Applicator Spacer for Sealing Flanged Seam Alignment
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Solution Overview
Problem
Current applicator technologies for sealing or bonding flanged seams on motor vehicle body components face challenges such as difficulty in programming due to the seam's rear location, alignment issues, and inefficiencies in both non-contact and tactile application methods, leading to time- and cost-intensive iterative optimization and additional hardware requirements.
Innovation Solution
The applicator features a nozzle carrier with angled limbs and a spacer that projects onto the component surface, maintaining a predetermined application distance to ensure precise alignment and maximize spray jet energy, while avoiding contact with surface irregularities, allowing for efficient application of sealants through a multi-axis robot with an elastic joint for evasive movements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If non-contact application method is used, then the applicator can pass through the gap between components, but programming becomes difficult and time-consuming due to invisible seam location and alignment issues
Solution Approach 1:
A laser scanner is introduced as an intermediary device to detect the flanged seam position and guide the applicator. The laser scanner creates a visible reference line that facilitates programming by providing real-time positional feedback, eliminating the need for iterative trial-and-error programming while maintaining contactless operation through the gap.
2Manufacturing precision
If tactile application method is used, then alignment is improved through contact, but the nozzle diameter must be large preventing passage through the gap
Solution Approach 1:
The applicator system is segmented into two functional components: a laser scanner unit for detection and guidance, and a separate applicator unit for coating. This segmentation allows the applicator nozzle to remain small for gap passage while the laser scanner provides the alignment function previously requiring direct nozzle contact.
3Manufacturing precision
If iterative programming optimization is performed, then application quality improves, but time and cost increase significantly
Solution Approach 1:
The laser scanner provides real-time feedback on the flanged seam position and geometry, enabling automatic adaptation of the application path. This feedback mechanism eliminates iterative programming optimization by providing continuous positional information that guides the applicator precisely along the seam without requiring multiple trial runs.
4Manufacturing precision
If door is opened for coating, then quality inspection is enabled, but cycle time increases and additional handling is required
Solution Approach 1:
The mechanical door opening operation is replaced by an optical inspection system. A camera or optical sensor captures images of the applied coating quality while the door remains closed, eliminating the need to open the door for inspection and maintaining the coating cycle time without sacrificing quality verification.
Data Source
AI summary
The disclosure concerns an applicator for applying a coating agent (e.g. sealing agent) to a component, in particular for sealing or bonding a flanged seam to the motor vehicle body component. The applicator in accordance with the disclosure first has a nozzle for dispensing the coating agent in a specific jet direction onto a component surface of the component to be coated. In addition, the applicator has a nozzle carrier for positioning the nozzle. The nozzle carrier is hollow on at least part of its length to pass the coating agent. Furthermore, the nozzle carrier comprises a plurality of limbs arranged one behind the other and angled relative to each other. The nozzle is arranged on the nozzle carrier, in particular on the distal limb of the nozzle carrier. The disclosure provides that a spacer, which projects from the distal limb in the jet direction and rests on the component surface of the component to be coated in the coating operation, is mounted externally on the nozzle carrier and thereby sets a predetermined application distance between the nozzle and the component surface.