ADHESIVE APPLICATOR, APPLICATOR SYSTEM, AND METHODS THEREFORE

Abstract

The present disclosure provides an adhesive applicator, an applicator system, and methods of applying an adhesive to a part. In one aspect, an applicator has an end effector that includes a roller wheel having a rotatable wheel and thermally-controlled tubes. The thermally-controlled tubes each define a chamber arranged to receive a heated working fluid. The end effector also includes leading rollers and lagging rollers that lead and lag the roller wheel, respectively. The leading and lagging rollers each define relief channels and are arranged to receive an adhesive substrate within their respective relief channels so as to pre-tension and align for placement of the adhesive substrate to a part to which the thermally-controlled tubes apply the adhesive substrate. The relief channels of the rollers along with controlled tensioning of the adhesive substrate and associated backing, maintain accurate placement of the adhesive substrate and removal of the backing during laydown.

Claims

1. An applicator, comprising: an end effector comprising: 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, 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.

2. The applicator of claim 1, wherein 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.

3. The applicator of claim 1, wherein 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.

4. The applicator of claim 1, wherein 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.

5. The applicator of claim 4, wherein the leading rollers each have a rim and a tapered portion that tapers from the rim to the leading shaft.

6. The applicator of claim 1, wherein 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.

7. The applicator of claim 1, wherein the roller wheel is received between a first end plate and a second end plate, and wherein the end effector further comprises: 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.

8. An applicator system, comprising: a hand-off assembly having a pincher; 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, and wherein the carriage comprises: 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.

9. The applicator system of claim 8, wherein the end effector comprises: 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.

10. The applicator system of claim 9, further comprising: 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.

11. The applicator system of claim 9, wherein 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.

12. A method, comprising: 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.

13. The method of claim 12, wherein handing off the portion of the adhesive substrate to the hand-off assembly so that the hand-off assembly holds the adhesive substrate comprises: 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.

14. The method of claim 13, further comprising: 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.

15. The method of claim 14, wherein 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.

16. The method of claim 14, wherein 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.

17. The method of claim 13, wherein 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.

18. The method of claim 13, wherein 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.

19. The method of claim 18, further comprising: 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.

20. The method of claim 18, wherein 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.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0024] So that the manner in which the above recited features can be understood in detail, a more particular description, briefly summarized above, may be had by reference to example aspects, some of which are illustrated in the appended drawings.

[0025] FIG. 1 is a side elevation view of an applicator system according to example aspects of the present disclosure.

[0026] FIG. 2 is a top-looking-down view of the applicator system of FIG. 1.

[0027] FIG. 3 is another elevation view of the applicator system of FIG. 1.

[0028] FIG. 4 is a close-up side elevation view of a carriage of the applicator system of FIG. 1.

[0029] FIG. 5 is a close-up perspective view of an end effector of the applicator system of FIG. 1.

[0030] FIG. 6 is another close-up perspective view of the end effector of the applicator system of FIG. 1.

[0031] FIG. 7 is a bottom-looking-up view of a cutter assembly engaged with a hand-off assembly of the applicator system of FIG. 1, with a pincher of the hand-off assembly having its pincher arms open and receiving a portion of an adhesive substrate.

[0032] FIG. 8 is another bottom-looking-up view of the cutter assembly engaged with the hand-off assembly of the applicator system of FIG. 1, with the pincher of the hand-off assembly having its pincher arms closed to pinch the portion of the adhesive substrate.

[0033] FIG. 9 is a flow diagram for a method of applying an adhesive substrate to a part using an applicator system according to example aspects of the present disclosure.

[0034] FIGS. 10 through 14 depict the applicator system of FIG. 1 in various stages of a laydown cycle.

[0035] FIG. 15 is a computing system according to example aspects of the present disclosure.

DETAILED DESCRIPTION

[0036] 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.

[0037] 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.

[0038] 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.

[0039] 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.

[0040] Turning now to the drawings with reference to FIGS. 1, 2, and 3, an applicator system 100 according to an example aspect of the present disclosure is depicted. FIG. 1 is a side elevation view of the applicator system 100, FIG. 2 is a top-looking-down view of the applicator system 100, and FIG. 3 is another elevation view of the applicator system 100. For reference, the applicator system 100 defines 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 system 100 has a first end 102 and a second end 104, which are spaced from one another along the first direction Y. FIG. 3 is a view of the applicator system 100 looking from the second end 104 toward the first end 102.

[0041] Generally, the applicator system 100 is arranged to automatically apply adhesive material on a part 50. In this example, the part 50 is a corrugated panel for an aircraft. The part 50 includes a plurality of ridges 52 to which respective adhesive strips can be applied automatically by the applicator system 100. Particularly, the applicator system 100 can apply an adhesive strip to the top of each one of the ridges 52. The part 50 has a first edge 54 and a second edge 56, which are spaced from one another along the first direction Y. It will be appreciated that the part 50 disclosed herein is provided by way of example and that the applicator system 100 can apply adhesive strips to parts having other configurations and geometries.

