Bi-component Sealant Mixing Machine for Aircraft Structures
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Solution Overview
Problem
The aeronautic industry faces high costs due to the use of bi-component sealant cartridges for aircraft structures, where the mixing of base and hardener initiates solidification, necessitating separation of mixing and application processes, and existing solutions do not effectively manage the precise proportioning of these components for quality sealant material.
Innovation Solution
A machine that mixes and applies a bi-component sealing material by using storage tanks, metering chambers, a pushing device with variable piston speeds, and flow measurement devices to maintain a pre-established weight ratio, integrated with an applicator device and control system, allowing for precise control of the mixing ratio directly at the application site without the need for cartridges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If sealant material is applied using pre-filled cartridges, then application is simplified and consistent mixing ratio is ensured, but cost increases significantly
Solution Approach 1:
The system separates the storage, metering, and application functions into distinct components: storage tanks for base and hardener, metering chambers with pistons for precise dosage, and an applicator device for application. This segmentation eliminates the need for expensive pre-filled cartridges while maintaining mixing ratio consistency through independent control of each component.
Solution Approach 2:
The metering chambers with pistons automatically measure and deliver the correct volume of base and hardener components, while flow measurement devices continuously monitor and provide feedback to the control system. This self-regulating system ensures consistent mixing ratios without requiring manual intervention or expensive pre-prepared cartridges.
2Productivity
If mixing of base and hardener is performed in advance in large amounts, then application process is simplified, but the curing reaction cannot be halted and material quality deteriorates
Solution Approach 1:
The system performs preliminary metering of the correct amounts of base and hardener into separate chambers before application, but keeps them physically separated until the moment of application. The pistons are positioned and ready, but the components only mix when pushed through the mixing nozzle, ensuring no premature curing occurs while maintaining application efficiency.
Solution Approach 2:
The system maintains physical separation of base and hardener components through dedicated storage tanks and metering chambers until the exact moment of application. This segmentation prevents premature mixing and curing, allowing the system to prepare large amounts of components in advance without quality deterioration, then mix them fresh at the point of use.
3Reliability
If separate storage and mixing systems are used, then material quality is maintained, but device complexity increases
Solution Approach 1:
The system combines storage tanks, metering chambers with pistons, flow measurement devices, and the applicator device into an integrated unit. The control system coordinates all components through a centralized control architecture, managing the complex functions of separate storage and mixing while maintaining material quality through precise control of the mixing process.
4Ease of operation
If volumetric ratio metering chambers are used, then mixing ratio control is simplified, but precision in weight ratio may be insufficient for high viscosity materials
Solution Approach 1:
The system incorporates flow measurement devices that continuously monitor the flow of base and hardener components and provide feedback to the control system. The control system uses this feedback to adjust piston displacement speeds and metering chamber operations in real-time, ensuring precise weight ratio control despite the high viscosity of the sealant materials and variations in flow characteristics.
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
This solution enables precise control of the mixing ratio, reducing costs by eliminating the need for cartridges and ensuring consistent quality of the sealant material, while allowing for flexible deployment via manual or robotic application.
Implementation Method 1
metering chambers of the base and the hardener configured with a volumetric ratio between them adapted to the volumetric mixing ratio of the base and the hardener
Implementation Method 2
at least two devices for measuring the flow of base and hardener in said outlet hoses; Preferably said flow measurement devices are mass flowmeters
Implementation Method 3
a control system, such as a processor executing program steps, that can vary the displacement speed of said pistons so that the outflow of the said metering chambers is that required for the base and the hardener can reach the mixing head in the pre-established weight ratio
Implementation Method 4
an applicator device of the sealing material including a mixing head connected to said outlet hoses and a static mixing device
Data Source
AI summary
A machine (21) for mixing and applying continuously a bi-component sealing material formed by mixing a base and a hardener in a pre-established ratio that is used, for example, in joining areas of structural elements of aircraft structures. Their metering chambers (25, 25′) are configured with a volumetric ratio between them adapted to the volumetric ratio of mixture of the base and the hardener and the pushing device (31) comprises means for actuating the pistons (33, 33′) allowing different displacement speeds and control means so that the outflow of said metering chambers (25, 25′) is that required for the base and hardener can reach the mixing head (43) in a pre-established weight ratio.