Cloud-based vibratory feeder controller

A method of monitoring a production level of a vibratory bowl feeder configured to process a workpiece, the method comprising operating a processor to:

• receive device data associated with the vibratory bowl feeder during operation of the vibratory bowl feeder, the device data including vibration data, temperature data, humidity data, bowl fill level data, start/stop control data, override control data, and/or part feed data;
• receive production data associated with the vibratory feeder, the production data indicating a production level of the vibratory feeder;
• determine, based on the device data and/or the production data, one or more faults corresponding to the vibratory feeder;
• identify, by the processor using a prediction made by an automatically trained machine leaning model, the one or more faults, the prediction model being based on data received by a modelling system, the data received by the modelling system including:
• the device data, historical feeder performance data, historical feeder settings controls, historical video feeds of the vibratory bowl feeder, machine learning training, historical alerts, and/or parameter history, the one or more faults being a sensor fault or an operational fault;
• determine, using the production model, a predicted production level of the vibratory feeder;
• initiate control, based on the identified one or more faults, of a corrective action of the vibratory feeder to return the production level to a threshold production level, the corrective action being one of:
• adjusting a power and/or a frequency of a vibratory drive of the vibratory feeder;
• activating a bowl blow off control;
• activating a hopper start/stop control;
• issuing a replenish parts warning;
• and
• indicating a part fault jam;
• and
• implementing the corrective action on the vibratory bowl feeder when the predicted production level falls below a threshold production level to return the vibratory bowl feeder to the threshold production level.