Systems and processes for bonded fastener installation

Abstract

A laser ablation containment system includes: a laser chamber having a Class 1M or higher graded laser integrated therewith; and a cleaning chamber coupled with and aligned with the laser chamber to selectively receive a light beam generated by the Class 1M or higher grading laser. The cleaning chamber includes a head selectively movable between a first position exposing an interior of the cleaning chamber for placement of a substrate therein and a second position exposing an exterior of the cleaning chamber for placement of a substrate therein. The second position securely encloses the interior of the cleaning chamber to form a Class 1 authentication laser operable enclosure in cooperation with the laser chamber, all of which can be integrated into a transferable workstation.

Description

(19) State Intellectual Property Office (12) Invention Patent Application (10) Application Publication Number (43) Application Publication Date (21) Application Number 202480048812.5 (22) Application Date 2024.07.01 (30) Priority Data 63 / 524,576 2023.06.30 US 63 / 524,581 2023.06.30 US 63 / 555,480 2024.02.20 US (85) PCT International Application Entering National Phase Date 2026.01.23 (86) PCT International Application Application Data PCT / US2024 / 036470 2024.07.01 (87) PCT International Application Publication Data WO2025 / 007160 EN 2025.01.02 (71) Applicant: Physical Systems, Inc. Address: USA (72) Inventors: J. Baratto-Soth, L. Krantz, R. Baruyut, A. Kapučinski, N. Johnson, M. Johnson, J. Janoska, R. Pingheiro (74) Patent Agency: China Council for the Promotion of International Trade Patent & Trademark Office Co., Ltd. 11038 Patent Attorney: Mogo (51) Int.Cl. B08B 7 / 00 (2006.01) B08B 13 / 00 (2006.01) F16B 11 / 00 (2006.01) B05C 5 / 02 (2006.01) (54) Invention Title: System and Method for Installing Adhesive Fasteners (57) Abstract: A laser ablation containment system comprises: a laser chamber having a Class 1M or higher laser integrated therewith; and a cleaning chamber coupled to and aligned with the laser chamber to selectively receive lasers of Class 1M or higher. A laser beam generated by a Class 1M or higher laser. The clean chamber includes a head that is selectively movable between a first position and a second position, the first position exposing the interior of the clean chamber for placing a substrate therein, and the second position securely closing the interior of the clean chamber to cooperate with the laser chamber to form a Class 1 certified laser-operable housing, all of which can be integrated into a portable workstation. Claims 9 pages Description 28 pages Drawings 45 pages CN 121794071 A 2026.04.03 CN 1 21 79 40 71 A 1. A laser ablation containment system comprising: a laser chamber having a Class 1M or higher laser integrated therewith; a clean chamber coupled to and aligned with the laser chamber to selectively receive a laser beam generated by the Class 1M or higher laser, the clean chamber including a head that is movable between a first position and a second position1. The system selectively moves between positions, the first position exposing the interior of the cleaning chamber for placing a substrate therein, and the second position securely closing the interior of the cleaning chamber to cooperate with the laser chamber in forming a Class 1 certified laser-operable housing. 2. The system of claim 1, wherein the laser chamber and the cleaning chamber are integrated as part of a transferable roller station. 3. The system of claim 1, wherein the cleaning chamber and the laser chamber are coupled to a robotic arm capable of moving to selectively position the head against the substrate to form the housing using the head. 4. The system of claim 1, wherein the cleaning chamber is in fluid communication with a debris removal chamber. 5. The system of claim 1, further comprising a gripper having a pair of actuated fingers positioned below an umbrella-shaped member and operable to selectively pick up the substrate and place it within the housing formed by a sealing engagement of the umbrella-shaped member with a sealing edge. 6. The system of claim 5, wherein the umbrella-shaped member is slidable along an axis perpendicular to the focusing lens of the Class 1M or higher laser mounted within the laser chamber. 7. The system of claim 5, further comprising a proximity sensor positioned to identify when the umbrella-shaped member is positioned on the sealing edge. 8. The system of claim 1, wherein the head includes an outwardly projecting compressible liner forming at least a portion of the outer periphery of the housing. 9. The system of claim 1, further comprising at least one sensor for measuring pressure or light within the housing. 10. The system of claim 1, further comprising a selectively removable and replaceable protective lens capable of being selectively positioned within a slot to substantially seal and separate the laser chamber from the cleaning chamber. 11. The system of claim 10, wherein the protective lens is carried by a lens holder having a front channel providing access to the protective lens when removed from the slot, the front channel being flush with the inner sidewall of the cleaning chamber when in the slot, thereby locking the protective lens therein. 12. The system of claim 1, wherein the head includes a clamp having a base having a lower sealing member extending upward therefrom, the lower sealing member cooperating with an upper sealing member to form the housing between them when the head is in the second position. 13. The system of claim 12, wherein the lower sealing member comprises a foam or rubber material and is movable relative to the upper sealing member comprising the foam or rubber material by means of a linear actuator or pneumatic piston. 14. The system of claim 1, wherein the laser chamber is offset relative to the cleaning chamber by an angle between 90° and 180°.15. The system of claim 1, comprising a mirror or prism located within one of the laser chamber or the cleaning chamber and positioned to receive the beam and redirect it by an offset of up to 180°. 16. The system of claim 15, wherein at least one of the mirror or the prism is mounted to a pivot and is capable of real-time repositioning within one of the laser chamber or the cleaning chamber. 17. The system of claim 16, wherein the pivot comprises a single-plane pivot, a multi-plane pivot, or a ball-and-socket pivot. 18. The system of claim 1, comprising a bracket projecting inwardly from an inner sidewall of the cleaning chamber, thereby forming a gap between them for selectively accommodating a receiving elastomeric fixing device projecting downward from a nut plate. 19. The system of claim 1, wherein the Class 1M or higher laser class includes a Class 4 laser. 20. A debris containment system comprising: a conduit for delivering pressurized fluid to a cleaning chamber; and an outlet coupled to the conduit and positioned to guide the pressurized fluid substantially across an internal channel of the cleaning chamber as an air curtain therethrough, thereby substantially preventing debris from one side of the internal channel of the cleaning chamber from passing through the air curtain to the other side of the internal channel of the cleaning chamber. 21. The system of claim 20, wherein the internal channel comprises a cylindrical channel, and the outlet comprises a quasi-hemispherical slot formed by an inner sidewall of the cleaning chamber. 22. The system of claim 21, wherein the quasi-hemispherical slot faces forward toward the internal channel, and the air curtain extends substantially horizontally across the internal channel of the cleaning chamber. 23. The system of claim 20, wherein the conduit comprises a first conduit and a second conduit, and the outlet comprises a first outlet and a second outlet, wherein each of the first outlet and the second outlet leads to the internal channel, thereby creating a first air curtain and a second air curtain offset from the first air curtain. 24. The system of claim 23, wherein the first air curtain and the second air curtain extend across the internal passage of the cleaning chamber at different angles relative to each other. 25. The system of claim 23, wherein the first conduit includes an upper conduit and the second conduit includes a lower conduit, wherein each of the upper and lower conduits includes a corresponding slot having a width approximately half the circumference of the internal passage of the cleaning chamber. 26. The system of claim 20, wherein the air curtain extends generally horizontally across the internal passage and toward a debris removal chamber in fluid communication therewith.27. The system of claim 26, comprising at least one of a HEPA filter or a carbon filter positioned within the debris removal chamber to adsorb debris. 28. The system of claim 26, comprising an air pressure sensor positioned within one of the cleaning chamber or the debris removal chamber. 29. The system of claim 20, wherein the outlet is positioned at an angle relative to the internal channel, wherein the air curtain extends across the internal channel at an angle relative to the internal channel. 30. The system of claim 20, wherein the outlet comprises a generally elongated slot formed by a tubular support extending within the internal channel of the cleaning chamber. 31. The system of claim 30, wherein the elongated slot positions the air curtain to flow at least partially vertically within the internal channel of the cleaning chamber. 32. The system of claim 31, wherein the at least partially vertical flow of the air curtain prevents debris from moving toward a laser chamber coupled to the cleaning chamber. 33. An adhesive dispenser system comprising: a frame on which a drive unit is mounted; and a screw threadedly operated by the drive unit and engaged with a carrier unit, the carrier unit being slidable relative to the frame and having at least one chuck mounting assembly rigidly coupled thereto; wherein the at least one chuck mounting assembly includes a piston chuck selectively and slidably engaged with a piston head and operable to dispense liquid from a barrel when the drive unit operates the screw in a first direction and to reduce liquid “dripping” when the drive unit operates the screw in a second direction opposite to the first direction. 34. The system of claim 33, wherein the drive unit is operable to move the screw at a certain rate to dispense liquid in increments of less than 0.1 grams (“g”). 35. The system of claim 33, wherein the adhesive dispenser system is coupled to a transferable roller station. 36. The system of claim 33, further comprising a support bracket having an extension sized to receive dispensing pins spaced apart relative to the frame, the support bracket being selectively adjustable relative to the frame via an elongated channel lockable to the frame by a locating pin therein. 37. The system of claim 33, wherein the piston chuck terminates at an outwardly flared mandrel sized for frictional engagement with the piston head. 38. The system of claim 33, wherein the at least one chuck mounting assembly comprises a pair of chuck mounting assemblies, each chuck mounting assembly including a corresponding piston chuck, the corresponding piston chuck being selectively engaged with a corresponding piston.39. The system of claim 38, wherein the respective piston heads comprise different dimensions relative to each other. 40. The system of claim 33, comprising at least one feedback sensor coupled to the drive unit for providing real-time sensing feedback regarding the adhesive viscosity. 41. The system of claim 40, wherein the at least one feedback sensor comprises a force feedback sensor for real-time measurement of current or voltage of the drive unit. 42. The system of claim 33, comprising a camera positioned to capture the adhesive dispensed from the barrel. 43. The system of claim 33, comprising a quick-release mechanism for disengaging the piston clamp from the barrel in one step. 44. The system of claim 43, wherein the quick-release mechanism comprises a sliding support having a step operable to compress a spring from a first normally extended position to a second compressed position, thereby withdrawing the piston clamp from engagement with the piston head. 45. The system of claim 44, wherein the sliding support includes a pull-back channel having a sliding pin therein, the sliding pin limiting movement of the sliding support relative to the carrier unit to a predetermined distance. 46. The system of claim 44, further comprising a stop member coupled to the carrier unit and positioned to terminate rearward movement of the sliding support relative to the carrier unit by a predetermined distance. 47. The system of claim 33, wherein the frame includes a thermal housing having a cooling or heating element adjacent to a quick-change carrier member therein. 48. A quick-change cartridge system comprising: a frame having a set of outwardly extending locating pins having dimensions and shapes for selectively slidingly engaging with a slotted housing of a dispenser unit; and a liquid-receiving cartridge having dimensions and shapes for selectively sliding into and / or removing from an opening in the frame when the frame is removed from the dispenser unit, wherein, when the frame is engaged with the dispenser unit, the liquid-receiving chamber is locating within the frame and, in a forward position, in fluid communication with a dispensing outlet. 49. The system of claim 48, wherein the frame includes a front opening having dimensions and shapes relatively smaller than the liquid-receiving cartridge but relatively larger than the dispensing outlet. 50. The system of claim 48, wherein the locating pins include bolts extending outwardly from the frame and having a relatively smooth shank portion of sufficient length to slide into and receive in the slotted housing.The system of claim 50, wherein the head portion of the bolt is positioned outside the slotted housing. 51. The system of claim 50, wherein the slotted housing includes a set of externally accessible L-shaped receiving channels, the externally accessible L-shaped receiving channels being relatively wider than the width of the shank portion and relatively smaller than the width of the head portion of the bolt. 52. The system of claim 51, wherein the externally accessible L-shaped receiving channels include an enlarged chamfered opening top accessible for receiving the frame into the slotted housing. 53. The system of claim 48, wherein the liquid receiving cylinder includes an outwardly extending base plate, the base plate being at least partially larger than the opening orifice for flush engagement with the liquid receiving cylinder when mounted within the frame. 54. The system of claim 48, wherein the liquid receiving cylinder includes a pair of liquid receiving cylinders, each liquid receiving cylinder in fluid communication with a cap having an outlet port selectively connectable to the dispensing outlet, the dispensing outlet including an inlet of a static mixer extending outward from the frame. 55. The system of claim 48, wherein the liquid receiving cylinder includes at least one rear receiving slot having dimensions and shape for selective engagement with a chuck mounting assembly of the dispenser unit. 56. An adhesive dispensing feedback method comprising the steps of: activating a drive unit for dispensing a quantity of adhesive at a desired flow rate; monitoring one or more dispensing characteristics associated with the quantity of the adhesive being dispensed; cross-referencing the one or more dispensing characteristics against a set of operating parameters for each of the one or more dispensing characteristics; and adjusting the desired flow rate of the quantity of adhesive using the drive unit if one or more of the dispensing characteristics fall outside any of the set of operating parameters. 57. The method of claim 56, further comprising the steps of: reversing the drive unit; pulling back a piston head operable by the drive unit within a liquid receiving cylinder to dispensing the adhesive from an outlet end; and creating a negative pressure at the outlet end to stop dispensing the adhesive and control dripping at the outlet end. 58. The method of claim 56, further comprising the step of reading the temperature of one or more liquid compounds in the liquid dispensing cylinder. 59. The method of claim 58, further comprising the step of using a heater or cooler to change the temperature of the one or more liquid compounds in the liquid dispensing cylinder. 60. The method of claim 56, further comprising the step of controlling the viscosity of the adhesive. Claims 4 / 9 pages 5 CN 121794071 A 61. The method of claim 56, further comprising the steps of:A carrier unit coupled with a pair of chuck mounting assemblies is slidably moved to engage with a corresponding pair of barrels positioned in a static relationship relative to the carrier unit; and liquid is dispensed from each of the pair of barrels into a static mixer for forming the adhesive. 62. The method of claim 61, further comprising engaging a piston chuck within each of the chuck mounting assemblies with a corresponding piston head, the corresponding piston head being in a fluid relationship with each of the pair of barrels. 63. The method of claim 61, wherein the adjusting step comprises changing the rotational speed of a threaded screw operated by the drive unit to slidably move the carrier unit. 64. The method of claim 56, wherein the monitoring step comprises sensing the viscosity of the dispensed adhesive and determining whether the viscosity is below a threshold or above a threshold. 65. The method of claim 56, wherein the monitoring step comprises sensing the current or voltage of the drive unit in real time and determining whether the current or voltage is below a threshold or above a threshold. 66. The method of claim 56, wherein the monitoring step comprises measuring the ambient temperature or the temperature of the adhesive. 67. The method of claim 56, wherein the monitoring step includes measuring the one or more dispensing characteristics in real time or in discrete time increments. 68. The method of claim 56, wherein the monitoring step includes observing the adhesive using a camera. 69. A protective lens holder, comprising: a frame having a forward-positioned receiving channel having dimensions and shape for selectively receiving a protective lens therein in a first open position and movable to a second position to cooperatively lock the protective lens therein with an inner sidewall when slidably engaged with it; and a handle extending outwardly from the frame relative to the receiving channel and having dimensions and shape for manual manipulation outside an outer sidewall of the cleaning chamber. 70. The protective lens holder of claim 69, wherein the protective lens is selectively replaceable and the protective lens holder is selectively reusable with the cleaning chamber. 71. The protective lens holder of claim 69, wherein the receiving channel includes a substantially horizontal opening slot for selectively inserting and removing the protective lens therein in a first open position. 72. The protective lens holder of claim 69, wherein the handle includes a pair of opposing arcuate recesses that enhance manual operation of the protective lens holder outside the outer wall of the cleanroom. 73. The protective lens holder of claim 69, wherein the protective lens comprises a light-transmitting protective lens.74. A debris removal system comprising: an outlet conduit in fluid communication with a cleaning chamber containing debris removed from a substrate; a port in the outlet conduit coupled to a pressure sensor in fluid communication therewith for real-time measurement of pressure in the outlet conduit; and a controller coupled to the pressure sensor and in communication with a laser, the laser operable to generate a light beam in the cleaning chamber for removing debris from the substrate, the controller operable to disable the light beam in response to a pressure loss measured by the pressure sensor in the outlet conduit. Claims 5 / 9, Page 6, CN 121794071 A 75. The system of claim 74, further comprising an inlet port selectively receiving pressurized fluid that at least partially creates a vacuum in the outlet conduit relative to the cleaning chamber. 76. The system of claim 75, wherein the inlet port is coupled to a pneumatic air pump. 77. The system of claim 75, further comprising a HEPA filter or carbon filter positioned within the outlet conduit for filtering debris. 78. A method for replacing a quick-change cartridge, comprising the steps of: sliding a carrier out of engagement with a frame of a dispensing unit; removing a liquid-containing cartridge from the carrier through an access port; inserting a new liquid-containing cartridge into the carrier through the access port; and reinserting the carrier carrying the new liquid-containing cartridge into the frame of the dispensing unit. 79. The method of claim 78, further comprising the step of disengaging the liquid-containing cartridge from a sliding unit of the dispensing unit. 80. The method of claim 79, wherein the disengagement step further comprises the steps of: moving an externally accessible sliding support rearward relative to the sliding unit; compressing the tension spring within a retraction channel by engaging an inwardly projecting step that engages with a washer positioned at one end of a normally forward-positioned tension spring; and retracting a flared mandrel of a piston collet in response to the compression of the tension spring, disengaging it from friction-fit engagement with a piston head associated with the liquid-containing cartridge. 81. The method of claim 80, wherein the compression step comprises compressing the tension spring using an intermediate projecting step positioned between coils of the tension spring. 82. The method of claim 80, wherein the moving step includes terminating the rearward movement of the sliding bracket by utilizing a stop integrated with or positioned within a pull-back channel formed within the sliding bracket. 83. The method of claim 78, further comprising the step of moving a set of locking pins projecting outward from the support member through an externally accessible L-shaped channel formed by the frame.84. The method of claim 83, wherein the outwardly projecting set of locking pins comprises a bolt having a shank portion movable within the L-shaped channel and a head portion relatively larger than the L-shaped channel and positioned outside thereon. 85. The method of claim 83, further comprising the step of locking the new liquid-containing cartridge into a forward slot of the L-shaped channel. 86. The method of claim 78, wherein the re-insertion step comprises reconnecting the sliding unit to the piston head associated with the new liquid-containing cartridge by tapping, rotating an externally accessible knob, or retracting the piston head to engage therewith. 87. A method for cleaning a surface, comprising the steps of: enclosing a laser chamber having a Class 1M or higher laser integrated therewith; positioning a substrate within an ablation chamber, the ablation chamber being coupled to the laser chamber and aligned with the Class 1M or higher laser; moving a head between a first position and a second position, the first position exposing the interior of the ablation chamber for placing the substrate therein, the second position enclosing the interior of the ablation chamber and cooperatively forming a Class 1 certified laser-operable housing with the laser chamber; generating a light beam using the Class 1M or higher laser; and contacting at least a portion of the substrate with the light beam, thereby removing debris from the substrate. 88. The method of claim 87, further comprising the step of picking up the substrate and placing it within the head. 89. The method of claim 87, further comprising the step of oriented the substrate relative to the light beam at an angle between 90° and 180°. 90. The method of claim 87, further comprising the step of inserting a protective lens between the laser chamber and the ablation chamber and substantially orthogonal to the beam. 91. The method of claim 90, wherein the generating step comprises the step of sending the beam through the protective lens and contacting the substrate. 92. The method of claim 90, further comprising the step of activating a proximity sensor in response to insertion of the protective lens or formation of the Class 1 certified laser-operable housing. 93. The method of claim 90, further comprising the step of abutting a front slot of a protective lens holder against an inner sidewall thereby locking the protective lens within the protective lens holder. 94. The method of claim 87, further comprising the step of clamping the substrate between an upper sealing member and a lower sealing member of the head. 95. The method of claim 87, further comprising the step of redirecting at least a portion of the beam from a mirror, wherein the contact step comprises simultaneously ablating the substrate at two different beam angles.96. The method of claim 95, further comprising the step of pivoting the mirror about at least one plane. 97. The method of claim 96, wherein the pivoting step comprises repositioning the mirror about a ball joint. 98. The method of claim 87, further comprising the step of using a prism to separate the beam before contacting the substrate. 99. The method of claim 87, further comprising the step of evacuating debris from the cleaning chamber. 100. The method of claim 99, wherein the evacuation step comprises pressurizing the housing and creating a vacuum at the outlet port to evacuate and ablate debris. 101. The method of claim 100, further comprising the steps of: measuring the pressure difference between the cleaning chamber and the outlet port, and deactivating the beam if the pressure difference between the cleaning chamber and the outlet port falls below a threshold. 102. The method of claim 87, further comprising the steps of: using at least one sensor to monitor the Class 1 certified laser-operable housing in real time, and terminating the beam if the housing no longer conforms to Class 1 standards based on real-time feedback from the at least one sensor. 103. The method of claim 102, wherein the sensor comprises a pressure sensor or a light sensor. 104. A method for mounting a fastener to a substrate, comprising the steps of: cleaning the bonding surface of the fastener and at least a portion of the substrate using a laser; positioning the cleaned bonding surface of the fastener near an adhesive dispenser; applying adhesive to the bonding surface of the fastener using the adhesive dispenser; and bonding the fastener to the substrate along an adhesive layer formed between the bonding surface of the fastener and the substrate. 105. The method of claim 104, wherein the cleaning step comprises operating a Class 1M or higher laser in a Class 1 certified laser housing. 106. The method of claim 105, wherein the cleaning step comprises the following steps: opening an ablation chamber coupled to the Class 1M or higher-class laser; placing the fastener or the substrate within the ablation chamber; and closing the head of the ablation chamber around at least a portion of the fastener or the substrate to be ablated, thereby forming the Class 1 certified laser housing around the portion of the fastener or the substrate to be ablated. 107. The method of claim 104, further comprising the steps of: using the laser to generate a beam, and contacting at least a portion of the bonding surface or the substrate with the beam. 108. The method of claim 104, wherein the cleaning step comprises the following steps:Select the fastener including the nut plate; position the nut plate relative to an internal support projecting inward from the inner sidewall of the cleaning chamber, such that an elastomeric member extending from the bottom surface of the nut plate bends away from the beam path of the laser; and ablate the bottom surface of the nut plate using the laser beam. 109. The method of claim 108, wherein the ablation step includes rotating the bottom surface of the nut plate relative to the laser beam while the elastomeric member remains bent outward and away from the laser beam. 110. The method of claim 108, wherein the positioning step includes the steps of: removing the ablated nut plate from the cleaning chamber; sliding the elastomeric member into a slot in the locator block; and aligning the bottom surface of the nut plate near the outlet of the adhesive dispenser while bending the elastomeric member away from the outlet. 111. The method of claim 110, wherein the application step includes rotating the bottom surface of the nut plate relative to the outlet of the adhesive dispenser while bending the elastomeric fastener away from the outlet. 112. The method of claim 111, wherein the rotating step includes adjusting the rotational speed of the bottom surface of the nut plate in response to a desired flow rate of the adhesive. 113. The method of claim 108, wherein the bonding step includes pulling an elastomeric member through an orifice in the substrate for pulling the bonding surface of the fastener into bond to the substrate. 114. A method for containing debris, comprising the steps of: delivering pressurized fluid into a debris-containing chamber; dispersing the pressurized fluid as an air curtain across an open internal channel within the debris-containing chamber; preventing at least some debris within the debris-containing chamber from passing through the air curtain; and simultaneously evacuating at least some of the pressurized fluid and at least some of the debris from an outlet port fluidly connected to the debris-containing chamber. 115. The method of claim 114, wherein the air curtain comprises a pair of air curtains: a first air curtain positioned substantially orthogonal to the internal channel and a second air curtain offset between 10 and 90 degrees from the internal channel. 116. The method of claim 115, wherein the dispersing step comprises forming a first air curtain from a slot formed by at least a portion of an internal channel of the opening of the debris receiving chamber. 117. The method of claim 115, wherein the dispersing step comprises forming a second air curtain from a tubular support extending within the internal channel of the opening of the debris receiving chamber. 118. The method of claim 114, comprising the step of monitoring real-time pressure within the debris receiving chamber.Systems and Methods for Installing Adhesive Fasteners Technical Field

