Adhesive Applicator, Applicator System, and Methods Therefore

Aspects of the present disclosure relate to an adhesive applicator, an applicator system, and methods therefore.

Placing adhesive material on a surface with precise placement has presented certain challenges. For example, placing an adhesive material on respective ridges of a corrugated aircraft panel has proven to be particular challenging. Conventionally, applying adhesive material on such ridges has been performed manually with an operator using gloves and finger pressure to apply the adhesive material to the ridge. Certain difficulties with such manual processes have arisen, including managing precise alignment of the adhesive material on the ridge, regulating temperature to tact the adhesive material to the ridge, and ergonomic issues for operators, such as hand, legs, back, and shoulder fatigue and standing for long-periods of time. Such difficulties have led to product waste due to human error and increased labor costs for re-work, and the desired application quality of the adhesive material to the ridge is typically achieved with well-trained operators with experience.

The present disclosure provides an applicator in one aspect, the applicator including an end effector that includes: a roller wheel having a plurality of thermally-controlled tubes circumferentially spaced from one another along an outer periphery of the roller wheel, the plurality of thermally-controlled tubes each define a chamber arranged to receive a heated working fluid; leading rollers that lead the roller wheel, the leading rollers define a leading relief channel; and lagging rollers that lag the roller wheel, the lagging rollers define a lagging relief channel. The leading rollers and the lagging rollers are arranged to receive an adhesive substrate within the leading relief channel and the lagging relief channel, respectively, so as to tension and align the adhesive substrate with a part to which the plurality of thermally-controlled tubes apply the adhesive substrate.

In one aspect, in combination with any example applicator above or below, the leading rollers are arranged to roll along the part and guide the adhesive substrate while holding the adhesive substrate offset from the part so as not to press the adhesive substrate to the part.

In one aspect, in combination with any example applicator above or below, the roller wheel is received between a first end plate and a second end plate of a swing arm of the applicator, and wherein the first end plate defines an inlet fluidly coupled with the chamber of each one of the thermally-controlled tubes, and wherein the heated working fluid is directed into the inlet and through the chamber of each one of the thermally-controlled tubes.

In one aspect, in combination with any example applicator above or below, the leading rollers are connected by a leading shaft and define the leading relief channel therebetween and the lagging rollers are connected by a lagging shaft and define the lagging relief channel therebetween, and wherein the adhesive substrate is arranged on the leading shaft within the leading relief channel and on the lagging shaft within the lagging relief channel so as to tension the adhesive substrate as the plurality of thermally-controlled tubes apply the adhesive substrate to the part.

In one aspect, in combination with any example applicator above or below, the leading rollers each have a rim and a tapered portion that tapers from the rim to the leading shaft.

In one aspect, in combination with any example applicator above or below, the leading and lagging rollers provide precise locating placement of the adhesive substrate as well as precision tracking of the adhesive substrate during laydown with assist of controlled adhesive substrate tensioning.

In one aspect, in combination with any example applicator above or below, the end effector is arranged on a distal end of a swing arm of the applicator, and wherein an actuator is coupled with the swing arm, the actuator being arranged to control a compressive force that the thermally-controlled tubes apply to the adhesive substrate as the plurality of thermally-controlled tubes apply the adhesive substrate to the part.

In one aspect, in combination with any example applicator above or below, the roller wheel is received between a first end plate and a second end plate, and wherein the end effector further includes: a pair of leading arms coupling the leading rollers to the first and second end plates, respectively; an adjustment screw extending through the first end plate and engaging a first leading arm of the pair of leading arms, the adjustment screw is adjustable so as to adjust a position of the leading rollers; and a leading spring coupled with the first leading arm and biasing the pair of leading arms against the adjustment screw.

The present disclosure provides an applicator system in another aspect, the applicator system including: a hand-off assembly having a pincher; and a carriage movable along a first direction so as to be selectively extended toward the hand-off assembly and selectively retracted away from the hand-off assembly. The carriage includes: a backing clamp arranged to selectively clamp a backing so as to couple the backing with an adhesive substrate or to allow the backing to peel away from the adhesive substrate; a cutter assembly arranged to receive the adhesive substrate and to be movable between a cut position and a collapsed position, wherein when in the collapsed position, the cutter assembly exposes a portion of the adhesive substrate to allow the pincher of the hand-off assembly to pinch and selectively hold the adhesive substrate, and when in the cut position, a cutter of the cutter assembly is arranged to selectively cut the adhesive substrate; and an applicator having a swing arm and an end effector arranged on the swing arm, the applicator is movable to an engaged position in which the end effector applies the adhesive substrate to a part.

