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AI Glue Robot Dispense
AI Glue Robot Dispense
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Part-to-part variation. This kind of part-to-part variation can be in the lateral direction
and/or the vertical direction. Sometimes, this variation can be big enough to cause large
quality spills. For example, with the closure panel hem seal application in automotive door
assembly, a few millimeters of lateral part variation from the stamping process can cause
either void in hem seal or squeeze-out, both of which will cause a pass-through failure in
the paint shop. Another example is the windshield polyurethane dispensing. The shape
of the glass can have up to ±4mm difference batch to batch. The high-profile triangular
polyurethane bead dispensing requires a constant distance between the nozzle tip and
the glass surface along the entire bead path. As a result, frequent robot program changes
become a common practice, whether it is right or wrong, to deal with this kind of variation.
2
Part fixturing inconsistency. A repeated process requires repeated part location in the
fixture nest. However, this is not always as easy as people would think. For example, the
vacuum suction cup is a common method for fixturing flexible or fragile parts. However,
parts from the stamping shop typically carry a thin film of oil, which is a big cause of suction
cup failure over time.
3
Robot programming. For many dispensing applications, good robot programming is an
“art”. How far do we want to keep the nozzle away from the part? How fast do we want
to run the nozzle around corners? For a 90° sharp turn in the confined 3D space, how do we
keep a good velocity between the nozzle tip and the part to avoid the nozzle dwell which
could cause a big blob? These all require a very good robot programming skillset, which
nowadays is a rare asset.
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4
Dispensing material property variation. The viscosity is one of the most important material
properties which can present big variations in the production environment because it
is highly dependent on the material temperature. More viscous materials tend to flow
less, which causes less volume of material dispensed under the same dispensing setup.
Air bubbles can be introduced during a barrel change if not handled carefully. These air
bubbles, when dispensed, can cause gaps or neck-downs in the bead path.
5
Limitation of current dispensing systems. The communication and response latency is a
practical limitation of even the state-of-the-art dispensing systems. The communication
commands sent from the robot can typically take 10s to 100s of milliseconds for a
dispenser to respond. And for a mass production line, robot speed can be up to 800 mm/s.
At this speed, every millisecond counts. Another common issue with the dispensing system
is the material drooling after the gun is turned off due to the liquidity of the material. This
problem is being addressed by many advanced dispensing equipment makers through their
clever “tip-seal” or “snuff-back” nozzle designs.
6
Improper system maintenance. In the production environment, lack of a good process to
maintain the dispensing process is not uncommon. For example, with a two-part Epoxy
application, the nozzle is typically made of plastic for easy disposal with a long mixing tube
to satisfy sufficient mixing before dispensing. If not handled appropriately, the frequent
nozzle replacement process can easily change the location of the nozzle tip.
2
Fundamentally, to check the volume and location of the bead as a quality control measure, is a
3D problem, which needs a 3D solution. Considering the in-process requirement with no added
cycle time, and the fact that many times the geometry of the part, where the bead is applied on,
is complex 3D free-form, an on-the-nozzle 3D vision solution is a reasonable choice. It is arguable
that a single laser line profiler integrated with the rotary mechanism and some sophisticated
algorithms might be sufficient given there is such an extensive variety of dispensing applications,
and some may be much more straightforward than the others. However, it is difficult to consider
this single laser line setup as a generalized bead quality control solution because:
1 The rotating mechanism is bulky and not very fast in response to sharp turns at
high robot speeds.
2 The performance is highly dependent on the integration and the ease of the job.
3
However, when the bead volume is trending or the bead
location is trending undesirably, an Artificial Intelligence
(AI) enabled adaptive process control capability to counter
these trends will be a game changer. This process control will
automatically adjust the dispenser or the robot programs to
deal with these inherent process variations accordingly. All of
this can only be possible with a real-time robust 3D inspection
system which can work closely with other automation
equipment, such as different robots and dispensers, with a
well-controlled latency. Coherix Predator3D™ presents a strong
technical potential to deliver this process control vision for the
dispensing process.
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