Knowledge Base

Introduction: The demand for smaller, more powerful, and increasingly functional devices continues to surge, spanning a wide range of applications—from implantable medical devices (such as pacemakers and miniaturized hearing aids) to non-invasive surgical tools and consumer electronics (like

smartwatches). However, this trend toward miniaturization presents a challenge: how can we efficiently assemble and manufacture these intricate and delicate devices on a large-scale production level?

Automate assembly methods require parts to be singulated such that they can be introduced into the assembly process in the correct orientation.  Many of the part singulation methodologies like b bowl feeder are designed for larger components, often cannot perform within the tight tolerances required by microscale intricate parts. This has spurred the development of innovative solutions for part presentation for automation solutions.

In this article we highlight a robotic assisted flex feeder as one solution IST precision has used to help with orienting small parts and placing them into an automation work cell for assembly purposes.

Micro assembly Challenges: Handling and Feeding Miniature Components

A core challenge in micro assembly is the efficient and precise feeding of components to robotic grippers for placement within a processing work cell. As components shrink in size, manual manipulation becomes increasingly difficult and error-prone, necessitating a shift towards automation. However, automating the handling of these miniature components presents its own set of challenges.

Parts often arrive in bulk quantities (e.g., bags or bins containing thousands of tiny parts), which can stick together due to electrostatic forces and other attractive forces. These forces make it difficult to separate and orient the parts correctly for robotic picking.

Traditionally, automation integrators would look to vibratory bowl feeders to assist in robotic pick and place. Bowl feeders operate on the principle of vibratory motion to feed and orient parts. The inside of the bowl is lined with a custom-designed track that spirals upwards. Parts within the bowl are agitated by the vibration, causing them to move along this track. As the parts ascend, the track’s geometry guides them into a single file line, a process referred to as part singulation. This ensures that parts are presented to the pick-up point in a consistent and predictable orientation. However, the traditional design and manufacturing methods for these custom tracks pose significant challenges when dealing with miniature components.

Flex Feeders: A Different Methodology in Robotic Part Feeding

IST Precision has used a type of feeder, known as a flex feeder which offers a departure from traditional part feeding methods. As opposed to relying solely on mechanical tracks and gravity, flex feeders, such as those developed by Asyril, leverage a combination of intelligent vibration and precision vision technology to manipulate and orient parts. This innovative approach transforms the feeding process, offering enhanced flexibility and control, particularly for the challenges posed by the need to orient small parts for micro assembly.

As illustrated below, a flex feeder system typically comprises a bulk feeder and a vibrating tray. The bulk feeder, initially filled with a large quantity of parts typically poured out of a bag, utilizes controlled vibration to dispense a precise number of components onto the vibrating tray. A camera monitors this process, ensuring accurate part counts and preventing overfilling. The vibrating tray then employs a series of carefully programmed vibrations to manipulate the parts. Generated by piezoelectric actuators, these vibrations can be precisely controlled in terms of frequency, amplitude, and direction across the tray surface. This enables gentle separation, orientation, and positioning of even the most delicate micro-components. Furthermore, the tray can be custom designed with features like pockets to facilitate specific orientations, such as aligning small pins vertically for efficient picking. Additionally, by adjusting the vibration intensity, parts can be flipped or repositioned as needed. This dynamic and adaptable approach to part feeding offers significant advantages over traditional methods, particularly for the stringent demands of orienting small parts for micro assembly, where precision, flexibility, and gentle handling are essential.

Advantages and Disadvantages of Flex Feeders

Flex feeders offer distinct advantages over traditional bowl feeders for orienting microscale parts. Their simplified design eliminates the need for intricate tracks, making them significantly more suitable for handling micro-sized parts. Furthermore, the controlled vibration within the flex feeder can overcome electrostatic forces, separating parts for easier robotic pick-up. A key advantage of flex feeders is their adaptability; a single system can be used for a range of parts by simply swapping out the vibrating tray. This flexibility makes them a versatile solution for diverse part geometries.

However, flex feeders do have some drawbacks. Primarily, the upfront cost is higher than that of traditional bowl feeders. This is attributed to the inclusion of advanced components like cameras and the need for customized programming to optimize part feeding and orientation. Additionally, throughput can be a concern, as bowl feeders generally offer higher speeds. However, as previously discussed, bowl feeders can be challenging to implement effectively for microscale parts. To address throughput concerns, multiple flex feeders can be integrated into a system, although this increases both cost and complexity. While the initial investment is higher, the flexibility and reliability of flex feeders can be crucial for successful microscale automation, especially when dealing with delicate and intricate components.