In one aspect, in combination with any example applicator system above or below, the end effector includes: a roller wheel having a wheel rotatable about an axis of rotation and a plurality of thermally-controlled tubes circumferentially spaced from one another along an outer periphery of the wheel, the plurality of thermally-controlled tubes each define a chamber arranged to receive a heated working fluid; leading rollers that lead the roller wheel, the leading rollers define a leading relief channel; and lagging rollers that lag the roller wheel, the lagging rollers define a lagging relief channel, and wherein the leading rollers and the lagging rollers are arranged to receive an adhesive substrate within the leading relief channel and the lagging relief channel, respectively, so as to tension and align the adhesive substrate with a part to which the plurality of thermally-controlled tubes apply the adhesive substrate.

In one aspect, in combination with any example applicator system above or below, the applicator system further includes: a heating system having one or more heaters, the heating system is fluidly coupled with the thermally-controlled tubes to provide the heated working fluid thereto.

In one aspect, in combination with any example applicator system above or below, the roller wheel is received between a first end plate and a second end plate of a swing arm of the applicator, and wherein the first end plate defines an inlet fluidly coupled with the chamber of each one of the thermally-controlled tubes, and wherein the heated working fluid is directed into the inlet and through the chamber of each one of the thermally-controlled tubes.

The present disclosure provides a method in another aspect, the method including: with an adhesive substrate having a backing clamped by a backing clamp of a carriage and the adhesive substrate extending into a cutter assembly of the carriage, moving the carriage along a first direction toward a hand-off assembly; handing off, by the cutter assembly to the hand-off assembly, a portion of the adhesive substrate without the backing so that the hand-off assembly holds the portion of the adhesive substrate; with the backing clamp released to allow the backing to peel from the adhesive substrate and an applicator of the carriage moved to an engaged position, moving the carriage along the first direction away from the hand-off assembly so that an end effector of the applicator applies the adhesive substrate to a part; cutting, by a cutter of the cutter assembly, the adhesive substrate; and releasing, by the hand-off assembly, the adhesive substrate.

In one aspect, in combination with any example method above or below, handing off the portion of the adhesive substrate to the hand-off assembly so that the hand-off assembly holds the adhesive substrate includes: moving the carriage along the first direction so that the cutter assembly engages the hand-off assembly and pushes the cutter assembly toward the backing clamp along the first direction so as to move the cutter assembly to a collapsed position in which the portion of the adhesive substrate is exposed; and pinching, with a pincher of the hand-off assembly, the portion of the adhesive substrate that is exposed.

In one aspect, in combination with any example method above or below, the method further includes: with the cutter assembly still engaged with the hand-off assembly, moving the carriage and the hand-off assembly along the first direction a predetermined distance from an edge of the part; and with the carriage and the hand-off assembly moved the predetermined distance from the edge of the part, setting a brake of the hand-off assembly, and wherein with the brake set and the backing clamp released, the carriage is moved along the first direction away from the hand-off assembly.

In one aspect, in combination with any example method above or below, as the carriage is moved along the first direction away from the hand-off assembly, the applicator of the carriage is moved to the engaged position after the end effector clears the hand-off assembly along the first direction.

In one aspect, in combination with any example method above or below, when the carriage is moved along the first direction away from the hand-off assembly, the cutter assembly disengages from the hand-off assembly and moves from the collapsed position to a cut position.

In one aspect, in combination with any example method above or below, the applicator is movable between a retracted position and the engaged position, and wherein a swing arm of the applicator is pivotably coupled with a carriage plate of the carriage and the end effector is arranged at a distal end of the swing arm.

