Danikor Automation_torque screwdriver_flex feeder system

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问 Can the tangled and intertwined materials be shaken apart?

答 The Danikor flexible feeder is equipped with four high-performance voice coil motors, which can easily shake apart even tangled and intertwined materials.

问 Can flexible feeders be used in mixed-product production lines?

答 The feeder surface is highly compatible, suitable for materials of various materials and sizes. Customization options are available to address material characteristics, such as perforation, grooving, anti-roll, and anti-static features, increasing the probability of correct orientation. Furthermore, the feeding system has multiple built-in material parameter programs, supporting one-click switching. For special materials, the quick-change feeder function enables rapid material changeovers. Additionally, the feeder surface can be designed with multiple configurations to fit compact workstations. Sequential picking and placement by robotic arms meets the needs of small-batch, multi-product mixed-product production lines.

问 How to prevent material stacking in a flexible feeder?

答 First, during the feeding process, the quantity of material is quantitatively controlled, following the principle of small, frequent feeding to avoid excessive accumulation. Second, the automatic frequency finding and intelligent amplitude stabilization functions of the feeder automatically locate the material frequency and adapt to the material amplitude, ensuring optimal vibration during feeding. Additionally, anti-static feeders can be used to prevent rubber materials from adhering to each other, ensuring effective material dispersion.

问 What to do if the flexible feeder resonates?

答 Danikor's vibration isolation technology can effectively isolate 95% of vibration energy, ensuring stable equipment operation and preventing interference between feeders. However, for materials requiring higher vibration power or those with unstable postures that are easily affected, the installation distance between the flexible feeders should also be considered; the greater the spacing, the smaller the vibration impact.

问 What factors influence the price of a flexible feeder?

答 First, the cost of the core components. The voice coil motor, as the core driving element, directly affects the overall performance and price. Second, the production process and technological barriers. The cost of developing and producing in-house using precision equipment is much higher than directly purchasing and assembling parts. The R&D costs for various high-end functions are also higher. Finally, after-sales service. Manufacturers that support initial technical training and subsequent equipment maintenance typically charge higher prices than those selling only hardware, but this significantly reduces the customer's maintenance threshold.

问 What if there is interference above the flexible feeder?

答 Danikor's flexible feeder, equipped with a vision system, can achieve intelligent material dispersion. The material dispersion area can be customized according to production needs, shifting the vibration center towards the non-interference zone, thereby preventing material accumulation in the interference area and increasing the amount of material in the effective zone.

问 Can flexible feeding be used for vulnerable parts?

答 Flexible feeders use polymer feeders, which are less prone to wear. Silicone pads can be added to create soft cushioning, further reducing damage from rigid collisions. Additionally, flexible vibratory feeders only vibrate when the material's posture needs to be adjusted, avoiding fatigue damage caused by prolonged ineffective vibration.

问 What factors should be considered when purchasing a flexible feeder?

答 First, select the appropriate feeder size based on the material's size and weight. For heavier metal materials, choose a larger size to avoid overload. Also consider the material's shape; custom-made feeders are necessary for special shapes to increase the probability of achieving the correct vibration posture. Finally, assess the supplier's service support capabilities. For example, Danicel offers free incoming material testing and customized solutions before sales to ensure the equipment meets production needs, and provides rapid after-sales response and timely troubleshooting.

问 How is material replenished in a flexible feeder?

答 Automatic feeding stations typically pair the flexible feeder with a direct-vibration hopper for collaborative operation. As the material level on the feeder decreases during the feeding process, when it falls below a set threshold, the system visually detects the material shortage and automatically triggers a replenishment signal. The hopper then vibrates to deliver a certain amount of material into the feeder. When the hopper is low on material, manual replenishment is usually required. To reduce manual intervention, a larger belt conveyor hopper can be added to replenish the direct-vibration hopper.

问 What is the material of the flexible vibratory feeder surface?

