PROBLEM<\/h2>\n
The adhesive application process on manufactured components required high repeatability and precise material volume control. Another significant challenge was the need to handle multiple product variants while maintaining required production efficiency. Production targets were set at approximately 400\u2013600 units per shift, with adhesive applied to a batch of 10 elements in under 4 minutes.<\/p>\n
The client needed a solution to relieve the operator from manually guiding the applicator, while ensuring higher repeatability, precise parameter control, and seamless adaptability to various product references.<\/p>\n
CHALLENGE<\/h2>\n
The project goal was to design and manufacture an automated gluing station to fully automate the adhesive dispensing process.<\/p>\n
A key objective was to minimize operator involvement in the application process itself. The operator\u2019s role was streamlined to component preparation, loading, cycle initiation, and unloading finished batches.<\/p>\n
At the same time, the station required high flexibility to accommodate a wide variety of product variants. The components varied significantly in size, requiring custom motion paths and dispensing parameters for each reference.<\/p>\n
SCOPE OF WORK<\/h2>\n
Our team delivered a comprehensive turn-key solution covering:<\/p>\n
<\/i>Station concept development<\/p>\n
<\/i>Mechanical design and fabrication<\/p>\n
<\/i>Electrical engineering and design<\/p>\n
<\/i>Control systems engineering<\/p>\n
<\/i>PLC programming<\/p>\n
<\/i>HMI operator interface design<\/p>\n
<\/i>3-axis manipulator programming<\/p>\n
<\/i>DavTech adhesive dispensing system integration<\/p>\n
<\/i>Safety systems design and implementation<\/p>\n
<\/i>Panel building and station assembly<\/p>\n
<\/i>Commissioning and functional testing<\/p>\n
<\/i>Factory Acceptance Testing (FAT)<\/p>\n
<\/i>Site Acceptance Testing (SAT) preparation and operator training<\/p>\n
The project was executed as an end-to-end custom solution, handling every stage from initial concept to final plant commissioning.<\/p>\n
SOLUTION<\/h2>\n
The implemented station centers around a 3-axis Cartesian manipulator equipped with a precision dispensing head. Servo motors drive the head along programmed X, Y, and Z paths to deliver fully automated, repeatable applications. Material delivery is managed via an integrated DavTech dispensing system.<\/p>\n
The system is powered by a PLC controller and an intuitive HMI panel for machine operation, product recipe selection, process parameter control, and active hardware\/alarm diagnostics. Network communication across all components uses the PROFINET protocol.<\/p>\n
A robust safety system continuously monitors safety doors and the positioning of the retractable drawer housing the component pallets.<\/p>\n
FLEXIBLE MULTI-REFERENCE HANDLING<\/h2>\n
A core feature of the station is its capability to handle diverse product variants. The system stores up to 30 unique product references, each configured with independent process parameters:<\/p>\n
<\/i>Manipulator travel trajectory<\/p>\n
<\/i>Individual axis positioning<\/p>\n
<\/i>Dispensing head height<\/p>\n
<\/i>Application speed<\/p>\n
<\/i>Idle transit speed<\/p>\n
<\/i>Dispensing unit program and material parameters<\/p>\n
A single path supports up to 60 sequential steps. Each step defines specific axis coordinates and toggles active adhesive dispensing. Product changeovers require zero mechanical re-tooling and are managed entirely by selecting the matching reference recipe on the panel.<\/p>\n
HOW IT WORKS<\/h2>\n
Preparation: The operator places 10 raw components onto a dedicated, interchangeable pallet inside the retractable drawer and closes the drawer.<\/p>\n
Initiation: The operator starts the automatic cycle on the HMI panel.<\/p>\n
Application: Once safety interlocks confirm the cell is secure, the 3-axis manipulator executes the reference trajectory. The head moves smoothly between target coordinates, triggering the DavTech unit to dispense adhesive along designated segments.<\/p>\n
Completion: Upon path completion, the manipulator homes, the drawer unlocks, and the HMI signals cycle completion. The operator removes the finished assembly and loads the next set.<\/p>\n
CONTROL AND DIAGNOSTIC SYSTEM<\/h2>\n
Daily operation is handled via the HMI panel. Operators select product references and launch production cycles, while authorized personnel can create or adjust recipes. Key configurable parameters include:<\/p>\n
<\/i>Sequence position coordinates<\/p>\n
<\/i>Active dispensing points<\/p>\n
<\/i>Transit clearance heights<\/p>\n
<\/i>Axis movement speeds<\/p>\n
<\/i>Reference-specific process parameters<\/p>\n
Real-time diagnostics cover hardware status, active alarms, and I\/O signal monitoring to accelerate troubleshooting and reduce downtime.<\/p>\n
RESULTS AND CLIENT BENEFITS<\/h2>\n
<\/i>Automated Application: Replaced manual tool guidance with precise 3-axis automation.<\/p>\n
<\/i>Higher Repeatability: Ensured consistent bead geometry and volume across all units.<\/p>\n
<\/i>Reduced Operator Dependency: Eliminated quality variations caused by manual application techniques.<\/p>\n
<\/i>Process Control: Provided tight parameter monitoring and recipe management.<\/p>\n
<\/i>Multi-Variant Capability: Consolidated up to 30 product variants onto a single cell.<\/p>\n
<\/i>Fast Changeovers: Streamlined product switching via panel recipe selection.<\/p>\n
<\/i>Improved Ergonomics: Removed repetitive manual tasks and enhanced operator safety.<\/p>\n
<\/i>Rapid Fault Resolution: Built-in I\/O and hardware diagnostics speed up troubleshooting.<\/p>\n
The modular recipe structure also future-proofs the line, enabling simple onboarding of new product variants without structural modifications.<\/p>\n
SUMMARY<\/h2>\n
This project demonstrates how automating adhesive application increases production consistency, minimizes manual error, and preserves product versatility. By integrating a 3-axis Cartesian manipulator, a DavTech dispensing system, PLC controls, and a flexible recipe engine, the station meets current throughput targets while remaining fully adaptable to future manufacturing demands.<\/p>\n
<\/p>\n
![\"\"](\"https:\/\/mjgroup.pl\/wp-content\/uploads\/2026\/08\/3.webp\")
<\/p>\n
![\"Stanowisko](\"https:\/\/mjgroup.pl\/wp-content\/uploads\/2026\/08\/C0441T01.webp\")
<\/p>\n
![\"\"](\"https:\/\/mjgroup.pl\/wp-content\/uploads\/2026\/08\/2.webp\")
<\/p>\n
![\"\"](\"https:\/\/mjgroup.pl\/wp-content\/uploads\/2026\/08\/1-1.png\")
<\/p>\n<\/div>