Claims:WE CLAIM:
1. An automated sealant refilling system (100) comprising:
• a sealant dispensing unit (102) configured to be in fluid communication with a sealant reservoir;
• a conveyor (104) configured to convey empty containers (106) to said sealant dispensing unit (102);
• a pair of sensors mounted proximal to the sealant dispensing unit (102), said sensors configured to generate signals when said empty containers (106) are in the vicinity of said sealant dispensing unit (102);
• a plurality of valves including a first valve connected to said conveyor (104) to divert fluid power to said conveyor (104), a second valve and a third valve connected to said sealant dispensing unit (102), said second and third valves configured to divert fluid power to said sealant dispensing unit (102); and
• a control unit communicatively coupled to said sensors and said valves, said control unit configured to receive said signals, and further configured to actuate said valves based on said signals to facilitate conveying of said containers (106) to said sealant dispensing unit (102), dispensation of a predetermined quantity of sealant in said container (106) and conveying of said filled container (106) away from sealant dispensing unit (102).
2. The system (100) as claimed in claim 1, wherein inlet of said sealant dispensing unit (102) is provided with a ram (108) configured to allow the flow of the sealant therethrough.
3. The system (100) as claimed in claim 1, wherein said conveyor (104) includes:
o a plurality of pallet bodies (110) configured to facilitate loading of said containers (106) thereon;
o a pair of guide rails (112) configured to facilitate mounting of said pallet bodies (110) thereon, and further configured to guide said pallet bodies (110) along a predefined track; and
o a pneumatic cylinder (114) connected to said first valve and said guide rails (112), said cylinder (114) configured to facilitate linear motion of said pallet bodies (110) on said guide rails (112).
4. The system (100) as claimed in claim 1, wherein said control unit is a programmable logic controller.
5. The system (100) as claimed in claim 1, wherein said fluid dispensing unit (102) includes a manual switching system (100).

Dated this 10th day of February, 2022

___________________________
MOHAN RAJKUMAR DEWAN, IN/PA – 25
of R.K.DEWAN & CO.
Authorized Agent of Applicant

TO,
THE CONTROLLER OF PATENTS
THE PATENT OFFICE, AT MUMBAI

, Description:FIELDs
The present disclosure relates to the field of sealant refilling systems.
BACKGROUND
The background information herein below relates to the present disclosure but is not necessarily prior art.
Automotive manufacturing units continuously require sealant fluids such as resins, glue, wax, and varnish for various applications. If at any instance, the sealant fluids are not available, the processing time and the capital are affected. It is, therefore, necessary that the containers carrying the sealant fluids are frequently replenished so that processes related thereto are not hampered.
However conventionally, for replenishment of the container, an operator has to pick the container and place it at the refilling unit, and again pick the filled container place it at the location of application. This practice consumes plenty of time which otherwise could have been productively utilized, and is also cumbersome.
There is therefore felt a need for a system that alleviates the afore-mentioned drawbacks.
OBJECTS
Some of the objects of the present disclosure are described herein below:
One object of the present disclosure is to provide an automated sealant refilling system.
Another object of the present disclosure is to provide a system that saves productive time.
Yet another object of the present disclosure is to provide a system that reduces human efforts.
Other objects and advantages of the present disclosure will be more apparent from the following description, which is not intended to limit the scope of the present disclosure.
SUMMARY
The present disclosure envisages an automated sealant refilling system. The system comprises a sealant dispensing unit, a conveyor, a pair of sensors, a plurality of valves, and a control unit. The sealant dispensing unit is configured to be in fluid communication with a sealant reservoir. The conveyor is configured to convey empty containers to the sealant dispensing unit. The pair of sensors is mounted proximal to the sealant dispensing unit. The sensors are configured to generate signals when the empty containers are in the vicinity of the sealant dispensing unit. The plurality of valves includes a first valve, a second valve and a third valve. A first valve of the plurality of valves is connected to the conveyor. The second valve and the third valve of the plurality of valves are connected to the sealant dispensing unit. The valves are configured to divert fluid power to the conveyor and the sealant dispensing unit. The control unit is communicatively coupled to the sensors and the valves. The control unit is configured to receive the signals, and is further configured to actuate the valves based on the signals to facilitate conveying of the containers to the sealant dispensing unit, dispensation of a predetermined quantity of sealant in the container and conveying of the filled container away from sealant dispensing unit.
In an embodiment, the inlet of the sealant dispensing unit is provided with a ram configured to allow the flow of the sealant therethrough.
In another embodiment, the conveyor includes:
o a plurality of pallet bodies configured to facilitate loading of the containers thereon;
o a pair of guide rails configured to facilitate mounting of the pallet bodies thereon, and further configured to guide the pallet bodies along a predefined track; and
o a pneumatic cylinder connected to the first valve and the guide rails, the cylinder configured to facilitate linear motion of the pallet bodies on the guide rails.
In yet another embodiment, the control unit is a programmable logic controller.
In still another embodiment, the fluid dispensing unit includes a manual switching system.