答 Ordinary feeders are mostly made of hard, wear-resistant materials (such as POM), which can withstand vibration and material friction for a long time and are suitable for most materials. When dealing with irregularly shaped materials, this material can also be used to make non-standard feeders with openings, slots, etc., ensuring the stability of the hole structure and preventing deformation over long-term use. In addition, there are ESD feeders for thin materials that are prone to adhesion. The anti-static rubber material can reduce static interference and prevent material adsorption.

问 Can materials with very minor differences be distinguished?

答 This can be solved using AI intelligent algorithms. Create two types of sample folders, collect a certain number of front and back image samples respectively, and save them to the sample folders. After collection, you can start model training with one click. Through AI self-learning the feature points of the material's front and back postures at different positions and angles, the stability of correct posture recognition is improved. After training is complete, you can select the required target posture for recognition and material loading.

问 How to solve the static electricity problem when flexibly feeding thin and light materials?

答 We can customize anti-static feeders using high-quality rubber materials. Their excellent insulation properties effectively isolate the generation and conduction of static electricity. Furthermore, the fine grooves on the feeder provide a discharge channel for static electricity, reducing its accumulation and further minimizing its impact.

问 Can one flexible feeder handle multiple materials simultaneously?

答 Depending on production needs, the feeder can be divided into two, three, or even four sections. A single vibratory feeder can handle multiple materials simultaneously. Compared to using a separate device for each material, this method is more cost-effective and saves more space.

问 In what aspects is the "flexibility" of a flexible feeder manifested?

答 Firstly, it is flexible in structure. The feeder surface can adapt to materials of various shapes and sizes, and can be quickly changed in 3 seconds according to production needs, flexibly adjusting to different products and saving production preparation time and costs. Secondly, it is flexible in control. The control software can control the movement of each voice coil motor, enabling the workpiece to perform actions such as flipping, spreading, and retracting, and to vibrate more effectively to achieve the target posture. It can be used in conjunction with vision systems and industrial robots.

问 Will the mechanical gripper touch the edge of the feeder during loading?

答 During loading, a visual algorithm will first eliminate interference space on the feeder, only identifying and gripping materials within the effective space, effectively avoiding interference and achieving stable loading.

问 Flexible feeding feeder: If the customer is using a robot, does the company's standard quotation include technical support fees for electrical interaction?

答 The company's quotation does not include the cost of electrical interaction and technical support with the robot design. We will only provide the company's standard parameter configuration manual and protocol format.

问 Which brands of robots can the flexible feeding feeder be integrated with?

答 At present, it has been stably connected with Yamaha, Epson, Zhongweixing and other robots.

问 Does the flexible feeding cycle time of 1.5~3S include the movement process of the robotic arm?

答 The 1.5 -3s includes the moving process of the manipulator, and the actual beat is also related to the moving range and beat of the manipulator. The parameters given now are based on if the material needs to execute 3 recipes at a time to find the correct material plus the time to fetch the material. The customer needs the actual beat and can provide a prototype for testing to give a clear range.

问 What materials are suitable for flexible feeding (overview)?

答 Applicable to a variety of materials, metal, plastic, glass, ceramics, wood, electronic components and so on.

问 Under what circumstances can a flexible feeding system be used?

答 The multi feeder system can meet the needs of multi-variety and small batch production, and is suitable for multi-variety co-production. It can quickly clear and change materials, and reduce the input of feeding equipment. For complex special-shaped parts, even deformable materials, it can be customized to improve the feeding efficiency.

问 How to choose an automatic screw-driving system for small-batch, multi-variety production?

答 Mechanical quick-change modules can be used for screws of different specifications. One tightening device can be equipped with multiple tightening nuts, automatically and quickly changing different bits and screw picks without stopping the machine. It also offers different avoidance stroke options to avoid interference issues caused by different product structures.

问 How to match the feeding cycle time of the screw feeder with the tightening cycle time?

答 During the design phase, the maximum tightening time for a single screw and the number of screws per station must be clearly defined. Ensure that the feeding capacity is ≥ tightening requirement × redundancy coefficient (usually 1.2–1.5), and incorporate a buffering mechanism to reduce the impact of feeding cycle time fluctuations on the tightening cycle time. This can be achieved by using a swing arm module to pre-store a screw in the nozzle, adding a nail storage module during feeding, and having the feeder pre-position the next nail into the blowpipe during tightening. Furthermore, select the feeder based on the slowest feeding time rather than the average cycle time to ensure the tightening cycle time is not constrained by the feeding system.

