, motion,
gripping, orientation, positioning, buffering, checking and controlling.
Fig. 7-1:
Examples of various
1 2 Workpieces are output with
equipment levels
desired orientation, but
system is not flexible
1 Hopper feed unit
2 Control unit
3 Orientating device
4 Controller Various different workpieces
3 can be orientated.
5 Level sensor
4 Flexibility is available
6 Top-up hopper with stand
7 Pick-and-place unit
8 Workstation
5
9 Assembly transfer line
A top-up hopper allows
6 2 longer periods of operation
without human intervention
7 8
Complete feeding and
4 handling system, suitable
9
for flexible applications
86 7 Handling technology system

Vibratory bowl feeders equipped with mechanical (i.e. contact-type) chicanes
7.2 for orientation continue to be used in mass production systems. The following
Examples examples illustrate which components need to be combined in order to obtain
of applications the desired orientation effect.
7.2.1 The first example (Fig. 7-2) involves the orientation of an open wire circlip.
Vibratory feeders Correctly orientated workpieces are taken up onto a mandrel and then align
themselves through vibration-induced auto-rotation relative to the web plate.
The workpieces are thus magazined. The crucial moment is the transfer of the
workpieces to the magazining mandrel.
Handling technology system: Notch – deflector for hanging workpieces (section

C-C) – top deflector – trough channel – threading mandrel – magazine rail.
Fig. 7-2:
Orientating open circlips
1 Magazining mandrel
2 Trough outlet
3 Web plate
4 Vibrator
5 Workpiece
A
B
1
2
View BB
Ansicht 4 1 3
Section C-C
Schnitt C-C View AA
Ansicht
7 Handling technology system 87

The next example concerns the feed of corner brackets with a fitted stud.
At the tipping point, the workpieces fall in such a way that some land with their
studs in the slot rail. These then align themselves in accordance with their centre
of gravity and are output. Although the workpiece is rather complex, relatively
uncomplicated chicanes are sufficient to achieve the desired orientation
(Fig. 7-3).
Handling technology system: Notch – tipping stage – spiral slot with raised
edge – Spiral slot – spiral slot with raised edge.
Fig. 7-3:
Orientation of corner bracket
with fitted studs
A
1 Tipping stage B 1
2 Notch in track
3 Workpiece 2
4 Outlet
A
b Workpiece width
C
B
s Clearance (0.2 to 1.0 mm)
3
C
3
4
b+s
30°
Schnitt A-A
Section A-A Section B-B
Schnitt B-B Section C-C
Schnitt C-C
View X X
Ansicht

In the third example (Fig. 7-4), we have a workpiece whose orientation cannot
immediately be recognised from a contour image obtained by optical means.
The visibility of the slot depends on the rotary attitude of the workpiece. As the
workpiece moves up the drum, an attempt is made to make it “ride” on a rail.
Incorrectly orientated workpieces are not able to do this and fall back into the
hopper.
Handling technology system: Wiper – deflector – profile rail – covered magazine

rail.
Fig. 7-4:
Orientation of a profiled disc
1 Rail 1
2 Raised edge
3 Wiper
4 Deflector 4
5 Workpiece
6 Correctly orientated B 2
workpiece
7 Incorrectly-orientated
B
workpiece
8 Direction of conveyance 3
A A
6
7
SectionA-A
Schnitt A-A
8
SectionB-B
Schnitt B-B

A final example (Fig. 7-5) shows that if high throughput performance is required,
a vibratory drum can be fitted with numerous outlet tracks. The workpieces are
gradually orientated within each channel, finally achieving the same orientation.
Handling technology system: Top deflector – spiral extension – profile channel –

longitudinal slot – magazine outlet.
Fig. 7-5:
Orientating syringes
1 Vibratory bowl feeder 1

2 Top deflector
2
3 Workpiece
4 Step
5 Parallel channel zone
6 Suspension slot
7 Channel magazine
3
A
B
D
6
4
D
3
C 5
Schnitt A-A
Section A-A SectionB-B
Schnitt B-B
SectionC-C
Schnitt C-C Section D-D
Schnitt D-D

We have already described in some detail the advantages of contactless work-
7.2.2 piece detection. Fig. 7-6 shows a typical equipment configuration of this kind,
System with contact- together with some examples of workpieces which have been fed successfully
less feature detection using this equipment. It is noteworthy that even features with only small dimen-
sional differences (conical springs, flats on chain links) can be detected reliably
even at high throughput speeds.
Handling technology system: Top deflector – notch – belt transfer – conveyance

– shape sensing/imaging evaluation – ejection – feeding into bulk containers.
Fig. 7-6:
Contactless optical contour 4 6 1
3
detection of conveyed
workpieces (Festo) 2
a) Overall view of device

b) Examples of fed
workpieces
1 Conveyor belt
2 Sorting box 5
3 Detection unit
4 Control and programming
unit
Workpiece
Werkstück Camera image
Kamerabild
6 Ejector nozzle
Messing-
Brass bush
buchse 256
128
0 128 256
Lüster-
Terminal 256
klemmen-
insert
einsatz
128
0 128
Ketten-link
Chain
lasche
128
Valve
Ventil-spring
feder

There are 10 good reasons to use imaging-based orientation systems:
1 Reliable stand-alone industrial-quality solutions are available

