Vision-Guided Sealant Bead Control for Robotic Caulking
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Solution Overview
Problem
Current methods for sealing large manufactured objects, such as aircraft wings, are labor-intensive and prone to inconsistencies due to the manual application of viscous sealing compounds, which can lead to inadequate sealing and contamination risks.
Innovation Solution
An automated vision-guided dispensing system that uses a housing with a dispensing device and vision sensor, interfaced with a vision processor for real-time image processing to determine the position and orientation of the dispensing nozzle, ensuring precise application and control of the sealant amount, and includes a mobile platform for positioning and a controller for managing the dispensing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual application of sealing compound is used, then ease of operation is maintained, but manufacturing precision and reliability deteriorate
Solution Approach 1:
The patent replaces manual mechanical application with an automated robotic dispensing system that uses computer vision guidance. The robot equipped with a dispensing device and vision sensor automatically positions and applies sealant based on real-time image processing, eliminating manual operation while achieving high precision sealing around fasteners and joints.
2Productivity
If automated robotic sealing is implemented, then productivity is improved, but device complexity increases
Solution Approach 1:
The patent integrates multiple functions into a single robotic system: the robot performs both positioning and dispensing operations, the vision sensor serves both for guidance and quality inspection, and the integrated controller manages the entire sealing process. This multi-functionality increases productivity while controlling overall system complexity through consolidation.
3Adaptability or versatility
If pre-programmed robot trajectory is used, then ease of operation is improved, but adaptability deteriorates
Solution Approach 1:
The patent implements real-time vision feedback during the sealing operation. The vision sensor continuously captures images of the sealing process, and the system adjusts the robot trajectory and dispensing parameters based on actual visual feedback, allowing the pre-programmed trajectory to adapt to real-world variations in joint positions and sealant flow characteristics.
4Manufacturing precision
If real-time vision processing is implemented, then manufacturing precision is improved, but use of energy increases
Solution Approach 1:
The patent applies real-time vision processing selectively during critical phases of the sealing operation, such as initial positioning and quality verification, rather than continuously throughout the entire process. This partial application maintains manufacturing precision where needed while reducing overall energy consumption compared to continuous real-time processing.
Data Source
AI summary
The present disclosure provides a method and system by which a precise amount of a viscous fluid sealing compound can be dispensed at required locations through computer vision-based observation of the fluid deposited, its rate and amount of deposition and location; and that the dispensed fluid may be accurately shaped through robotic or other special purpose mechanism motion. The invention enables instant quality inspection of the dispensing process in terms of the locations, amounts and shapes of newly created seals.