On-Site Troubleshooting

Terminology

• Air Jet:
  Small diameter tubing used to assist in moving or orienting parts.  Air is adjusted by trial and error. Air jets are used sparingly.


• Amplitude Control:
  A controller that uses voltage change to control speed. 


• Back Pressure:
  The force of the parts pushing one against the other as they are feed. 


• Back Pressure Relief Device:
  A sensor used to detect part levels in the discharge to control a solenoid that blows air too remove parts from the tooling. Used to keep difficult parts from jamming in tooling areas, or to help keep multiple lane systems even. 


• Back Pressure Relief (Bubble-Off):
  A section of tooling just prior to entering the bowl discharge. Used to allow parts to fall from the tooling back into the return pan without jamming a full bowl discharge.


• Back Pressure Relief Tooling:
  The area just prior to the entrance of the confined area where the parts will buckle if the discharge is full, the parts can then re-circulate in the feeder.  This will relieve part pressure at any previous are to prevent problems.


• Baffle:
  A stainless steel deflector placed on the inside of the bowl bottom to guard the return hole thus allowing parts to flow evenly back up the track from the return pan.


• Bowl Basic:
  The cylindrical “vertical”  band and its internal tracks. Each bowl basic is custom fabricated per part and feed specifications, band height and diameter, internal track separation (height distance between tracks) angle and width.


• Bowl Tuning:
  A technical/craft to develop maximum spring energy level but to keep the coil assembly cool.  Changing spring tension of the drive unit to allow the feeder mass to return to its neutral position before the next magnetic pulse takes over.
  The driving force used to drive the bowl feeders is accomplished by using two or three electromagnetic coils which act upon and pulls face plates which are constrained by leaf springs attached to the cross arms, causing a torsion vibration and translating the vibrations in a vertical direction.  When the drive base moves the parts at maximum efficiency with minimum current effort the unit is said to be tuned. The mass of the feeder bowl is the determining factor in tuning the unit.  The rubber feet placed at each corner of the base drive play an important part in tuning as well as a solid/firm mounting of the feed system.


• Cord Section:
  A straight section of either stainless or tool steel used to select or orient parts. (can be inside or outside of the feeder).


• Confinement:
  A section of the feeder used to control parts through the selector, or discharge chute. Confinements are provided to allow access to parts by removing a bolted on section.


• Counter-Balance Weight:
  A piece of metal of predetermined size and weight that is added to the exterior of the feeder at a location determined by a counter-balance wheel in effort to off-set the weight of the external tooling.


• Dirt Chute / Dirt Relief:
  Used to discharge small particles of foreign material from the feeder.  Must not be larger than the smallest dimension of the parts being used in the feeder.


• Discharge Chute:
  This controls the parts in the orientation achieved in the feeder.  It is mounted tangent to the centerline of the feeder.


• Down Angle Discharge Chute:
  Used to assist parts from the vibratory parts feeder into a gravity track section or to meet a customer specification.


• Escapement:
  A mechanical device placed at the end of the feeder discharge that allows only one part at a time to move into another place, such as a dead nest, to be picked up by a placing device.


• External Tooling
  Any construction outside of the cylindrical “vertical” band.  This tooling selects, separates, orients and relieves pressure build-up on oriented parts. A rule of thumb for a basic tooling area extending from the band/bowl diameter is 1/3 the bowl diameter.


• Fan:
  An adjustable gap which allows part to swing or hang and separate.


• Feed Rate:
  The number of parts per minute or hour discharge from the vibratory parts feeder to maintain production requirements set by the manufacturer. It is good practice to require a 20% higher feed rate of the feeder bowl then the equipment it is supplying product too.


• Full Track Shut-off:
  A means of providing a pressure relief when the parts will not efficiently bubble off of their own accord. This device can be either a proximity, photocell, L.E.D. fiber optic, or pneumatic type sensor to signal the feeder to start or stop. Also a sensor can activate an air jet to eject excess parts from the entrance to confinement, in which case the feeder would continue to run (latter is most generally used with multiple tack feeders).