2 Systems can be programmed quickly and easily using the teach-in method
and sample workpieces
3 High-volume throughput can be achieved even with “orientation
by selection”
4 Can be combined with various hopper feeding systems
5 Can be used to separate out different workpiece types from workpiece mix
6 Various different quality features can be evaluated
7 Hardware is largely not specific to a given workpiece shape, resulting
in increased flexibility
8 High residual value of equipment when a particular automation solution
is dismantled
9 Systems can supply data to allow counting of “good” or correctly-
orientated workpieces
10 Systems can be linked into higher-level information structures.
EMAGO is an acronym for ElectroMAGnetic Orientation of workpieces. This is a

7.2.3 method for the automatic orientation of small metallic components, particularly
Orientation using those with internal contours (hidden features). With this method, the workpieces
the EMAGO method pass through an electromagnetic field. The principle of this is shown in Fig. 7-7.
As we can see, the electromagnetic field penetrates the workpieces and genera-
tes forces within the metal which are more than adequate for the orientation of
small workpieces.
Fig. 7-7:
Electromagnetic orientation
1
a) Schematic view
b) Direction of magnetic field
c) Action of forces in
magnetic field

2 Workpiece b)
3 Feed channel
2 6
4 Pole shoe for magnetic M
field generation
5 Coil B
6 Magnet
3
B Magnetic induction
FM Electrodynamic force 4
action
5 FM
M Torque
a) c)
The motion effect is due to the fact that the magnetic forces have an unbalanced
action with asymmetrical workpieces and cause the workpiece to turn until it
reaches a new orientation in which there is an equilibrium of forces.

The workpieces must be metallic but need not be ferromagnetic – this method
also works with materials such as brass, silver, copper and aluminium. Examples
of especially suitable workpieces are shown in Fig. 7-8. Technical parameters are
as follows:
• Induction 0.1 ... 1.0 T

• Frequency 50 ... 50,000 Hz
• Effective power 0.1 ... 1.5 kW
• Time required for orientation 0.1...1.2 s
With workpiece dimensions of 10 x 10 x 2.5 mm, the orientation throughput can

be 350 to 400 workpieces per minute, using an effective power of no more than
100 W. Systems of this kind are simple and exhibit hardly any wear [31, 32].
Typical workpiece masses are around 20 grams, with a maximum of 50 grams.
Throughput may be up to 400 workpieces a minute.
Fig. 7- 8:
Examples of workpieces sui-
table for the EMAGO method
1 3
1 Workpiece
2 Material different from
workpiece material, e.g.
bimetallic component
3 This method is highly
suitable for workpieces
with internal contours

A device that operates on the principle of orientation by correction is shown in
7.2.4 Fig. 7-9. This uses a number of active components in order to change the instan-
Stepwise orientation taneous workpiece orientation. As we have seen, orientation is a process that
using imaging systems requires constant alternation between stable and unstable workpiece positions
until the desired position is reached. In order to do this, however, the workpie-
ces must be set in motion. In the solution shown above, this is achieved in a
virtually perfect textbook manner. Vibration-induced motion is used to break
up the workpiece heap and ensure that workpieces arrive singly (although still
randomly orientated) on the second continuously running conveyor belt.
Fig. 7-9:
Workpiece feed and
orientation system (Adept)
1 5
1 Camera to monitor pick-up 2 6 7 8 9
position
2 Industrial robot
3 Pulsed drive, controlled 3 4
in X/Y direction
4 Workpiece
5 Camera to control position
of pulse ram
6 Field of vision 10
7 Sensors to monitor 15
11
break-up of workpiece 12
heap
13 14
8 Workpiece heap
9 Infeed hopper
10 X/Y slide
11 Continuously running
conveyor belt
12 Lighting For this purpose, the hopper conveyor belt is able to execute forward and back-
13 Impact vibrator
14 Return flow of incorrectly ward steps. In a second phase, the incorrectly orientated workpieces are ma-
orientated and excess nipulated via a camera-guided pulse head. A selected workpiece is given a
workpieces targeted blow, thus generating torque and turning the workpiece round. The
15 Parametrisable conveyors
with vibratory effect blow is against the conveyor belt. The pulsed driver is positioned at a suitable
point on the X/Y plane in accordance with the result of an image evaluation.
Following this, a further camera localises the gripper position and supplies the
robot controller with the pick-up coordinates. Any remaining incorrectly orien-
tated or excess workpieces are returned to the hopper. This system, too, ope-
rates in a way that is very largely independent of a specific workpiece shape.
Lightweight workpieces can be orientated by using an appropriate combination

7.2.5 of mechanical and aerodynamic means, which allows a high throughput. One
Orientation using example of this is the plastic workpiece shown in Fig. 7-10 [36]. This has a
aerodynamic devices complex shape with many details. Orientation using only mechanical chicanes
would be difficult and also highly susceptible to malfunction.

