Parts Accumulators Information
Figure 1: Conveyor belt in manufacturing facility. Source: Pxfuel
Parts accumulators may also be called product accumulators. Parts accumulators play a pivotal role in automating the assembly of parts for machinery like computer numerical control (CNC) lathes and other automated manufacturing equipment. They are used to increase the efficiency of production lines and reduce expenses by facilitating machine operation without the need for continuous supervision. The variety of parts accumulators spans from vertical and horizontal accumulators to bi-flow and rotary accumulators.
The specific type of parts accumulator required depends on the demands of the application it is intended for, as well as the space availability. For instance, in constrained spaces, vertical accumulators are often an ideal choice. Horizontal accumulators, bearing resemblance to conveyors, are capable of altering the flow direction. Bi-flow accumulators have the ability to transport parts bi-directionally. Spiral accumulators, which combine the features of both vertical and horizontal accumulators, move parts in a vertical spiral fashion.
Configurations
Vertical Accumulators
https://www.youtube.com/watch?v=vARM0mkg73U
Video: Vertical accumulators. Source: Nercon Conveyor Systems
Vertical accumulators are particularly useful in environments where floor space is at a premium, but vertical space is ample. These accumulators store parts in a stacked configuration. This makes them ideal for high-volume, high-speed operations where there is continuous production, and the physical footprint of the storage solution needs to be minimal. For instance, in operations like CNC lathing, where components are manufactured at a rapid pace, vertical accumulators can help maintain a streamlined workflow without the need for large amounts of floor space.
Horizontal Accumulators
Resembling traditional conveyor systems, horizontal accumulators are designed for operations where there's sufficient floor space. They can accommodate changes in the part’s flow direction, making them a flexible option in complex production lines. They're best suited for applications requiring inspection processes or sorting as the parts move along the accumulator, as workers can easily access parts at a comfortable height.
Rotary Accumulators
Rotary accumulators consist of a rotating platform that collects parts from an output chute, providing a continuous flow of production. They're typically used in applications requiring the constant unloading of parts, such as in packaging or filling operations. Their continuous operation allows for smooth workflow and reduces the risk of jamming or backups on the production line. Some rotary accumulators also keep finished parts in sequential order, which can help in quality control and inspection. As well, many rotary accumulators help to protect the straight edges of milled parts, which can be challenging in other parts accumulator configurations.
Bi-Flow Accumulators
https://www.youtube.com/watch?v=RfDWh6GRzwE
Video: Bi-directional accumulation table. Source: BellatRx Inc.
Bi-flow accumulators possess the capacity to transport parts in dual directions, a feature that renders them ideal for applications demanding rework or retracing steps within the production line. They play a role in quality control procedures, where parts may require return for further processing or verification before advancing to subsequent stages. Additionally, their design allows for the circulation of parts within the system until they are required, ensuring optimal usage and efficiency throughout the production process.
Spiral Accumulators
Spiral accumulators make efficient use of both vertical and horizontal space by moving parts in a spiral and vertical direction. They are ideal for operations with limited floor space but high ceilings, allowing for a larger accumulation of parts. They're commonly used in high-throughput applications like automated assembly lines where both the pace of production and the physical footprint of the accumulator are important considerations.
The choice of a specific type of parts accumulator will depend on the unique needs of the manufacturing process, the physical constraints of the facility, and the characteristics of the parts being handled.
Components
A parts accumulator's exact components can vary based on its type and the specific needs of the application. However, there are several common parts found in most types of accumulators.
Infeed System
This is where parts enter the accumulator. It may include a conveyor, chute, or other mechanism to guide parts into the accumulator. The infeed system is designed to handle parts gently and efficiently to prevent damage and ensure they enter the accumulator in the correct orientation.
Storage Area or Accumulation Zone
This is where the parts are collected and stored. In a vertical accumulator, this may consist of a vertical stack or tower. In a horizontal or bi-flow accumulator, it could be a conveyor or series of chutes. The design of the storage area is dependent on the type of parts being handled, the space available, and the desired rate of accumulation.
Outfeed System
This is where parts exit the accumulator. Like the infeed system, it may consist of a conveyor, chute, or other mechanism. The outfeed system should be designed to release parts at the desired rate and in the correct orientation for the next step in the production process.