[0001] This invention generally relates to systems and methods for installing adhesive fasteners. Generally, systems and methods for installing adhesive fasteners as disclosed herein are designed to prepare fasteners and / or substrates for bonding, apply adhesives to fasteners, and / or install fasteners onto substrates / subassemblies with high-quality bonding. Background Art

[0002] Surface preparation is a critical step in achieving durable adhesive bonding to substrates, as the effectiveness of the bonding depends largely on the quality or cleanliness of the substrate surface preparation. Conventional methods for substrate surface preparation typically involve manually abrading the substrate or surface using abrasive materials such as sandpaper, grinders, or scrubbing pads designed to remove layers of oxides and contaminants deposited thereon. Alternatively, chemicals such as acetone can be used to manually scrub the surface to remove debris and paint by chemically breaking down unwanted particles from the substrate. Manual methods tend to be relatively laborious, time-consuming, and produce mixed and / or inconsistent results at the treated surface or substrate due to inconsistencies associated with the abrasive materials used and manual application.

[0003] Furthermore, more highly automated techniques (such as abrasive blasting and / or solvent blasting chemical methods) may be more efficient, but they tend to generate considerable amounts of waste because the ablation materials (e.g., substrate abrasive materials, such as abrasives and / or solvents) and foreign matter ablated from the substrate mix with each other, creating a source of secondary waste and / or chemicals that are generally harmful to people and the environment. Environmental regulations have been implemented to restrict the use of hazardous chemicals, and the high cost of waste disposal has prompted a focus on minimizing the amount of secondary waste generated during contaminant removal. In addition, these manual techniques are also laborious and time-consuming methods, and the manual implementation also results in varying degrees of uniformity on the treated substrate and surface.

[0004] Newer laser ablation methods are generally considered an enhancement of the aforementioned mechanical and / or chemical removal methods. In this respect, laser ablation is a method of removing surface materials and debris by irradiating the substrate with a high-intensity laser beam. The laser generates a focused beam with a power density sufficient to be absorbed by the target substrate to produce a plasma plume and shock wave. The plasma plume and shock wave effectively break down foreign matter adhered to or otherwise attached to the substrate, causing it to detach effectively and be ejected into the surrounding environment as debris. Most laser-based methods are automated, thus saving the labor costs associated with the manual sandpaper or abrasive blasting methods mentioned above. Furthermore, laser-based ablation generates less waste because the method does not use mechanical abrasives or potentially hazardous chemicals to remove foreign matter from the substrate. Therefore, laser ablation methods help minimize environmental impact by reducing the amount of secondary waste generated.

[0005] In a prior art reference, U.S. Patent No. 5,780,806, granted to Ferguson, discloses a laser ablation system and a method for decontaminating surfaces using the same, the contents of which are incorporated herein by reference in their entirety. Ferguson more specifically discloses a laser ablation system comprising: a laser; a flexible fiber optic cable optically coupled to the laser to emit laser light for ablation and decontamination of surfaces; and an output optics assembly including a nozzle through which the laser light passes. The assembly also includes an exhaust pipe typically connected to the nozzle and a blower for creating a vacuum within the exhaust pipe. In operation, the laser ablation system generates an acousto-optic Q-switched Nd:YAG laser to produce an irradiance greater than 1 × 10⁷ W / cm² and a pulse width between 80 and 170 nanoseconds (“ns”) to ablate foreign matter from a substrate. Ableasing the substrate surface with this irradiance can effectively remove debris from it, which is then removed through a vacuum exhaust pipe (page 1 / 28, CN 121794071 A). However, Ferguson does not appear to include an air knife or air curtain to protect the laser shield, or a structure that allows for easy replacement of the shield after extensive use.

[0006] Additionally, the National Robotics Engineering Center (“NREC”) at Carnegie Mellon University in Pittsburgh, Pennsylvania, in collaboration with Parallel Technologies Inc. (“CTC”) in Johnstown, Pennsylvania, developed the Advanced Robotic Laser Coating Removal System (“ARLCRS”) for removing coatings and debris from US Air Force aircraft. More specifically, the ARLCRS system includes a commercially available laser integrated with a scanner and particle capture system mounted and integrated with a mobile robot base and surface monitoring sensors. The robotic arm scans the aircraft surface to locate debris and paint that need to be removed, and a high-power laser is used to ablate the substrate to remove the paint and coating from the aircraft. In this way, a team of robots equipped with debris and paint stripping lasers can work together to synchronously remove paint and coatings from aircraft. ARLCRS is an automated improvement on handheld infrared laser devices (e.g., with a wavelength of 1064 nanometers (“nm”)), which can also be used manually to remove rust or paint / primer from large surfaces such as aircraft fuselages and ships in shipyards. The problem with these systems is the lack of containment of the emitted laser. Therefore, although the amount of waste generated is less than that of sand or chemical-based solutions, potentially harmful laser light remains in and / or around the ablated surface, necessitating that the workspace environment meet higher laser safety standards (e.g., Class 1M or higher). Adherence to laser safety regulations is crucial.Protocol and the wearing of protective eyewear are crucial, as these devices could expose personnel to the laser beam path without adequate safety measures. Therefore, ARLCRS is ideally used in a dedicated laser room, which is certainly expensive to manufacture and is generally considered completely immobile because ARLCRS is designed to ablate relatively large vehicle structures (e.g., aircraft).

[0007] Therefore, in general, known laser ablation methods have disadvantages primarily associated with the fact that known Class 1 laser ablation housing systems cannot be used to remove debris from substrates, let alone be portable or easily deployed in existing manufacturing environments. Thus, laser ablation methods must still be carried out in dedicated rooms constructed to current safety standards for operating high-class lasers, including requiring operators within the room to wear protective equipment and / or other specialized eyewear. Performing ablation methods in these rooms is not particularly advantageous for implementing laser ablation methods as an existing step in a manufacturing process (e.g., in an existing assembly plant) or at existing maintenance facilities. At least, for example, as part of the manufacturing process, the substrate to be ablated must be moved into and / or out of a room with sufficient built-in safety mechanisms. This can delay and unnecessarily increase the costs associated with cleaning the substrate before applying, for example, a nut plate with adhesive.

[0008] Another problem in the aerospace industry involves methods for automatically dispensing adhesives relative to relatively small volumes, such as those relative to the aforementioned nut plates. Micro-dispensing techniques known in the art produce or dispense liquid media in relatively small dose volumes, such as on the order of less than 0.1 grams (“g”). Reliably and accurately dispensing adhesives, liquids, oils, greases, and / or other viscous media in such small doses is particularly difficult. Precise positioning and fluid volume, reagent, and cycle time have a considerable impact on the overall quality of the adhesive being dispensed, and in particular on the ability to consistently and repeatably control the dispensing volume and location of the applied adhesive. When applied to relatively small parts, such as nut plates that may be used in aerospace applications, the ability to control these relatively small volumes of adhesive (i.e., on the order of <0.1 g) becomes important.

[0009] In a prior art device, U.S. Patent No. 9,931,665, granted to Cheung, discloses a liquid compound dispensing apparatus for dispensing a controlled amount of liquid compound onto a workpiece, the entire contents of which are incorporated herein by reference. More specifically, Cheung discloses a cartridge system for selectively receiving and holding a cartridge containing a liquid compound. A plate having a threaded hole is positioned above the cartridge system and coupled to one end of a plunger, the other end of which is coupled to a piston. The piston is sized and shaped to move within the liquid-containing cartridge to discharge the liquefied compound. (Specification 2 / 28 pages 12 CN)121794071 A compound. In operation, the drive system operates to move a plate with a plunger and piston attached in a forward direction, thereby dispensing liquid from the barrel, and stops the piston when dispensing stops. Thereafter, once the contents of the barrel have been exhausted, the barrel can be removed and replaced. As with known prior art designs, the liquid compound dispensing rate is controlled by the motor drive system to control how quickly the piston moves within the barrel.

[0010] In another design, U.S. Patent No. 8469231 to Strecker discloses a dispensing system for delivering a quantity of liquid with a volume less than one cubic millimeter (“mm3”), the contents of which are incorporated herein by reference in their entirety. More specifically, Strecker discloses a housing having a pair of liquid holding containers fluidly connected to a corresponding pair of input channels that selectively guide liquid from the holding containers into corresponding first and second feed screws. The liquid compound within each holding container is delivered to the input channels via a pair of pistons designed to be driven into or inserted into the holding container to expel the liquid compound through the input channels. The pistons provide back pressure to remove the liquid compound from each liquid holding container and into the pair of input channels, ultimately contacting a pair of feed screws. Dispensing is then driven by operating the feed screws, which have helical threads set in chambers that mix the entering compound during rotation. Continued rotation then drives the mixed liquid compound out through the dispensing end. However, Strecker has not disclosed any feedback sensors to monitor the quantity or quality of liquid dispensed from the end, and Strecker also appears not to disclose that the pistons can be pneumatically removed from the liquid holding containers to prevent subsequent “dripping” or “flowing,” since the dispensed liquid has already left the corresponding input channel and is primarily driven by the rotation of the feed screws.

[0011] In another prior art reference, U.S. Patent No. 8,578,729, granted to Fiske, discloses a system for dispensing relatively small amounts of viscous material onto a workpiece using a dispenser with a relatively narrow profile, the contents of which are incorporated herein by reference in their entirety. More specifically, the dispenser disclosed by Fiske includes a fluid chamber, a nozzle, and a valve seat disc with separate components, each removable from the body of the dispenser for cleaning and / or replacement. The viscous material is supplied under pressure from a supply container through a fluid conduit to an inlet port for dispensing through the nozzle.

[0012] A problem with adhesive dispensing systems known in the art (such as those discussed above) is the difficulty in consistently and reliably dispensing relatively small volumes of liquid under pressure, such as by means of a piston located behind a liquid compound within a barrel container.A pneumatic system applying constant pressure is used for dispensing because it requires a valve to “start” and / or “stop” the adhesive flow. The valve is typically located within the adhesive flow and thus maintains constant contact with the adhesive. This “wet” valve is affected by the adhesive in a constant curing state and is not particularly advantageous in preventing “dripping” or “flowing” after dispensing should have completely stopped. Furthermore, known pneumatic systems do not include a “pull-back” function to control adhesive flow, which is considered incompatible with pneumatic systems due to the inherent limitations of the aforementioned pneumatic functions.

[0013] Therefore, there is a great need in the art for systems and methods for bonding fastener installations that are designed to prepare fasteners and substrates for bonding, such as by laser ablation using a Class 1 laser housing with an integrated air curtain or air knife and vacuum evacuation system, applying adhesive to fasteners at a consistent rate without “dripping” or “flowing,” and installing fasteners onto substrates / subassemblies with high-quality bonding. The present invention addresses these needs and provides additional related advantages.

[0014] In one embodiment disclosed herein, a laser ablation containment system may be integrated as part of a transferable roller station and includes: a laser chamber having a Class 1M or higher grade laser (e.g., a Class 4 laser) integrated therewith; and a cleaning chamber coupled to and aligned with the laser chamber to selectively receive a beam generated by the Class 1M or higher grade laser. Here, the cleaning chamber may include a head that is selectively movable between a first position exposing the interior of the cleaning chamber for placing a substrate therein, and a second position securely closing the interior of the cleaning chamber to cooperate with the laser chamber in forming a Class 1 certified laser-operable housing.

[0015] The cleaning chamber and the laser chamber may be coupled to a robotic arm movable to selectively position the head against a substrate to utilize it for forming the housing. The robotic system can also operate a gripper having a pair of actuating fingers positioned below the umbrella-shaped member and operable to selectively pick up a substrate and place it within a housing formed by a sealing engagement between the umbrella-shaped member and a sealing edge. Here, the robotic system can selectively position an elastomeric fixing device projecting downwards from a nut plate to be received in a bracket that projects inwardly from the inner wall of the cleaning chamber, thereby creating a gap between the bracket and the inner wall.

[0016] In one embodiment, the umbrella-shaped member can slide along an axis perpendicular to the focusing lens of a Class 1M or higher laser mounted within the laser chamber. In another embodiment, a proximity sensor can be positioned to identify the umbrella-shaped member.When to position it on the sealing edge to ensure the laser ablation containment system continues to operate with a Class 1 certified housing and a Class 1M or higher laser. In these embodiments, the head may be an outwardly projecting compressible liner that forms at least a portion of the outer periphery of the housing, and at least one sensor may be positioned to measure pressure or light within the housing.

[0017] In another aspect of these embodiments, the clean chamber of the laser ablation containment system may be in fluid communication with a debris removal chamber. Furthermore, a selectively removable and replaceable protective lens may be selectively positioned within a slot to substantially seal the laser chamber from the clean chamber for further protection of a Class 1M or higher laser. Here, the protective lens may be carried by a protective lens holder having a front channel that provides access to the protective lens when removed from the slot. However, when inserted into the slot, the front channel is positioned flush with the inner wall of the clean chamber, thereby locking the protective lens therein.

[0018] Furthermore, the head may include a clamp having a base with a lower sealing member extending upward therefrom, the lower sealing member cooperating with an upper sealing member to form a shell between the two when the head is in a second position. Here, the lower sealing member may be made of foam or rubber material and may be moved relative to the upper sealing member by a linear actuator or pneumatic piston, the upper sealing member also being made of foam or rubber material.

[0019] In another aspect of these embodiments, the laser chamber may be offset relative to the cleanroom by an angle between 90° and 180°. Additionally or alternatively, a mirror or prism located within one of the laser chamber or the cleanroom may be positioned to receive the beam and redirect it with an offset of up to 180°. Here, at least one of the mirrors or prisms may be mounted to a pivot (e.g., a single-plane pivot, a multi-plane pivot, or a ball-and-socket pivot) and may be repositioned in real time within one of the laser chamber or the cleanroom.

[0020] In another embodiment, a debris containment system as disclosed herein includes: a conduit for delivering pressurized fluid to a cleaning chamber; and an outlet coupled to the conduit and positioned to guide the pressurized fluid substantially across an internal channel of the cleaning chamber as an air curtain therethrough, thereby substantially preventing debris on one side of the internal channel of the cleaning chamber from passing through the air curtain to the other side of the internal channel of the cleaning chamber. Thus, the air curtain may extend generally horizontally across the internal channel and toward a debris removal chamber in fluid communication therewith. The outlet may also be a generally elongated slot formed by a tubular support extending within the internal channel of the cleaning chamber, and / or the outlet may be angled relative to the internal channel such that the air curtain extends across the internal channel at an angle relative to the internal channel.

[0021] More specifically, the internal channel may be a cylindrical channel, and the outlet may be formed by the inner sidewall of the cleaning chamber.The quasi-hemispherical slot of CN 121794071 A, page 4 / 28. Here, the quasi-hemispherical slot faces forward toward the internal channel, and the air curtain extends generally horizontally across the internal channel of the cleaning chamber toward the debris removal chamber. Thus, the elongated slot can be positioned such that the air curtain flows at least partially vertically within the internal channel of the cleaning chamber to prevent debris from moving toward the laser chamber coupled to the cleaning chamber.

[0022] In another embodiment, the conduit may include a first conduit and a second conduit, and the outlet may include a first outlet and a second outlet. Here, each of the first outlet and the second outlet may lead to the internal channel to create a first air curtain and a second air curtain offset from each other. More specifically, the first conduit may include an upper conduit and the second conduit may include a lower conduit, wherein each of the upper conduit and the lower conduit includes a corresponding slot having a width of approximately half the circumference of the internal channel of the cleaning chamber. In this embodiment, both the first air curtain and the second air curtain are capable of extending substantially across the internal channel of the cleaning chamber at the same or different angles relative to each other. An air pressure sensor may be positioned within either the cleaning chamber or the debris removal chamber to ensure sufficient pressure and airflow within both chambers. In this regard, at least one of a HEPA filter or a carbon filter may be positioned within the debris removal chamber to trap debris evacuated from the cleaning chamber.

[0023] In another embodiment disclosed herein, an adhesive dispenser system may also be integrated with a transferable roller station and includes: a frame on which a drive unit is mounted; and a screw threadedly operated by the drive unit and engaged with a carrier unit slidable relative to the frame and having at least one chuck mounting assembly rigidly coupled thereto. The at least one chuck mounting assembly may include a piston chuck selectively slidably engaged with a piston head and operable to dispense liquid from a barrel when the drive unit operates the screw in a first direction and to reduce and / or eliminate liquid “dripping” or “flowing” when the drive unit operates the screw in a second direction opposite to the first direction. The drive unit may operate the screw to dispense liquid in amounts as small as 0.1 grams (“g”) or less at a time.

