WO2025007160A2

WO2025007160A2 - Systems and processes for bonded fastener installation

Info

Publication number: WO2025007160A2
Application number: PCT/US2024/036470
Authority: WO
Inventors: Julian BALLATORE-SOUTH; Logan KRANTZ; Reuel BALUYUT; Andrew KAPCZYNSKI; Nathaniel Johnson; Michael Johnson; Joseph YANOSKA; Rodrigo Pinheiro
Original assignee: Physical Systems Inc
Current assignee: Physical Systems Inc
Priority date: 2023-06-30
Filing date: 2024-07-01
Publication date: 2025-01-02
Anticipated expiration: 2025-12-30
Also published as: WO2025007160A3

Abstract

A laser ablation containment system includes a laser chamber having a Class IM or higher rated laser integrated therewith and a cleaning chamber coupled with the laser chamber and aligned therewith to selectively receive a beam generated by the Class IM or higher rated laser. The cleaning chamber includes a header selectively movable between a first position exposing an interior of the cleaning chamber for placement of a substrate therein and a second position securely closing the interior of the cleaning chamber to form a Class 1 certified laser operable enclosure in cooperation with the laser chamber, all of which may be integrated into a portable workstation.

Description

SYSTEMS AND PROCESSES FOR BONDED FASTENER INSTALLATION

DESCRIPTION

BACKGROUND OF THE INVENTION

[Para 1] The present invention generally relates to systems and processes for bonded fastener installation. In general, the systems and processes for bonded fastener installation as disclosed herein are designed to prepare a fastener and/or substrate for bonding, apply adhesive to the fastener, and/or install the fastener onto a substrate/sub-assembly with a high-quality bond. [Para 2] Surface preparation is a critical step in achieving a durable adhesive bond to a substrate because the efficacy of the bond relies heavily on the quality or cleanliness of the surface preparation of the substrate. Conventional methods for substrate surface preparation have typically involved manual abrasion of a substrate or surface using abrasive materials such as sandpaper, grinders, or scouring pads designed to remove oxide and contaminant layers deposited thereon. Alternatively, chemicals such as acetone may be used to manually scrub a surface to remove debris and paint by way of chemically breaking down unwanted particles from the substrate. Manual processes tend to be relatively laborious, time consuming, and produce mixed and/or inconsistent results at the surface or substrate being treated due to inconsistencies related to the abrasive materials used and human application.

[Para 3] Moreover, more highly automated techniques such as abrasive grit blasting and/or solvent-blasting chemical processes may be more efficient, but they tend to generate a considerable amount of waste as the ablating materials (e.g., the substrate grinding material, such as the grit and/or solvent) and the foreign material ablated from the substrate intermix and create a source of secondary waste and/or chemicals that are generally hazardous to personnel and the environment. Environmental regulations have been put in place to restrict the use of hazardous chemicals and high waste disposal costs have placed an emphasis on minimizing the amount of secondary waste generated during contaminant removal. This is in addition to the fact that these manual techniques are also laborious and time-consuming processes, and human implementation again results in varying degrees of uniformity across the treated substrates and surfaces.

[Para 4] More recent laser ablation processes are generally considered enhancements over the above-mentioned mechanical and/or chemical removal processes. In this respect, laser ablation is a process for removing surface material and debris through use of a high intensity laser light beam that irradiates a substrate. The laser generates a focused beam having a power density sufficient for absorption into the subject substrate to create a plasma plume and shock waves that effectively disrupt foreign material adhered or otherwise attached to the substrate, for effective dislodgment and ejection into the surrounding environment as debris. Most laser-based processes are automated, thereby saving on manual labor costs with respect to manual sandpaper or grit blasting processes mentioned above. Moreover, laser-based ablation creates less waste because the process does not use mechanical abrasive grit or potentially harmful chemicals to remove the foreign materials from the substrate. As such, laser-ablation processes help minimize the environmental impact by reducing the amount of secondary waste generated.