In summary, flex feeders offer a compelling solution for orienting microscale parts for automation, providing benefits in terms of adaptability, part separation, and gentle handling. While the upfront cost and throughput considerations need to be weighed, the overall advantages make them a valuable tool for achieving efficient and reliable microscale automation.

IST’s Experience with Flex Feeders

IST’s automation team has successfully integrated flex feeders into a recent automation system, as pictured below. The Asyril bulk feeder, visible on the machine’s exterior, is where operators load large quantities of microscale parts. These parts are then automatically fed into the machine’s interior, where a vision system monitors their orientation and separation. A Fanuc SCARA robot subsequently picks and places the parts precisely into the processing work cell for further operations.

There are certainly other vibrating flex feeder systems but what sets Asyril apart is their 3-axis vibration technology which enables parts to be intentionally moved in all directions on the vibrating plate with sufficient energy to controllably flip the parts over. This degree of flexibility in multi-axis vibration is why we selected Asyril for this project.

Conclusion

While bowl feeders have long served as a reliable part-feeding solution across various industries, their limitations in handling small, delicate components can make them less suitable for microscale automation applications. In contrast, flex feeders offer a more fitting and efficient solution, provided that integrators consider their higher upfront cost and potential throughput limitations.

IST Precision possesses expertise in precision automation and has direct experience with various vibratory feeding technologies, including Asyril flex feeders. We know how to strike a balance between cost and performance, and we are well-equipped to assist you in evaluating and implementing the optimal feeding solution for your microscale and precision automation needs. Contact us to explore how we can support your manufacturing goals.

At IST Precision, we foster a culture of collaboration, innovation, and variation. We specialize in developing precision automation processes and products as a high-tech engineering and manufacturing company. Since our inception in 2001, our team has grown to 25 employees, including mechanical engineers, electrical engineers, electronics technicians, machinists, build technicians, and welders. We are constantly expanding our team and offering abundant opportunities for career advancement. If you’re considering a career at IST Precision, continue reading to discover what sets us apart and why our employees love working here.

Founded over 20 years ago by Dr. Shane Woody and Dr. Bethany Woody, both with extensive precision engineering and manufacturing backgrounds, IST Precision is nestled in the charming town of Mooresville, North Carolina, just 30 miles north of Charlotte. Our employees love the proximity to Charlotte and the abundance of outdoor activities like hiking, racing, and enjoying a day on Lake Norman or at the Whitewater Center. This strategic location offers a unique blend of small-town charm and access to urban amenities, making it a perfect balance of work and leisure. It’s one of the many things our engineers adore about Mooresville.

What is the culture at IST like?

“We have a strong team with a wide range of skill sets. Shane and Bethany have done a good job identifying people that work well together, and everyone gets along well.” – Dylan

“IST is a nice place to work largely due to the staff. There are many great people who are really knowledgeable in their fields and willing to help you if you need it. IST also has a nice facility that has everything you will need to succeed in your projects.” – Austin

“Inquisitive, always searching for answers and ways to improve things. Highly dynamic, always learning something new.” – Levi

What do you find most interesting about working at IST?

“We work on various engineering projects, from huge automation systems to precision benchtop systems. I was surprised by how quickly we can complete a project from inception to completion.” – Aaron

“Variety, in terms of the industries we serve and the types of technologies within the industries. I was surprised that there was no limit on what we can learn and what skills we can take on.” – Connor

“Always working on something new, which helps keep me engaged and driven at work.” – Tyler

What is the most satisfying part of your job?

“Being able to work on very challenging problems, and being allowed to find solutions to those problems.” – Levi

“We get to go through the full design process, from conception at the beginning of a project, to prototyping initial designs and making tweaks, to fully detailing a design and building the final version. It is gratifying to get to the end of a build and see what you’ve accomplished.” – Dylan

“I love spending weeks and weeks trying to tackle a problem that’s never been solved before and then getting the results I have been looking for.” – Connor

How does the variety of engineering challenges compare to previous work experience?