In one aspect, in combination with any example method above or below, the end effector has a roller wheel having a plurality of thermally-controlled tubes, and wherein in moving the carriage along the first direction away from the hand-off assembly so that the end effector of the applicator applies the adhesive substrate to the part, the roller wheel rotates allowing the plurality of thermally-controlled tubes to apply the adhesive substrate to the part.

In one aspect, in combination with any example method above or below, the method further includes flowing a heated working fluid through the plurality of thermally-controlled tubes as the roller wheel rotates to allow the plurality of thermally-controlled tubes to apply the adhesive substrate to the part in rolling thermally-controlled pulses.

In one aspect, in combination with any example method above or below, the end effector includes leading rollers and lagging rollers that lead and lag the roller wheel, respectively, and wherein the leading rollers are connected by a leading shaft and define a leading relief channel therebetween and the lagging rollers are connected by a lagging shaft and define a lagging relief channel therebetween, and wherein the adhesive substrate is arranged on the leading shaft within the leading relief channel and on the lagging shaft within the lagging relief channel so as to be tensioned as the plurality of thermally-controlled tubes apply the adhesive substrate to the part, and wherein the method further comprises: actively controlling a tension of the adhesive substrate and a tension of the backing by way of a tape spool and a backing spool, respectively.

An adhesive applicator for applying an adhesive material to a part is disclosed. In at least some aspects, an adhesive applicator can be used to install an adhesive substrate onto an aircraft part, such as to a corrugated panel. The adhesive applicator can include an end effector arranged to apply the adhesive substrate to the part. The end effector can include features that provide a thermally-controlled, flexible compressive force for applying the adhesive onto the part, such as to a ridge of a corrugation. Specifically, the end effector can include a roller wheel with a plurality of thermally-controlled tubes arranged to apply the adhesive substrate to the part. The end effector also may include leading and lagging rollers, which lead and lag the roller wheel. The leading and lagging rollers provide simultaneous tensioning and alignment of the adhesive substrate to the part. As the adhesive substrate is tensioned and aligned by the leading and lagging rollers, the roller wheel is rotated so that the thermally-controlled tubes apply the adhesive substrate to the part with rolling thermally-controlled pulses, with each pulse corresponding to one of the thermally-controlled tubes contacting and pressing the adhesive substrate against the part. Accordingly, the leading and lagging rollers function as a tensioner and aligner for the adhesive substrate while the roller wheel lays down the adhesive substrate onto the part with thermally-controlled physical force.

In some further aspects, an applicator system equipped with an adhesive applicator and method of using the applicator system are disclosed. The applicator system can include features to automate or semi-automate the process of applying the adhesive substrate to the part using the applicator. The applicator system can include a carriage that is movable along a first direction so as to be selectively extended toward a hand-off assembly and selectively retracted away from the hand-off assembly. The carriage acts as a “first hand” while the hand-off assembly acts as a “second hand” in a laydown process. In one aspect, the carriage includes a backing clamp arranged to selectively clamp a backing so as to couple the backing with an adhesive substrate or to allow the backing to peel from the adhesive substrate. The carriage also includes a cutter assembly arranged to receive the adhesive substrate. When the carriage is moved toward the hand-off assembly, the cutter assembly and the hand-off assembly engage one another, causing the cutter assembly to expose a portion of the adhesive substrate. A pincher of the hand-off assembly pinches the adhesive substrate and holds it as the end effector applies the adhesive substrate to the part. Accordingly, the first and second hands, or the cutter assembly and hand-off assembly, “meet up” where the adhesive substrate is “handed off” to the hand-off assembly, and after the hand off, the carriage is eventually moved away from the hand-off assembly. With the hand-off assembly holding the adhesive substrate, the end effector is moved into position and applies the adhesive substrate to the part. After the application of the adhesive substrate to the part, a cutter of the cutter assembly can cut the adhesive substrate while the hand-off assembly can release the other end. A traverse assembly can move the application components to a subsequent position and the laydown cycle can be repeated.