Control System
This manages the operation of the accumulator, including the rate at which parts are fed in and out, any sorting or organizing processes, and any interaction with other machines or systems. The control system may be manual, semi-automatic, or fully automatic, depending on the level of automation in the production line.
Sensors
These monitor the status of the accumulator, such as the level of parts in the storage area, the rate at which parts are moving, or any issues like jams or faults. This information is fed back to the control system, which adjusts the accumulator's operation as needed.
Drive Mechanism
This powers the movement of parts within the accumulator, such as a conveyor belt, rotating platform, or lifting mechanism. The drive mechanism could be powered by a motor, pneumatic system, hydraulic system, or other means, depending on the application.
Frame or Housing
This supports the various components of the accumulator and provides a structure for the system. It should be robust and durable to withstand the demands of the production environment.
Safety Features
Depending on the nature of the system and local regulations, safety features may include emergency stop buttons, guards to prevent access to moving parts, warning lights or sounds, or other features to protect workers and prevent accidents.
Industry Applications
Parts accumulators are versatile and can be found in a variety of industries due to their capability to improve production efficiency and allow for unattended machine operation. Here are some industries where parts accumulators are commonly used:
Automotive Industry
The production of vehicles requires many small parts and components. Parts accumulators can be utilized to organize and streamline these components for various manufacturing processes, from engine assembly to the production of smaller components like screws and bolts.
Electronics Industry
The manufacturing of electronic goods, such as computers, mobile phones, and other devices, requires dealing with numerous small parts. Accumulators can help to automate this process, improving efficiency and productivity.
Food and Beverage Industry
Figure 2: Bottle production. Source: Pxfuel
Parts accumulators are also useful in food and beverage manufacturing for collecting, organizing, and moving packaged goods along the production line.
Pharmaceutical Industry
In the pharmaceutical industry, accumulators can help manage the high-speed production and packaging of various drugs and medications, ensuring a smooth and continuous operation.
Metal Fabrication Industry
In metal fabrication processes, such as CNC machining or lathing, accumulators can handle the output of machined parts, aiding in consistent and efficient production.
The specific type of parts accumulator used in each industry will vary depending on the nature of the parts, the production line setup, and the specific needs of the manufacturing process.
Selecting Parts Accumulator
When selecting a parts accumulator for a specific application, there are several factors that may be taken into consideration to choose the correct equipment.
Space Availability
The physical space where the accumulator will be located is a critical factor. For limited floor spaces, vertical or spiral accumulators may be the most suitable. If ample floor space is available, horizontal or bi-flow accumulators might be more suitable.
Part Characteristics
The size, shape, weight, and material of the parts being worked with will influence the type of accumulator needed. For example, delicate parts may need an accumulator that reduces the chance of damage, while heavier parts might require a stronger system.
Production Volume and Speed
The number of parts that need to be accumulated during a specific period will affect the choice of accumulator. If a large volume of parts is being produced, a larger, more efficient accumulator may be needed.
If the production line operates at a high speed, an accumulator that can keep up and manage a quick flow of parts without causing delays or backups will be needed.
Maintenance Requirements
Different accumulators have different maintenance needs. Some may need regular cleaning or parts replaced, which could have an impact on ongoing costs and the time the machine is available for use.
Cost
The initial cost of the accumulator, as well as ongoing costs such as maintenance and energy use, should also be taken into account when choosing a parts accumulator.
History
Parts accumulators, as a concept, have evolved over time in tandem with advancements in manufacturing technology and techniques. Parts accumulators emerged and developed as part of broader trends in the industrialization and automation of manufacturing processes.
Though their history is not well documented, the evolution of parts accumulators is likely closely tied to significant industrial milestones. During the Industrial Revolution in the 18th and 19th centuries, the shift from manual labor to mechanized production laid the groundwork for an organized, sequential production process. In the early 20th century, conveyor belts revolutionized assembly lines, notably in Henry Ford's car factories. This period marked the inception of methods for storing, organizing, and retrieving parts, likely the earliest form of parts accumulators that reflect modern variations.
Advances in technology during the mid-20th century until today, including automation, computer-controlled systems, robotics, and machine vision, significantly improved parts accumulator technology, leading to the development of more complex and efficient systems such as vertical, horizontal, bi-flow, and rotary accumulators.
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