Single Axis Applicator for Insulated Glass Units
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Highly automated and complex robotic machinery for applying adhesives to insulated glass units is expensive and not suitable for small-scale or custom window manufacturing, necessitating a simpler and less costly application solution.
Innovation Solution
A single axis application unit with a movable applicator and suction grippers that can handle glass workpieces of varying sizes, featuring a central suction gripper, off-center suction grippers, and a corner suction gripper, along with a spacer applicator and edge sealant dispenser, to apply adhesive materials efficiently and accurately.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If fully automated robotic machinery is used to apply adhesives to insulated glass units, then productivity and manufacturing precision are improved, but device complexity and cost increase significantly
Solution Approach 1:
The robotic system is divided into modular components: a movable carriage that travels along the glass unit, applicator heads that can be positioned at different locations, and suction grippers that can be independently controlled. This segmentation allows each component to perform its function simply while the coordinated system achieves high productivity.
Solution Approach 2:
The applicator system is designed to handle multiple tasks: applying adhesive to different edges of the glass unit, adjusting application parameters for different glass sizes and shapes, and accommodating various adhesive types. This multi-functionality maintains high productivity across diverse manufacturing needs without requiring separate specialized equipment for each task.
2Manufacturing precision
If fully automated robotic machinery is used to apply adhesives to insulated glass units, then manufacturing precision is improved, but device complexity and cost increase significantly
Solution Approach 1:
The system incorporates sensors that detect the position of the applicator relative to the glass unit edges and provide real-time feedback to the control system. This feedback mechanism enables precise adhesive application by continuously adjusting the applicator position based on actual measurements rather than relying solely on pre-programmed coordinates, thereby achieving high precision with reduced system complexity.
Solution Approach 2:
The system replaces complex mechanical positioning mechanisms with a combination of movable carriage, suction grippers, and electronic control. The suction grippers provide stable mechanical attachment while electronic sensors and controllers handle precision positioning, substituting purely mechanical complexity with a hybrid electro-mechanical approach that achieves comparable or superior precision.
3Productivity
If high-volume automated systems are used, then productivity is improved, but cost and complexity increase making them unsuitable for small-scale manufacturing
Solution Approach 1:
The system incorporates dynamically adjustable parameters including carriage speed, applicator positioning, and suction gripper activation timing. These dynamic adjustments allow the system to optimize for high-volume production when needed while maintaining the capability to operate at lower speeds for small-scale manufacturing, thereby achieving high productivity potential without the fixed high cost structure of dedicated high-volume equipment.
Solution Approach 2:
The system allows modification of operational parameters such as adhesive application rate, carriage traversal speed, and gripper suction force to match production volume requirements. This parameter flexibility enables the same equipment to serve both high-volume and small-scale manufacturing needs, reducing the barrier to entry for small manufacturers while maintaining productivity benefits for larger operations.
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
The solution provides a cost-effective and versatile method for applying adhesives to glass units, accommodating various sizes and shapes, and reducing the complexity and cost associated with high-volume automated systems, making it suitable for both large-scale and small-scale manufacturing.
Implementation Method 1
a corner suction gripper (52) selectively engageable to hold the glass workpiece (204) in a fixed orientation relative to the table (16) edge
Data Source
AI summary
A single axis application unit for processing a glass workpiece includes a workpiece supporting table, an applicator movable on a traveler shiftable along a first linear axis and a central suction unit that is activateable to grip the glass workpiece that travels along a second linear axis oriented generally perpendicular to the first linear axis. A central suction unit brake selectively secures the central suction unit both rotationally and translationally. The central suction unit is freely moveable both translationally and rotationally when the central suction unit brake is released. A mid-peripheral suction unit is located at a fixed location remote from the central suction unit and selectively activateable to grip the glass workpiece to hold the glass workpiece in a fixed orientation. A corner suction gripper is movable with the applicator parallel to the first linear axis, and is selectively activateable to grip the glass workpiece.