Vehicle Seal Application with Dynamic Defect Cutoff

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Solution Overview

Problem

Existing application devices for vehicle seals consume excessive defect-free material due to their inability to accurately detect the end of defect markings, leading to unnecessary material waste and increased downtime.

Innovation Solution

The application device incorporates a second sensor installation capable of detecting the end position of defect markings, allowing for a more precise definition of the elimination portion based on the actual length of the defect, thereby minimizing the amount of defect-free material eliminated.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a predetermined length elimination portion is used to ensure reliable defect diversion, then defect elimination reliability is improved, but material consumption increases and productivity decreases

Engineering Contradiction:

Improvedefect elimination reliabilityVSAvoidapplication device productivity

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The elimination portion length is made dynamic rather than fixed. The system adjusts the elimination portion length based on the actual detected defect length, allowing it to be short for small defects and long for large defects, thereby optimizing both reliability and productivity

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The fixed mechanical elimination system is replaced with an optical detection system (sensors) that measures defect length and controls the elimination process, enabling precise, adaptive elimination portion sizing based on actual defect characteristics

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Ease of manufacture

If a fixed predetermined length elimination portion is applied, then defect elimination is simplified, but defect-free material is unnecessarily eliminated

Engineering Contradiction:

Improveelimination process simplicityVSAvoiddefect-free material loss

Core Design Contradiction:

Ease of manufactureVSLoss of substance

Solution Approach 1:

The elimination portion length transitions from a static predetermined value to a dynamic value that adapts to the actual defect length detected by sensors, minimizing waste of defect-free material while maintaining elimination effectiveness

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system uses sensor feedback to detect the actual defect length and adjusts the elimination portion accordingly. This closed-loop feedback mechanism ensures that only the necessary amount of material is eliminated, reducing waste while maintaining simplicity through automated control

Inventive Principle:

Principle #23Feedback

Data Source

PatentUS20240316913A1Application Device Designed to Apply a Seal to a Body Element of a Vehicle and Method

Publication Date: 2024.09.26 BAYERISCHE MOTOREN WERKE AG

AI summary

An application device for applying a seal to a body element of a vehicle, comprising a guiding apparatus to feed continuous material to an outlet apparatus. The application device has a first sensor apparatus to check a predefined end portion of the continuous material for the presence of at least one predefined defect mark. The outlet apparatus has a second sensor apparatus wherein, in the event that the at least one predefined defect mark is present in the predefined end portion, the second sensor apparatus senses an end position of the predefined at least one defect mark along a longitudinal direction of the continuous material. In the event that the at least one predefined defect mark is present in the predefined end portion, the outlet apparatus cuts off a rejection portion of the fed continuous material and feeds said rejection portion to a rejection apparatus.