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In automated tightening and assembly applications, blow-type screw feeders are widely used in various production lines due to their high-speed screw feeding capability. However, during high-speed feeding, issues such as screws not reaching the correct position, jamming, or missed feeds—if not detected promptly—can lead to assembly failure or even equipment damage. Therefore, an accurate in-position detection mechanism is a core technical support for blow-type feeders. The following analysis explores the core logic behind determining whether a screw has been successfully blown into place, from three perspectives: detection principles, system composition, and practical value.

I. Core Detection Principle: Precise Identification via Sensor Technology

The in-position detection of blow-type feeders mainly relies on real-time sensing of screws via sensors, determining the screw’s positional status through changes in physical signals. Among these, ring-type proximity sensors are the most widely used technical solution.

1. Working Mechanism of Ring-Type Proximity Sensors
   These sensors operate on the principle of electromagnetic induction. When energized, the internal coil generates a stable magnetic field. When a metal screw passes through the sensor’s ring-shaped detection area, an induced current (eddy current effect) is generated inside the screw. The magnetic field created by this induced current disrupts the original magnetic balance of the sensor. By detecting this change, the sensor can accurately determine whether a screw has passed the detection point and immediately output an electrical signal to the control system.

1. Dual-Point Detection for Double Verification
   To avoid misjudgment from a single detection point, a common solution is to install one sensor at the inlet end of the blow tube and another near the outlet end (close to the tightening mechanism). Only when the screw sequentially triggers both sensors does the control system confirm that the screw has fully passed through the feeding path and reached the designated position. If only one sensor is triggered or the signal interval is abnormal, the system determines a feeding anomaly (e.g., jamming or incorrect screw orientation). This dual-point verification mechanism significantly improves detection accuracy and reduces false positives.

2. Adaptability Optimization Design
   For screws of different specifications, sensors can adjust parameters such as detection distance and sensitivity to achieve compatibility. Some advanced systems also incorporate infrared auxiliary detection, using light obstruction to determine screw presence, complementing electromagnetic induction and enhancing detection reliability for special screws (e.g., those with insulated surface coatings).

II. Detection System Composition: Closed-Loop Control from Perception to Execution

In-position detection is not the independent operation of a single sensor but a closed-loop system composed of three major modules: perception, control, and execution, ensuring coordinated interaction between detection and subsequent operations.

1. Perception Layer: Multi-Dimensional Status Monitoring
   In addition to the core in-position sensors, the perception layer includes material presence sensors and fault detection components. The material presence sensor is installed at the junction between the hopper and the feeding track to monitor whether screws have entered the feeding channel, preventing empty blowing operations. Fault detection components can sense pressure changes inside the blow tube—if a jam causes blockage, air pressure will fluctuate abnormally. The system can then combine sensor signals to determine the jam location, trigger an alarm, and initiate a fault-clearing procedure.

2. Control Layer: Logic Judgment and Command Output
   The control system acts as the core hub. After receiving signals from the perception layer, it performs logical operations through preset programs. When a screw is confirmed to be in place, it immediately sends a start command to the tightening mechanism and simultaneously coordinates the pneumatic feeding system to pause feeding. If an abnormal signal is detected (e.g., dual-sensor signal mismatch or timeout without screw detection), it triggers an alarm, cuts power to the tightening mechanism, and stops feeding to prevent invalid operations or equipment jamming.

3. Execution Layer: Precise Response of Coordinated Actions
   The execution layer includes the tightening mechanism, pneumatic pressure regulation device, and alarm components. Upon receiving the “screw in place” command, the bit of the tightening mechanism accurately aligns with the screw and performs the tightening operation. The pneumatic pressure regulation device dynamically adjusts the feeding pressure based on detection signals to prevent screws from overshooting the detection zone due to excessive pressure or slow feeding due to insufficient pressure. Alarm components notify operators of anomalies via sound and light signals.

III. Practical Value: Ensuring Production Stability and Quality Control

Accurate in-position detection not only solves the problem of identifying feeding anomalies but also provides multiple safeguards for production efficiency and product quality—especially in precision manufacturing scenarios.

1. Reduced Assembly Defect Rate
   In precision assembly scenarios such as new energy batteries and automotive electronic control systems, virtual or missed locks caused by screws not being in place can directly affect product safety. Through dual-point detection and closed-loop control, such issues can be prevented at the source. For example, Danikor integrates in-position detection with defective screw rejection in its blow-type feeding systems. The system can not only determine whether a screw is in place but also identify defective screws (e.g., missing washers or deformed screw heads) through sensor signal differences, completing quality screening during the feeding process and further reducing downstream assembly risks.

2. Improved Production Continuity
   Traditional manual inspections are unable to detect feeding anomalies in real time. Automated detection systems can respond to faults within milliseconds, halt operations, and trigger alarms—preventing equipment overload damage due to jamming and reducing batch rework caused by abnormal feeding. Feeders equipped with comprehensive detection systems can significantly shorten effective fault handling time and increase line uptime.

The in-position detection of blow-type screw feeders is essentially achieved through “precise sensor perception + closed-loop system control + intelligent adaptability optimization.” Against the backdrop of smart manufacturing upgrades, such detection technologies will continue to evolve, further enhancing the intelligence level of feeding systems. The technical practices of professional brands like Danikor also demonstrate that a robust detection mechanism is not only a reflection of equipment performance but also a key support for ensuring production quality and efficiency.