[Para 5] In one prior art reference, U.S. Patent No. 5,780,806 to Ferguson, the contents of which are herein incorporated by reference in its entirety, discloses a laser ablation system and method for decontaminating surfaces therewith. Ferguson more specifically discloses a laser ablation system that includes a laser, a flexible fiber optic cable optically coupled to the laser to transmit laser light for ablating or decontaminating a surface, and an output optics assembly that includes a nozzle through which the laser light passes. The assembly further includes an exhaust tube generally in communication with the nozzle along with a blower that generates a vacuum within the exhaust tube. In operation, the laser ablation system generates an acousto-optic, Q- switched Nd:YAG laser light to produce an irradiance greater than IxlO⁷ W/cm², and a pulse width between 80 and 170 nanoseconds (“ns”) to ablate foreign substances off the substrate.

Ablating the substrate surface with such an irradiance is typically effective at removing debris thereon, which is then removed therefrom by the vacuum exhaust tube. Even so, Ferguson does not appear to include an air knife or curtain protecting the laser protective cover, or a structure that allows easy replacement of the protective cover after extensive use.

[Para 6] Additionally, the National Robotics Engineering Center (“NREC”) at Carnegie Mellon University in Pittsburgh, Pennsylvania co-developed an Advanced Robotic Laser Coating Removal System (“ARLCRS”) with Concurrent Technologies Corporation (“CTC”) of Johnstown, Pennsylvania to remove coatings and debris from U.S. Air Force aircraft. More specifically, the ARLCRS system includes a commercially available laser integrated with a scanner and particle capture system mounted to and integrated with a mobile robotic base and surface monitoring sensors. The robotic arm scans surfaces of the airplane for debris and paint requiring removal therefrom, and uses a powerful laser to ablate the substrate to remove paint and coatings from the aircraft. This way, a team of robots having the debris and paint stripping lasers mounted thereto can work cooperatively together to remove paint and coatings from the aircraft synchronously. The ARLCRS is an automated improvement over handheld infrared laser devices (e.g., with a wavelength of 1064 nanometers (“nm”)), which can also be used to manually remove rust or paint/primer from large surfaces, such as airplane bodies and ships in a shipyard. The problem with these systems is that there is no containment of the emitted laser light. Thus, while the amount of waste generated is less than that of grit or chemical-based solutions, potentially harmful laser light is still present in and/or around the ablated surfaces, whereby the workspace environment must be made to conform to higher class (e.g., Class IM or higher) laser safety standards. It is crucial to follow laser safety protocols and wear protective eyewear as these devices can expose personnel to the laser beam path without adequate safety measures. The ARLCRS is thus ideally used in a dedicated lasering room, which can certainly be expensive to fabricate, and are generally considered completely immobile due to the relatively large vehicle structures (e.g., airplanes) the ARLCRS are designed to ablate.

[Para 7] As such, in general, known laser ablation processes have drawbacks associated primarily with the fact that there are no known Class 1 laser ablation enclosure systems for use in removing debris from a substrate, much less being portable or easily deployable in an existing manufacturing environment. As a result, the laser ablation process must still occur in specialized rooms built to adhere to current safety standards for operating higher class lasers, including that operators in the room must wear protective gear and/or other specialized eyewear. Performing the ablation process in these rooms is not particularly conducive for implementing the laser ablation process as an existing step in a manufacturing process (e.g., in an existing assembly plant) or at an existing repair facility. At a minimum, e.g., substrates to be ablated must be moved into and/or out from rooms having adequate built-in safety mechanisms, as part of the manufacturing process. This can delay and unnecessarily increase the costs associated with cleaning a substrate prior to application of, e.g., a nutplate with an adhesive.

[Para 8] Another problem in the aerospace industry relates to the processes for automating adhesive dispensing with respect to relatively small volumes, such as to the aforementioned nutplate. Micro-dispensing techniques known in the art produce or dispense liquid media in relatively small dosage volumes, such as on the order of less than 0.1 gram (“g”). Dispensing adhesive, liquid, oil, grease and/or other viscous media is particularly difficult to accomplish reliably and accurately in such small dosages. The precise positioning and fluid quantity, reagents, and cycle times has considerable influence on the overall quality of the adhesive being dispensed, and specifically with respect to the ability to consistently and repeatably control the dispensed volume and location of the applied adhesive. The ability to control these relatively small volumes of adhesive (i.e., on the order of < 0.1 g) becomes important when applied on to relatively small parts, such as nutplates as may be used in aerospace applications.

