Robotic Dispensing System for Adhesive for Large Weldments Saves Costs & Speeds Cycle Times
Genesis recycled a client’s old welding robot to create an automated adhesive dispensing system that beat the manufacturer’s cycle time goals by nearly 50%.
Genesis was asked by a client to recycle a 5-year old welding robot for a new automated dispensing system. The application was to dispense structural adhesive material to seal sheet metal panels to large weldments. The client wanted to recycle the robot to significantly reduce the initial capital investment of automation processes.
Not only did the integration project involve incorporating a 5-year old welding robot, but the client also needed the automated dispensing system to be incorporated into existing production processes. Parts were inconsistently rolled into the fixture from an assembly pallet, the dispensed material had a high viscosity curve requiring temperature-control, and overall cycle time needed to be under 8 minutes.
The 5-year old FANUC M710i, 50kg capacity robot was resurrected with entirely new software programs for compatibility with application requirements as well as easier operation.
A custom roller turntable/fixture was implemented so that parts could be lowered onto rest pads and clamped into place. A servo-controlled dispenser, who’s parameters were controlled by the robot, would then dispense the adhesive material onto the secured part.
A Temperature Conditioning Unit was integrated to keep the high viscosity dispensing material at 88°
F (plus or minus 1° F). A non-contact sensor was also integrated to ensure part location and orientation before the system began dispensing material.
Genesis delivered a low-cost, high-speed automated dispensing system that outperformed manual processes by a wide margin.
The robotic system was capable of dispensing materials at speeds of 500 to 800 inches per minute (IPM). These high speeds meant the manufacturer could dispense 24 meters of bead in about 3.5 minutes. When including loading and unloading time, overall cycle time was under five minutes – nearly half of the manufacturer’s goal.
In the end, the integration project was a success and the automated dispensing system worked exactly as the manufacturer needed. They were able to improve their production processes while minimizing their initial capital investment in automation.