Adhesive Bead Modeling for Stable Robotic Dispensing Paths
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Solution Overview
Problem
Existing automated liquid adhesive dispensing systems face challenges in achieving a stable and controlled process, particularly in measuring and adjusting process parameters to achieve a desired adhesive bead shape, especially for complex dispensing paths.
Innovation Solution
The system uses a robot and a portable measuring device to dispense and measure liquid adhesive beads, accessing response surface profiles to compare the measured bead shape to a reference shape. Based on these comparisons, the system determines updated process parameters to adjust the dispensing process and achieve the desired bead shape.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If automated liquid adhesive dispensing systems use complex dispensing paths, then the ability to apply adhesive to complex geometries is improved, but the process stability and control deteriorate
Solution Approach 1:
The patent segments the complex dispensing path into multiple linear path segments. Each segment is evaluated and optimized independently using linear modeling, which simplifies the control calculations and improves process stability while maintaining the ability to handle complex geometries.
Solution Approach 2:
The system performs preliminary evaluation of linear path segments to predict adhesive bead shape characteristics before actual dispensing. This allows pre-calculation of optimal process parameters, enabling stable and controlled dispensing even for complex geometries.
2Manufacturing precision
If the system performs detailed measurement and adjustment of process parameters, then the bead shape control is improved, but the production time increases
Solution Approach 1:
The system performs preliminary evaluation of linear path segments to predict adhesive bead shape characteristics before actual dispensing. This pre-calculation allows the system to determine optimal process parameters in advance, achieving precise bead shape control without adding time during production.
Solution Approach 2:
The system uses feedback from measured bead shape characteristics to iteratively adjust process parameters. The feedback loop enables rapid convergence to optimal parameters, improving bead shape control while minimizing the number of iterations required and thus reducing overall production time.
3Device complexity
If the system uses traditional measurement and adjustment methods, then the process control is simplified, but the ability to achieve desired bead shape deteriorates
Solution Approach 1:
The system performs preliminary evaluation of linear path segments to predict adhesive bead shape characteristics before actual dispensing. This pre-calculation capability enables precise bead shape control without requiring complex real-time measurement and adjustment equipment during the dispensing process.
Solution Approach 2:
The patent replaces traditional mechanical measurement and adjustment methods with computational modeling and optimization. By using linear modeling and mathematical optimization algorithms, the system achieves precise bead shape control through calculation rather than iterative mechanical adjustment, maintaining simplicity while improving precision.
Data Source
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AI summary
A method includes dispensing, by a robot within a manufacturing environment using at least one process parameter, one or more linear beads of a liquid adhesive representative of a target complex dispense path onto a surface of a substrate, the linear beads extending along a longitudinal axis and having a bead shape transverse to the longitudinal axis based on the at least one process parameter; and measuring, via a one-dimensional scan by a measuring device positioned within the manufacturing environment, at a plurality of discrete positions along the longitudinal axis of the linear beads, at least one characteristic of the bead shape.