Profilometer-Guided Sealant Bead Application in Variable Grooves
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Solution Overview
Problem
Existing systems struggle to apply a precise amount of sealant in a peripheral groove between two elements with variable dimensions, due to manufacturing tolerances and continuous variations in the groove's profile, necessitating a method for automated and rapid sealant application.
Innovation Solution
A system comprising a manipulating robot with a sealant dispensing head equipped with a profilometer and an electronic controller to detect the groove's profile, calculate the sealant quantity, and adjust the dispensing speed to ensure precise application, using a replaceable plastic nozzle and vision system for accurate positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If a robot with sealant dispensing head is used to automatically apply sealant, then automation and speed are improved, but measurement precision of groove dimensions deteriorates due to variable manufacturing tolerances
Solution Approach 1:
The system performs a preliminary scanning pass before sealant application to detect and store the actual groove profile. This preliminary measurement allows the control unit to calculate the specific sealant quantity needed for each groove, enabling precise automated application despite manufacturing tolerances in container and lid dimensions.
Solution Approach 2:
The profilometer provides real-time feedback on the groove dimensions during the scanning pass. The control unit uses this feedback information to dynamically adjust the sealant dispensing parameters, ensuring precise sealant application that adapts to the actual groove geometry rather than relying on predetermined dimensions.
2Loss of substance
If the correct quantity of sealant is precisely controlled, then material waste is reduced, but application time increases due to complex measurement and calculation requirements
Solution Approach 1:
The groove profile is detected and the sealant quantity is calculated in advance during a scanning pass before the actual application. This preliminary calculation eliminates the need for complex real-time adjustments during dispensing, maintaining fast application speed while ensuring precise material control.
Solution Approach 2:
The system performs the scanning and sealant application in continuous sequential passes without interrupting the production flow. The profilometer rapidly scans the groove profile, the control unit immediately calculates the required sealant quantity, and the dispensing head immediately applies the precise amount, maintaining continuous productive action throughout the process.
3Measurement precision
If a rigid dispensing nozzle is used, then positioning precision is improved, but adaptability to variable groove geometries deteriorates
Solution Approach 1:
The system performs a preliminary scan of the groove profile before sealant application. This advance knowledge of the groove geometry allows the control unit to calculate the optimal dispensing parameters and position the nozzle accurately, combining the precision of a rigid nozzle with adaptability to variable geometries through pre-acquired spatial information.
Solution Approach 2:
The system replaces mechanical adaptability (flexible or adjustable nozzles) with a combination of precise robotic positioning and real-time profilometry. The rigid nozzle maintains its positioning precision while the system adapts to groove variations through optical measurement and computational control of the dispensing parameters.
Data Source
AI summary
A system for automatically applying a bead of sealant within a peripheral groove defined between two elements coupled to each other and having dimensions that are not strictly predetermined. In one example, a manipulator robot includes a sealant dispensing head including a dispensing nozzle and a profilometer. An electronic controller moves the sealant dispensing head for a first pass along the peripheral groove to detect the profile of the facing lateral surfaces defining the peripheral groove. The correct amount of sealant is calculated based on the detected profile of the groove. The electronic controller moves the dispensing head for a second pass to dispense the calculated amount of sealant in the peripheral groove. In one example, the sealant is dispensed with a constant flow rate and the speed of movement of the dispensing nozzle varies to apply the calculated amount of sealant to each portion of the peripheral groove.