End Effector Nozzles and Roller for Adhesive Gap Control
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Solution Overview
Problem
Automating the deposition of adhesive between parts in assembly processes, such as aircraft components, is complicated by the need for precise gap creation and control to prevent adhesive from being deposited in undesirable locations.
Innovation Solution
An end effector with movable nozzles and a roller is used to deposit adhesive between parts, featuring separator plates that create and maintain a gap while ensuring uniform distribution and preventing excessive adhesive thickness, utilizing a roller to counteract adhesive pressure and maintain part alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automated deposition of adhesive is implemented, then manufacturing lead time and cost are reduced, but precise gap creation and control become more complex
Solution Approach 1:
The adhesive deposition system is segmented into multiple nozzles (first nozzle for deposition, second nozzle for removal) with separate functions. Each nozzle has dedicated separator plates, dividing the complex task of gap control into manageable components that can be independently controlled during automated deposition
Solution Approach 2:
Separator plates are introduced as intermediary elements between the nozzles and the faying surfaces. These plates automatically create and maintain the required gap without requiring complex external positioning systems, simplifying the automated deposition process while ensuring precise adhesive placement
2Manufacturing precision
If separator plates are used to create gap, then adhesive is deposited in correct locations, but device complexity increases
Solution Approach 1:
The separator plates are merged with the nozzle structures, forming an integrated assembly where the separator plate and nozzle function as a unified component. This reduces the number of separate parts and simplifies the overall end effector structure while maintaining precise adhesive deposition control
Solution Approach 2:
The nozzle assembly serves multiple functions: depositing adhesive, creating gap through separator plates, and controlling adhesive flow. The second nozzle additionally removes excess adhesive, making the system multi-functional without requiring separate dedicated components for each function
3Strength
If adhesive is deposited into space between parts, then bonding is achieved, but adhesive may overflow to undesirable locations
Solution Approach 1:
The second nozzle and its separator plate are positioned to receive and remove excess adhesive that would otherwise overflow to undesirable locations. The system converts the potential harmful effect of adhesive overflow into a controlled process where excess adhesive is deliberately directed to the second nozzle for removal, ensuring clean bonding surfaces
4Quantity of substance
If gap between parts is increased for adhesive deposition, then adhesive flow is improved, but part alignment control becomes difficult
Solution Approach 1:
The separator plates are designed to dynamically maintain a consistent gap distance as the end effector moves along the parts. The plates flex or adjust to accommodate variations in part positioning while maintaining the required gap for proper adhesive flow, thereby preserving both adhesive deposition quality and part alignment precision
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
Facilitates efficient, automated adhesive deposition with precise control, ensuring uniform adhesive distribution and preventing adhesive overflow, thereby reducing manufacturing time and costs.
Implementation Method 1
the second-nozzle-body inlet port and the second-nozzle separator plate enable the adhesive, deposited through the first-nozzle-body outlet port to be urged (e.g., drawn via a suction force) from the space into the second-nozzle-body inlet port
Implementation Method 2
the roller provides a force, directed toward the first part, against the second part that counters a force, directed away from the first part, generated by the adhesive filling the space between the first part and the second part
Data Source
AI summary
An end effector, for adhesively attaching a first part to a second part, comprises a support and a first nozzle, coupled to the support and movable relative to the support, and a second nozzle, coupled to the support and movable relative to the support. The first nozzle comprises a first-nozzle body, comprising a first-nozzle-body outlet port and a first-nozzle separator plate, extending from the first-nozzle body. The second nozzle comprises a second-nozzle body, comprising a second-nozzle-body inlet port and a second-nozzle separator plate, extending from the second-nozzle body. The end effector further comprises a roller, coupled to the support, rotatable relative to the support about a roller axis, and located between the first nozzle and the second nozzle.