Fig. 7-10:
Sequence of orientation
components for aerodynamic
orientation (according to
Lorenz and Grimm)
3 5
1 Workpiece
2 Feed hopper
1
4
3 Gravity track
4 Point nozzle
2
5 Direction of travel,
S 5
6 Honeycomb-shaped
nozzle array
7 Guide rail
6
S Centre of gravity
L = 42 mm 7
L/D = 7
The workpieces are fed at high speed from a conveyor (centrifugal conveyor or
high-capacity vibration conveyor). In the first orientation stage, incorrectly
orientated workpieces are turned through 180° about an axis at right angles to
the conveyance direction by exploiting the position of the centre of gravity. In the
case correctly orientated workpieces, the spin generated by the
air nozzle is not sufficient to turn these workpieces around in “mid-air”. The
second phase is concerned with orientation about the longitudinal axis. For this
purpose, the workpieces pass by a nozzle array, in which the air exits via honey-
comb-like channels. The orientated workpieces must then be picked up in such
a way that they retain their orientation, which is not so easy. The throughput of
systems of this kind can be around 250 workpieces per minute, considerably
better than with other orientation methods, particularly mechanical ones.

The selection of workpiece feeding devices is a multi-stage process, and the
8 equipment technology chosen for the functional sequence; hopper filling –
Selection of workpiece feeding – orientating/sorting – magazining/bulk storage may vary. The equip-
feeding devices ment must be appropriate to the workpieces, the required performance level and
degree of flexibility and feed conditions. The equipment should also be available
at short notice at the right price.
The difficulty of handling different components varies. Characteristic features of

8.1 difficult components are as follows:
Workpiece shape and
degree of handling • Asymmetrical dimensions
difficulty • Asymmetrical position of centre of gravity
• Asymmetrical internal contours and features
• Asymmetrical physical properties, such as difference in materials
• Asymmetrical surface features, such as engraved logos.
The greater the degree to which features are asymmetrical, the more handling
operations are required to bring a workpiece into the desired orientation, or the
greater the number of workpieces which need to be separated out of a random
heap. The greatest influence on handling behaviour is the workpiece shape. To
illustrate this, Fig. 8-1 shows typical workpieces classified according to features.
The principle of this table is that the difficulty of handling increases from top left
to bottom right. This is easy to understand – a sphere is ideally symmetrical.
Irregular built-up workpieces, on the other hand, have many points that may
lock together with other workpieces in a random heap and can in fact be fed
automatically, if at all, only by using special untangling technology. Designers
are of course called on to keep their workpiece designs as simple as possible in
the interests of easy handling [5]. Experience has shown however, that when
automating handling processes, it is generally no longer possible to change
workpiece properties.
Fig. 8-1:
Examples of basic workpiece shapes
Classification of workpieces
according to basic shapes and Form elements Sphere Bar Flat Mushroom Irregular
form elements
Workpieces with
smooth exterior
Internal and external

contour features
Workpieces with
eccentric features
Irregular built-in
workpieces
96 8 Selection of workpiece feeding devices

In order to evaluate the suitability of feed technology for a given task, we must
8.2 first decide which properties and characteristic data are relevant. We can use the
Performance profile following as the basis for comparisons:
• Maximum permissible workpiece mass

• Feed throughput per unit time
• Maximum storage capacity or achievable operating time without human
intervention
• Workpiece stress during feeding operation (risk of damage)
• Compatibility of technology with relevant workpieces
• Conversion capability or properties giving enhanced flexibility
• Verified technical availability and service life
• Accuracy (precision) of detection of workpiece features and dimensions
• Accessibility to allow correction of malfunctions
• Facility for incorporation of additional functions
• Facility for linkage of control unit to higher-level control systems.
The required feed speed is heavily dependent on the orientation method used.
If this involves correcting the orientation of workpieces where necessary, which
is often the case with vibratory feed devices, initially incorrectly orientated
workpieces will also be counted as successes in the end. If, on the other hand,
the orientation method involves separating-out incorrectly orientated work-
pieces, which is often the case with orientation based on imaging systems, only
a fraction of the initial volume of workpieces will pass through as correctly orien-
tated. It will thus be necessary in this case to feed larger quantities of work-
pieces through the orientation (detection) system, which in turn demands a
higher speed of conveyance. These two orientation methods are also described
as “active” and “passive” orientation respectively.
The process of defining the feed speed will now be explained by taking the
example of the frequently used spiral vibratory conveyor. The feed speed must
be chosen in such a way as to ensure that the machine being fed is never forced
to wait for workpieces. The feed throughput PZ must therefore be slightly higher
than the throughput PS of the processing machine (PZ = (1.1...1.3) PS ).
Allowance must also be made for fluctuations in the flow of workpieces on the
vibratory conveyor.
Our first calculation is as follows:
PZ = PS/(1-k1) in r.p.m. or workpieces/min. where
k1 Coefficient of fluctuation of workpiece delivery (k1 is approx. 0.2...0.3

with a vibratory conveyor)
Our next step is to determine the required feed speed v. This is calculated
as follows:
v = PZ · L/(60 k2) in mm/s where
L Workpiece length in direction of travel in mm

k2 Coefficient of filling level of spiral with already correctly orientated
workpieces
8 Selection of workpiece feeding devices 97