[0024] The adhesive dispenser system may further include a support bracket with an extension sized to receive dispensing needles spaced apart relative to a frame, wherein the support bracket is selectively adjustable relative to the frame via an elongated channel that can be locked to the frame by a locating pin located therein. The adhesive dispenser system may also include at least one feedback sensor (e.g., a force feedback sensor that measures the current or voltage of the drive unit in real time), which is coupled to the drive unit to provide real-time sensing feedback on the adhesive viscosity.Alternatively, the camera can be positioned to photograph the adhesive dispensed from the barrel. The flow rate operated by the drive unit and screw can be varied based on force feedback and / or the visual appearance of the adhesive dispensed from the end. Another feature of these embodiments is that the frame may include a thermal housing having cooling or heating elements adjacent to a quick-change carrier therein for real-time temperature regulation of one or more fluids within the barrel.

[0025] In another aspect of these embodiments, at least one chuck mounting assembly includes a pair of chuck mounting assemblies, each including a respective piston chuck selectively slidably engaging a respective piston head operable to dispense adhesive from the dual-barrel assembly. Here, the respective piston heads may each have different dimensions relative to each other, depending on the liquid stored in the dual-barrel assembly and required to produce the adhesive. Additionally, the piston chuck may terminate at an outwardly flared mandrel sized to frictionally engage with the piston head.

[0026] Once complete, the liquid barrel can be released for replacement via a one-step quick-release mechanism that disengages the piston chuck from the barrel. Here, the quick-release mechanism may include a sliding bracket having a step operable to compress the spring from a first normally extended position to a second compressed position, thereby disengaging the piston collet from engagement with the piston head. The sliding bracket may include a pull-back channel with a sliding pin that limits movement of the sliding bracket relative to the carrier unit to a predetermined distance. Alternatively, as an addition to or alternative to the pull-back channel, a stop coupled to the carrier unit may be positioned to terminate rearward movement of the sliding bracket relative to the carrier unit by a predetermined distance.

[0027] In another embodiment, a quick-change cartridge system may include: a frame having a set of outwardly extending locating pins having dimensions and shapes for selectively sliding into and / or out of a slotted housing of a dispenser unit; and a liquid-receiving cartridge having dimensions and shapes for selectively sliding into and / or removing from an opening in the receiving frame when the frame is removed from the dispenser unit, wherein when the frame is engaged with the dispenser unit, a liquid-receiving chamber may be positioned within the frame and, in a forward position, in fluid communication with a dispensing outlet.

[0028] The frame may include a front opening having dimensions and shapes relatively smaller than the liquid-receiving cartridge but relatively larger than the dispensing outlet. This allows the liquid-receiving cartridge to selectively slide into and / or out of the frame. Furthermore, the locating pins of the frame may include an outwardly extending bolt having a relatively smooth shank portion, the length of which is sufficient to slide into and be received within the slotted housing to position the head portion of the bolt to the outside of the slotted housing. The slotted housing may include aAn externally accessible L-shaped receiving channel is provided, which is relatively wider than the width of the shank portion of the bolt and relatively smaller than the width of the head portion of the bolt. In this respect, the externally accessible L-shaped receiving channel may also include an enlarged chamfered opening top accessible for dropping the frame into the slotted housing via a locating pin.

[0029] In another aspect of these embodiments, the liquid receiving cylinder may include an outwardly extending base plate, which is at least partially larger than the opening orifice for flush engagement with it when the liquid receiving cylinder is mounted within the frame. Additionally, the liquid receiving cylinder may include a pair of liquid receiving cylinders, each in fluid communication with a cap having an outlet port selectively connected to a dispensing outlet including an inlet of a static mixer extending outward from the frame. The liquid receiving cylinder may also include at least one rear receiving slot having dimensions and shape for selective engagement with a chuck mounting assembly of the dispenser unit.

[0030] An adhesive dispensing feedback method disclosed herein includes the following steps: activating a drive unit for dispensing a quantity of adhesive at a desired flow rate; monitoring one or more dispensing characteristics associated with the amount of adhesive being dispensed; cross-referencing the one or more dispensing characteristics against a set of operating parameters for each of the one or more dispensing characteristics; and adjusting the desired flow rate of the quantity of adhesive using the drive unit if one or more of the dispensing characteristics fall outside any of the set of operating parameters.

[0031] More specifically, firstly, a carrier unit coupled with a pair of chuck mounting assemblies is slidably moved to engage with a corresponding pair of barrels positioned in a static relationship relative to the carrier unit. Here, a pair of piston chucks within each of the chuck mounting assemblies can engage with a corresponding piston head in a fluid relationship with each of the pair of barrels, each of the pair of barrels engaging in a frictional fit with the piston head. A screw is rotated in a first direction to move the chuck mounting assembly forward, dispensing liquid from each of the pair of barrels into a static mixer for forming an adhesive, which is ultimately delivered to an outlet end. When dispensing stops, the drive unit can reverse the screw in the second direction, thereby pulling back the piston head in the liquid receiving cylinder via the chuck mounting assembly. This creates a negative pressure at the outlet end, and any excess adhesive is pulled back, thereby effectively preventing "dripping" or "flowing" from the outlet end.

[0032] In another aspect of these embodiments, the monitoring step may further include the following steps: sensing the viscosity of the dispensed adhesive and determining whether the viscosity is below or above a threshold; sensing the current or voltage of the drive unit in real time and determining whether the current or voltage is below or above a threshold; measuring the ambient temperature or the temperature of the adhesive; and measuring the temperature in real time or by means of the current or voltage of the drive unit.Discrete-time increments measure one or more dispensing characteristics; and / or utilize a camera to observe the adhesive. Reading the temperature of one or more liquid compounds in the liquid dispensing barrel can help regulate the quality and quantity of the adhesive being dispensed in real time. This regulation may involve using a heater or cooler to change the temperature of one or more liquid compounds in the liquid dispensing barrel to help control, for example, the viscosity of the adhesive. In response, the adjustment steps may include changing the rotational speed of a screw operated by the drive unit to slidably move the carrier unit via the drive unit.

[0033] In another embodiment, a selectively removable and / or replaceable protective lens holder as disclosed herein may include a frame having a forward-positioned receiving channel having a size and shape in which a protective lens (e.g., which is light-transmitting) is selectively received when in a first open position. The protective lens holder can be moved to a second position to cooperatively lock the protective lens therein when slidably engaged with the inner wall of the cleaning chamber. The receiving channel may include a substantially horizontal opening slot for selectively inserting and / or removing a protective lens therein when the protective lens holder is in a first position.

[0034] Additionally, the protective lens holder may also include a handle extending outward from the frame opposite the receiving channel and having dimensions and shape for manual operation outside the outer wall of the cleaning chamber. Here, the handle may also include a pair of opposing arcuate recesses that enhance manual operation of the protective lens holder outside the outer wall of the cleaning chamber.

[0035] In another embodiment, a debris removal system may include an outlet conduit in fluid communication with a cleaning chamber containing debris removed from a substrate. A port in the outlet conduit may be coupled to a pressure sensor in fluid communication therewith for real-time measurement of pressure in the outlet conduit, and a controller coupled to the pressure sensor may communicate with a laser operable to generate a beam in the cleaning chamber for debris removal from the substrate. Here, the controller may be operable to disable the beam in response to a pressure loss measured by the pressure sensor in the outlet conduit. Additionally, the inlet port can selectively receive pressurized fluid that creates at least a partial vacuum relative to the clean chamber in the outlet conduit, wherein the inlet port can be coupled to a pneumatic air pump. A HEPA filter or carbon filter can also be positioned within the outlet conduit to filter out debris.

[0036] In another embodiment, a method for replacing a quick-change cartridge includes: sliding a carrier out of engagement with the frame of the dispensing unit; removing the liquid-containing cartridge from the carrier through the access port; and inserting...Insert a new liquid container into the container; and reinsert the carrier holding the new liquid container into the frame of the dispensing unit. The method may also include moving a set of locking pins protruding outward from the carrier through an externally accessible L-shaped channel formed by the frame. Here, the set of outwardly protruding locking pins may be bolts having a shank portion that is movable within the L-shaped channel and a head portion that is relatively larger than the L-shaped channel and positioned outside it. Thus, in one embodiment, when the carrier is reinserted into the frame, the new liquid container may be locked in the forward slot of the L-shaped channel.

[0037] The method may also include the step of disengaging the liquid container from the sliding unit. This can be done by: moving the externally accessible sliding support rearward relative to the sliding unit; compressing the tension spring within the retraction channel by engaging an inwardly protruding step that engages with a washer positioned at one end of a tension spring that is normally positioned forward; and retracting the flared mandrel of the piston chuck in response to the compression of the tension spring, disengaging it from frictional engagement with the piston head associated with the liquid container. Here, the compression step may include compressing the tension spring using an intermediate protruding step positioned between the coils of the tension spring, and the moving step may include terminating the backward movement of the sliding support using a stop integrated with the frame or positioned within a pull-back channel formed within the sliding support. Once the new liquid container has been engaged with the frame, the re-insertion step includes reconnecting the sliding unit to the piston head associated with the new liquid container by tapping a screw, rotating an externally accessible knob, or retracting the piston head to engage it.

[0038] In another method disclosed herein, cleaning the surface of a substrate, etc., may include: enclosing a laser chamber having a Class 1M or higher laser integrated therewith; positioning the substrate within an ablation chamber coupled to the laser chamber and aligned with the Class 1M or higher laser; moving a head between a first position and a second position, wherein the first position exposes the interior of the ablation chamber for placing the substrate therein, and the second position encloses the interior of the ablation chamber and cooperates with the laser chamber to form a Class 1 certified laser-operable housing; generating a beam using a Class 1M or higher laser; and bringing at least a portion of the substrate into contact with the beam, thereby removing debris from the substrate.

[0039] Alternatively, the method may include the steps of: picking up the substrate and placing it within the head, and clamping the substrate between an upper sealing member and a lower sealing member of the head. Furthermore, the substrate may be oriented at an angle between 90° and 180° relative to the beam, such as by redirecting at least a portion of the beam from a mirror, such that the contact step includes twoDifferent beam angles simultaneously ablate the substrate. In this embodiment, the mirror can pivot in real time (e.g., around the ball joint) to reposition the angle at which the mirror and the beam contact the substrate. Alternatively or additionally, the beam can be split by a prism before contacting the substrate.

[0040] The method may also include the steps of: inserting a protective lens approximately orthogonal to the beam between the laser chamber and the ablation chamber (e.g., such that the beam is guided through the protective lens and contacts the substrate), and activating a proximity sensor in response to the insertion of the protective lens or the formation of a Class 1 certified laser operable housing. Here, as part of the insertion step, the front slot of the protective lens holder can be abutted against the inner sidewall, thereby locking the protective lens within the protective lens holder.

[0041] Additionally, the method may also include: using at least one sensor to monitor the Class 1 certified laser operable housing in real time, and terminating the beam if the housing no longer meets Class 1 standards based on real-time feedback from at least one sensor (e.g., a pressure sensor or a light sensor). In another aspect, the pressure difference between the cleaning chamber and the outlet port can be measured in real time, and the beam can be deactivated if the pressure difference between the cleaning chamber and the outlet port drops below a threshold. Pressure differential is also important for evacuating debris from the cleaning chamber by pressurizing the housing and creating a vacuum at the outlet port.

[0042] Another method disclosed herein for mounting fasteners to a substrate includes: cleaning the bonding surface of the fastener and at least a portion of the substrate using a laser; positioning the cleaned bonding surface of the fastener close to an adhesive dispenser; applying adhesive to the bonding surface of the fastener using the adhesive dispenser; and bonding the fastener to the substrate along an adhesive layer formed between the bonding surface of the fastener and the substrate. Here, the cleaning step may include: operating a Class 1M or higher grade laser in a Class 1 certified laser housing (such as by opening an ablation chamber coupled to a Class 1M or higher grade laser), placing the fastener or substrate in the ablation chamber, and closing the head of the ablation chamber around at least a portion of the fastener or substrate to be ablated, thereby forming a Class 1 certified laser housing around the portion of the fastener or substrate to be ablated. Alternatively, the laser may be used to generate a beam so that at least a portion of the bonding surface or substrate comes into contact with the beam.

[0043] Furthermore, the cleaning step may also include: selecting a fastener comprising one of a plurality of nut plates; positioning the nut plates relative to an internal support protruding inward from the inner sidewall of the cleaning chamber, such that an elastomeric member extending from the bottom surface of the nut plates bends away from the laser beam path; and using the laser beam to ablate the bottom surface of the nut plates. Here, the ablation step may include rotating the bottom surface of the nut plates relative to the laser beam while the elastomeric member remains bent outward and away from the laser beam.

[0044] Additionally, the positioning step may include: removing the ablated nut plate from the cleaning chamber; sliding the elastomer member into the slot of the locator block; and aligning the bottom surface of the nut plate near the outlet of the adhesive dispenser while simultaneously bending the elastomer member away from the outlet. Furthermore, the application step may include rotating the bottom surface of the nut plate relative to the outlet of the adhesive dispenser while simultaneously bending the elastomer fastener away from the outlet, and the rotation step may include adjusting the rotational speed of the bottom surface of the nut plate in response to a desired flow rate of adhesive, wherein the bonding step includes pulling the elastomer member through an orifice in the substrate to pull the bonding surface of the fastener into bond to the substrate.

[0045] In another method disclosed herein, a method for containing debris within a cleaning chamber may include: delivering pressurized fluid (as described in page 8 / 28 of CN 121794071 A) into the debris-containing chamber; dispersing the pressurized fluid as an air curtain across an open internal passage within the debris-containing chamber; preventing at least some debris within the debris-containing chamber from passing through the air curtain; and simultaneously evacuating at least some of the pressurized fluid and at least some of the debris from an outlet port fluidly connected to the debris-containing chamber.

[0046] Here, the air curtain may include a pair of air curtains, wherein a first air curtain may be positioned substantially orthogonal to the internal passage, and a second air curtain may be offset from orthogonal to the internal passage by between 10 degrees and 90 degrees. Thus, the dispersing step may include forming the first air curtain from a slot formed by at least a portion of the open internal passage of the debris-containing chamber, and the second air curtain may be formed from a tubular support extending within the open internal passage of the debris-containing chamber. The system may also monitor the real-time pressure within the debris-containing chamber to ensure that debris is efficiently and effectively evacuated from it.

[0047] Other features and advantages of the invention will become apparent from the following more detailed description, taken in conjunction with the accompanying drawings, which illustrate the principles of the invention by way of example. Brief Description of the Drawings

[0048] The accompanying drawings illustrate the invention. In these figures:

[0049] Figure 1 is an environmental perspective view of a laser ablation containment and debris removal system integrated as part of a portable roller station having a selectively compliant assembly robotic arm (“SCARA”) and an adhesive dispenser;

[0050] Figure 2 is an enlarged environmental perspective view taken along square 2 in Figure 1, showing more specifically the Class 4 laser coupled to the laser ablation containment and debris removal system and the adhesive dispenser integrated with the laser ablation containment and debris removal system;

[0051] Figure 3 is a perspective view showing more specifically the fully assembled laser ablation containment and debris removal system;

[0052] Figure 4 is an exploded perspective view of the laser ablation containment and debris removal system of Figure 3, showing more specifically the gripper operable by the SCARA when operating the Class 4 laser, which can be sealed within the ablation chamber;

[0053] Figure 5 is an enlarged environmental perspective view showing the gripper holding the nut plate and biasing the elastomer fixing device away from the distributor, thereby applying adhesive under the nut plate using an adhesive dispenser;

[0054] Figure 6 is a top perspective view of the laser ablation containment and debris removal system of Figure 3 without the upper umbrella-shaped member, further showing the ablation chamber in which a V-shaped cross bracket is housed;

[0055] Figure 7 is a bottom perspective view of the laser ablation containment and debris removal system, further showing the vacuum pressure sensor and air inlet port for supplying pressurized air into the ablation chamber to operate one or more air curtains and guide debris out through the vacuum chamber;

[0056] Figure 8 is a partial cross-sectional view taken along line 8-8 in Figure 6, more specifically showing the selectively removable protective lens holder separating the laser protection chamber from the ablation chamber, and the vacuum pressure sensor connected to the vacuum chamber;

[0057] Figure 9 is an enlarged partial cross-sectional view taken along circle 9 in Figure 8, further showing the V-shaped cross bracket in the ablation chamber, which is positioned to guide airflow from the ablation chamber to the vacuum chamber in fluid connection with it;

[0058] Figure 10 is a partial cross-sectional view taken along line 10-10 in Figure 3, showing more specifically the pressurized air passage connected to the ablation chamber;

[0059] Figure 11 is a cross-sectional view taken along line 11-11 in Figure 3, showing more specifically the opening port of the vacuum pressure sensor connected to the vacuum chamber;

[0060] Figure 12 is a cross-sectional view taken along line 12-12 in Figure 4, showing more specifically the vacuum pressure sensor and a portion of the pressurized air passage connected to the vacuum chamber;

[0061] Figure 13 is a cross-sectional view taken along line 13-13 in Figure 4, showing more specifically the pressurized air passage branching into a pair of... (The last part is a reference to a document, page 9 / 28, CN 121794071 A, which is not translated as it is not part of the main text.) The conduit is used to guide pressurized air into the interior of the ablation chamber to create a pair of air curtains during use;

[0062] FIG14 is a cross-sectional view similar to FIG13, wherein the laser ablation containment and debris removal system is rotated by approximately 270 degrees to more specifically show the pressurized air channel branching into a lower quasi-hemispherical conduit and an upper horizontal conduit;

[0063] FIG15 is a cross-sectional view taken along line 15-15 of FIG4, more specifically showing the lower quasi-hemispherical conduit feeding pressurized air into the quasi-hemispherical slit, thereby creating a horizontal air curtain across the open interior of the ablation chamber;

[0064] FIG16 is a cross-sectional view taken along line 16-16 of FIG4, more specifically showing the upper horizontal conduit feeding pressurized air into the vertically facing horizontal slit in the support to create at least a partially vertical air curtain, thereby guiding debris upward away from the protective lens holder and into the vacuum chamber;

[0065] FIG17 is a perspective view more specifically showing an embodiment of the protective lens holder as disclosed herein;

[0066] Figure 18 is a rear perspective view of the adhesive dispenser as disclosed herein;

[0067] Figure 19 is a partial cross-sectional top view of the adhesive dispenser taken along line 19-19 in Figure 18, further showing a pair of colleting assemblies forwardly engaged with a pair of barrels of the dual-barrel dispensing system;

[0068] Figure 20 is an enlarged partial cross-sectional top view taken along circle 20 in Figure 19, further showing that each of the pair of colleting assemblies includes a spring-biased sliding bracket movable to disengage the pair of colleting assemblies from the pair of barrels;

[0069] Figure 21 is a rear perspective view shown in exploded view relative to the adhesive dispenser;

[0070] Figure 22 is an enlarged front perspective view taken along circle 22 in Figure 21, more specifically showing the quick-change carrier engaged with the dual-barrel replaceable system;

[0071] Figure 23 is a rear perspective view of the dual-cylinder replaceable system shown in Figures 21 and 22, which is slidably engaged with a quick-change carrier;

[0072] Figure 24 is a similar rear perspective view to Figure 23, showing the dual-cylinder replaceable system being slid out and removed from the quick-change carrier;

[0073] Figure 25 is a side view of the adhesive dispenser of Figure 18;

[0074] Figure 26 is a cross-sectional view taken generally along line 26-26 in Figure 25, further showing the threaded screw in a threaded relationship with the piston sliding carrier;

[0075] Figure 27 is an ambient perspective view showing the adhesive applied below the nut plate by the adhesive dispenser disclosed herein;

[0076] Figure 28 is an enlarged perspective view of one of the chuck mounting assemblies, further showing an outwardly flared mandrel located within a flared sleeve, which is selectively coupled to a piston head within the dual-cylinder replaceable system;

[0077] Figure 29 is a perspective view of an alternative adhesive dispenser including an externally accessible rotatable knob operable to turn a tapping screw to engage or disengage from a thread in a piston head of a dual-cylinder replaceable system;

[0078] Figure 30 is a perspective view of another adhesive dispenser as disclosed herein, including a thermal housing housing a dual-cylinder replaceable system;

