Vibratory parts feeders have become a fundamental element in modern manufacturing processes. These precision-engineered systems are designed to efficiently orientate and feed small parts into production lines, significantly improving productivity and accuracy. The history of vibratory parts feeders is a testament to innovation and technological evolution, driven by the constant demand for greater efficiency in industrial automation.
Understanding the Core Components of Vibratory Feeders
The core components of vibratory feeders have remained unchanged for centuries. The process begins with a bulk supply of product, which is then separated and organized. A bulk separation area refines the mass, followed by a sorting section that selects the desired product. Any unsorted material is either returned to the system or ejected. Finally, the orientated product is stored for the next phase of production.
Since their introduction in the early 20th century, vibratory feeders have relied on the same fundamental technology—using vibration to move components. However, as manufacturing technology advanced, precision became increasingly important, and parts required more precise orientation. In response to these evolving demands, vibratory feeders adapted, improving accuracy and accommodating more complex part orientations to keep pace with industry advancements.
The Evolution of Vibratory Bowl Feeders
In North America, Europe, and Asia, vibratory feeders were traditionally hand-fabricated from stainless steel. This process relied heavily on the skill of individual artisans who patterned and crafted feeders for each specific component. While technological advancements introduced new construction methods, much of the orientation tooling and structural elements remained hand-fabricated, resulting in unavoidable variations. Unlike precision machining, hand fabrication made it difficult to maintain tight tolerances and repeatability. Recognizing this limitation, manufacturers sought new methods to improve feeder reliability and consistency.
In Europe, the shift toward step feeders and drum feeders represented an early effort to enhance repeatability. However, while these bulk delivery methods improved efficiency, the orientation tooling still relied on hand fabrication, limiting overall precision.
By the late 20th century, a German company pioneered the first fully machined vibratory feeders, introducing polyamide machined bowls. These polyamide machined bowls provided a more consistent and repeatable solution, marking a significant step forward in feeder technology. The design remains in use today for certain applications.
The Birth of VTR’s Machined Feeding Systems
In 1996, Tom Davies, founder and President of VTR Feeder Solutions, had a pivotal conversation with Klaus Warner, founder of Automated Tooling Systems (ATS), about the challenges in vibratory feeding technology. Klaus expressed frustration over the reliability and repeatability of vibratory feeders in his automated lines.
Klaus proposed using a step feeder or small elevator as a bulk delivery system, feeding parts into a cam-driven drive unit that generated linear vibration. However, the tooling on top of this drive unit was still hand-fabricated.
Tom advised Klaus that the weak point in his design was the tooling itself, which needed to be fully designed and machined for precision and repeatability. Tom began envisioning feeding systems that would include machined and designed components, and this conversation marked the beginning of where VTR Feeder Solutions is today – precise, designed, machined components in all of our product offerings. From machined bowls, linear feeders, robotic solutions and everything in between, VTR plunged into this challenge.
The Future of Vibratory and Robotic Parts Feeders
The heart of our vision at VTR Feeder Solutions is ensuring repeatable, reliable feeding systems through our meticulous manufacturing process. Every feeding system we produce is fully designed using cutting-edge technologies, then assembled by a team of experts. The key advantage of working with recognized professionals is the ability to replicate the business model and ensure consistent results.
Our vibratory parts feeders are fully designed, tested in virtual simulations, and manufactured using precision machining techniques. This approach eliminates the guesswork and inconsistency associated with traditional hand fabrication.
Key advantages of our advanced manufacturing process include:
- Consistent Performance & Repeatability – Every vibratory or robotic feeder we produce can be precisely replicated, ensuring consistent performance across multiple units, providing common parts and spares.
- Efficient Testing – Single-lane testing drives refinement before full-scale production.
- Modular Adjustments – When part changes or external variables require adjustments, updates can be made in SolidWorks, simulated, and seamlessly implemented.
- Scalability – With production methods like CNC routing, laser cutting, and CNC machining, feeder systems can be produced in a scalable, production-style environment.
- Ease of Maintenance: No More Hand Fabrication – The days of manually grinding and welding on-site are over. Wear components can be replaced quickly without requiring specialized skills or on-site welding, minimizing downtime, while maintaining a clean environment.
Data-Driven Innovation & Scalable Production
VTR’s data-driven approach ensures that knowledge is not lost with individual artisans but is instead stored, refined, and carried forward for future development. As we all know—data is king. By continually building on our knowledge base, we improve our systems and streamline production.
With modern manufacturing techniques, our feeding systems can now be produced in a scalable production environment. Fully machined components, CNC routing, and laser cutting allow for mass production while maintaining high precision. Assembly no longer requires specialized artisans. Component assembly can be performed by skilled technicians readily available in the industry, without requiring specialized training. In contrast, traditional vibratory feeding companies rely on a limited number of artisans, restricting their output capacity, with many years of training.
Material Innovation & Maintenance Advancements
Unlike traditional vibratory feeders, which rely on stainless steel or mild steel with coatings, modern feeders can incorporate a variety of materials, including:
- Hardened tool steel
- Stainless steel
- Aluminum
- Acetals including Delrin
- Peak
- Nylons
This flexibility with various coatings allows us to tailor each feeder system to the specific needs of the components being handled, improving both durability and performance.
Maintenance has also been revolutionized. In a fully designed and manufactured system, most repairs are as simple as swapping out a pre-machined part. Unlike traditional feeders, which require a skilled technician to perform on-site repairs or return the system to the manufacturer, modern systems allow for quick, user-friendly maintenance. Wear components or critical areas can be kept in spare parts to maximize up time of the production line.
The Future: Robotics & Vision Systems in Feeding
Vibratory parts feeders continue to evolve, with robotics and vision systems now playing their part in the industry. One of the remaining challenges for vibratory feeders is the ability to handle unknown variables such as incorrect parts, debris, environmental changes, and human intervention. Robotic feeding systems help compensate for these variables but have limitations in high-speed applications due to robot speed constraints. Overcoming these speed limitations typically requires additional robots, which can impact cost efficiency.
In our next blog, we’ll explore how robotic feeding systems are shaping the future of automation and how they compare to vibratory feeding in modern manufacturing.
To learn more about the best feeding solution for your application, contact VTR Feeder Solutions today.