The factor k2 is determined as follows:
k2 = F · L/(L + s) where
F Coefficient of probability of correctly orientated workpieces on the spiral

s Average value for gap between workpieces travelling on spiral.
The factor k2 represents the density of the flow of workpieces and the probabil-
ity of correctly-orientated workpieces on the spiral. It will generally be deter-
mined by experiment. It will thus also incorporate allowance for the preferred
orientation which workpieces assume when input into the system. Fig. 8-2
shows the average preferred orientation assumed by simple rotationally sym-
metrical workpieces. As we can see, dimensional conditions play an important
part, as described already in chapter 3.1 (Fig. 3-4). The coefficient F depends on
the following factors:
• Workpiece shape
• Materials properties
• Orientation system (chicane sequence)
• Design features of spiral
• The method used for separation from a random heap
• The projection factor of the vibratory conveyor.
Fig. 8-2:
Preferred orientations
of a simple workpiece D
Werkstück
Workpiece L
L/D 2 1 0,5
Preferred
Vorzugs-
assumed
lage in
orien-
Prozent
tations
in percent
90 10 70 30 44 56
The following equation provides a guide value for F with passive orientation:
F = 1/√1 + (d/L)2
In the above, L must be > d; the equation applies to symmetrical shafts and
shouldered workpieces with a cylindrical shape. For these workpieces, the equa-
tion also applies for active orientation.

In the case of the passive orientation of shafts with asymmetrical ends, the
following applies:
F = 0.5/√¯1 + (d/L)2
For the feeding of thin symmetrical panels with b < L >> a and of long sym-
metrical cylindrical workpieces (L > 10 d), we can take F = 1 (b = Width,
a = Thickness). The feeding of asymmetrical workpieces requires a more com-
plicated orientation system. The coefficient F can be determined on by experi-
mental means in these cases.
Example: We wish to calculate the required average feed speed for the work-
piece shown in Fig. 8-3. The automatic machine to be fed requires PS = 80 cor-
rectly orientated workpieces per minute. If we take the factor k1 as = 0.25, we
obtain the following:
F = 1/√¯1 + (d/L)2 = 1/√¯1 + (8/40)2 = 0.98
In the case of active orientation at the top of the spiral, we can assume a
gap-free chain of workpieces, i.e. s = 0. We now determine the factor k2:
k2 = F · L/(L + s) = 0.98 · 40/(40 – 0) = 0.98
The feed speed v thus becomes:
v = L · PZ · 1.2/(60 k2) = 40 · 80 · 1.2/(60 · 0.98) = 65 mm/s
Fig. 8-3:
Workpiece for sample
calculation 40
8

The steps in the selection process can be specified only in general terms, as
8.3 shown in Fig. 8-4. The reason for this is that the decisive factor may often be
Selection algorithm specific parameters. In the case of an assembly line, for example, the question
of space requirements may be very important. This means that selection criteria
must be weighted, and this weighting will vary from one application to another.
One of the parameters at the start of the process will always be an estimation
of the workpiece behaviour and properties (tendency to assume stable positions
during orientation or pre-orientation, edge strength, brittleness, reaction to
frequent handling, tendency to electrostatic charges, etc.).
The choice of a hopper feeding device will also depend on the equipment al-
ready in service at the location in question. A uniform pool of equipment can
simplify maintenance work and the management of stock of spare parts. The
need for top-up hoppers will depend on the size of the workpieces concerned
and the required performance. In many cases, hopper feeding devices are availa-
ble already combined with top-up systems, which means of course that there is
no need to select a top-up system separately.
The question of the best orientation method will depend primarily on the state in
which workpieces are intended to be after this procedure, for example sorted
but not orientated or else orientated and magazined. Features need to be availa-
ble which the orientation method concerned can use. It is, for example, entirely
possible to check internal features by means of mechanical chicanes, which is
not possible with optical scanning by a camera.
The type of magazining chosen will be governed by the way workpieces or mag-
azines are transferred to the relevant production system. Distribution can be
carried out by means of slides, a gravity feed or a pick-up by a gripper.
We must consider the following cost factors and parameters:

• Hardware costs
- Design and development costs
- Planning, construction, testing, functional testing
- Installation costs
- Minimisation of hardware costs by boosting performance
- Costs resulting from equipment depreciation
• Operating costs
- Servicing and maintenance costs
- Conversion and reprogramming costs
- Costs of debugging operating sequence
- Cost of installation space
• Purchasing cost
- Purchasing of pre-tested off-the-shelf modules
• Residual value
- Reuse value after end production of initial workpiece
• Personnel costs
- Training costs
- Proportional personnel costs for supervision of feeding device.

Fig. 8-4: Start Ve Mo
Equipment
General steps in the selection
of a hopper feeding device A Centrifugal conveyor
Record initial data and parameters: B Vibratory bowl feeder

Au Cost
Investigate workpiece behaviour
Fl Flexibility C Inclined or steep conveyor
Ge Noise level
Le Performance D Multi-stage conveyor
Ma Mass of individual E Segment conveyor
Select a hopper feeding device on
workpiece the basis of weighted criteria
Sp Storage capacity F Other conveyor
Ve Tendency to tangle
Vo Maximum storage No
Device found? Equipment Vo Ge Ve
capacity
G Hopper conveyor
H Vibratory hopper
Select a hopper top-up
deviceg I Inclined conveyor
J Magnetic gripper
No Other equipment
K
Device found?
Methods Le Fl
Select an orientation, sorting L Active orientation, mechanical

and counting method
M Passive orientation, mechanical
No N Orientation using imaging system