“From previously working in the automotive industry to working for IST Precision, it is night and day. I would have projects that lasted 3-5 years, which were very repetitive. Now I get assigned new projects to work on regularly and I work through new challenges daily.” – Tyler

“The variety of engineering challenges here at IST Precision is greater than what I have experienced with previous work, which is why working here is so enjoyable.” – Mitchell

“Variety is one of the biggest selling points when working at IST. We have a wide range of projects at any given time, from designing compact precision measuring devices to large industrial equipment for cutting wood. Work doesn’t get boring because new challenges are always presented.” – Dylan

What advice would you give to someone new in the engineering industry?

“Find a job that exposes you to a lot of different engineering disciplines so that you can grow in a very broad way / develop a broad set of skills that will be useful in your career and get a feel for what you do and don’t like.” – Aaron

“Learn everything that you can. You will meet many people from different fields throughout your career, and learning everything from them will make you a better engineer.” – Austin

“Take the time to find what you enjoy doing and find a place that challenges you but aligns with those desires.” – Mitchell

For more information about our company, we encourage you to visit our website, check out our LinkedIn page to view insights into some of our work, and be on the lookout for any job openings. If you don’t see a position you are interested in, email us at [email protected].

For over 20 years, IST Precision has been a trusted partner for manufacturers seeking customized metrology systems and solutions.

The Challenge: The Hidden Cost of Reactive Quality Control

While some manufacturer’s view metrology equipment as an unnecessary upfront cost, neglecting proper quality control in the manufacturing environment can have far-reaching consequences. At IST Precision, we’ve witnessed firsthand how a lack of proper inspection allows faulty parts to slip through the cracks. Even seemingly minor issues like low manufacturing yields can have a major impact on production efficiency and profitability. In these scenarios, companies are often forced into reactive mode, scrambling to implement quality control measures after the fact.

This reactive approach isn’t just costly; it also exposes companies to potential safety risks and reputational damage. The ideal scenario is to be proactive with quality control, preventing problems before they occur. In the next section, we’ll explore a real-world example of how a custom metrology system helped a manufacturer address a costly yield issue, demonstrating the true value that goes beyond simple measurement.

Collaborative Development: From Concept to Completion

A recent project at IST Precision involved a customer facing inconsistent production yields at one of their manufacturing plants. The culprit was an assembly process that relied solely on a manually adjusted screw torque setting to ensure consistent deformation of a spring membrane element. Unfortunately, variations in friction and mechanical interfaces were causing inconsistencies in the spring element’s deformation.

IST Precision identified the Keyence LJ-X8000 series high-resolution laser line scanner as the ideal solution for this application. These scanners offer exceptional profile data making them well-suited for inspecting cavities and holes like the one in our customer’s assembly process. A key advantage of the LJ-X8000 series is its high-speed data capture, allowing for rapid inspections (under a second) with results reported directly on the HMI screen. In this case, the LJ-X8200 model was chosen due to its vertical resolution and sampling rate for the entire laser line.

Our team designed a system that mounted the laser line scanner on a servo Z axis stage for optimal focus distance, ensuring precise measurements within the cavity. The customer’s parts were placed on a custom-designed clamping fixture for easy positioning, and the entire system was built with the operator in mind.

This custom metrology system allowed the customer to directly measure the spring element, ensuring consistent deformation and leading to a dramatic improvement in production yields. The system was designed for simple operation and was successfully commissioned at the customer’s inspection lab.

Conclusion: Proactive Quality Control for Long-Term Success

By implementing IST Precision’s custom metrology solutions, manufacturers gain a powerful advantage. They can elevate their quality control processes, reduce production costs, and achieve consistent yields. This proactive approach to quality control empowers manufacturers to avoid costly problems and ensure long-term success.

While the system discussed here is a standalone solution, IST Precision’s expertise extends far beyond. We are highly experienced in integrating metrology systems seamlessly into automation lines. This capability allows for high-throughput, in-line inspections, further optimizing production efficiency and yield.

If you’re a manufacturer seeking to elevate your quality control processes and integrate them into your automation lines, IST Precision is the ideal partner. Our combined expertise in metrology and automation ensures a seamless and effective solution, tailored to your specific needs.

Mobile line scanner cart and custom fixtures

The Industrial Automation market is expected to reach $𝟒𝟎𝟎 𝐁𝐢𝐥𝐥𝐢𝐨𝐧 annually by 2029. This growth is only possible by making automation more flexible and easier to adopt in to manufacturing [i]. The rise in the need for more automation in U.S. manufacturing is in part driven by two factors: a shrinking skilled workforce and the need for cost-effective processes. As companies bring production back to the U.S. (onshoring), staying competitive requires streamlined workflows, and reduced labor costs.

