In modern automated production, the screw feeder is one of the indispensable devices on an assembly line. However, during operation, a feeder may encounter problems such as missing screws, wrong screws, or slow supply. These issues not only reduce production efficiency but can also lead to product-quality defects. This article discusses how to avoid these problems through technical means and equipment optimization, and it mentions the technological applications of the Danikor brand in this field.

I. Solutions for Missing-Screw Problems

A missing-screw event means the feeder fails to deliver a screw to the tightening module, so the tightening step cannot proceed. It is usually caused by a screw jamming during transport or by failing to be detected correctly. To solve this, the feeder needs a reliable detection and feedback mechanism.

1. Ring Sensors
   After the PLC issues a “screw requested” signal, the feeder blows the screw through the blow tube to the tightening module. To ensure the screw arrives correctly, a ring sensor is normally installed at each end of the blow tube. The sensors detect the screw’s passage in real time and send an “in-position” signal so that tightening can be executed. This closed-loop control effectively prevents missing screws.

2. Detection & Feedback Mechanism
   The sensitivity and accuracy of the ring sensors are key to reliable feeder operation. Danikor screw feeders are equipped with high-precision ring sensors that can reliably detect screw passage. By optimizing sensor mounting positions and parameter settings, detection reliability is further improved so that no screw is missed during transport.

II. Solutions for Wrong-Screw Problems

Wrong-screw supply means the feeder delivers an incorrect screw to the tightening module, usually caused by mixed screws or by the feeder’s inability to identify screw specifications. To solve this, the feeder must have automatic detection and sorting functions.

1. Length-Detection Module
   A length-detection (long/short screw) module can be added to check screw length and specification. Even if screws are mixed, the module automatically rejects the wrong ones, ensuring only correct screws reach the tightening module. This automatic sorting effectively prevents wrong-screw events and raises process reliability.

III. Solutions for Slow-Supply Problems

Slow supply means the feeder cannot meet the cycle-time demand, lowering production efficiency. To solve this, the feeder needs a high-efficiency feeding mechanism and optimized process flow.

1. Optimized Feeding Speed
   Feeding speed is a key factor in production efficiency. Danikor screw feeders are designed for high speed; for ordinary screws the rate easily exceeds 40 pcs/min, satisfying most cycle-time requirements. By optimizing the feed path and blow pressure, screws are delivered quickly and steadily to the tightening module.

2. Process-Flow Optimization
   Besides hardware optimization, process flow is equally important. By rationally designing the feed path and optimizing feed logic, speed can be increased further. Danikor’s technical team can provide customized process-flow optimization according to customer cycle-time needs, ensuring the feeder runs at high speed while maintaining high reliability.

Missing, wrong, and slow screw supply are major factors that hurt efficiency and quality. By adopting Danikor’s intelligent feeding solutions, these problems can be effectively eliminated.