BRIEF DESCRIPTION OF ACCOMPANYING DRAWING
An automated sealant refilling system, of the present disclosure, will now be described with the help of the accompanying drawing, in which:
Figure 1 illustrates an isometric view of the system, in accordance with an embodiment of the present disclosure; and
Figure 2 illustrates an isometric view of a conveyor of the system of Figure 1.
LIST OF REFERENCE NUMERALS
100 – System
102 – Sealant dispensing unit
104 – Conveyor
106 – Container
108 – Ram
110 – Pallet body
112 – Guide rail
114 – Pneumatic cylinder
DETAILED DESCRIPTION
Embodiments, of the present disclosure, will now be described with reference to the accompanying drawing.
Embodiments are provided so as to thoroughly and fully convey the scope of the present disclosure to the person skilled in the art. Numerous details are set forth, relating to specific components, and methods, to provide a complete understanding of embodiments of the present disclosure. It will be apparent to the person skilled in the art that the details provided in the embodiments should not be construed to limit the scope of the present disclosure. In some embodiments, well-known processes, well-known apparatus structures, and well-known techniques are not described in detail.
The terminology used, in the present disclosure, is only for the purpose of explaining a particular embodiment and such terminology shall not be considered to limit the scope of the present disclosure. As used in the present disclosure, the forms "a,” "an," and "the" may be intended to include the plural forms as well, unless the context clearly suggests otherwise. The terms "comprises," "comprising," “including,” and “having,” are open ended transitional phrases and therefore specify the presence of stated features, elements, modules, units and/or components, but do not forbid the presence or addition of one or more other features, elements, components, and/or groups thereof. The particular order of steps disclosed in the method and process of the present disclosure is not to be construed as necessarily requiring their performance as described or illustrated. It is also to be understood that additional or alternative steps may be employed.
When an element is referred to as being "mounted on," “engaged to,” "connected to," or "coupled to" another element, it may be directly on, engaged, connected or coupled to the other element.
The terms first, second, third, etc., should not be construed to limit the scope of the present disclosure as the aforementioned terms may be only used to distinguish one element or component from another element or component. Terms such as first, second, third etc., when used herein do not imply a specific sequence or order unless clearly suggested by the present disclosure.
Terms such as "below," "lower," "above," and the like, may be used in the present disclosure to describe relationships between different elements as depicted from the figures.
Automotive manufacturing units have a variety of sealant dispensing units which are employed for various applications. Presently, containers are carried manually to and fro from the sealant dispensing unit to the job location. However, each container weighs at least 18 kilograms of weight when filled. Therefore, manually conveying the container is both tedious and time-consuming. There is therefore required a system that adds to the convenience and saves time.
A preferred embodiment of an automated sealant refilling system (100) (hereinafter referred to as ‘system 100’) of the present disclosure will now be described in detail with reference to Figure 1 through Figure 4. The preferred embodiment does not limit the scope and ambit of the disclosure.
The automated sealant refilling system (100) comprises a sealant dispensing unit (102), a conveyor (104), a pair of sensors, a plurality of valves and a control unit. The sealant dispensing unit (102) is configured to be in fluid communication with a reservoir containing the sealant. The reservoir is additionally provided with a pumping mechanism which, when required pumps the sealant to the tank. The conveyor (104) is configured to convey empty containers (106) to the sealant dispensing unit (102). The sensors are mounted proximal to the sealant dispensing unit (102). The sensors are configured to generate signals when the empty containers (106) are in the vicinity of the sealant dispensing unit (102). The valves are configured to be interconnected with each other. A first valve of the plurality of valves is connected to the conveyor (104), and is configured to divert fluid power to the conveyor (104). A second valve and a third valve of the plurality of valves are connected to the sealant dispensing unit (102). The second and the third valves are configured to divert fluid power to the sealant dispensing unit (102). The control unit is communicatively coupled to the sensors and the valves. The control unit is configured to receive the signals and process the received signals. The control unit is further configured to actuate the valves to facilitate conveying of the containers (106) to the sealant dispensing unit (102) and dispense a predetermined quantity of sealant in the container (106). Thereafter, the control unit conveys the filled container (106) away from sealant dispensing unit (102) to a desired location where sealant applications are conducted.
The control unit is further configured to actuate the pumping mechanism of the reservoir.
The control unit is configured for the control of manufacturing processes such as assembly lines that require high reliability control and ease of programming and process fault diagnosis. The control unit includes a memory and a processor. The memory is configured to store a set of predetermined rules and threshold parameter values. The memory may include any computer-readable medium known in the art including, for example, volatile memory, such as static random access memory (SRAM) and dynamic random access memory (DRAM), and/or a non-volatile memory, such as read only memory (ROM), erasable programmable ROM, flash memories, hard disks, optical disks, and magnetic tapes. The processor is configured to cooperate with the memory to receive the set of pre-defined rules and is further configured to generate processing commands. The processor is further configured to generate processing commands. The processor may be implemented as one or more microprocessors, microcomputers, digital signal processors, central processing units, state machines, logic circuitries, and/or any devices that manipulate signals based on operational instructions. Among other capabilities, the processor is configured to fetch and execute the predetermined set of rules stored in the memory.