[Para 9] In one prior art device, U.S. Patent No. 9,931,665 to Cheung, the contents of which are herein incorporated by reference in its entirety, discloses a liquid compound dispensing apparatus for dispensing a controlled amount of liquid compound onto a workpiece. More specifically, Cheung discloses a cartridge system for selectively receiving and retaining a cartridge containing a liquid compound therein. A plate having a threaded bore is positioned above the cartridge system and coupled to one end of a plunger having a piston coupled to the other end. The piston is of a size and shape to move within the liquid containing cartridge to displace liquid compound therefrom. In operation, drive system operates to move the plate with the plunger and piston attached thereto in a forward direction to dispense liquid out from the cartridge, and to stop the piston when dispensing stops. Thereafter, the cartridge can be removed and replaced once the contents therein have been expended. As with known prior art designs, the liquid compound dispensing rate is controlled by how fast the motor drives the system to displace the piston within the cartridge.

[Para 10] In another design, U.S. Patent No. 8,469,231 to Strecker, the contents of which are herein incorporated by reference in its entirety, discloses a dispensing system for delivering quantities of a liquid less than one cubic millimeter (“mm³”) in volume. More specifically, Strecker discloses a housing having a pair of liquid retaining containers that fluidly couple with a respective pair of input channels that selectively direct liquid from the retaining containers into a respective first and second feed screws. Liquid compounds within each of the retaining containers may be delivered to the input channels by a pair of pistons therein designed to drive or plunge into the retaining containers to drive the liquid compounds therein out through the input channels. The pistons provide back pressure to move the liquid compounds out from within each of the liquid retaining containers and into the pair of input channels for eventual contact with the pair of feed screws. Dispensing is then driven by operating the feed screw having helical threads disposed in the chamber that intermix incoming compounds therein during rotation. Continued rotation then drives the intermixed liquid compounds out through a dispense tip. Strecker, however, does not disclose any feedback sensors to monitor the quantity or quality of liquid dispensing out from the tip, and Strecker does not appear to disclose that the pistons can be pneumatically moved out from within the liquid retaining containers to stop subsequent “drip” or “drool” because the dispensing liquid has already exited the respective input channels and is being primarily driven by rotation of the feed screw.

[Para 11] In another prior art reference, U.S. Patent No. 8,578,729 to Fiske, the contents of which are herein incorporated by reference in its entirety, discloses a system for dispensing relatively small amounts of a viscous material onto a workpiece using a relatively narrow-profile dispenser. More specifically, the dispenser disclosed by Fiske includes a fluid chamber, a nozzle, and a valve seat disk having individual components, each of which are removable from a main body of the dispenser for cleaning and/or replacement. Viscous material is supplied under pressure from a supply container through a fluid tube to an inlet port for dispensing out through the nozzle.

[Para 12] Problems with adhesive dispensing systems known in the art, such as those discussed above, is that it is difficult to consistently and reliably dispense a relatively small volume of liquid under pressure, such as by way of a pneumatic system that applies constant pressure to pistons position behind liquid compounds within the cartridge containers - this is because pneumatic systems require a valve to “start” and/or “stop” adhesive flow. The physical location of the valve is typically within the flow of the adhesive and, as such, remains in constant contact with the adhesive. Such a “wet” valve is subject to adhesive in a constant curing state and is not particularly conducive to prevent “drip” or “drool” after dispensing is supposed to stop in its entirety. Also, known pneumatic systems also do not include a “pull back” feature to control adhesive flow, which is not believed to be compatible with pneumatic systems in the first place due to inherent limitations with the aforementioned pneumatic functionality.

[Para 13] There exists, therefore, a significant need in the ail for systems and processes for bonded fastener installation designed to prepare a fastener and substrate for bonding, such as by laser ablation utilizing a Class 1 laser enclosure having an integrated air curtain or knife and vacuum evacuation system, applying adhesive to the fastener at a consistent rate with no “drip” or “drool”, and installing the fastener onto a substrate/sub-assembly with a high-quality bond.