One approach to achieve this is robotic tending, where robots load and unload parts in CNC machining centers. These robots operate like setup operators, tied directly to the machining center’s controls. Another strategy involves automatically transferring parts between dedicated machining centers. Overhead gantry systems, conveyor belts, or a combination of these can be used to automate this process between machine tools to omit the need for an operator to transfer parts from one machine tool to the next.

Both robotic tending and part handling are areas that IST can support you in.

IST Precision offers automated part transfer solutions to manufacturers in the southeast.

A Client’s Challenge: Seamless Part Transfer Between Machining Centers and Part Cleaning

A recent client needed an automation cell to automatically transfer parts between two machining centers and to coat the part after the machining processes were complete. They approached us with a prototype design, and IST collaborated to bring the design to reality and to enhance it for additional functionality requested by the customer.

• Part Transfer and Coating Station: An overhead gantry system with pick-and-place functionality seamlessly moves parts between machines. An integrated coating station to protect the part from oxidation.
• Intuitive Control System: An HMI touch panel provides an operator-friendly interface for interacting with the gantry system and monitoring the work cell.
• Safety First: Safety meshing surrounds the work cell to ensure operator safety
• Electrical Control Panel: Updated control panel design and build

Figure 1: IST automation cell handing off parts between two machines

Collaboration for a Turnkey Solution

IST provided a complete turnkey package, including:

• Detailed CAD Drawings: Streamlined the build process and ensured future maintainability.
• Comprehensive Bill of Materials: Provided complete transparency and component information.
• Programming Code: Enabled the work cell’s precise operation.
• In-House Fabrication: Guaranteed a quick turnaround and efficient production.

Figure 2 and 3 show a few more images of the system which was completed in a matter of a few months.

Figure 2: Gantry gripper, coating station, and conveyor system

Figure 3: Electrical panel and touch screen

[i] Jake Hall, The Manufacturing Millennial https://www.linkedin.com/in/jacobrhall/

IST Precision develops a wide range of industrial automation and high-end precision instrumentation devices. This article explores the critical role of flexure rotational pivots in achieving exceptional motion control within these instruments. IST in general uses these precision pivots in ultra precision applications including laser steering gimbals and surface profilometer sensors for the inspection industry.

Introducing C-Flex: A Vendor in Precision Flexure Bearings

C-Flex [https://c-flex.com/] plays a vital role in our success. They are a valued vendor who supplies us with high-quality flexure bearings. These bearings enable frictionless and exceptionally precise motion in meticulously designed mechanical devices.

The Need for Frictionless Motion

In precision instrumentation, achieving smooth motion at the nanometer or sub-arc second level is paramount. Traditional bearings can introduce friction, leading to non-linear motion and errors in the nanometer range. This ultimately compromises instrument performance.

Several options exist for rotary-motion bearings, including air bearings, jeweled bearings, and ceramic bearings. While air bearings excel in achieving near-zero friction and smooth motion, they can be expensive to operate, requiring dry air and additional design space.

Flexure Bearings: A Compact and Cost-Effective Alternative

For applications with limited space (e.g., satellites) and small angular range requirements, flexure bearings offer an attractive alternative. They boast several advantages:

• Zero friction: Ensures smooth and highly linear motion.
• Compactness: Saves valuable space within the instrument.
• No air requirement: Eliminates the complexity and cost associated with dry air systems.

However, it’s important to note that flexure bearings typically have a small amount of rotational stiffness and a limited angular range which need to be accounted for in the design.

IST Precision: Experts in Flexure Design

While C-Flex doesn’t disclose the specific spring steel material and heat treatment used in their bearings, we understand the importance of exceptionally high yield stresses for flexure pivots. In critical applications, these pivots must maintain precise rotation angles over millions of cycles. In other flexure designs that IST designs we tend to use, materials like 17-4 SS with an H900 heat treatment, known for exceeding 1000 MPa yield stress. This enables the flexure mechanism to reach higher stresses leading to increased bearing life and capability to reach millions of rotational cycles.

Cost-Effective and Versatile

Flexure pivots are a cost-effective solution in a precision application, typically ranging from $50-$100 per pivot in low quantities. Pivot size is a key cost factor, with our designs often utilizing some of the smallest commercially available bearings (1/8 mm or 3.175 mm OD barrel size).