[0079] Figure 31 is a perspective view of an alternative adhesive dispenser similar to Figure 30, showing a cooler and a pair of heating elements for temperature control of the dual-cylinder replaceable system within the thermal housing;

[0080] Figure 32 is an environmental perspective view of a substrate ablation and debris evacuation system integrated as part of a transferable roller station for use with a collaborative robot (“cobot”); Specification 10 / 28 pages 20 CN 121794071 A

[0081] Figure 33 is a perspective view of the fully assembled substrate ablation and debris evacuation system;

[0082] Figure 34 is an alternative perspective view of a substrate ablation and debris evacuation system similar to Figure 33, rotated to show the ablation shell and gripper more specifically;

[0083] Figure 35 is a partially exploded perspective view of the substrate ablation and debris evacuation system of Figure 34;

[0084] Figure 36 is an ambient perspective view showing the ablation shell in the open position aligned with the bracket to be ablated on the carrier;

[0085] Figure 37 is an ambient perspective view similar to Figure 36, further showing the upper sealing member engaging with the top surface of the carrier in a vacuum-sealed relationship to enclose the bracket internally;

[0086] Figure 38 is an ambient perspective view similar to Figures 36 and 37, further showing the lower sealing member engaging with the bottom surface of the carrier in a vacuum-sealed relationship;

[0087] Figure 39 is a cross-sectional view taken along line 39-39 of Figure 33, showing more specifically the dust extractor fluidly connected to the ablation shell;

[0088] Figure 40 is a partial cross-sectional view taken along line 40-40 of Figure 34, showing more specifically the air pressure sensor and its opening port fluidly connected to the dust extractor;

[0089] Figure 41 is a partial cross-sectional view taken along line 41-41 of Figure 33, showing more specifically the protective lens retainer located between the laser protection zone and the ablation shell fluidly connected to the dust extractor;

[0090] Figure 42 is a cross-sectional view taken along line 42-42 of Figure 33, showing more specifically a pair of air curtains above the opening between the ablation shell and the dust extractor;

[0091] Figure 43 is a cross-sectional view taken along line 43-43 of Figure 33, showing more specifically the air pressure sensor connected to the dust extractor and the inlet port for receiving pressurized air;

[0092] Figure 44 is a cross-sectional view taken along line 44-44 of Figure 33, showing more specifically the movement of pressurized air through the internal channels;

[0093] Figure 45 is a cross-sectional view taken along line 45-45 of Figure 36, showing more specifically the internal channels branching into a lower conduit and an upper conduit;

[0094] Figure 46 is a cross-sectional view taken along line 46-46 of Figure 36, showing more specifically the lower conduit delivering pressurized air to the lower quasi-hemispherical slit to create a lower air curtain across the internal opening of the ablation shell, and the upper conduit delivering pressurized air to the upper quasi-hemispherical slit to create an upper air curtain across the internal opening of the ablation shell;

[0095] Figure 47 is a cross-sectional view similar to Figure 46, rotated to further show the pressurized airflow from the ablation shell to the dust extractor through the openings between them forming an upper and lower air curtain. Detailed Description

[0096] As shown in the exemplary figures, for illustrative purposes, this document illustrates, with respect to Figures 1 through 47, a method for bonding fasteners.Systems and methods. As will be discussed in more detail below, the systems and methods disclosed herein can generally be used, for example, to automate the preparation and installation of bonded fasteners, including cleaning the fasteners and / or substrates prior to the application of adhesive, applying adhesive to at least a portion of one of the fasteners or substrates, and then adhering the fasteners and substrates along the adhesive layer. One or more robotic systems can operate independently and / or simultaneously with each other to prepare fasteners and / or substrates for bonding, accurately and consistently apply adhesive to the fasteners and / or substrates, and then secure the fasteners to the substrate to achieve consistent and repeatable results, all of which can be integrated into adaptive, modular systems that can be deployed in environments such as existing manufacturing facilities without requiring personal protective equipment (“PPE”). Instruction manual 11 / 28 pages 21 CN 121794071 A

[0097] The bondable surfaces of fasteners and substrates can be prepared by laser ablation, wherein a Class 1M or higher laser (such as an Nd:YAG infrared laser operating at a pulsed wavelength of 1064 nm) operates within a Class 1 certified laser housing to ablate oxides and other contaminants from fasteners (e.g., nut plates, etc.) and / or substrates (e.g., aircraft flanges) by rapidly heating the base surface and the contamination layer thereon. Typically, the base surface of the fastener and / or substrate (which may be made of metal, etc.) has different thermal properties than the contamination layer from which the laser ablation method is designed to remove. Therefore, the heating and / or cooling rates of the base material (the ablated material) and the contamination material (if present) vary based on several different factors (such as thermal conductivity, mass, thickness, specific heat capacity, laser parameters, and the surrounding environment). The difference in rapid temperature change of the laser causes the contamination layer to become brittle and detach from the base material without damaging the base material of the fastener or substrate.

[0098] The safety system can monitor laser operation in real time to ensure continuous operation within certain parameters deemed safe, without requiring the operator to use or wear PPE (e.g., laser safety goggles) or construct a protective laser safety cage. This makes the systems and methods disclosed herein particularly suitable for deployment in environments such as existing manufacturing assembly lines, including as part of a portable or mobile workstation. Furthermore, a dual-check safety (“DCS”) system can be programmed to prevent laser operation unless sensors confirm that the housing is properly sealed and operating in accordance with Class 1 certification specifications. Such sensors may include optical sensors that monitor the amount of light escaping from the housing (if present), proximity sensors that ensure the housing is closed, and pressure and / or flow sensors that continuously check the seal and measure the debris evacuation efficiency of a vacuum or fume extractor designed to remove ablation debris during operation. Inadequate sealing or a drop in airflow below a threshold level can cause the system to disable the safety interlock, thereby halting laser operation.

[0099] The systems and methods disclosed herein are also designed to reduce the variability of the installation process and improve its reliability in a faster and more robust manner than other methods known in the art, including manual installation. The systems and methods disclosed herein also provide the correct amount of adhesive for properly prepared fasteners to produce a repeatable and reliable adhesive layer, which improves efficiency and reduces waste (e.g., discarded adhesive), thereby reducing manufacturing and assembly costs in addition to increasing deployment flexibility and security.

[0100] In one aspect of the embodiments disclosed herein, a laser ablation containment and debris removal system 50 is generally shown in Figures 1 through 14 and Figures 6 through 16. As best shown in Figures 1 and 3, the laser ablation containment and debris removal system 50 is generally formed by three sections: a laser protection chamber 52 generally aligned with an ablation chamber 54, and a vacuum chamber 56 in fluid communication with the ablation chamber 54. In this respect, vacuum chamber 56 is designed to continuously remove debris selectively ablated from the substrate in ablation chamber 54 by laser 58 (Figures 1 and 2), which is selectively mounted or otherwise integrated into laser protection chamber 52 relative to ablation chamber 54. In normal operation, laser 58 emits a beam that travels through laser protection chamber 52, through a selectively removable and replaceable protective lens holder 60 (Figure 17) positioned between laser protection chamber 52 and ablation chamber 54, which has a protective lens (not shown in Figure 17), and enters ablation chamber 54 to selectively clean the substrate therein. As discussed in more detail below, the protective lens in holder 60 is designed to protect laser 58 from debris ablated from the substrate within ablation chamber 54. The debris removed from the cleaned substrate is then extracted from ablation chamber 54 by vacuum chamber 56, which is fluidly connected to ablation chamber 54, as discussed in more detail below.

[0101] In one embodiment, to improve the efficiency and accuracy of laser ablation of substrates to achieve consistently higher quality surface preparation with six sigma reliability during the manufacturing process while reducing surface preparation time and cost, the laser ablation containment and debris removal system 50 may be used in conjunction with a selective compliant assembly robotic arm (“SCARA”) 62 and / or an adhesive dispenser 64 (such as part of a transferable roller station 66), as shown in Figures 1 and 2. Of course, although any of the laser ablation containment and debris removal system 50, the SCARA 62, and / or the adhesive dispenser 64 can be integrated as part of a fixed or semi-fixed system for use in manufacturing methods that can utilize or integrate the laser ablation containment and debris removal system 50 disclosed herein. In alternative embodiments, other robotic arms and / or mechanical gantry systems known in the art may be used instead of the SCARA 62.

[0102] As shown in Figure 1, the SCARA...62 includes an end effector 68 that selectively engages with a coupling 70 of the laser ablation containment and debris removal system 50. This coupling extends generally through the upper umbrella-shaped member 72 and into the ablation chamber 54 (Figures 3 and 4) to engage with a downwardly positioned gripper 74, which generally includes a pair of actuating fingers 76 having dimensions and shapes for selectively picking up and moving substrates (such as the nut plate 78 shown in Figure 5) that need to be cleaned within the ablation chamber 54. In one embodiment, the gripper 74 may be mechanically or pneumatically driven. However, in general, the gripper 74 may be replaced by another system capable of picking up and moving parts to be laser-treated, as disclosed herein.

[0103] The ablation chamber 54 is generally formed by the cooperation of the umbrella-shaped member 72, which has a sealing ring 80 made of foam or rubber material, generally circumferentially coupled to the umbrella-shaped member and having dimensions and shapes for selective placement on the upper edge 82 shown in Figure 4. Therefore, in operation, the SCARA 62 operates by positioning a gripper 74 relative to one of the plurality of nut plates 78 to be ablated (e.g., as shown in FIG. 5), actuating fingers 76 to grip one of the nut plates 78 to remove it from the nut plate carrier 84, and then transporting the selected nut plate 78 above the upper edge 82 of the opening of the laser ablation receiving and debris removal system 50. Here, the SCARA 62 lowers the gripper 74 holding the selected nut plate 78 into the interior of the ablation chamber 54, which is sealed when the sealing ring 80 rests on the upper edge 82. To better ensure an airtight or substantially airtight seal, the foam or rubber material of the sealing ring 80 may be at least partially compressed between the umbrella-shaped member 72 and the upper edge 82. A similar foam or rubber material may be coupled between the end effector 68 of the SCARA 62 and the coupling 70 extending upward from the umbrella-shaped member 72 to also form an airtight or substantially airtight seal between them. In this respect, the ablation chamber 54 is effectively sealed to ensure that no laser is emitted from within the ablation chamber 54 when ablation of the nut plate 78 or another substrate is performed.

[0104] Although a Class 4 laser 58 is used, this sealed arrangement allows the laser ablation containment and debris removal system 50 to operate as a Class 1 enclosure. Therefore, the laser ablation containment and debris removal system 50 can be deployed and operated in a manufacturing environment without the need for laser safety goggles or a protective laser safety cage. This is particularly advantageous when the laser ablation containment and debris removal system 50 is used in conjunction with a portable roller station 66, as the laser ablation containment and debris removal system 50 can be effectively deployed in existing manufacturing environments without requiring the manufacturing environment to meet certain higher-level laser safety standards (e.g., requiring operators to wear laser safety goggles and / or requiring additional laser safety enclosures to enclose the SCARA).62). Therefore, the ablation chamber 54 is a fully integrated Class 1 laser safety enclosure designed to ensure safety by preventing light from the laser 58 from escaping from within the ablation chamber 54 during operation.

[0105] In another aspect of these embodiments, the umbrella-shaped member 72 can slide along an axis 86 (Figures 3 and 4) perpendicular to the focusing lens of the laser 58, which is mounted opposite to the laser protection chamber 52. This can help maintain the desired focal length of the ablated substrate within the ablation chamber 54 relative to the laser 58 based on the geometry of the ablated substrate, while also maintaining the proper seal required for operating the laser ablation containment and debris removal system 50 as a Class 1 enclosure.

[0106] Additionally, combinations of the geometry of each of the umbrella-shaped member 72, the sealing ring 80, and the upper edge 82 can vary depending on the desired size and / or shape of the component or substrate to be ablated in the laser ablation containment and debris removal system 50. For example, in the embodiments disclosed herein, each of the umbrella-shaped member 72, the sealing ring 80, and the upper edge 82 is generally depicted as cylindrical. However, in other embodiments, depending on the application, each of the umbrella-shaped member 72, the sealing ring 80, and the upper edge 82 may be made of different geometries (e.g., squares, rectangles, triangles, etc.). Furthermore, the depth of the ablation chamber 54 formed by the interaction of the umbrella-shaped member 72 with the sealing ring 80 and the upper edge 82 can also vary depending on the size and shape of the ablation component. In this regard, for example, larger components may require a greater depth, while smaller components (such as the nut plate 78 disclosed herein) may require a relatively smaller depth. Furthermore, depending on the desired application, the size and shape of the gripper 74 operated by the SCARA 62 and / or the actuating fingers 76 therein can also vary (e.g., to accommodate components of different sizes and / or surface areas). Similarly, larger parts to be cleaned by the laser ablation containment and debris removal system 50 may require relatively large grippers and / or actuating fingers, while smaller parts may require relatively small grippers and / or relatively small actuating fingers. In one embodiment, the gripper 74 may have dimensions and / or shape for manipulating scalable materials and remain controllable by SCARA 62 using input / output (“I / O”) command control. Additionally, for larger parts, an auxiliary and relatively large umbrella-shaped member may be nested over the upper edge 82 to accommodate more space below it.

[0107] In another aspect of the embodiments disclosed herein, parts within the ablation chamber 54 may generally be oriented relative to the laser 58 at an angular orientation between 90° and 180° relative to its focusing lens. In these embodiments, the laser ablation containmentThe debris removal system 50 can still operate as a Class 1 enclosure because the light from the Class 4 laser 58 is still confined within it during operation, as described above. This again provides greater flexibility, as the laser ablation containment and debris removal system 50 can be deployed in a manufacturing environment without requiring the enhanced safety protocols typically associated with higher-class laser operations (e.g., Class 1M and higher). Further integration with the SCARA 62 and the ability to position components requiring cleaning within the ablation chamber 54 without emitting any significant amount of laser light from it ensure repeatable and accurate laser operation while maintaining safety.

[0108] Figures 3 and 4 show more specifically a slot 88 formed within the sidewall 90 of the laser ablation containment and debris removal system 50, which effectively forms a natural transition between the laser protection chamber 52 and the ablation chamber 54. The slot 88 has dimensions and shape for selectively receiving and retaining the protective lens holder 60 therein, for example, as shown generally in Figure 2 and more specifically in Figure 17. In one embodiment, the protective lens holder 60 is positioned within the laser protective chamber 52, substantially perpendicular to the direction of light emitted by the laser 58 below. Thus, the laser beam from 58 travels upward through the protective lens in the holder 60 and into the ablation chamber 54 to contact the substrate requiring cleaning (such as the aforementioned nut plate 78). During ablation, debris ablated from the surface of the substrate enters the ablation chamber 54. While all debris is preferably immediately extracted from the ablation chamber 54 through the vacuum chamber 56, some debris is expected to remain there and travel back towards the laser 58. In this respect, the protective lens holder 60 acts as an intermediary to prevent protruding debris remaining in the ablation chamber 54 from contacting or otherwise damaging the output lens of the laser 58. Instead, over time, debris may accumulate or otherwise damage the protective lens in the holder 60. Therefore, the protective lens holder 60 can be periodically and selectively removed from the laser protective chamber 52 from a slot 88 in the sidewall 94. Once removed, the protective lens in the retainer 60 can be cleaned and / or selectively replaced, for example, by replacing the retainer 60 with a brand new one; or only the protective lens can be replaced, as discussed in more detail below.

[0109] The protective lens retainer 60 ensures that the laser 58 remains substantially undamaged by debris within the ablation chamber 54 during operation, while also allowing for quick and easy replacement of the protective lens retainer 60 after extensive use of the laser ablation containment and debris removal system 50 disclosed herein. Thus, the protective lens retainer 60 is able to protect the relatively expensive laser focusing lens of the laser 58 from debris and other particles within the ablation chamber 54.

[0110] Another feature of the laser ablation containment and debris removal system 50 disclosed herein is a support 92, which is removed from the ablation chamber 54.The inner wall 94 within the ablation chamber 54 protrudes inward, as best shown in Figure 6 and further shown in Figure 7. The bracket 92 cooperates with the inner wall 94 to form a space or gap 96 between them for selectively sliding into a receiving elastomeric fixture 98, such as an elastomeric fixture that may be pre-installed with any of the nut plates 78 shown in Figure 5. Thus, the SCARA 62 can selectively reposition the nut plate 78 within the ablation chamber 54 such that the lower portion 100 of the elastomeric fixture 98 (see page 14 / 28 of specification CN 121794071 A) is positioned within the V-shaped intersection 102 (Figure 6) of the bracket 92. The SCARA 62 can then selectively horizontally reposition the nut plate 78, thereby moving the lower portion 100 of the elastomeric retainer 98 within the gap 96 to engage with the V-shaped cross 102, causing the lower portion 100 to bend outward from the path of the laser 58, similar to the position shown in Figure 5 when adhesive is applied to the bottom surface of the nut plate 78 from the end 104 of the adhesive dispenser 64. In a similar manner, this moves the bottom portion of the nut plate 78 into the unobstructed path of the laser beam from the laser 58, thus allowing the nut plate 78 to be cleaned without interfering with the elastomeric retainer 98. Furthermore, the SCARA 62 can operate the gripper 74 to rotate the nut plate 78 approximately 360 degrees, allowing the incident beam from the laser 58 to ablate its entire bottom surface. Of course, the lower portion 100 of the elastomeric retainer 98 remains substantially bent outward and away from the incident beam throughout the rotation by engaging with the V-shaped cross 102 of the inwardly projecting bracket 92, as mentioned above regarding the position in Figure 5.

[0111] The ablation chamber 54 may also include one or more sensors positioned therein for real-time monitoring, such as ensuring that the ablation chamber 54 remains adequately sealed to ensure that little or no laser light is emitted from it. Such sensors may include a pressure sensor to ensure that the ablation chamber 54 is pressurized when the laser 58 is activated, a proximity sensor to ensure that the sealing ring 80 is positioned on the upper edge 82, a light sensor capable of measuring the amount of light escaping from the ablation chamber 54 during use, or another sensor known in the art capable of checking and / or verifying the sealing quality between the sealing ring 80 and the upper edge 82. Each of these one or more sensors integrated with the laser ablation containment and debris removal system 50 may be used individually or in combination with each other to improve safety before, during, and / or after the operation of the laser ablation containment and debris removal system 50.

[0112] In another aspect of these embodiments, FIG8 is a partial cross-sectional view showing more specifically the internal construction of the respective laser protection chamber 52, ablation chamber 54, and vacuum chamber 56, and FIG9 is an enlarged partial cross-sectional view taken along circle 9 in FIG8. MoreSpecifically, Figure 8 generally shows a protective lens holder 60 positioned between the laser protective chamber 52 and the ablation chamber 54 to effectively seal and isolate the laser 58 from it. Furthermore, Figure 8 also shows the ablation chamber 54 in fluid communication with a vacuum chamber 56 to allow for the extraction or removal of debris from the ablation chamber 54 during the ablation process. In this regard, the vacuum chamber 56 may include a pressure sensor 106 having an open port 108 exposed to the vacuum chamber 56 and capable of monitoring the vacuum pressure within the vacuum chamber in real time. The air pressure sensor 106 provides feedback to the ablation containment and debris removal system 50 to ensure that the ablation chamber 54 is adequately sealed before operating the laser 58, otherwise the laser ablation containment and debris removal system 50 will not activate the laser 58. The air pressure sensor 106 also provides real-time feedback during operation, thereby allowing the laser ablation containment and debris removal system 50 to actively shut down the laser 58 in the event of a predetermined pressure loss or low pressure reading in the vacuum chamber 56 during operation. Maintaining sufficient pressure within the laser ablation containment and debris removal system 50 further ensures a sufficient vacuum within chamber 26 during operation, for example, to efficiently remove debris from ablation chamber 54.

[0113] An inlet port 110 is also shown in the bottom perspective view of FIG. 7, which selectively receives pressurized fluid (e.g., from a pneumatic system), such as compressed or pressurized air, to help generate the aforementioned vacuum in ablation chamber 54. In this regard, FIG. 10 is a partial cross-sectional view showing the fluid connection between inlet port 110 and discrete pressurized air passage 112 formed between vacuum chamber 56 and ablation chamber 54. Vacuum pressure sensor 106 can ensure sufficient airflow within passage 112 to generate a suitable vacuum between inlet port 110 and outlet port 114 (FIG. 11) of vacuum chamber 56, which is sufficient to efficiently extract debris from ablation chamber 54 during operation.

