Ultra Compact Computer Solution for High-Speed Adhesive Dispenser

Ultra Compact Computer Solution for High-Speed Adhesive Dispenser

In manual electronics manufacturing processes that require the application of adhesives, it generally takes double the effort to complete in comparison to when automated dispensers are used. When traditional adhesive dispensers are used, the process involves using contact-type dispensers to apply adhesives to such surfaces as electronic components and LED packaging.However, with the miniaturization of products, these traditional dispensers can no longer be used. High-speed automated adhesive dispensers that provide accurate flow control as well as high-precision and contact less application are instead required for the forming of often micro-sized points, lines, and other shapes.

System Requirements

The customer required an automated adhesive dispensing system comprising pneumatic machines, image processors, I/O modules, and Internet communication control modules.Industrial computers were needed to integrate motor drivers, adhesive dispenser controllers, and high-speed cameras. The dispensing system had to maintain stable adhesive control and trajectory planning. During operation, this not only includes controlling the pneumatic cylinder but also monitoring the environmental temperature and signals from various sensors. Once dispensing is completed, the system needed to confirm that the adhesive had been applied correctly to the surface via machine visual inspection.

System Description

By industrial equipment size limitation, compact size micro computer is more essential. To ensure precise multi-task motion control and accurate image inspection, an IPC-220/240 ultra compact computer with Intel® 6th/7th Core™ i processor, and a PCI-1756 high-speed I/O card was installed to connect to pneumatic components in order to control the electromagnetic valves and acquire signal data. A PCI-1245 4-axis DSP-based motor control card was considered ideal for the server motor controllers because it has reserved memory for trajectory planning and a maximum pulse output of 5 Mpps. It also supports Advantech’s Common Motion API, which enables the customization of trajectories with linear and arc functions while controlling the dispensing nozzles with PWM, thereby being able to set the output volume according to the nozzle cycle (referring to the time between opening and closing the nozzle). Intricate coating patterns could thus be achieved by controlling the distribution via speed limitations. Specifically, the dispenser valve and adhesive amount could be managed at jetting speeds of 100~200 Hz and the spacing could be controlled by adjusting the nozzle’s movement speed.