Case Study: Dual Step Feeders, One Vision System, Zero Operator Input

33 PPM Precision Tube Feeding for a High-Volume GDI Connector Grinding Cell

A precision machined components manufacturer was ramping up production on a GDI4 Inlet Connector — a small, tapered tube that feeds directly into a CNC grinding cell. Two machines, two jobs, one continuous production line. The challenge wasn't just feed rate: one machine needed to deliver parts in any orientation for a grinder that didn't care which end came first. The other needed to singulate parts into a specific nose-end-leading orientation, across two parallel lanes simultaneously, at 33 PPM — with a vision system to catch and reject anything that wasn't right before it ever touched the downstream tooling. 

Bellco designed and built both machines from scratch: a compact tabletop step feeder for the simpler grinder application, and a full stand-alone step feeder with Keyence IV4 vision, dual-lane exit, and a 45° diverter chute that could route parts to either of two downstream tubes on command. Both were delivered to the Autocam precision machining plant as a matched pair. Total project value: $85,700. 

The Challenge: Two Machines, Two Very Different Requirements

This wasn't a standard two-of-the-same quote. The customer needed two step feeders for two completely different points in their production line — each with its own requirements, its own engineering constraints, and its own integration challenges.

Machine A — The Simple One (That Isn't Actually Simple)

• Feed tapered tube connectors into a CNC grinder, either end first — no orientation required
• No vibration allowed — parts cannot be damaged before grinding; vibratory bowl feeder was ruled out entirely
• No linear rail — customer wanted gravity/tube feed only, not a conveyor-rail delivery system
• Table-top form factor — no floor stand; must mount on the customer's existing equipment stand
• Outfeed height precisely matched to customer's stand: 882.196mm (34.732")
• Hopper capacity to hold approximately two full boxes of parts without operator intervention
• Dual-lane exit: both lanes exactly 44mm center-to-center to match the customer's nest fixture
• Orientation required: nose end must lead into the downstream process, every single part
• Keyence IV4 vision camera integrated inline — inspects orientation and ejects rejects back into the hopper via air blow; no human sorting required
• 33 PPM total output split across two lanes (16.5 PPM per lane), continuous
• Diverter chute added mid-project: a 45° pneumatic diverter at the exit allows the machine to feed Tube A or Tube B on demand — enabling a single feeder to serve two different downstream positions
• Stand-alone with rolling casters and leveling feet — the machine needs to be repositionable on the floor
• Gravity tube connection: 17mm ID × 21mm OD — parts feed by gravity into a tube, not a conveyor track

Machine B — The Precision Feeder

The common thread: both machines had to interface precisely with the customer's existing tooling and stand heights, both needed to feed into gravity tubes rather than track systems, and both needed to be robust enough for high-volume continuous production. 

• Dual-lane exit: both lanes exactly 44mm center-to-center to match the customer's nest fixture
• Orientation required: nose end must lead into the downstream process, every single part
• Keyence IV4 vision camera integrated inline — inspects orientation and ejects rejects back into the hopper via air blow; no human sorting required
• 33 PPM total output split across two lanes (16.5 PPM per lane), continuous
• Diverter chute added mid-project: a 45° pneumatic diverter at the exit allows the machine to feed Tube A or Tube B on demand — enabling a single feeder to serve two different downstream positions
• Stand-alone with rolling casters and leveling feet — the machine needs to be repositionable on the floor
• Gravity tube connection: 17mm ID × 21mm OD — parts feed by gravity into a tube, not a conveyor track

The common thread: both machines had to interface precisely with the customer's existing tooling and stand heights, both needed to feed into gravity tubes rather than track systems, and both needed to be robust enough for high-volume continuous production. 

The Bellco Solution: Engineered to the Inch, Proven Before It Shipped

Bellco approached this project as two distinct engineering problems that happened to share a customer. Machine A and Machine B were designed independently, each optimized for its specific application — then delivered as a matched pair.

Machine A — Table Top Step Feeder

The table-top feeder is the understated workhorse of this installation. It handles the high-volume, no-orientation side of the operation:

• Step Feeder: stainless steel construction, clockwise, table-top mount with 25mm nickel-plated steel baseplate
• Hopper: integrated, 720–1,000 part capacity (two full boxes), no discharge chute required — customer loads from the top
• Feed delivery: gravity tube, parts exit at 45° into the customer's grinder intake — either end leading, no tooling required for orientation
• Outfeed height: machined precisely to 882.196mm to mate with the customer's stand — no shimming, no adjustment needed after install
• No vibration: the step-elevator mechanism lifts parts gently upward one at a time; unlike vibratory bowls, no part contact forces, no noise-induced movement, no risk of surface marring before grinding
• Controls: CUH Variable Frequency Digital (PNP), lockable box, I/O block; 220V with customer-supplied plug
• Inline conveyor: ~36" single-lane belt, with sensor-based stop and timer control — parts back up in the gravity tube; when the tube is full, the conveyor pauses; when parts clear, it resumes automatically
• Step Feeder: stainless steel construction, dual-lane exit tooling designed for 44mm center-to-center spacing — matched to the customer's downstream nest fixture
• Hopper: integrated, 720–1,000 part capacity; casters + leveling feet for floor mobility and precise positioning at install
• Orientation: Keyence IV4 vision camera monitors part orientation inline; any part presenting tail-first rather than nose-first triggers an air-blow reject — part is returned to the hopper and recirculated automatically; no operator sorting, zero orientation errors downstream
• Diverter chute: 45° pneumatic diverter installed at the exit — routes the singulated, oriented part stream to Tube A or Tube B on a programmed cycle or on-demand I/O command; one feeder serves two downstream positions
• Gravity tube delivery: 17mm ID × 21mm OD — parts gravity-feed into the customer's tube system, filling until a sensor detects full-tube backpressure; system pauses, then resumes on timer
• Controls: CUH Variable Frequency Digital (PNP), lockable box with Keyence IV4 display; I/O block for escapement and step feeder coordination; 220V

Machine B — Stand Alone Step Feeder with Vision + Diverter

Machine B is the more complex system — and the engineering centerpiece of this project:

SolidWorks Design Review. Before a single part was machined, Bellco shared full SolidWorks 3D models of both systems with the customer's engineering team. The models confirmed outfeed heights, lane spacing, tube connection geometry, and stand interface dimensions. The customer signed off on both designs before fabrication began — no surprises at delivery.

In-House Testing and Video Run-Off. Bellco ran both machines in-house using the customer's actual production parts — the same tapered tube connectors that would run in the live grinder cell. Both machines were validated at 33 PPM. The vision system on Machine B was calibrated with customer parts. A video run-off was conducted and delivered to the customer's engineering team prior to shipment.

The Results

✅ 33 PPM sustained across both machines — validated with customer production parts before shipment 
✅ Machine B dual-lane exit: 44mm center-to-center lane spacing matched the customer's nest fixture exactly — no modification needed at install 
✅ Keyence IV4 vision: zero orientation errors downstream — all mis-oriented parts detected and returned to hopper automatically 
✅ Diverter chute: single feeder serves two downstream positions, reducing equipment footprint and capital cost 
Gravity tube delivery on both machines: no exposed conveyor rail, no part transfer damage, clean integration with customer's tube system 
✅ Outfeed height: 882.196mm — machined to specification, fits customer's stand without modification 
✅ Full SolidWorks approval before build + video run-off before shipment — customer had zero surprises at delivery

Why Bellco Feeders?
This project required Bellco to engineer two fundamentally different machines under the same program — different form factors, different orientation requirements, different integration constraints. That kind of parallel engineering is where Bellco earns its reputation.

SolidWorks 3D model reviews before every build. In-house testing with customer production parts. Video run-off before every shipment. One-year warranty, Ohio-built, short lead times. That's the Bellco standard — on every job, every time.

Why This Matters for Precision Machined Components Manufacturing

High-volume precision machining operations — particularly in automotive fuel systems and similar applications — face a consistent parts-feeding challenge: the parts are small, the tolerances are tight, and the downstream tooling is unforgiving. A mis-oriented part in a grinding nest doesn't just slow production — it risks tooling damage, part damage, and scrap costs that add up fast at 30+ PPM.

Step feeders are the right choice for these applications for three reasons:

• No vibration: vibratory bowl feeders can mar precision surfaces before they reach the grinder; step feeders lift parts gently and mechanically, with no surface contact forces
• Higher hopper capacity: step feeder hopper geometry holds more parts per load than most vibratory bowl hoppers of equivalent footprint — less frequent operator intervention on high-volume lines
• Better for tubes and sleeves: cylindrical, tapered, and sleeve-type parts that would roll and tangle in a vibratory bowl singulate cleanly on a step feeder's elevator blades

The addition of the Keyence IV4 vision system on Machine B reflects a broader trend in precision parts feeding: customers increasingly need 100% orientation verification, not just statistical sampling. When every part must present in a specific orientation — nose-end leading, flange-down, head-up — a vision-reject loop is the only reliable way to guarantee it at production rates.

The diverter chute on Machine B is worth noting separately. Rather than install a second feeder for the second downstream position, the customer added a diverter to route a single, well-engineered machine to two positions. That's smart capital deployment — and it's the kind of engineering conversation Bellco has with customers during the design phase, not after the fact.

Need a Step Feeder for Precision Machined Parts?

Whether it's a single tabletop unit or a dual-lane, vision-equipped system with a diverter — Bellco engineers each feeder to your exact integration requirements. We share 3D models before we build and run your parts in-house before we ship.

Contact Jon Belliveau at jon@bellcofeeders.com | (440) 728-5590 | bellcofeeders.com/get-a-quote