Automated Seal Cap Filling for Precise Sealant Dosing
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Solution Overview
Problem
Existing methods for filling seal caps with sealant are time-consuming, prone to over or underdosing, and require manual handling, which can lead to logistical challenges and increased costs.
Innovation Solution
An automated method and device for filling cured seal caps with sealant, where the positioning and filling of the seal caps are controlled automatically, allowing for precise filling without the need for deep freezers or manual handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If seal caps are filled manually using cartridge guns, then flexibility in operation is maintained, but filling time increases and dosing precision deteriorates
Solution Approach 1:
The patent replaces manual mechanical filling operations with an automated filling device that uses a filling needle and controlled dispensing mechanism. This substitution enables both faster filling speeds and precise dosing control through automated movement and metering systems, resolving the contradiction between productivity and manufacturing precision.
Solution Approach 2:
The filling device incorporates automated positioning systems that enable the device to locate and fill seal caps without manual intervention. The system self-regulates the filling process including needle insertion, sealant dispensing, and needle retraction, achieving both high productivity and consistent dosing precision through automated control.
2Ease of operation
If seal caps are filled manually, then equipment complexity is reduced, but handling convenience deteriorates and time consumption increases
Solution Approach 1:
The patent replaces manual handling operations with an automated device that performs positioning, filling, and retraction automatically. This mechanical substitution eliminates the need for operators to manually handle both cartridge guns and seal caps simultaneously, greatly improving ease of operation while reducing time consumption through automated sequences.
Solution Approach 2:
The filling device acts as an intermediary between the sealant source and the seal caps, automating the transfer process. This intermediary system handles the complex coordination of needle positioning, sealant flow control, and cap positioning, making the overall process easier to operate while reducing manual handling time.
3Reliability
If deep freezers are used for storing filled seal caps, then sealant reaction is prevented, but device complexity and logistical requirements increase
Solution Approach 1:
The patent applies preliminary action by filling seal caps with sealant shortly before application rather than in advance. This eliminates the need for deep freezer storage and complex logistical chains, while maintaining sealant stability through timing the filling operation to occur just before the seal cap is needed for service.
Solution Approach 2:
The approach treats filled seal caps as short-living objects that are filled and used within a short timeframe without requiring long-term preservation. This eliminates the need for expensive deep freezer infrastructure and complex storage logistics, accepting that the filled caps are intended for near-term use only.
Data Source
AI summary
Described herein is a method for filling seal caps and a corresponding automated device for filling seal caps. The method for filling seal caps includes carrying out the filling of the seal caps using an automated process, where positioning a filling unit and/or positioning the seal caps by means of movement in an XYZ coordinate system as well as filling the seal caps is automated, and where the seal caps are positioned on a support plate.