Lecture 12

Manufacturing Automation for Assembly and Inspection MM453
Manufacturing Automation for Assembly and

Inspection
MM453
Dr. Nigel Kent

Rm S366
nigel.kent@dcu.ie
Dublin City University
Sem 1 2021
Dr. Nigel Kent Manufacturing Automation for Assembly and Inspection, MM453 1/19
Lecture 12
Lecture 12
Lecture 12
Non Vibratory Feeders
Reciprocating Tube Hopper Feeder
Lecture 12
Design Analysis of Hopper angle Φ

1. Φ must be set large enough so parts do not jam.
Side of reciprocating
tube
Hopper Wall W
N1
Φ
D
A 2 F1
Φ
N2 Φ
F2
Φ
Lecture 12
Vertical force equilibrium:

F1 + W + F2 cos Φ = N2 sin Φ W
tube
Hopper Wall
Horizontal Force Equilibrium:

N1
N1 = N2 cos Φ + F2 sin Φ A
Φ
D
2 F1
Φ
Moments about A: N2 Φ
F2
Φ
D D D
F1 (1 + cos Φ) + W cos Φ = N1 sin Φ
2 2 2
F2 = µN2 and if the part jams then F1 = µN1
1 − cos Φ
Rearranging we get µ =
sin Φ
1 − cos Φ
So to avoid jamming µ <
sin Φ
Lecture 12
Design Analysis of Hopper angle Φ

2. The previous equation indicates Φ should be as large as possible
to avoid jamming. However Φ should be small enough to ensure
parts slide down the hopper
N
tube
Hopper Wall
Φ
F
mg
Lecture 12
For the block to slide on the plane:

µ < cot Φ
Previously we had:
1 − cos Φ
µ<
sin Φ
Equating the two expressions for friction gives Φ = 60◦
1 − cos Φ
For Φ < 60◦ , µ = dictates friction
sin Φ
For Φ > 60◦ , µ < cot Φ dictates friction
For example if Φ = 45◦
1 − cos Φ
Jamming is a problem when µ > 0.41 based on µ <
sin Φ
Lecture 12
Notes:
• Ideally the hopper should be half full.
• The delivery tube should rise above the maximum level.
• The internal profile of the tube should only accept correctly
oriented parts.
• The linear velocity of the delivery tube should be less than
0.6m/s.
Lecture 12
Centreboard Hopper Feeder
Lecture 12
In this analysis we will determine the track inclination at its highest

point to maximise feed rate.
The motion of the centreboard consists of five phases
1 Accelerate uniformly from rest to mid height.
2 Decelerate uniformly from mid height to become stationary at
max height.
3 Remain at maximum height until parts exit the track.
4 Decelerate (accelerate down) uniformly from max height to
mid height.
5 Accelerate uniformly from mid height to become stationary at
the fully down position.
Phases 1,2,4 and 5 all take the same length of time.
Lecture 12
The deceleration during phase 2 is chosen so that the normal

reaction between the part and the track at max height is zero.
This ensures that the part will start to slide down the track.
L
r− 2
L
θm
r θ F
mg
θm
Lecture 12
Cycle time calculation
L
r− 2
L
θm
r θ F
mg
θm
For zero reaction:

Track acceleration = acceleration due to gravity
mθ̈(r − L2 ) = −mg cos θm where θm = max track angle
Since L << r
g cos θm
θ̈ = −
r
Lecture 12
The acceleration during the upward motion phase will be

g cos θm
θ̈ = +
r
A) Accelerate uniformly from rest to mid height
Considering the first phase and using the standard formula
s = ut + 12 f t2
Where:
θm
• s = displacement = i.e. mid height
2
• u = initial velocity = 0
g cos θm
• f = acceleration =
r
Lecture 12
Substituting we have:
θm 1 g cos θm 2
⇒ = t
2 2 r
Rearranging gives:
r
θm r
t= = time for phases 1,2,4,5
g cos θm
B) Where the track stays stationary to allow parts to slide
In this case gravity pushes the part down the track and friction
resists this. Friction is given by:
F = µN = µmg cos θm
mẍ = mg sin θm − µmg cos θm
Lecture 12
Again using: s = ut + 12 f t2
Where:
• s = displacement = r i.e. length or track
• u = initial velocity = 0
• f = acceleration = ẍ
Substituting gives:
1
⇒ r = (g sin θm − µg cos θm )t2
2
Rearranging gives:
r
2r
t=
g(sin θm − µ cos θm )
Lecture 12
Thus the total time for all five phases is:

r r
θm r 2r
T =4 +
g cos θm g(sin θm − µ cos θm )
There ia an angle θm which minimises the total time. The equation
above is differentiated w.r.t θm equated to zero and then solved for
θm . The equation is complex and is therefore solved numerically.
Lecture 12
The efficiency of the device depends on how many parts can be

picked up at one time. This in turn depends on the track design
and the hopper load and is resolved empirically.
Feed rate is given by:
number of parts selected
F =
total cycle time
Lecture 12
Lecture 12
Load sensitivity of a centreboard hopper


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Manufacturing Automation for Assembly and Inspection MM453

Manufacturing Automation for Assembly and

Dr. Nigel Kent

Dublin City University

Reciprocating Tube Hopper Feeder

Design Analysis of Hopper angle Φ

Vertical force equilibrium:

Horizontal Force Equilibrium:

Design Analysis of Hopper angle Φ

For the block to slide on the plane:

Centreboard Hopper Feeder

In this analysis we will determine the track inclination at its highest

The deceleration during phase 2 is chosen so that the normal

Cycle time calculation

For zero reaction:

The acceleration during the upward motion phase will be

Thus the total time for all five phases is:

The efficiency of the device depends on how many parts can be

Load sensitivity of a centreboard hopper

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