End Effector with Ultrasonic Sensor Rollers for Adhesive Deposition
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Solution Overview
Problem
Automating the deposition of adhesive between parts during assembly, such as in aircraft construction, is complicated by the need to maintain a proper gap between faying surfaces and prevent adhesive from being deposited in undesirable locations.
Innovation Solution
An end effector with movable nozzles and ultrasonic-sensor rollers that deposit adhesive into defined spaces between parts while maintaining separation and monitoring the spread to prevent unwanted adhesive placement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automated adhesive deposition is implemented, then productivity and manufacturing efficiency are improved, but the complexity of maintaining proper gap between faying surfaces and controlling adhesive propagation increases
Solution Approach 1:
The end effector integrates multiple functions into a single device: adhesive deposition through nozzles, gap maintenance through separator plates, and adhesive propagation control through sensor rollers. This multi-functional integration resolves the contradiction by consolidating complex operations into one automated system rather than requiring separate mechanisms for each function.
Solution Approach 2:
Separator plates are introduced as intermediary elements between the nozzles and the faying surfaces. These plates maintain the necessary gap distance while allowing adhesive to be deposited in controlled spaces, thereby simplifying the gap maintenance function and enabling automated deposition without complex positioning systems.
2Manufacturing precision
If separator plates are used to maintain gap, then adhesive deposition control is improved, but the device complexity increases due to additional components
Solution Approach 1:
The separator plates are integrated with the nozzle assemblies, forming a combined structure where the nozzle body and separator plate work together as a single functional unit. This merging reduces the number of separate components and simplifies the overall device structure while maintaining precise adhesive deposition control.
3Manufacturing precision
If ultrasonic sensor rollers are added to monitor adhesive spread, then manufacturing precision is improved, but device complexity and cost increase
Solution Approach 1:
The ultrasonic sensor rollers are positioned to contact the workpiece surface and automatically detect adhesive propagation as the end effector moves. The system uses the natural contact between the rollers and the workpiece during the deposition process itself, rather than requiring separate sensing mechanisms, thereby reducing overall system complexity.
4Productivity
If multiple nozzles are used for adhesive deposition, then productivity is improved through parallel deposition, but control of adhesive propagation becomes more difficult
Solution Approach 1:
Ultrasonic sensor rollers are positioned between the nozzles and the workpiece surface to provide real-time feedback on adhesive propagation. This feedback loop allows the control system to monitor and adjust the deposition process, ensuring that multiple nozzles can operate in parallel while maintaining precise control over where adhesive is placed and how far it propagates.
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 automated, precise, and controlled adhesive deposition between parts, ensuring accurate bonding while avoiding unnecessary adhesive application, thus reducing manufacturing costs and lead time.
Implementation Method 1
a first ultrasonic-sensor roller, coupled to the support such that the first ultrasonic-sensor roller is rotatable relative to the support and is translationally fixed relative to the support
Data Source
AI summary
An end effector, for adhesively attaching a first part to a second part, comprises a support, a first nozzle, movable relative to the support, and a second nozzle, movable relative to the support. The first nozzle comprises a first-nozzle-body outlet port and a first-nozzle separator plate. The second nozzle comprises a second-nozzle-body outlet port and a second-nozzle separator plate. The end effector additionally comprises a first ultrasonic-sensor roller that is rotatable relative to the support, translationally fixed relative to support, and located between the first nozzle and the second nozzle. The end effector also comprises a second ultrasonic-sensor roller that is rotatable relative to the support, translationally fixed relative to support, and located between the first ultrasonic-sensor roller and the second nozzle.