Method defined?
O Orientation from workpiece mix
P Orientation and counting

Possible verification of
checking parameters Q Other method (EMAGO, etc.)
Magazines Sp Au
Define magazining technology R Shaft, channel, tube
S Bulk container
No
Magazine found? T Indexing magazine
V Assortment magazine, multi-row
Define overall solution, e.g. B-G-N-T U Custom solution
Price/performance ratio
Clarification of all commercial Amortisation

and economic questions
Self-built
No Price service life

Solution accepted Good
Finance
Unsuitable
End Other criteria

In conclusion, we should emphasise that the selection algorithm presented
above is a working guide which can be expanded or reduced at any time as
appropriate to a given requirement profile.
It is typical of modern industry that the work which is still carried out manually,
8.4 often referred to as “residual” work, is gradually being automated. This work
Economic factors includes handling operations such as the orientation and feeding of small work-
pieces. From the economic point of view, it is generally a question of comparing
variants, for example the variants “manual feed” (extremely flexible), “hopper
feeding device with mechanical chicanes for orientation” (extremely workpiece-
specific, virtually inflexible) and “feed technology with optoelectronic workpiece
detection” (teach-in programming, flexible).
The vital factor after all comparisons have been made is the cost per workpiece
or per workpiece batch. For individual automation measures, the criterion of
success is the break-even point [33]. Up to this point, the costs are higher than
the benefits, and the measure concerned is thus making a loss. Only after the
break-even point has been passed does the automation measure concerned
generate an economic advantage (Fig. 8-5).
Fig. 8-5:
The break-even point is the
gateway to economic savings
Total benefit
Costs, benefits
Break-even
point
Total costs
Throughput, volume

Aerodynamic orientation
9 Orientation of workpieces in air-flow zones using air nozzles, the cw coefficient of
Glossary the workpiece, the position of its centre of gravity and other useful aerodynamic
features of the workpiece.
Asymmetry
Geometrical irregularity in cases where there is no mirror image on either side of
the axis of a body.
Resolution
In imaging systems, the number of scanning points per unit length in a digitised
image in the horizontal or vertical direction.
Throughput
Number of workpieces that are output via a vibratory or other hopper feeding
device in the desired orientation per unit time (workpieces per minute).
CCD
Charge-coupled device, a light-sensitive sensor which supplies an analogue
signal which must then be digitised before processing in a computer.
Single-mass oscillator
Vibratory system for vibrators in which the working mass is formed by the con-
veyor channel, the oscillator to which this is permanently linked and the working
material in the channel.
Speed of conveyance
Speed at which workpieces (or to be exact, their centres of gravity) move on a
linear or curved path.
Guide stability
Ability of a workpiece to maintain a defined orientation during motion on a
support surface.
Friction conveyance
Forward motion of a workpiece on a vibrating track in which the workpieces do
not lift off the track but flow like a viscous mass.
Good workpiece
Workpiece which is identical with the specified sample workpiece on the basis of
all criteria and thus does not does exceed any permissible deviations.
Workpiece heap
Term for working material lying in random arrangement in a hopper. Describes a
chaotic state with regard to position and orientation.
9 Glossary 103
High-performance vibrator
Vibrator designed for a very high speed of conveyance well in excess of the
usual speed of 10 m/min.
Edge finding
A mathematical process used in imaging systems to find edges (lines) in an
image (scene, subject map). Operations such as smoothing and edge en-
hancement are usually carried out before the edge image is produced by
digitising a greyscale image.
Contour
Enclosed area that generally represents the outline of an object. Contour
segments are non-enclosed lines.
Positional stability
Ability of a workpiece to remain standing on the same face during friction
conveyance on an inclined and/or vibrating surface.
Feature
Special physical or calculable attribute of a workpiece that distinguishes this
from other workpieces of a different type.
Feature memory
In imaging systems, a memory that holds data on the features to be used to
identify (compare) objects.
Feature distribution
The degree of fluctuation of features which is recorded in the teach-in mode with
one or more sample workpieces and a detection device due to shape-related,
dimensional and positional errors.
Micro-projection
Forward motion of a workpiece on a vibrating track in which the workpieces are
thrown forward by distance in the micron range.
Sample workpiece
Workpiece used in the teach-in mode of a detection device to supply data on
characteristic features. This data is stored for reference purposes.
Top-up system
System that automatically supplies hopper feeding devices with fresh work-
pieces and is generally activated periodically.
Orientation probability
Statistical relationship between the number of favourable orientations for a
given purpose to the overall number of possible orientations (positions and
attitudes).
104 9 Glossary
Orientation
The process of changing the axial direction of workpieces from undefined to
defined, without consideration of the workpiece position.
Positioning
The process of changing the position of workpieces from undefined to defined,
without consideration of the workpiece orientation.
Chicanes
Orientating devices in the motion path of a workpiece which use a selection
or correction function to change the workpiece orientation from undefined to
defined.
Vibration mechanics
The sub-area of mechanics (dynamics) that is concerned with the study
of vibration.
Subpixeling
In imaging systems, a method for “photometry averaging”. This gives a higher
theoretical resolution and thus more precise data concerning an object imaged
by a sensor array. The scanning accuracy is thus higher than that indicated by
the pixel centre-to-centre distance.
Symmetry
Characteristic of bodies and figures in which there is a mirror image on either
side of an (imaginary) centre axis.
Degree of disorientation
Indication of the maximum number of translatory and /or rotational motions that
are required for a workpiece to reach a desired defined state. In the case of
workpieces in a random heap, U = 6.
Preferred orientation
Stable workpiece orientation that a workpiece tends to assume on an even
surface or vibrating conveyor due to its geometry and the position of its centre
of gravity. The preferred orientation can be determined approximately by experi-
ment.
Projection index
Indication of the drive acceleration of a vibratory conveyor. This expresses the
ratio of the drive acceleration component aligned normally to the conveyor track
to the gravitational acceleration component acting in the same direction. With a
micro-projection vibrator, the projection index is between 1 and 3.3.
9 Glossary 105
Dual-mass oscillator
Vibratory system for vibrators in which the effective mass mN is linked to a
counter-mass mG consisting of a supported or suspended frame (Fig. 9-1).
Fig. 9-1:
Principle of dual-mass
oscillator
FN 1
1 Spiral drum
mN
mG
FG
106 9 Glossary
[1] Jacques, N.: Wirbel der Welt (“The way of the world”),
Further literature published in German by L.E. Wittich Verlag, Darmstadt 1942
[2] Schütze, R.: Lagerichtiges Zuführen – Voraussetzung für automatisiertes