The applicator, applicator system, and methods therefore can provide certain advantages, benefits, and/or technical effects. For instance, the applicator can allow for controlled alignment, tensioning, and thermal application of an adhesive product to a part, either manually or by way of an automated system, to achieve product requirements, process specifications, and/or manufacturing requirements. The applicator can address multiple challenges associated with conventional apparatuses/systems simultaneously, such as tensioning, alignment, and/or thermal requirements during the application of an adhesive product. Further, the applicator, system, and/or methods disclosed herein can address other challenges associated with conventional apparatuses/systems, such as operator ergonomics, safety concerns of handling adhesives with chemical compositions, reducing or eliminating foreign object debris, and improving first-pass quality. In addition, the applicator, system, and/or methods disclosed herein can provide efficient use of the adhesive product within the “out-time” limitations imposed by a manufacturer of an adhesive product, wherein such time constraints can cause operators to rush application of the adhesive produce, which can create defects and stress during the laydown process. Additionally, the disclosed applicator, system, and/or methods can help reduce or eliminate waste of the adhesive product by misapplication or accidental application requiring substantial labor hours, clean-up, and prep-time for re-application/re-work.

Moreover, the applicator can provide manual, automated, and/or semi-automated-assisted solutions requiring different levels of human interaction. While operating the applicator in a manual configuration, an operator can apply an adhesive substrate by rolling the applicator across the intended surface in a smooth and effortless path, creating a repeatable and precise placement of the adhesive substrate onto the part. As the thermally-controlled roller wheel transverses over the designated surface, the operator can manipulate the heat, pressure, and/or speed to meet requirements and quality standards. When the applicator is fully automated or arranged in an automated-assist configuration, a reduction in ergonomic issue, safety and quality may be achieved.

Turning now to the drawings with reference to, an applicator systemaccording to an example aspect of the present disclosure is depicted.is a side elevation view of the applicator system,is a top-looking-down view of the applicator system, andis another elevation view of the applicator system. For reference, the applicator systemdefines a first direction Y, a second direction X, and a third direction Z, which are mutually perpendicular to one another and form an orthogonal direction system. The first direction Y can be a lateral direction, the second direction X can be a transverse direction, and the third direction Z can be a vertical direction, for example. The applicator systemhas a first endand a second end, which are spaced from one another along the first direction Y.is a view of the applicator systemlooking from the second endtoward the first end.

Generally, the applicator systemis arranged to automatically apply adhesive material on a part. In this example, the partis a corrugated panel for an aircraft. The partincludes a plurality of ridgesto which respective adhesive strips can be applied automatically by the applicator system. Particularly, the applicator systemcan apply an adhesive strip to the top of each one of the ridges. The parthas a first edgeand a second edge, which are spaced from one another along the first direction Y. It will be appreciated that the partdisclosed herein is provided by way of example and that the applicator systemcan apply adhesive strips to parts having other configurations and geometries.

An adhesive tapehaving an adhesive substrateand a backingcan be provided to the applicator system. When the adhesive substratehas the backingremoved therefrom and is laid down and cut to shape on the part, e.g., on a top of one of the ridges, the adhesive substrateis arranged as an adhesive strip on the part. In some aspects, the adhesive tapecan be arranged so that the adhesive substrateis sandwiched between two backings, e.g., top and bottom backings. In one example, the adhesive substratecan be sandwiched between the backingand a poly film. The poly film can be stripped off near the tape spool, e.g., using a friction wind process at a follower spool. The adhesive tapecan be wound on a tape spool, which can be rotated in a controlled manner by an electric motorcoupled thereto so as to control the tension of the adhesive tape. The follower spoolcan receive the adhesive tapefrom the tape spooland can direct the adhesive tapeto a tape rollercoupled with a frame plate. The backingstripped from the adhesive substrateand certain stages of a laydown process, can be wound on a backing spool, which can be rotated in a controlled manner by an electric motorcoupled thereto so as to control tension of the backing. The backingwound on the backing spoolcan be directed from a backing rollercoupled with the frame plate. A tension directionof the tension on the adhesive tapeat the tape spoolis shown in, and similarly, a tension directionof the tension on the backingat the backing spoolis likewise shown in. In some instances during the laydown process, as depicted in, the tension directions,can be opposite one another.