问 Can one module be compatible with different screws?

答 If the screws are of the same specification but differ only in length, then one module can achieve compatibility through "multiple screw feeders + multi-in-one screw divider switching channels". If the specifications differ significantly and core components such as the bit and screw feeding channel need to be replaced, then a mechanical quick-change module can be used to flexibly achieve automatic switching of tightening heads. Combined with the receiving platform module, it can be compatible with screws of various specifications.

问 How to choose a tightening module?

答 If there is no interference, a blowing module can be used directly. If there is interference, a vacuum module is required to avoid it. The appropriate nozzle type should be selected based on the screw's length-to-diameter ratio. For screws with a length-to-diameter ratio of 1.4 < L/D < 1.8, a swing-arm nozzle is needed to prevent screw flipping. For screws with a length-to-diameter ratio of 1.8 < L/D < 3.5, a standard nozzle can be used. If the length-to-diameter ratio is too long or screws of different lengths need to be shared, a swing-arm nozzle can be used to ensure the screw passes smoothly through the three-way junction.

问 What are the suitable applications for disc, vibratory, and step screw feeders?

答 Disc screw feeders are suitable for micro screws from M0.5 to M2, primarily used in the 3C industry, and can achieve a 0% nail jam rate. Vibratory screw feeders are suitable for standard screws from M2 to M6, primarily used in the automotive electronics and home appliance industries, and offer high feeding speeds. Step screw feeders are suitable for large screws from M2 to M24, primarily used in the automotive industry, and can achieve clean feeding and additional functions to meet different application needs.

问 Under what circumstances can blowing screw tightening module be selected?

答 Short screws with an aspect ratio ≤ 1.3 are prone to jamming and tipping during the blowing process if the angle between the screw and the pipe is less than 30°, making them unsuitable for air blowing. Long screws with a large aspect ratio require sufficient turning radius in the blow pipe; generally, they are blown to the receiving table and then picked up to shorten the screw-picking stroke. Only screws with a suitable aspect ratio can be directly blown to the nozzle.

问 How many workstations can one screw feeder supply screws to?

答 When used with a screw divider, it can support up to four screws from one. One screw feeder can continuously supply screws to multiple modules. Each channel has an individual sensor that can monitor and adjust the feeding status of each channel, ensuring the continuity and accuracy of the screw feeding process.

问 How many screw feeders can the main controller be configured with?

答 The standard configuration is that one General Controller controls one feeder, and the program is standardized. If two feeders need to be controlled, non-standard design is required.

问 Communication methods between the main controller and the client, and communication methods between the main controller and the screw feeder and module controllers.

答 The General Controller and the client are preferably connected through Modbus TCP. If IO is connected, the input and output lines are required. The General Controller connects the three controllers of feeder, module and screw driver through the network cable to form an intelligent control system for screw feeding and tightening, and the General Controller plays a key control role in the whole system. The client can also directly connect with the screw driver controller to obtain tightening data, curves and other information in real time.

问 Could you provide a solution and recommend a suitable module model?

答 In order to provide an exact solution, we need the screw drawing, 3D file of product, project cycle time, etc. If it is not convenient to provide 3D file or screw drawing, we have a form for you to fill in the information based on the measurement data

问 What is the maintenance cycle for the integrated module?

答 1 million times or 1 year. It is recommended that the customer make an annual maintenance plan, and the warranty period can be extended appropriately.

问 If the customer requires an IP54 protection rating:

答 The feeder controller board can be customized into a sealed box, with switches and interfaces that meet IP54 requirements. If there are splashing water droplets falling into the interior of the feeder, it will not affect the working. After the dripping water on the mechanical structure being wiped dry, the feeder can be normally used.

问 Does the screw feeder have CE certification?

