Automated Sealant Bead Application for Variable Peripheral Grooves
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Solution Overview
Problem
Existing systems struggle to apply a precise amount of sealant in a peripheral groove between two elements with variable dimensions, particularly in battery pack assembly, due to manufacturing tolerances and unpredictable geometry, necessitating a solution for automated and rapid application.
Innovation Solution
A system using a dispensing nozzle with a profilometer to detect groove profiles, an electronically-controlled robot to adjust movement speed, and a vision system to ensure precise sealant application, allowing for a constant flow rate and variable speed to match groove dimensions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automated sealant dispensing is used with fixed geometry nozzles, then productivity is improved, but manufacturing precision deteriorates due to variable groove dimensions
Solution Approach 1:
The patent applies dynamics by making the dispensing nozzle geometry variable rather than fixed. The nozzle cross-sectional area changes dynamically along its length to compensate for variations in groove dimensions, allowing the system to maintain both high productivity through automation and precise sealant quantity control despite manufacturing tolerances in the container and lid components.
Solution Approach 2:
The patent changes the geometric parameters of the dispensing nozzle along its longitudinal axis. By varying the nozzle cross-sectional area from the inlet to the outlet, the system adapts to different groove depths and widths, ensuring accurate sealant application while maintaining rapid automated dispensing capability.
2Productivity
If sealant is applied before lid assembly, then productivity is improved, but manufacturing precision deteriorates due to excess sealant leakage
Solution Approach 1:
The patent applies preliminary action by performing a detection phase before the actual sealant dispensing. A profilometer scans the peripheral groove to measure its exact geometry, and this information is stored in a database. This preliminary measurement allows the variable geometry nozzle to be configured in advance, enabling precise sealant application without excess leakage while maintaining efficient assembly timing.
Solution Approach 2:
The patent implements feedback through the profilometer detection system that measures groove dimensions and feeds this information back to control the dispensing process. The measured groove geometry data is used to adjust the variable nozzle configuration, creating a closed-loop system that ensures precise sealant quantity control while maintaining productivity.
3Manufacturing precision
If variable geometry nozzle is used, then manufacturing precision is improved for sealant quantity control, but device complexity increases
Solution Approach 1:
The patent applies segmentation by dividing the dispensing nozzle into multiple cross-sectional sections along its longitudinal axis, each with different geometries optimized for specific groove regions. This segmentation allows precise control of sealant quantity in different areas while keeping each individual nozzle section relatively simple in structure.
Solution Approach 2:
The patent uses a profilometer to create a digital copy or model of the peripheral groove geometry before dispensing. This digital replica is stored and used to control the variable nozzle, replacing the need for complex mechanical adjustment mechanisms and simplifying the overall device while maintaining high manufacturing precision.
4Manufacturing precision
If profilometer detection and variable speed control are added, then manufacturing precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent applies self-service by using the profilometer to automatically detect and measure the groove geometry, with the system then using this self-obtained data to control the dispensing process. This eliminates the need for external measurement devices or complex manual adjustment mechanisms, reducing overall device complexity while maintaining high precision.
Solution Approach 2:
The patent changes the operational parameters of the robotically-controlled dispensing head by dynamically adjusting movement speed based on groove dimensions. This parameter adjustment, controlled by the profilometer data, achieves high manufacturing precision without requiring complex mechanical modifications, thereby limiting the increase in device complexity.
Data Source
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AI summary
A system for automatically applying a bead of sealant within a peripheral groove (4), which is defined between two elements (2, 3) coupled to each other and having dimensions that are not strictly predetermined, comprises a manipulator robot (R) equipped with a sealant dispensing head (12). An electronic controller (E) makes the sealant dispensing head (12) perform a first pass along the peripheral groove (4) without dispensing sealant, to detect the profile of the facing lateral surfaces of the peripheral groove (4), by means of a profilometer. The data relating to the detected profiles are processed to calculate the correct amount of sealant to be applied within each portion of the peripheral groove (4) along the perimeter extension of the peripheral groove. The sealant dispensing head (12) then carries out a second pass along the peripheral groove (4), while dispensing sealant in the calculated quantity in each portion of the peripheral groove (4) along the perimeter of the peripheral groove (4). In one example, the sealant is dispensed with a constant flow rate, and the electronic controller (E) varies the speed of movement of the dispensing nozzle (14) during the second pass, so as to apply the calculated amount of sealant to each portion of the peripheral groove (4) along the perimeter of the peripheral groove. The dispensing nozzle consists of a replaceable element of plastic material. After its replacement, a vision system is used to detect the position of the dispensing tip of the dispensing nozzle (14) with respect to a reference element (30) carried by the robot adjacent to the dispensing nozzle (14) and having a predetermined geometry.