Viscous Material Discharge Device with Time Delay Control
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Solution Overview
Problem
Existing devices for applying viscous materials to joints of parts face challenges in accurately controlling the discharge amount due to varying viscosity caused by temperature distribution and chemical reactions, leading to complex systems requiring multiple sensors for estimation.
Innovation Solution
A viscous material discharge device with a controller that measures a time delay in discharge to determine the operation speed of the plunger and nozzle, allowing for precise control of the discharge amount and bead width without relying on viscosity estimation, using a combination of a reservoir, extrusion mechanism, nozzle, and moving mechanism.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If viscosity estimation based on temperature and material properties is used to set plunger speed, then the discharge device can operate with simple control, but the discharge amount control accuracy deteriorates due to widely distributed viscosity
Solution Approach 1:
The system performs a preliminary discharge action at a measurement speed before the actual application to measure the time delay. This preliminary action allows the system to characterize the viscous material's flow properties in advance, enabling accurate control during the subsequent application phase without requiring complex real-time viscosity estimation.
Solution Approach 2:
The system uses the measured time delay from the preliminary discharge as feedback to determine the appropriate plunger operation speed and nozzle moving speed for the actual application. This feedback mechanism allows the system to adapt to varying viscosity conditions dynamically, maintaining high discharge amount control accuracy without requiring multiple sensors or complex control algorithms.
2Measurement precision
If multiple sensors are added to increase viscosity estimation accuracy, then the discharge amount control can be improved, but the device complexity increases
Solution Approach 1:
The system uses the discharge device itself to perform the viscosity measurement by discharging the viscous material at a measurement speed and measuring the time delay. This self-service approach eliminates the need for separate sensors or external measurement devices, as the discharge process itself provides the necessary information about the material's flow characteristics.
Solution Approach 2:
The system changes the operational parameter (plunger speed) to a measurement speed that is optimized for characterizing the viscous material's flow properties. By operating at this specific measurement speed, the system can accurately determine the time delay parameter that reflects the material's viscosity, enabling precise control without requiring multiple sensors.
3Productivity
If the plunger operates at high speed to increase productivity, then the application efficiency improves, but the discharge amount control accuracy deteriorates due to viscosity variations
Solution Approach 1:
The system dynamically adjusts the plunger operation speed based on the measured time delay from the preliminary discharge. Instead of using a fixed high speed that may compromise control accuracy, the system optimizes the speed in real-time according to the actual viscous material properties, maintaining both high productivity and accurate discharge amount control.
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 approach improves the control accuracy of the discharge amount and bead width, maintaining high precision even with changing viscosity and temperature conditions, and allows for efficient application of viscous materials in a bead shape.
Implementation Method 1
an extrusion mechanism (4) for extruding the viscous material (95) in the reservoir (3) by a plunger (9)
Data Source
AI summary
A controller controls a plunger to operate at a measurement speed and discharge the viscous material from the nozzle before applying the viscous material to the workpiece. The controller measures a period of time, from when the plunger starts operating at the measurement speed until a discharge amount of the viscous material reaches a predetermined value, as a time delay amount. The controller further determines an operation speed of the plunger and/or a moving speed of the nozzle during application of the viscous material to the workpiece according to the measured time delay amount.