Next-Level Precision: The Impact of Motion Controllers on Glue Dispensing Applications

Detailed Mechanics of Glue Dispensing Machines

Glue dispensing machines consist of several critical mechanical and electronic components, such as a reservoir to hold the glue before application, a pump that is pneumatically or mechanically driven, a nozzle for precision application, a gantry system (X-Y-Z axes) to enable the nozzle to move over the target area, controlled by servo motors for precision, and a motion controller to create motion trajectories and IO commands to operate the motors and manage glue flow.

Typical Motion Requirements of a Glue Dispensing Machine

A high-precision dispensing machine would need accurate positioning to apply the glue precisely to specified coordinates, optimized trajectories for smooth movement to prevent sudden starts and stops, and speed control to balance speed with precision to maintain productivity without sacrificing quality.

Typical IO Requirements

A combination of Digital Inputs and outputs controls solenoids, pumps, and valves for the glue dispensing mechanism and receives signals from sensors, like proximity or pressure sensors, that monitor operation and safety conditions.

A combination of analog inputs and outputs measures variables such as the glue's pressure or flow rate, which are essential for maintaining consistent glue application. In addition, outputs can control analog devices like proportional valves, enabling fine adjustments to the glue flow.

Precision in Glue Dispensing

Micro-dispensing nozzles achieve precision, allowing small amounts of adhesive to be applied accurately. Vision systems can be incorporated into the machine to verify that the glue is applied precisely where it needs to be by checking and adjusting the nozzle's position in real time. Additional feedback loops using sensors can be integrated to provide feedback on the machine's performance and the characteristics of the glue during application, allowing for dynamic adjustments.

Use a PC-based motion controller instead of a PLC for such applications

PC-based controllers offer several advantages over traditional PLCs:

• Complex Algorithm Processing: They can run more complex algorithms for advanced motion control and pattern recognition.
• Compute User Logic in RTOS: A huge advantage is the ability to process and execute the motion controller commands and math logic on the user’s end, all in a real-time deterministic OS.
• Higher Data Handling Capabilities: PC-based systems typically have greater memory and processing power, which is beneficial for managing large datasets and high-resolution control.
• Flexible Software Integration: Easier integration with other software tools for design, monitoring, and quality assurance, providing a more cohesive system environment.

Why use the RMP EtherCAT motion controller for your next Glue Dispensing Application

The RMP EtherCAT motion controller, being PC-based, is designed to handle complex and precise motion control tasks. This capability is essential in glue dispensing machines, where intricate motion trajectories are critical for precise and efficient operations. Here are some of the key features of the RMP EtherCAT motion controller that make it suitable for controlling intricate motion trajectories:

1. High-Speed Communication

• EtherCAT Protocol: EtherCAT (Ethernet for Control Automation Technology) is known for its high-speed data exchange and low communication delay, allowing for real-time control of motion devices. This is crucial when executing complex motion trajectories that require rapid adjustments and synchronization between multiple axes and devices. Users can start from 1Khz and go as high as the supported servo drive interpolation rate. The network and controller sample rate is dependent on the CPU power.

2. Multi-Axis Synchronization

• Coordinated Motion: The controller can manage and synchronize multiple axes simultaneously, ensuring smooth and precise movement patterns essential for intricate trajectories. This is particularly important for applications requiring complex geometric patterns and timing precision.

3. Advanced Motion Planning

• Path Interpolation: The controller supports various types of interpolation, such as linear, circular, and helical, which are crucial for creating complex motion paths.
• Look-Ahead Functionality: This feature allows the controller to anticipate future path points and adjust the motion accordingly to maintain speed and accuracy without unnecessary stops and starts. RMP, by default, takes the entire user-designated path and prepares the trajectories. This is included in our G Code feature.

4. Advanced IO Control

• User Limits with Math Block: Users can control IOs with specific math conditions to control digital outputs or inputs and Analog outputs or inputs.

Precision Control

• Low-microsecond Jitter: Timing precision in motion control is crucial, especially for applications requiring high detail and accuracy. RMP controllers can achieve timing precision with very low jitter, which is essential for maintaining consistency in adhesive applications.

Scalability

• Modular Configuration: Users can scale the system depending on the complexity and requirements of their application, from single-axis setups to multi-axis configurations, without losing performance or control quality.

Programmability

• Customizable Scripting and Logic: The controller allows for custom programming and logic adjustments, which is beneficial for adapting the machine to different types of glues, patterns, or operational parameters.
• Integration with Advanced Programming Environments: Integration with PC-based systems often allows for programming in higher-level languages, which can incorporate advanced algorithms, machine learning, and more detailed control strategies.

Comprehensive Diagnostics and Feedback

• Real-Time Monitoring and Adjustment: The ability to monitor system performance in real time and make immediate adjustments based on feedback is crucial for maintaining the accuracy of intricate motion trajectories, mainly where environmental factors or material properties may introduce variability.