Viscous Fluid Dispensing Repair With Vision-Guided Air Reshaping
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Solution Overview
Problem
The existing methods for inspecting and repairing dispensed viscous fluids, such as thermal adhesive used in battery module manufacturing, fail to ensure consistent application quality, leading to potential damage from impact or vibration due to poor adhesion, and cannot form the desired shape after initial dispensing as the fluid hardens quickly.
Innovation Solution
An apparatus and method that includes a dispenser module, vision module, robot module, and control module to inspect and repair the dispensed viscous fluid by analyzing images in real-time, and a correction module using air nozzles to reshape the fluid according to a reference pattern, ensuring proper adhesion and shape formation before the fluid hardens.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If real-time inspection and repair is implemented, then dispensing quality is improved, but device complexity increases
Solution Approach 1:
The system is divided into distinct functional modules: dispenser module for fluid application, vision module for inspection, robot module for positioning, correction module for repair, and control module for coordination. This segmentation allows each module to perform its specific function efficiently while maintaining overall system precision without excessive complexity.
Solution Approach 2:
The vision module continuously monitors the dispensed fluid in real-time and provides feedback to the control module. When defects are detected, the control module automatically activates the correction module to repair the fluid shape, creating a closed-loop feedback system that ensures high dispensing quality without requiring complex manual intervention.
2Reliability
If the fluid is inspected and repaired before hardening, then adhesion quality is improved, but the time window for correction is limited
Solution Approach 1:
The system performs inspection and correction actions during the dispensing process itself, before the fluid hardens. The vision module captures images of the fluid immediately after dispensing, and the correction module repairs any shape defects while the fluid is still in its workable state, ensuring optimal adhesion quality without waiting for hardening.
Solution Approach 2:
The inspection and correction operations continue throughout the dispensing process in real-time, rather than as separate batch operations. This continuous monitoring and immediate correction approach maximizes the utilization of the fluid's workable time window, ensuring that all defects are addressed before the fluid hardens.
3Manufacturing precision
If the correction module uses air nozzles to reshape the fluid, then shape precision is improved, but the control complexity increases
Solution Approach 1:
The correction module replaces direct mechanical contact methods with pneumatic action using air nozzles. Compressed air is directed at the fluid to reshape it into the desired pattern, eliminating the need for complex mechanical contactors or tools while achieving precise shape control through aerodynamic forces.
Solution Approach 2:
The system controls the fluid shape by adjusting pneumatic parameters such as air pressure, flow rate, and nozzle positioning. The control module modulates these parameters in real-time based on vision feedback, enabling precise shape control through non-contact pneumatic actuation rather than complex mechanical mechanisms.
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
Enables real-time inspection and repair of dispensed viscous fluids, improving the dispensing quality by forming the fluid into the correct shape according to a reference pattern, thus enhancing the adhesion and preventing damage from vibration or impact.
Implementation Method 1
a correction module which is moved by the robot module and forms a shape of the viscous fluid by discharging air to the viscous fluid dispensed to the defective part
Data Source
AI summary
Proposed is an apparatus for inspecting and repairing a dispensed viscous fluid, the apparatus including a dispenser module dispensing a viscous fluid on a workpiece, a vision module generating original images by photographing the viscous fluid dispensed on the workpiece, a robot module moving the dispenser module and the vision module through predetermined paths, respectively, and a control module determining whether a defective part exists in the dispensed viscous fluid by analyzing the original images and controlling the dispenser module and the robot module to dispense a viscous fluid to a defective part when the defective part exists. Accordingly, a defect occurring in the viscous fluid dispensed on the workpiece can be repaired, and furthermore, the shape of the viscous fluid in the repaired part can be formed by using a correction module, thereby improving application quality.