In automated dispensing processes, the performance of the dispensing pump is central to ensuring product quality and production efficiency. However, even when high-performance equipment is selected, falling into common operational pitfalls can still lead to poor dispensing results, accelerated equipment wear, or even production halts. Identifying these misunderstandings and mastering the correct solutions is crucial for fully realizing the equipment’s potential and ensuring process stability.
Misunderstanding 1: Neglecting Fluid Compatibility and Pump Suitability
l Problem Manifestation: This is the most fundamental error. For example, using a pump unsuitable for high-viscosity fluids to handle paste adhesives, resulting in difficult dispensing, extremely high pressure, or even motor overload; or using a precision metering pump to handle adhesives containing large abrasive particles, causing rapid wear or blockage of internal precision components (such as screws, pistons, or gears).
l Solution: Key fluid parameters, especially viscosity, corrosiveness, and presence of fillers, must be clarified before selection. High-viscosity fluids containing fillers should prioritize strongly driven progressive cavity pumps or specialized piston pumps. For corrosive fluids, confirm material compatibility for all wetted parts. Always refer to the fluid compatibility guide provided by the pump manufacturer or conduct thorough testing before application.
Misunderstanding 2: Non-standardized Cleaning and Maintenance Procedures
l Problem Manifestation: Inadequate cleaning at the end of production or when switching adhesives leads to residual adhesive curing inside the pump, lines, or valves, causing blockages and potentially damaging equipment upon next startup. Simultaneously, neglecting regular inspection and replacement of wear parts like seals and filters leads to gradual loss of accuracy, leaks, and ultimately sudden failure.
l Solution: Establish and strictly enforce Standard Operating Procedures (SOPs). Before any shutdown or adhesive change, thorough flushing with a dedicated cleaner compatible with the original adhesive is mandatory, following the manufacturer’s recommended procedure and duration. Cleaning requirements are even stricter for two-component adhesives. Implement a preventive maintenance plan, regularly replacing seals, filters, etc., and maintain detailed records. Uphold the principle of “prevention first.”
Misunderstanding 3: Arbitrary Parameter Setting and Calibration
l Problem Manifestation: Operators rely solely on experience to roughly set pressure, time, or speed without scientific calibration based on adhesive properties, ambient temperature, and target dispense volume. This results in inconsistent dot sizes, stringing, tailing, or insufficient adhesive, leading to poor product consistency and high rework rates.
l Solution: Perform scientific parameter calibration. Systematically test the actual dispensed volume under different parameter combinations using methods like electronic weighing or volumetric measurement to establish a “parameter-to-volume” reference table or curve. Pay special attention to the impact of ambient temperature changes on adhesive viscosity, establishing compensation parameters for different temperatures if necessary. For precision applications, re-validate key parameters after each adhesive batch change or following extended downtime.
Misunderstanding 4: Improper Management of the Feeding System
l Problem Manifestation: Unstable feed pressure, insufficient adhesive in the reservoir causing air ingestion, or lack of agitation for adhesives prone to settling result in uneven fluid, air bubbles, or intermittent flow entering the dispensing pump. This directly causes issues like dispensing breaks, bubbles within dots, and fluctuating output, severely impacting the reliability of seals or bonds.
l Solution: Ensure the entire feeding system is in good condition. Use feeding equipment with pressure regulation and stabilization. Implement low-level alarms for adhesive reservoirs to prevent dry running. For fluids prone to settling or separation, use pressure pots or barrel feeders with integrated agitation. Install high-quality de-aeration devices or filters in the feed line before the pump to ensure fluid homogeneity and purity.
Misunderstanding 5: Ignoring Environmental Factors and Equipment Foundation
l Problem Manifestation: Treating dispensing as an isolated step, ignoring the impact of workshop temperature and humidity changes on adhesive flow, as well as the stability of the equipment mounting platform. Excessively low ambient temperature causes a sharp increase in adhesive viscosity, overloading the pump; vibrations directly affect dispensing path and dot placement accuracy.
l Solution: Strive to control the dispensing environment’s temperature and humidity within the range recommended by the adhesive manufacturer. For particularly precise processes, consider implementing a locally controlled environment. Mount the dispensing equipment on a stable, vibration-dampening work platform and ensure secure connections to motion stages. Regularly check for loose anchor bolts and main connection points on the equipment.
Misunderstanding 6: Continuing Operation Despite Minor Issues
l Problem Manifestation: Choosing to ignore early warning signs like unstable output, unusual noises, or minor leaks to meet production deadlines, and continuing operation. This often allows minor faults to escalate into serious mechanical damage, such as complete seizure or motor burnout, causing repair costs and downtime to increase exponentially.
l Solution: Enhance operator training to enable recognition of early equipment abnormality signals. Establish a clear “stop-and-report” protocol. Upon detecting any abnormal condition, stop immediately for investigation to nip problems in the bud. Instill the core philosophy that “a brief preventive stoppage is far superior to lengthy repair downtime.”
Avoiding these common misunderstandings essentially represents a shift from “extensive usage” to “refined, scientific management.” Correctly operating and maintaining a dispensing pump not only ensures its output is as precise and reliable as a Swiss watch but also significantly extends its service life, reduces overall production costs, and provides the most solid guarantee for a company’s stable production and product excellence.
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