Two-Stage Metering System for High Viscosity Coating Robots
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Solution Overview
Problem
Conventional metering systems for high viscosity coating materials used in vehicle body coating are inadequate due to low accuracy, high pressure losses, and bulkiness, making them unsuitable for integration with application robots, which results in reduced metering precision and increased material losses.
Innovation Solution
A two-stage metering system with a rotating positive-displacement pump integrated into the application robot arm, allowing for direct connection to the nozzle and independent pressure control, eliminating the need for external control valves and minimizing hose length, thereby achieving precise and dynamic metering with reduced system weight and complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional metering systems are used for high viscosity coating materials, then the system structure is simple, but the metering precision is insufficient and pressure losses are high
Solution Approach 1:
The metering system is divided into two independent stages: a first metering device for rough metering and a second metering device for precision metering. This segmentation allows each stage to be optimized for its specific function, with the first stage handling bulk material flow and the second stage providing precise metering control, thereby achieving high metering precision without requiring a single overly complex device
Solution Approach 2:
The first metering device acts as an intermediary between the material supply and the second precision metering device. It prepares the material flow and pressure conditions, enabling the second device to operate more effectively with reduced complexity while maintaining high precision
2Loss of substance
If external control valves and long hose connections are used, then the system is flexible, but material losses increase and response time decreases
Solution Approach 1:
The control valve is merged with the second metering device, eliminating the need for separate external control valves and long hose connections. This integration minimizes the material path, reducing material losses and improving response time by eliminating intermediate connection points and reducing dead volume
Solution Approach 2:
The unnecessary external control valves and long hose connections are extracted from the system. By removing these components and replacing them with an integrated valve-metering device combination, the system achieves lower material losses and faster response times
3Manufacturing precision
If conventional metering systems with long hose connections are used, then installation is easy, but metering dynamics are reduced and accuracy decreases
Solution Approach 1:
The control valve and second metering device are merged into a single integrated unit, eliminating the need for long hose connections and complex assembly. This integration maintains high metering accuracy by minimizing dead volume while simplifying installation through a compact, pre-assembled module
4Speed
If the metering device is integrated into the robot arm, then the connection to nozzle is direct, but the load carrying capacity is reduced
Solution Approach 1:
The integrated metering device is designed as a compact, lightweight module that can be mounted on the robot arm without exceeding load limits. The segmentation of functions and compact design enable direct connection to the nozzle for improved application dynamics while maintaining compatibility with robot arm weight constraints
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 configuration enables precise metering with less than 1% deviation from setpoints, rapid response times, and increased production capacity while minimizing material losses and system weight, allowing for efficient application of high viscosity materials on complex workpieces.
Implementation Method 1
a rotating positive-displacement pump (32) integrated into the application robot arm (2)
Data Source
AI summary
An application system is disclosed, e.g., for the application of a sealing, adhesive or other coating material having a high viscosity, for example, on vehicle bodies. An exemplary application system may include an application robot fitted with an applicator having at least one application nozzle for the coating material, and a dosing device for general dosing of the coating material applied by the application nozzle, as may be desired. An exemplary dosing device may include a screw pump or a spiral pump that is built into or onto the applicator, or into or onto a robot arm of the displacement machine.