The applicator systemincludes a framethat supports the frame plate, which is arranged orthogonal to the second direction X in this example. The frame platehas a trackhaving a first rail(or top rail) and a second rail(or bottom rail) spaced from the first railalong the third direction Z. The frame platealso defines a carriage slotthat extends lengthwise along the first direction Y between the first railand the second railalong the third direction Z. The frame platealso defines a hand-off slotbetween the first railand the second railalong the third direction Z. The hand-off slotis arranged below the carriage slotalong the third direction Z.

The applicator systemfurther includes a carriagemovable along the first direction Y. Specifically, the carriageis slidable along the trackin the first direction Y. The carriagecan include wheels that engage and allow for movement of the carriage relative to the track. The carriagecan be mechanically coupled with a drive mechanism, such as an electric motor, via a shuttle movable along the first direction Y. The shuttle can be coupled with the carriage through the carriage slot. The electric motor can drive the shuttle along the first direction Y, which can in turn move the carriagealong the first direction Y. When the carriagemoves away from the first endand toward the second end(or to the right in), the carriageis extending along the first direction Y. In contrast, when the carriagemoves away from the second endand toward the first end(or to the left in), the carriageis retracting along the first direction Y. The carriageis selectively extendable and retractable along the first direction Y, depending on the stage of a laydown process of the adhesive material on the part. The carriagehas a carriage platethat carries or support various components.

With reference toin addition to,is a close-up view of the carriage. As shown, the carriageincludes a backing clamp assemblycoupled with the carriage plate. The backing clamp assemblyincludes a backing clamparranged to selectively clamp the backingof the adhesive tapeso as to keep the backingcoupled with the adhesive substrate, e.g., as the carriage is extended along the first direction Y, or to selectively unclamp or release the backingto allow the backingto peel or be stripped from the adhesive substrate. The backing clampincludes a clamp arm, a backing clamp base, and a roller pin. When the clamp armis engaged, the roller pindoes not strip the backingfrom the adhesive substrate. When the clamp armis disengaged, the roller pinstrips the backingfrom the adhesive substrate, which allows the adhesive substrateto be laid down on one of the ridgesof the partwithout the backingpresent. The backingstripped from the adhesive substratecan be directed by way of the roller pinto the backing rollerand onward to the backing spool.

The carriagealso includes a cutter assembly. The cutter assemblycan be arranged within a cutoutdefined by the carriage plate. The cutter assemblycan be coupled with an adhesive guidethat guides the adhesive substrateinto the cutter assembly. The adhesive guideis coupled with a bracket of the backing clamp assemblyat one end and the cutter assemblyat its other end. The cutter assemblycan be slidably coupled with the second railof the track. In, for example, the cutter assemblyis illustrated in sliding engagement with the second rail.

The cutter assemblyincludes a housingand a cutter. The cutter assemblyis arranged to receive the adhesive substrate, e.g., within the housing. Indeed, the adhesive substratecan be arranged to pass through the cutter assembly, and in doing so, the adhesive substratecan pass within cutting range of the cutter. In this way, when controlled to do so, the cuttercan cut the adhesive substrate. The cuttercan be controlled pneumatically, for example. Moreover, the cutter assemblyis movable along the first direction Y between a cut position and a collapsed position, e.g., within the cutout. That is, the cutter assemblyis slidable along the first direction Y relative to the carriage plateso as to be movable between the cut position and the collapsed position. In the collapsed position, the cutter assemblyis engaged by a hand-off assembly, and this engagement causes a portion of the adhesive substrateto be exposed, which allows a pincher(of the hand-off assembly) having pincher arms,() to pinch and selectively hold the adhesive substrate. When the cutter assemblyis moved to the collapsed position, the adhesive guide(e.g., a cylindrical guide thereof) can be received, at least in part, within the housingof the cutter assembly. This “hand-off” process will be described in greater detail below. In the cut position, the cutteris arranged to selectively cut the adhesive substrate, e.g., after the adhesive substrateis laid down on the part. In some aspects, the cutter assemblycan include opposing cutter blade and shear backplate actuators that allow the adhesive to cut and release without sticking to the cutter assembly. Such features can facilitate the capability of placing multiple strips of the adhesive substrateonto the part.