[0042] An adhesive tape 60 having an adhesive substrate 62 and a backing 64 can be provided to the applicator system 100. When the adhesive substrate 62 has the backing 64 removed therefrom and is laid down and cut to shape on the part 50, e.g., on a top of one of the ridges 52, the adhesive substrate 62 is arranged as an adhesive strip on the part 50. In some aspects, the adhesive tape 60 can be arranged so that the adhesive substrate 62 is sandwiched between two backings, e.g., top and bottom backings. In one example, the adhesive substrate 62 can be sandwiched between the backing 64 and a poly film. The poly film can be stripped off near the tape spool 106, e.g., using a friction wind process at a follower spool 110. The adhesive tape 60 can be wound on a tape spool 106, which can be rotated in a controlled manner by an electric motor 108 coupled thereto so as to control the tension of the adhesive tape 60. The follower spool 110 can receive the adhesive tape 60 from the tape spool 106 and can direct the adhesive tape 60 to a tape roller 112 coupled with a frame plate 114. The backing 64 stripped from the adhesive substrate 62 and certain stages of a laydown process, can be wound on a backing spool 116, which can be rotated in a controlled manner by an electric motor 118 coupled thereto so as to control tension of the backing 64. The backing 64 wound on the backing spool 116 can be directed from a backing roller 120 coupled with the frame plate 114. A tension direction 122 of the tension on the adhesive tape 60 at the tape spool 106 is shown in FIG. 1, and similarly, a tension direction 124 of the tension on the backing 64 at the backing spool 116 is likewise shown in FIG. 1. In some instances during the laydown process, as depicted in FIG. 1, the tension directions 122, 124 can be opposite one another.

[0043] The applicator system 100 includes a frame 126 that supports the frame plate 114, which is arranged orthogonal to the second direction X in this example. The frame plate 114 has a track 128 having a first rail 130 (or top rail) and a second rail 132 (or bottom rail) spaced from the first rail 130 along the third direction Z. The frame plate 114 also defines a carriage slot 134 that extends lengthwise along the first direction Y between the first rail 130 and the second rail 132 along the third direction Z. The frame plate 114 also defines a hand-off slot 136 between the first rail 130 and the second rail 132 along the third direction Z. The hand-off slot 136 is arranged below the carriage slot 134 along the third direction Z.

[0044] The applicator system 100 further includes a carriage 138 movable along the first direction Y. Specifically, the carriage 138 is slidable along the track 128 in the first direction Y. The carriage 138 can include wheels that engage and allow for movement of the carriage relative to the track 128. The carriage 138 can be mechanically coupled with a drive mechanism, such as an electric motor 139, via a shuttle movable along the first direction Y. The shuttle can be coupled with the carriage through the carriage slot 134. The electric motor can drive the shuttle along the first direction Y, which can in turn move the carriage 138 along the first direction Y. When the carriage 138 moves away from the first end 102 and toward the second end 104 (or to the right in FIG. 1), the carriage 138 is extending along the first direction Y. In contrast, when the carriage 138 moves away from the second end 104 and toward the first end 102 (or to the left in FIG. 1), the carriage 138 is retracting along the first direction Y. The carriage 138 is selectively extendable and retractable along the first direction Y, depending on the stage of a laydown process of the adhesive material on the part 50. The carriage 138 has a carriage plate 140 that carries or support various components.

[0045] With reference to FIG. 4 in addition to FIGS. 1 through 3, FIG. 4 is a close-up view of the carriage 138. As shown, the carriage 138 includes a backing clamp assembly 142 coupled with the carriage plate 140. The backing clamp assembly 142 includes a backing clamp 144 arranged to selectively clamp the backing 64 of the adhesive tape 60 so as to keep the backing 64 coupled with the adhesive substrate 62, e.g., as the carriage is extended along the first direction Y, or to selectively unclamp or release the backing 64 to allow the backing 64 to peel or be stripped from the adhesive substrate 62. The backing clamp 144 includes a clamp arm 146, a backing clamp base 148, and a roller pin 150. When the clamp arm 146 is engaged, the roller pin 150 does not strip the backing 64 from the adhesive substrate 62. When the clamp arm 146 is disengaged, the roller pin 150 strips the backing 64 from the adhesive substrate 62, which allows the adhesive substrate 62 to be laid down on one of the ridges 52 of the part 50 without the backing 64 present. The backing 64 stripped from the adhesive substrate 62 can be directed by way of the roller pin 150 to the backing roller 120 and onward to the backing spool 116.

[0046] The carriage 138 also includes a cutter assembly 152. The cutter assembly 152 can be arranged within a cutout 154 defined by the carriage plate 140. The cutter assembly 152 can be coupled with an adhesive guide 156 that guides the adhesive substrate 62 into the cutter assembly 152. The adhesive guide 156 is coupled with a bracket of the backing clamp assembly 142 at one end and the cutter assembly 152 at its other end. The cutter assembly 152 can be slidably coupled with the second rail 132 of the track 128. In FIG. 2, for example, the cutter assembly 152 is illustrated in sliding engagement with the second rail 132.

[0047] The cutter assembly 152 includes a housing 158 and a cutter 160. The cutter assembly 152 is arranged to receive the adhesive substrate 62, e.g., within the housing 158. Indeed, the adhesive substrate 62 can be arranged to pass through the cutter assembly 152, and in doing so, the adhesive substrate 62 can pass within cutting range of the cutter 160. In this way, when controlled to do so, the cutter 160 can cut the adhesive substrate 62. The cutter 160 can be controlled pneumatically, for example. Moreover, the cutter assembly 152 is movable along the first direction Y between a cut position and a collapsed position, e.g., within the cutout 154. That is, the cutter assembly 152 is slidable along the first direction Y relative to the carriage plate 140 so as to be movable between the cut position and the collapsed position. In the collapsed position, the cutter assembly 152 is engaged by a hand-off assembly 162, and this engagement causes a portion of the adhesive substrate 62 to be exposed, which allows a pincher 164 (of the hand-off assembly 162) having pincher arms 166, 168 (FIGS. 7 and 8) to pinch and selectively hold the adhesive substrate 62. When the cutter assembly 152 is moved to the collapsed position, the adhesive guide 156 (e.g., a cylindrical guide thereof) can be received, at least in part, within the housing 158 of the cutter assembly 152. This hand-off process will be described in greater detail below. In the cut position, the cutter 160 is arranged to selectively cut the adhesive substrate 62, e.g., after the adhesive substrate 62 is laid down on the part 50. In some aspects, the cutter assembly 152 can include opposing cutter blade and shear backplate actuators that allow the adhesive to cut and release without sticking to the cutter assembly 152. Such features can facilitate the capability of placing multiple strips of the adhesive substrate 62 onto the part 50.