C-Flex: User-Friendly Features

The C-Flex website provides valuable resources for instrumentation designers, including information on bearing loads and clamping methods. We particularly appreciate their laser engraving of part numbers on the outer diameter of the pivots. This simple yet effective feature helps prevent mix-ups during assembly, especially when using multiple pivots with varying torsional rigidity.

Pivot Design Options

C-Flex offers two main pivot body types:

• Single End Bearing: One end is clamped to the device’s frame, while the other end flexes and rotates.
• Double End Bearing: Both ends are clamped to the frame, with the middle section free to flex and rotate.

The choice depends entirely on the specific application and instrument design. IST has experience utilizing both types of bearings in various projects.

Clamping Methods for Flexure Pivots

Here are three common clamping methods for flexure pivots:

• Squeeze Clamp: A traditional method that mechanically clamps around the pivot. While effective, it requires more space and often screws, which might not be ideal for all compact designs.
• Set Screws: An alternative method but carries the risk of pivot slippage. If using screws, opt for soft-tipped ones.
• Bonding:Offers the most compact approach and is ideal for designs requiring minimal parts. However, it also carries the highest risk since the bearings are permanent and can’t be removed during a prototype development phase of a project.

Featured Design: A Case Study in Precision for Surface Profilometer Sensors

The CAD model below showcases an interesting design utilizing a flexure bearing. This design features a small shaft (1.2 mm diameter) with a custom diamond tip bonded to its end. The shaft is part of a rotating mechanism that employs a flexure bearing pivot within the green body.

Using custom displacement sensors (differential capacitance sensors), we can detect motions of the shaft relative to the green body down to single digit nanometers. While the sensor itself is crucial, the flexure bearing enables frictionless and highly accurate movement of the shaft about the pivot’s rotational axis.

Furthermore, precision motion stages (not shown) allow our surface profilometer tip to scan along a surface. By monitoring the sensors with a very fast sampling rate (exceeding 10,000 samples per second), we can acquire detailed surface profile data. Ultimately, this design with the flexure pivot allows us to create a simple and elegant contact based profilometer sensor.

IST’s team is working with cutting-edge robotics on two exciting automation work cells currently in development. These projects showcase our ability to deliver solutions for a wide range of applications.

Micro-Scale Part Pick and Place with Fanuc Scara:

Our first work cell tackles the intricate task of rapidly picking and placing microscale parts with precise control. To achieve this, we’ve integrated a Fanuc SR-3ia Scara robot with a camera, optimized lighting, and an Asyril vibratory feeder. This combination allows our vision system to identify correctly oriented parts within the feeder and pick them up rapidly, regardless of initial rotation. The Fanuc SR-3ia was selected for its compact size, throughput speeds, field reliability, and excellent service. Over the next month our team will complete build, programming, and integration of this system.  The image below shows the robot on a simple test stand to enable our programmers to setup code prior to the entire automation work cell (not shown) being built. We look forward to meeting and exceeding our customers needs in the months to come.

Large-Scale Automation with Kuka Robots:

While we excel at small part material handling, IST also has a team of experts with extensive experience in designing and building large-scale material handling systems. Our second work cell underway features two powerful Kuka KR 140 R3200-2PA industrial robots. This will be used to handle a heavy end of arm tooling as well as the need for large reach and access in an automation line.  Our process will be able to handle a wide variety of parts with over 100 product variations being presented to this robotic work cell.

To ensure accurate picking of these diverse products, we’re integrating custom multi-zoned vacuum grippers with the robots. Additionally, Cognex vision cameras will be employed to further enhance the picking process. It’s important to note that IST’s dedication to thorough analysis was a key factor in winning this project. Through extensive robotic simulations conducted collaboratively with Kuka’s team, we were able to demonstrate the need and benefits of two robots to achieve optimal cycle times, ultimately surpassing our competitors. Safety remains paramount, and we’re currently installing guarding and completing custom robotic welded pedestals to securely fasten these powerful robots to our factory floor.

These projects highlight IST’s robotics and imaging capabilities. Our team is adept at tackling challenges across the spectrum, from small-scale precision handling to large-scale automation. We look forward to partnering with you to develop innovative solutions that meet your specific needs. Stay tuned for more to come on these projects.