Adhesive Bead Dispensing Feedback Control for Shape Consistency
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Solution Overview
Problem
Existing automated liquid adhesive dispensing processes face challenges in achieving consistent bead shapes due to uncontrollable and controllable process parameters, leading to inefficiencies and variability in bond integrity, particularly in complex dispensing paths.
Innovation Solution
The system measures adhesive bead shapes, generates response surface profiles, and adjusts controllable process parameters to achieve stable and controlled dispensing processes, using a robot, measuring device, and processor to automate the adjustment of parameters based on bead shape measurements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automated liquid adhesive dispensing is performed with complex dispensing paths, then productivity and automation are improved, but manufacturing precision and bead shape consistency deteriorate due to uncontrollable process parameters
Solution Approach 1:
The system employs real-time feedback by measuring actual adhesive bead shapes during dispensing and comparing them to target shapes. The measurement device captures bead geometry data, which is then fed back to the controller to dynamically adjust dispensing parameters such as adhesive flow rate and nozzle movement speed, ensuring consistent bead shapes even during complex dispensing operations
Solution Approach 2:
The system dynamically changes dispensing parameters based on real-time measurements. When bead shape deviations are detected, the controller automatically adjusts process parameters including adhesive flow rate, nozzle height, and dispensing speed to compensate for variations and maintain manufacturing precision throughout the dispensing process
2Manufacturing precision
If process parameters are manually adjusted to achieve target bead shapes, then manufacturing precision is improved, but loss of time and productivity deteriorate due to iterative calibration requirements
Solution Approach 1:
The system performs self-calibration by automatically measuring its own dispensing output and adjusting its parameters without human intervention. The measurement device continuously monitors bead shapes and the controller autonomously modifies dispensing parameters to maintain target bead shapes, eliminating the need for manual calibration operations
Solution Approach 2:
Real-time feedback loops enable the system to automatically detect bead shape deviations and correct them through dynamic parameter adjustment. This closed-loop control eliminates the time-consuming iterative manual calibration process by continuously self-correcting dispensing parameters based on measured outcomes
3Manufacturing precision
If real-time bead shape measurement and parameter adjustment is implemented, then manufacturing precision and reliability are improved, but device complexity increases due to additional measurement and control systems
Solution Approach 1:
The dispensing nozzle serves multiple functions: it dispenses adhesive and simultaneously acts as a reference feature for optical measurement. The measurement device captures both the bead shape and nozzle position data in a single operation, reducing the need for separate measurement systems and minimizing overall system complexity while maintaining high manufacturing precision
4Manufacturing precision
If iterative adjustment of process parameters is performed manually, then manufacturing precision is improved, but productivity and duration of action deteriorate due to multiple calibration cycles
Solution Approach 1:
The system implements continuous real-time feedback during the dispensing process, automatically measuring bead shapes and adjusting parameters on-the-fly. This eliminates the need for stopping production to perform manual calibration cycles, maintaining high manufacturing precision while preserving dispensing throughput and productivity
Solution Approach 2:
The measurement and parameter adjustment processes occur continuously during adhesive dispensing without interrupting the production flow. The system maintains continuous dispensing operation while simultaneously measuring bead shapes and adjusting parameters, ensuring both high precision and sustained productivity throughout the manufacturing process
Data Source
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AI summary
A system includes a robot, a measuring device, and a processor. The robot is configured to dispense, based on at least one process parameter, a liquid adhesive bead onto a substrate. The measuring device is configured to measure at least one characteristic of the bead shape. The processor is configured to determine, based on a reference bead shape and at least one reference process parameter, a response surface profile of the liquid adhesive. The processor is configured to compare the measured bead shape to a reference bead shape and, responsive to determining the measured bead shape is different than the reference bead shape, determine, based on the response surface profile, at least one updated process parameter. The updated process parameter is configured to cause the robot to dispense a second bead having the reference bead shape.