[0048] As further shown in FIG. 4, the carriage 138 further includes an applicator 170 coupled with the carriage plate 140. The applicator 170 has a swing arm 172 and an end effector 174. The swing arm 172 has a proximal end 176 and a distal end 178. The proximal end 176 is pivotably coupled with the carriage plate 140. The end effector 174 is arranged at the distal end 178 of the swing arm 172. An actuator 180 of the carriage 138 can move the applicator 170 between a retracted position and an engaged position. In FIGS. 1 through 4, the applicator 170 is shown in the retracted position. In the retracted position, the applicator 170 is generally positioned away from the part 50 and at a height along the third direction Z so that the end effector 174 does not engage the hand-off assembly 162 when the carriage 138 is moved in close proximity thereto. The actuator 180 (e.g., a pneumatic actuator, an electric actuator, etc.) can be controlled to push the swing arm 172 downward, which causes the proximal end 176 to pivot and the distal end 178 to swing downward so that the applicator 170 is moved to the engaged position. In the engaged position, the end effector 174 is arranged to apply the adhesive substrate 62 to the part 50. To return to the retracted position, the actuator 180 can be controlled to pull the swing arm 172 upward, which causes the proximal end 176 to pivot and the distal end 178 to swing upward so that the applicator 170 is moved to the retracted position.

[0049] With reference now to FIGS. 5 and 6, the end effector 174, or device arranged to apply the adhesive substrate 62 to the part 50, will be described in further detail. The end effector 174 can facilitate alignment, tensioning, and thermal requirements in the application of the adhesive substrate 62 to the part 50. As illustrated, the end effector 174 includes a roller wheel assembly 182 having a roller wheel 184 rotatable about an axis of rotation and a plurality of thermally-controlled tubes 186 circumferentially spaced from one another along an outer periphery 188 of the roller wheel 184. In this regard, the thermally-controlled tubes 186 are externally exposed, e.g., so that the thermally-controlled tubes 186 can make contact with the adhesive substrate 62 to apply the adhesive substrate 62 to the part 50. The thermally-controlled tubes 186 can extend along the second direction X between opposing rims 190 of the roller wheel 184.

[0050] The thermally-controlled tubes 186 each define a chamber 192 arranged to receive a heated working fluid, such as heated air driven by a fan. Specifically, the roller wheel 184 is received between a first end plate 194 and a second end plate 196 of the swing arm 172. The first end plate 194 defines an inlet 198 fluidly coupled with tube inlets of the thermally-controlled tubes 186 and the second end plate 196 defines one or more outlets in fluid communication with tube outlets of the thermally-controlled tubes 186. In this way, a heated working fluid can be directed into the inlet 198, through the thermally-controlled tubes 186, and exhausted through the one or more outlets defined by the second end plate 196 (with the heated working fluid flowing through the thermally-controlled tubes 186 in a left-to-right direction in FIG. 5). Accordingly, the thermally-controlled tubes 186 can apply respective thermally-controlled physical forces to tact or apply the adhesive substrate 62 to the part 50. Moreover, the thermally-controlled physical forces can be applied by the thermally-controlled tubes 186 in rolling pulses, with each pulse corresponding to one of the thermally-controlled tubes 186 contacting and pressing the adhesive substrate 62 against the part 50. The thermal application in combination with the physical force provided by the thermally-controlled tubes 186 can enhance the mating of the adhesive substrate 62 to the part 50. A pneumatic regular can be used to control the physical compressive force applied on the adhesive substrate 62 by the thermally-controlled tubes 186 of the roller wheel 184. For instance, the actuator 180 can be arranged to pneumatically control a compressive force that the thermally-controlled tubes 186 apply to the adhesive substrate 62 as the plurality of thermally-controlled tubes 186 tact the adhesive substrate 62 to the part 50. In other example aspects, the actuator 180 can be electrically actuated and controlled, e.g., by a linear electric motor and corresponding drive system.

[0051] The end effector 174 also includes a leading assembly 200. The leading assembly 200 includes leading rollers 202 that lead the roller wheel 184. The leading rollers 202 function as guides for aligning the adhesive substrate 62, e.g., with a top of one of the ridges 52 of the part 50 (FIGS. 1 and 3). The leading rollers 202 are supported by a pair of leading arms, including a first leading arm 204 and a second leading arm 206, that couple the leading rollers 202 to the first end plate 194 and the second end plate 196, respectively. A leading axle 208 extends between the first and second leading arms 204, 206 and provides a mount for the leading rollers 202. The leading rollers 202 are carried by the leading axle 208 and are rotatable about an axis of rotation. A position of the leading rollers 202 can be adjusted by an adjustment screw 210 that extends through the first end plate 194 and contacts the first leading arm 204. By adjusting the adjustment screw 210, the position of the leading rollers 202 can be adjusted. A leading spring 212 coupled with the first leading arm 204 can bias the first and second leading arms 204, 206 against an end of the adjustment screw 210 to keep the leading rollers 202 in the desired position. In this example, the leading rollers 202 are connected by a leading shaft 214 and define a leading relief channel 216 therebetween. The leading rollers 202 each have a rim 218 and a tapered portion 220 that tapers from the rim 218 toward the leading shaft 214. The arrangement of the leading rollers 202 thus maintains the adhesive substrate 62 within the leading relief channel 216 and in contact with the leading shaft 214, allowing for some compliance between the pair of leading rollers 202. In some aspects, the leading rollers 202 and the leading shaft 214 are formed as a single piece that rotates about the leading axel 208.