As further shown in, the carriagefurther includes an applicatorcoupled with the carriage plate. The applicatorhas a swing armand an end effector. The swing armhas a proximal endand a distal end. The proximal endis pivotably coupled with the carriage plate. The end effectoris arranged at the distal endof the swing arm. An actuatorof the carriagecan move the applicatorbetween a retracted position and an engaged position. In, the applicatoris shown in the retracted position. In the retracted position, the applicatoris generally positioned away from the partand at a height along the third direction Z so that the end effectordoes not engage the hand-off assemblywhen the carriageis moved in close proximity thereto. The actuator(e.g., a pneumatic actuator, an electric actuator, etc.) can be controlled to push the swing armdownward, which causes the proximal endto pivot and the distal endto swing downward so that the applicatoris moved to the engaged position. In the engaged position, the end effectoris arranged to apply the adhesive substrateto the part. To return to the retracted position, the actuatorcan be controlled to pull the swing armupward, which causes the proximal endto pivot and the distal endto swing upward so that the applicatoris moved to the retracted position.

With reference now to, the end effector, or device arranged to apply the adhesive substrateto the part, will be described in further detail. The end effectorcan facilitate alignment, tensioning, and thermal requirements in the application of the adhesive substrateto the part. As illustrated, the end effectorincludes a roller wheel assemblyhaving a roller wheelrotatable about an axis of rotation and a plurality of thermally-controlled tubescircumferentially spaced from one another along an outer peripheryof the roller wheel. In this regard, the thermally-controlled tubesare externally exposed, e.g., so that the thermally-controlled tubescan make contact with the adhesive substrateto apply the adhesive substrateto the part. The thermally-controlled tubescan extend along the second direction X between opposing rimsof the roller wheel.

The thermally-controlled tubeseach define a chamberarranged to receive a heated working fluid, such as heated air driven by a fan. Specifically, the roller wheelis received between a first end plateand a second end plateof the swing arm. The first end platedefines an inletfluidly coupled with tube inlets of the thermally-controlled tubesand the second end platedefines one or more outlets in fluid communication with tube outlets of the thermally-controlled tubes. In this way, a heated working fluid can be directed into the inlet, through the thermally-controlled tubes, and exhausted through the one or more outlets defined by the second end plate(with the heated working fluid flowing through the thermally-controlled tubesin a left-to-right direction in). Accordingly, the thermally-controlled tubescan apply respective thermally-controlled physical forces to tact or apply the adhesive substrateto the part. Moreover, the thermally-controlled physical forces can be applied by the thermally-controlled tubesin rolling pulses, with each pulse corresponding to one of the thermally-controlled tubescontacting and pressing the adhesive substrateagainst the part. The thermal application in combination with the physical force provided by the thermally-controlled tubescan enhance the mating of the adhesive substrateto the part. A pneumatic regular can be used to control the physical compressive force applied on the adhesive substrateby the thermally-controlled tubesof the roller wheel. For instance, the actuatorcan be arranged to pneumatically control a compressive force that the thermally-controlled tubesapply to the adhesive substrateas the plurality of thermally-controlled tubestact the adhesive substrateto the part. In other example aspects, the actuatorcan be electrically actuated and controlled, e.g., by a linear electric motor and corresponding drive system.

The end effectoralso includes a leading assembly. The leading assemblyincludes leading rollersthat lead the roller wheel. The leading rollersfunction as guides for aligning the adhesive substrate, e.g., with a top of one of the ridgesof the part(). The leading rollersare supported by a pair of leading arms, including a first leading armand a second leading arm, that couple the leading rollersto the first end plateand the second end plate, respectively. A leading axleextends between the first and second leading arms,and provides a mount for the leading rollers. The leading rollersare carried by the leading axleand are rotatable about an axis of rotation. A position of the leading rollerscan be adjusted by an adjustment screwthat extends through the first end plateand contacts the first leading arm. By adjusting the adjustment screw, the position of the leading rollerscan be adjusted. A leading springcoupled with the first leading armcan bias the first and second leading arms,against an end of the adjustment screwto keep the leading rollersin the desired position. In this example, the leading rollersare connected by a leading shaftand define a leading relief channeltherebetween. The leading rollerseach have a rimand a tapered portionthat tapers from the rimtoward the leading shaft. The arrangement of the leading rollersthus maintains the adhesive substratewithin the leading relief channeland in contact with the leading shaft, allowing for some compliance between the pair of leading rollers. In some aspects, the leading rollersand the leading shaftare formed as a single piece that rotates about the leading axel.