The present invention fulfills these needs and provides further related advantages.

SUMMARY OF THE INVENTION

[Para 14] In one embodiment as disclosed herein, a laser ablation containment system may be integrated as part of a portable roller station and include a laser chamber having a Class IM or higher rated laser (e.g., a Class 4 laser) integrated therewith and a cleaning chamber coupled with the laser chamber and aligned therewith to selectively receive a beam generated by the Class IM or higher rated laser. Here, the cleaning chamber may include a header selectively movable between a first position exposing an interior of the cleaning chamber for placement of a substrate therein and a second position securely closing the interior of the cleaning chamber to form a Class 1 certified laser operable enclosure in cooperation with the laser chamber.

[Para 15] The cleaning chamber and the laser chamber may be coupled with a robotic arm movable to selectively position the header against the substrate to form the enclosure therewith. The robotic system may also operate a gripper having a pair of actuating fingers positioned underneath an umbrella and operable to selectively pick-and-place the substrate within the enclosure formed by sealing engagement of the umbrella with a sealing rim. Here, the robotic system may selectively position an elastomeric fixture downwardly protruding from a nutplate in seated reception in a bracket inwardly projecting from an inner sidewall of the cleaning chamber forming a gap in between.

[Para 16] In one embodiment, the umbrella may be slidable along an axis normal to a focal lens of the Class IM or higher rated laser mounted within the laser chamber. In another embodiment, a proximity sensor may be positioned to identify when umbrella is seated on the sealing rim to ensure the laser ablation containment system continues to operate a Class 1 certified enclosure with the Class IM or higher rated laser. In these embodiments, the header may be an outwardly projecting compressible liner that forms at least part of an outer perimeter of the enclosure, and at least one sensor may be positioned to measure pressure or light within the enclosure.

[Para 17] In another aspect of these embodiments, the cleaning chamber of the laser ablation containment system may be in fluid communication with a debris removal chamber. Moreover, a selectively removable and replaceable protective lens may be selectively positionable within a slot substantially sealing off the laser chamber from the cleaning chamber, to provide further protection of the Class IM or higher rated laser. Here, the protective lens may be carried by a protective lens holder having a front channel providing access to the protective lens when removed from the slot. Although, when inserted in the slot, the front channel is positioned flush with an inner sidewall of the cleaning chamber, thereby locking the protective lens therein.

[Para 18] Furthermore, the header may include a clamp having a base with a lower sealing member upwardly extending therefrom that cooperates with an upper sealing member to form the enclosure in between when the header is in the second position. Here, the lower sealing member may be made from a foam or rubber material and may be movable relative to the upper sealing member, which may also be made from a foam or rubber material, by way of a linear actuator or a pneumatic piston.

[Para 19] In another aspect of these embodiments, the laser chamber may be offset relative to the cleaning chamber by an angle between 90° and 180°. Additionally, or alternatively, a mirror or a prism located within one of the laser chamber or the cleaning chamber may be positioned to receive and redirect the beam by up to an offset of 180°. Here, at least one of the mirror or the prism may be mounted to a pivot (e.g., a single plane pivot, a multi-plane pivot, or a ball-and-socket pivot) and repositionable in real-time within one of the laser chamber or the cleaning chamber.

[Para 20] In another embodiment, a debris containment system as disclosed herein includes a conduit for delivering a pressurized fluid to a cleaning chamber and an outlet coupled with the conduit and positioned to direct the pressurized fluid substantially across an interior channel of the cleaning chamber as an air curtain thereacross substantially preventing debris on one side of the interior channel of the cleaning chamber from crossing the air curtain to another side of the interior channel of the cleaning chamber. As such, the air curtain may extend generally horizontally across the interior channel and toward a debris removal chamber in fluid communication therewith. The outlet may also be a generally elongated slot formed from a tubular bracket extending within the interior channel of the cleaning chamber and/or the outlet may be positioned at an angle relative to the interior channel such that the air curtain extends across the interior channel at an angle relative thereto. [Para 21] More specifically, the interior channel may be a cylindrical channel and the outlet may be a scmi-hcmisphcrical slot formed from an interior sidewall of the cleaning chamber. Here, the semi-hemispherical slot forwardly faces the interior channel and the air curtain extends generally horizontally across the interior channel of the cleaning chamber toward the debris removal chamber. As such, the elongated slot may be positioned so the air curtain flows at least partially vertically within the interior channel of the cleaning chamber to oppose movement of debris toward a laser chamber coupled to the cleaning chamber.

