fall 2024
Students: Eusebius Vercelli Ananda Satya Ardany, Sem de Blaeij, Boaz van der Vijver, Arek de Graaf, Jason Browne
Meester Techniek Unveils an Automated Caulking System for High-Precision Sealing in Industrial Applications
Launch Date:
The automation package will be available to the public from November 4th (4/11/2024).
Overview
Meester Techniek has introduced a groundbreaking robotized caulking system designed to improve the precision and efficiency of sealing processes for data logger insulation boxes, which are critical in high-temperature industrial ovens. By automating the sealing application, Meester Techniek is addressing the industry’s need for consistent quality, reduced manual labor, and higher production speeds.
The Need for Automation
The data logger insulation boxes that Meester Techniek produces, require precise sealing lines to ensure complete isolation, as these boxes are used to protect sensitive sensors in extreme heat environments. Traditionally, sealing these stainless steel boxes was a manual and time-intensive process prone to inconsistency and human error. Variability in sealing quality can lead to leaks, increasing labor costs and compromising product reliability. To address this challenge, Meester Techniek developed an automated solution that ensures repeatability and precision.
The Technical Solution
The automated caulking system leverages advanced robotics and custom-designed components to achieve high-precision sealing:
- Robotic Arm with End-of-Arm Tool: At the core of the system is a Universal Cobot equipped with a specialized end-effector, designed specifically to apply a consistent layer of silicone sealant along the seams of each box. This end-effector is also equipped with a finisher that follows the sealant application to create a smooth, uniform fillet for maximum closure.
Dispensing end-effector
- Precision Path Control Using URScript: The system’s path is programmed using URScript on a UR5e robotic arm. The team optimized movement for straight lines and corners by using ‘movel’ and ‘movep’ commands. A hardware button box connected to the Polyscope teaching pendant provides easy, step-by-step control, showing real-time pop-ups during operation.
Accurate pathing for dispensing and finishing steps
- Enhanced Reliability Through Real-Time Monitoring: The system monitors the amount of sealant throughout the process to prevent shortages, ensuring a continuous application. Safety planes and an added digital ‘Stop’ function allow the robot to pause and be moved manually, offering flexibility and enhanced safety during operation.
- Machine Vision for Perfect Alignment: The product is positioned on a light-pane backlight system, with a Cognex camera placed above the setup to verify alignment before each sealing pass. This ensures that each box is correctly positioned, allowing the robot to adapt to various box sizes and shapes seamlessly.
Final product
Ease of Integration
The caulking system is designed for straightforward integration into existing production lines. Initialization involves mapping key coordinates on the robotic arm, and users can fine-tune the sealant dose as needed. Meester Techniek provides a comprehensive guide and training to ensure that manufacturers can quickly implement the system, with minimal adjustments to their current setup.
Customer Quote
“We’re very pleased with the automated sealant dispenser’s performance. The solution offers excellent repeatability and speed, delivering a high-quality sealant line that significantly improves our process. While minor touch-ups are occasionally needed, the system has greatly streamlined our workflow and achieved our key objectives for precision and efficiency.”