Further, the end effectorincludes a lagging assembly. The lagging assemblyincludes lagging rollersthat lag the roller wheel. The lagging rollersfunction to, in combination with the leading rollers, tension and align the adhesive substratewith the part. The lagging rollersare supported by a pair of lagging arms, including a first lagging armand a second lagging arm, that couple the lagging rollersto the first end plateand the second end plate, respectively. A lagging axleextends between the first and second lagging arms,and provides a mount for the lagging rollers. The lagging rollersare carried by the lagging axleand are rotatable about an axis of rotation. A position of the lagging rollerscan be maintained by a lagging springthat is coupled with the lagging axleand engages a cross-memberextending between the first and second lagging arms,. In this example, the lagging rollersare connected by a lagging shaftand define a lagging relief channeltherebetween. The lagging rollerseach have a rimand a tapered portionthat tapers from the rimto the lagging shaft. The arrangement of the lagging rollersthus maintains the adhesive substratewithin the lagging relief channeland in contact with the lagging shaft. In some aspects, the lagging rollersand the lagging shaftare formed as a single piece that rotates about the lagging axel.

When the applicatoris initially pivoted downward to the engaged position, the leading rollersand lagging rollerscan prepare the adhesive substratefor the laydown process. Specifically, the leading rollersand the lagging rollerscan be arranged to receive the adhesive substratewithin the leading relief channeland the lagging relief channel, respectively, so as to tension and align the adhesive substratein a straight line with the part, e.g., to one of the ridgesof the part. Accordingly, in this initialization process, the adhesive substrateis offset from the partalong the third direction Z and is suspended underneath the roller wheelbetween the leading and lagging rollers,, e.g., like a trapeze wire. This effectively tensions and aligns the adhesive substratewith the partprior to the roller wheelcoming down and engaging the adhesive substrateto the part. After this initialization of the adhesive substrate, the roller wheelcan compress the adhesive substrateagainst the partas the carriage retracts along the first direction Y. The leading rollerscan roll along the partas the carriage retracts along the first direction Y but the leading rollersare arranged to roll along the partbut offset the adhesive substratefrom the partso as not to press the adhesive substrateto the part. In this regard, as noted above, the leading rollersact as guides and maintain alignment of the adhesive substrate. The lagging rollerscan roll along the adhesive substrateafter the thermally-controlled tubestact the adhesive substrateto the partor can be suspended in the air, depending on the position of the carriagealong the first direction Y.

As further shown in, the first end platecan also define a sensor inlet in which a temperature sensor(e.g., a thermocouple) can be arranged. The temperature sensorcan sense a temperature of the heated working fluid delivered to the thermally-controlled tubes. A temperature of the heated working fluid can be increased or decreased based at least in part on feedback provided by the temperature sensor. For instance, in at least some example aspects, air can be passed across one or more heaters(e.g., electric resistance heaters) of a heating system() of the applicator system. The heating systemcan include one or more fans to move the air across the heatersand to the end effector, e.g., by way of a conduit. The temperature sensorcan provide feedback indicating a temperature of the heated working fluid (or heated air) at the end effector. The feedback can be provided to a computing system() arranged to control the various controllable devices of the applicator system. The temperature sensorcan be communicatively coupled with the computing system, e.g., via a wired and/or wireless communication links. One or more processors of the computing systemcan cause the heatersto generate additional heat so as to increase the temperature of the air provided to the thermally-controlled tubes, e.g., by increasing the electric current therethrough, or to provide less heat so as to decrease the temperature of the air provided to the thermally-controlled tubes, e.g., by decreasing the electric current through the heaters. In some aspects, heated air passed through the thermally-controlled tubesis generated by passing preheated, pressurized air through a stationary mounted, temperature-controlled heating element and fed into the inlet. The temperature sensorcan provide feedback to a temperature controller of the computing system.