Handhaben (“Orientated feeding - the prerequisite for automated hand-
ling”), article in German in Fachberichte Metallbearbeitung Coburg 62
(1985) 7-8, pp. 390 to 391
[3] Frank, H.-E.: Das Verhalten von Werkstücken in der Fertigung bei automati-
scher Handhabung (“The behaviour of production workpieces during auto-
matic handling”), article in German in VDI-Zeitschrift 118 (1976) 12,
pp. 573 to 578
[4] Schmid, pp.: Lagerichtig eingeschleust ("Orientated feeding”), article in

German in Schweizer Maschinenmarkt No. 16, 1993, pp. 16 to 21
[5] Hesse, S.: Montageatlas – Montage- und automatisierungsgerecht konstru-

ieren (“The assembly atlas - Designing for easy assembly and automation”),
published by Vieweg Verlag, Wiesbaden 1994
[6] Frank, E.: Das Ordnungsverhalten von Werkstücken bei automatisierter

Handhabung (“The orientation behaviour of workpieces during automatic
handling”), article in German in wt-Z. ind. Fertigung 62 (1972),
pp. 154 to 160
[7] Weiss, K.: Entwicklung flexibler Ordnungssysteme für die Automatisierung

der Werkstückhandhabung in der Klein- und Mittelserienfertigung
(“Development of flexible orientation systems for the automation of work-
piece handling in small- and medium-run production”),
published in German by Springer Verlag, Berlin and Heidelberg 1985
[8] Hilgenböcker, H.: Methodische Entwicklung von Zuführsystemen

(“Methodical development of feeding systems”), in German in
Betriebstechnik No. 97, VDI-Fortschrittsberichte Reihe 2,
published by VDI Verlag, Düsseldorf 1985
[9] Schmidt, I.: Ordnen von Werkstücken mit programmierbaren Handhabungs-

geräten und Werkstückerkennungssensoren (“Orientation of workpieces
using programmable handling devices and workpiece detection sensors”),
published in German by Springer Verlag, Berlin and Heidelberg 1984
[10] Sabajkovic, V. A.: Programmiertes Ordnen von Teilen (“Programmed orien-

tation of workpieces”), published in Russian by Verlag Hochschule,
Lwow 1983
[11] Spur, G.; Stöferle, Th.: Handbuch der Fertigungstechnik, Band 5: Fügen,
Handhaben, Montieren (“Manual of production technology. Volume 5:
Joining, handling, assembly”), pp. 499 to 589,
published in German by Hanser Verlag, Munich 1986
Further literature 107

[12] Hesse, S.; Mittag, G.: Handhabetechnik (“Handling technology”),
published in German by Hüthig Verlag, Heidelberg 1989
[13] Hesse, S.: Systematisches Entwerfen von Einrichtungen zum automatischen

Ordnen von Werkstücken (“Systematic development of devices for the auto-
matic orientation of workpieces”), article in German in Feingerätetechnik
Berlin, 32 (1983) 7, pp. 292 to 295
[14] Habenicht, D.: Die Gleitförderung von Werkstücken in Schwingzuführsys-

temen (“Friction conveyance of workpieces in vibratory feeding systems”),
article in German in fördern und heben 35 (1985) 2, pp. 90 to 93
[15] Ahrens, H.; Habenicht, D.: Werkstückbewegung beim Zuführen und Ordnen
mit Vibrationswendelförderern “Workpiece motion during feeding and
orientation with vibratory bowl feeders”), article in German in wt-Z. ind.
Fertigung 74 (1984), pp. 23 to 26
[16] Ahrens, H.: Vorgehen zur Auslegung von Vibrationswendelförderern