答 DK standard feeder has CE certificate. For non-standard customized feeder, DK can provide products that meet CE requirements.

问 Screw Feeder Electrical Interface Description

答 A reserved opening, which is plugged: if a connector is installed, it can be used for electromagnetic lock IO interaction, etc Power switch: realizes the on/off of the internal power supply of the screw feeder Power input interface: power adapter insertion port, providing internal power supply for the screw feeder Power output interface: DC24V can be output to supply power to the general control teaching pendent RS485 interface: It is the interface for communication with the hopper, which is used when the customer configures hopper. IO interface: It is the interface used for IO communication between the screw feeder and the customer control system RJ45 Ethernet interface: It is the interface used for TCP/IP communication between the screw feeder and the customer control system or the general control teaching pendent USB debugging interface: It is the interface used for electrical program maintenance and debugging. It is connected to the computer through a USB cable, and the engineer can do the operation on the computer DIP switch: When a hopper is configured, if the connected cable is lengthened and occurs an impedance matching problem, it can be adjusted through this switch. One key recovery: can restore factory settings with one click

问 Are there any safety risks associated with the step feeder?

答 The screw feeder has an independent cover with a mechanical lock on the top cover, and when the top cover is closed, the operator cannot touch the moving parts. When the cover is opened, it can be accessed There are five moving parts: pushing mechanism, track blowing, direct vibration track, separating mechanism, and screw blowing. The gap between the pushing plate is only 0.5mm, which will not cause harm to human hands Track blowing and direct vibration have no effect Separating mechanism: cylinder connected slider movement, all gaps<2mm, CE certified Screw blowing: Lock the feeding tube and the joint with a clamp; The joint structure has burrs, making it difficult for the feeding tube to fall off

问 What is the communication method of the screw feeder? How does it interact with the PLC and how is it controlled?

答 The screw feeder communicates with the PLC of the client through TCPIP. The client sends the signals of material demand and material preparation, and the screw feeder outputs the signals of material preparation, material shortage, fault and operation. The screw feeder is connected to the tightening module or other optional functional modules through IO communication. The tightening module and the screw driver are communicated through TCPIP or IO. The screw feeder is connected with the hopper through RS485.

问 What is the lifespan of common wear parts?

答 The service life of vulnerable parts such as vacuum tube, screw blowing tube, bit and socket is related to screw type, screw pattern, torque, interference, etc. The vacuum tube is recommended to be replaced after being used for 500,000 times, and it is still in use after being used for 2.5 million times; The screw blowing tube is recommended to be replaced 2 million times, and 3.5 million times are still in use on site; The bit is recommended to be replaced 50,000 times, and 380,000 times are still in use on site; The socket is recommended to be replaced for 100,000 times, and it is still used for 500,000 times on site.

问 What is the screw feeding cycle time?

答 The feeding rhythm of the screw feeding machine is related to the specification and size of the screw, the number of channels, and the length of the screw blowing tube. The feeding time is divided into the screw preparation time and the screw blowing time. The minimum screw preparation time is 1.1 seconds, and the minimum screw blowing time is 0.6 seconds.

问 What is the range of screws that can be covered?

答 The applicable range of screws is wider. The maximum screw specification is M24, the Screw length is 250 mm, the cap diameter is 43 mm, and the minimum screw specification is M0.5

问 What is the screw jamming rate of the screw feeder?

答 The screw jamming rate of the new step feeder is as low as 50 ppm, which is far below the industry average of 200 ppm.

问 Is the screwdriver anti-static?

答 The Danikor’s low-torque screwdriver is made of anti-static engineering plastic and has a built-in grounding wire with a grounding impedance of <10Ω. This allows for rapid dissipation of static electricity accumulated on the tool surface, preventing discharge damage to sensitive electronic components. The friction voltage is <100V, far below the ESD tolerance threshold of most semiconductor components, essentially eliminating the risk of discharge damage. Furthermore, the bit end, as the metal part that directly contacts the workpiece, has a resistance to ground of <4Ω and a voltage of <0.2V, ensuring the effectiveness of the static discharge path.