[0052] Further, the end effector 174 includes a lagging assembly 222. The lagging assembly 222 includes lagging rollers 224 that lag the roller wheel 184. The lagging rollers 224 function to, in combination with the leading rollers 202, tension and align the adhesive substrate 62 with the part 50. The lagging rollers 224 are supported by a pair of lagging arms, including a first lagging arm 226 and a second lagging arm 228, that couple the lagging rollers 224 to the first end plate 194 and the second end plate 196, respectively. A lagging axle 230 extends between the first and second lagging arms 226, 228 and provides a mount for the lagging rollers 224. The lagging rollers 224 are carried by the lagging axle 230 and are rotatable about an axis of rotation. A position of the lagging rollers 224 can be maintained by a lagging spring 232 that is coupled with the lagging axle 230 and engages a cross-member 234 extending between the first and second lagging arms 226, 228. In this example, the lagging rollers 224 are connected by a lagging shaft 236 and define a lagging relief channel 238 therebetween. The lagging rollers 224 each have a rim 240 and a tapered portion 242 that tapers from the rim 240 to the lagging shaft 236. The arrangement of the lagging rollers 224 thus maintains the adhesive substrate 62 within the lagging relief channel 238 and in contact with the lagging shaft 236. In some aspects, the lagging rollers 224 and the lagging shaft 236 are formed as a single piece that rotates about the lagging axel 230.

[0053] When the applicator 170 is initially pivoted downward to the engaged position, the leading rollers 202 and lagging rollers 224 can prepare the adhesive substrate 62 for the laydown process. Specifically, the leading rollers 202 and the lagging rollers 224 can be arranged to receive the adhesive substrate 62 within the leading relief channel 216 and the lagging relief channel 238, respectively, so as to tension and align the adhesive substrate 62 in a straight line with the part 50, e.g., to one of the ridges 52 of the part 50. Accordingly, in this initialization process, the adhesive substrate 62 is offset from the part 50 along the third direction Z and is suspended underneath the roller wheel 184 between the leading and lagging rollers 202, 224, e.g., like a trapeze wire. This effectively tensions and aligns the adhesive substrate 62 with the part 50 prior to the roller wheel 184 coming down and engaging the adhesive substrate 62 to the part 50. After this initialization of the adhesive substrate 62, the roller wheel 184 can compress the adhesive substrate 62 against the part 50 as the carriage retracts along the first direction Y. The leading rollers 202 can roll along the part 50 as the carriage retracts along the first direction Y but the leading rollers 202 are arranged to roll along the part 50 but offset the adhesive substrate 62 from the part 50 so as not to press the adhesive substrate 62 to the part 50. In this regard, as noted above, the leading rollers 202 act as guides and maintain alignment of the adhesive substrate 62. The lagging rollers 224 can roll along the adhesive substrate 62 after the thermally-controlled tubes 186 tact the adhesive substrate 62 to the part 50 or can be suspended in the air, depending on the position of the carriage 138 along the first direction Y.

[0054] As further shown in FIG. 5, the first end plate 194 can also define a sensor inlet in which a temperature sensor 244 (e.g., a thermocouple) can be arranged. The temperature sensor 244 can sense a temperature of the heated working fluid delivered to the thermally-controlled tubes 186. A temperature of the heated working fluid can be increased or decreased based at least in part on feedback provided by the temperature sensor 244. For instance, in at least some example aspects, air can be passed across one or more heaters 246 (e.g., electric resistance heaters) of a heating system 248 (FIG. 3) of the applicator system 100. The heating system 248 can include one or more fans to move the air across the heaters 246 and to the end effector 174, e.g., by way of a conduit. The temperature sensor 244 can provide feedback indicating a temperature of the heated working fluid (or heated air) at the end effector 174. The feedback can be provided to a computing system 250 (FIG. 1) arranged to control the various controllable devices of the applicator system 100. The temperature sensor 244 can be communicatively coupled with the computing system 250, e.g., via a wired and/or wireless communication links. One or more processors of the computing system 250 can cause the heaters 246 to generate additional heat so as to increase the temperature of the air provided to the thermally-controlled tubes 186, 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 186, e.g., by decreasing the electric current through the heaters 246. In some aspects, heated air passed through the thermally-controlled tubes 186 is generated by passing preheated, pressurized air through a stationary mounted, temperature-controlled heating element and fed into the inlet 198. The temperature sensor 244 can provide feedback to a temperature controller of the computing system 250.

[0055] With reference again to FIGS. 1 through 4, the carriage 138 also includes a sensor 252, which can be coupled with the carriage plate 140. The sensor 252 is arranged to detect the edges of the part 50. For instance, as the carriage 138 is extended along the first direction Y (moving toward the second end 104), the sensor 252 can sense a position of the first edge 54 of the part 50, and as the carriage 138 continues to be extended along the first direction Y toward the second end 104, the sensor 252 can sense a position of the second edge 56 of the part 50. The position of the first edge 54 and the position of the second edge 56 can be stored, e.g., in one or more memory devices of the computing system 250 of the applicator system 100. The temperature sensor 244 can be communicatively coupled with the computing system 250, e.g., via a wired and/or wireless communication links. The applicator 170 can be moved the to the engaged position and retracted from the engaged position based at least in part on the position of the first edge 54 and the position of the second edge 56.

