Composite Bead Metering Control for Uniform Thickness at Speed
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Solution Overview
Problem
Existing metering systems for multi-component composite materials struggle to balance rapid application with uniform cross-sectional area along trajectories with varying curvatures, as they require uniform metering output, limiting movement speed and efficiency.
Innovation Solution
A metering system with a control unit that adjusts metering output based on trajectory path velocity, using separate control signals for each portion of the trajectory to maintain a consistent cross-sectional area, incorporating metering and supply pumps closely positioned to the outlet opening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If uniform metering output is used to maintain predetermined bead thickness, then manufacturing precision is improved, but productivity deteriorates due to limited movement speed
Solution Approach 1:
The patent applies dynamics by making the metering output variable rather than uniform. The control unit dynamically adjusts the metering output based on the instantaneous speed of the outlet opening along the trajectory, allowing the system to adapt to changing motion conditions while maintaining consistent bead cross-sectional area.
Solution Approach 2:
The patent changes the parameter of metering output from a fixed uniform value to a variable parameter that depends on the path velocity. By adjusting the metering output proportionally to the instantaneous speed, the system maintains constant bead thickness despite variations in movement speed along different trajectory portions.
2Productivity
If movement speed is increased for rapid application, then productivity is improved, but manufacturing precision deteriorates due to varying bead thickness
Solution Approach 1:
The control unit receives information about the trajectory and path velocity of the outlet opening, using this feedback to adjust the metering output accordingly. This closed-loop control ensures that the bead cross-sectional area remains substantially constant despite variations in movement speed.
3Device complexity
If metering pump is positioned far from outlet opening, then device complexity is reduced, but manufacturing precision deteriorates due to increased response time
Solution Approach 1:
The control unit is configured to output control information to the metering pump in advance, based on predicted trajectory and velocity data. This preliminary control action allows the metering pump to adjust its output before the outlet opening reaches positions where precise metering is critical, compensating for the distance between pump and outlet.
Data Source
AI summary
A metering system for applying a bead of a multi-component composite material to a component. The metering system comprises a mixing head including a mixing chamber. The metering system includes one supply line for each component of a multi-component composite material, leading from a source of each component to the mixing chamber. The mixing chamber is configured to mix the components of the multi-component composite material in the mixing chamber and has an outlet opening through which the mixed multi-component composite material exits the mixing head. The metering system includes a metering pump to convey a discharge of the multi-component composite material through the outlet opening. The metering system includes a control unit to output, to the metering pump, a control signal comprising control information and adjust a metering output of the multi-component composite material through the outlet opening of the mixing head based on the control signal.