|Q. What are nesting machines?|
|Q. What is the purpose of using nesting machines?|
|Q. What are differences between the ball feeder and the automatic nesting machine?|
|Q. What kinds of parts can be nested?|
|Q. How long is the nesting time?|
|Q. What is the nesting rate？|
|Q. How is the pallet size determined?|
|Q. How are parts assembled?|
|Q. Can the parts nested with the nesting machine be transferred automatically to the final jig?|
1. The nesting machine has essentially two functions of swing motion and horizontal vibration.
2. The "pallet", the "collecting pallet (large)" and the "collecting pallet (small)" are placed on the vibration base as shown in the figure titled "Viewed from A", then parts are placed on the collecting pallet (large).
3. Switching the nesting machine on starts both swing motion and horizontal vibration, which carry and scatter the parts from the collecting pallet (large), and finally nest them in the shaped holes in the pallet during their reciprocating movement by the swing motion.
4. When the specified number of swings is complete, excess parts are collected in the collecting pallet (large). Now the nesting process is all completed.
5. After the parts are loaded, remove the pallet first, then the collecting pallet (small). You can repeat the nesting process by setting unloaded pallets and turn the "Start"switch on again.
6. One to sixteen pallets can be set depending on the type of nesting machine and the pallet size.
7. In some cases, different types of parts may be nested at the same time by dividing the pallets by columns. The settable number of pallets can also be changed.
The nesting machines are full of activity in the fields of visual inspection, counting, alignment and assembly of parts in various kinds of industries.
Please note that these machines are not designed for fully automatic and unmanned operation, but for saving in time and labor to handle small parts that are hard by manual operation. Though requiring an operator to feed the pallets to the next process, the machines are proud of their high productivities.
Automatic nesting machine:
Some examples are given left.
Besides the left-mentioned parts, many more still exist but they can also be aligned in a direction as the nesting machine recognizes the characteristics of the shapes of parts.
Note, however, that since the nesting machine judges different parts by the shapes when aligning, it cannot take the differences in the electrical characteristics and the colors.
Though the nesting time differs depending on the shape of parts and the nesting direction, it usually ranges from 30 seconds to 3 minutes.
As an example, the capacity of the nesting machine when aligning stepped pins on a 120 mm x 240 mm pallet has been verified as follows:
Supposed that stepped pins are nested on a 120 mm x 240 mm pallet at an 8-mm pitch, then 30 rows x 15 columns = 450 pieces can be aligned.
If two pallets are used at the same time, 450 pieces x 2 = 900 pieces are nested.
Supposed the nesting time is 150 seconds including pallet replacement work, it takes 0.16 seconds per piece.
Though the nesting time differs depending on the shape and quantity of the supplied parts, 95% to 100% of them can usually be nested.
Generally, the relationship between the nesting time and the nesting rate is expressed by a curve as shown below:
Though depending on the shape of parts, up to 99% of them can be nested in a short time in many examples. To improve the nesting rate to 99.5%, 99.9% or 99.99%, the nesting time increases synergistically. (Number of swings increases.)
Therefore, the target value is generally set to 99% to 99.5% depending on the characteristics of the next process. Unloaded holes, if any, can be visually found and manually filled to improve productivity.
Since the next pallet can be set on the nesting machine during manual work, you will have no loss of time.
The pallet size is determined according to the carbon jig, the assembly jig, etc. that you are now using.
Needless to say, the parts are assembled on the final jig by adapting the hole pitch and the locate pin positions.
If your final jigs are small, two or more of them may be set on one pallet at the same time.
Example: If the final jig dimensions are 60 x 60 and the pallet dimensions are 120 x 240, then eight jigs are set at the same time:
Several examples of assembling many pieces at the same time are given below.
◆Inverting the pieces when they are placed on the final tray:
◆Making the final jig and the pallet face in the same direction:
◆Transferring the parts by means of a suction unit（1）:
◆Transferring the parts by means of a suction unit（2）:
◆Using a shutter plate（1）:
◆Using a shutter plate（2）:
◆Making horizontally nested parts upright:
Since numberless of user specifications exist for automatic nesting machines, typical examples are given below.
This operation is repeated.