Pneumatic Handling

7,5 mm
327,5 mm 160 mm 120 mm 42 mm
Handling
Handling
Machining
Assembly
47,5 mm
Organisation
Pneumatics
Pneumatics
Electronics
Electrical
Mechanics
Sensorics
88,5 mm
Software
Hesse Rationalization with Handling Technology

Hesse
Rationalization
with Handling
Technology
158,5 mm
English
Chinese
English
French
195 mm
German
Russian
Spanish
Blue Digest
Blue Digest
on Automation
225 mm
053 583
Hesse
Rationalization
with handling technology
Handling
Pneumatics
Stefan Hesse
Rationalization
with Handling Technology
Blue Digest
on Automation
Blue Digest on Automation
© 1999 by Festo AG & Co.

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D-73734 Esslingen
Tel. (0711) 347-0
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apply for patents or to register designs. No part of this publication may be
reproduced or transmitted in any form or by any means, electronic, mechanical,
photocopying, or otherwise, without the prior written permission
of Festo AG & Co. Any contravention to this effect will be subject to damages.
This book deals with the automatic handling of workpieces. It is a highly con-
Foreword densed version of the loose-leaf collection “Compendium of Modern Handling
Technology” [1]. The handling of workpieces is an area that is associated with
workpiece flow; workers are still required to perform strenuous, barely creative
and sometimes even dangerous work in many parts of industry.
What do we understand by handling technology?

This term describes a technical area that deals with the manipulation of objects.
Like many other disciplines, handling technology has produced its own world of
terminology. Technical expressions are necessary for general understanding.
They can be defined as follows:
Handling technology comprises all means and processes that serve to handle
geometrically-determined objectives (handling objects) in the immediate area of
a workplace, especially mechanically [2].
Handling is the creating, defined changing or temporary maintaining of a pre-

scribed spatial orientation of geometrically determined bodies in a reference
coordination system. Geometrically undefined material cannot be oriented and
thereby generally not be considered.
Handling functions result when handling sequences are broken down into
individual activities [3]. This is necessary for planning purposes. The represen-
tation of a handling sequence through solution-independent functions, is the
first working step in solving a handling problem.
Handling technology has many facets; simple magazines, complicated robots,

workpiece carriers, vibrators, rotary bunkers, feeders, grippers, ... and is, above
all, a connecting link between different workstations. Handling itself should run
as automatically as possible, although this is often only possible in mass
production and with materials suitable for handling.
Flexible handling equipment creates new possibilities in this regard.

Nevertheless, it’s use does not always fulfil every expectation and sometimes
even creates considerable technical difficulties as, for example, in the handling
of pliable parts.
Handling technology is ultimately also a cost factor. It is worth nothing, that it is

not unusual for more than half of the total investment in production and as-
sembly systems to be in respect of workpiece supply and interlinkage of equip-
ment. This requires a comparison of alternatives and strict systematic planning
of handling techniques.
It is gradually being recognised that robots are not required for everything.
A balance between conventional handling and high-tech equipment also offers
a basis for viable automation solutions.
5
Handling devices can be classified from different points of view. Accordingly,
expressions are used in accordance with the global functions that they have to
fulfil, such as supply fixture, interlinking system, feed system, etc. Such terms
do not clearly indicate their function. Terms which relate directly to the handling
operations to be performed, such as bunker, feeder, magazine, etc. are better.
Since the development of industrial robots, programmability has also become an
important factor. Accordingly, a distinction is made between programmed, pro-
grammable (variable sequence devices) and freely programmable devices (axes,
industrial robots).
The automation of handling is not bound to particular branches of industry in

any way, nor is it of importance only where it is possible to build new manu-
facturing lines. The need and potential exists in almost any company that pro-
cesses loose parts, strips and band materials. In the automation of assembly
processes, handling tasks can be seen in concentrated form, where many indi-
vidual parts must be handled reliably at very short intervals, often with com-
plicated arrangements. This is a task of considerable complexity.
In general, the level of automation to be achieved must be defined and justified

before commencing automation projects of this type, and evidence of the econ-
omic benefit needs to be prepared. There is a close relationship between work-
piece design and independent workpiece flow, which requires a joint approach
by product designers, planners and technologists. These considerations must
therefore be taken into account when designing individual parts suitable for
handling and also when making the correct selection of the technical handling
tools.
Handling equipment was first used in mass production. The first examples can
be found in the previous century, as the following examples show:
1873 Spencer (USA) builds automatic lathes with magazine feeding

1880 Worley manufactures turret lathes with rod guides
1923 Morris Motors (Great Britain) commissions a mechanically-controlled
indexing line for the machining of cylinder heads
1924 Rotary table machines with automatic part feed are introduced in the
light bulb industry
1958 Development of the first industrial robot in the USA
6
It is a generally known fact today, that the handling process is a part of manufac-
turing which is just as important as the actual machining process of the work-
piece itself. In particular, the unproductive waiting time during workpiece change
can be reduced significantly through automatic handling. With the industrial
robot, a technology was finally created, which was suitable for use in the manu-
facturing of small series, in assembly processes and for the guidance of tools.
The “conventional” handling equipment has not been eliminated in any way. It
will still be needed in the manufacture of medium and large series. In fact it is
still gaining in importance, as feed devices of different kinds are often needed as
peripherals in robot working cells.
Without giving preference to certain areas, this book aims to present a cross-
section of handling techniques. This is done, above all, from the design/planning
point of view. For reasons of space, many points are kept brief and merely give a
broad outline. This book should also serve as a means of reflection and refer-
ence. Patented solutions and details are not shown comprehensively. The reader
may have to conduct his own research.
Plauen, November 1997
Dr. Stefan Hesse
7
Foreword 5
Table of contents
Table of contents 7
1 Functions and objects 11
2 Bin feed devices 16
3 Stack devices 21
4 Magazines 24
5 Orienting devices 33
6 Metering and dosing 47
7 Clamping 56
8 Output, alignment, branching 58
9 Feed devices 62
10 Handling systems 85
11 Grippers 95
12 Sensors 99
13 Further reading and list of sources 101
14 Glossary of technical terms 103
9
How can handling functions be represented?
1
Functions and objects Symbols are used to compile function charts. It is possible to specify only the
characteristics functions of a sequence or also all installed functions,
if appropriate broken down to elementary functions [3].
Symbols for functions
1 Arranged storage
2 Part arranged storage
3 Unarranged storage
4 Divide
1 2 3 4 5 6
5 Combine
6 Separate
7 Allocate
8 Branch
9 Combine 7 8 9 10 11 12
10 Sort
11 Turn
12 Slew
13 Displace
14 Orient
15 Position 13 14 15 16 17 18
16 Arrange
17 Guide
18 Transfer
19 Convey
20 Stop
21 Release 19 20 21 22 23 24
22 Clamp
23 Release
24 Test
25 Check availability
26 Check identity
25 26 27 28 29 30
27 Check form
28 Check size
29 Check colour
30 Check weight
31 Check position
32 Check orientation 31 32 33 34 35 36
33 Measure
34 Measure position
35 Measure orientation
36 Counting
37 Handling
38 Inspection 37 38 39 40 41 42
39 Production stage
40 Form
41 Change form Composition of functions
42 Assemble
1 = n · 20
6 = 36 + 4
7 = 6 + 18
8 = 18 + 4 + 18
9 = 18 + 5 + 18
10 = 26 + 8
12 = 11 + 13
14 = 32 + 11
15 = 31 + 13
16 = 14 + 15
16 = 32 + 8 + 17 + 19
17 = 20 + 18
18 = 13 + 11

How can we distinguish between workpieces?
Distinguishing between Workpieces can be classified on the basis of numerous criteria. The classification
objects on the basis of below is based on types of behavior. Classification of workpieces is particularly
types of behavior. important in order to allow selection of suitable function devices for handling
operations [4].
Complex workpieces are some-

times referred to as “hay- No. Type of behavior Examples
stack” workpieces, since they
can tangle to form random
combinations.
Types of behavior can be furt- 1 Complex workpieces

her classified, for example on
the basis of dimensional
ratios.
2 Flat workpieces
W ~ H ~ L
W ~ H ‹ L
W ‹ H › L 3 Cylindrical
W ~ H workpieces
L/D ‹ 0.5
L/D ≥ 0.5 4 Block-shaped
L/D › 1 workpieces
L/D ~ 1
L/D ≤ 2
L/D › 2
5 Conical workpieces
6 Pyramid-shaped
workpieces
7 Mushroom-shaped
workpieces
8 Hollow workpieces
9 Built-up shaped
workpieces
10 Irregular solid
workpieces
11 Spherical
workpieces
12 Bulk-length
workpieces
12 1 Functions and objects

What typical behavior groups can be specified for round-section workpieces?
Behavior groups,
shown by the example Depending on its geometrical shape, size (mass), material and surface pro-
of round-section perties, every workpiece has certain rest and motion behavior and a certain
workpieces stacking capacity. This is shown by examples of axially-symmetrical workpieces.
These properties have an influence on the design of handling devices.
L/D > 1 L/D < 1 L1, L2, D1, D2
Free rest positions
Guided motion positions

(rolling)
Guided motion positions

(sliding)
Creation of workpiece groups

(axially parallel)
Creation of workpiece groups

(coaxial)
Random order
(batched good)

Is it possible to handle flexible workpieces?
Workpieces with
unstable shapes The increased use today of innovative workpieces such as technical textiles,
plastic sheeting, etc. means more hard-to-handle workpieces with unstable
shapes. Experiments will generally be required to find a suitable handling
method. Possible gripping methods include pairings of shapes, forces and mate-
rials. Force fields are generally the only option for large workpieces [5] to [7].
Examples
1 Flat complex shapes (2D)

2 2 1/2-D cut shapes
3 Bellows, sleeves
4 3D shaped workpieces
5 Strips, belts, cables
6 Foil cut shapes
7 3D tubes/hoses
8 Tubes/hoses with end
reinforcements
1 2
Notes
• Avoid 3D shaping of rubber

moldings if possible
• Create easy-to-handle ends

(easy to grip and join)
• Create broad gripping areas

to ensure low gripping
pressure 3 4
• Produce cut shapes
locally from roll material
if possible
• Allow for folds in the design

5 6
of gripper components
• Edge reinforcements are

always an advantage, as
are beads and mirror
images
• Moldings can be made 7 8

temporarily more rigid by
cooling
Handling methods
• Suction cups with widely-distributed suction openings

• Needle grippers with micro-needle arrays
• Combinations of suction cups and aerodynamic paradoxes
• Layer or drop of adhesive on gripper component
• Gripping by freezing to refrigerated sheets
• Electrostatic gripping
• Oversize flat or shaped gripper jaws
14 1 Functions and objects

How can we influence frictional behavior?
The frictional behavior of workpieces is an important factor in situations where

these workpieces are able to move freely and depends principally on the
relevant coefficient of friction. Experiments will generally be required in order to
identify this behavior. Frictional behavior can be influenced to a large degree by
changing frictional pairings, for example by using air cushions.
Sliding on an inclined plane
e Constant (2.718)
g Gravitational acceleration
h Height of fall
v Velocity at radius end R
h
R Path radius L
· Path angle
Ê Radius angular pitch
α
l Coefficient of friction R
Sliding on air-cushion trough
1 Compressed air supply

µ
2 Air nozzle 1
3 Air film
p Pressure
α
t Time
l Coefficient of (air) friction
~ 10 –4
G Dynamic frictional force F F
3
F Weight force
F=m·g 2
H Static frictional force
1
· 1° ... 3°
m Mass
g Gravitational acceleration
s Gap
F P
H
G
t s

Can workpieces be sorted in a bin?
2
Bin feed devices In handling systems, bins are generally equipped with sorting or removal
devices. The workpieces are aligned by the alignment edges of the removal
devices. Scoop bins are particularly suitable for smaller workpieces.
Scoop bins
n Double strokes per minute

p Occupation coefficient (0.5
B1 B2
to 0.7), depends on filling
level of bin
B1 = (8 ... 10 L)
B2 = (12 ... 15 L)
L Workpiece length
L1 = (7 ... 10 L)
L1 Scoop component length
v Sliding velocity to desti-
nation point in m/min.
z Number of scoop compo-
nents
α ≤ 20° ... 45°
L1
Delivery capacity
α
Q = n · L1· p · z/L
in units/min.
Drive rating
N = 0.008 · L1
in kW
n = v/L1 · p)
in double strokes/min.
16 2 Bin feed devices

What is the best design for scoop segments?
The scoop segment of a scoop bin must be designed to match the workpiece
concerned. In the case of troughs, it must be ensured that dirt and chips can be
discharged automatically, for example through side slots.
Scoop segment design

(dimensions in mm)
Some design tips:

• Segments should be made
of wear-resistant material;
surfaces should be hard-
chrome-plated if necessary
• Discharge openings should
be provided for dirt
• Avoid V-slot abrasion with
conical workpieces
• Protect segments against
overload (adhering residues)
l1 = l + 1 l1 = R l1 = 0.5 · d
l2 = d + 1 R = (0.6…0.7) d l2 = b + 1
l1 = (0.5…1.0) · l l1 = l + (1…2) l1 = l – (1…2)

l2 = d + (1…2) l2 = b + 1
l3 = d1 + (2…3)
l1 = d1 + (1…2) l1 = l · 0.6 l1 = 1.1 · d

l2 = d + (1…2) β = α + 2° l2 = 0.1 · d
α = 30°…45°

What may causes problems with scoop segment bins?
Scoop segment bins
Problem areas are the points of transfer from the bin to the scoop segment and
from this to the output channel. In the first case, scraping and abrasion of
stationary workpieces against the segment may lead to malfunctions, as may
also result if several workpieces jam against the bin wall if half the bin width
is ‹ 4x the length of the workpieces. There must be no collisions or jamming
during output [8].
1 Rodless pneumatic
cylinder
2 Bin
3 Thrust rod 3 2 7 4
4 Sensor to detect ring slot
5 Output wheel for incorrect-
6
ly-oriented workpieces
6 Thrust output for correctly-
oriented workpieces
7 Solenoid actuator to index
wheel 5
8 Workpiece (example) 1 5
Possible sources of faults

in segment design
Wrong
Tilting and jamming at the out-
let must be avoided.
Right
Spring-loaded components,
sliding radii and push ejectors
for sideways workpieces