• Horizontal Cam:
  An irregular shaped piece of metal placed inside the feeder above the parts at different points to control level of parts on the track. Used to reduce the amount of product as it is transferred up the internal tracks.


• Inline Vibratory Track/Feeder:
  A vibratory drive unit designed to produce a straight-line motion.  Used with a straight track to transport parts from the feeder discharge to a dead nest or a pick up point for removal via the customer.  When used with a feeder they are mounted on risers so the inline tooling can be matched to the feeder discharge. A line track is critical to achieve a consistent feed rate and product accumulation.


• Alternative Tracks to Vibratory:
  Gravity tracks and vertical magazines are ways of getting parts from one location to another.   Gravity tracks set on an angle great enough that the gravity will pull the part to its proper location.  A magazine is a channel in which oriented parts are stacked.


• Internal Tooling:
  Any construction inside of the cylindrical “vertical” band.  This tooling selects, separates, orients and relieves pressure build-up on oriented parts. Typically used on simple to orientate product (headless pins, balls, discs). The benefit of internal styled feeder bowls is reduced bowl size, there is very little material extending outside of the bowl diameter, unlike with an externally tooled bowl.


• Orientation:
  The position of the part as it exits the discharge required by manufacturer specifications.


• Overhang:
  The amount of straight track tooling that extends beyond either end of the inline drive-mounting bar.


• Pre-Orientor:
  Properly placed tooling to change the attitude of a part to the proper position for final selection. A pre-orientor will generate higher feed rates and minimize recirculation of the parts, thus extending the life of the bowl, especially with the regard to metal or abrasive parts.


• Quick Dump Chute:
  A quick opening “window” to allow a quick part change when multiple styles or sizes of parts are being fed in the same feeder.


• Rate:
  The number of parts discharged per minute or hour, as needed to maintain production requirements.


• Return Pan:
  An area attached to the band, so the parts that have rejected due to incorrect orientation can be re-circulated back into the bottom of the bowl.


• Running Surface:
  The portion of the discharge chute that the part makes contact with product. The running surface is the surface specified for discharge height.


• Selector:
  The tooling designed specifically to accept only parts that will be used to accomplish proper orientation and feed rate.


• Storage Supply Hopper:
  Used to store extra parts to replenish the supply in the feeder.  Hoppers operate automatically upon a demand from the feeder eliminating a deficiency or over supply of parts in the feeder which causes the feeder to malfunction. The used of an automated supply hopper is recommended for the feeding of product into a feeder bowl to maintain an optimum level of product in the bowl. Most all feeder bowls can be adversely effected by the quantity of product placed in the feeder bowl (too much or too little product) hindering feed rates, drive coil and spring fatigue.


• Sweep or Cam:
  A strip of metal placed on the inside of the feeder bottom to guard the return hole and allow parts to flow evenly back up the track from the return pan.


• Vibratory Parts Feeder Bowl:
  The vibratory parts feeder is the basic bowl custom designed with the external or in some cases internal tooling to meet the specifications required by the manufacturer such as feed rate and part orientation.  Jerhen Industries, Inc. constructs all of it feeders of 304 stainless steel (316 stainless steel when specified).  Tool steels are used in tooling areas of the feeder if there are wear issues and when high degrees of precision are required.

Preventative Maintenance

A good maintenance program is the key to long and successful machine life and trouble-free operation. There are a few very important steps that you can perform in order to get the best performance from your Jerhen Industries, Inc. feeding equipment.

Cleaning Schedule and Procedure

NOTE: The primary cause of decreased system performance is the presence of oil and/or debris within the system from the parts and product atmospheres.

Clean, dry parts and a clean system are essential for optimum feeder performance. The frequency of the cleaning schedule is entirely dependent upon the operating environment. In conditions that are less than ideal, it may be necessary to perform cleaning procedures once a day, once a shift, or even more frequently. In very clean environments, once a week or less may be adequate. It is the responsibility of the Purchaser to determine and adhere to an appropriate cleaning schedule.