问 What causes unstable torque in a torque screwdriver?

答 This could be due to improper strategy settings. For example, using a higher speed in a hard-joint scenario can cause torque overshoot, resulting in output torque exceeding the set value. The speed during the final tightening stage should be appropriately reduced to avoid overshoot. Additionally, prolonged high-frequency use can cause wear on internal gears and other mechanical components, leading to torque deviations. Regular calibration is necessary to compensate for these errors.

问 Can a handheld electric screwdriver be used in an automated workstation?

答 Smart screwdrivers support multiple remote control methods such as IO, RS485, Modbus RTU, and TCP/IP. They can be connected to factory MES and PLC control modules to achieve remote command reception and data feedback, and work collaboratively with other automated workstation equipment to form a closed-loop control system. Therefore, they can be used in automated workstations provided the required torque is met.

问 Can the torque tolerance of bolt assembly be the same as the precision of the tightening tool?

答 Tool precision only represents the performance index of the tool itself, considering only the error of the equipment. However, in actual assembly, tool precision is only one source of error. Factors such as personnel, machine, material, method, and environment must also be considered. Therefore, when selecting tools, their precision should be higher than the process tolerance, usually 1/3 to 1/2 of the tolerance. In addition, SPC analysis of torque distribution should be used to verify process capability. Generally, CPK should be at least greater than 1.33, and for higher requirements, it should be greater than 1.67.

问 Why do smart electric screwdrivers with higher torque have lower maximum permissible speeds?

答 This is mainly related to their core component, the servo motor. The torque and speed of a servo motor can be calculated using the formula T=9550*P/N, where T represents rated torque, P represents rated power, and N represents rated speed. Therefore, under the same power conditions, the motor's torque and speed are inversely proportional. This is why, for the same power, electric screwdrivers with a higher torque range often have lower maximum speeds.

问 What is the difference between fixed intelligent electric screwdrivers and handheld intelligent electric screwdrivers?

答 Fixed intelligent electric screwdrivers are designed for use in automated production lines, can operate stably at high speeds, and are suitable for continuous, high-intensity work environments, meeting most bolt assembly needs. Handheld intelligent electric screwdrivers are generally operated by the operator, have a more ergonomic overall structure, lower initial investment, and are relatively simple to maintain; they are mainly used for small to medium-sized assembly tasks.

问 What are the advantages of a servo tightening machine?

答 Servo tightening machines offer higher precision and consistency in torque, angle, and speed. They also feature data analysis capabilities, enabling intelligent monitoring and adjustment of the production process. Furthermore, they offer high traceability, recording the tightening process of each screw and integrating with the MES to achieve interconnected production data. Additionally, the user interface is more user-friendly, allowing direct parameter setting, process monitoring, and fault diagnosis via touchscreen or software.

问 If a workpiece has screws with different torques, can the tightening parameters be automatically switched?

答 Danikor electric screwdriver can be set as a Job, and within the Job, tightening programs (Pset) for all screws are added in the tightening sequence. During assembly, after each screw is tightened, the program automatically switches to the next screw's tightening program. After the last screw is tightened, the Job automatically refreshes and continues to the next workpiece. If an NG (Not Acceptable) error occurs, a password protection message will pop up to prevent employee misoperation.

问 How to solve the problem of screw floating?

答 Currently, most methods use torque control and angle monitoring to prevent errors. However, this method can only detect obvious floating height and is easily affected by product consistency issues. It cannot identify floating lock phenomena where the screw reaches the contact point but the clamping force is insufficient. Danikor’s clamping torque control strategy can automatically detect the contact point during tightening and then apply a fixed clamping torque. This not only accurately detects floating lock problems but also effectively solves them.

问 What is the difference between one-step tightening and two-step tightening?

答 The main difference lies in the final tightening stage. One-step tightening involves deceleration to prevent torque overshoot and damage to the bolt. Two-step tightening, on the other hand, pauses to release elastic strain when approaching the target torque before continuing the final tightening, thus reducing torque attenuation and ensuring residual torque.

问 How to start a handheld screwdriver?

