Robotic Tape Applicator With Liner-Preserving Precision Cutting
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Solution Overview
Problem
Existing automated systems for applying adhesive tape on substrates face challenges such as inaccurate placement, equipment jams, tape breakages due to tension control issues, and limited roll sizes, leading to inefficiencies and increased labor costs.
Innovation Solution
A robotized tape applicator system that includes a payout device, a flexible conduit, and an applicator head mounted on a robotic arm, allowing for precise and consistent application of tape along complex paths with minimal human intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual application methods are used, then flexibility and adaptability are maintained, but productivity and manufacturing precision deteriorate
Solution Approach 1:
The robotic tape applicator system is divided into distinct functional modules: a robotic manipulator for positioning, a separate dispensing mechanism for tape application, a vision system for guidance, and a control system for coordination. This segmentation allows each component to be optimized independently while maintaining overall system productivity and managing complexity through modular architecture.
Solution Approach 2:
The robotic manipulator serves multiple functions: it positions the dispensing mechanism, adjusts application angles, and coordinates with the vision system for precise tape placement. This multi-functionality improves productivity by eliminating the need for separate manual operations while the programmable nature maintains adaptability to different application scenarios.
2Manufacturing precision
If automated robotic systems are implemented, then productivity and precision are improved, but device complexity and initial cost increase
Solution Approach 1:
The vision system continuously monitors the tape application process and provides real-time feedback to the control system. This feedback loop enables automatic adjustment of positioning and dispensing parameters, achieving high manufacturing precision while the automated feedback mechanism reduces the need for complex manual intervention systems.
Solution Approach 2:
The robotic system performs self-positioning and self-adjustment through integrated sensors and control algorithms. The vision system automatically detects target locations and the robotic manipulator autonomously adjusts its positioning, eliminating the need for complex external guidance systems and reducing overall device complexity.
3Manufacturing precision
If conventional dispensing mechanisms are used, then device complexity is minimized, but manufacturing precision and consistency deteriorate
Solution Approach 1:
The conventional manual dispensing mechanism is replaced with an automated dispensing system controlled by the robotic manipulator and coordinated by the vision system. This substitution provides precise control over tape application while the integrated control system maintains operational simplicity through automated coordination of all components.
Data Source
Figure 1A
Figure 1B~1E
Figure 2A~2B
AI summary
A system comprising: a source of a tape comprising a material associated with an adhesive and at least one removable liner; an applicator head; a cutting mechanism; at least one drive feeding mechanism configured to index the tape from the source to the applicator head at a controlled rate; wherein the applicator head is controllable to apply the material on a surface or a substrate; and wherein the applicator head comprises a cutting mechanism configured to sever the material while leaving the at least one removable liner intact.