WARNING: Turn off main power switch and disconnect power sources while performing cleaning procedures.

Parts:

• Parts must be clean and lubricant free.
• DO NOT reuse parts that have run through the system without first cleaning them.

Bowl and Hopper:

• Remove all parts before attempting to clean.
• Remove any visible debris and foreign objects.
• Clean by wiping down with lacquer thinner, acetone, or enamel reducer and a clean cloth.

Daily Maintenance Schedule:

Inspect the system for the presence of debris or oil and perform any necessary cleaning procedures.

Weekly Maintenance Schedule:

Inspect the system for proper tightness of all nuts, bolts, and screws to be sure the machine is in safe working condition. Specifically, turn off the power to the bowl and check the drive unit bolts, the bowl's center bolt, all top and bottom spring clamp bolts, toe clamp bolts, and the coil bolts.

Quick Reference:

1. Control switch may be in the “off” position.
2. The power supply to the control may be inadequate.
3. The cord from the feeder to the control may be unplugged or damaged.
4. A fuse may be blown in the controller.
5. A coil may be shorted out.
6. A wire lead may be unplugged at the coil.
7. The gap between the coil and striker plate may be closed or damaged.
8. Metal shavings may have entered the controller and shorted it out.
9. A foreign object may be lodged between the coil and striker plate
10. The feeder bowl may have been attached to a rigid track, or the bowl and/ or drive unit may be making contact with other equipment.
11. One or more springs may be cracked or broken.

Detailed Reference:

Potential Failure Mode	Potential Effect(s) of Failure	Potential Cause(s) / Mechanism(s) of Failure	Current Process Controls	Recommended Action(s)	Responsibility & Target Completion Date
Fails to feed any product, Bowl is vibrating	Staves down stream equipment of product	Bad Product	Low track & part presence sensors	Turn equipment off and remove bad product	Equipment operator
		Product jam	Low track & part presence sensors	Turn equipment off and remove jammed product	Equipment operator
		Wrong product	Low track & part presence sensors	Verify product and rev level to bowl design product	Manufacturing/production technician/engineer
		Incorrect power service, drive coils over heat, fire potential	Low track & part presence sensors	Inspect coil temperature, verify incoming power to equipment specifications	Electrical technician
Fails to feed at desired rate, bowl is vibrating	Staves down stream equipment of product at desired rate	Bad Product	Low track & part presence sensors, timing fault	Inspect product for defects, flash, burrs, particulate, cleanliness, etc.	Equipment technician
		Product level in bowl to high, to much product	Low track & part presence sensors, timing fault	Review bowl spec/operation sheet  optimum level	Equipment technician/operator
		Product level in bowl to low, not enough product	Low track & part presence sensors, timing fault	Review bowl spec/operation sheet optimum level	Equipment technician/operator
		Wrong product	Low track & part presence sensors, timing fault	Verify product and rev level to bowl design product	Manufacturing/production technician/engineer
		Static build-up	Low track & part presence sensors, timing fault	Inspect product for possible static charge	Manufacturing/production technician/engineer
			Low track & part presence sensors, timing fault	Install de-ionizing equipment at problem spots (Simco HS nozzle)	Manufacturing/production technician/engineer
		Dirty/film build up on bowl, from product (oil, paint, release agents, etc.)	Low track & part presence sensors, timing fault	Inspect and clean internal surfaces with approved solvents (lint-less)	Equipment technician/operator
			Low track & part presence sensors, timing fault	Revise product processing/handling, clean product before feed	Manufacturing/production technician/engineer
		Drive control setting to low	Low track & part presence sensors, timing fault	Increase control setting (to no more than 80%)	Equipment technician
		Drive spring damage/wear	Low track & part presence sensors, timing fault	Contact for service	Jerhen 815.397.0400
		Unlevel feeder support table	Low track & part presence sensors, timing fault	Inspect for table level and that it is in firm contact with floor	Equipment technician/operator
		Loose bolts/fasteners	Low track & part presence sensors, timing fault	Inspect for tightness and presence of bolts and fasteners	Equipment technician/operator
		Incorrect power service, drive coils over heat, fire potential	Low track & part presence sensors, timing fault	inspect coil temperature, verify incoming power to equipment specifications. Voltage and hertz	Electrical technician
Fails to feed, bowl is not vibrating	Staves down stream equipment of product	Incorrect power service, drive coils over heat, fire potential	Low track & part presence sensors, timing fault	inspect coil temperature, verify incoming power to equipment specifications. Voltage and hertz	Electrical technician
		Power failure	Low track & part presence sensors, timing fault	Check power switch	Equipment technician/operator
			Low track & part presence sensors, timing fault	Check power plug at outlet receptacle	Equipment technician/operator
			Low track & part presence sensors, timing fault	Check system/controller fuse(s)	Equipment technician/operator
			Low track & part presence sensors, timing fault	Check incoming power, from service	Electrical technician
			Low track & part presence sensors, timing fault	Check power to drive coil	Electrical technician
		Drive control setting to low	Low track & part presence sensors, timing fault	Increase control setting (to no more than 80%)	Equipment technician
		Drive coil support failure	Low track & part presence sensors, timing fault	Inspect drive coil mounting for tightness and/or cracks. Set correct gap spacing. Contact service	Jerhen 815.397.0400
		Controller failure	Low track & part presence sensors, timing fault	After complete inspection, no power to coil/drivers, fuse replaced, power in - OK	Jerhen 815.397.0400

