Material Dispenser Control Using 3D Bead Feedback
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Solution Overview
Problem
In material dispensing operations, existing systems face challenges in maintaining consistent material bead volume and accuracy due to variations in robotic mechanism speed, temperature, humidity, and material viscosity, leading to inaccuracies and inefficiencies in adhesive and sealing applications.
Innovation Solution
A system and method that utilize sensors to generate three-dimensional data of material beads, characterizing dispenser parameters by adjusting flow rates and pre-pressure values dynamically, and updating models of both the dispenser and robotic mechanism to ensure precise material application, using a controlling device with a processor and memory to communicate inputs and adjust settings in real-time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If robotic mechanism speed is increased to improve productivity, then production efficiency is improved, but material bead volume consistency deteriorates
Solution Approach 1:
The system dynamically adjusts the flow rate of material dispensing based on the real-time speed of the robotic mechanism. When the robotic mechanism speed changes, the flow rate is automatically modified to maintain consistent material bead volume, resolving the contradiction between productivity improvement through speed increase and manufacturing precision maintenance.
Solution Approach 2:
The system incorporates sensors that continuously monitor the robotic mechanism speed and provide feedback to the control system. This feedback loop enables real-time adjustments to the flow rate, ensuring that material bead volume consistency is maintained even when productivity is increased through higher speeds.
2Adaptability or versatility
If environmental conditions (temperature, humidity) and material viscosity vary, then adaptability to different conditions is improved, but material bead accuracy deteriorates
Solution Approach 1:
The system modifies dispensing parameters such as flow rate and pre-pressure values in response to variations in environmental conditions and material viscosity. By dynamically adjusting these parameters, the system adapts to different conditions while maintaining material bead accuracy, resolving the contradiction between adaptability and precision.
Solution Approach 2:
Sensors monitor environmental conditions and material properties, providing feedback that enables the control system to adjust dispensing parameters in real-time. This feedback mechanism allows the system to adapt to changing conditions while maintaining consistent material bead accuracy.
3Adaptability or versatility
If trial-and-error setup processes are used to adjust dispenser parameters, then adaptability to different materials is improved, but setup time and productivity deteriorates
Solution Approach 1:
The system performs preliminary characterization of the material dispenser to establish baseline parameters before actual dispensing operations. This preliminary action includes determining initial flow rate and pre-pressure values, which eliminates the need for time-consuming trial-and-error setup processes while maintaining adaptability to different materials.
Solution Approach 2:
The system automatically characterizes and adjusts dispenser parameters based on sensor data and pre-programmed algorithms, eliminating the need for manual trial-and-error adjustment. This self-service capability reduces setup time while maintaining the ability to adapt to different materials through automated parameter optimization.
Data Source
AI summary
A method includes receiving a model of the material dispenser and, at a first characterization period of a material bead dispensing operation, communicating, to the material dispenser, a first characterization flow rate input. The method also includes, at a second characterization period of the material bead dispensing operation, communicating, to the material dispenser, a second characterization flow rate input. The method also includes generating, using at least one sensor, three-dimensional data associated with a material bead corresponding to the material bead dispensing operation. The method also includes characterizing at least one parameter of the model of the material dispenser using at least the first characterization flow rate input, the second characterization flow rate input, and the three-dimensional data associated with the material bead.