“Method of sizing vibratory bowl feeders”), article in German in Z. wirtsch.
Fertigung, Munich 79 (1984) 8, pp. 401 to 404
[17] Habenicht, D.: Hilfen zur Optimierung von Vibrationswendelbunkern – För-

derarten (“A guide to the optimisation of vibratory hoppers – Conveyance
methods”), article in German in VDI-Zeitschrift 123 (1981) 8, pp. 297 to 301
[18] Habenicht, D.: Hilfen zur Optimierung von Vibrationswendelbunkern – Be-

rechnungsgrundlagen (“A guide to the optimisation of vibratory hoppers –
Principles of calculation”), article in German in VDI-Zeitschrift 123 (1981) 3,
pp. 82 to 86
[19] Ahrens, H.: Auslegungs- und Betriebskriterien für Vibrationswendelförderer

(“Dimensioning and operating criteria for vibratory bowl feeders”),
article in German in VDI-Zeitschrift 126 (1984) 22, pp. 881 to 884
[20] Habenicht, D.: Hilfen zur Optimierung von Vibrationswendelbunkern –

Parametereinfluss (“Aids for the optimisation of vibratory bowl feeders –
The influence of parameters”), article in German in VDI-Zeitschrift 123
(1981) 6, pp. 215 to 218
[21] Stoevesandt, G.: Auslegung von Vibrationswendelförderern (“Sizing of

vibratory bowl feeders”), article in German in VDI-Berichte 323,
pp. 49 to 54, published by VDI Verlag, Düsseldorf 1978
[22] Cokayne, A.: The Way of the World – A Review of Current Practice in
Automatic Parts Recognition, Feeding and Orientation, Assembly
Automation 11 (1991) 4, pp. 29 to 32
[23] Hesse, S.: Atlas der modernen Handhabungstechnik “Atlas of modern hand-
ling technology”), published in German by Vieweg Verlag, Wiesbaden 1995
108 Further literature

[24] Groh, W.: Das Ordnen von Massenteilen und ihre selbständige Zuführung in
die Werkzeugmaschine (“Orientation of bulk workpieces and automatic feed
to machine tools”), article in German in Werkstattstechnik und Maschinen-
bau 47 (1957) 8, pp. 402 to 410
[25] Hesse, S.: Betrachtungen zum automatischen Ordnen von Werkstücken

(“Notes on the automatic orientation of workpieces”), article in German in
Maschinenbautechnik Berlin, 24 (1975) 8, pp. 374 to 378
[26] Hesse, S.: Selbständiges Ordnen von Massenteilen (“Automatic orientation

of bulk workpieces”), article in German in Fertigungstechnik und Betrieb 23
(1973) 8, pp. 462 to 466
[27] Rockland, M.; Stetter, R.: Flexibles Ordnen und Zuführen (“Flexible orienta-
ting and feeding”), article in German in Z. wirtsch. Fertigung 89 (1994) 1-2,
pp. 55 to 57
[28] Caine, M.: The Design of Shape Interactions Using Motion Constraints,
Proceedings IEEE Robotics and Automation Society, May 1994, California,
pp. 366-371
[29] Kettner, H.; Ahrens, H.; Stoevesandt, G.: Zum Fördervorgang im Vibrations-
wendelförderer “The conveyance process in vibratory bowl feeders”), article
in German in VDI-Zeitschrift Düsseldorf, 122 (1981) 8, pp. 311 to 315
[30] Redford, A.: Small Parts Feeding, Assembly Automation 11 (1991) 4,

pp. 8 to 11
[31] Blume, F.: Elektromagnetische Orientierung – eine neue Methode zur

Handhabung von Bauteilen (“Electromagnetic orientation – A new method
for the handling of workpieces”), article in German in Fertigungstechnik und
Betrieb, Berlin, 27 (1977) 10, pp. 612 to 613
[32] Davidenko, E. P. et alia: Elektromagnetische Verfahren und Vorrichtungen

zur Orientierung, Fixierung und Erkennung von Geräte- und Maschinenteilen
(“Electromagnetic methods and equipment for the orientation, positioning
and detection of device and machine components”), article in German in
Maschinenbautechnik Berlin, 26 (1977) 10, pp. 470 to 473
[33] Boothroyd, G.; Dewhurst, P.: Part Presentation Costs in Robot Assembly,
Assembly Automation 5 (1985) 8, pp. 138 to 145
[34] Werkstückhandhabung in der automatisierten Fertigung – Ein Leitfaden zur

Lehrschau (“Workpiece handling in automated production – A training
guide”), published in German by Württembergischer Ingenieurverein,
Stuttgart 1968
Further literature 109

[35] Richtlinie VDI 2860, Handhabungsfunktionen, Handhabungseinrichtungen,
Begriffe, Definitionen, Symbole (“VDI guideline 2860: Handling functions
and equipment – Terminology, definitions and symbols”), 1990
[36] Lorenz, B.-M.: Aerodynamische Zuführtechnik (Diss. Uni Hannover)

(“Aerodynamic feed technology – A Hanover University thesis”),
published in German by VDI-Verlag, Düsseldorf 1999
[37] Lund, M.B.; Boothroyd, G.: A compendium of small parts feeders,

Massachusetts (USA) 1979
110 Further literature

A Air jet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
Glossary Air nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95, 103
of technical items Alignment edges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
B Basic behavioural types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Break-even point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
Brush lining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
C CCD camera . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60, 69

Centrifugal conveyors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19, 30, 31
Centrifugal feeders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Chicanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39, 40, 48, 105
Contour image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
Conveyance speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22, 60, 97
Counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
D Decremental counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72

