Robot Tape Applicator for Short Tape on Recessed Paths
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Solution Overview
Problem
Conventional tape material applicators using vacuum chucks face difficulties in applying relatively short lengths of tape material, especially when encountering recesses smaller than the vacuum chuck or obstructions along the application path, leading to inconsistent application.
Innovation Solution
A tape material applicator with a clamping device, holding member, and roller mechanism, controlled by a robot, applies tape material by clamping one end, holding the other end, and pressing it onto a workpiece while maintaining the unapplied portion elevated, allowing for precise application along predefined paths, minimizing interference with obstructions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a vacuum chuck with vacuum holes arranged at predetermined intervals is used, then the tape material can be suctioned and wound up, but relatively short lengths of tape material that do not reach the vacuum holes cannot be applied
Solution Approach 1:
The invention extracts the tape material supply function from the vacuum chuck itself. Instead of relying on the vacuum chuck's vacuum holes to supply and hold the tape material, the system uses a separate supply unit that feeds the tape material to the application mechanism. This allows the application mechanism to handle tape materials of any length, including very short lengths that cannot reach the vacuum holes.
Solution Approach 2:
The invention introduces an intermediary supply unit between the tape material source and the application mechanism. This supply unit acts as a mediator that feeds the tape material to the application mechanism, enabling precise control over tape material delivery regardless of the tape length. The supply unit bridges the gap between the tape material and the application point, solving the problem of short tape lengths.
2Area of stationary object
If a large vacuum chuck is used to cover recesses, then the tape material can be applied to larger areas, but the outer surface of the vacuum chuck lifts away from the walls of small recesses, making it impossible to press and apply the tape material into these recesses
Solution Approach 1:
The invention segments the application mechanism into a roller that can press the tape material onto the workpiece surface. This roller can conform to and press into recesses and irregular surfaces, unlike the rigid vacuum chuck surface. The segmentation allows the pressing function to be independent from the supply function, enabling precise application in recesses regardless of the supply unit's size.
Solution Approach 2:
The invention makes the application mechanism dynamic by using a roller that can rotate and adapt to the workpiece surface contours. The roller dynamically adjusts its contact with the workpiece surface, allowing it to press tape material into recesses and along irregular surfaces. This dynamic pressing action enables precise application in areas that a static vacuum chuck surface cannot reach.
3Reliability
If a large vacuum chuck is used to avoid obstructions, then the tape material supply is more stable, but the outer edge of the vacuum chuck may interfere with obstructions such as protrusions next to the application path
Solution Approach 1:
The invention extracts the tape material supply function from the application mechanism and places it in a separate supply unit. This allows the application mechanism (roller) to be small and maneuverable, reducing interference with obstructions while the supply unit maintains stable tape material supply. The separation of supply and application functions resolves the conflict between supply stability and obstruction interference.
Solution Approach 2:
The supply unit acts as an intermediary that maintains stable tape material supply without directly contacting the workpiece or obstructions. It feeds the tape material to the application mechanism, which then handles the actual application. This intermediary arrangement allows the supply system to be large and stable while the application mechanism remains small and agile, avoiding interference with obstructions.
4Productivity
If the conventional vacuum chuck method is used, then the tape material can be applied by pressing and rotating, but there are relatively many cases where it is difficult to apply the tape material due to various geometric constraints
Solution Approach 1:
The invention creates a universal application mechanism that can handle various workpiece geometries through the roller pressing action. The roller can apply tape material to flat surfaces, recesses, curved surfaces, and areas near obstructions. This multi-functional capability increases adaptability to different geometries while maintaining application efficiency through automated robot control.
Solution Approach 2:
The invention makes the application mechanism dynamic through the roller's rotation and the robot's multi-axis movement. The roller rotates to advance the tape material while the robot dynamically positions the application mechanism to follow complex application paths. This dynamic operation enables efficient application on various geometries without the geometric constraints that limit static vacuum chuck methods.
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 the application of relatively short tape lengths with reduced difficulty, ensuring consistent adhesion and directional control, even on curved paths, while reducing interference with protrusions and recesses.
Implementation Method 1
a roller (90: FIG. 1) for pressing and applying the tape material (300) to the workpiece (40)
Data Source
AI summary
The invention provides a tape material applicator and computer program capable of applying relatively short tape materials and reducing the difficulty in tape application. The tape material applicator unit (60), mounted on the sixth axis of a robot, includes a disc-shaped member (50) and a roller swing mechanism (80). The tape material clamping device (200), attached to the disc-shaped member (50), clamps one end (304) of the tape material (300), while the guide (100) attached to the roller swing mechanism (80), holds the other end (305) of the tape material (300). The roller (90) presses the tape material (300) onto the workpiece (40). The tape material (300) is applied from one end (304) to the other end (305) along the application path by pressing with the roller (90), while maintaining the unattached part of the tape material (300) elevated from the workpiece (40).