[0114] Furthermore, Figure 13 shows a cross-sectional view of the laser ablation containment and debris removal system 50 in more detail, wherein the channel 112 for transporting the incoming pressurized air eventually splits into a lower conduit 116 and an upper conduit 118 at its branch 120. In this respect, Figure 14 is an alternative cross-sectional view showing that the pressurized air channel 112 splits at the branch 120 to immediately redirect the incoming pressurized air into the lower conduit 116 and the upper conduit 118.

[0115] Figure 15 shows that the lower conduit 116 is generally quasi-hemispherical and follows the geometry of the outer surface of the ablation chamber 54. The lower conduit 116 is in fluid communication with a quasi-hemispherical slit 124 leading to the interior 126 of the ablation chamber 54. Therefore, pressurized air flows out through the quasi-hemispherical slit 124 across an opening in the ablation chamber 54, thereby creating a generally horizontal air knife or air curtain.128, the air blade or air curtain is designed to significantly reduce slag and / or prevent ablation debris from traveling downwards into the laser protection chamber 52. Furthermore, the directional arrows in Figure 15 show pressurized air flowing out from the quasi-hemispherical slit 124 as the horizontal air curtain 128 is guided into the vacuum chamber 56. Therefore, any debris trapped in the horizontal air curtain 128 is immediately removed from the laser ablation containment and debris removal system 50. Thus, the air curtain 128 provides a continuously flowing layer of pressurized air that substantially prevents debris from traveling back into the laser protection chamber 52 where the protective lens holder 60 is located.

[0116] Furthermore, Figure 16 further illustrates the travel of pressurized air guided into the upper conduit 118 into the hollow portion of the support 92. Here, Figure 16 shows the support 92 including a horizontal slit 130 that forms an upwardly projecting air curtain 132. Given the proximity of the ablated surface to the horizontal slit 130, ablation debris from the target substrate is immediately pushed upwards by the air curtain 132 and naturally away from the ablated substrate, the horizontal air curtain 128, and the laser protective chamber 52. This reduces the concentration of debris that might tend to move toward the horizontal air curtain 128 and the ablated substrate. Of course, the horizontal slit 130 and the associated air curtain 132 can be slightly oriented to push pressurized air toward the vacuum chamber 56, or the horizontal slit 130 and the associated air curtain 132 can be aligned substantially vertically to maximize the upward pushing of ablation debris away from the horizontal air curtain 128, thereby essentially acting as another barrier for the protective lens holder 60. The vertical air curtain 132 also serves to push air toward the vacuum chamber 56 and away from the impacted surface of the substrate to prevent debris deposition on the just-impacted surface. This further facilitates the movement of debris into the vacuum chamber 56 for removal from the laser ablation containment and debris removal system 50 during operation.

[0117] Alternatively, the horizontal air curtain 128 and / or the vertical air curtain 132 may be angled at any position between horizontal and / or vertical, depending on the structure of the laser ablation containment and debris removal system 50 and / or the ablated component. For example, the vertical air curtain 132 may be offset by forty-five degrees to more effectively prevent ablation debris from settling back along the ablated substrate positioned within the ablation chamber 54. Furthermore, either of the curtains 128, 132 may also be positioned at an offset position relative to either the vertical plane or the horizontal plane to more effectively guide the pressurized airflow into the vacuum chamber 56. In any of these embodiments, the vacuum chamber 56 may also include one or more HEPA filters and / or one or more carbon filters to collect hazardous or harmful fumes and / or particles as needed at the outlet port 114 or elsewhere.

[0118] FIG17 shows more specifically an embodiment of a protective lens holder 60 having a structure composed ofA handle 134 formed by a pair of opposing, curved recesses 136 facilitates hand gripping, thus allowing the protective lens holder 60 to be more easily inserted into and removed from the slot 88. Furthermore, the protective lens holder 60 includes a generally circular opening 138 with a receiving channel 140 accessible through the front slot 142. This receiving channel has the size and shape for selectively receiving and holding (e.g., in a friction-fitting relationship) a protective lens 143, etc. In this respect, the receiving channel 140 effectively holds the protective lens 143 in the proper position within the laser ablation containment and debris removal system 50, allowing the beam emitted by the laser 58 to pass through it, whether orthogonally or otherwise. Simultaneously, due to its positioning between the laser protection chamber 52 and the ablation chamber 54, the protective lens 143 effectively prevents ablation debris from traveling back to the laser 58.

[0119] The protective lens holder 60 can be easily accessed by selectively gripping the outwardly extending handle 134 and pulling the arcuate recess 136 to retract the protective lens holder 60 out of engagement with the slot 88. In one embodiment, the entire assembly of the protective lens holder 60 (i.e., including the handle 134, the receiving channel 244, and the protective lens 143 therein) can be simply discarded and replaced with a new protective lens holder 60 having a clean or undamaged protective lens 143. In an alternative embodiment, once removed, the protective lens 143 can slide out of the receiving channel 140 through the front slot 142 for cleaning (e.g., removing debris that may accumulate over time) or replacement (e.g., if scratched or damaged) in case of excessive contamination. Afterwards, the cleaned or replaced protective lens 143 can be reinserted into the receiving channel 140 through the front slot 142 (see manual page 16 / 28, CN 121794071 A). Then, the components of the protective lens holder 60 can be reinserted back into the slot 88 for further use in the laser ablation containment and debris removal system 50. Once reinserted into the slot 88, the protective lens 143 is effectively wedged between the inner wall and the receiving channel 140 for secure retention. Furthermore, inserting the protective lens holder 60 into the slot 88 can activate proximity sensors, etc., to ensure that the protective lens holder 60 and the protective lens 143 are in proper position before and during operation of the laser 58.

[0120] Therefore, the laser ablation containment and debris removal system 50 disclosed herein cooperates with a SCARA 62 and a Class 4 laser 58 to achieve excellent surface preparation of nut plates 78, etc., using a Class 1 graded enclosure comprising a laser protection chamber 52 (to which the laser 58 is coupled) and an ablation chamber 54 in fluid communication with a vacuum chamber 56.During operation, debris and other fumes are extracted from the vacuum chamber. One or more air curtains 128, 132 reduce slag and prevent the ejected debris from settling back onto the protective lens in the cleaned substrate and / or retainer 60, and help facilitate directional airflow into the vacuum chamber 56. SCARA 62 ensures that the ablation chamber 54 remains properly sealed so that the user or those nearby have little or no contact with the laser during operation. Of course, the ablation chamber 54 can be modified to include the ability to laser process different surfaces at different angles, using different lengths and diameters, and can be manufactured using various methods, including 3D printing and investment casting.

[0121] Once the nut plate 78 has been ablated using the laser ablation containment and debris removal system 50, the next step is to apply an adhesive thereon, such as by using an adhesive dispenser 64 as shown with respect to Figures 1-2, 18-19, 21 and 25-26. As briefly mentioned above, the adhesive dispenser 64 addresses the problem in the art of accurately and repeatably dispensing controlled amounts of adhesive in the order of less than about 0.1 grams (“g”) by volume, while controlling the inherent “dripping” or “flowing” of the adhesive at the location where it is dispensed. In this regard, in one embodiment, the adhesive dispenser 64 can be integrated as part of a laser ablation containment and debris removal system 50, as discussed in detail above, such as by combining with the SCARA 62 as part of the transferable roller station 66 shown in Figures 1 and 2. But of course, the adhesive dispenser 64 can be integrated as part of a fixed or semi-fixed system for use in manufacturing methods that can utilize or integrate the dispenser 64 disclosed herein.

[0122] As briefly mentioned above, the SCARA 62 works in conjunction with a downwardly presented gripper 74 and an extended actuating finger 76 to automate the selective picking and moving of a substrate to receive adhesive 144 (Figure 27) (such as along the bottom surface 146 of the nut plate 78). In one embodiment, the SCARA 62 operates to position a gripper 74 relative to one of a plurality of nut plates 78 on a carrier 84 (e.g., as shown in FIG. 5), actuating fingers 76 to grip one of the nut plates 78 to remove it from the carrier 84, and then the selected nut plate 78 is transported within a laser ablation containment and debris removal system 50 for adhesive 144 to be applied by an adhesive dispenser 64.

[0123] To apply adhesive 144, and as shown in FIG. 5, the SCARA 62 selectively repositions the nut plate 78 such that the lower portion 100 of the elastomeric retainer 98 extending through the nut plate 78 slides within a slot 148 of the locator block 150, which is substantially offset from the pin 152 of the adhesive dispenser 64. The SCARA 62 can then selectively horizontally reposition the nut.Plate 78 causes the elastomeric retainer 98 to bend around the lower portion 100, as shown in FIG. 5, that is, to bend at least where the bottom surface 146 of the nut plate 78 aligns with the end 104 of the pin 152, at which point the adhesive 144 is dispensed without interference from the elastomeric retainer 98. Furthermore, the SCARA 62 can operate the gripper 74 to rotate the nut plate 78 approximately 360 degrees, thus applying the adhesive 144 dispensed from the end 104 uniformly axially to the nut plate. As discussed in more detail below, the adhesive dispenser 64 ensures that the beads of applied adhesive 144 are applied substantially uniformly to the bottom surface 146, as shown in FIG. 27. Of course, during the circumferential application of the adhesive 144, the lower portion 100 of the elastomeric retainer 98 remains substantially bent outward and away from the end 104 and rotates within the slot 148 of the locator block 150.

[0124] FIG18 shows more specifically an embodiment of the adhesive dispenser 64 as disclosed herein, including a dispensing needle. The end 104 of the needle 152 is in a generally forward position and fluidly coupled to an adhesive static mixer 154, which selectively receives fluid from a pair of liquid containment cylinders 156, 158 during operation. The needle 152 can be held in the forward position by a bracket 160 substantially coaxially aligned with the end 104 and the adhesive static mixer 154. The bracket 160 can be coupled to an extension 162, which extends in a generally perpendicular axial orientation to the needle 104 as shown in FIG19, to offset coupling to the front end 164 of a support bracket 166. The support bracket 166 can be selectively slidably positioned relative to the housing 168 of the adhesive dispenser 64 by an elongated channel 170 formed along its length. Here, the elongated channel 170 has dimensions and shape for selectively passing through the shank portion of a pair of bolts 172, which are selectively threaded into corresponding pairs of orifices formed in the housing 168. Each of the bolts 172 has a head 174 that is relatively larger than the elongated channel 170, such that when the bolt 172 is threaded into the housing 168, the corresponding head 174 cooperates with the housing 168 to clamp the support bracket 166 between them in a flush-locking engagement.

[0125] The position of the front end 164 can be selectively adjusted by at least partially releasing each of the bolts 172 from the housing 168 to release or disengage the support bracket 166 from its friction-fit engagement between the head 174 of the bolt 172 and the housing 168. Here, the support bracket 166 remains connected to the housing 168 by the bolts 172, but can be retained or residing within the elongated channel 170 by the shank of each of the bolts 172 and at least partially engaged with the threaded orifice in the housing 168.The support bracket 166 slides relative to the housing 168. Therefore, the positioning of the support bracket 166 relative to the housing 168 effectively determines the distance at which the supported needle 152 (and ultimately its extended end 104) is positioned relative to the housing 168. Once the desired positioning of the support bracket 160 holding the needle 152 is established, each of the bolts 172 can be retightened to hold or hold the support bracket 166 against the housing 168.

[0126] The top view in FIG19 and the perspective views in FIGS21-24 best illustrate that the adhesive dispenser 64 is designed to work in conjunction with a dual-canister replacement system 176, which generally comprises a pair of canisters 156, 158 (e.g., standard two-part adhesive canisters known in the art) terminating in a fluid relationship at a dual-canister cap 178 (FIG. 19), which is fluidly coupled to an adhesive static mixer 154 for delivering adhesive 144 through the needle 152 to the end 104, as will be discussed in more detail below. In one embodiment, for example, needle 152 may thread-engage one end of adhesive static mixer 154, and dual-canister cap 178 may be integrally formed with each of the canisters 156, 158 known in the art and configured for snap-fit ​​fluid connection with adhesive static mixer 154 at the end opposite the position where needle 152 thread-engages adhesive static mixer 154. In an alternative embodiment, each of needle 152, adhesive static mixer 154, a pair of canisters 156, 158, and / or dual-canister cap 178 may be manufactured individually and assembled in such a way that the liquid compound within each of canisters 156, 158 can be dispensed therefrom into dual-canister cap 178, and then mixed with each other within adhesive static mixer 154 to exit through end 104 as adhesive 144 travels through needle 152. In an alternative embodiment, dual-canister replacement system 176 may have a one-piece structure, including fabrication by means of 3D printing, etc.

[0127] As best shown in the perspective views of Figures 21-24, the dual-cylinder changing system 176 selectively engages slidably with a quick-change carrier 180, which is designed to be received via a slot in the housing 168 of the adhesive dispenser 64. Figures 22-24 show the quick-change carrier 180 comprising a plurality of outwardly extending bolts 182 having a diameter relatively smaller than the corresponding shank portions 184 of the corresponding head portions 184. Thus, each of the shank portions 184 has a diameter sized to engage via a slot within a corresponding set of receiving channels 188 formed by a pair of receiving rails 190 of the housing 168, where the corresponding head portion 186 is too large to fit. The receiving channels 188 may include generally enlarged chamfered openings formed by the receiving rails 190, these chamfered openings being designed to provide additional clearance toThis initially makes it easier to position each of the handle portions 184 in the corresponding receiving channel 188. The receiving channel 188 then tapers inward to a width slightly larger than the diameter of the handle portion 184 for better fixation. The length of the handle portion 184 between the frame 192 of the quick-change carrier 180 and the head portion 184, as per page 18 / 28 of the quick-change instruction manual (CN 121794071 A), is approximately the width of the receiving track 190 in the housing 168, to further prevent side-to-side movement of the quick-change carrier 180 when engaged with the housing 168. After the quick-change carrier 180 has fully descended into the receiving channel 188, each of the handle portions 184 can forward engage a corresponding set of locking slots 194, which are rotated forward approximately 90 degrees relative to the receiving channel 188. The quick-change carrier 180 is held forward engaged within the locking slot 194 during operation by, for example, a pair of clamp mounting assemblies 196, 198, as discussed in more detail below.

[0128] In one embodiment, the quick-change carrier 180 may include a generally open frame structure, as best shown in Figures 21 through 24. In an alternative embodiment, the quick-change carrier 180 may be housed within a thermal housing 200 (Figures 30 and 31), which is temperature-controlled by a cooler 202 (Figure 30) and / or one or more heating elements 204 (Figure 31) located within the thermal housing 200. Here, the adhesive dispenser 64 is able to control the temperature of the liquid compound within the barrels 156, 158 of the dual-barrel replaceable system 176 based on feedback from one or more temperature sensors located within the housing. For example, a single temperature sensor can continuously read the overall temperature within the quick-change carrier 180, or alternatively, a pair of temperature sensors can individually and continuously read the individual temperature of each of the cartridges 156, 158. In this latter embodiment, the adhesive dispenser 64 can individually control the temperature of each of the cartridges 156, 158 and the liquid compound within them within a specific temperature range or temperature difference. Thus, the adhesive dispenser 64 can control the temperature of the compound within the cartridges 156, 158 from which it dispenses. This feature provides greater control over the amount of fluid dispensed from each of the cartridges 156, 158 to further control the viscosity of the adhesive 144 dispensed from the tip 104 of the needle 152.

[0129] Figures 22 and 23 best illustrate a dual-cartridge replacement system 176 fully engaged with the quick-change carrier 180. Here, the frame 192 of the quick-change carrier 180 may include a front orifice 206 having a size and shape that allows the adhesive static mixer 154 to extend through. Similarly, as best shown in Figure 24, frame 192 may also include relatively largeThe rear orifice 208 has a size and shape generally capable of sliding through each of the receiving cylinders 156, 158. Simultaneously, the dual cylinder changing system 176 may also include an outwardly extending base plate 210 relatively larger than the rear orifice 208 in the frame 192 to prevent the dual cylinder changing system 176 from sliding out of the frame 192. In this respect, as best shown in FIG. 23, the base plate 210 has a surface area that selectively engages the frame 192 in a flush relationship when the chuck mounting assemblies 196, 198 are forwardly engaged with the quick-change carrier 180 within the locking slot 194 of the housing 168, as discussed in detail above.

[0130] Furthermore, when the frame 192 carrying the dual-cylinder replacement system 176 has been removed from engagement with the housing 168 (e.g., as shown in FIG. 21), the dual-cylinder replacement system 176 can be easily replaced by simply sliding it out of engagement with the frame 192 through the rear port 208, as generally shown in FIG. 24. After removal, a new (new / filled) dual-cylinder replacement system 176 (to the extent extending from it) can then be reinserted through each of the rear port 208 and the front port 206 until it is in the position generally shown in FIGS. 21 to 23. Thereafter, the quick-change carrier 180 carrying the new dual-cylinder replacement system 176 can be quickly and easily re-engaged to the housing 168 by simply sliding the shank portion 184 of the bolt 182 extending from the frame 192 back into the corresponding receiving channel 188 and the corresponding locking slot 194. Subsequently, according to the embodiments disclosed herein, the adhesive dispenser 64 can be operated to dispense adhesive 144 from the end 104 of the needle 152.

[0131] Once the shank portion 184 is fully positioned within each of the receiving channels 188, the quick-change carrier 180 can be pushed forward by the drive unit 212 to help position the shank portion 184 into the corresponding locking slot 194 to prepare for operation of the adhesive dispenser 64. Here, the drive unit 212 operates a forward-extending threaded screw 214 threadedly engaged with a piston sliding carrier 216 having a pair of collet mounting assemblies 196, 198 rigidly coupled thereto. In operation, the drive unit 212 controls the forward and backward movement of the piston sliding carrier 216 by rotating the threaded screw 214 clockwise or counterclockwise. For example, in one embodiment, clockwise rotation of the operating threaded screw 214 causes the piston sliding support 216 (see page 19 / 28 of specification, CN 121794071 A) to move forward within the housing 168, pulling each of the chuck mounting assemblies 196, 198 to engage each of the barrels 156, 158. Conversely, counterclockwise rotation of the operating threaded screw 214 causes the piston sliding support 118 to move backward within the housing 168.The movement of the chuck mounting assemblies 196, 198 disengages them from each of the barrels 156, 158.

[0132] An upright chuck clamp 218 (best shown in the side view of FIG. 18 and FIG. 25) rigidly coupled to the piston sliding support 216 selectively clamps each of the chuck mounting assemblies 196, 198 therein. Thus, as described above with respect to the threaded screw 214, movement of the piston sliding support 216 driven by the drive unit 212 results in proportional movement of the chuck mounting assemblies 196, 198. As shown in the enlarged partial cross-sectional top view of FIG. 20, each of the chuck mounting assemblies 196, 198 includes an internal piston chuck 220 threaded therein. Each piston chuck 220 terminates in an outwardly flared mandrel 222 held within a flared sleeve 224, as best shown in FIG. 28. The piston chuck 220 of the chuck mounting assemblies 196, 198 is connected to the piston head 226 by moving the relatively thin-walled flared sleeve 224 and the outwardly flared mandrel 222 of the piston chuck 220 forward into a relatively small recess 228 formed within the piston head 226 for frictional engagement. Here, the relatively thin-walled flared sleeve 224 has the capability of being positively attached to the piston head 226. Alternatively, attachment to the piston head 226 can be achieved by screwing a tapped screw 230 (FIG. 29) into the piston head 226, such as by rotating an externally accessible knob 232. In another alternative embodiment, the piston head 226 can be modified so that an internal feature can "grab" the piston head 226 from the rear. Each piston head 226 has a size and shape that extends substantially within the interior of one of the respective barrels 156, 158 to expel a liquid compound from each of the respective barrels 156, 158 into the aforementioned double barrel cap 178. Each of the piston heads 226 may be of the same or different size, depending on the size of the corresponding barrels 156, 158 and / or the liquid compound to be dispensed from them to form the adhesive 144.