[0056] While the carriage 138 can be considered to be one hand of the applicator system 100, the hand-off assembly 162 can function as the other hand in that the pincher 164 of the hand-off assembly 162 pinches and accepts the adhesive substrate 62 during a meet up or hand-off between the cutter assembly 152 and the hand-off assembly 162. The pincher 164 then holds the adhesive substrate 62, at least for a period of time, as the applicator 170 applies the adhesive substrate 62 to the part 50. When the carriage 138 is moved so that the cutter assembly 152 engages the hand-off assembly 162, the cutter assembly 152 is moved to the collapsed position. This causes the carriage plate 140 to move relative to the cutter assembly 152 along the first direction Y.

[0057] As shown in FIG. 7, when the cutter assembly 152 is in the collapsed position, the cutter assembly 152 exposes a portion 66 of the adhesive substrate 62 (e.g., a tongue of material) to allow the pincher 164 of the hand-off assembly 162 to pinch and selectively hold the adhesive substrate 62. More specifically, the pincher 164 has pinch arms, including a first pinch arm 166 and a second pinch arm 168, which are movable between an open position and a closed position. Before the meet up between the cutter assembly 152 and the hand-off assembly 162 (i.e., before the cutter assembly 152 engages the hand-off assembly 162), the first and second pinch arms 166, 168 of the pincher 164 are moved to or kept in the open position. Then, when the cutter assembly 152 engages the hand-off assembly 162 causing the cutter assembly 152 to move to the collapsed position, the portion 66 of the adhesive substrate 62 becomes exposed and ready to be pinched. Accordingly, the first and second pinch arms 166, 168 are controlled to move to the closed position to pinch the exposed portion 66 of the adhesive substrate 62, e.g., as shown in the close-up view of FIG. 8. In this regard, the portion 66 of the adhesive substrate 62 is handed off and held by the hand-off assembly 162.

[0058] In addition, the hand-off assembly 162 can be movable along the first direction Y. In at least some example aspects, with the cutter assembly 152 still engaged with the hand-off assembly 162, the carriage 138 and the hand-off assembly 162 can be moved along the first direction Y a predetermined distance from the second edge 56 of the part 50. With the carriage 138 and the hand-off assembly 162 moved the predetermined distance from the second edge 56 of the part 50, a brake 254 (e.g., a piston-applied brake as shown in FIG. 7) of the hand-off assembly 162 can be set so that the position of the hand-off assembly 162 is held in place, which consequently holds the portion 66 of the adhesive substrate 62 held by the pincher 164 in place. Accordingly, the other hand or hand-off assembly 162 has prepared the adhesive substrate 62 for application to the part 50.

[0059] The applicator system 100 also includes a traverse assembly 256. The traverse assembly 256 includes a part clamp 258 that clamps to the part 50 to hold the applicator system 100 in place during application of an adhesive substrate to one of the ridges 52 of the part 50. 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 clamp 258 can be controlled to unclamp from the part 50, and a drive mechanism (e.g., an electric motor) can shuffle the part clamp 258 along 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 system 100 can be slid relative to the frame 126 along the second direction X and another cycle of the laydown process can commence.

[0060] With the applicator system 100 generally described, an example manner in which the applicator system 100 can apply an adhesive material to the part 50 will be provided below.

[0061] FIG. 9 is a flow diagram for a method 300 for applying an adhesive substrate to a part using an applicator system. For context, the method 300 will be described with respect to the applicator system 100. Accordingly, reference to FIGS. 1 through 8 in addition to FIG. 9 will be made below. It will be appreciated, however, that the method 300 can be implemented using an applicator system having a different configuration than the applicator system 100.

[0062] At 302, the method 300 can 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 system 100 can be used to implement a laydown process in which an adhesive substrate is applied to each one of the ridges 52 of the part 50. A laydown cycle can be implemented to lay down an adhesive substrate on a given one of the ridges 52.

[0063] In commencing a lay down cycle, as shown in FIG. 1, the part clamp 258 is clamped onto the part 50 so as to prevent movement of the application components of the applicator system 100 in the second direction X. Further, the carriage 138 can be moved to or positioned in a retracted position, which is a position to the far left in FIG. 1. The backing clamp 144 is engaged to clamp the backing 64 so that the roller pin 150 does not strip or peel the backing 64 from the adhesive substrate 62, e.g., as the carriage 138 is extended along the first direction Y toward the hand-off assembly 162. In addition, tension between the adhesive substrate 62 on the tape spool 106 and the backing 64 on the backing spool 116 is balanced so as not to allow adhesive substrate 62 to slack. While the backing clamp 144 is clamping the backing 64, the backing spool 116 is clutched to provide constant tension in the tension direction 122 to dispense the backing 64 from the backing spool 116 while extending without or with negligible slack. The tape spool 106 can be tensioned in the tension direction 124 to eliminate slack while extending out the adhesive tape 60. The adhesive substrate 62 is loaded into the cutter assembly 152. The cutter assembly 152 is arranged in the cut position, the applicator 170 is arranged in the retracted position, and the pincher 164 of the hand-off assembly 162 is in the opened position while the brake 254 (FIG. 7) is released. The hand-off assembly 162 is arranged in a retracted position, which is a position to the far left of the hand-off slot 136 in FIG. 1.

[0064] At 304, with the backing clamp engaged, the method 300 can include extending the carriage toward the hand-off assembly along the first direction Y. For instance, with the backing 64 clamped by the backing clamp 144 of the carriage 138 and the adhesive substrate 62 extending into the cutter assembly 152, the carriage 138 can be moved along the first direction Y toward the hand-off assembly 162. Engaging the backing clamp 144 can allow the adhesive substrate 62 to be extended without being stretched. The electric motor 139 can drive a shuttle coupled with the carriage 138, which consequently moves the carriage 138 along the first direction Y toward the hand-off assembly 162. As the carriage 138 extends along the first direction Y toward the hand-off assembly 162, the adhesive tape 60 unwinds from the tape spool 106 and the backing spool 116 allows the backing 64 to unwind therefrom, e.g., so that the backing 64 stays with the adhesive substrate 62 to provide strength thereto, at least up to the adhesive guide 156.

