Overview:

The Valve Spool Load & Feed System is used to protectively transport transmission valve spools between fabrication and assembly.  The EIA pocket tape individually protects each physical damage and contamination.

Process Description:

Valve spools are stripped from anodizing racks into a multi-lane feeding conveyor.  The valves are transported down the conveyor and dropped into a loading chute.  The 120mm EAI pocket tape is passed below the loading chute with an indexing mechanism.  As empty pockets are positioned below the chute, the valve escapement is opened and the valve spools are released into the pockets. The tape is then sealed with a mechanically interlocked cover.

In the assembly room, the pocket tape reels are loaded into customed pocket tape feeders.  Each feeder includes the typical tape dereeling and opening system, and a specialized buffering conveyor to ensure constant supply to the operator. In the machine, the tape is first opened and then indexed to present a spool.  The spools are dropped onto the buffering conveyor, which is fitted with individual cleats to maintain separation between the spools.  The buffering conveyor indexes to present a new spool to the operator in a custom adjustable pick tray. A new spool is fed whenever the operator removes a spool from the tray.

Technical Challenge:

The main technical challenge with this project concerned the sharpness of the valve spools, and the effect that this had on the feeding mechanism. It was found during development that the spool sharpness rapidly decreased with minimial handling. Spools were essentially conditioned by the machine such that they flowed smoothly through the device after a few cycles.  However, new spools taken directly from the anodizing process would jam the machine approximately once every 500 cycles.

The solution involved videotaping the machine over many cycles to capture the failure mode, and test a variety of corrective modifications. Ultimately, the drop feeding concept was altered to ensure that the spools rolled out of the tape without tipping.  

Features:

EIA pocket tape;
Custom feeding;
PLC control.