[0133] More specifically, in operation, the drive unit 212 activates the threaded screw 214 to drive the piston sliding carrier 216 forward, such that the chuck mounting assemblies 196, 198 rigidly attached thereto each extend the corresponding piston chuck 220 and the corresponding piston head 226 coupled thereto into the corresponding barrels 156, 158. Thus, in response, a defined amount of liquid compound in each of the barrels 156, 158 is ejected into the dual barrel cap 178 and ultimately into the adhesive static mixer 154, in which the compound from each of the barrels 156, 158 is thoroughly mixed to form the adhesive 144, which is ultimately dispensed from the dual barrel changing system 176 through the end 104 at the end of the needle 152.

[0134] The drive unit 212 may include one or more sensors that provide real-time feedback on the viscosity of the adhesive 144 dispensed from the tip 104 of the needle 152. In one embodiment, the sensor is a force feedback sensor that monitors changes in current and / or voltage within the drive motor of the drive unit 212. In response to information from the force feedback sensor, the drive unit 212 adjusts the operation of the threaded screw 214 to dispensing the liquid compound from the respective barrels 156, 158. For example, a higher current and / or voltage is an indication that the adhesive 144 has a relatively high viscosity (i.e., the adhesive 144 cures more than expected before being dispensed from the tip 104). Here, the drive unit 212 can adjust the operation of the threaded screw 214 to dispense the adhesive 144 by increasing the drive rate of the barrels 156, 158. Simultaneously, the drive unit 212 can communicate with the SCARA 62 to ensure that the nut plate 78 rotates at a sufficient speed to ensure that the adhesive 144 dispensed from the end 104 is still applied uniformly circumferentially along the bottom surface 146 of the nut plate 78 at an increasing rate, as shown in FIG27. Conversely, when the force feedback sensor determines that the viscosity of the adhesive 144 is lower than desired, the drive unit 212 can reduce the operation of the threaded screw 214 to dispensing the adhesive 144 by reducing the drive rate of the barrels 156, 158. Similarly, for example, the drive unit 212 can communicate with the SCARA 62 to ensure that the nut plate 78 rotates at a sufficient speed to ensure that the adhesive 144 dispensed from the end 104 is still applied uniformly circumferentially along the bottom surface 146 of the nut plate 78 at a decreasing rate, as shown in FIG27. Therefore, the force feedback sensor can monitor electronic feedback to control the dispensing volume of the adhesive 144 by taking into account changes in the viscosity of the adhesive 144. Specification 20 / 28 pages 30 CN 121794071 A

[0135] In alternative embodiments, the drive unit 212 may include additional or alternative sensors that provide alternative and / or additional feedback. For example, in one embodiment, a temperature sensor may also provide feedback on ambient and adhesive temperatures, so the drive unit 212 can better calculate the viscosity of the adhesive 144 based on the curing rate within the dual-barrel changing system 176. For example, in some embodiments, higher temperatures may cause the mixture of liquid compounds within the adhesive static mixer 154 to cure faster than at lower temperatures, and vice versa. Therefore, the drive unit 212 may adjust the operating rate of the threaded screw 214 to ensure that the adhesive 144 dispensed from the end 104 continues to have a consistent viscosity. Additionally, in other embodiments, other sensors known in the art for assisting in determining the viscosity of the adhesive 144 may also be integrated with the drive unit 212. RegardlessWhether the measurement is performed in real time or periodically, the feedback system can optimize and adjust the drive motor as needed to dispense the adhesive 144 with greater accuracy and repeatability.

[0136] In an alternative embodiment, the adhesive dispenser 64 may include additional “smart” features, such as a timer system and / or a vision system, to provide additional feedback on the physical state of the adhesive 144 dispensed from the end 104. Such information can be used to further improve the reliability and repeatability of the adhesive dispenser 64 as disclosed herein, i.e., to apply the adhesive 144 to small parts (e.g., for aircraft, etc.) in a repeatable and reliable manner.

[0137] After the adhesive 144 has been fully circumferentially applied along the bottom surface 146 of the nut plate 78, the drive unit 212 aborts the forward movement of the piston sliding support 216 to stop the flow of adhesive 144 from the end 104 of the needle 152, while the SCARA 62 selects another nut plate to which the adhesive 144 needs to be applied. However, simply stopping the forward movement of the threaded screw 214 may not necessarily cause the adhesive 144 to completely stop dispensing from the end 104; that is, this is the so-called "dripping" or "flowing" problem known in the art caused by residual pressure within the dispensing system. Therefore, to correct this problem, the drive unit 212 not only stops the forward movement of the threaded screw 214, but also immediately reverses the threaded screw 214 a predetermined distance to pull each of the piston heads 226 backward within the barrels 156, 158, thereby creating back pressure or vacuum therein to stop or halt any potential forward movement of the adhesive 144 remaining in the adhesive static mixer 154, the needle 152, and ultimately at the end 104. The drive unit 212 can achieve this retraction by the rigid engagement of the piston chuck 220 with the corresponding recess 216 in the respective piston head 226. In this way, the drive unit 212 can operate the threaded screw 214 to prevent so-called "dripping" or "flowing". For example, in one embodiment, the corresponding piston head 226 can be retracted within the barrels 156, 158 by a tapping screw 230 screwed into the piston head 226, thereby causing the adhesive 144 to also be "pulled back" to reduce or stop "dripping" or "flowing" at the end 104. The amount of retraction can depend on a variety of factors, including the type of adhesive 144 and feedback received by the drive unit 212 from one or more sensors integrated with the automatic adhesive dispenser 64. As an example, when the force feedback sensor measures in real time, the drive unit 212 can determine that the threaded screw 214 needs to retract a greater distance when the adhesive 144 has a relatively low viscosity, and vice versa.

[0138] When the dual barrel changing system 176 needs to be replaced, the piston chuck 220 disengages from each of the piston heads 226, so that the chuck mounting assemblies 196, 198 are no longer rigidly connected to the barrels 156, 158. This disengagement is achieved via the chuck mounting assemblyThis is achieved by one or both of the outwardly extending flanges 236 (Figures 18 and 19) of components 196, 198, internally located within a sliding bracket 234 in each of the chuck mounting assemblies 196, 198. During normal operation, an inwardly projecting step 238 of the sliding bracket 234 abuts against a washer 240 spring-biased in a forward position by a spring 242 positioned within a retraction channel 244. Pulling each of the flanges 236 backward toward the drive unit 212 causes the sliding bracket 234 to move relative to the chuck mounting assemblies 196, 198, such that the inwardly projecting step 238 contacts the washer 240 to compress the spring 242 within the retraction channel 244. In this respect, a central inwardly projecting step 246 (Figure 28) may extend between the coils of the spring 242 to aid in compressing the spring 242. Therefore, the sliding bracket 234 can move a predetermined distance relative to the chuck mounting assemblies 196, 198, the predetermined distance being set along the length of one or more pull-back channels 248 positioned along the length of the sliding bracket 234, in which a sliding pin 250 is positioned. The rearward movement of the sliding bracket 234 can also be terminated by a step or stop 252 at the location forming the flange 236. This retraction causes the piston chuck 220 to be withdrawn from its corresponding recess 228, thereby disengaging each of the chuck mounting assemblies 196, 198 from the cylinders 156, 158 of the dual-cylinder changing system 176. In this way, the physical attachment to the piston head 226 within the dual-cylinder changing system 176 can be quickly disconnected from the chuck mounting assemblies 196, 198 by a release mechanism operated by the sliding bracket 234. Once disconnected, the dual-cylinder replacement system 176 can be cleanly and easily replaced by removing the quick-change carrier 180 from the housing 168, thus allowing the removal and replacement of the dual-cylinder replacement system 176, as discussed in detail above.

[0139] Another feature of the adhesive dispenser 64 is an adhesive removal system that automatically dispenses adhesive 144 to a waste location when the adhesive's "working life" expires.

[0140] To this end, the adhesive dispenser 64 addresses the problem of accurate and repeatable volumetric dispensing of adhesive, such as from the two-part cylinders, by controlling the amount dispensed onto components (such as the bottom surface 146 of the nut plate 78 shown in FIG. 27) using one or more sensors that measure the viscosity of the adhesive in real time. Furthermore, the adhesive dispenser 64 includes a "pull-back" chuck mounting feature that allows the dispenser 64 to retract the piston head 226 within the cylinders 156, 158 to control the inherent "dripping" and / or "flowing" of adhesive 144 at the location of the dispensed material caused by residual pressure within the dispensing system.

[0141] In another aspect of the systems and methods disclosed herein, the substrate ablation and debris removal system 254 (shown in Figures 32 through 47) can be integrated with the laser ablation containment and debris removal system 50 and / or the adhesive dispenser 64 as another step or station to provide a more flexible, efficient, and consistent method for cleaning parts and adhesively securing them to the substrate. More specifically, as shown in Figure 32, a collaborative robot (“cobot”) 256 is coupled to the substrate ablation and debris removal system 254 via a mounting base 258 that selectively engages a housing 260 containing an infrared laser 262 (e.g., a Class 4 laser), as best shown in Figure 32. The infrared laser 262 generates a laser beam that transmits infrared light through the mounting base 258, through the laser protection zone 264, and into the Class 1 ablation housing 266 to ablate the parts or substrate therein. In the embodiments disclosed herein, the infrared laser 262 can be used to ablate a substrate, such as a bracket 268 (e.g., as shown in Figures 36-38), to prepare the bracket 268 for mounting a nut plate 78 thereon via adhesive 144. Of course, according to the embodiments disclosed herein, the infrared laser 262 can be used to ablate other substrates, such as aircraft wings (or other surfaces of aircraft or vehicles). Therefore, the mounting base 258 is designed to secure the infrared laser 262 in a suitable position cooperating with the laser protection zone 264 and the ablation housing 266 to prepare the bracket 268 for adhesively receiving the nut plate 78 by removing debris (e.g., primer, etc.) from the bracket 268 without damaging the material composition of the ablated bracket 268. For this purpose, the mounting base 258, housing 260, laser protection zone 264, and ablation housing 266 cooperate to operate the Class 4 infrared laser 262 within a Class 1 graded housing. Therefore, the infrared laser 262 can be operated in a safer manner, eliminating the need for the operator to wear goggles and / or otherwise require an additional laser safety housing.

[0142] Figures 33 to 35 show more specifically a mounting base 258 mounted to the top or upper portion of a laser protection zone 264 having a generally conical or truncated conical construction. The laser protection zone 264 and the ablation housing 266 are generally defined separately by another selectively removable and replaceable protective lens holder 60' (Figure 17) positioned between them, for example, as best shown in Figures 33 and 34. The protective lens holder 60' completely or substantially seals and isolates the laser protection zone 264 from the ablation housing 266, so that the laser lens within the housing 260 is not affected by dispersed debris and / or other particulate matter impacted from the target support 268 during ablation.

[0143] In addition, the substrate ablation and debris evacuation system 254 may also include a dust extraction system in fluid communication with the ablation shell 266.Extractor 270, for example, is best shown in the cross-sectional views of Figures 39 and 42. In this respect, extractor 270 is designed to continuously remove debris selectively ablated from the support 268 in the ablation housing 266 by infrared laser 262 (Figure 32). In normal operation, infrared laser 262 emits a beam that travels through laser protection zone 264, through a selectively removable and replaceable protective lens holder 60' positioned between laser protection zone 264 and ablation housing 266, and into ablation housing 266 to selectively clean the support 268 enclosed therein. The debris ablated from the support 268 within ablation housing 266 is then removed from the ablation housing by a vacuum generated within substrate ablation and debris evacuation system 254 to fluidly extract or remove debris from within ablation housing 266, as discussed in more detail below.

[0144] Similar to the laser ablation containment and debris removal system 50 and the adhesive dispenser 64, the substrate ablation and debris evacuation system 254 can also be used as part of the transferable roller station 66', for example, as shown in FIG32. However, the substrate ablation and debris evacuation system 254, the cobot 256, and related components (such as the mounting base 258, housing 260, infrared laser 262, laser protection zone 264, ablation housing 266, and / or fume extractor 270) can certainly be integrated as part of a fixed or semi-fixed system for use in manufacturing methods that can more permanently utilize or integrate the substrate ablation and debris evacuation system 254 as disclosed herein. In another alternative embodiment, any robotic arm known in the art can be used instead of the cobot 256.

[0145] As best shown in Figures 33 to 35, the ablation housing 266 includes a relatively rigid base 272 having a lower sealing member 274 (best shown in Figure 44) coupled to its upper surface 276, which cooperates with an upper sealing member 278 extending outward from one end of the laser protection zone 264 generally opposite the mounting base 258. In one embodiment, the base 272 coupled with the lower sealing member 274 can be selectively moved relative to the upper sealing member 278 by coupling to a linear actuator or pneumatic piston 280. Here, the piston 280 can move the base 272 between an open position (Figures 33 to 34 and Figures 36 to 37) and a closed position (Figure 38). To provide additional stability during movement between the open and closed positions, the base 272 may include a pair of upwardly extending guide posts 282 that selectively slide within a corresponding pair of sliding channels 284 (Figures 45 and 47), which are supported by a pair of supports extending outward from the outer surface 288 (Figure 36).Foot 286 is formed. The pair of guide posts 282 effectively prevent the base 272 from rotating relative to the laser protection zone 264 during its pneumatic movement.

[0146] The lower sealing member 274 includes an upright circumferential sidewall 290 terminating at an upper edge 292, thereby forming an inner cavity 294 therein. The upper edge 292 is a generally flat surface designed to engage flush with the bottom surface 296 of a carrier 298 (Figures 36 to 38), which is connected to one or more of the supports 268. Similarly, the upper sealing member 278 includes a downwardly projecting circumferential sidewall 300 terminating at a lower edge 302, thereby forming an inner cavity 304 (Figure 35). The lower edge 302 is a generally flat surface designed to engage flush with the top surface 306 of a carrier 298, which is connected to one or more of the supports 268. Furthermore, each of the cavities 294, 304 is generally wider and / or has sufficient depth to completely surround and enclose the target support 268 or other components that can be used in conjunction with the substrate ablation and debris evacuation system 254 when resting on the respective bottom surface 296 and top surface 306 of the carrier 298. Each of the lower sealing member 274 and / or the upper sealing member 278 may be made of at least slightly compressible foam or rubber material such that the target support 268 or other components are vacuum-sealed therein when placed on the respective surfaces 296, 306. However, in other embodiments, the lower sealing member 274 and / or the upper sealing member 278 may be made of other materials, provided that the lower sealing member 274 and the upper sealing member 278 can form the vacuum seal disclosed herein. Compressing the sealing members 274, 278 against the surfaces 296, 306 ensures that no laser is emitted from within the ablation housing 266 when the infrared laser 262 is operated.

[0147] Therefore, in one embodiment, the depth of the respective cavities 294, 304 can be selected to provide compatibility with target components of different sizes, such as the bracket 268 shown in Figures 36 to 38. In the embodiment shown in Figures 36 to 38, the upper edge 292 of the lower sealing member 274 rests on the bottom surface 296 of the carrier 298 to form a circumferential seal below the bracket 268, and the lower edge 302 of the upper sealing member 278 rests on the top surface 306 of the carrier 298 to form a circumferential seal above the bracket 268 (including above the substrate 308 and the upwardly extending flange 310). Here, the sealing members 274, 278 sandwich the carrier 298 between them and effectively seal the bracket 268 therein. This seal helps prevent light from the infrared laser device 262 from escaping from the ablation housing 266 and helps to create a vacuum therein. Of course, in alternative embodiments, the sealing structureThe dimensions of each of components 274 and 278 may be varied and / or selectively removable and / or replaceable, for example, in cases where sealing components 274 and 278 wear over time, or in cases where different sizes of sealing components 274 and 278 are required for component compatibility.

[0148] In the operation shown in Figures 36 to 38, the cobot 256 first operates to position the ablation housing 266 such that the upper sealing component 278 is positioned on one of the supports 268 in the carrier 298 to be ablated, for example, as shown in Figure 36. Then, the cobot 256 lowers the assembly so that the lower edge 302 of the upper sealing component 278 rests on the top surface 306 of the carrier 298, thereby enclosing the support 268 (including the substrate 308 and the upwardly extending flange 310) therein. The upper sealing component 278 forms a generally hermetically sealed seal with the top surface 306, as shown in Figure 37. In some embodiments, this seal may be sufficient to form a Class 1 enclosure, for example, when the ablation is too large to clamp onto surfaces such as aircraft wings or other surfaces. In another embodiment, cobot 256 may activate piston 280 to pull the upper edge 292 of the lower sealing member 274 upward to engage it with the bottom surface 296 of the carrier member 298, as shown in FIG38. When in this position, the lower sealing member 274 and the upper sealing member 278 work together to form an hermetically or substantially hermetically sealed seal, with the carrier member 298 clamped between them. Here, the ablation enclosure 266 is effectively sealed to prevent or substantially prevent the escape of light emitted by the infrared laser 262 from the ablation enclosure 266. Thus, the Class 4 infrared laser 262 operates within a Class 1 graded enclosure within the substrate ablation and debris evacuation system 254. Here, the infrared laser 262 is considered to be able to operate safely in the manufacturing environment without requiring additional safety precautions such as goggles or laser safety cages, as discussed above. This is particularly advantageous when the substrate ablation and debris evacuation system 254 is used in conjunction with the portable roller station 66', as the substrate ablation and debris evacuation system 254 can be effectively deployed anywhere, including in existing manufacturing environments, without requiring the production environment to meet certain higher-level laser safety standards (e.g., requiring operators to wear laser safety goggles or constructing laser safety cages to enclose the cobot 256 and its components). Therefore, the ablation housing 266 is a fully integrated Class 1 laser safety housing designed to ensure safety by preventing light from the infrared laser 262 from escaping from within the ablation housing 266 during operation.

[0149] The geometry of each of the lower sealing member 274 and the upper sealing member 278 can be varied at angles according to the desired size and / or shape of the support, component, or substrate to be ablated in the substrate ablation and debris evacuation system 254.As you can see, the lower sealing member and the upper sealing member are interchangeable. For example, in some embodiments disclosed herein, each of the lower sealing member 274 and the upper sealing member 278 is generally depicted as cylindrical, and the upper sealing member 278 is generally attached to a laser protection zone 264 having a conical shape. In other embodiments, depending on the application, each of the lower sealing member 274 and the upper sealing member 278 may be made of different geometries (e.g., square, rectangular, triangular, etc.). Furthermore, the depth of the ablation shell 266 formed by the generally hollow cavities 294, 304 of the lower sealing member 274 and the upper sealing member 278, or in embodiments where the lower sealing member 274 is not required, by only the hollow cavity 294 of the upper sealing member 278, can also vary depending on the size and shape of the ablated part or surface. In this respect, for example, larger parts may require a deeper depth, while smaller parts (such as the bracket 268 disclosed herein) may require a relatively shallower depth. Additionally, the size of the opening between the lower sealing member 274 and the upper sealing member 278 may also vary in height based on the length of the piston 280 and the support guide post 282, for example, to accommodate larger or smaller components therein.

[0150] In another aspect of the embodiments disclosed herein, one or more surfaces to be cleaned within the ablation housing 266 may generally be oriented at an angle between 90° and 180° relative to the focusing lens of the infrared laser 262. For example, in the embodiments shown in Figures 36-38, the substrate 308 is positioned at approximately 90° relative to the focusing lens of the infrared laser 262 by means of its surface plane being positioned generally perpendicular to the ablation beam. Alternatively, the laser protection zone 264 may be internally adjusted so that the emitted beam better ablates the one or more surfaces to be cleaned. For example, in one embodiment, to prepare a surface perpendicular or orthogonal to the focusing lens of the infrared laser 262 (pages 24 / 28, CN 121794071 A), the housing 260 can be angle-coupled to the mounting base 258 to offset the beam angle, such that the infrared laser 262 is not concentric or otherwise centered within the laser protection zone 264. Here, and even in embodiments where the laser beam is concentric within the laser protection zone 264, adding one or more adjustable fixing devices (such as mirrors 311 (FIG. 39)) within the laser protection zone 264 can be used to redirect the beam path to ablate surfaces offset upwards by 180° relative to the focusing lens of the infrared laser 262. Furthermore, positioning one or more prisms 313 within the interior of the laser protection zone 264 can split the beam into multiple beams to simultaneously ablate multiple surfaces. In this embodiment, these internally located mirrors 311 and / or prisms 313 can allow simultaneous ablation of the substrate 308 substantially perpendicular to the beam path and deflected beams.A flange 310 extending upwards approximately 180° along the beam path. Of course, depending on the application, the prism 313 can be used alone or in combination with one or more of the mirrors 311 mentioned above. Mirrors 311 and / or prisms 313 can be mounted to a pivot 315 (e.g., a single-plane or multi-plane pivot similar to a ball-and-socket joint) and can be repositioned in real-time within the laser protection zone 264 during the ablation process. Modifying the laser protection zone 264 to include mirrors 311 and / or prisms 313 helps prepare and clean hard-to-reach surfaces that may not be easily accessible within the straight beam path.