[0065] At 306, the method 300 can include sensing the edges of the part. For instance, as the carriage 138 is extended along the first direction Y toward the hand-off assembly 162, the sensor 252, or edge detection sensor, can monitor for detection of the first edge 54 and for detection of the second edge 56. In this regard, the method 300 can include sensing the first edge 54 of the part 50 as the carriage 138 is moved along the first direction Y toward the hand-off assembly 162, sensing the second edge 56 of the part 50 as the carriage 138 is moved along the first direction Y toward the hand-off assembly 162, and storing a position of the first edge 54 and a position of the second edge 56 in one or more memory devices, e.g., of the computing system 250. During the laydown cycle, the applicator 170 can be moved to the engaged position and retracted from the engaged position based at least in part on the position of the first edge 54 and the position of the second edge 56.

[0066] At 308, the method 300 can include handing off, by the cutter assembly to the handoff assembly, a portion of the adhesive substrate without the backing so that the hand-off assembly holds the portion of the adhesive substrate. For instance, as the carriage 138 continues to extend along the first direction Y, the cutter assembly 152 eventually meets up with the hand-off assembly 162, e.g., as shown in FIG. 10, which corresponds to a location where the cutter assembly 152 is positioned directly over the second edge 56 of the part 50 in this example. Specifically, the cutter assembly 152 of the carriage 138 engages the hand-off assembly 162, which causes the cutter assembly 152 to be pushed back along the first direction Y relative to the carriage plate 140, or rather, toward the backing clamp assembly 142 within the cutout 154. The relative movement of the cutter assembly 152 can be appreciated by comparing the position of the cutter assembly 152 within the cutout 154 in FIG. 10 (the collapsed position in which the cutter assembly 152 is engaged with the hand-off assembly 162) with the position of the cutter assembly 152 within the cutout 154 in FIG. 4 (the cut position). When the cutter assembly 152 is pushed back or moved to the collapsed position, the portion 66 of the adhesive substrate 62 becomes exposed, e.g., as shown in FIG. 7. To complete the hand off, the pincher arms 166, 168 of the pincher 164 pinch the portion 66 of the adhesive substrate 62 by moving closed, e.g., as shown in FIG. 8. The pinched portion 66 is then held onto by the hand-off assembly 162 for a period of time, such as at least until the adhesive substrate 62 is applied to the part 50. When the cutter assembly 152 is not in the collapsed position, the portion 66 is arranged within an interior of the housing 158 of the cutter assembly 152 and is not exposed.

[0067] Accordingly, handing off the portion 66 of the adhesive substrate 62 to the hand-off assembly 162 so that the hand-off assembly 162 holds the adhesive substrate 62 can include moving the carriage 138 along the first direction Y so that the cutter assembly 152 engages the hand-off assembly 162 and pushes the cutter assembly 152 toward the backing clamp 144 along the first direction Y so as to move the cutter assembly 152 to a collapsed position in which the portion 66 of the adhesive substrate 62 is exposed, and then, pinching, with the pincher 164 of the hand-off assembly 162, the portion 66 of the adhesive substrate 62 that is exposed. The pincher 164 can then hold the portion 66 of the adhesive substrate 62 for a period of time.

[0068] At 310, the method 300 can include, with the cutter assembly still engaged with the hand-off assembly, further extending the carriage to move the hand-off assembly a predetermined distance from an edge of the part. For instance, after the cutter assembly 152 meets up with the hand-off assembly 162, e.g., as shown in FIG. 10, the cutter assembly 152 can remain engaged with the hand-off assembly 162 as the carriage 138 and the hand-off assembly 162 are further extended along the first direction Y (moved to the right in FIG. 10). Eventually, as shown in FIG. 11, the hand-off assembly 162 can be moved a predetermined distance from the second edge 56 of the part 50. The predetermined distance can be determined, for example, as a distance to allow for enough clearance for the applicator 170 to swing down and apply the adhesive substrate 62 to the second edge 56 without hitting the hand-off assembly 162.

[0069] At 312, the method 300 can include setting a brake of the hand-off assembly. For instance, with the hand-off assembly 162 moved the predetermined distance from the second edge 56 of the part 50, the brake 254 of the hand-off assembly 162 can be set to lock in the position of the hand-off assembly 162.

[0070] At 314, with the backing clamp released, the method 300 can include retracting the carriage away from the hand-off assembly. For instance, with the brake 254 of the hand-off assembly 162 set and the backing clamp 144 released, the carriage 138 can be moved along the first direction Y away from the hand-off assembly 162. Setting the brake 254 locks the hand-off assembly 162 in place, e.g., along the first direction Y, and releasing the backing clamp 144 allows the backing 64 to peel from the adhesive substrate 62 as the carriage is retracted away from the hand-off assembly 162, or stated differently, moved away from the second end 104 and toward the first end 102. In this regard, the backing clamp 144 releases the backing 64 during the laydown portion of the cycle. The tension direction 122 remains in a same direction on the backing spool 116 to allow expelled backing being peeled off during laydown to wind up onto the backing spool 116. When the carriage 138 is retracted away from the hand-off assembly 162, the cutter assembly 152 disengages from the hand-off assembly 162 and moves from the collapsed position to the cut position within the cutout 154 defined by the carriage plate 140.

