Insert Adhesive Charging for Honeycomb Panel Assembly
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Solution Overview
Problem
The existing methods for charging fillers in honeycomb sandwich panels are manual and time-consuming, especially when dealing with a large number of inserts, requiring significant time for both the charging operation and recording operations due to the short pot life of epoxy adhesives.
Innovation Solution
An automatic charging apparatus comprising an operation stage, a dispenser with a discharge port, and an air cylinder that presses the dispenser's edge onto the insert's injection hole, allowing for precise and efficient filling of the gap between the insert and the honeycomb core with adhesive.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual charging method is used, then operation flexibility is maintained, but productivity is low and time consumption is high
Solution Approach 1:
The system performs automatic recording of charging operations and mixture ratios without requiring manual intervention. The control unit automatically logs charging locations, timing, and adhesive mixture ratios, eliminating the need for separate manual recording operations and significantly improving productivity.
Solution Approach 2:
The patent replaces manual mechanical operations with an automated control system that uses sensors and control units to manage the charging process. The air cylinder automatically positions the dispenser, and the control unit automatically records all operations, substituting human labor with automated mechanical and electronic systems.
2Reliability
If mixture and recording operations are performed frequently, then quality control is improved, but loss of time increases
Solution Approach 1:
The system maintains continuous operation by automatically recording charging information in real-time without interrupting the charging process. The control unit continuously logs charging locations, timing, and adhesive ratios, eliminating the need to stop operations for manual recording and thus reducing time loss while maintaining quality control.
Solution Approach 2:
The control unit acts as an intermediary that automatically captures and records charging operation data. This intermediary system bridges the gap between the charging operation and quality control requirements, automatically logging all necessary information without requiring separate manual intervention, thereby maintaining reliability while reducing time consumption.
3Reliability
If air cylinder pressing force is increased, then sealing performance is improved, but risk of damaging insert or panel increases
Solution Approach 1:
The air cylinder dynamically adjusts its pressing force based on the actual charging conditions and insert type. The system can vary the pressing force during operation to maintain optimal sealing without causing damage, adapting to different scenarios such as different insert materials, hole sizes, and panel types rather than using a fixed high pressing force.
Solution Approach 2:
The system changes the pressing force parameter according to the specific charging requirements. By adjusting the air pressure parameter dynamically, the system achieves sufficient sealing performance while avoiding excessive force that could damage the insert or panel, optimizing the balance between sealing and damage prevention.
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
Enables automated filler charging, simplifying the adhesive application process and reducing the need for manual recording, thereby increasing efficiency and accuracy, especially in large-scale applications like artificial satellites and automotive shelters.
Implementation Method 1
an air cylinder to press an edge of the discharge port of the dispenser on an edge of the injection hole of the insert
Data Source
AI summary
In a state in which an insert (310) is embedded in an embedding opening of a panel (300) and a nozzle (211) of a dispenser (210) is located above an injection hole of the insert, an air cylinder (230) presses an edge of a discharge port (212) of the nozzle on an edge of the injection hole of the insert. Subsequently, the dispenser discharges an adhesive from the discharge port of the nozzle. The adhesive is injected from the injection hole of the insert, and fills a gap between the insert and the panel. Therefore, the insert is fixed to the panel.