Liquid Adhesive Dispensing with Response-Surface Bead Shape Control
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Solution Overview
Problem
Automated liquid adhesive dispensing processes face challenges in achieving stable and controlled bead shapes due to uncontrollable process conditions and the need for complex dispensing paths, often requiring manual iterative adjustments of process parameters, which are time-consuming and prone to human error.
Innovation Solution
The system measures the output adhesive bead shape, compares it to a target shape, and automatically adjusts controllable process parameters using response surface profiles to achieve a stable bead shape, enabling faster iterative adjustments and dynamic control of the dispensing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual iterative adjustments of process parameters are used to achieve target bead shape, then bead shape control can be achieved, but the process is time-consuming and prone to human error
Solution Approach 1:
The system enables self-service by automatically determining updated process parameters based on measured bead shapes and response surface profiles, eliminating the need for manual iterative adjustments. The processor autonomously compares measured bead shapes to target shapes and selects optimal process parameters from the response surface profiles, allowing the system to self-correct and self-optimize without human intervention.
Solution Approach 2:
The system implements feedback by measuring the actual bead shape produced, comparing it to the target bead shape, and using this information to automatically adjust process parameters. The measured bead shape feedback is fed back into the system through the processor, which then determines updated process parameters based on the response surface profiles to achieve the desired bead shape in subsequent dispensing operations.
2Adaptability or versatility
If complex dispensing paths are used to meet manufacturing requirements, then adaptability to different manufacturing needs is improved, but process control stability deteriorates
Solution Approach 1:
The system applies parameter changes by utilizing response surface profiles that contain pre-determined relationships between process parameters and bead shape characteristics. When the bead shape deviates from the target, the processor automatically selects updated process parameters from the response surface profiles, adjusting parameters such as dispensing velocity, adhesive flow rate, or nozzle positioning to compensate for the effects of complex dispensing paths and maintain process stability.
3Productivity
If automated parameter adjustment is implemented to reduce time, then productivity increases, but the complexity of the control system increases
Solution Approach 1:
The system applies preliminary action by pre-generating response surface profiles that contain optimized relationships between process parameters and bead shape outcomes. These profiles are created in advance through design of experiments and statistical analysis, storing the results of numerous simulations or physical experiments. During actual production, the processor simply queries these pre-computed profiles to rapidly determine updated process parameters, avoiding the need for real-time complex calculations while maintaining high productivity.
Data Source
AI summary
A method includes dispensing, by a robot within a manufacturing environment using at least one process parameter, one or more linear beads of a liquid adhesive representative of a target complex dispense path onto a surface of a substrate, the linear beads extending along a longitudinal axis and having a bead shape transverse to the longitudinal axis based on the at least one process parameter; and measuring, via a one-dimensional scan by a measuring device positioned within the manufacturing environment, at a plurality of discrete positions along the longitudinal axis of the linear beads, at least one characteristic of the bead shape.