Improper Mounting This feeder is not properly mounted. One-half of it is off the machine. The bearing weight of two of the rubber feet is not supported, which robs the feeder of the vibration needed from the drive unit. This kind of mounting will cause loss of feed rate.	Proper Mounting This feeder is mounted properly. Note the bearing weight of all four-rubber feet is supported. There is not strain on the unit and it will stay level. The brace reinforcement to the floor provided a solid support and can be lagged to the floor. Another way to correct the above mentioned mounting problem is to provide a separate table off the machine for the vibratory parts feeder. Feeders that are isolated from the machine cannot pick up counter motion from an indexing machine. If the feeder is isolated, it can be easily leveled and lagged down to ensure maximum performance.
Improper Mounting This feeder is not mounted properly. Risers constructed of small diameter bar stock are too thin and improperly reinforced. In this example, the sub-base plate is being used as a top plate, which is not rigid enough. It may seem to be working, but the feeder cannot reach maximum performance.	Proper Mounting This feeder is mounted properly. Due to the large dimension of the bar stock used for the riser and reinforcement, and the thick top and bottom plate, this drive unit will transfer sufficient vibration to the bowl to reach maximum performance in orienting the parts and delivering the maximum feed rate. Also note that the weight of the four rubber feet of the drive unit are well supported, which is vital to proper performance.
Improper Mounting This feeder is not mounted properly. Note the thin top and bottom plates. Also there are not gusset reinforcements under the feet on the drive unit. The plates can flex and absorb vibration from the drive unit. The plates can flex and absorb vibration from the drive unit. A center column that is too small cause the top plate to warp, which robs the feeder of the necessary power required to function properly.	Proper Mounting This feeder is mounted properly. The top and bottom plates are thick enough to transfer sufficient vibration to the feeder from the drive unit. Also note the four gusset reinforcements under the feet of the drive unit, which adds durability to the spring set-up on the drive unit and prolongs the life of the coil.

Proper Mounting

Each table or stand that supports a vibratory feeder must be rigid, reinforced, level, and lagged down to the floor on all four corners. This will ensure maximum performance and tends to reduce noise level. A stand should be constructed of steel or aluminum. Wooden tables or benches will absorb vibration required to reach the maximum performance.