With reference again to, the carriagealso includes a sensor, which can be coupled with the carriage plate. The sensoris arranged to detect the edges of the part. For instance, as the carriageis extended along the first direction Y (moving toward the second end), the sensorcan sense a position of the first edgeof the part, and as the carriagecontinues to be extended along the first direction Y toward the second end, the sensorcan sense a position of the second edgeof the part. The position of the first edgeand the position of the second edgecan be stored, e.g., in one or more memory devices of the computing systemof the applicator system. The temperature sensorcan be communicatively coupled with the computing system, e.g., via a wired and/or wireless communication links. The applicatorcan be moved the to the engaged position and retracted from the engaged position based at least in part on the position of the first edgeand the position of the second edge.

While the carriagecan be considered to be “one hand” of the applicator system, the hand-off assemblycan function as the “other hand” in that the pincherof the hand-off assemblypinches and accepts the adhesive substrateduring a meet up or “hand-off” between the cutter assemblyand the hand-off assembly. The pincherthen holds the adhesive substrate, at least for a period of time, as the applicatorapplies the adhesive substrateto the part. When the carriageis moved so that the cutter assemblyengages the hand-off assembly, the cutter assemblyis moved to the collapsed position. This causes the carriage plateto move relative to the cutter assemblyalong the first direction Y.

As shown in, when the cutter assemblyis in the collapsed position, the cutter assemblyexposes a portionof the adhesive substrate(e.g., a tongue of material) to allow the pincherof the hand-off assemblyto pinch and selectively hold the adhesive substrate. More specifically, the pincherhas pinch arms, including a first pinch armand a second pinch arm, which are movable between an open position and a closed position. Before the meet up between the cutter assemblyand the hand-off assembly(i.e., before the cutter assemblyengages the hand-off assembly), the first and second pinch arms,of the pincherare moved to or kept in the open position. Then, when the cutter assemblyengages the hand-off assemblycausing the cutter assemblyto move to the collapsed position, the portionof the adhesive substratebecomes exposed and ready to be pinched. Accordingly, the first and second pinch arms,are controlled to move to the closed position to pinch the exposed portionof the adhesive substrate, e.g., as shown in the close-up view of. In this regard, the portionof the adhesive substrateis “handed off” and held by the hand-off assembly.

In addition, the hand-off assemblycan be movable along the first direction Y. In at least some example aspects, with the cutter assemblystill engaged with the hand-off assembly, the carriageand the hand-off assemblycan be moved along the first direction Y a predetermined distance from the second edgeof the part. With the carriageand the hand-off assemblymoved the predetermined distance from the second edgeof the part, a brake(e.g., a piston-applied brake as shown in) of the hand-off assemblycan be set so that the position of the hand-off assemblyis held in place, which consequently holds the portionof the adhesive substrateheld by the pincherin place. Accordingly, the “other hand” or hand-off assemblyhas prepared the adhesive substratefor application to the part.

The applicator systemalso includes a traverse assembly. The traverse assemblyincludes a part clampthat clamps to the partto hold the applicator systemin place during application of an adhesive substrate to one of the ridgesof the part. Then, once a cycle of the laydown process is complete (e.g., when an adhesive substrate is laid down on the given ridge and cut to shape), the part clampcan be controlled to unclamp from the part, and a drive mechanism (e.g., an electric motor) can shuffle the part clampalong the second direction X to a subsequent clamp location. At the subsequent clamp location, the part clamp can be clamped in place and application components of the applicator systemcan be slid relative to the framealong the second direction X and another cycle of the laydown process can commence.

With the applicator systemgenerally described, an example manner in which the applicator systemcan apply an adhesive material to the partwill be provided below.

is a flow diagram for a methodfor applying an adhesive substrate to a part using an applicator system. For context, the methodwill be described with respect to the applicator system. Accordingly, reference toin addition towill be made below. It will be appreciated, however, that the methodcan be implemented using an applicator system having a different configuration than the applicator system.

At, the methodcan include commencing a laydown process in which one or more laydown cycles can be implemented to apply an adhesive material to various portions of a part, such as a corrugated panel for an aircraft. For instance, the applicator systemcan be used to implement a laydown process in which an adhesive substrate is applied to each one of the ridgesof the part. A laydown cycle can be implemented to lay down an adhesive substrate on a given one of the ridges.