Robotic Sealant Dispensing and Skiving Tool
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Solution Overview
Problem
Current vehicle paint shop sealing processes are labor-intensive and wasteful, as manual operators must apply and remove sealant from seams, which is affected by viscosity variations and dimensional instability of vehicle seams.
Innovation Solution
A robotic sealant dispensing and skive tool that simultaneously applies and removes sealant from vehicle seams using a precision applicator and skive assembly, with a vision system and control algorithm to adjust dispensing pressure for viscosity compensation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual operators apply and remove sealant from seams, then the sealing process can be performed, but the process becomes labor-intensive and wasteful of excess sealant
Solution Approach 1:
The patent combines the sealant dispensing function and the skiving (excess material removal) function into a single integrated robotic tool. The tool includes a dispensing nozzle for applying sealant and a skive blade for simultaneously removing excess material, eliminating the need for separate manual operations and reducing overall sealant waste through precise control of application and removal.
Solution Approach 2:
The patent replaces manual mechanical operations with an automated robotic system. The robot controls the applicator tool to perform both dispensing and skiving operations automatically, providing consistent precision and eliminating human labor intensity while reducing material waste through programmed precision.
2Manufacturing precision
If vision sensors measure seam drift to maintain dimensional requirements, then key body features can be maintained, but the process becomes very time consuming
Solution Approach 1:
The patent incorporates a vision system that pre-measures seam positions and drift conditions before the robotic sealing operation begins. By capturing images of gauge holes and seams in advance, the system calculates drift compensation values and programs the robot's path and dispensing parameters beforehand, enabling rapid automated sealing without time-consuming measurements during the sealing process.
3Reliability
If PVC sealant is applied continuously to seams, then complete sealing coverage is achieved, but viscosity variations cause variation in bead seam widths
Solution Approach 1:
The patent implements a dynamic control system that continuously monitors sealant viscosity and adjusts dispensing parameters in real-time. The vision system monitors bead formation and provides feedback to control the dispensing rate and skiving action, dynamically adapting to viscosity changes to maintain consistent bead widths while ensuring complete sealing coverage.
Solution Approach 2:
The patent uses a feedback loop where the vision system continuously measures the actual bead seam width and compares it to the target dimension. This feedback information is fed back to the control system, which adjusts the dispensing rate and skiving parameters accordingly, compensating for viscosity variations and maintaining precise bead dimensions throughout the sealing process.
4Manufacturing precision
If manual operators adjust pre-pressure of each bead to compensate for viscosity changes, then bead width variations can be corrected, but the adjustment procedure becomes very time consuming
Solution Approach 1:
The patent replaces manual pressure adjustment with an automated robotic control system that electronically regulates dispensing pressure. The robot controller automatically compensates for viscosity changes by adjusting pump speed, nozzle pressure, and skiving force based on real-time vision feedback, eliminating the need for manual intervention and significantly reducing adjustment time while maintaining precise bead width control.
Data Source
AI summary
A sealant dispensing tool for a robot. The tool includes a rod having a first end and a second end, and a chamber extending from the first end to the second end. The tool also includes a skive coupled to the first end of the rod, where the skive includes an opening and a hollow portion in communication with the opening and the chamber in the rod. The tool further includes a dispensing nozzle positioned with the opening in the skive, and an applicator coupled to the nozzle and extending through the hollow portion of the skive and the chamber in the rod.