Robotic Dispenser Bead Shape Control
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Solution Overview
Problem
Conventional methods for dispensing substances with variable viscosities, such as sealants on aircraft parts, face challenges in achieving uniform application due to changing viscosity conditions, leading to inefficiencies like material waste, excess application, or insufficient coverage, which increases manufacturing cycle time and costs.
Innovation Solution
A method and system that monitor the leading portion of the dispensed bead and adjust the dispenser's speed or flow rate in real-time to maintain a substantially uniform cross-sectional shape, using a dispenser with a contact portion and trailing edge that moves along a virtual travel plane parallel to the path, ensuring consistent application without overflow or underfill.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If flow meters are used to control the flow rate of the substance, then the desired bead shape may be achieved, but the flow meters cause interference with the dispensing process and are difficult to clean
Solution Approach 1:
The patent removes flow meters from the dispensing system entirely, replacing them with a robotic dispenser that controls substance flow through programmed motion and dispensing parameters. This extraction eliminates the cleaning difficulty and interference issues while maintaining bead shape control through alternative means (robotic positioning and dispensing rate control).
Solution Approach 2:
The patent replaces the mechanical flow meter system with a robotic control system that uses programmed motion along predetermined paths to control dispensing. The robotic system controls the dispenser's position, speed, and orientation to achieve consistent bead geometry without requiring flow meters, thereby eliminating their associated problems.
2Loss of substance
If the flow rate is controlled for substances with variable viscosities, then material waste may be reduced, but achieving uniform application becomes difficult due to viscosity changes
Solution Approach 1:
The patent employs a dynamic control system where the robotic dispenser adjusts its motion parameters (speed, position, orientation) in real-time based on the substance's variable viscosity characteristics. The system adapts dispensing rates and travel speeds dynamically to compensate for viscosity changes, maintaining uniform application while minimizing material waste through precise control.
Solution Approach 2:
The patent implements a feedback control mechanism where the robotic system monitors dispensing parameters and adjusts flow rate and motion speed based on observed bead formation characteristics. This closed-loop control compensates for viscosity variations by continuously adjusting dispensing parameters to maintain consistent application quality and reduce material waste.
3Reliability
If excess amounts of substance are dispensed to ensure coverage, then specification requirements may be met, but material waste increases and weight increases
Solution Approach 1:
The patent applies partial action by dispensing substance only where and when needed along predetermined paths, rather than excessive application. The robotic system precisely controls dispensing location and quantity to meet minimum specification requirements without over-application, thereby reducing material waste while ensuring compliance through accurate placement.
4Productivity
If conventional dispensing methods are used for substances with short cure times, then dispensing speed may be maintained, but the substance cannot be properly cleaned or adjusted once dispensed
Solution Approach 1:
The patent implements preliminary action by using robotic precision to ensure correct dispensing on the first attempt, eliminating the need for subsequent cleaning or rework. The system carefully controls dispensing parameters before the substance cures, ensuring proper application that prevents the need for cleaning operations once the short-cure-time substance sets.
Data Source
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AI summary
One example of the present disclosure relates to a system (100) for dispensing a substance (102) in a form of a bead (104) on a surface (106) in a progression direction (P) along a path (108). The system (100) includes a dispenser (110) having, while the substance (102) is being dispensed: a leading edge (118), a contact portion (112) including two contact points (114, 116) with the surface (106), and a trailing edge (120) that extends between the two contact points (114, 116) and terminates therein. The system (100) also includes first means (122) for moving the dispenser (110) along a virtual travel plane (124), which is parallel to the path (108) and passes through the two contact points (114, 116), while maintaining the contact portion (112) in communication with the surface (106) as the substance (102) is being dispensed. The system (00) also includes second means (126) for monitoring a leading portion (128) of the bead (104) and for generating a signal responsive to at least one characteristic of the leading portion (128), wherein the leading portion (128) is located ahead of a portion of the leading edge (118) in the progression direction (P) along the path (108). The system (100) further includes third means (130) for controlling, responsive to the signal generated by the second means (126), at least one of a speed of the dispenser (110) along the path (108) or a flow rate of the substance (102) to the dispenser (110) to provide a substantially uniform cross-sectional shape of the bead (104) along the path (108).