Automated Dispensing Enables Continuous Sealing
Challenge
A high-volume manufacturer required a precise and repeatable method for dispensing a liquid sealant onto large, insulated enclosures. The application demanded consistent bead placement along integrated copper tubing in a high-mix production environment, with the ability to switch between multiple enclosure configurations without stopping production or requiring operator setup.
A key requirement was eliminating downtime and variability associated with manual changeovers.
Solution
All World Automation engineered a fully automated dispensing cell designed for continuous, changeover-free operation with minimal operator dependency.
The system automatically manages part flow into the cell and positions each enclosure through a controlled, repeatable process. Once located, a FANUC M-20 robot applies a continuous, controlled bead of sealant with consistent geometry around each enclosure perimeter. Material is delivered through a stainless steel hose to ensure stable application performance.
The system is designed for intelligent mixed-model production, where a barcode reader identifies each incoming enclosure and automatically selects the correct robot program from a library of eight. This enables seamless, fully automatic changeover between part numbers with no manual setup, tool changes, or operator intervention.
Safety & Controls
The system incorporates integrated safety features and was reviewed and evaluated by a third-party safety provider to support compliance with applicable industrial automation safety standards.
Light curtains at infeed and outfeed points, combined with muting functionality, differentiate between product movement and personnel access. This maintains a controlled, safeguarded operating envelope while allowing continuous production flow. All safety devices are fully integrated into the control architecture for immediate response to access events without interrupting validated cycle conditions.
Results
The automated cell improves application consistency and significantly reduces variability associated with manual processes. Precise sealant placement eliminates gaps and missed coverage, resulting in a more reliable sealing process and improved product quality.
Just as importantly, the system removes changeovers as a production constraint. Multiple enclosure types can now run sequentially without operator intervention, eliminating setup delays and reducing downtime between part numbers. This enables more flexible scheduling and higher sustained throughput in a mixed-model environment.
The combination of consistent application and fully automated changeover capability has significantly improved overall process stability and reduced the need for operator involvement in day-to-day production decisions.
“The biggest advantage is consistency. We can run multiple enclosure types back-to-back with no intervention, and the sealing quality never changes,” said Project Manager Todd Narkis.