Desired orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
Detection device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
Digital image . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64, 67
Direction of workpiece travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Drop opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
E EMAGO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
F Feed vibrator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

Feeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12, 102
Flat belt conveyors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Flat magazines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Friction conveyance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21, 103
Further conveyor devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
H Handling technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86

Hopper feed device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18, 19, 84, 101
I Imaging systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59

Inclined spiral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48, 49
Incremental counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
L Lifting-plate feeders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
M Magazine zone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85

Magazine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77, 78
Micro-projection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
N Notch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
O Optical detection systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60

Order picking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
Orientation probability factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38, 39
Orientation . . . . . . . . . . . . . . . . . . . . . . . . .35, 36, 38, 45, 46, 47, 53, 54, 94
P Packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
Glossary of technical items 111

Pneumatic workpiece conveyor systems . . . . . . . . . . . . . . . . . . . . . . . . . . .83
Profile openings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Profile rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
R Reference data list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66

Reference patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
Relative comparisons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
Rotationally-symmetrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
S Scoop-segment hopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19, 32, 33

Segment feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32, 33
Separating-out of defective workpieces . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Sequence tapes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Shaped deflectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Shaped nests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Sound . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
Spiral conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23, 69
Spiral drum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25, 44, 106
Spiral feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Standard spiral pitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Steep conveyors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33, 34
Stepped feeders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31, 32
Storage vibrator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23, 24
Subpixeling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60, 105
Surface qualities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
T Teach-in method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66

Teach-in workpieces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
Test algorithm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
Tipping stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Tower vibrator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23, 68
Tube feeders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
U Ultrasound measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
V Vertical feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

Vibrator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Vibratory bowl feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10, 69
Vibratory conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
Vibratory feeders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Vibratory system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Visual contour detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
W Wiper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40, 89
Workpiece behaviour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Workpiece detection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
Workpiece flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
Workpiece images . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
Workpiece maps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
Workpiece mix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
112 Glossary of technical items

Pneumatic Feeding

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Pneumatic Feeding

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328 mm 8 mm 120 mm 42 mm

Hesse Rationalization of Small workpiece feeding

Rationalisation of Small workpiece feeding

© 2000 by Festo AG & Co.

2 Workpiece hopper feeding devices ............................................................................ 18

3 Orientation technology .................................................................................................. 35

4 Checking and counting workpieces ........................................................................... 71

5 Magazining orientated workpieces ........................................................................... 74

6 Ancillary equipment ........................................................................................................ 81

8 Selection of workpiece feeding devices ................................................................... 96

9 Glossary ........................................................................................................................... 103

Further literature ............................................................................................ 107

Glossary of technical items ............................................................................................ 111

1 Workpiece handling in component production and assembly 9

Workpieces of many different shapes can be easily orientated in a vibrator. As

The orientation technology in the vibrator naturally becomes more complicated

10 1 Workpiece handling in component production and assembly

We must never consider feed technology in isolation. It is part of the overall

Feeding Orientating Feeding Feeding Production

1 Workpiece handling in component production and assembly 11

1 Workpieces in undefined U = Umax U = Umin = 0

In order to choose suitable orientating components, we need to know the

12 1 Workpiece handling in component production and assembly

We distinguish between 12 basic behavioural types according to their shape:

In order to automate feeding operations, we must possess adequate knowledge

A handling workpiece can be described by the following variables:

1 Workpiece handling in component production and assembly 13

Applications cover all areas of industry whereby which small-sized material is

14 1 Workpiece handling in component production and assembly

1 Workpiece handling in component production and assembly 15

16 1 Workpiece handling in component production and assembly

1 Workpiece handling in component production and assembly 17

• Scooping with swivel segments, rams, wing rails or tubes

• Roughness or loss of gloss due to friction

Electromagnetic vibratory feeders are especially important in conveying

18 2 Workpiece hopper feeding devices

1 Drum-type feeding device

2 Workpiece hopper feeding devices 19

20 2 Workpiece hopper feeding devices

Conveyance behaviour depends on the relevant vibration characteristics, which

• Relationship of working mass to counter-mass

For friction conveyance, sensor-guided spring/mass drives can be used. An

2 Workpiece hopper feeding devices 21

Of all the types of vibratory conveyors used in mechanical engineering, elec-

We can distinguish between electromechanical vibratory systems on the basis of

• The number and orientation of the electromagnets fitted to conveyors with

22 2 Workpiece hopper feeding devices

1 Spiral feeder with

2 Workpiece hopper feeding devices 23

24 2 Workpiece hopper feeding devices

2 Workpiece hopper feeding devices 25

0 200 400 600 800 1000

The spiral pitch H must be selected so as to ensure that workpieces on 2 spiral

26 2 Workpiece hopper feeding devices

2 Workpiece hopper feeding devices 27

But let us return to spiral feeders: In the interests of better understanding, we

28 2 Workpiece hopper feeding devices

2 Workpiece hopper feeding devices 29

30 2 Workpiece hopper feeding devices

In the case of stepped or lifting-plate feeders, small workpieces are conveyed

Fig. 2-15 shows a special stepped feeder in which an additional pendulum

a) Stepped feeders with

2 Workpiece hopper feeding devices 31