In an embodiment, the control unit is a programmable logic controller.
In an embodiment, the sensors are proximity sensors.
In an embodiment, the first and second valves are 5/3 valves. In another embodiment, the third valve is a 3/2 valve. In yet another embodiment, the second and third valves are solenoid valves configured to regulate the flow of the sealant from the tank and the sealant dispensing unit (102) respectively.
In an embodiment, the inlet of the sealant dispensing unit (102) is provided with a ram (108) configured to generate the flow of the sealant therethrough. The ram (108) is specifically, a plunger that is connected to the third valve. When in an operative configuration, the third valve is actuated to lower the ram (108) to reach out to the container (106) and dispense the sealant. After the dispensing operation is concluded, the third valve is deactivated to raise the ram (108) back to its original position.
The conveyor (104) is a pneumatically actuated conveyor (104). The conveyor (104) comprises a plurality of pallet bodies (110), a pair of guide rails (112) and a pneumatic cylinder (114). The containers (106) are loaded on the pallet bodies (110). The guide rails (112) are configured to facilitate mounting of the pallet bodies (110) thereon. The guide rails (112) are further configured to guide the pallet bodies (110) along a predefined track which is from the job location to the sealant dispensing unit (102) and from the sealant dispensing unit (102) to the location of the sealant application. The pneumatic cylinder (114) is connected to the guide rails (112), and is connected to the first valve to facilitate linear motion of the pallet bodies (110) on the guide rails (112).
Alternatively, a hydraulic cylinder is connected to the first valve and guide rails (112) to facilitate linear motion of the pallet bodies (110) on the guide rails (112).
In an operative configuration, an empty container (106) is loaded on the pallet bodies (110) that are mounted on guide rails (112). The first valve is manipulated to facilitate the linear motion of the pallet bodies (110) along the predefined track. More specifically, the container (106) loaded on the pallet body (110) is transported from the job location where the sealant is required to the sealant dispensing unit (102). When in the vicinity of the sealant dispensing unit (102), the proximity sensors sense the location of the containers (106) and generate signals. The sensed signals are received by the control unit. Based on the sensed signals, the control unit actuates the second valve and the third valve. As a result, the flow of the sealant from reservoir to the tank and from the tank to the container (106) via the ram (108) is enabled. After a predefined quantity of sealant is dispensed, the control unit stops dispensing the liquid.
In an embodiment, the system (100) includes a fluid level measurement sensor selected from the group consisting of IR sensors and ultra-sonic sensors. The level measurement sensors are mounted on the sealant dispensing unit (102). The level measurement sensors are configured to determine the level of sealant in the container (106) and generate a signal based on the level measured. The signal is received by the control unit which processes the signal, and then after determining the quantity of sealant dispensed de-actuates the second valve and the third valve thereby stopping the flow of sealant through the valves. The filled container (106) is conveyed back to the job location.
In one embodiment, the sealant dispensing unit (102) includes a manual switching system (100) which enables an operator to run the unit according to requirements.
The system (100) of the present disclosure facilitates automated transportation of the empty container (106) to the sealant dispensing unit (102), and back from the sealant dispensing unit (102) to a desired location without the need for human interference. As a result, productive time and capital is saved to a relatively greater extent.
The foregoing description of the embodiments has been provided for purposes of illustration and not intended to limit the scope of the present disclosure. Individual components of a particular embodiment are generally not limited to that particular embodiment, but, are interchangeable. Such variations are not to be regarded as a departure from the present disclosure, and all such modifications are considered to be within the scope of the present disclosure.
TECHNICAL ADVANCES AND ECONOMICAL SIGNIFICANCE
The present disclosure described herein above has several technical advantages including, but not limited to, the realization of an automated sealant refilling system, that:
• saves productive time; and
• reduces human efforts.
The foregoing description of the specific embodiments so fully reveals the general nature of the embodiments herein that others may, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein may be practiced with modification within the spirit and scope of the embodiments as described herein.
Throughout this specification the word “comprise”, or variations such as “comprises” or “comprising”, will be understood to imply the inclusion of a stated element or group of elements, but not the exclusion of any other element or group of elements.
The use of the expression “at least” or “at least one” suggests the use of one or more elements or ingredients or quantities, as the use may be in the embodiment of the disclosure to achieve one or more of the desired objects or results.
Any discussion of documents, acts, materials, apparatus, articles or the like that has been included in this specification is solely for the purpose of providing a context for the disclosure. It is not to be taken as an admission that any or all of these matters form a part of the prior art base or were common general knowledge in the field relevant to the disclosure as it existed anywhere before the priority date of this application.
While considerable emphasis has been placed herein on the components and component parts of the preferred embodiments, it will be appreciated that many embodiments may be made and that many changes may be made in the preferred embodiments without departing from the principles of the disclosure. These and other changes in the preferred embodiment as well as other embodiments of the disclosure will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the disclosure and not as a limitation.