Custom Dispensing System Integration in 3 Days: Robotic Upgrade for Glass Adhesive Application

Inside a Custom Dispensing System Integration Designed for High-Viscosity Adhesives and Tight Timelines

When a major appliance manufacturer set out to automate a critical adhesive application on one of its glass assembly lines, their goal was to improve consistency, reduce rework, and complete a custom dispensing system integration during a tight three-day shutdown window. This case study details how DRM designed and commissioned a custom fixed-head dispensing system tailored to the plant’s high-viscosity adhesive, integrating seamlessly with operator workflows and meeting all production and quality targets.

Project Background

This manufacturer was preparing to automate an adhesive application process on one of its glass assembly lines. Historically, the process was manual, with operators applying a bead of industrial adhesive to sheet glass; an approach prone to inconsistencies at bead corners and endpoints. These irregularities resulted in frequent rework and quality variability, especially under high-throughput conditions.

As part of a broader automation initiative, the company sought to reduce process variability and improve consistency while integrating the new robotic system into an existing line during a planned three-day shutdown window. The project required a custom dispensing solution that accounted for the adhesive’s material properties and fit seamlessly into current plant workflows with minimal impact on cycle time or operator retraining.

DRM had previously delivered successful robotic dispensing solutions in related applications, bringing both hardware expertise and process knowledge to the table. Their deep experience with high-viscosity adhesive systems and collaborative approach made them the integrator of choice for this project.

Challenge

The project called for a robotic solution capable of applying a consistent bead of high-viscosity industrial adhesive around the perimeter of sheet glass products. Due to the adhesive’s short curing time and sensitivity to ambient conditions, even small inconsistencies in start/stop transitions could compromise bond integrity.

The solution had to:

‣ Fit within an existing line footprint

‣ Complete all commissioning within a planned three-day shutdown

‣ Deliver clean adhesive transitions at corners and bead terminations

‣ Minimize complexity for plant operators and maintenance staff

Solution

Controls Hardware and Dispensing Architecture

DRM deployed a FANUC M-20iA six-axis robot with a fixed dispensing head configuration. Unlike traditional systems that move the nozzle across the part, DRM’s design involved positioning the part itself beneath a stationary dispense head. This architecture reduced robot motion complexity and allowed for more controlled adhesive pathing, especially during starts and stops.

To ensure compatibility with the material properties of the plant’s preferred adhesive, the team used a commercial-grade adhesive valve integrated with a metering system and flow regulator. The setup featured closed-loop control for pressure and flow to accommodate the adhesive’s cure profile and viscosity. Dispensing parameters were tuned dynamically based on part orientation; particularly on the rear side of the glass, where flow initiation and ramp-down were most sensitive.

Engineers used early process simulation to refine flow control and bead timing without consuming materials during development. This step allowed DRM engineers to identify key adjustments before adhesive trials began.

A part-detection camera system was integrated to verify glass presence and position prior to bead application. Though not vision-guided, the camera provided a reliable go/no-go check and supported consistent part orientation before each cycle.

Additional control hardware included:

‣ Pressure regulation valve with feedback loop

‣ Safety-rated interlocks on access doors

‣ HMI interface designed with plant operator feedback

‣ Ethernet/IP-based I/O for real-time status and diagnostics

Controls Software Engineering

DRM developed custom routines within the FANUC Teach Pendant and integrated external logic via a safety-rated PLC. Safety zones and stop conditions were programmed for the cell, including state transitions for part present, cycle start, and emergency override.

The PLC logic included:

‣ Timing coordination between part clamp actuation and dispense trigger

‣ Bead start/stop logic for sharp transitions

‣ Pressure ramp logic for clean corner turns

‣ Motion control refinement to reduce dwell time and bead build-up at corners

To support flexibility on the floor, DRM also built adjustable parameters into the HMI, allowing operators to tweak bead size or modify production recipes without controls engineer intervention.

Runtime assurance features included:

‣ Status dashboards on the HMI

‣ Recipe lockout and validation

‣ Integrated purge cycle and test mode

Commissioning and Collaboration

All installation, commissioning, and validation occurred within a planned three-day shutdown window. To meet the timeline, DRM conducted upfront simulation and worked closely with plant operators and facility teams throughout the project.

Operator engagement was prioritized early in the project. The team collaborated on HMI layouts, adjusted logic based on operator input, and built plant-specific diagnostics into the interface.

“It was a tight timeline, but our team and theirs were totally aligned,” said Doyle Cooper, Controls Engineer at DRM. “Operator training and dry runs ahead of time made all the difference. We had them running confidently by Day 3.”

Results

The new robotic dispensing system met production and quality goals:

‣ Bead quality variation significantly reduced across all product variants

‣ Adhesive waste minimized through start/stop optimization

‣ Cycle time targets preserved

‣ Operator involvement reduced to part loading and recipe selection

According to plant operators, the process was highly repeatable with minimal variation. Stakeholders also reported strong satisfaction with the system’s reliability and ease of use.

By combining fixed-head architecture, pressure-tuned dispensing, and operator-focused design, DRM delivered consistent performance with minimal post-installation adjustments.

The project demonstrated DRM’s ability to blend precise material handling, robot path planning, and adhesive-specific engineering into a compact, maintainable solution integrated within tight operational windows.

Considering a Similar Approach?

If your team is weighing the trade-offs of robotic dispensing, fixed head vs. moving nozzle, pressure tuning strategies, or integration with high-viscosity adhesives, projects like this one can offer a practical frame of reference.

If you’re facing similar constraints or evaluating dispensing strategies, we’re happy to share what we’ve learned to support better project outcomes and stronger system performance.