What is a stack bin?
Stack bins
Stack bins contain workpieces which have degree of freedom 2 with regard to
their position. For orderly feed to take place, they must be brought or sorted into
a line. The appropriate motion can be executed either continuously or intermit-
tently. Additional vibrators are generally also required in order to break up any
bridge accumulations.
Sliding and rotary bins
1 Slide path
2 Vibrator
3 Rotary disc
4 Workpiece
α Angle of inclination
α
2 3
2 1 4
Friction bin
1
1 Bin
α
2 Roller, eccentrically-
pivoted
2
3 Conveyor belt
4 Rocker arm
α = 4° ... 6° 4
3
Pipe feed bin

1
1 Bin
2 Stand
3 Drive shaft with overload
coupling
4 Rotary metering device
4
5 Outlet 3
6 Flat to create vibrator
effect 5
2

Are multiple arrays of scoop segments advantageous?
The principle of a scoop segment can be produced in a variety of designs,

with both linear and arc motions, and in single and multiple configurations. The
solution shown below is used to separate workpieces out of a bin and provide
pre-orientation, or if required also full orientation. Further orientation devices
can be used downstream.
Lifting-plate bins
1 Outlet conveyor zone 7

2 Linear vibrator
1
8
3 Scoop segment 2
4 Return path
5 Bin 3
6 Base frame
7 Orientation zone
8 Overhead transfer from
top conveyor zone to
4
orientation zone
B, L Main dimensions of scoop
5
segment, matched to work-
piece class
9
6
Motion phases of segments
Workpiece classes
Dimensions range 10…50 mm 50…100 mm 100…300 mm

Mass in kg ‹ 0.05 ‹ 0.2 ‹2
Throughput in units/min. 1…120 1…60 1…30

Can a stack be created and broken up by using the same principle
3 in two different directions?
Stack devices
The main problem with buffer concepts is integration. The way a buffer is filled is
just as important as the way it is emptied. One suitable automation solution is
to use steel-strip or fabric-belt troughs to create “sack” buffers.
Buffer system with steel-strip

or fabric-belt trough
1 2
a) Loading station
b) Loading; the buffer volume
is continuously adjusted
during filling to match the
filling level
c) Loading completed
d) Pallet removed; transport 3
can now be carried out 5
e) Unloading station with
filled pallet
f ) Break-up of stack by step-
wise shortening of trough a b
strip
1 Feed zone
2 Strip roll
3 Frame 4
4 Steel strip, chain, belt,
cable
5 Pallet
6 Outlet zone
7 Workpieces (pipes, shafts,
rods, posts)
8 Metering device
c d
6 7
e f
3 Stack devices 21
How can workpiece stacks be broken up?
Long workpieces such as pipes, rods, boards and tree-trunks are often fed in
bundles. The bundles are then broken up by feeding the workpieces stepwise
into a line configuration. When breaking up stacks of sheet-metal workpieces, it
is advantageous to use an intermediate setdown position in order to allow large
distances to be bridged.
Example 1:
Phases of operation of a stack
trough 1
1 Workpiece holder 4
2 Support
5 7
3 Pneumatic cylinder
2 8
4 Pivot arm
5 Workpieces
9
6 Lowering unit 6
7 Rolling track
8 Metering device
3
9 Tapered roller
A Lowering of workpiece
holder
B Opening of pivot arm
A B
Example 2:
Swivel-plate device
1 Workpiece outfeed 10
2 Outfeed track 2 3 5 8 6 4 7 9 2
3 Lifting segment 1
4 Fixed track
5 Separator
6 Rolling track
7 Divider/metering device
8 Workpiece
9 Swivel plate
10 Workpiece feed
11 Hydraulic cylinder 11
Example 3:
Destacking device for sheet-
metal workpieces 7 2 3 5
8
1 Intermediate setdown
position
2 Suction cup
3 Spreader magnet
4 Lifting unit 1
5 Arm guide
6 Frame
7 Ejector finger
8 Reserve stack
9 Supply trolley
10 Sub-frame 4 6 5 9
22 3 Stack devices
How can small flat workpieces be stacked?
Small flat workpieces can be stacked, for example as a preparation for packing,
by using conveyor belts running at different speeds. The workpieces need to be
stood on edge as they pass from one belt to the other. Stacking rollers and
wheels can be used for this purpose.
Example 4:
Stacking roller
1 5
Variant 1
1 Conveyor belt V1
2 Stacking wheels at left and
V2
right of conveyor belt
3 Setdown rail
4 Conveyor belt 2 3 4
5 Workpiece stack
5
Variant 2
4
1 Sliding track 1
2 Segmented roller
3 Setdown zone 2
4 Workpiece 3
5 Workpiece stack
Example 5: 1
Stacking with stacking roller 2
V1 3
1 Infeed belt
2 Metering device
3 Stacking roller
4 Vibrator conveyor
5 Outfeed belt
V2
4 5
Example 6: 3 5
Stacking with rotary brush
V1
1 Infeed belt
2 Sliding track
1
3 Rotary brush V2
4 Outfeed belt 2
5 Workpiece stack 4
V2 ‹ V1
3 Stack devices 23
How can workpieces be removed from stack magazines?
4
Magazines One frequently-used solution is indexed drums. Workpieces are output by being
tipped into a channel. The indexing motion is generally provided by a control
cam and lifter rod. It is important that the actuating stroke should be produced
by spring force (to provide overload protection), with a direct linkage only for the
return stroke.
Stack magazine 1
1 Magazine wall
2 Ratchet
3 Drive rod for ratchet
4 Drive shaft
5 Metering drum
6 Workpiece
1 A
7 Gravity shaft
6
Tool to aid rapid filling 4
of magazine 5
2 5
4
7
6
3
7 A
Output with slide metering device

In the case of solution A, the upper side of the slide is ridged to generate motion
Avoidance of bridge formation
in the workpieces and thus prevent the formation of bridges. In the case of sol-
1 Air-pressurized rubber ution B, the gripper arm is fed with a workpiece for further handling (machine
diaphragm feed).
2 Air injection point (L)
1 L
A B
2
24 4 Magazines
What is the best design for the workpieces outlets of stack magazines?
These should be designed so as to avoid the risk of bridge formation, which can
seriously impede the flow of workpieces. Moving components are thus fitted
which interfere with the formation of workpiece arches. These components may
be pivoted levers or lugs and rotary devices. If possible, bin walls should be
straight and not inclined, and smooth rather than rough.
Stack magazine 2
1 Multiple swivel metering

device and pivoted lever
2 Pair of pivoted levers
3 Two-channel outlet and
clockwise/counterclock-
wise rotor
4 Sickle metering device
with modified outlet shape
5 Straight-walled bin and
toggle lever
6 Counter-rotating brush
1 2
Note
Design measures should be

taken to absorb the weight
forces of upper layers of work-
pieces.
S Poor
G Good, better
3 4
5 6
4 Magazines 25
When are special magazines used to hold supplies of workpieces?
Special magazines are used in response to special requirements, resulting either

from the process concerned or the properties of the workpiece in question. The
recirculating magazine shown here has been designed to store large quantities
of small workpieces so that one filling will be sufficient for a complete shift. The
chain is endless and runs in numerous convolutions. The box magazine is
intended for reels of thread, fed in automatically. An interesting feature of this is
the pin rake which engages periodically in the workpieces and, in a second
motion phase, pushes a reel into the output shaft. The disc magazine in the third
example can be reset quickly when required, since all storage positions can be
adjusted in one operation.
A Recirculating magazine
1 2
This is an active buffer. All
workpieces are removed at the
same point.
3
1 Control panel
2 Drive motor
3 Schematic chain run
4 Frame
B Box magazine with

metering device for reels
of thread 1 2 3 4 5
1 Infeed device
2 Drive rod
3 Reel in waiting position
4 Slide for adjustment
of outlet
5 Reel magazine
7 Linkage bearing
8 Make-up feed linkage
9 Retaining pin
10 Lifting linkage
B 6 7 8 9 10 11
11 Drive for lifting linkage
C Disc magazine with

adjustable workpiece a
holders
The left and right retaining

jaws are connected to two
separate rings a and b. The
jaws are adjusted for different b
workpiece dimensions by
turning the rings in opposite
directions. C
26 4 Magazines
What do we mean by buffering with direct or indirect feed?
Emergency buffers
Workpieces can be fed directly or via magazine locations which allow an
indefinite dwell time and whose contents are drawn on as a reserve only when
required (recirculating buffers). The creation of buffers of this kind not only
requires the solution of technical problems but must also be justified in
economic terms. This will generally require an analysis of the reliability of the
overall system concerned.
A Throughflow buffer
In an emergency, the part of

the device which is normally
the empty return side of the
chain can store a certain
number of workpieces, de- 4
pending in the length of the 1
chain.
B Throughflow buffer 5
(plan view) 2
3
The continuously-rotating disc
is used as a linking device but
can also act as a buffer for a A B
small quantity of workpieces,
depending on the size of the
disc.
C Recirculating buffer
Workpieces can be buffered in

a secondary stream. The work- 6
pieces must be fed in singly.
7
D Recirculating buffer
(plan view)
Any temporary excess of work-

pieces can be buffered in
tracks at right angles to the
main conveyor direction.
C D
1 Metering device
2 Monitoring sensor
3 Controllable output device
4 Buffer disc
5 Outfeed zone
6 Indexing during filling
7 Indexing during emptying
4 Magazines 27
What is the best design for rolling channels and sliding tracks?
Many methods can be used to magazine and forward individual workpieces,

pipes, bars and profiles. It is often possible to create channels using only a small
number of standard components. The track width can easily be adapted, for
example for bends, using spacer sleeves and washers.
Example 1:
Rolling channels, sliding
and roller tracks
1 Workpiece
2 Long material
3 Electronic components for
SMT systems
4 Trough
5 Roller
6 Wire
1
7 Circuitry
Important:
• Provide space to accommo-

date dirt deposits.
• Spring steel is a good
material for rolling channels 6
and adapts well to bends
(provide elongated mounting
holes instead of round
ones).
• Straight-cut gear wheels will 1
not roll if they are in contact
with each other.
V trough
1
‚ Half V angle
‚ = 45° for light workpieces
‚ = 60° for heavy work-
pieces
B = 0.8 D
7 5 3 5
U trough
H = 0.33 D (sphere)
H = 0.27 D (cylinder)
H = 0.5 D (ring) β D
4
d Workpiece diameter
B
H Edge height
H
6 1 2
28 4 Magazines
When do we need special components to ensure a defined position and orien-
tation?
In general, we can say that with V-shaped workpieces we can always do without
orientation aids, with axially symmetrical workpieces very often, particularly in
devices used to feed machines. In automated assembly systems, on the other
hand, it is often necessary for functional reasons to maintain a certain orien-
tation, for example when meshing gear wheels (example 2). The examples below
maintain position only:
Example 2:
Holder for straight-cut spur
gears
1 2 2
1 Positioning mandrel
2 Bar to prevent rotation
3 Workpiece 3
4 Pallet base
The feather-key slot of gear- 4

wheels can also often be used
to prevent rotation. The most
suitable type of workpiece
holder will also depend on the
type of gripper to be used.
Example 3:
Holder for round workpieces
1 Compact inclined holder

2 Plug-in holder with drawn
collar
3 Plug-in holder with
pressed raised edge
4 Pallet base with support 1 2 3
plate and template
5 Plug-in holder with turned-
up raised edge
6 V strips for wave-shaped
workpieces
4 5 6
4 Magazines 29
When do we need special magazines?
Special magazines are used to provide particular handling functions or meet

certain process conditions. This type of magazine is generally not available off
the shelf.
Example 4: 1
Shaft magazine with auxiliary
rail for non-stackable work- 4
pieces
2 3
1 Magazine shaft
2 Auxiliary rail
3 Metering slide
4 Workpiece
Example 5: 2 1 1 2
Disc magazines
3 3
1 Input side
2 Removal side
3 Workpiece
Inclined-axis magazines have

the advantage that stored
workpieces move to the edge 1
of the magazine by gravity, 2 2 1
3
Example 6:
6
Magazine plate feed device
1
1 Feed arm
2 Pivoted guide rail
3 Plate
4 Workpiece
5 Edge
6 Vibrator chute 4
30 4 Magazines
How do lifting magazines work?
In the case of lifting magazines, workpieces are removed from the top. This type
of magazine is thus very suitable for workpieces with sensitive surfaces which
cannot be slid, for example workpieces with polished, coated or galvanized sur-
faces. The lifting function is provided by similar mechanisms to those used in
drum magazines.
Example 7: Lifting magazine

D
1 Workpiece
2 Light barrier 2
3 Magazine shaft 2
4 Rotary plate 3
5 Drive motor
1
6 Lifting device
7 Gear rack 4
8 Relay
D Reference circle diameter, 5 6
e.g. 150, 200 or 260 mm 8
3
7 6
Drive systems for lifting

devices
Indirect drive
1 Ratchet mechanism
2 Spindle/nut transmission
3 Rack-and-pinion trans-
mission 1 2 3 4 5
4 Friction-wheel trans-
mission
5 Gravity drive
Direct drive
6 Lifting spring drive

7 Pneumatic or hydraulic
cylinder
8 Rodless cylinder
9 Linear electric motor
6 7 8 9
4 Magazines 31
How do climbing magazines work?
Climbing magazines are shaft magazines equipped with lifting pistons which
advance in a stepwise manner. The lifting pistons are self-locking and can be
released to allow filling of the magazines. They can be driven economically by
compressed-air pulses. The workpieces are always removed from the top of the
magazines [9].
Example 8:
Climbing magazines
1
1 Workpiece stack
2 Magazine shaft 10
3 Bayonet lock 6
4 Lifting piston
5 Air supply
6 Lifting-piston seal 6 6
7 Pressure pin 10
8 Pressure plate to transmit
a load-dependent force 2 2
to the internal pressure 5
medium
9 Pressure-medium reservoir 1 1
10 Light barrier 4
4
8
6
3 7
9
5
2
5
Gravity shaft Lifting Lifting piston Climber

Comparison of magazines magazine
Good Type of magazine
Limited suitability
Poor
Interchangeability
Convertability
Automatic filling
capability
Examples of parallel oper- 5

ation of climbing components 4
1 - 3 Guide rod
4 Workpiece
5 Magazine rod
6 Lifting mechanism
7 Support plate
7
6
32 4 Magazines
Should we also carry out orientation operations within a magazine?
5
Orienting devices It is often easier to fill a magazine with only partly sorted workpieces, particu-
larly when these are filled by hand, and then eliminate the remaining undesired
degree of freedom within the magazine. This can be carried out in free fall
at turning points, or swivel turning devices can be used. In either case, signal
processing and a controller are not required [10].
Sorting shouldered sleeves

in a step magazine (A)
1
1 Workpiece
2 Step magazine
3 Metering device 2 3
4 Sorting channel 1 6
5 Metering slide 4
6 Helix guide slot
7 Correctly oriented 2 5
workpiece
3
Sorting cups in a shaft 5

magazine (B) 4
1 Magazine shaft
2 Metering device 6
3 Workpiece
4 Carrier pin, operative
if opening first
5 Fall-through opening
6 Swivel segment
a Operation in the case
6 a b
of incorrect orientation B
b Operation in the case
of correct orientation 1
3
7
4
Sorting collared work-
6 5
pieces (C)
1 Feed channel
2 Rotatable but non-driven
2
core piece
3 Rotating outer ring
with drop-in opening
4 Workpiece
5 Output channel
a Operation in the case
of incorrect orientation
b Operation in the case a b
of correct orientation A C
5 Sorting devices 33
What principle can be used to sort transformer core stampings?
If it is not possible to magazine stampings directly from the stamping tool, they
must be sorted from a random accumulation. In many cases, step-by-step
sorting will be advantageous or necessary. A sorting drum is first used to
produce a string of single workpieces. The remaining degrees of freedom are
then eliminated.
Sorting drums
The workpieces are aligned by

bead rings. Workpieces which
have been aligned exit from
the drum via slots in the drum
shell.
Separating unequal-leg
stampings
On the vibrator unit 7, the

workpieces 4 are aligned
according to their longer legs
and thus pass from the rail 5
to the magazine rail 6.
S Vibrations
4
5
Suspension 6
S
M-shaped stampings suspend
themselves when they pass
over the tilting edge 2 and
reach the rails 3.
The four possible orientations

of L-shaped stampings
7
3 2
34 5 Sorting devices
How can guidance and correctly-oriented buffering be combined?
Ducts and channels can be used to link various workstations. The workpieces
can be fed along these links either singly or in groups. Flat workpieces can
generally be transferred using this method only in a continuous workpiece
stream [13].
Example 1:
Orientated forwarding from
a press
1
1 Press tool 2
2 Material strip
3 Guide channel
4 Level monitoring
4
Example 2: 5
Orientated forwarding
to a flat pallet 4
1 Workpiece in working 1
position
2 Rotary disc
3 Compressed-air nozzle
4 Guide channel 2 3
5 Flat pallet
1
Example 3:
6
Orientated output to a press
2
1 Cutting tool 5
2 Rotary disc 3
3 Magazine rail
4 Rail mounting
5 Workpiece 4
6 Compressed air 4
Example 4: 4
Orientated output from 1 3
a stamping tool
1 Stamping tool
2 Rotary disc 2
3 Magazine bar
4 Rail mounting 5 6
5 Compressed air
6 Workpiece
What workpiece features can be utilized for sorting ?
The features of a workpiece and the selection of technical equipment for sorting
are closely related. We will always attempt to utilize the features which can
assure maximum reliability of the sorting process. The resulting solutions can
often be surprisingly simple, as the example of air-jet sorting shows.
Sorting with air jets
Two air jets ensure that in-

coming workpieces are sorted D D
into two channels according
to their orientation.
D Compressed air
Sorting pins D
D
A recirculating double wedge
slide picks up randomly- D
ordered workpieces and
transports these to an output
point.
D
Sorting with a video system
One workpiece at a time oc-

cupies the lowest position in a 1
parabolic trough. The rotary
motion is then halted precisely 2
when the desired orientation
is reached.
1 Camera
2 Monitored area
3 Drive motor
4 Support structure
with vibrator
3
S Vibration
S
4
How can we describe the logical relationships involved in sorting with rotary
and inverting devices?
In order to determine the control functions required with a sorting device, we

must study the logic relating to the rotation and inversion of workpieces present
in random order. The example below assumes 4 possible positions. We first com-
pile a function table with yes/no information (1/0). Workpieces which do not
conform to any one of the 4 signal patterns will be declared as defective. The
switching functions for inversion about x (Wx), inversion about z (Wz) and ex-
clusion (F) are then simplified with the aid of Karnaugh diagrams. Finally, the
signal circuit diagram is drawn [11].
Detecting shape with spot

sensors Y
Y Z 1 0 Wz
Z
0 0
1 X 0
(Soll-Lage)
Desired 1
X position 2
Workpiece
Werkstück
3
A
Position 1 Position 2
A Stop S2 S1
S1 to S3 Sensors
W Inversion
1 Wz 1
Karnaugh diagram 0 1
This is a graphical method of

0 0
simplifying logical switching
functions with several vari-
ables to find the shortest form.
Wx Wx
Wx = S1 ^ S3 Position 3 Position 4
S1
S2
Wx
Wz
S1
S2
S3
S3 S3 S2 S1 Wx Wz F &
S1
S2
0 0 0 0 1 0 Position 2 &
0 0 1 1 1 0 Position 3
S3 0 1 0 0 0 1 Wrong
Wz = S3 ^ S2
&
S1
0 1 1 1 0 0 Position 4
1 0 0 0 0 1 Wrong
S2 & 1
1 0 1 0 0 0 Position 1
1 1 0 0 0 1 Wrong
S3 1 1 1 0 0 1 Wrong &
F = (S2 ^ S3) v (S3 ^ S1) v
(S2 ^ S1)
Function table Signal circuit diagram
Is it possible to sort and check workpieces in a single device?
Programmable sorting
In applications involving the feed of mass workpieces, it is often desirable not
only to ensure the correct orientation of workpieces but also to check important
workpiece features. One way of doing this is to use classic feed systems but
with the addition of an optoelectronic detection system. If this detection system
can be programmed for small features, it can be used in a flexible sorting device
(at least for workpiece families). The system can “learn” from master workpieces
and can evaluate up to 2500 elements of the silhouette of workpieces.
A Complete system
for sorting and checking
B Sectional view of detection

system (Rhein-Nadel- 1
Automation)
2
1 Controller
and programmer
2 Lighting
3 Camera 3
4 Conveyor belt
5 Deflector for exclusion 4
7
6 Discharge chute 5
7 Preliminary bin 8
8 Helicoidal vibrating bin 9
9 Workpiece
10 Conveyor belt drive 6
C Programmable measure-
ment criteria
1 Comparison of heights 1
without determination of
absolute measurement Measurement criteria
2 Comparison of heights
with absolute reference
dimensions
2 1 Relative comparison
3 Comparison of all measu- 2 Absolute comparison
rement points (x, y values) 3 3 Contour
4 Precise determination of x 4 4 Edge detection:
dimension for workpieces
with a recess
10 Positive edge
5 Measurement of work- Negative edge
piece height at any
5 Height measurement
desired number of indi-
vidually-definable points 6 Length measurement
6 Determination of the over-
all length of a workpiece B C
What active components can be used for sorting?
Sorting can be carried out using all kinds of components. A typical feature of
sorting devices is that these components are required to provide continuous or
intermittent motions. In the first example below, sorting is carried out in two
stages – orientation based on the longitudinal axis of the workpiece, followed by
inversion of incorrectly-oriented workpieces detected by the design of their front
faces. This process utilizes the eccentricity of the center of gravity. In the case of
sorting in a magazine, an eccentric rotor turns the workpieces in steps until their
electrode connections have reached a certain position. In the third example, an
impaled workpiece is pulled out of the bin. An elastic wall piece prevents other
workpieces from following.
A Sorting in a rotary bin
1 Pierced rotor 1
2 Workpiece 2
3 Bin 3
4 Retaining plate
5 Conveyor belt
6 Outlet tube for sorted
workpieces
7 Stop edge to invert work-
4
pieces
5
B Sorting in a magazine
6
1 Workpiece (electronic 2
component)
2 Shaft magazine 7
3 Rotor
4 Retaining plate
5
C Sorting by picking
from heap
2
1 Bin
2 Workpiece 3
3 Elastic slotted wall piece
4 Hook gripper
5 Linear axes 1
2
1 4
5
B C
What conveyor components can be used to aid mechanical sorting
Sorting with shaped in a vibrating conveyor?
devices
Although there are only a few basic workpiece shapes, there are many different
variants, for which the solutions are often surprisingly simple. Most variants will
admittedly require refinement during the experimental stage before they work
perfectly, but once this is done the resulting sorting mechanism is in most cases
uncomplicated.
A Toggle lever
A toggle lever 2 oscillates

along with the main system. 1
If its motion is restricted as a 2
workpiece 3 passes through
on the helix 4, this causes a
change in the reaction of the
ejector lever 5. 1
3
1 Transmission lever 4
5 2
A
B Tilting edge
1 Helicoidal vibrator
2 Workpiece in “good” 3
position
B
3 Workpieces in “bad”
position tilt over
C Suspension rail
1
1 Workpiece in “good” 4
position is suspended
1
2 Helicoidal vibrator
2
2
D Aligning post
3
1 Tube with profile opening 1
in infeed
2 Post edge, operative only
with incorrectly-aligned C D
workpiece
3 Aligned workpiece
4 Vibrator attachment
E Aligning post
1 Workpiece shapes
2 Tilting zone in helicoidal
vibrator
3 Post edge
4 Aligned workpiece
E 1 2 3 4
What workpiece features should be exploited for sorting?
Every object has a wealth of features. For the purposes of sorting, we select
the features which can be used to obtain a reliable result at minimum cost.
Mechanical methods are usually cheap but inflexible. The greater the number
of free workpiece motions involved, the more unreliable the sorting operation
generally becomes. The answer in most cases is to provide more results
monitoring.
Sorting using profile openings

1 A 2 B 3 4 5
1 Vibrator chute
2 Wiper
3 Returned incorrectly-
oriented workpieces
4 Vibratory motion
5 Correctly-oriented work- A B
piece
6 Return track for incorrect- 6
ly-oriented workpieces
7 Ejected workpiece
2
8 Profile openings for incor-
rectly-oriented workpieces
(3 windows in succession) 7 8
α Angle (approx. 70°)
A–A B–B
Sorting in a shaped trough
This exploits the effect of the

center of gravity. The work-
pieces gradually assume the
correct position. Figs. I to IV
show the orientation
sequence.
I II III IV
Sorting using a catch hook 1

5
4
Incorrectly-oriented work- 2
4 5
pieces are impaled and rotate.
2
1 Correctly-oriented work- 3
piece
2 Incorrectly-oriented work-
piece
3 Discharge channel 4
4 Vibrator device 5
5 Catch hook
2
How can chicanes be designed to provide a sorting function within vibrators?
Sorting in a vibrator
There are many ways of using workpiece features for sorting by making work-
pieces tilt, fall or align themselves. The example shows an unusual way of
sorting open rings [12]. The workpieces pass from the flat track into a trough and
are then impaled on a mandrel. Some of the rings rotate on the mandrel about
their own axis until the annular gap in the rings lines up with the web plate.
A Standing cylinders on end
1 Workpiece
2 Edge to produce tipping
against the outer wall 2
3 Helicoidal vibrator 3
B Sorting right-angle work-
pieces with unequal-length
sides
1
1 Workpiece
2 Retaining bracket 2 1
3 Inclined inversion track 3
with aperture
B
A
5
C Sorting open circlips
4 1 3
1 Magazining mandrel
2 Trough exit
3 Web plate
4 Vibrator 1
5 Workpiece
2
D Sorting right-angle work- 1 1

pieces with equal-length
sides
1 Helicoidal vibrator bin

2 Helicoidal zone produced
2
by milling 2
3 Workpiece 3
3
E Sorting tapered control
knobs
D E
1 Helicoidal vibrator bin
2 Sliding path matched
to workpiece
3 Correctly-oriented
workpiece
How can a fuse-holder be sorted in a vibrator?
A facility is provided for workpieces to hang in a slot 0.5 mm wide. Workpieces

which fail to do this fall back into the bin. The workpieces are then picked up by
a hanging ledge, followed by transfer to a slot magazine.
Example 1:
Workpiece
1 2 3 4 5
0.4 mm
4
1 Inclined helix B
2 Lower part of helix
3 Retainer C
4 Hanging ledge 6
5 Sorted workpiece
6 Magazine exit B
7 Workpiece
Roughly 20% of conveyed C

components exit from the
A A
vibrator in a sorted state.
Handling technology
Deflector
3
Notch
1 7
4
Slot
Incorrectly- 6
Hanging ledge oriented
workpieces
2
Slot magazine
Section A – A Section B – B Section C – C
How can a suspendable workpiece be sorted?
The success of the sorting operation depends on two factors – the workpiece
reaching a state of lying on its back, and the subsequent longitudinal orien-
tation. Following this, there are two possible orientations – bushing at the front,
or bushing at the rear. Uniform orientation is achieved as the workpieces are
suspended in a slot.
Example 2:
Workpiece
2 3 4
A
1 Lateral slot to allow exit of B
workpieces with incorrect
bushing orientation
2 Ramp to stand workpieces A
on edge
3 Flange
4 Slot B
C
C
Handling technology
Deflector
Notch
D
Lateral slot
Incorrectly-
Ramp oriented
workpieces
Suspended
workpieces
Section A – A Section B – B Section C – C
What sorting components can be used with small surface features?
For the stamping shown below and similar workpieces, guide edges can be pro-
vided against which lugs, projections, hooks, etc. can align themselves.
Incorrectly-oriented workpieces must then be removed via a separate guide
track in order to obtain uniform orientation at the exit.
Example 3:
Workpiece
5 6
4
B C
B C
1 Notch
2 Workpiece
3 Guide slot to allow exit of
incorrectly-oriented work-
pieces
4 Inclined support surface A A
5 Curved guide to achieve
“stud-first” orientation
6 Covered slide track
7 Vertical wiper
8 Cover plate
9 Stop edge for stud
2
1 7
Handling technology
2 8 6
Deflector
9
Notch
Guide slot
3
Suspended
workpieces Section A – A Section B – B Section C – C
Curved Guidance
guide
How do we carry out sorting in scoop bins?
A typical feature of this is that workpieces are drawn directly from a heaped con-
figuration. This can be achieved through linear or rotary motions of the active
components. The scoop components may be mandrels, troughs, cups or strips.
Scoop bins are particularly suitable for feeding small workpieces to automatic
machine tools.
Example 4:
Scoop bin
1 Bin
2 Workpiece
3 Discharge track
4 Scoop segment
5 Scoop mandrel
6 Release tube, relative 3
motion after ejection
position is reached 1 2
7 Shaft magazine
4
6
5 2
Example 5: 1
Scoop-wheel bin
1 Bin
2 Scoop wheel
3 Gravity shaft
4 Workpiece
Does the motion sequence have an effect on the reliability of a metering
6 device?
Metering and dosing
The motion of a metering device (start and end) may comprise a step change,
may be jerky, jerk-free but non-linear or jerk-free and linear. We must decide on
the basis of the active forces what motion function can be accepted.
Motion sequences
with “metering” function
s s s
a Acceleration
s Distance
t Time
v Velocity
t t t
v v v
t t t
a a a
8
t t t
Jerk at start Shock-free but Shock-free and

and end non-jerk-free motion jerk-free motion
Examples
4
4
1
Brake motor
4
2
Switching cam 5 9
3
Drive crank 5
4
Shaft magazine
5
Workpiece
6
Metering slide
7
Metering chain
8
Rotary metering device 10
with Archimedian screw 2
9 Rotary table with roller 1 11
crown
10 Swivel-segment metering 4
device 4 4 7
11 Roller metering device
8 5
6

How should metering devices be designed for heavy or undercut workpieces?
In the case of heavy workpieces, the workpiece to be metered should be freed of

the weight forces of the other workpieces in the magazine. This can be achieved
by using single-acting, double-acting, mechanically- or pneumatically-controlled
workpiece barriers. These not only relieve weight but provide stepwise release
of the next workpiece.
Example 1:
Metering device with barrier
1 Magazine shaft
2 Barrier 1
3 Metering bar
4 Workpieces
4
Example 2:
Metering slide with double
barrier
1 Magazine shaft 3
2 Metering slide
3 Workpiece 1
4 Barrier in lock configur-
ation
5 Clamping point 4
2
5
Example 3: 1
Metering device for undercut 4 3
workpieces
1 Magazine shaft 5
2 Metering slide
3 Barrier 2
5 Gripper for workpiece
transfer
48 6 Metering and dosing

Does the workpiece shape influence the design of the metering device?
Metering devices must often be specially matched to a particular workpiece and

pick-up direction. The illustrations below show two typical phases of a metering
operation.
Example 4:
Metering flat workpieces
1 Metering slide 1
2 Swivel segment
3 Slide for feed to machine
4 Workpiece
3
4
2
Example 5: 1
Metering of ball bearings 2
from a bar magazine, removal
3
from above by an industrial
robot
1 Spring-loaded segment
2 Workpiece stop plate
3 Workpiece
4 Spring cap
5 Spring
4
5
Example 6: 1
4
Metering of pipe fittings
(T pieces)
1 Spring-loaded detent
2 Housing
3 Drive yoke
4 Workpiece
5 Return stroke
6 Metering stroke
5 6 2

What special points must be noted regarding distribution?
In the case of the rotary distributor A, the driver compartment is designed to

provide a reliable pick-up function while ejecting excess workpieces. This is
carried out using compressed air while one workpiece at a time is held by
vacuum. Wherever possible, use should be made in distribution of the workpiece
shape, as shown in example B. Workpieces with an almost symmetrical center of
gravity tend to overturn when they impact on the distributor slide. A diagonal
distributor channel D avoids hard impacts [15].
A Rotary metering device
1 Workpiece held in position

2 Compressed air channel
3 Suction air channel 1 4
4 Workpiece to be ejected 2
5 Magazined workpieces 3 2
6 Stack magazine
1
7 Rotor
B Slide metering device

5
6
1 Metering slide
7
2 Workpiece with shape
features
A B
C Double metering device
1 Shaft magazine 1
2 Driver cam
3 Roller chain
4 Slide
v Metering speed = Chain
speed 2
4
D Inclined channel metering 3 v
device
1 Feed track
2 Metering slide with
diagonal channel C
3 Workpiece which over-
turned during metering
and was then wrongly
machined
4 Correctly machined
workpiece
3
1
2 4

How can thin stampings, foils, metal and paper sheets and textiles
be separated?
Thin workpieces can be separated and metered by pairings of force, shape or

material. This is especially difficult with two-dimensional textile workpieces.
Separating thin stampings
1 Electrostatic
2 Air suction
3 Velcro
4 Freezing
5 Needle grippers
6 Aerostatic paradox
7 Suction air and silk-paper 1 2 3
separator
8 Staggered setdown
and gripper
9 Push-off with ratcheted
roller
10 Roller pull-off
11 Air suction roller
12 Adhesive roller 4 5 6
13 Spring-loaded press-on
suction cup
14 Local cutting instead
of metering
15 Magnetic roller conveyor
7 8 9
10 11 12
13 14 15

How can we assist the metering of thin flat materials?
Separating flat
workpieces It is difficult to separate thin materials and workpieces, since these may stick
together. Separating can be improved by using various aids, for example by
blowing compressed air between the upper layers, by creating different pressure
zones, or generating repulsion forces with spreader magnets. Among the mech-
anical devices which can be used are precision exit apertures and stop edges.
A Separating thin plates

Air can be blown in by several
nozzles all round the work-
piece. 1 1
1 Suction cup 2 2
2 Air nozzle 3
3 Pallet lifting device 7 4
6
B Pneumatic separator
1 Gripper head
2 Flat textile
5
3 Compressed-air supply
4 Exiting air
5 Impermeable table
6 Vacuum zone 3
A B
7 Atmospheric pressure area
C Spreader magnets as
separator aid
1 Suction cup
1
2 Top floating workpiece
(ferrous sheet) 2 1
3 Spreader magnet 3 3 2
4 Stack of sheets
D Rotary brush as
separator aid
1 Rotary brush
4
2 Textile stack 4
3 Counterholder bar C D
4 Table surface
E Magazine and separator

for solder contacts
1 Magazine 1 1
2 Metering slide
3 Retainer 2 2
4 Workpiece
7
F Separating cards 3
1 Belt
5
2 Guide roller
3 Pressure roller
3 6
4 Knife edge as retainer
5 Card stack 4
6 Lifting device
7 Air suction
4
E F

How can layers of paper be separated?
Separating paper
layers Particularly in industrial bookbinding, there is a need to separate and compile
single and folded paper sheets. Some remarkable cycle times are achieved – for
example, 250 to 350 workpieces per minute with rotary systems. The gripper
drums do not, however, rotate at a constant speed – this is reduced at the
moment of gripping. The collector bins generally pass through numerous
metering units until a book block has been compiled [14].
A Metering and assembly

using translatory components
1 Stack in magazine 1 1
2 Pivoted suction cup used 3 3
2 2
to separate bottom layer
from stack
4
3 Movable stack support 5 4
4 Tongs gripper
5 Monitoring of closing
operation (check for no 9
workpiece/double work- 10
6
piece)
6 Driver 8
7 Collector channel
8 Conveyor chain in collector
9 Gripper arm
7
10 Collector bin 8
A
B Metering and assembly

using rotary components 1 1
3
1 Stack in magazine
2 2
2 Pivoted suction cup 7
3 Movable stack support 4
4 Clamp gripper 4
5 No workpiece/double
workpiece monitoring 6
6 Gripper drum
7 Separator worm drive
8 Driver pin 5
9 Conveyor chain
5
10 Collector channel 6
9
8
10 10
9

What are the problems associated with the separation of thin cut workpieces?
Separating thin cut
workpieces Often, the only effective way to separate thin cut workpieces is by using friction;
the main problem is then to hold back the subsequent workpieces in a stack.
Highly-developed devices have been produced in this area for the automatic
feed of punched cards. These solutions can be used today for other purposes in
a similar or modified form.
A Separating by friction
1 2 3
1 Driven roller for forwarding
2 Guide plate
3 Pull-off roller
4 Metering roller
5 Counterrotating wiper belt 4
6 Lifting magazine
7 Held-back second work-
piece
5
3
5 7
A
B Combination separation
1 Suction trough 3
2 Perforated conveyor belt
1
(permeable to suction air)
3 Suction air connection 2
4 Cam to pull off top work- 4
piece
5 Held-back workpiece 5
6 Lifting magazine
7 Retrodirective belt
8 Suspension mounting
for retrodirective belt
8
B 6

What physical variable is used as the basis for dosing?
Dosing is carried out on the basis of mass, volume or number of units [16].
Mass dosing takes the form of a direct comparison of mass on weighing devices,
volume dosing measures out a certain volume (mass = volume x density,
assuming that density is a constant), while unit dosing counts out a certain
number of units (mass = number of units x unit mass).
Example 1:
Mass metering
1 Bin
2 Screw conveyor
3 Stirrer 3
4 Switch-off device 3
5 Shut-off flap 1
2
2
4
Example 2:
Volumetric metering
1 Suction phase: Piston

dosing device
2 Ejection phase
3 Drop piston
4 Level-controlled shut-off
1 2
3 4

What basic clamping methods are available?
7
Clamping Clamping is an operation which is of particular importance in jig construction. It
involves the temporary securing of a material object in a specified orientation
and position by the application of a clamping force by mechanical (springs), flui-
dic, electromechanical or electromagnetic means. Mechanical clamping grippers
incorporate a large number of lever transmission systems.
Theoretical possibilities
1 V-jaw clamp
2 Pressure plate
3 Double clamp
4 Spring clamp
5 Clamp pin
6 Clamp lever
7 Clamping against fixed
corner
8 Centering action 1 2 3
9 Hold-down clamp
10 Clamping against
centering jaw
11 Leaf-spring clamp
12 Permanent-magnet clamp
13 Spindle-driven jaws
14 Pneumatically-driven jaws
4 5 6
P Compressed air
M Permanent magnet
7 8 9
10 11 12
13 14
56 7 Clamping
How can we protect clamping points against the input of incorrect workpieces?
Avoidance of incorrect-
ly-oriented workpieces Incorrect or incorrectly-oriented workpieces may cause serious damage to a feed
in clamping devices or machining operation. Monitoring is therefore always advantageous. In many
cases, even simple technical means will be sufficient to prevent an incorrect
input. In all the examples below, salient points of the workpiece are sensed. If
the contour is incorrect, the device refuses to accept the workpiece in question.
Monitoring devices of this kind are particularly advisable when magazines are
filled manually.
A Protection for a clamping

device
1 2 3 3
Incorrectly-oriented work-
pieces cannot be inserted.
1 Clamping device
2 Spacer bracket
3 Workpiece
B Protection for a feed

channel
A
1 Workpiece
2 Uncontrolled tactile-
sensor lever which
engages in the slot
in the workpiece
3 Sliding channel 1
2
1
C Protection for a rolling 2
channel
1 Workpiece
2 Tactile-sensor roller
with mirror-image profile 3 3
of workpiece
3 Rolling channel B C
D Protection for magazine

input
1 1
An insertion template allows
only correctly-oriented work- 2 2
pieces to be inserted.
1 Magazine tube or shaft

2 Adjustable or fixed
contour-checking
component, template
3 Workpiece
3
D 3
7 Clamping 57
What physical effects can be exploited during the output of workpieces
8 from clamping devices?
Output, alignment,
branching It takes little equipment to blow workpieces out of clamps using compressed air
or allow these to fall by gravity. The major disadvantage of this, however, is that
the orientation of the workpiece is lost. The first examples below show the use
of magnetic force. In example C, as the book block is released, it is stood on
edge and its direction of motion is changed. In the fourth example, the output
operation controls itself by mechanical means.
A Magnetic extractor
1 Electromagnet
1
2 Ferritic rail 2 1
3 Brass wedge to increase
air gap and allow detach- 2
ment of workpiece 3
4 Inclined track
4
3
B Magnetic gripper
4
1 Magnetic gripper housing
with appropriately-shaped
pole pieces
2 Coil
3 Ferromagnetic workpiece
A B
4 Workpiece holder
C Output and alignment
1 Sliding track
2 Output workpiece, in this
case a book block
3 Rotary turning device
4 Spring-loaded output 1
device, yoke-shaped
2
3
D Self-controlling output 4
device C
1
1 V support with drilled
bushing 2
2 Workpiece
3 Output trough 4
4 Spring-loaded
yoke-shaped output 3
device
5 V clamp = Metering device
6 Feed zone 6
58 8 Output, alignment, branching

How can we split a workpiece flow?
Branching
Branching is required particularly when we wish to feed workpieces to parallel
coupled machines or store these in buffers. In most cases, workpieces are
required to arrive singly and must thus be separated beforehand. The technical
means used to achieve this are controlled deflectors and multiple metering
devices.
Example 1:
Track multiplier
1 Feed track
2 Pivoted lever
5
4 Workpiece
5 Output track 4
1
2
3
Example 2:
Deflector
1 Rolling track 3
2 Workpiece
1
3 Stop 2
4 Controlled deflector
5 Output track 4
5
1
2
Example 3:
Metering slide 3 4
1 Shaft magazine
2 Workpiece
3 Slide
5
5 Output shaft
1 2
Example 4: 4
Track distributor
5
1 Feed track
2 Track distributor
4 Workpiece
5 Output track
3

How can we branch flows of material?
There are numerous reasons why it may be necessary in automated systems to

branch bulk materials or small workpieces – to distribute material, such as
powder, to the production machines currently operating, to divert material
because of a malfunction, and to distribute material to several workstations
within an installation, such as bolts from a feed unit to several bolt fitting points.
Pipe switches are often used to route flows of bulk materials. The rotor should
always be driven via a slipper clutch. Devices of this kind are also known as two-
way distributors. In the second example, the skilful use of an air jet allows the
outward transfer of workpieces made necessary by a workpiece jam. The bypass
is activated automatically whenever a jam occurs. Even an ordinary gripper can
be used as a distributor.
Example 5:
Pipe switch 1
2
Piping systems are very
suitable for the pneumatic
conveyance of bulk materials.
1 Distributor housing 3
2 Rotor
3 Pipe connection
Example 6:
Pneumatic switch
If a workpiece jam occurs, the

thrust of the air jet is 1 a a
deflected, causing subsequent
workpieces to be fed into the
bypass channel. In order to
achieve this, the distance a is
2
defined as an appropriate mul-
tiple of the workpiece length.
2 Conveyor channel
Example 7:
Mechanical switch a
1
The basic component of this is
a parallel-jaw gripper. Both 2
sides of the switch and
connected tubing are moved at 3
the same time. The distance by
which they are moved is the 4
gripper stroke.
1 Supply tube
5
2 Retainer
3 Gripper
4 Gripper jaw
5 Bolt 6
6 Outlet tube
60 8 Output, alignment, branching

When is it necessary to align workpieces and how is this done?
Alignment
It is often necessary to align workpieces before they are transferred and packed
or before they enter the feed zone of a processing machine or machine tool. In
the simplest case, inclined conveyors are used, on which the workpieces align
themselves by gravity. The examples show solutions for powered alignment in
the center of a conveyor belt. Alignment is, however, also possible using fixed
guides or template end stops (bends, V-shapes), particularly when workpieces
are to be picked up in this position. Alignment should be regarded as a special
type of orientation.
Example 1:
Alignment using a gripper
1
1 Diffuse sensor
2
2 Alignment plate
3 Conveyor belt
4 Parallel-jaw gripper
Example 2:
Alignment in stack 4
1 Guide plates 3
2 Conveyor belts 1
3 Lifting cylinder 4
4 Rack-and-pinion
mechanism
2
Example 3:
Alignment with guide 6 1 3
components
2
1 Workpiece
2 Trigger cam
3 Stop bracket
3
4 Conveyor belt
5 Guide plate
6 Pick-up position for robot
handling
5
4 4
Example 4:
Alignment with template
1 Workpiece
3
2 Conveyor belt
3 Template; V-shape also
possible
4 Pick-up position for hand- 1
ling device
2

What feed systems are used with grinding machines?
9
Feed devices In view of the need to grind large quantities of standard components, the feed
systems used for this have long since been automated. The solutions concerned
are simple and reliable and provide a good example of dedicated feed systems.
Feed for grinding

machines
Example 1:
3 1
Rolling track
1 Infeed track 2
2 Workpiece
3 Metering device 5
4 Input/output device
5 Outfeed track
6 Grinding disc
6 4
Example 2: 3 1
Chain
4
1 Chain buffer
2 Rotary feed device
3 Workpiece
4 Grinding disc
5 Outfeed track
2
5
Example 3: 1 3
Conveyor belt
4
1 Magazine
2 Conveyor belt
3 Pair of rollers
4 Pair of surface-grinding
2 5
discs
5 Outfeed track
Example 4:
Feed chute
3 2 1
1 Drum bin
2 Vibratory feed chute
3 Grinding disc
4 Vibratory storage bin 4
5 Vibrator drive
5
62 9 Feed devices
What feed methods are often used with automatic machines?
Feed for automatic
machines There are various feed devices, such as continuously vibrating and rotating
systems, rotors which hold workpieces during their motion, and also lever
mechanisms for infeed and outfeed.
Example 5:
Feed of small workpieces
to an automatic packing
machine
1 Bin 1
2 Vibrator
3 Rotary table with driver
pockets
4 Conveyor chain with driver 3 5
5 Transfer position
2
Example 6:
Feed of workpieces 4
to an automatic lathe
1 Shaft magazine
2 Input device 1
3 Separator
4 Drive cylinder 3
5 Workpiece removal device
6 Quadruple chain
4
2
Example 7: 6
Feed of workpieces
to an automatic grinding
machine
1
1 Workpiece
2
2 Metering device
3 Measuring/control device
3
4 Regulating device
5 Workpiece output
9 Feed devices 63
Can particular workpiece properties be exploited in feed devices?
Solutions which exploit particular workpiece properties generally produce well-

designed feed systems. These properties may be ferromagnetism, surface
resilience (wood) or particular frictional and rolling characteristics.
Example 8:
Feed and fitting of pins
1 Bin
2 Pivoted lever 9
3 Permanently-magnetic
10 1
carrier wheel 2
4 Bracket
5 Feed tube
6 Lift cam for pivoted lever
7 Press-fitting cylinder
3
8 Metering device
9 Workpiece
10 Metering device drive 5
11 Base
12 Non-ferrous metal
or plastic
13 Permanent magnet 4 6
8
7
11
12
13
Example 9:
Feed device for profile milling
machine
1
1 Magazine 2
2 Workpiece
3 Sensor for start 3 4
of metering device 5
4 Roller feed device
5 Milling station
6 Metering slide
7 Start pushbutton
8 Roller lever valve 9
9 Cam valve for return
stroke 6
10 Directional control valve
8
10
7
64 9 Feed devices
How can circular blanks be fed by electromagnetic means?
There are numerous possible methods, generally involving an electromagnet

which picks the workpiece up. If this method is used with a stack, however,
several workpieces may stick together. In the example below, a “gripper roller” is
used to remove the workpieces from a magazine and place these on a roller con-
veyor [17].
Example 10:
Magnetic gripper roller
1 2 3 4 5 6
1 Power cylinder
2 Output roller conveyor
3 Castor
4 Roller conveyor
5 Magnetic roller
6 Circular blank, metal
stamping
7 Slide track for empty pal-
lets
8 Drive for magnetic roller
rotation
9 Pallet with compartments
7 8 9
Design of magnetic roller N S N S N
1 Slip ring for power supply

2 Non-magnetic steel sleeve
3 Ferromagnetic pole pieces
4 Solenoid coil
5 Axis
N North pole
S South pole 3 5 4 2 1
Sequence of gripping
operation
1 Approach to pallet
2 Lifting out a workpiece
3 Tilting onto roller conveyor
4 Rolling away
1 2
3 4
9 Feed devices 65
How can spinning tubes be fed automatically?
Ring spinning tubes are collected after use and must then be cleaned, sorted
and magazined. The tubes are 220 to 310 mm long and have diameters of up to
38 mm. They are conical. Sorting is carried out in two stages. A conveyor belt is
used to align the tubes by their longitudinal axis. A second stage is then used to
produce a uniform small/large diameter orientation (Brouwer & Co.).
Example 11:
Feed of conical workpieces
Detailed view of a tube hand-

2
ling station
5
1 Lifting device
2 Collector bin in emptying 3 4
position
3 Trough bin 1 6
4 Internal conveyor belt
5 Buffer store
6 Sleeve sorting station
(Cleaning station not shown)
Sorting operation
A The workpieces are

brought by a conveyor belt
to the tipping point.
B The sleeves are still just

held by the belt.
A
C The end with the smaller
diameter is released first
and is able to fall. A fast-
running conveyor belt
moves the falling work-
piece onwards, always
with the smaller diameter
leading (v2 › v1).
66 9 Feed devices
How can we separate long thin rods?
It is difficult to remove long thin rods or pipes, plastic rails and similar work-
pieces from a trough, since the workpieces may be intertwined and there is no
guarantee that they will be in a partly-sorted state. One patented solution [18]
uses the principle of picking up one end of a workpiece and then running
rotating arms below this point. This gradually raise the rod from the bin. Once
the bar is fully raised, the arms are tilted to allow the workpiece to roll off.
Different methods are used to separate large rigid pipes.
Example 12: Pipe separation

and feed
1 Support arm
2 Holding trough 1
3 Gripper 1
4 Partially raised workpiece
5 Pulling device (chain)
6 Frame
7 Workpiece
8 Swiveling device 2
9 Lifting device
10 Support arm in tilted
position
α Tilting angle
5
Ways of separating pipes
a Pressure gripping and

pulling out
b Pushing out
c Magnetic holding and 4
lifting
3
3
a
7
b
10
1
4
1
c
2
10
7
6
9
9 Feed devices 67
What methods can be used to feed bar materials?
Because of their length, bar materials require special storage and feed systems.
One solution can be to use large swiveling yokes to fill and empty special
pallets. In the example below, bar material is transferred from and to a tapered
roller conveyor.
Example 13:
Feeding and buffering of long
workpieces
1 2 3 5
6
1 Ejector lever
2 Tapered roller conveyor
3 Rolling track
4 Frame
5 Lifting yoke
6 Transport beam 7
4
7 Special pallet
8 Workpiece
9 Pallet stacking location
9 8
A Transfer of bar material
for magazining A
B Transfer of bar material
from buffer to roller
conveyor
Example 14:
Feeding glass flasks
1 Swivel magazine
2 Magazine rail
3 Yoke carrier in feed chain
4 Glass flask
5 Rotary axis
6 Swivel motion
for reloading B
7 Filling zone 7
1
2
4
2
3 6
4
5
68 9 Feed devices
What do we mean by derivative feed motions?
Every motion within a feed sequence needs a drive and must be controlled. We
therefore attempt to derive, or directly couple, any necessary feed motions to
other operations which are required in any case. This has been achieved in an
ideal way in the automatic knurling machine shown below. Skilful design has
made it possible to derive all the necessary feed motions from the pressing
operation.
Example 15:
Feed system
for an automatic knurling
1
machine
1 Knurling wheel
2 Workpiece, e.g. rotor shaft 2
of electric motor
3 Lifting and press-fitting
unit
4 Outfeed rolling track 3
5 Stop lug
6 Finished workpiece
7 Support rollers in lifting
Vee 8
8 Metering device A
9 Tension spring
10 Feed track
9
A The knurling operation

begins. Contact pressure
approx. 50 to 60 bar.
B The lifting Vee is lowered

4
and sets the finished
workpiece down on the
back of the stop lug.
Simultaneously, the
metering device releases
the next workpiece. There 10
is no need for a special
controller for this.
B
C The new workpiece rolls
up to the stop lug. The
finished workpiece rolls
away to the left. During
the subsequent stroke of
the Vee, the workpiece is 5
picked up and then lies on
the support rollers.
6
9 Feed devices 69
What methods can we use to feed long cylindrical components?
There are probably more solutions for the feed of cylindrical components than
for anything else, since this application is very common. Example 17 shows a
solution in which a stack magazine is used as a buffer store from which work-
pieces can be output again. A special gripper is required in order to pick up
workpieces from a stack at an angle (example 18).
Example 16:
Feed of workpieces for thread
rolling
1 Workpiece
2 Output device, 1 6
self-swiveling
3 Input device 2
4 Metering device 6
5 Rolling track magazine
6 Examples of workpieces
5 3
4
Example 17:
Feeding or buffering of work-
pieces
1
1 Deflector 2 7
2 Roller conveyor
3 Workpiece
6
4 Thrust insertion device
5 Return feed device
6 Metering device, barrier
3 5
7 Stack magazine
4
Workpiece diameters:
10 to 30 mm
Cycle time: 5 s
1
2
3
Example 18:
Feed of heavy bar sections
4
1 Handling device
2 Gantry carriage 4
3 Gantry support
5
4 Gripper
5 Roller conveyor as infeed
or outfeed device
6
6 Workpiece 7
7 Transport pallet
α Angle, 60°
70 9 Feed devices
What are the points to note when feeding workpieces from a stack magazine?
The main problem is to ensure a constant flow of workpieces to the metering

device. Interruptions may occur due to bridge formation; to counteract this,
many types of vibrator devices are used. In the case of the magazine filling
device in example 20, a conveyor belt running against the outlet of the stack bin
is used to ensure a continuous flow of workpieces from this.
Example 19: Feed from

a stack magazine
1 Moving half of magazine

2 Lever vibrator
3 Ball bearing
4 Detent pin
1
6 Cover plate
7 Workpiece output
a Metering device form
for workpiece diameters 2 a
≤ 6 mm, 60 to 200 mm
long
b For workpiece diameters
› 6 mm
I Rotor with vibrator cam
II Rotor with multple cells 3
for metering, vibrating
and locking
4
5 6 b
7
I 1 2 5
II 6
7
Example 20:
Magazine filling device
1 Stack magazine
2 Deflector belt
3
3 Metering wheel, running
synchronously 4
with covneyor chain
4 Conveyor chain
5 Workpiece
6 Magazine
7 Light barrier as level
8 9
monitor
8 Metering device
9 Feed to machine tool
9 Feed devices 71
What is a good way of feeding light shaped workpieces?
Light shaped workpieces, such as cans, tubs and lids, need to be fed with short
cycle times in processign and packing systems. The first example shows the
cleaning of cans, using a magnetic conveyor belt. The other examples show
further types of covneyors as alternatives to a vibrator. These exploit a
centrifugal conveyor principle. Sorting is generally carried out by other down-
stream devices.
Example 21:
Handling cans 1 2 3 4
1 Magnetic conveyor belt
2 Workpiece (can open
at top)
3 Inward transfer track
4 Output of cleaned cans
5 Guide plate
6 Rotary output device
7 Spray nozzle
8 Feed zone
9 Input side 5
7 8 9
Example 22:
Inclined-disc bin
1 Adjustable suspension
mounting of bin
2 Workpiece already
on output track 1
3 Bin lining
2
4 Inclined disc, continuously
rotating 3
Example 23:
Conical disc centrifugal con-
veyor
1 Output track
1
2 Bin
3 Rotating conical disc 2
4 Base of bin
5 Motor with gear unit 3
4
5
72 9 Feed devices
Are special devices necessary to handle glass? (1)
Glass items are mass-produced, with smelt temperature always a factor. The
special parameters with glass are thus primarily the effects of heat and the high
volume of production, rather than the shape of the workpieces. This is shown in
the examples. In the first example, glass tubes are lifted to transport them from
one pair of rollers to the next. They rotate on the rollers, which allows their ends
to be shaped, for example to be fusion-sealed. The second example shows a
feed system which is able to operate either cyclically or continuously.
Example 24:
Cyclical advance of glass
tubes (after Loewinger)
1 2 3
1 Output track
2 V-shaped bar for lifting
and advance
3 Workpiece
4 Support roller or disc
5 L-shaped lever for motion
transmission
4
6 Parallelogram lever
5
7 Roller lever
8 Cam for lifting motion
9 Motion for longitudinal
transfer
10 Return spring 6
Cycle time ›4 s
7
10 8
Example 25: A
Continuous feed of glass
tubes
5
6
1
1 Driver pin
2 Roller chain, double or 2
multiple running in parallel 3
3 Sprocket A
4 Bulk bin
5 Stack magazine
6 Workpiece (glass tube) 7
7 Chain tensioner
4 2
1
9 Feed devices 73
Are special devices necessary to handle glass? (2)
Heating and cooling are major factors in the production of glass workpieces.
Cooling must take place slowly and is carried out in cooling or tempering zones.
Handling devices are required to re-orient the workpieces. The upper example
shows hollow glass workpieces being stood on end, while the second example
shows the handling of bottles. In order to prepare the bottles to pass through an
optical test machine, they must be formed into a string one workpiece wide. This
function is provided by the fast-running center outfeed belt.
Example 26:
Re-orienting glass workpieces
4 v1
Workpieces which arrive in a
horizontal position need to be
stood on end for feed to the
next machine. The workpieces
are gripped at the top by their
blowing heads.
1 Hollow glass workpiece 1 v2

2 Stop bar 2
3 Conveyor belt
3
4 Sprocket chain
5 Feed belt, v1 = v2 4
5
Example 27:
Formation of bottles into a
workpiece string (plan view).
Throughputs are achieved of
up to 10,000 units per shift
1
1 Cooling zone, hinged chain
2
2 Workpiece, e.g. bottle
3 Conveyor belt 3 4 5
4 Guide plate
5 Center outfeed belt 9 v2
6 Feed to test machine
7 Counterrotating belt
8 v2
for excess workpieces 7 v1 6
8 Guide plate
9 Guide web, fixed, v1 › v2
74 9 Feed devices
Are pneumatic feed systems feasible?
Piece goods can also be transported on the principle of a pneumatic tube

system. One particularly important factor is the transfer of workpieces into the
system. Pneumatics can also be used for the final phase of the motion – inser-
tion into a workpiece holder. Endless threads or ribbons can also be transported
in this way. Here the axial air flow exerts a force on the belt, which is moving
more slowly due to air friction. This force conveys the ribbon continuously [19].
Pneumatic feed
A – CPhases of feed operation

1 Workpiece
1 2 3
2 Openings
3 Feed tube
lw Workpiece length
l Distance to holder disc
m Workpiece mass
p Pressure in pneumatic line
v Peripheral velocity
F Thrust force produced v
by a vibrator A p
FR Frictional force lw
H Resulting force
k Coefficient making
allowance for the frictional
force between the work- F
piece and pipe wall FR F
s Minimum clearance be-
H
tween workpiece and hole
in holder v
p
B
Pneumatic conveyance
of a piston motor valve
1 Pipe run
s
2 Compressed air
at velocity v
3 Workpiece at velocity c C v
2 3
1
Pneumatic conveyance
of ribbons and threads
v
1 Pipe run
2 Compressed air flow
3 Handling material 2 1
4 Injector with annular gap 3 4
v c
9 Feed devices 75
How can flat pallets be handled automatically?
Automatic pallet handling can be necessary for two reasons – to activate a

passive pallet in order to be able to work with simple handling devices (point
access), or to create large buffer stores upstream of or between machines. The
technical solutions used range from simple switching-cam rollers to complex
pallet stores.
Pallet indexing device
1 Pallet frame 1
2 Indexing stop
3 Switching roller
4 Cam
5 Double cylinder to pro-
duce 3 switching positions 2
(stop 1, stop 2, run-
through without stops) 4
l Step width during indexing 3
5
l
Stacking/destacking unit
1 Full pallet stack

1 2
2 Handling device
3 Empty pallet stack
4 Stacking unit 3
5 Destacking unit
6 Lateral slide
6
4
5
Shaft buffer unit

1
1 Shaft with guides
2 Flat pallet, crate, etc. 2
3 Retainer
4 Roller conveyor 3
5 Lifting/lowering device
6 Stop device 6
4
76 9 Feed devices
How can blanks be fed to shaping machines?
The process of feeding cutting and bending machines with circular or other
blanks is determined by one factor in particular – the distance between the
magazine and the point of action of the machine. For constructional reasons,
magazines cannot be positioned directly adjacent to this point.
Handling small blanks
1 Metering slide,
single-acting
2 Magazine shaft
3 Gravity shaft 2
4 Deep-drawing tool
Feed in mm Strokes per min. 1

4
≤ 20 ≤ 150
20 – 40 100 – 120
Tapered-slide metering device

5
1 Metering slide,
double-acting
2 Taper drive 4
3 Drawing tool 2 1
4 Cutting tool 3
5 Clamping pin
Feed in mm Strokes per min.

≤ 20 ≤ 150
20 – 40 100 – 120
1
Metering slide
with pneumatic drive
4
1 Magazine shaft
2 Metering slide E
3 Pneumatic cylinder E
4 Punch tool
E Limit switch
2 3
1
50 – 250 30 – 60
Metering slide driven

by press ram
1 Magazine shaft
2 Angle lever 2 3
3 Metering slide

≤ 20 ≤ 140
20 – 50 100– 120
9 Feed devices 77
Can all types of bolts be fed equally easily?
The answer is no! Bolt feed devices must take into account the behavior of the
bolts during feeding. The major factors are the position of the center of gravity,
the length, the shape of the bolt head, the ratio of diameter to length and the
presence of surface coatings. Bottom-heavy bolts will hang on rails and can also
be fed effectively using chutes. Top-heavy bolts, on the other hand, must be pre-
vented from falling over. These can be fed effectively in profile tubes and rails.
Difficulties will be experienced with all bolts whose heads have a tendency to
lock together, tangle or slide one inside the other.
A Feeding bottom-heavy
bolts
A 1 2 3
1 Angle rail
2 Covered parallel rail
3 Feed pipe or tube
B Feeding top-heavy bolts
1 2
1 U rail
2 Profile tube
3 Turning by inverter rail
after conveyance
from vibrator
4 Turning by turning unit
B 3 4
C Difficult bolt shapes

t
s
Flat-head bolts can overlap,

small-head bolts may tilt in the
rail, and combination bolts
may lock together head to
head.
s‹t
C
78 9 Feed devices
Do transfer devices need to be matched to materials?
Automatic transfer from one machine to the next is vital in high-throughput

installations. In these cases, an optimum solution can be achieved only if hand-
ling devices are closely matched to the properties of the workpieces concerned.
In the case of cans, for example, these are first formed into groups and then
gripped as a block. If the cans were handling individually, this would lead to very
short cycle times. The second example, too, has been specially designed to deal
with pipe or bar material and uses a custom-made metering disc to transfer
workpieces from the rolling track to the longitudinal conveyor. The shape of the
driver compartments eliminates the need for any further retaining plates or
similar.
A Transfer of cans
1 Transfer gripper device of

a gang press (output side)
2 Workpiece, hollow sheet-
metal with base upper-
most
1 5
3 Handling device 6
4 Multiple suction cups 2
5 Permanent magnet 7
6 Switchable electromagnet 3
7 Conveyor belt 4
8 Collector conveyor belt
8
2
A
B Transfer of pipes 3
1 Metering disc 1
2 Driven tapered roller of a
longitudinal conveyor zone 2
3 Step stop
4 Rolling path with or with-
out steps to align rolling 4
pipes
5 Workpiece, pipe or bar 5
9 Feed devices 79
How can workpiece damage be avoided during handling? (1)
Soft contact surfaces
Workpieces are not improved by constant handling. Impacts, jolts, abrasion, dirt,
etc, cannot be avoided but can be reduced. Speeds of motion can be cut, and
drop heights made smaller. The use of air-cushion troughs for transfer avoids
direct contact between workpieces and guide components. Plastic liners can
also often be useful. Dirt slots ensure that particles are swept away from contact
surfaces.
Typical workpiece damage

resulting from handling
Handling operation
In the case of sensitive work-
pieces, we must determine Workpiece damage
0.1 0.2 0.3 0.4 0.5 0.6
what possible damage may
occur and then select suitable Abrasion marks, scoring, groves 1.
technical means of avoiding
this.The table lists the main
factors. Accumulation impact damage 2.
Solid black = Pronounced
effect Corner-to-corner impact damage 3.
White = No or low-level
damage
Plastic deformation, dents 4.
Example:
Case 2.5 = Damage resulting Micro-scoring on surfaces, scratches 5.
from accumulation impact
damage during transfer. 6.
Deposits of foreign matter
Remedy: Reduced speed, pro-
vision of shock absorbers and
braking devices.
1
Brush conveyors
1
2 3
A Vertical conveyance with
arched brush array
B Vertical conveyance with
vibrator 3 2
C Conveyance with brush
belt 5
D Gentle conveyance 4 3
of brush conveyor
E Horizontal conveyance
1
on double brush conveyor A B C
1 Brush array
2 Vibrator 3 1
3 Workpiece
1 3
4 Infeed ram
5 Conveyor belt
D E
80 9 Feed devices
How can workpiece damage be avoided during handling? (2)
Braking devices and
shock absorbers An important way to reducing workpiece damage is to incorporate braking
devices into the workpiece flow. This applies in particular to cases where work-
pieces can move freely. In the case of heavy workpieces, braking devices are
also necessary in order to protect equipment, while in the case of bulk
containers, braking device protect the contents of these. It is therefore necess-
ary during the planning stage to specify all the points at which workpieces or
workpiece carriers are to be brought to defined speeds.
A Overtravelable brake
1 Package, container
2 Small-roller conveyor 1
3 Impact lever
4 Shock absorber
B Tandem brake
1 Roller with elastomer ring 2
coating able to absorbs 1 2 3
energy through defor-
3
mation
2 Roller conveyor 4
3 Workpiece, container
C Rolling-track shock A B
absorber 1
1 Heavy shaft
2 Rolling track 2
1 3 4 5
3 Destination position
for workpiece
4 Stop lever
5 Brake arm 3
6 Shock absorber
4
D Pneumatic braking device 5
[22]
1 Workpiece 6
2 Feed tube
2
3 Compressed-air 6
connection C D
4 Controlled pressure 1
chamber
5 Elastomer component
2
6 Steel sleeve
E Overtravelable shock
absorber
1 Adjustable plate
2 Workpiece
3 Rolling track frame
4 Rotary cam
5 Shock absorber
F Rotary shock absorber

1 Sliding track 3 4 5
2 Workpiece E
3 Impact roller
4 Rotary shock absorber
F 1 2 3 4
9 Feed devices 81
Should we check features in the main workpiece flow? (1)
If this were done in cases where the proportion of defective workpieces to be

eliminated was relatively high, this would mean turning a handling unit into a
test machine. This would not be correct. It would be better in these cases to
install test stations upstream. If, on the other hand, faults occur relatively
seldom, it is often possible to incorporate very simple mechanical checks,
particularly of geometrical properties. Each incorrect workpiece, however, means
an interruption in the workpiece flow and generally requires a manual inter-
vention [15].
A Checking a welded
assembly
Base components without

welded-on pins are eliminated.
1 Complete assembly
2 Base component
B Check of progress
of machining
Workpieces without a
1 1 2
machined recess will not fit 1 2
into the shape-monitoring A B
magazine (left).
1 Correctly-machined
workpiece
2 Incorrectly-machined
workpiece
C Check of diameter
All workpieces deviating “Good” “Bad”

workpiece workpiece
from the check dimension
= 0.5 (D+d) are held back. 1
2
1 Roller diameter D
2 Pivot diameter d
C
D Checking brush assemblies
Workpieces with a brush insert

missing on one side slide
crookedly and are held back
by a monitoring lug.
1
1 Workpiece (brush
assembly)
“Good” “Bad”
2 Slide trough workpiece workpiece
2
D
82 9 Feed devices
Should we check features in the main workpiece flow? (2)
9
Feed devices Incorrectly-oriented workpieces can cause feed mechanisms to jam, particularly
when the workpieces are asymmetrical. Simple monitoring devices are highly
advisable in order to protect machines and equipment. The automatic elimina-
tion of incorrectly-oriented workpieces is effectively the same as sorting work-
pieces and can thus utilize several of the same principles.
A Hook spring
The hook engages in the slot

of incorrectly-oriented work-
pieces and pulls the workpiece
concerned off the track.
B Slide track with opening
Incorrectly-oriented work-
pieces do not lie on the
suspension rail and fall
a b
through the opening.
Condition: a › b
A B
C Profile check
The set screws in the feed

trough are adjusted to match
the profile of a correctly-
oriented workpiece.
Workpiece
D Slide track with lifting

ramp [15]
If blanks which are too long

h
are accidentally inserted into 5

the feed track, they are raised
and, for example, ejected 1
upwards by an air jet.
2
a = h – 1 mm 3
a
1 Workpiece
4
2 Feed track
3 Thread-rolling tool
4 Ramp D
9 Feed devices 83
How can we guard against two workpieces being fed at once?
Monitoring for double
sheet-metal work- Accidental feed of two workpieces at once occurs particularly with flat work-
pieces pieces; this interrupts the flow of work and may lead to serious damage to
stamping tools. Safety devices must therefore be provided. In example A, a
second workpiece is pulled away by a magnet as it travels over this at a distance
h. In the case of solution B, each flat workpiece is fed through a template before
being inserted into the tool. The third example also includes a facility for
checking thickness.
A Magnetic “suction“
1 Handling device
2 Gripper (magnetic or
suction)
3 Ferromagnetic workpiece 1
4 Magnet over which work- 2
piece must travel at 3
h
precisely defined height h
4
1
A
2
B Panel handling (Englert)
The thickness templates 4

swivel upwards after the
checking operation in order
not to impede the insertion of
a panel into a workpiece.
1 Industrial robot
2 Hand joint
3 Linear slide unit
3
4 Adjustable thickness
gauge
5 Gripped metal panel
6 Suction cups
4
5
6
B
C Monitoring within tool
The workpiece thickness is

monitored via the ram guide 1
plate. 2
3
1 Ram retaining plate
2 Electrical contact
4
3 Contact lever 5
4 Adjusting screw 6
5 Ram guide plate
6 Workpiece (cut sheet
metal)
C
84 9 Feed devices
What are the typical forms in which industrial robots are produced?
10
Handling systems By “form” we mean the configuration of the modules of a machine. This is the
result of a process of adapting the robot for a certain handling task, taking into
account operating conditions and other restrictions and the basic design
parameters of the robot in question (structure).
Industrial robots
Designs
1 Column form
2 C-frame column form
3, 4 Column forms
5 Column form
with traveling axis
6 Gantry form with wall
mounting
7, 8 Gantry form with one
or two columns
9 Special form 1 2 3
with double arm
10, 11 Special forms
Basic design
Sequence of rotary and pusher

units with defined position or
direction created by guide
mechanism of an industrial
robot. The basic design
reflects the kinematic structure
of the main axes; one major
parameter is the presence of 4 5 6
floor- or gantry-based travel
units.
7 8
9 10 11
In what different versions are positioning units available?
Linear drives
A wealth of well-proven standard components, such as those by Festo, are
available for controlled positioning. The drives used include electric motors and
hydraulic and pneumatic cylinders. Motions can be programmed by means of
end stops or free positioning.
Systems may include

components such as:
• Translatory units
• Short-stroke units
• Grippers
• Carriages
• Lateral carriages
• Gantries
Each module is generally

available in a range of sizes.
Other modules may include
rotary or swivel units.
86 10 Handling systems
How do rotary fluid-power units work?
Fluid-power units are used in large quantities to move handling objects. These
units provide linear motions and also swivel and rotary functions.
Swivel drives
1 Servo drives with levers

