Robotic Sealant Flow Control System for Aircraft Manufacturing
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Solution Overview
Problem
The application of sealant in aircraft manufacturing is time-consuming and requires skilled operators due to the need for precise placement and volume control, often necessitating rework and increased costs, especially when using robots that lack precise control over sealant flow from pressurized cartridges.
Innovation Solution
A sealant flow control system integrated with a robotic arm, featuring a clamp and actuator to reduce the nozzle opening size, combined with a sensor system and plunger-driven sealant flow generation, allowing for precise control of sealant application by adjusting the flow based on desired amounts and locations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If sealant is applied using a pressurized cartridge system, then sealant can be delivered to the application point, but the flow rate cannot be precisely controlled
Solution Approach 1:
A flow control valve is introduced as an intermediary device between the pressurized sealant cartridge and the nozzle. This valve acts as a mediator that regulates the sealant flow rate, enabling precise control while maintaining the simplicity of the overall pressurized cartridge system. The valve translates simple actuation inputs into precise flow control without requiring complex system redesign.
2Manufacturing precision
If manual sealant application is performed by skilled operators, then precise placement and volume control can be achieved, but the process is time-consuming and requires skilled labor
Solution Approach 1:
The robotic sealant application system is equipped with integrated flow control and positioning capabilities that enable it to autonomously achieve precise sealant placement without requiring skilled human operators. The system self-regulates flow rate and nozzle positioning, performing functions that previously required human skill and judgment, thereby increasing productivity while maintaining precision.
Solution Approach 2:
The system incorporates feedback mechanisms including sensors that monitor sealant flow rate, nozzle position, and application parameters. This feedback enables real-time adjustments to maintain precise sealant placement, allowing the robotic system to achieve the precision previously only attainable by skilled operators while working continuously at high speed.
3Reliability
If sealant application requires inspections and reworking to meet requirements, then quality standards can be met, but the overall process time increases
Solution Approach 1:
The system performs preliminary actions by precisely controlling sealant flow rate and nozzle positioning before application begins. Flow control valves pre-regulate the sealant flow, and the robotic system pre-positions the nozzle with high accuracy. This preliminary preparation ensures that the sealant is applied correctly the first time, eliminating the need for subsequent inspections and rework, thereby reducing total cycle time while maintaining high quality standards.
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
This solution reduces application time and costs by enabling precise control over sealant flow, minimizing waste and rework, and allowing robots to accurately apply sealant to hard-to-reach areas with improved precision.
Implementation Method 1
a spring configured to bias the clamp towards the open state
Implementation Method 2
a motor configured to move the plunger. The plunger may be configured to engage the sealant container. The plunger may cause the sealant in the sealant container to move through the nozzle when moved in a direction towards the nozzle
Implementation Method 3
engage the nozzle to reduce a flow of sealant from the nozzle... clamp the nozzle such that an opening in the nozzle may be reduced in size
Data Source
AI summary
A method and apparatus for applying sealant. The apparatus may comprise a sealant flow control system. The sealant flow control system may be configured to engage a nozzle of a sealant container to reduce a flow of sealant from the nozzle.