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Dispensing applications using industrial robots involve the automated application of materials like adhesives, sealants, coatings, or lubricants onto parts or surfaces with high precision, speed, and consistency. These applications are widely used in manufacturing industries such as automotive, aerospace, electronics, and medical device production to improve efficiency, reduce waste, and ensure quality. Below is an explanation of key aspects of dispensing applications using industrial robots:

1. What Are Dispensing Applications?

Dispensing refers to the controlled application of liquid or semi-liquid materials, such as:

Adhesives: Glues, epoxies, or hot-melt materials for bonding components.
Sealants: Silicones or polyurethanes to seal joints or prevent leaks.
Coatings: Paints, conformal coatings, or protective layers for surfaces.
Lubricants: Oils or greases for mechanical assemblies.
Other Materials: Foams, gaskets, or potting compounds for insulation or encapsulation.

Industrial robots perform these tasks by precisely controlling the volume, flow rate, and placement of the material, ensuring uniformity and accuracy that manual processes often cannot achieve.

2. Role of Industrial Robots in Dispensing

Industrial robots, typically articulated robotic arms with multiple degrees of freedom, are equipped with specialized dispensing tools (e.g., nozzles, syringes, or valves) to apply materials. Key features of robots in dispensing include:

Precision and Accuracy: Robots follow programmed paths to apply materials in exact locations, with tolerances often in the range of micrometers.
Repeatability: Robots ensure consistent application across thousands of parts, reducing defects.
Flexibility: Robots can be reprogrammed for different patterns, materials, or products, making them adaptable to various production needs.
Speed: Robots perform dispensing tasks faster than manual methods, increasing throughput.
Complex Geometries: Robots can navigate intricate shapes or 3D surfaces, applying materials in hard-to-reach areas.

3. Key Components of Robotic Dispensing Systems

Robotic Arm: Typically a 6-axis articulated arm (e.g., from FANUC, ABB, KUKA, or Universal Robots) for precise movement in three-dimensional space.
Dispensing Tool: Includes nozzles, valves (e.g., jetting or needle valves), or syringes tailored to the material’s viscosity and application requirements.
Material Delivery System: Pumps, reservoirs, or pressure systems that supply the material to the dispensing tool.
Control System: Software for programming the robot’s path, flow rate, and dispensing parameters, often integrated with CAD/CAM systems.
Vision Systems: Cameras or sensors for real-time inspection, alignment, or quality control, ensuring accurate placement on complex parts.
End-of-Arm Tooling (EOAT): Customizable tools designed for specific dispensing tasks, such as multi-head dispensers for simultaneous application.

4. Types of Dispensing Applications

Robotic dispensing is used in various applications, including:

Adhesive Bonding: Applying glue for assembling components in automotive (e.g., bonding car body panels) or electronics (e.g., securing circuit board components).
Sealing: Dispensing sealants for waterproofing or dustproofing in automotive door seals, battery packs, or electronic enclosures.
Gasketing: Applying foam or liquid gaskets for sealing enclosures, such as in HVAC systems or consumer electronics.
Potting and Encapsulation: Filling electronic components with insulating compounds to protect against moisture, vibration, or thermal stress.
Painting and Coating: Applying uniform paint layers or conformal coatings for corrosion resistance or aesthetic purposes.
Lubrication: Precisely applying grease or oil to moving parts in machinery or automotive assemblies.

5. Benefits of Robotic Dispensing

Improved Quality: Consistent material application reduces defects like voids, over-application, or uneven coverage.
Cost Efficiency: Minimizes material waste by controlling dispensing volumes precisely.
Increased Productivity: High-speed operation and 24/7 capability boost production rates.
Safety: Robots handle hazardous materials (e.g., volatile adhesives or paints), reducing worker exposure.
Scalability: Systems can be scaled or reconfigured for new products or higher volumes.

6. Challenges in Robotic Dispensing

Material Variability: Different materials (e.g., high-viscosity adhesives vs. low-viscosity lubricants) require specific equipment and tuning.
Programming Complexity: Precise path planning for complex geometries can be time-consuming.
Maintenance: Dispensing systems require regular cleaning and maintenance to prevent clogs or wear.
Initial Costs: High upfront investment for robots, tooling, and integration.
Part Variability: Variations in part dimensions or positioning may require adaptive systems like vision-guided robots.

7. Industries and Examples

Automotive: Dispensing adhesives for windshield bonding, sealants for battery packs in electric vehicles, or lubricants for engine components.
Electronics: Applying conformal coatings to circuit boards or potting compounds for sensors.
Aerospace: Dispensing lightweight sealants for aircraft panels or coatings for corrosion resistance.
Medical Devices: Precise adhesive application for assembling syringes, catheters, or implants.
Consumer Goods: Dispensing glue for packaging or sealing home appliances.

8. Technological Advancements

Vision-Guided Dispensing: Cameras and AI enable robots to adjust to part misalignment or variations in real time.
Collaborative Robots (Cobots): Smaller, safer robots work alongside humans for flexible dispensing tasks in smaller production lines.
Smart Dispensing Systems: Integration with IoT for real-time monitoring of material flow, pressure, and quality.
Multi-Material Dispensing: Robots equipped to handle multiple materials in a single operation, reducing cycle times.
Automation Integration: Dispensing robots are often part of larger automated systems, synchronized with conveyors, inspection stations, or other robots.

9. How It Works in Practice

Setup: The robot is programmed with the dispensing path, typically using CAD models or teach-pendant programming.
Material Preparation: The material is loaded into a reservoir and calibrated for flow rate and pressure.
Execution: The robot moves the dispensing tool along the programmed path, applying the material to the workpiece.
Inspection: Vision systems or sensors verify the quality of the dispensed material (e.g., bead width, continuity).
Curing/Finishing: The part may undergo curing (e.g., UV curing for adhesives) or further processing.

10. Example Scenario

In an automotive assembly line, a 6-axis robot equipped with a needle valve dispenses a polyurethane sealant along the edges of a car door. A vision system ensures the sealant bead is uniformly 3mm wide, adjusting for slight variations in door positioning. The robot completes the task in 15 seconds per door, compared to 40 seconds for manual application, with 50% less material waste.

If you’d like a deeper dive into a specific industry, material, or robotic system, or if you want a visual representation (e.g., a chart of dispensing applications by industry), let us know! Call RAB Industries, Inc. to speak to one of our associates (586)752-0090