[0071] At 316, the method 300 can include moving the applicator to an engaged position. For instance, as the carriage 138 is moved along the first direction Y away from the hand-off assembly 162, the applicator 170 of the carriage 138 can be moved to the engaged position, e.g., after the end effector 174 clears the hand-off assembly 162 along the first direction Y. In FIG. 12, the applicator 170 is shown being moved from its retracted position, which is shown in phantom lines, to its engaged position so that the end effector 174 can apply the adhesive substrate 62 to the part 50.

[0072] In some example implementations, when the carriage 138 is initially moved along the first direction Y away from the hand-off assembly 162 at 314, the tape spool 106 can be controlled by the electric motor 108 so that the tension direction 124 reverses or so that at least the tension of the adhesive tape 60 is loosened. Then, at 316 when the applicator 170 is moved to the engaged position in which the end effector 174 engages the adhesive substrate 62, the tape spool 106 can be controlled by the electric motor 108 to reverse the direction back to the tension direction 124 shown in FIG. 12 or to take the slack out of the adhesive tape 60, and consequently the adhesive substrate 62 being applied to the part 50. In some aspects, the tension in the tension direction 124 can be altered to a light tension for initial material placement with the applicator 170. The tension in the tension direction 124 can be increased slightly thereafter to assure the material is able to maintain alignment under the leading and lagging rollers 202, 224 of the applicator 170.

[0073] At 318, the method 300 can include initializing the adhesive substrate by leading and lagging rollers of an end effector of the applicator. For instance, when the applicator 170 is initially pivoted downward to the engaged position, e.g., as shown in FIG. 12, the leading rollers 202 and the lagging rollers 224 can initialize or prepare the adhesive substrate 62 for the laydown process. In particular, the leading rollers 202 and the lagging rollers 224 can be arranged to receive the adhesive substrate 62 within the leading relief channel 216 and the lagging relief channel 238, respectively, so as to tension and align the adhesive substrate 62 in a straight line with the part 50, e.g., to one of the ridges 52 of the part 50. In this way, the adhesive substrate 62 is offset from the part 50 along the third direction Z and is suspended underneath the roller wheel 184 between the leading and lagging rollers 202, 224. This effectively tensions and aligns the adhesive substrate 62 with the part 50 prior to the roller wheel 184 coming down and engaging the adhesive substrate 62 to the part 50.

[0074] At 320, the method 300 can include flowing a heated working fluid through the plurality of thermally-controlled tubes. For instance, air can be passed across the heaters 246 of the heating system 248. The heating system 248 can include one or more fans to move the air across the heaters 246 and to the end effector 174, e.g., by way of a conduit. The heated air can enter the end effector 174 via the inlet 198. The heated working fluid can be directed into the inlet 198, through the thermally-controlled tubes 186, and exhausted through the one or more outlets defined by the second end plate 196. Accordingly, the heating system 248 can be fluidly coupled with the thermally-controlled tubes 186.

[0075] In some implementations, a temperature of the working fluid provided to the thermally-controlled tubes 186 can be controlled based at least in part on feedback provided by the temperature sensor 244. For instance, one or more processors of the computing system 250 can cause, based at least in part on the feedback provided by the temperature sensor 244, the heaters 246 to generate additional heat so as to increase the temperature of the air provided to the thermally-controlled tubes 186, 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 186, e.g., by decreasing the electric current through the heaters 246.

[0076] At 322, the method 300 can include applying the adhesive substrate to the part via the thermally-controlled tubes of the roller wheel, with the leading rollers guiding the adhesive substrate. For instance, with the backing clamp 144 released to allow the backing 64 to peel from the adhesive substrate 62, the applicator 170 of the carriage moved to the engaged position at 316, the adhesive substrate 62 initialized at 318, and the heated working fluid flowing through the thermally-controlled tubes 186 at 320, the carriage 138 can be moved along the first direction Y away from the hand-off assembly 162 so that the end effector 174 of the applicator 170 applies the adhesive substrate 62 to the part 50.

[0077] In moving the carriage 138 along the first direction Y away from the hand-off assembly 162 so that the end effector 174 of the applicator 170 applies the adhesive substrate 62 to the part 50, the roller wheel 184 rotates allowing the plurality of thermally-controlled tubes 186 to tact the adhesive substrate 62 to the part 50. The heated working fluid flowing through the plurality of thermally-controlled tubes 186 as the roller wheel 184 rotates allows the plurality of thermally-controlled tubes 186 to tact the adhesive substrate 62 to the part 50 in rolling thermally-controlled pulses, with each pulse corresponding to one of the thermally-controlled tubes 186 contacting and pressing the adhesive substrate 62 against the part 50. The thermal application in combination with the physical force provided by the thermally-controlled tubes 186 can enhance the mating of the adhesive substrate 62 to the part 50. Accordingly, the thermally-controlled tubes 186 can apply respective thermally-controlled physical forces to tact the adhesive substrate 62 to the part 50.

[0078] The leading rollers 202 and lagging rollers 224 lead and lag the roller wheel 184, respectively, as the roller wheel 184 applies the adhesive substrate 62. The adhesive substrate 62 is arranged on the leading shaft 214 and within the leading relief channel 216 and on the lagging shaft 236 within the lagging relief channel 238 so as to be tensioned in a straight line as the plurality of thermally-controlled tubes 186 tact the adhesive substrate 62 to the part 50. The leading rollers 202 roll along the part 50 but the adhesive substrate 62 is offset from the part 50, at the leading rollers 202, namely because the adhesive substrate 62 is arranged within the leading relief channel 216. In this regard, the leading rollers 202 guide the adhesive substrate 62 into alignment with the ridge 52 but the roller wheel 184 performs the application function. The lagging rollers 224 can roll along the adhesive substrate 62 after the thermally-controlled tubes 186 tact the adhesive substrate 62 to the part 50 or can be suspended in the air, depending on the position of the carriage 138 along the first direction Y. In FIG. 13, the applicator 170 is shown at the first edge 54 after applying the adhesive substrate 62 along the ridge 52, e.g., from the second edge 56 to the first edge 54.

