Force-Guided Sticker Affixing to Prevent Wrinkles on Curved Surfaces
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Solution Overview
Problem
Existing sticker affixing systems often generate warpage or wrinkles when stickers are peeled off from release paper and affixed to objects, leading to inadequate adhesion due to deformation during the process.
Innovation Solution
A sticker affixing system utilizing an articulated robot with a suction tool equipped with a force sensor, which adjusts the inclination and posture of the suction tool to maintain uniform force application along the object's surface, preventing wrinkles and ensuring proper adhesion even on non-flat surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a suction tool is used to peel off the sticker from the release paper, then the sticker can be affixed to the object, but warpage or wrinkles are generated in the sticker during the process
Solution Approach 1:
The suction tool's inclination angle is dynamically adjusted during the affixing process based on force sensor feedback. The controller modifies the tool's posture in real-time to maintain optimal contact with the sticker surface, preventing warpage while ensuring complete adhesion. This dynamic adjustment resolves the contradiction between maintaining sticker flatness and achieving reliable adhesion.
Solution Approach 2:
A force sensor is integrated into the suction tool to detect contact force between the tool and the sticker. The sensor signal is fed back to the controller, which adjusts the suction tool's inclination angle accordingly. This closed-loop feedback system ensures that the sticker is affixed without wrinkles while maintaining uniform contact pressure, simultaneously improving both shape preservation and adhesion quality.
2Manufacturing precision
If the suction tool maintains a fixed inclination during affixing, then the device complexity is reduced, but uniform force cannot be applied to the sticker on non-flat surfaces
Solution Approach 1:
The force sensor provides real-time feedback on the contact force between the suction tool and the sticker. The controller processes this feedback signal and dynamically adjusts the tool's inclination angle to maintain uniform force distribution across the sticker surface, even when the underlying object has non-flat geometry. This feedback mechanism achieves high force uniformity without requiring complex multi-sensor arrays or sophisticated control algorithms.
Solution Approach 2:
The system changes the inclination angle parameter of the suction tool based on force sensor feedback. By dynamically modifying this single geometric parameter, the system adapts to variations in object surface geometry, ensuring uniform force application. This approach achieves high manufacturing precision through simple parameter adjustment rather than complex mechanical structures.
3Productivity
If the suction tool moves quickly along the object surface, then productivity is improved, but wrinkles may be generated due to insufficient force application time
Solution Approach 1:
The suction tool operates in a dynamic state during affixing, with its inclination angle continuously adjusted based on force sensor feedback. This dynamic posture control allows the system to maintain optimal contact conditions even at higher travel speeds, ensuring complete adhesion without wrinkles. The dynamic adaptation compensates for the reduced interaction time, resolving the contradiction between speed and quality.
Solution Approach 2:
The force sensor provides real-time feedback that enables the controller to adjust the suction tool's inclination during rapid movement. This feedback mechanism ensures that sufficient contact force is maintained throughout the affixing process regardless of travel speed, allowing high productivity to be achieved without compromising adhesion quality or generating wrinkles.
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
The system effectively prevents sticker wrinkles during affixing by maintaining constant force and adjusting posture based on force sensor feedback, ensuring reliable adhesion to various surface shapes, including corners and curved surfaces.
Implementation Method 1
a suction tool attached to a distal end of the articulated robot
Data Source
AI summary
Generation of a wrinkle is prevented when a sticker is affixed to an object. A sticker affixing system includes an articulated robot, a controller configured to control the articulated robot, a suction tool attached to a distal end of the articulated robot, and a force sensor configured to detect force applied to the suction tool. The controller causes the articulated robot to execute: an operation of moving the suction tool holding a sticker along a surface of an object to which the sticker is affixed; and an operation of adjusting an inclination of the suction tool with respect to a traveling direction (roll axis) of the suction tool and the traveling direction of the suction tool based on a signal from the force sensor.