2 Servo piston with rack-
and-pinion mechanism
1 2
Rotary drives
1 Axial-piston motor
2 Gear motor
3 Vane motor
4 Radial-piston motor 1 2
5 Roots motor
6 Turbine motor
3 4
5 6
What are the advantages of modular systems for industrial robots?
Industrial robots
Modular solutions exploit the possibility of using a given range of modules, each
with defined sub-functions, assembled in various ways to create numerous
systems with different overall functions (Mecana).
Modular systems
These systems may comprise

the following:
Horizontal linear units

Vertical linear units
Short-stroke units
Gantry motion units
Gantry beams
Gantry columns
Gantry cross-motion units
Rotary units for angles ‹ 360°
Rotary units for angles › 360°
Swivel units
Floor motion units
Hand-joint rotary units
Base units with rotary axes
Grippers
Gripper-changing systems
Gripper stores
Sensor units
Workpiece carrier units
Controllers
Monitoring units
Protective systems
Software modules
Programming units
Modular construction
This is a method of creating

technical products with certain
functions using one or a small
number of standardized
modules (assemblies) in such
a way as to make it possible
with these modules to produce
either a limited or unlimited
range of different devices
within a product line.
How do we ensure that modules can be combined together?
Industrial robots
Especially important are uniform connections and good module centering
systems to allow modules to be centered one to another (by means of pins, ring
inserts, slot nuts, etc.). Good connectivity must also be ensured for power and
data by means of suitable interfaces (Mecana).
Modular systems
Modular solutions can be

described in terms of the
following characteristics:
Working space (shape,

volume)
Working range of arm
Mobility
Mobility range
Momentary path velocities
Momentary path acceleration
values
Travel times
Positional deviations
Orientational deviations
Path errors
Rigidity
Efficiency
Price/performance ratio
Scope of control facilities
(flexibility within the context
of the application)
Re-usability of modules
Interfaces for power and data
Are special application-specific handling units better?
It is not possible to give a general answer to this question. Even if an appli-

cation-specific handling unit is considered necessary, this should be based on
standard modules. The first example shows the feed of large bolts. In the second
example, the handling unit is very simple but requires a magazine which can
move up as necessary.
Large-bolt feed (Hitachi)
1 Linear unit
2 Controller
3 Parallel-jaw gripper 1
4 Partly-sorted bolts
5 Bin
3
6 Feed chute 2
7 Linear vibrator
8 Presence monitoring 4
device
9 Base frame
5
Flat-workpiece feed device
1 Magazine wall
6
2 Workpiece
3 Lifting cylinder
4 Parallelogram guide 7
5 suction cup
6 Pneumatic cylinder for
8
swivel or clamping motion
7 Machining system
8 Geneva movement 9
7
3
6
1 2
4
5
6
What are the advantages of mechanically-controlled pick and place devices?
Pick and place devices
Mechanically-controlled pick and place devices have proved valuable in all appli-
cations where simple insertion and removal motions are required, with no need
for resetting. These devices are fast and operate free of jerks and non-linearities,
since the motion sequence can be optimized and stored in a control cam. There
are no drift effects even after long periods of operation. The cams generally
operate in an oil bath. The noise level is low. The use of modular construction
means that user-specific solutions can be produced cost-effectively.
Lifting/turning loading device

(Ferguson)
1 Loading arm
1 5
2 Gripper
3 Lifting/turning unit
4 Gear unit
5 Electric motor
6 Pneumatic linear unit used 2 5
in place of a fixed arm
7 Straight guide 3
4
Examples of possible motion
patterns
1
H Stopping point 6
2
1 7 8
H 3
Equipment variant (Ferguson)
1 Outfeed belt
2 Machine tool
3 Finished workpiece
4 Linkage for arm drive 4 9
5 Lifting/turning loading
5
device
6 Electrical motor 6
7 Feed belt
8 Blank workpiece
9 Linear guide
A B
The rotary motion of the lifting/turning loading device shown above is used as
the mechanical drive for two linear units. One loader is thus sufficient for a com-
plete infeed and outfeed operation.
A Unloading operation
B Loading operation
What advantages do rodless pneumatic cylinders offer in handling devices?
Rodless cylinders are highly reliable and occupy much less space in the direction
of motion in handling devices in comparison with other designs of cylinders.
They are thus very suitable for simple multi-axis handling devices. They also
save a great deal of space with infeed, removal and transfer functions. There is
no need to protect the piston against torsion.
Multi-axis handling device

(Origa)
1 Boom arm 1
2 Rodless power cylinder 6
3 Gripper, suction cup 2
4 Linear guide
5 Rack
6 Cable guide chain 2
Stroke lengths:
Up to 12,000 mm
Cylinder diameters:
10 to 32 mm
5
Combination of rodless
2
cylinder and integrated guide
3 4
5
Infeed device
1 Rod-type power cylinder

2 Infeed cam 1 2 3
3 Workpiece
4 Guide rod
5 Sliding surface
6 Rodless power cylinder
h1
h1, l1 Installation space

with piston rod
h2, l2 Installation space
without piston rod
l1 4
3
5
h2
l2 6
What are the major steps involved in planning handling systems?
Planning
Overall procedure
A “handling system” is all the

technical equipment used at a • Analysis of given
workstation for handling situation
(generally automatic hand-
• Concretization of
ling). This equipment may
include industrial robots, grip-
planning objectives Planning preparation
pers, drives, sensors, control-
lers, programming systems, Rough planning
clamping devices within
machines and peripheral feed
Rough planning
devices.
Fine planning Detailed planning

Implementation
• System installation
• System operation
Workpiece Planning of
analysis required hand-
ling devices
Workpiece flow concept

Planning
optimization
Documentation Scope and type
Project coordination of handling functions
Evaluation Drafting of hand-

ling system
Control system Integration

concept into system
The process moves from general planning to detailed planning. Optimization of

planning is achieved by running through the procedure shown above several
times and refining the results of previous planning steps, discarding details if
necessary and devising substitutes. Planning should always be carried out on
the basis of several variants which should then be compared to determine the
most suitable solution for the given application [23].
What data do we use to describe a handling application?
Planning
There will always be a number of important basic requirements which determine
the major features of a handling system. This data can be used to make an initial
selection.
Specification
Number of workpieces per unit time
The specification for a hand-
ling system is made up of Workpiece types and variants
three parts:
Batch size
• Requirements regarding
process changes Suitability of workpieces for automatic handling
• Requirements regarding – Sliding capability
object changes – Rolling capability
• Requirements regarding – Suspension capability
handling system – Stacking capability
– Dimensional stability
The requirements are made up – Robustness
of fixed requirements,
minimum requirements State at start of handling process:
and desirables. Degree of orientation/positioning
State at end of handling process:

Motion axes Orientation/positioning after setdown
X Y Z Major handling sub-functions:

s
v
A B C
ϕ
ω
U V W
s
v
D E F
ϕ Distances s and angles j of positions to be approached in a three-dimensional coordinate
ω system. Intermediate points (e.g. to bypass obstacles).
Approach and dwell times
Number and sequence of positions to be approached
Permissible positioning errors ±
Dimensions of possible
gripping areas on object
Required load-bearing capacity
Preferred power source
Number of control signal inputs/outputs
How can we achieve flexible designs of gripper jaws?
11
Grippers The increasing demands for flexibility in production systems also require
grippers which in particular are able to deal with differently-shaped workpieces.
There are many possible technical solutions to this problem, some of which,
however, are not ideal for harsh industrial environments. The most common
Classification system solution is reversible gripper jaws, frequently equipped with numerous
mechanical or special features [24, 25, 29].
The most importance factor in

a classification system is a
description of the way contact Ways of achieving flexibility with gripper jaws
is made between the gripper
object and the gripper jaws. In
cases where force fields are Fixed active area Variable active area
used (vacuum, magnetism),
conditions are somewhat diffe-
rent. It is also important to Choice of slots Interchangeable Reversible Non-reversible
define what we mean by “flexi-
bility“.
Example 1:
Adjustable-shape grippers 1
4 7
A The gripper jaws are com-
posed of adjustable metal 2 1
leaves.
B The jaws consist of hollow 6
bodies filled with powder
and made rigid by the 5
application of vacuum. 3
1 Gripper finger
2 Adjustable metal leaves
4
3 Clamp screw
4 Workpiece A B
5 Elastic bag
6 Powder or granulate filling
7 Vacuum connection
Example 2:
Jaws filled with kneading
mass
The gripper jaws are filled with

silicone mass (soft) or
kneading mass (liquid
aluminum) (1). This is used
to take an impression of the
workpiece shape (2) and
is then allowed to harden
(3) (Sommer).
1 2 3
11 Grippers 95
How can we grip free-formed workpieces? (1)
Free-formed workpieces are frequently encountered in the automobile industry,

the construction of lighting fittings, etc. These workpieces can be gripped easily
using adapted suction grippers. Special modular systems have been created for
this purpose which allow suction cups to be distributed over an area and inter-
changed rapidly. The systems shown below are patented and have been taken
Example 3: from [26]. Particular emphasis has been placed on a relatively large degree of
Grippers for sheet-metal flexibility regarding applications.
workpieces
A Large-area suction cup

array
4
1 Sheet-metal workpiece 5
2 Boom arm
3 Suction cup module 1 6
4 Robot arm
5 Coupling 2
6 Oval suction cup 3
B Suction-cup module
1 Compressed-air
connection
2 Suction-cup changing
button
3
3 Support arm
4 Ball joint
4
5
5 Silencer A 1
7 Ejector device 6
8 Suction cup 2
7
C Large-area suction cup 8
array (plan view)
1 Electrical plug
2 Connector adapter
3 Boom arm B
4 Clamping gripper module
5 Ball-joint connection 1
6 Extension piece
7 Suction cup module 2
Clamping gripper module
1 Mounting component
2 Gripper
3 Gripper finger
4 Sheet-metal clamp pins 3
4
5
3 6
7
4
C
96 11 Grippers
How can we grip free-formed workpieces? (2)
The efficiency of large-area grippers depends largely on the vacuum-manage-

ment system used. Modern systems offer good facilities for optimization [28].
For example, the compressed-air supply to the vacuum generator is switched
back on only when the vacuum level falls below a threshold value. Controllable
ejector systems, integrated into suction cups, ensure the fast release of work-
pieces, which is particularly important in the handling of fragile or very light
workpieces. Example B shows a 20-second handling sequence.
Example 4:
Shaped-workpiece gripper 1 2 3
A Large-area gripper
Combination of suction and

clamping modules
1 Clamping gripper module
2 Quick-action clamping
device
3 Robot hand joint
4 Workpiece
5 Suction-cup module with
integrated venturi system
A 4 5
B Vacuum control system

1 3
1 Control signal for vacuum
on/off 1 1
2 Automatic regulation t
t
of vacuum to compensate 0 0
for leakage losses 0 5 10 15 20 0 5 10 15 20
3 Sensor signal (workpiece 4
present)
2 1
4 Control signal for vacuum
regulation P t
0
5 Controlled ejection 0 5 10 15 20
of workpiece from 5
suction cup
0/1 Off/on 1
t Time in s 0 t t
0
0 5 10 15 20 0 5 10 15 20
C Pneumatic circuit
B
1 Directional control valve
2 Pressure adjustment
3 Compressed-air line 1 2 3 4 5
4 Venturi nozzle
5 Silencer
6 Suction air line
7 Ejector line
8 Suction cup
9 Workpiece
6
7
8
9
11 Grippers 97
In what forms are electromagnetic grippers used in handling systems?
The main variable in the design of electromagnetic grippers is the way the pole
pieces are matched to the workpiece. In examples A and B, the electromagnet is
spring-loaded. Once a workpiece has been picked up and the magnet has been
switched on, the workpiece holder is also locked magnetically. During setdown,
the springs act as a workpiece wiper.
Example 5:
Electromagnetic gripper
1 1
A External electromagnetic
gripper
2 2
B Internal electromagnetic
gripper 3 3
C Electromagnet
with centering pin
D Pole-piece design 4 4
for round workpieces
E Magnetic pin gripper 5 5
F Combination
magnetic/suction gripper;
the workpiece is picked up
A B
by suction and held by
magnetic force during the
hand motion
G Magnetic gripper with pin
to produce arching effect
and guard against picking
up 2 workpieces at a time
1 Gripper arm
2 Spring
3 Electromagnet coil
4 Workpiece holder
5 Workpiece
6 Suction air
7 Sealing ring 5 5
8 Power cylinder
C D E
6
3 8
5
200 mm
F G
98 11 Grippers
What are sensors and how can we classify these?
12
Sensors Sensors react to conditions by generating signals in a form which can be pro-
cessed by a control system. Internal sensors measure distances, angles and
forces in the components and joints of handling devices. External sensors react
to workpiece features and provide information on conditions in the environment
Classification of a handling device [27].
of sensors
Sensors for handling devices
Internal sensors External sensors
Workpiece- Non-tactile- Force and torque

contact sensors sensors sensors
Electrical Electrical, Electrical

and pneumatic magnetic, sensors (strain-
contacts and acoustic, gauges, etc.,
microswitches optical, chiefly in grip-
fluidic and pers and had
Piezoresistive in particular joints for force
sensors for pneumatic feedback), pneu-
enhanced sensors matic sensors
sensitivity (large- (jet sensors) (chiefly in auxili-
area ary devices to
configuration measure weights
for object and joining
detection) forces)
Examples
Internal sensors
1 Potentiometer
2 Inductosyn
3 Incremental encoder
4 Orifice disc 1 2 3 4
External sensors
1 Row camera
2 Strain gauge
3 Reflex sensor
4 Nozzle baffle
W Resistor
1 2 3 4
12 Sensors 99
When is it necessary to monitor workpiece ejection?
Checking for output
Particularly in stamping and injection-molding processes, there are cases in
which the failure of workpieces to be ejected may result in serious damage to
tooling. It is then necessary to provide monitoring to ensure that a complete
workpiece has been ejected before the next working stroke is triggered. This will
furthermore make it possible to check the workpiece flow. The method used may
be optical, inductive or tactile sensing or even weighing. This last method also
A Inductive method (plan
view) provides an indication that the ejected workpiece is complete.
1 Workpiece from press