[0151] Additionally, the laser protection zone 264 can be further modified to include an external mount or bracket to help maintain the alignment of the infrared laser 262 perpendicular to the target workpiece (such as a bracket 268). Additionally, the length and diameter of the laser protection zone 264 can be varied to accommodate the desired laser processing area and different focal lengths. These and other modifications, as disclosed herein, enhance the versatility and functionality of the laser protection zone 264, making it more efficient and effective in a range of applications.

[0152] As shown in the cross-sectional views of Figures 35 and 39, the laser protection zone 264 includes a slot 312 formed within its sidewalls for selectively receiving and retaining the protective lens holder 60' therein. This creates a natural transition between the end of the laser protection zone 264 and the beginning of the ablation housing 266. The beam of the infrared laser 262 travels through the protective lens holder 60' and into the ablation housing 266 to contact components requiring cleaning, such as the aforementioned bracket 268. During ablation, debris ablated from the surface of the bracket 268 (e.g., the substrate 308 or the upwardly extending flange 310) enters the ablation housing 266. While all debris is preferably immediately removed from the ablation housing 266 by the fume extractor 270, some debris is expected to remain there and may have a tendency to travel back toward the infrared laser 262. In this respect, the protective lens holder 60' serves as an intermediary to prevent protruding debris remaining within the ablation housing 266 from contacting or otherwise damaging the output lens of the infrared laser 262, similar to the lens 60 discussed above. Over time, debris may accumulate or otherwise damage the protective lens 143 within the protective lens holder 60', rather than the relatively more expensive laser lens. Given that the protective lens holder 60' is selectively removable and replaceable within the slot 312, if the protective lens 143 is damaged or contains excessive debris, it can be periodically removed for cleaning and replacement.

[0153] In one embodiment, the protective lens holder 60' may have the same or similar structure as disclosed above and shown with respect to the protective lens holder 60 of FIG. 17 for protecting the laser 58. For example, the protective lens holder 60' may also include a handle 134 formed by a pair of opposing arcuate recesses 136 for easy hand gripping, thus the protective lens holder60' can be more easily inserted into and / or removed from the slot 312. Furthermore, the protective lens holder 60' can similarly include a generally circular opening 138 having a receiving channel 140 accessible through the front slot 142, the receiving channel having the size and shape for selectively receiving and retaining (e.g., in a friction-fit relationship) the protective lens 143, etc. In this respect, similar to the above, the receiving channel 140 holds the protective lens 143 in the proper position within the substrate ablation and debris removal system 254 to allow the beam emitted by the infrared laser 262 to pass through it, whether orthogonally or otherwise. Simultaneously, due to its positioning between the laser protection zone 264 and the ablation housing 266, the protective lens 143 effectively prevents ablation debris from traveling back to the infrared laser 262.

[0154] The protective lens 143 can be easily accessed by selectively gripping the outwardly extending handle 134 and pulling the arcuate recess 136 to retract and disengage the protective lens holder 60' from the slot 312. In one embodiment, the entire assembly of the protective lens holder 60' (i.e., including the handle 134, the receiving channel 140, and the protective lens 143) can be simply discarded and replaced with a new protective lens holder 60' having a clean or undamaged protective lens 143. In an alternative embodiment, once removed, the protective lens 143 can slide out of the receiving channel 140 through the front slot 142 for cleaning (e.g., removing debris that may accumulate over time) or replacement (e.g., if scratched or damaged). Subsequently, the cleaned or replaced protective lens 143 can be reinserted into the receiving channel 140 through the front slot 142, and then the components of the protective lens holder 60 can be reinserted back into the slot 312 for further use in the substrate ablation and debris evacuation system 254. Once reinserted into the slot 312, the protective lens 143 can be effectively wedged between the inner wall and the receiving channel 140 for secure retention. Furthermore, inserting the protective lens holder 60' into the slot 312 can activate proximity sensors, etc., to ensure that the protective lens holder 60' is in the proper position before and during operation of the laser 262.

[0155] In operation, when the housing 266 is in a sealed relationship with the carrier 298 (e.g., as shown in FIG. 38), the substrate ablation and debris evacuation system 254 can pressurize the housing 266 and the corresponding fume extractor 270 (FIG. 42) fluidly connected thereto to create a vacuum therein, thereby extracting debris through the fume extractor 270 during operation. Here, the air pressure sensor 314 may include an open port 316 (FIGs 40 and 43-44) fluidly connected to the fume extractor 270 to measure the ablation of the housing.The real-time pressure within 266 and the fume extractor 270 ensures that one or both of the lower sealing member 274 and the upper sealing member 278 form an airtight seal with, for example, the carrier 298. The presence of this pressure difference verifies the closure and sealing of the ablation housing 266, thereby ensuring the continued operation of the Class 4 infrared laser 262 within the Class 1 housing and ensuring that debris ablated from the target workpiece during its operation is efficiently removed from the ablation housing 266. This pressurization can be achieved using a pneumatic system utilizing compressed air.

[0156] In another aspect of the embodiments disclosed herein, the substrate ablation and debris evacuation system 254 may also include a gripper 318, which generally comprises a pair of fingers 320 operated by, for example, an air solenoid valve 322 or a similar pneumatic or electric actuator to facilitate manipulation of stretchable materials, such as the elastomeric retainer 98 shown in Figures 5 through 7. Here, the finger 320 is pneumatically operated by the air solenoid valve 322 to compress against one end of the elastomeric retainer 98 and establish a gripping relationship therewith. Therefore, the cobot 256 can then pull down the elastomeric retainer 98 to engage the nut plate 78, which is attached thereto and has adhesive 144 underneath, with the substrate 308. In these embodiments, the gripper 318 and / or the aforementioned pneumatic sealing system can be integrated with and controlled by a robotic system utilizing input-output (“I / O” commands.

[0157] Depending on the desired application, the size and shape of the gripper 318 and / or the actuated finger 320 operated by the cobot 256 can also vary (e.g., to accommodate parts of different sizes / shapes). Similarly, larger parts to be cleaned by the substrate ablation and debris evacuation system 254 may require a relatively large gripper and / or relatively large actuated finger, while smaller parts may require a relatively small gripper and / or relatively small actuated finger. In one embodiment, the gripper 318 may have a size and / or shape for manipulating a stretchable material (such as the aforementioned elastomeric fixing device 98) and be controllable by the cobot 256 using input / output (“I / O” command control.

[0158] In another aspect of these embodiments, Figures 39 and 41-42 are cross-sectional views showing more specifically the internal construction of the respective laser protection zone 264, ablation housing 266, and fume extractor 270. More specifically, Figures 39 and 42 generally show a protective lens retainer 60' positioned between the laser protection zone 264 and the ablation housing 266 to effectively seal and isolate the infrared laser 262 from its seal. Furthermore, Figures 39 and 42 also show the ablation housing 266 in fluid communication with the fume extractor 270, such as through an opening 324 between them, to allow for the extraction or removal of debris from within the ablation housing 266 during the ablation process. As aboveAs briefly mentioned in the text and as shown in Figure 40, the fume extractor 270 may include an air pressure sensor 314, and an open port 316 may be exposed to the fume extractor 270 and be able to monitor the vacuum pressure in the fume extractor in real time. The air pressure sensor 314 provides feedback to the substrate ablation and debris evacuation system 254 to ensure that the ablation housing 266 is completely sealed before operating the infrared laser 262. The air pressure sensor 314 may also help ensure that the vacuum within the fume extractor 270 is sufficient during operation, for example, to ensure efficient removal of debris from the ablation housing 266 during use of the substrate ablation and debris evacuation system 254.

[0159] Alternatively or additionally, the ablation housing 266 may also include sensors positioned therein for real-time monitoring, such as ensuring that the ablation housing 266 remains adequately sealed so that light from the infrared laser 262 does not escape during use. This helps ensure that the substrate ablation and debris evacuation system 254 continues to operate as a Class 1 enclosure even when a Class 4 laser is used. Such sensors may include pressure sensors equivalent to air pressure sensors 314 to further ensure that the ablation enclosure 266 remains pressurized when the infrared laser 262 is activated. In another embodiment, the ablation enclosure 266 may include one or more proximity sensors to help ensure that the lower sealing member 274 is properly positioned on the bottom surface 296 of the carrier 298 and / or to ensure that the upper sealing member 278 is properly positioned on the top surface 306 of the carrier 298. In another embodiment, the ablation enclosure 266 may include a light sensor capable of measuring the relative amount of light escaping from the ablation enclosure 266 during use. In this embodiment, a light curtain may be used to protect the sensor from inaccurate readings caused by ambient light in the production environment. Alternatively, other sensors known in the art may be used, provided they are capable of inspecting and / or verifying the seal quality between the sealing members 274, 278 and the carrier 298 and providing real-time feedback, so that the substrate ablation and debris evacuation system 254 can shut down the infrared laser 262 if the housing no longer meets Class 1 standards. Each of these one or more sensors integrated with the substrate ablation and debris evacuation system 254 may be used individually or in combination with each other to improve safety before, during, and / or after the operation of the substrate ablation and debris evacuation system 254.

[0160] As best shown in Figures 42 to 44, the inlet port 326, generally formed between the laser protection zone 264 and the fume extractor 270, selectively receives pressurized fluid, such as compressed or pressurized air from a pneumatic system. More specifically,Figures 42 and 44 show that inlet port 326 is fluidly connected to channel 328, which carries incoming pressurized air downward between fume extractor 270 and ablation housing 266. The pressurized air is used to create the aforementioned vacuum to extract debris through fume extractor 270. Therefore, the aforementioned air pressure sensor 314 in fume extractor 270 can ensure sufficient airflow within channel 328 to create a proper vacuum between inlet port 326 and outlet port 330 of fume extractor 270 (Figures 33 to 35 and Figures 40 to 42), thereby extracting debris from ablation housing 266 during operation.

[0161] Figures 45 and 46 show that pressurized air channel 328 eventually branches into lower conduit 332 and upper conduit 334 at its branch 336. From here, Figures 45 through 47 best illustrate that the lower conduit 332 is generally hemispherical and follows the curved inner surface 338 of the ablation housing 266. The lower conduit 332 is in fluid communication with a lower hemispherical slit 340 leading to an internal opening 342 of the ablation housing 266. Therefore, pressurized air flows out through the lower hemispherical slit 340 across the internal opening 342 to create a lower air knife or air curtain 344 (as indicated by one set of directional arrows), which is designed to significantly reduce slag and / or prevent ablation debris from traveling into the laser protection zone 264. The lower hemispherical slit 340 is positioned slightly above the internal opening 324 between the ablation housing 266 and the fume extractor 270, such that the pressurized air flowing out of the lower hemispherical slit 340 as the lower air curtain 344 provides a certain downward pressure to the opening 324 for eventual extraction through the fume extractor 270. Therefore, the lower air curtain 344 provides an initial barrier by providing a first layer of continuously flowing pressurized air across the internal opening 342 to redirect or prevent upward-projected ablation debris from traveling toward the protective lens holder 60' and the laser protection zone 264.

[0162] Furthermore, Figures 45 to 47 also show that the upper conduit 334 is generally hemispherical and also follows the curved inner surface 338 of the ablation shell 266, which is proportionate to the lower conduit 332. Here, the upper conduit 334 is in fluid communication with the upper hemispherical slit 346 leading to the internal opening 342 of the ablation shell 266. Therefore, pressurized air flows out through the upper hemispherical slit 346 across the internal opening 342 in the ablation shell 266 (pages 27 / 28, CN 121794071 A) to create a second upper air knife or air curtain 348, which is designed to reduce any residual slag and / or ablation debris that may escape or otherwise travel around the lower air curtain 344. Because it is located above the lower hemispherical slit 340, the pressurized air exiting from the upper hemispherical slit 346 exerts additional downward pressure to...To counteract any upward-moving ablation debris, the upper hemispherical slit 346 and upper air curtain 348 provide a second barrier designed to deflect debris and other particulate matter away from the laser protection zone 264 and into the fume extractor 270 through the opening 324 in fluid communication with the ablation housing 266.

[0163] When each of the sealing members 274, 278 rests on the respective surfaces 296, 306 of the carrier 298, the fume extractor 270 is completely enclosed by the ablation housing 266 and facilitates efficient removal of contaminants through a tight vacuum seal therewith, which prevents the user from being exposed to harmful airborne particles. Thus, the vacuum generated within the fume extractor 270 extracts the smoke and other particles generated by laser processing within the ablation housing 266. In one embodiment, the fume extractor 270 may, if desired, have one or more HEPA filters and / or one or more carbon filters to collect these hazardous or harmful smoke and / or particles at the outlet port 330 or elsewhere. Air pressure sensor 314 acquires real-time pressure readings from within fume extractor 270 to provide feedback to substrate ablation and debris evacuation system 254 regarding the quality of the vacuum therein, ensuring that the ablation housing 266 remains sealed for safety purposes. If the pressure drops below a predetermined threshold, substrate ablation and debris evacuation system 254 can shut off infrared laser 262 in real time to halt the ablation process.

[0164] Laser protection zone 264, ablation housing 266, and / or fume extractor 270 can be manufactured using various manufacturing methods, such as 3D printing using FDM, 3D printing using SLA resin, 3D printing using SLS, investment casting of internal channels (e.g., channel 328) using wax cores, or machining. The shape of substrate ablation and debris evacuation system 254 is not necessarily limited to a conical shape and can be designed as a box or any other shape as needed.

[0165] Additionally, the substrate ablation and debris evacuation system 254 can also be used with alternative methods for surface preparation / activation, such as dry ice, plasma, and media blasting. These alternative methods offer additional flexibility in selecting the most suitable method for surface ablation, depending on specific manufacturing, assembly, or repair needs.

[0166] Thus, generally, the substrate ablation and debris evacuation system 254 is configured to use a Class 4 infrared laser 262 within a Class 1 laser safety enclosure, which includes a generally aligned laser protection zone 264 to emit a beam that passes through a protective lens holder 60' and enters an ablation enclosure 266 fluidly connected to a fume extractor 270, wherein debris and other fumes are evacuated from the substrate ablation and debris evacuation system 254 during operation. One or more air curtains 344, 348 help reduce slag and prevent impacted debris from settling back onto the cleaned substrate and / or protective lens.The protective lens 143 within the retainer 60' and helps to promote directional airflow into the fume extractor 270. The cobot 256 ensures that the two-piece ablation housing 266 remains properly sealed, thereby emitting little or no laser light during operation. Of course, the ablation housing 266 can be modified to include the ability to laser process different surfaces at different angles, using different lengths and diameters, and can be manufactured using various methods, including 3D printing and investment casting, as mentioned above.

[0167] Although several embodiments have been described in detail for illustrative purposes, various modifications can be made without departing from the scope and spirit of the invention. Therefore, the invention is not limited except by the appended claims. Instruction manual page 28 / 28, page 38, CN 121794071 A, Figure 1; Instruction manual figure 1 / 45, page 39, CN 121794071 A, Figure 2; Instruction manual figure 2 / 45, page 40, CN 121794071 A, Figure 3; Instruction manual figure 3 / 45, page 41, CN 121794071 A, Figure 4; Instruction manual figure 4 / 45, page 42, CN 121794071 A, Figure 5; Instruction manual figure 5 / 45, page 43, CN 121794071 A, Figure 6; Instruction manual figure 6 / 45, page 44, CN 121794071 A, Figure 7; Instruction manual figure 7 / 45, page 45, CN 121794071 A, Figure 8; Instruction manual figure 8 / 45, page 46, CN 121794071 A, Figure 9; Instruction manual figure 9 / 45, page 47, CN 121794071 A, Figure 10. Figure 11 of Figure 12 (Page 45, CN 121794071 A) Figure 13 of Figure 14 (Page 45, CN 121794071 A) Figure 15 of Figure 16 (Page 16, CN 121794071 A) Figure 17 of Figure 18 (Page 18, CN 121794071 A)Figure 19 Appendix to the Instruction Manual, Page 19 / 45, 57 CN 121794071 A Figure 20 Appendix to the Instruction Manual, Page 20 / 45, 58 CN 121794071 A Figure 21 Appendix to the Instruction Manual, Page 21 / 45, 59 CN 121794071 A Figure 22 Appendix to the Instruction Manual, Page 22 / 45, 60 CN 121794071 A Figure 23 Appendix to the Instruction Manual, Page 23 / 45, 61 CN 121794071 A Figure 24 Appendix to the Instruction Manual, Page 24 / 45, 62 CN 121794071 A Figure 25 Appendix to the Instruction Manual, Page 25 / 45, 63 CN 121794071 A Figure 26 Appendix to the Instruction Manual, Page 26 / 45, 64 CN 121794071 A Figure 27 Figure 28 Appendix to the Instruction Manual, Page 27 / 45, 65 CN 121794071 A Figure 29 Figure 30 Instruction manual illustrations, page 28 / 45, 66 CN 121794071 A, Figure 31; Instruction manual illustrations, page 29 / 45, 67 CN 121794071 A, Figure 32; Instruction manual illustrations, page 30 / 45, 68 CN 121794071 A, Figure 33; Instruction manual illustrations, page 31 / 45, 69 CN 121794071 A, Figure 34; Instruction manual illustrations, page 32 / 45, 70 CN 121794071 A, Figure 35; Instruction manual illustrations, page 33 / 45, 71 CN 121794071 A, Figure 36; Instruction manual illustrations, page 34 / 45, 72 CN 121794071 A, Figure 37; Instruction manual illustrations, page 35 / 45, 73 CN 121794071 A, Figure 38; Instruction manual illustrations, page 36 / 45, 74 CN 121794071 A, Figure 39; Instruction manual illustrations, page 37 / 45, 75 CN 121794071 A Figure 40 Instruction Manual Appendix 38 / 45 Page 76 CN 121794071 A Figure 41 Instruction Manual Appendix 39 / 45 Page 77 CN 121794071 A Figure 42 Instruction Manual Appendix 40 / 45 Page 78 CN 121794071 A Figure 43 Instruction Manual Appendix 41 / 45 Page 79 CN 121794071 A Figure 44 Instruction Manual Appendix 42 / 45 Page 80 CN 121794071 A Figure 45 Instruction Manual Appendix 43 / 45 Page 81 CN121794071 A Figure 46 Instruction Manual Drawings, Pages 44 / 45, 82 CN 121794071 A Figure 47 Instruction Manual Drawings, Pages 45 / 45, 83 CN 121794071 A

Claims

1. A laser ablation containment system, comprising: A laser room having an integrated Class 1M or higher laser; A cleaning chamber, coupled to and aligned with the laser chamber, is provided to selectively receive a beam of light generated by a Class 1M or higher laser. The cleaning chamber includes a head that is selectively movable between a first position and a second position. The first position exposes the interior of the cleaning chamber for placing a substrate therein, and the second position securely closes the interior of the cleaning chamber to cooperate with the laser chamber in forming a Class 1 certified laser-operable housing.

2. The system of claim 1, wherein the laser chamber and the cleaning chamber are integrated as part of a portable roller station.

3. The system of claim 1, wherein the cleaning chamber and the laser chamber are connected to a robotic arm, the robotic arm being movable to selectively position the head against the substrate to form the housing using the head.

4. The system of claim 1, wherein the cleaning chamber is in fluid communication with the debris removal chamber.

5. The system of claim 1, further comprising a gripper having a pair of actuating fingers positioned below an umbrella-shaped member and operable to selectively pick up the substrate and place it within the housing formed by a sealing engagement of the umbrella-shaped member and a sealing edge.

6. The system of claim 5, wherein the umbrella-shaped member is slidable along an axis perpendicular to the focusing lens of the Class 1M or higher laser mounted in the laser chamber.

7. The system of claim 5, further comprising a proximity sensor positioned to identify when the umbrella-shaped member is placed on the sealing edge.

8. The system of claim 1, wherein the head includes an outwardly projecting compressible liner that forms at least a portion of the outer periphery of the housing.