答 Customers can choose to press down, trigger (lever) or remote start mode

问 Does the screwdriver have a CE certificate?

答 At present, our TTC and TTD screwdrivers have CE. Other series: we are preparing for obtaining CE certificates. If your order is urgent, we will prioritize the certificates required for the project

问 Is the tool cable a flexible cable? Can it be used towed and robot cable packages? What is its approximate lifespan? And what is the bending radius of the cable?

答 The cable is a flexible cable, which can be towed, and its service life is not less than 2 million times. According to the national standard and industry regulations, the bending radius of the cable shall not be less than 66mm.

问 How is heat dissipation of the screwdrivers addressed?

答 Screw driver heat dissipation is divided into screw driver body heat dissipation and controller heat dissipation. The heat dissipation of the screw driver body mainly includes the heat dissipation capacity of the motor and the peripheral heat dissipation capacity, the temperature rise and temperature drop performance of the motor are evaluated as important indicators in the motor selection, the control strategy in the motor control process ensures the effective power of the motor, avoids the generation of excessive ineffective heat, and ensures that the temperature rise of the screw driver body is stable and controllable from the source selection and process control; Heat dissipation measures are also taken in the hardware circuit design and circuit components to ensure that the temperature rise of the controller is stable and controllable. The housing temperature at room temperature is around 40 ° C.

问 How much tightening data can be stored?

答 The CK controller of the transducer can store 500000 sets of data, and the CS controller can store 200000 sets of data. Electrical type controller can store 200000 sets of data. If there is a large number of traceability requirements for historical data, USB interface, memory card or TCP/IP interface can be used for remote communication and remote storage.

问 What are the communication methods of this tool? How does it interface with a PLC or MES?

答 The communication modes include TCPIP, IO, Modbus TCP, bus to ensure stable collection of all tightening data and transmission to the client MES system for monitoring and data analysis of the tightening process. The communication with PLC is through TCPIP, which can share the screw driver torque data, and even start and stop the controller by PLC , The tightening data is uploaded to the MES system by the PLC.

问 What are the calibration and time requirements for the screwdrivers?

答 During the use of the screw driver, the torque check and system calibration shall be carried out regularly for deviation compensation. The actual calibration cycle needs to be determined according to the use of the site, the use of measuring instruments, the frequency of use and the safety requirements of the assembled products. We recommend to calibrate the measuring system once at 250,000 times/1 month or 500,000 times/2 months according to the site conditions. The general calibration method is as follows: test 25 groups of screw driver display readings X and dynamic torque tester readings y, perform linear fitting y = KX + B, and fill the percentage K of the mean value deviating from the target torque and the deviation value B in the corresponding box of the controller interface. Wherein the percentage K is adjusted as a coarse adjustment, and the deviation B is adjusted as a fine adjustment.

问 What are the calibration and time requirements for the screwdrivers?

问 What is the lifespan of the screwdriver?

答 There are two indicators of screw driver service life: mean time between failures (mean number of times without failure) and screw driver service life. Mean time between failures (mean number of times of use without failure) is mainly related to the minimum number of times of use of each part of the screw driver that is, to the life of the wearing parts, 1million times without failure. In addition, the service life of the screw driver is related to the number of times the core components are used, that is, related to the service life of the motor/reducer and the controller. We use the imported brushless motor, and the service life is at least 10 million times (Fixed screw driver), 10 million times (Handheld screw driver), and 10 million times (sensor screw driver).

问 What is the torque range?

答 0.02-20 NM TTD 0.4~80 NM TBD&TBE 0.03~600 NM TTC 0.4~20NM TCP 0.14~200 NM TTA 0.0075~18 NM TTB 0.02~20 NM TCD 0.1~200 NM TCA

问 How accurate is the screwdriver?

答 Based on ISO5393 (the same as Atlas), we have developed a high-precision algorithm with full-range accuracy of 6σ ± 5% for transducer tightening screw driver; full-range accuracy of 6σ ± 7.5% for handheld current screw driver full-range accuracy of 6σ ± 7.5% for fixed current screw driver