Lead Forming and Feeding Machine for Film Capacitor Lead-Trimming Machine Feeder Improvement

Project scope

We prepared an electronics capacitor improvement package for an existing film-capacitor lead-trimming machine. The work focuses on feeder reliability, material receiving stability and control logic around the vibratory bowl rather than replacing the whole machine. That makes the scope a Lead Forming and Feeding Machine application for capacitor lead trimming and feeder reliability improvement.

The improvement scope includes optical fiber detection for vibratory bowl full-material status, optical fiber detection for direct-vibration material shortage, an extended receiving hopper and a fixed receiving-tray structure.

Feeding stability

The existing machine needed better control of incoming material status. We identified two conditions that should be detected automatically: shortage at the direct-vibration feed and full-material status at the downstream area. Without these signals, the vibratory bowl start/stop action is harder to control consistently.

Receiving and anti-flip control

The receiving area also needed mechanical improvement. The plan adds a longer receiving hopper, a buffer zone for falling material, anti-static lining, a receiving tray fixed bracket and an anti-flip pressing block so that parts do not turn over or move unpredictably after trimming.

Detection and timing logic

We configured two optical fiber sensing functions:

1. If the shortage-detection fiber sees no material for 2 seconds, the vibratory bowl starts feeding.
2. If the full-material fiber senses material for 2 seconds, the vibratory bowl stops feeding.

The added touch screen is used because vibratory bowl start and stop actions require time-parameter settings rather than fixed manual switching.

Added mechanical and control parts

Improvement area	Confirmed addition
Material status detection	Two groups of full-material and shortage optical fibers
Receiving stability	Extended receiving hopper and buffer area
Part orientation	Anti-flip pressing block
Tray handling	Receiving tray fixed bracket
Vibratory bowl control	Frequency controller
Electrical control	Electrical box for optical fiber 24 V power, vibratory bowl start/stop relays and PLC control-board placement

Proposed operating result

The retrofit turns a manually sensitive feeding and receiving area into a controlled machine section with material-status sensing, timed vibratory bowl start/stop logic and a more stable receiving structure.

Improvement package

The confirmed part package includes optical fibers, an extended receiving hopper, anti-flip pressing, a receiving tray fixed bracket, a vibratory bowl frequency controller, touch screen, 24 V control power and relay/PLC placement for the added controls.