9 May 2008, 12:00:00

The accurate and reproducible application of media with varying viscosities is a key quality factor in modern production and assembly processes. Increasing automation, ongoing miniaturisation of components and rising material costs are driving the demand for non-contact dispensing systems capable of applying extremely small quantities of media.

Many non-contact dispensing solutions currently available on the market are technically complex and associated with high investment costs. With the newly developed Micro Point Pulse Valve (MPP), a compact and cost-effective alternative is available that achieves dispensing results at least equivalent to those of significantly more expensive systems.

Precise application of the smallest media quantities: The MPP is designed for non-contact, position-accurate pulsed application of even very small amounts of highly viscous media. Typical materials include greases, oils, adhesives, lacquers, fluxes and solvents. Especially with increasingly short cycle times and ever smaller component geometries, the system meets rising requirements for accuracy, repeatability and process speed.

The nozzles used, with diameters ranging from 0.3 mm to 2.0 mm, can be replaced quickly and without tools. The valve is designed for material pressures of up to 100 bar. The maintenance-free drive unit and the straightforward cleaning of the complete system ensure high system availability.

Depending on the medium, free-flying droplets can be applied with positional accuracy over distances of more than 100 mm. This eliminates process-related movements of the dispensing needle, significantly reducing both dispensing time and mechanical effort within the process.

Increased efficiency and material savings: Non-contact application enables significant savings in the amount of medium used while simultaneously reducing throughput times in assembly and production processes. Compared to contact dispensing, additional travel movements are avoided, allowing cycle times to be reduced.

Another key advantage is the complete avoidance of grease migration. Wetting occurs exclusively at defined locations on the component, reliably preventing contamination.

Superior dispensing results without heating: In test series, the MPP achieved significantly more precise results in terms of dispensing volume and placement accuracy than functionally comparable but considerably more expensive competitor systems. No heating of the medium was required. This is particularly advantageous for sensitive media, as temperature increases can alter material properties or cause separation of individual components. In medical technology applications, heating is often not permitted, as it may affect active substances.

Proven industrial applications: The system is already in use in numerous industrial applications. At a major German manufacturer of wall plugs, for example, 30 mg of lubricant is dispensed contactlessly into each component per cycle. In shift operation, more than 115,000 components per day are reliably wetted in this way.

A manufacturer of electronic components uses the MPP to apply 300 µg of contact grease prior to final assembly. Due to the generation of extremely small, free-flying droplets and the resulting high level of cleanliness, the process is also particularly suitable for applications in medical technology.

Short amortisation times through process optimisation: The precise, clean and process-reliable mode of operation extends maintenance intervals and reduces downtime caused by stoppages. Maintenance-intensive disassembly operations for relubrication can be selectively minimised. The combination of time savings, reduced material consumption and high process stability results in very short amortisation periods.

This raises the justified question of whether the Micro Point Pulse Valve will replace conventional contact dispensing in many applications in the long term.