Viscous Fluid Bead Deposition With Speed-Synchronized Flow Control
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Solution Overview
Problem
Current methods for depositing viscous fluids like glue or sealing materials at high speeds in the automotive industry face challenges in achieving uniform bead quality and high average movement speeds due to the need for constant flow rate adjustments and speed recalculations, which hinder cycle time reduction.
Innovation Solution
A method and device that utilize a poly-articulated arm with an extrusion nozzle and axial compensation system, allowing for variable speed movements and rotation, coupled with a control system that adjusts flow rates based on real-time speed readings and response delays to maintain bead uniformity and achieve speeds exceeding 600 mm/sec.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the number of predetermined points of passage is increased to achieve a fine and precise trajectory, then the trajectory precision is improved, but the speed of movement of the support by the polyarticulated arm is reduced due to frequent recalculation of trajectories and speeds
Solution Approach 1:
The control unit pre-calculates and stores speed profiles for different sections of the deposition trajectory before the actual deposition process. This allows the system to execute pre-planned speed variations without real-time recalculation, maintaining both high precision and high speed during deposition
Solution Approach 2:
The system dynamically adjusts the flow rate of the metering pump based on pre-determined speed profiles that correspond to different sections of the trajectory. This dynamic coordination between pump flow rate and arm speed allows precise bead deposition even during speed transitions, resolving the contradiction between precision and speed
2Manufacturing precision
If the flow rate of the metering pump is varied proportionally to the movement speed to maintain bead uniformity, then the bead quality is improved, but the average travel speed is reduced due to the need for constant flow rate adjustments
Solution Approach 1:
The control unit receives actual speed feedback from the polyarticulated arm and automatically adjusts the metering pump flow rate accordingly. This closed-loop feedback system maintains bead uniformity without requiring manual intervention or slowing down the overall process, as the system adapts in real-time to speed variations
Solution Approach 2:
The system replaces mechanical coordination between pump and arm with an electronic control system that automatically synchronizes flow rate with movement speed. This substitution allows for faster response times and higher average speeds while maintaining bead quality, as electronic control is faster and more precise than mechanical coupling
3Productivity
If the speed of the polyarticulated arm is increased to reduce cycle times, then the productivity is improved, but the bead quality deteriorates due to speed variations during start-up, stop phases and curves
Solution Approach 1:
The control unit pre-programmes speed profiles that anticipate start-up, stop, and curve sections of the trajectory. By preparing these speed variations in advance, the system can execute high-speed cycles while maintaining consistent bead quality, as the pump flow rate is pre-coordinated with the planned speed changes
Solution Approach 2:
The system continuously monitors actual arm speed and adjusts pump flow rate in real-time to compensate for speed variations during dynamic phases. This feedback mechanism ensures that even during rapid acceleration, deceleration, or curve execution, the bead deposition remains uniform, allowing high productivity without quality sacrifice
Data Source
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AI summary
Method for depositing a bead (71) of a viscous fluid onto a support (7) for placement implemented by a depositing device (1) using a multi-articulated robot (2).The process includes steps of determining a relationship (A) between the flow rate required by the metering pump (4) and a speed (V) of movement of the support (7) to obtain the desired bead cross-section, of the response time (B) of the circuit (42) supplying the extrusion nozzle (30), of carrying out an initial learning cycle, without bead deposition, according to trajectory instructions (T) and speeds (V) of movement of the support (7) during which, on a number (N) of points of the trajectory, an actual speed (Vr) of movement of the support (7) at the nozzle (30) is determined, and of carrying out production cycles, with bead deposition with, at each of the points (N) of the trajectory (T), a corrected flow rate instruction of the metering pump (4) taking into account the response time (B) and the actual speed (Vr) of movement of the support, weighted by the relationship (A).