[0079] After the adhesive substrate 62 is laid down on the part 50, the method 300 can include moving the applicator to the retracted position, e.g., as shown in FIG. 14. For instance, the actuator 180 can be controlled to pull the swing arm 172 upward, which causes the proximal end 176 to pivot and the distal end 178 to swing upward so that the applicator 170 is moved to the retracted position.

[0080] At 324, the method 300 can include cutting, by a cutter of the cutter assembly, the adhesive substrate and also releasing, by the hand-off assembly, the adhesive substrate. For instance, after the adhesive substrate 62 is applied to the ridge 52 of the part 50, the cutter 160 of the cutter assembly 152 can cut the adhesive substrate 62. As shown in FIG. 14, the adhesive substrate 62 can be cut by the cutter 160 a predetermined distance from the first edge 54 of the part 50, which creates a first end tail 68 of the adhesive substrate 62 that hangs off the first edge 54 of the part 50. The first end tail 68 can be cut or utilized in some way by an operator, for example. As further illustrated in FIG. 14, the hand-off assembly 162 can release the adhesive substrate 62 to render a second end tail 70 of the adhesive substrate 62. The second end tail 70 of the adhesive substrate 62 hangs off the second edge 56 of the part 50. Like the first end tail 68, the second end tail 70 can be cut or utilized in some way by an operator. The adhesive substrate 62 laid down on the ridge becomes an adhesive strip.

[0081] At 326, the method 300 can include determining whether the laydown process is complete. For instance, when all laydown cycles are complete, the laydown process can be determined as complete. Accordingly, the method 300 can proceed to 328 in which the laydown process is ended. In contrast, when further laydown cycles are needed to lay down further adhesive strips on other ridges 52 of the part 50, the method 300 can proceed to 330.

[0082] At 328, as noted above, the method 300 can include ending the laydown process, e.g., when all laydown cycles are complete.

[0083] At 330, the method 300 can include controlling the traverse assembly to move the application components to a subsequent position, e.g., so that an adhesive strip can be applied to another ridge of the part. For instance, the part clamp 258 of the traverse assembly 256 that clamps to the part 50 to hold the applicator system 100 in place during application of the adhesive substrate 62 to one of the ridges 52 of the part 50 can be released. The part clamp 258 can be controlled to unclamp from the part 50, and a drive mechanism (e.g., an electric motor) can shuffle the part clamp 258 along the second direction X to a subsequent clamp location. At the subsequent clamp location, the part clamp 258 can be clamped in place and application components of the applicator system 100 can be slid relative to the frame 126 along the second direction X. Consequently, another laydown cycle of the laydown process can commence, which is represented in FIG. 9 with operation 330 connecting with operation 302.

[0084] FIG. 15 is a block diagram of the computing system 250 in accordance with various aspects of the present disclosure. The computing system 250 can be configured to control the various controllable devices of the applicator system 100 of FIG. 1.

[0085] As shown in FIG. 15, the computing system 250 can include one or more processor(s) 250B and one or more memory device(s) 250C. The one or more processor(s) 250B and the one or more memory device(s) 250C can be embodied in one or more computing device(s) 250A. The one or more processor(s) 250B can include any suitable processing device, such as a microprocessor, microcontroller, integrated circuit, logic device, or other suitable processing device. The one or more memory device(s) 250C can include one or more computer-readable medium, including, but not limited to, non-transitory computer-readable medium, RAM, ROM, hard drives, flash drives, and other memory devices.

[0086] The one or more memory device(s) 250C can store information accessible by the one or more processor(s) 250B, including computer-readable instructions 250D or computer-readable program code that can be executed by the one or more processor(s) 250B. The instructions 250D can be any set of instructions that, when executed by the one or more processor(s) 250B, cause the one or more processor(s) 250B to perform operations, such as operations for controlling the controllable devices of the applicator system 100 in a laydown process. The instructions 250D can be software written in any suitable programming language or can be implemented in hardware. The memory device(s) 250C can further store data 250E that can be accessed by the processor(s) 250B. For example, the data 250E can include any of the data noted herein. The data 250E can include one or more table(s), function(s), algorithm(s), model(s), equation(s), libraries, etc. according to example aspects of the present disclosure.

[0087] The computing system 250, or the computing device(s) 250A thereof, can include a communication interface 250F used to communicate with the other components, such as the controllable devices of the applicator system 100. The communication interface 250F can include any suitable components for interfacing with one or more network(s), including for example, transmitters, receivers, ports, controllers, antennas, or other suitable components.

[0088] In the current disclosure, reference is made to various aspects. However, it should be understood that the present disclosure is not limited to specific described aspects. Instead, any combination of the following features and elements, whether related to different aspects or not, is contemplated to implement and practice the teachings provided herein. Additionally, when elements of the aspects are described in the form of at least one of A and B, it will be understood that aspects including element A exclusively, including element B exclusively, and including element A and B are each contemplated. Furthermore, although some aspects may achieve advantages over other possible solutions and/or over the prior art, whether or not a particular advantage is achieved by a given aspect is not limiting of the present disclosure. Thus, the aspects, features, aspects and advantages disclosed herein are merely illustrative and are not considered elements or limitations of the appended claims except where explicitly recited in a claim(s).

[0089] While the foregoing is directed to aspects of the present disclosure, other and further aspects of the disclosure may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow.