Achieving uniform and precise adhesive coating of sealing resin on connectors requires high-precision dispensing technology, equipment selection, and process optimization. This, combined with the connector’s structural characteristics and sealing requirements, necessitates breakthroughs in core technologies and system collaboration to achieve precise control of adhesive quantity and consistent coating. The following details the implementation path from four dimensions: technical solutions, core equipment, process optimization, and application effects:
Core Technology Support: Precise Control of Adhesive Uniformity and Stability
● Non-Contact Spray Dispensing Technology
a.Technical Principle:Using Piezoelectric Injection glue dispensing valve or Pneumatic injection glue dispensing valve, the adhesive is atomized or quantitatively sprayed onto the connector surface under high pressure, eliminating contact with the workpiece and avoiding scratches to precision connector components. Piezoelectric spray valves can achieve high-frequency spraying of 300 dots/second, suitable for medium to high viscosity sealing resins, and particularly suitable for scenarios with small connector pin pitch and sensitive surfaces.
Piezoelectric Injection dispensing valve Pneumatic jet glue dispensing valve
b.Precise Control:Through air pressure regulation, screw pump drive, or piston push, the adhesive quantity error is precisely controlled within ±3%, and the adhesive dot diameter matches the connector pitch, ensuring uniform and deviation-free coating.
●High-Precision Needle and Fluid Control Technology
a.Needle Design: Utilizes a customized high-precision dispensing needle, optimizing the internal flow channel through precision machining technology to eliminate unnecessary tubing resistance, prevent solid particle retention, and ensure consistent needle outlet and body diameter. This achieves smooth adhesive flow, reduces solid-liquid separation, and suppresses coating separation by up to 80%, solving the problems of clogging and stringing in high-viscosity sealing resins.
b.Dynamic Adhesive Quantity Adjustment:Employs PWM functionality to precisely control the opening and closing time of the dispensing valve, combined with a screw pump PID control system, dynamically adjusting the dispensing quantity and speed to adapt to the adhesive application needs of different parts of the connector, ensuring consistent adhesive line width and thickness.
●Intelligent Motion Control and Path Planning
a.Multi-Axis Linkage System: Equipped with a servo motor or DD motor drive and a five-axis linkage algorithm, achieves micron-level positioning accuracy, up to ±0.01 mm, with stable repeatability. This ensures the dispensing head moves precisely along the complex contours of the connector, covering straight lines, arcs, and 3D curved surfaces.
b.Trajectory interpolation algorithm:For complex parts such as connector corners and gaps, a speed look-ahead algorithm and continuous trajectory interpolation technology are used to avoid glue breakage and glue accumulation at corners and ensure continuous closure of the glue path.
Key Equipment Selection: Customized Configurations for Connector Dispensing
● Fully Automatic Dispensing Machine
a.Core Configuration: Equipped with a CCD vision positioning system, achieving a positioning accuracy of ±0.02 mm. It can identify connector model, location, and dispensing area, automatically calibrating the dispensing head coordinates to avoid dispensing deviations caused by workpiece offset. It features a non-contact jet valve, adaptable to sealing resins of different viscosities, and supports high-speed dispensing.
Automatic In-line PCB Glue Dispensing Machine SEC-DH400L
Second Intelligent In-line Automated Glue Dispensing Machine SEC-DH400L adopts an integrated mineral casting design, with ultra-high precision and super stability, powerful expansion capabilities, and can realize ion cleaning, dispensing, detection, UV exposure and other functions;
Adopting a gantry structure, it can bear large loads, stable structure, and a powerful CCD visual positioning system, which can meet the requirements of Mark point positioning, edge positioning, and 3D scanning positioning; strong scalability, and can expand AOI detection 3D detection, UV exposure curing and other functions;
Strong platform compatibility, contact and non-contact dispensing, single-head and multi-head synchronous dispensing, automatic compensation and adjustment of double-head spacing, five-axis dispensing function based on needle A/R displacement, etc.
b.Functional Advantages:Supports programmable control of dispensing path, glue volume, speed, and other parameters, enabling 24-hour continuous production. Dispensing speeds up to 100 mm/s meet the needs of mass production of connectors, with consistency far superior to manual operation.
●Intelligent Dispensing Robot
a.Integrated AI Vision and Dynamic Adjustment:Integrates an AI vision system to detect and automatically correct dispensing path errors in real time. Combined with a dual-liquid screw pump PID control system, it can handle high-viscosity sealing materials and is suitable for connectors with high sealing performance requirements, such as connectors for new energy vehicles and medical sensor connectors.
b.Flexible Changeover Capability: Supports DXF map functionality and rapid switching of process formulas, adapting to different connector specifications without hardware replacement, shortening changeover time and reducing inventory costs.
● Two-Component Glue Potting Machine
a.Applicable Scenarios: If the sealing resin is a two-component material, a two-component dispensing machine must be selected. The dispensing accuracy must reach 1.5% or higher to ensure accurate mixing ratios of components A and B, avoiding uneven curing and sealing failure due to uneven mixing.
Fully Automatic 3-Axis Potting Machine SEC-S3030B & SEC-S3030C
The work of the glue potting machine mainly depends on air pressure control. Through the air pressure device, the glue is pressed out by pressure, and the size of the glue is controlled by the pump body. At the same time, the robotic arm is responsible for controlling the moving position of the glue discharge to achieve fully automated operation. This automated operation not only solves the problem of low labor efficiency, but also greatly improves the quality of production.
b.High-Efficiency Production: Dispensing speed can reach 5-6 seconds/cycle. The daily output of a single machine is equivalent to 4-6 workers, while reducing inconsistent glue dosage caused by human operation and improving connector sealing yield.
Process Optimization: Solving Core Pain Points in Connector Dispensing
● Stringing and Adhesive Cut-off Control for High-Viscosity Resins
a.Optimized Retraction Function: Addressing the stringing issue of high-viscosity sealing resins, a retraction function in the dispensing valve quickly retracts the adhesive at the end of dispensing, preventing adhesive residue. Simultaneously, an adhesive wiping function automatically wipes away adhesive after reaching a set value, ensuring a uniform adhesive path and reducing material waste.
b.Anti-clogging Design: The dispensing function automatically activates during machine shutdown to prevent resin from solidifying and clogging within the valve body, ensuring continuous and stable equipment operation and reducing downtime for maintenance.
● Uniform Coating for Complex Trajectories
a.Path Planning and Interpolation Algorithm: For complex trajectories such as connector pins and terminals, a spatial circular interpolation algorithm is used to achieve contour dispensing at different angles, ensuring uniform adhesive formation along the connector mating surface and avoiding uneven coating due to complex trajectories.
b.Early Dispensing Control:An early dispensing function dispenses adhesive at the start of the trajectory and closes it at the end, ensuring consistent adhesive volume at both ends and avoiding discrepancies in dispensing volume.
● Coordinated Control of Dispensing and Curing
a.Synchronous Signal Trigger:Utilizing high-speed PSO output, millisecond-level signal synchronization between dispensing and curing processes is achieved. This avoids delays in assembly or curing after dispensing due to signal latency, ensuring the adhesive bonds with the connector in optimal condition and improving sealing reliability.
b.Curing Process Matching: Based on the curing characteristics of the sealing resin, the curing time and temperature after dispensing are adjusted to ensure uniform curing of the adhesive on the connector surface, preventing seal failure caused by uneven curing.
Application Effects and Verification: Achieving uniform and precise coating is a key indicator.
● Improved Adhesive Quantity Consistency and Precision
a.Through the above technologies and processes, adhesive quantity error can be controlled within ±3%, the adhesive dot diameter matches the connector spacing, and coating uniformity is significantly improved, avoiding problems such as missed or excessive application caused by manual operation.
b.Non-contact dispensing avoids damage to precision connector components while ensuring regular adhesive dot shape, meeting the high-precision sealing requirements of the connector.
● Production Efficiency and Cost Optimization
a.Fully automated dispensing equipment and intelligent robots enable automated mass production of connector dispensing, increasing dispensing efficiency by more than 14 times compared to manual methods. Dispensing time per connector can be reduced to 0.5-2 seconds, significantly increasing production capacity.
b.High-precision needles and precise glue volume control reduce sealant waste, increasing coating utilization to over 90%. This also reduces needle replacement frequency, cleaning time, and detergent consumption, lowering overall production costs.
● Guaranteed Sealing Reliability
a.Uniform and precise glue coating ensures a continuous, closed sealing layer on the connector mating surfaces, preventing leaks and other problems caused by uneven glue application. This improves the connector’s temperature resistance, weather resistance, and chemical corrosion resistance, meeting the stringent sealing performance requirements of high-end fields such as automotive, new energy, and medical.
Second Intelligent has played an important role in theresearch, development, manufacturing, pre-sales and after-sales services of fluid dispensing robot, potting and coating solutions which range from various types of automatic fluid dispensing, potting, two-component potting machines and coating machines with desktop, free-standing, inline or cobot combined systems, and widely used in global electrical, electronics, home appliances, automobile, telecom, pharmaceutical, automotive electronics, semiconductor, aerospace, LED and more.
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