Caulking Method Using Pre-Stored Stroke Data
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Solution Overview
Problem
Existing caulking devices face increased processing load and time, along with higher costs due to the need for sensors to measure stroke amounts and perform feedback control.
Innovation Solution
A caulking method that determines the necessary release torque and caulking depth to set the stroke amount of the push-in part and drive unit, controlling the drive unit to achieve a target stroke amount that prevents damage while ensuring effective caulk fixing without the need for additional sensors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a sensor is added to measure the stroke amount of the caulk roller, then the measurement precision is improved, but the device complexity and cost increase
Solution Approach 1:
The system uses the existing sensor that detects the rotation amount of the drive unit to simultaneously determine both the drive unit stroke amount and the push-in part stroke amount through pre-stored relational data, eliminating the need for separate sensors for each measurement
2Manufacturing precision
If feedback control is implemented based on measured stroke amount, then the manufacturing precision is improved, but the processing load and processing time increase
Solution Approach 1:
The system pre-stores relational data between the rotation amount of the drive unit and the stroke amounts of both the drive unit and push-in part before operation. During actual caulking, the controller directly retrieves the target stroke amount from this pre-stored data based on the detected rotation amount, eliminating the need for real-time feedback control calculations
Solution Approach 2:
The system uses pre-measured and stored relational data that copies the physical relationships between components, allowing the controller to determine stroke amounts through data lookup rather than real-time measurement and calculation, thereby reducing processing load while maintaining precision
Data Source
AI summary
A caulking method includes: determining a caulking depth which becomes equal to or larger than a necessary release torque that has been set in advance, determining a stroke amount of a push-in part which becomes equal to or larger than the caulking depth that has been determined; determining the stroke amount of a drive unit which becomes equal to or larger than the stroke amount of the push-in part that has been determined, and controlling the drive unit at a target control stroke amount that is equal to or larger than the stroke amount of the drive unit that has been determined but is smaller than the stroke amount of the drive unit at which the caulk part is damaged.