2 Slide plate
3 Induction coil
B Pivoted plate as check 4

weigher
5
1 Adjusting screw 1
2 Return spring 1
3 Limit switch 2 2
4 Baffle 3 3
5 Pivoted plate
C Optical method
Workpiece ejection is
monitored within the tooling. A B
1 Cutter insert
2 Workpiece
3 Light barrier
D Monitoring within tooling 1

1
2
1 Drawing ring 3 2
2 Workpiece, bowl
3 Lower part of tooling 4
4 Induction coil
3
E Light barrier
The workpiece path is C D
monitored at two points during
output.
1 Light barrier to monitor

whether workpiece has
been gripped 1 1 2 3
2 Handling device 4
3 Light barrier to monitor 2 5
setdown on conveyor belt
3
F Inductive proximity sensor
1 Ejector
2 Bending tool
3 Workpiece E F
4 Baffle
5 Proximity sensor
100 12 Sensors
[1] Hesse, S.: Atlas der modernen Handhabungstechnik, published in German
13 by Vieweg Verlag, Wiesbaden 1995
Further reading [2] Hesse, S.: Lexikon Handhabungstechnik und Industrierobotik (Lexicon
and list of sources of Handling Technology and Industrial Robotics), published in German
by expert Verlag, Renningen 1995
[3] VDI Guideline 2860: Handling and Assembly Technology: Handling
Functions, Handling Devices: Terminology, Definitions, Symbols, published
in German by Beuth Verlag, Berlin 1990
[4] Frank, H.-E.: Handhabungseinrichtungen (Handling Devices), published
in German by Krausskopf-Verlag, Mainz 1975
[5] Frankenhauser, B.: Montage von Schläuchen mit Industrierobotern
(Assembly of Hoses Using Industrial Robots), published in German
by Springer Verlag, Berlin, Heidelberg etc. 1988
[6] Schlaich, G.: Kabelbaummontage mit Industrierobotern (Assembly of Wiring
Looms Using Industrial Robots), from the series IPA-IAO Research and
Practice, Volume 118, published in German by Springer Verlag, Berlin,
Heidelberg etc. 1988
[7] Braun, D.: Industrieroboter: Auslegung von pneumatischen Flächengreifern
(Industrial Robots: Design of Pneumatic Large-Area Grippers), published
in German by Verlag TÜV Rheinland, Cologne 1989
[8] Hesse, S., Mittag, G.: Handhabetechnik. Technische Lösungen
für Konstrukteure (Handling Technology: Technical Solutions for Designers),
published in German by Verlag Technik, Berlin 1989 and Hüthig-Verlag,
Heidelberg 1989
[9] Kleest, P.; Reibke, H.: Flexible Magazine für die automatische Montage
(Flexible Magazines for Automatic Assembly, article in German
in “Feingerätetechnik” (“Precision Engineering”) magazine, Berlin, No. 39
(1990) 9, pp. 393-398
[10] Hesse, S.: Montagemaschinen (Assembly Machines), published in German
by Vogel Buchverlag, Würzburg, 1992
[11] Nist, G. et alia: Steuern und Regeln im Maschinenbau (Open- and Closed-
Loop Control in Mechanical Engineering), published in German by Verlag
Europa-Lehrmittel, Haan-Gruiten 1989
[12] Serkiz, O.R.; Gnativ, I.M.; Gavrilschenko, A.B.: Automation of Feed
Operations on Assembly Lines and Robot Cells, published in Russian
by Lwov University Press 1985
[13] Romanowski, W.P.: Handbuch der Stanzereitechnik (Manual of Stamping
Technology), published in German by Verlag Technik, Berlin 1965
[14] Lehrbuch der industriellen Buchbinderei (Manual of Industrial
Bookbinding), published in German by Fachbuchverlag, Leipzig 1987
[15] Hirano, H.: Poka-Yoke, Landsberg, published in German by Verlag Moderne
Industrie 1992
[16] Tränkner, G. (ed.): Taschenbuch Maschinenbau (Pocket Guide to Mechanical
Engineering), Vol. 3/11, 3rd edition, Berlin, published in German by Verlag
Technik 1980
13 Further reading and list of sources 101

[17] Schevzov, Ju. A.: Einrichtung mit rotierendem elektromagnetischen Greifer
(Device With Rotating Electromagnetic Gripper), article in Russian in
“Production Mechanization and Automation” magazine, Moscow, No. 42
(1989) 5, p. 20
[18] Bültmann, M.: Maschine zum Vereinzeln von in einer Mulde gestapelten
Rohren (Stangen) (Machine to Separate Pipes or Bar Material Stacked in a
Trough), German Disclosure Publication 3900201, Class B65G, Group 1/07
1989
[19] Siegel, W.: Pneumatische Förderung (Pneumatic Conveyor Systems),
published in German by Vogel Buchverlag, Würzburg 1991
[20] VDI Guideline 3246, Zubringeeinrichtungen für Blechkleinteile in der
Blechverarbeitung (Feed Devices for Small Sheet-Metal Workpieces), 1965
[21] Großberndt, H.: Automatische Montage erfordert verbesserte
Schraubenqualität (Automated Assembly Demands Bolts of Better Quality),
VDI Magazine, Düsseldorf 127 (1985), No. 19, pp. 107 to 115
[22] Drexel, P. et alia: Neue Handhabungssysteme als technische Hilfen für den
Arbeitsprozeß (New Handling Systems as Technical Aids to Work
Processes), Research Report HA 82-002, Federal German Ministry of
Research and Technology 1982
[23] Konold, P.; Reger, H.: Angewandte Montagetechnik (Applied Assembly
Technology), published in German by Vieweg Verlag, Wiesbaden 1997
[24] Hesse, S.: Gripper Technology, published in English by Festo Esslingen,
1997
[25] Hesse, S.: Greifer-Praxis (Gripper Technology), published in German
by Vogel Buchverlag, Würzburg 1991
[26] Modulares Greifsystem Grip-Lok (Grip-Lok Modular Gripper System), article
in German in company magazine of ISI Automation GmbH, Wiesbaden 1992
[27] Hesse, S.: Lexikon Sensoren in Fertigung und Betrieb (Lexicon of Sensors
for Production and Other Industrial Purposes), published in German
by expert Verlag, Renningen 1996
[28] Hesse, S.: Praxiswissen Handhabungstechnik in 36 Lektionen (Practical
Handling in 36 Lessons), published in German by expert Verlag, Renningen
1996
[29] VDI Guideline 2740 Sheet 1 (Draft): Mechanical Automation Equipment;
Grippers for Handling Devices and Industrial Robots, published in German
by Beuth Verlag, Berlin 1991
102 13 Further reading and list of sources

A Adjustable-shape grippers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
14 Advance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Glossary Air jets, Air-jet sorting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
of technical terms Air-cushion trough . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Align workpieces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
B Behavior groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Bins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Bolt shapes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Box magazine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Braking devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Branching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Bridge accumulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Bridge formation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24, 25,71
Brush conveyors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
C Cans, handling of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Carrier wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Centrifugal conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Chain buffer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Channels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Check of features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Check of diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Clamping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Clamping device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Clamping gripper module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Climbing magazines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Collector conveyor belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Components to ensure a defined position . . . . . . . . . . . . . . . . . . . . . . . . . 29
Cylindrical components, feed of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
D Deflector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Detection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Destacking unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Disc magazines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26,30
Double clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Double metering device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
E Electromagnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Electromagnetic gripper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Elementary functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Emergency buffers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
F Feed chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Feed channel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33, 57
Feed chute . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Feed methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Feed of cylindrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Feed systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62, 69
Feed tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Feeding small workpieces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Flat workpieces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Flat-workpiece feed device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Formation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Forwarding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Friction bin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Frictional behavior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
G Grippers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Gripper jaws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Gripper roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
H Handling cans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Handling device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Handling functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Handling technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Handling units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Hanging ledge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Helicoidal vibrating bin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38, 42
Helicoidal vibrator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
I Inclined channel metering device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Inclined-disc bin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Incorrectly-oriented . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Industrial robots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Infeed device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
K Karnaugh diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
L Large-area suction cup array . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

Large-bolt feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Layers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Lever vibrator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Lifting device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Lifting magazine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Lifting Vee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Lifting-plate bins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Lifting/turning loading device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Light barrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Long workpieces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
M Magazine filling device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Magazine plate feed device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Magazines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Magnetic gripper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Magnetic roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
104 14 Glossary of technical terms

Mass metering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Metering device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27, 47, 48, 69
Metering operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Metering slide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47, 59, 64, 77
Modular construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Modular systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Monitoring for double sheet-metal workpieces . . . . . . . . . . . . . . . . . . . . . 84
Multiple metering devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
O Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
P Pallet handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Pallet indexing device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Panel handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Pick and place devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Pipe feed bin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Pipe separation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Pipe switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Positioning units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Profile check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Profile tubes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Protection for magazine input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Proximity sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
R Re-orienting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Recirculating buffer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Recirculating magazine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Rodless cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Roller metering device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Roller pull-off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Rolling channels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28, 57
Rolling path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Rolling track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Rolling-track shock-absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Rotary bins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19, 39
Rotary brush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Rotary drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Rotary metering device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47, 50
Rotary shock absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Rotary table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Rotary turning devic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Rubber moldings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
S Sack buffers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Scoop bins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16, 46
Scoop segment, Scoop segment design . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Scoop-wheel bin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Separating paper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Separating thin cut workpieces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Separating thin plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Shaft buffer unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Shaft magazines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30, 32, 33, 39, 63
Shock absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Sleeve sorting station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Slide metering device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24, 50
Sliding tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Small workpieces, feeding of . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Sorting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33, 39, 66
Sorting device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Sorting drums . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Spot sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Spreader magnets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Stack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Stack bins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Stack magazine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24, 70
Stack trough . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Stacking roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Step magazine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Suction grippers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Suction-cup module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Swivel drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Swivel-plate device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Swivel-segment metering device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Symbols vor functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
T Tapered-slide metering device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Test station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Throughflow buffer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Track distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Track multiplier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Transfer devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Two-way distributors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Types of behavior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
V V-jaw clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Vacuum control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Vibrator chute . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Video system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Volumetric metering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
W Workpiece barriers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Workpiece damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Workpiece ejection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Workpieces with unstable shapes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
106 14 Glossary of technical terms

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7,5 mm

327,5 mm 160 mm 120 mm 42 mm

Hesse Rationalization with Handling Technology

© 1999 by Festo AG & Co.

What do we understand by handling technology?

Handling is the creating, defined changing or temporary maintaining of a pre-

Handling technology has many facets; simple magazines, complicated robots,

Flexible handling equipment creates new possibilities in this regard.

Handling technology is ultimately also a cost factor. It is worth nothing, that it is

The automation of handling is not bound to particular branches of industry in

In general, the level of automation to be achieved must be defined and justified

1873 Spencer (USA) builds automatic lathes with magazine feeding

Plauen, November 1997

Dr. Stefan Hesse

1 Functions and objects 11

2 Bin feed devices 16

6 Metering and dosing 47

8 Output, alignment, branching 58

13 Further reading and list of sources 101

14 Glossary of technical terms 103

Symbols for functions

1 Functions and objects 11

Complex workpieces are some-

Types of behavior can be furt- 1 Complex workpieces

12 1 Functions and objects

L/D > 1 L/D < 1 L1, L2, D1, D2

Free rest positions

Guided motion positions

Guided motion positions

Creation of workpiece groups

Creation of workpiece groups

1 Functions and objects 13

1 Flat complex shapes (2D)

• Avoid 3D shaping of rubber

• Create easy-to-handle ends

• Create broad gripping areas

• Allow for folds in the design

• Edge reinforcements are

• Moldings can be made 7 8

• Suction cups with widely-distributed suction openings

14 1 Functions and objects

The frictional behavior of workpieces is an important factor in situations where

Sliding on an inclined plane

Sliding on air-cushion trough

1 Compressed air supply

1 Functions and objects 15

n Double strokes per minute

16 2 Bin feed devices

Scoop segment design

Some design tips:

l1 = (0.5…1.0) · l l1 = l + (1…2) l1 = l – (1…2)

l1 = d1 + (1…2) l1 = l · 0.6 l1 = 1.1 · d

2 Bin feed devices 17

Possible sources of faults

18 2 Bin feed devices

Sliding and rotary bins

Pipe feed bin

2 Bin feed devices 19

The principle of a scoop segment can be produced in a variety of designs,

1 Outlet conveyor zone 7

Motion phases of segments

Dimensions range 10…50 mm 50…100 mm 100…300 mm

20 2 Bin feed devices