Thermally Controlled Adhesive Roller for Corrugated Panel Alignment
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Solution Overview
Problem
Placing adhesive material on the ridges of corrugated aircraft panels is challenging due to issues with precise alignment, temperature regulation, and ergonomic concerns, leading to product waste and increased labor costs.
Innovation Solution
An adhesive applicator system with a thermally-controlled roller wheel and leading/lagging rollers that provide precise alignment, tensioning, and thermal application, using a carriage and hand-off assembly for automated or semi-automated adhesive application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual application with operator using gloves and finger pressure is used, then flexibility and adaptability are maintained, but manufacturing precision and consistency deteriorate
Solution Approach 1:
The patent introduces a roller wheel with multiple thermally-controlled tubes as an intermediary device between the operator and the adhesive substrate. This roller wheel maintains adaptability through manual operation while achieving precise alignment through its structured design with multiple tubes that can be independently controlled, thereby resolving the contradiction between flexibility and precision
Solution Approach 2:
The roller wheel is segmented into multiple thermally-controlled tubes arranged circumferentially around its periphery. Each tube can be independently controlled to apply adhesive at specific locations, enabling precise alignment while maintaining the overall flexibility of manual operation. This segmentation allows the system to achieve both adaptability and manufacturing precision
2Device complexity
If manual application with finger pressure is used, then device complexity is minimized, but manufacturing precision and temperature control deteriorate
Solution Approach 1:
The roller wheel serves multiple functions simultaneously: it provides structural support, enables precise positioning through its segmented tube design, delivers thermal energy through heated adhesive material, and facilitates controlled application pressure. This multi-functionality allows the device to achieve high manufacturing precision without proportionally increasing complexity
3Device complexity
If manual application is used, then equipment cost is reduced, but productivity and consistency deteriorate
Solution Approach 1:
The roller wheel design enables continuous adhesive application through its rotating mechanism with multiple tubes. As the roller wheel rotates, multiple tubes can apply adhesive simultaneously or in rapid succession, creating a continuous application process that significantly improves productivity compared to traditional manual finger application while maintaining relatively simple equipment
4Ease of operation
If traditional manual application is used, then ergonomic issues are avoided through simple operation, but operator fatigue and standing for long periods worsen
Solution Approach 1:
The patent replaces the manual finger-pressure mechanical system with a roller wheel mechanism that can be operated with reduced physical effort. The roller wheel's rotation and the thermally-controlled tubes' operation reduce the need for sustained finger pressure and prolonged standing, thereby mitigating operator fatigue while maintaining ease of operation
5Manufacturing precision
If precise alignment is pursued through manual skill, then manufacturing precision improves, but loss of time for training and re-work increases
Solution Approach 1:
The roller wheel with its structured array of thermally-controlled tubes provides self-aligning capabilities through its design. The tubes are pre-positioned at specific locations around the wheel's periphery, allowing the system to automatically achieve precise adhesive placement without requiring extensive operator training or manual alignment skills, thereby reducing time loss for training and re-work
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The applicator system achieves controlled alignment, tensioning, and thermal application of adhesive substrates, reducing waste, ergonomic issues, and improving first-pass quality while meeting product and manufacturing requirements.
Implementation Method 1
a roller wheel with a plurality of thermally-controlled tubes arranged to apply the adhesive substrate to the part
Data Source
AI summary
The present disclosure provides an adhesive applicator, an applicator system, and methods of applying an adhesive to a part. In one aspect, an applicator has an end effector that includes a roller wheel having a rotatable wheel and thermally-controlled tubes. The thermally-controlled tubes each define a chamber arranged to receive a heated working fluid. The end effector also includes leading rollers and lagging rollers that lead and lag the roller wheel, respectively. The leading and lagging rollers each define relief channels and are arranged to receive an adhesive substrate within their respective relief channels so as to pre-tension and align for placement of the adhesive substrate to a part to which the thermally-controlled tubes apply the adhesive substrate. The relief channels of the rollers along with controlled tensioning of the adhesive substrate and associated backing, maintain accurate placement of the adhesive substrate and removal of the backing during laydown.