9. The system of claim 1, comprising at least one sensor for measuring pressure or light within the housing.

10. The system of claim 1, further comprising a selectively removable and replaceable protective lens, the protective lens being selectively positioned within a slot to substantially seal and separate the laser chamber from the cleanroom.

11. The system of claim 10, wherein the protective lens is carried by a lens holder having a front channel providing access to the protective lens when removed from the slot, the front channel being flush with the inner wall of the cleaning chamber when in the slot, thereby locking the protective lens therein.

12. The system of claim 1, wherein the head includes a clamp having a base having a lower sealing member extending upward therefrom, the lower sealing member cooperating with an upper sealing member to form the housing between the two when the head is in the second position.

13. The system of claim 12, wherein the lower sealing member comprises a foam or rubber material and is movable relative to the upper sealing member comprising the foam or rubber material by means of a linear actuator or a pneumatic piston.

14. The system of claim 1, wherein the laser chamber is offset relative to the cleaning chamber by an angle between 90° and 180°.

15. The system of claim 1, comprising a mirror or prism located within one of the laser chamber or the cleaning chamber and positioned to receive the beam and redirect it by an offset of up to 180°.

16. The system of claim 15, wherein at least one of the mirrors or the prisms is mounted to a pivot and is capable of real-time repositioning within one of the laser chamber or the cleaning chamber.

17. The system of claim 16, wherein the pivot comprises a single-plane pivot, a multi-plane pivot, or a ball-and-socket pivot.

18. The system of claim 1, further comprising a support that projects inwardly from the inner sidewall of the cleaning chamber to form a gap therebetween for selectively accommodating an elastomeric fixing device that projects downwardly from a nut plate.

19. The system of claim 1, wherein the Class 1M or higher laser class includes a Class 4 laser.

20. A debris-containing system, comprising: The conduit is used to deliver pressurized fluid into the cleanroom; as well as An outlet, connected to the conduit and positioned to guide the pressurized fluid substantially across the internal passage of the cleaning chamber as an air curtain across it, thereby substantially preventing debris from one side of the internal passage of the cleaning chamber from passing through the air curtain to the other side of the internal passage of the cleaning chamber.

21. The system of claim 20, wherein the internal channel comprises a cylindrical channel, and the outlet comprises a quasi-hemispherical slot formed by the inner sidewall of the cleaning chamber.

22. The system of claim 21, wherein the quasi-hemispherical slot faces forward toward the internal passage, and the air curtain extends substantially horizontally across the internal passage of the cleaning chamber.

23. The system of claim 20, wherein the conduit includes a first conduit and a second conduit, and the outlet includes a first outlet and a second outlet, wherein each of the first outlet and the second outlet leads to the internal channel, thereby creating a first air curtain and a second air curtain offset from the first air curtain.

24. The system of claim 23, wherein the first air curtain and the second air curtain extend across the internal passage of the cleaning room at different angles relative to each other.

25. The system of claim 23, wherein the first conduit includes an upper conduit and the second conduit includes a lower conduit, wherein each of the upper conduit and the lower conduit includes a corresponding slot having a width of approximately half the circumference of the internal passage of the cleanroom.

26. The system of claim 20, wherein the air curtain extends generally horizontally across the internal channel and toward a debris removal chamber in fluid communication therewith.

27. The system of claim 26, comprising at least one of a HEPA filter or a carbon filter positioned within the debris removal chamber to adsorb debris.

28. The system of claim 26, comprising an air pressure sensor located within one of the cleaning chamber or the debris removal chamber.

29. The system of claim 20, wherein the outlet is positioned at an angle relative to the internal channel, and wherein the air curtain extends across the internal channel at an angle relative to the internal channel.

30. The system of claim 20, wherein the outlet comprises a generally elongated slot formed by a tubular support extending within the internal passage of the cleanroom.

31. The system of claim 30, wherein the elongated slot positions the air curtain to flow at least partially vertically within the internal passage of the cleanroom.

32. The system of claim 31, wherein the at least partially vertical flow of the air curtain prevents debris from moving toward the laser chamber coupled to the cleanroom.

33. An adhesive dispenser system, comprising: A frame, wherein a drive unit is mounted on the frame; as well as A screw, which is threadedly operated by the drive unit and engages with a carrier unit, the carrier unit being slidable relative to the frame and having at least one chuck mounting assembly rigidly connected thereto. The at least one chuck mounting assembly includes a piston chuck that can selectively and slidably engage with a piston head and can be operated to dispense liquid from the barrel when the drive unit operates the screw in a first direction and to reduce liquid "dripping" when the drive unit operates the screw in a second direction opposite to the first direction.

34. The system of claim 33, wherein the drive unit is operable to move the screw at a certain rate to dispense liquid in increments of less than 0.1 grams ("g").

35. The system of claim 33, wherein the adhesive dispenser system is coupled to a transferable roller station.

36. The system of claim 33, further comprising a support bracket having an extension sized to receive dispensing pins spaced apart relative to the frame, the support bracket being selectively adjustable relative to the frame via an elongated channel, the elongated channel being lockable to the frame by a locating pin located therein.

37. The system of claim 33, wherein the piston collet terminates at an outwardly flared mandrel, the outwardly flared mandrel being sized for frictional engagement with the piston head.

38. The system of claim 33, wherein the at least one chuck mounting assembly comprises a pair of chuck mounting assemblies, each chuck mounting assembly comprising a corresponding piston chuck selectively and slidably engaging with a corresponding piston head operable to dispense adhesive from the dual-barrel assembly.

39. The system of claim 38, wherein the respective piston heads comprise different dimensions relative to each other.

40. The system of claim 33, comprising at least one feedback sensor coupled to the drive unit for providing real-time sensing feedback on the adhesive viscosity.

41. The system of claim 40, wherein the at least one feedback sensor comprises a force feedback sensor that measures the current or voltage of the drive unit in real time.

42. The system of claim 33, further comprising a camera positioned to capture the adhesive dispensed from the barrel.

43. The system of claim 33, further comprising a quick-release mechanism for disengaging the piston chuck from the barrel in one step.

44. The system of claim 43, wherein the quick release mechanism includes a sliding bracket having a step operable to compress the spring from a first normally extended position to a second compressed position, thereby disengaging the piston chuck from engagement with the piston head.

45. The system of claim 44, wherein the sliding support includes a pull-back channel having a sliding pin that limits the movement of the sliding support relative to the carrier unit to a predetermined distance.

46. ​​The system of claim 44, further comprising a stop member connected to the carrier unit and positioned to terminate rearward movement of the sliding support relative to the carrier unit by a predetermined distance.

47. The system of claim 33, wherein the frame includes a thermal housing having a cooling element or a heating element adjacent to a quick-change carrier therein.

48. A quick-change feeder system, comprising: A frame having a set of outwardly extending locating pins having dimensions and shape for selective sliding engagement with a slotted housing of a dispenser unit; as well as A liquid receiving cylinder having dimensions and shape for selectively sliding into and / or removing from an opening in the frame when the frame is removed from the dispenser unit, wherein the liquid receiving chamber is positioned within the frame when the frame is engaged with the dispenser unit, and in a forward position is in fluid communication with a dispensing outlet.

49. The system of claim 48, wherein the frame includes a front orifice having a size and shape relatively smaller than the liquid containment cylinder but relatively larger than the dispensing outlet.

50. The system of claim 48, wherein the locating pin comprises a bolt extending outward from the frame and having a relatively smooth shank portion, the length of the shank portion being sufficient to slide into and receive in the slotted housing and to position the head portion of the bolt to the outside of the slotted housing.

51. The system of claim 50, wherein the slotted housing includes a set of externally accessible L-shaped receiving channels, the externally accessible L-shaped receiving channels being relatively wider than the width of the shank portion and relatively smaller than the width of the head portion of the bolt.

52. The system of claim 51, wherein the externally accessible L-shaped receiving channel includes an enlarged chamfered opening top, the enlarged chamfered opening top being accessible for dropping the frame into the receiving portion of the slotted housing.

53. The system of claim 48, wherein the liquid container includes an outwardly extending substrate, the substrate being at least partially larger than the opening orifice for flush engagement with the liquid container when it is mounted within the frame.

54. The system of claim 48, wherein the liquid containment cylinder comprises a pair of liquid containment cylinders, each liquid containment cylinder being in fluid communication with a cap having an outlet port selectively connectable to the dispensing outlet, the dispensing outlet comprising an inlet of a static mixer extending outward from the frame.

55. The system of claim 48, wherein the liquid receiving cylinder includes at least one rear receiving slot having dimensions and shape for selective engagement with a chuck mounting assembly of the dispenser unit.

56. A method for providing feedback on adhesive dispensing, comprising the following steps: Activate the drive unit to dispense a certain amount of adhesive at the desired flow rate; Monitor one or more dispensing characteristics associated with the amount of the adhesive being dispensed; For each of the one or more allocation characteristics, the one or more allocation characteristics are cross-referenced against a set of operating parameters; as well as If one or more of the dispensing characteristics fall outside any of the set of operating parameters, the drive unit is used to adjust the desired flow rate of the given amount of adhesive.

57. The method of claim 56, comprising the following steps: Reverse the drive unit; Pull back the piston head, which is operable by the drive unit, within the liquid-containing barrel to dispense the adhesive from the outlet end; as well as A negative pressure is created at the outlet end to stop dispensing the adhesive and control dripping at the outlet end.

58. The method of claim 56, further comprising the step of reading the temperature of one or more liquid compounds in a liquid dispensing cylinder.

59. The method of claim 58, further comprising the step of using a heater or cooler to change the temperature of the one or more liquid compounds in the liquid dispensing cylinder.

60. The method of claim 56, further comprising the step of controlling the viscosity of the adhesive.

61. The method of claim 56, comprising the following steps: The carrier unit, connected to a pair of clamp mounting assemblies, is slidably moved to engage with a corresponding pair of barrels positioned in a static relationship relative to the carrier unit; and Liquid is dispensed from each of the pair of barrels into a static mixer for use in forming the adhesive.

62. The method of claim 61, further comprising the step of engaging a piston chuck within each of the chuck mounting assemblies with a corresponding piston head, the corresponding piston head being in fluid relation to each of the pair of barrels.

63. The method of claim 61, wherein the adjusting step includes changing the rotational speed of the threaded screw, the threaded screw being operated by the drive unit to slidably move the carrier unit.

64. The method of claim 56, wherein the monitoring step includes sensing the viscosity of the dispensed adhesive and determining whether the viscosity is below a threshold or above a threshold.

65. The method of claim 56, wherein the monitoring step includes the step of sensing the current or voltage of the drive unit in real time and determining whether the current or voltage is below a threshold or the current or voltage is above a threshold.

66. The method of claim 56, wherein the monitoring step includes measuring the ambient temperature or the temperature of the adhesive.

67. The method of claim 56, wherein the monitoring step includes measuring the one or more allocation characteristics in real time or in discrete time increments.

68. The method of claim 56, wherein the monitoring step includes the step of observing the adhesive using a camera.

69. A protective lens holder, comprising: A frame having a forward-positioned receiving channel having a size and shape for selectively receiving a protective lens in a first open position, and being movable to a second position to cooperatively lock the protective lens therein when slidably engaged with the inner wall of the cleaning chamber. as well as A handle, which extends outward from the frame relative to the receiving channel and has dimensions and shape for manual operation outside the outer wall of the cleaning chamber.

70. The protective lens holder of claim 69, wherein the protective lens is selectively replaceable and the protective lens holder is selectively reusable with the cleanroom.

71. The protective lens holder of claim 69, wherein the receiving channel includes a substantially horizontal opening slot for selectively inserting and removing the protective lens therein when in the first open position.

72. The protective lens holder of claim 69, wherein the handle includes a pair of opposing arcuate recesses that enhance manual operation of the protective lens holder outside the outer wall of the cleanroom.

73. The protective lens holder according to claim 69, wherein the protective lens comprises a light-transmitting protective lens.

74. A debris removal system, comprising: An outlet conduit is in fluid communication with a cleanroom containing debris removed from the substrate. The port in the outlet conduit is connected to a pressure sensor in fluid communication with it for real-time measurement of the pressure in the outlet conduit; as well as A controller, coupled to the pressure sensor and communicating with a laser, operable to generate a beam in the cleaning chamber for removing debris from the substrate, and operable to disable the beam in response to a pressure loss measured by the pressure sensor in the outlet conduit.

75. The system of claim 74, comprising an inlet port that selectively receives pressurized fluid that creates at least a partial vacuum in the outlet conduit relative to the clean chamber.

76. The system of claim 75, wherein the inlet port is connected to a pneumatic air pump.

77. The system of claim 75, comprising a HEPA filter or carbon filter positioned within the outlet duct for filtering debris.

78. A method for replacing a quick-change barrel, comprising the following steps: The load-bearing component is slid out and detached from the frame of the distribution unit; The liquid-containing cylinder is removed from the carrier through the access port; A new liquid-containing cylinder is inserted into the carrier through the access port; as well as The carrier holding the new liquid container is reinserted into the frame of the dispensing unit.

79. The method of claim 78, further comprising the step of disengaging the liquid container from the sliding unit of the dispensing unit.

80. The method of claim 79, wherein the detachment step further comprises the following step: Move the externally accessible sliding bracket backward relative to the sliding unit; The tension spring is compressed within the retraction channel by engaging an inwardly projecting step that engages with a washer positioned at one end of the tension spring, which is normally positioned forward. as well as The flared mandrel of the piston collet retracts in response to compression of the tension spring, disengaging it from frictional engagement with the piston head associated with the liquid containment cylinder.

81. The method of claim 80, wherein the compression step comprises compressing the tension spring using an intermediate protruding step positioned between the coils of the tension spring.

82. The method of claim 80, wherein the moving step includes terminating the rearward movement of the sliding bracket by means of a stop integrated with or positioned within a pull-back channel formed in the sliding bracket.

83. The method of claim 78, further comprising the step of moving a set of locking pins projecting outward from the carrier through an externally accessible L-shaped channel formed by the frame.

84. The method of claim 83, wherein the outwardly projecting set of locking pins comprises a bolt having a shank portion movable within the L-shaped channel and a head portion relatively larger than the L-shaped channel and positioned outside thereon.

85. The method of claim 83, further comprising the step of locking the new liquid-containing cylinder into the forward slot of the L-shaped channel.

86. The method of claim 78, wherein the re-insertion step comprises reconnecting the sliding unit to the piston head associated with the new liquid containment cylinder by tapping, rotating an externally accessible knob, or retracting the piston head to engage therewith.

87. A method for cleaning surfaces, Includes the following steps: A closed laser chamber having an integrated Class 1M or higher laser. The substrate is positioned in the ablation chamber, which is connected to the laser chamber and aligned with the Class 1M or higher laser. The head is moved between a first position and a second position, the first position exposing the interior of the ablation chamber for placing the substrate therein, and the second position closing the interior of the ablation chamber and cooperating with the laser chamber to form a Class 1 certified laser operable housing; The beam is generated using a Class 1M or higher laser; and At least a portion of the substrate is brought into contact with the light beam, thereby removing debris from the substrate.

88. The method of claim 87, further comprising the step of picking up the substrate and placing it within the head.

89. The method of claim 87, further comprising the step of oriented the substrate relative to the light beam at an angle between 90° and 180°.

90. The method of claim 87, further comprising the step of inserting a protective lens between the laser chamber and the ablation chamber and substantially orthogonal to the beam.

91. The method of claim 90, wherein the generating step includes sending the light beam through the protective lens and into contact with the substrate.

92. The method of claim 90, further comprising the step of activating the proximity sensor in response to insertion of the protective lens or formation of the Class 1 certified laser-operable housing.

93. The method of claim 90, further comprising the step of abutting the front slot of the protective lens holder against the inner wall thereby locking the protective lens within the protective lens holder.

94. The method of claim 87, further comprising the step of clamping the substrate between the upper sealing member and the lower sealing member of the head.

95. The method of claim 87, further comprising the step of redirecting at least a portion of the beam from a mirror, wherein the contact step comprises simultaneously ablating the substrate at two different beam angles.

96. The method of claim 95, further comprising the step of pivoting the mirror about at least one plane.

97. The method of claim 96, wherein the pivoting step comprises repositioning the mirror around the ball joint.

98. The method of claim 87, further comprising the step of using a prism to separate the light beam before contacting the substrate.

99. The method of claim 87, further comprising the step of evacuating and removing debris from the cleaning chamber.

100. The method of claim 99, wherein the evacuation step comprises pressurizing the housing and creating a vacuum at the outlet port to evacuate the ablation debris.

101. The method of claim 100, comprising the following steps: The pressure difference between the cleaning chamber and the outlet port is measured, and the beam is deactivated if the pressure difference between the cleaning chamber and the outlet port drops below a threshold.

102. The method of claim 87, comprising the following steps: The Class 1 certified laser-operable housing is monitored in real time using at least one sensor, and the beam is terminated if the housing no longer meets the Class 1 standard based on real-time feedback from the at least one sensor.

103. The method of claim 102, wherein the sensor comprises a pressure sensor or a light sensor.

104. A method for mounting fasteners to a substrate, comprising the following steps: Using a laser to clean the bonding surface of the fastener and at least a portion of the substrate; Position the cleaned bonding surface of the fastener close to the adhesive dispenser; The adhesive dispenser is used to apply adhesive to the bonding surface of the fastener; as well as The fastener is bonded to the substrate along an adhesive layer formed between the bonding surface of the fastener and the substrate.

105. The method of claim 104, wherein the cleaning step comprises operating a Class 1M or higher-class laser in a Class 1 certified laser housing.

106. The method of claim 105, wherein the cleaning step comprises the following steps: Open the ablation chamber connected to the laser of Class 1M or higher. Place the fastener or the substrate in the ablation chamber; as well as The head of the ablation chamber is closed around at least a portion of the fastener or substrate to be ablated, thereby forming the Class 1 certified laser housing around the portion of the fastener or substrate to be ablated.

107. The method of claim 104, comprising the following steps: The laser is used to generate a light beam, and at least a portion of the bonding surface or the substrate is brought into contact with the light beam.

108. The method of claim 104, wherein the cleaning step comprises the following steps: Select the fasteners that include the nut plate; The nut plate is positioned relative to an internal support protruding inward from the inner sidewall of the cleanroom, such that the elastomeric member extending from the bottom surface of the nut plate bends away from the beam path of the laser. as well as The light beam is used to ablate the bottom surface of the nut plate.

109. The method of claim 108, wherein the ablation step includes rotating the bottom surface of the nut plate relative to the light beam while the elastomeric member remains bent outward and away from the light beam.

110. The method of claim 108, wherein the positioning step comprises the following steps: Remove the ablated nut plate from the cleaning chamber; The elastomeric component is slid into the slot of the locator block; as well as Align the bottom surface of the nut plate with the outlet of the adhesive dispenser while simultaneously bending the elastomer member away from the outlet.

111. The method of claim 110, wherein the applying step includes rotating the bottom surface of the nut plate relative to the outlet of the adhesive dispenser while simultaneously bending the elastomeric fixing device away from the outlet.

112. The method of claim 111, wherein the rotating step includes adjusting the rotational speed of the bottom surface of the nut plate in response to a desired flow rate of the adhesive.

113. The method of claim 108, wherein the bonding step comprises pulling the elastomeric member through an orifice in the substrate to pull the bonding surface of the fastener into the substrate for bonding.

114. A method for containing debris, comprising the following steps: Pressurized fluid is delivered into the debris containment chamber; The pressurized fluid is dispersed to act as an air curtain across the opening of the internal passageway within the debris-containing chamber; Prevent at least some debris from passing through the air curtain within the debris containment chamber; as well as At least some of the pressurized fluid and at least some debris are simultaneously evacuated from the outlet port that is fluidly connected to the debris receiving chamber.

115. The method of claim 114, wherein the air curtain comprises a pair of air curtains: a first air curtain positioned substantially orthogonal to the internal channel and a second air curtain offset between 10 and 90 degrees from the internal channel.

116. The method of claim 115, wherein the dispersing step comprises forming the first air curtain from a slot formed by at least a portion of the internal passage of the opening of the debris receiving chamber.

117. The method of claim 115, wherein the dispersing step comprises forming the second air curtain from a tubular support extending within a channel inside the opening of the debris receiving chamber.

118. The method of claim 114, further comprising the step of monitoring the real-time pressure within the debris containment chamber.

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