[Para 22] In another embodiment, the conduit may include a first conduit and a second conduit, and the outlet may include a first outlet and a second outlet. Here, each of the first and second outlets may open to the interior channel to produce a first air curtain and a second air curtain offset from each other. More specifically, the first conduit may include an upper conduit and the second conduit may include a lower conduit, wherein each of the upper conduit and the lower conduit includes a respective slot having a width approximately half of a perimeter of the interior channel of the cleaning chamber. In this embodiment, the first air curtain and the second air curtain are both able to substantially extend across the interior channel of the cleaning chamber at the same or different angles relative to one another. An air pressure sensor may be positioned within one of the cleaning chamber or the debris removal chamber to ensure adequate pressure and airflow is within the cleaning chamber and/or the debris removal chamber. In this respect, at least one of a HEPA filter or a carbon filter may be positioned within the debris removal chamber to absorb debris being evacuated from the cleaning chamber.

[Para 23] In another embodiment as disclosed herein, an adhesive dispenser system may also be integrated with a portable roller station and include a frame having a drive unit mounted thereto and a screw threadingly operated by the drive unit and engaged with a carrier unit slidable relative to the frame and having at least one colleting assembly rigidly coupled thereto. The at least one colleting assembly may include a piston collet selectively slidably engageable with a piston head and operable to dispense liquid from a cartridge when the drive unit operates the screw in a first direction and to reduce and/or eliminate liquid “drip” or “drool” when the drive unit operates the screw in a second direction opposite the first direction. The drive unit may operate the screw to dispense liquid in amounts as small as 0.1 gram (“g”) or less at a time. [Para 24] The adhesive dispenser system may also include a support bracket having an extension sized to receive a dispensing needle in spaced apart relation relative to the frame, wherein the support bracket is selectively adjustable relative to the frame by an elongated channel lockable to the frame by a positioning pin located therein. The adhesive dispenser system may also include at least one feedback sensor (e.g., a force-feedback sensor measuring a current or a voltage of the drive unit in real-time) coupled to the drive unit for providing realtime sensing feedback regarding adhesive viscosity. Alternatively, a camera may be positioned to photograph adhesive dispensed from the cartridge. The flow rate operated by the drive unit and the screw may be changed based on the force-feedback and/or the visual appearance of the adhesive being dispensed out the tip. Another feature of these embodiments is that the frame may include a thermal enclosure having a cooling element or a heating element proximate the quick- change carrier therein to temperature regulate one or more fluids within the cartridge in realtime.

[Para 25] In another aspect of these embodiments, the at least one colleting assembly may include a pair of colleting assemblies, each of which includes a respective piston collet selectively slidably engageable with a respective piston head operable to dispense adhesive from a dual-cartridge assembly. Here, the respective piston heads may each be a different size relative to one another, depending on the liquid stored in the dual-cartridge assembly and needed to produce the adhesive. Additionally, the piston collet may terminate in an outwardly flaring mandrel sized for friction fit engagement with the piston head.

[Para 26] Once finished, the liquid cartridge may be released for replacement by way of a one-step quick release mechanism that disengages the piston collet from the cartridge. Here, the quick release mechanism may include a slide bracket having a step operable to compress a spring from a first normal extended position to a second compressed position withdrawing the piston collet out from engagement with the piston head. The slide bracket may include a pull-back channel having a slide pin therein confining movement of the slide bracket relative to the carrier unit by a predetermined distance. Alternately, a stop coupled with the carrier unit may be positioned to terminate rearward movement of the slide bracket relative to the carrier unit by a predetermined distance instead of or in addition to the pull-back channel.

[Para 27] In another embodiment, a quick change cartridge system may include a frame having a set of outwardly extending locator pins having a size and shape for select slide-fit engagement with a slotted housing of a dispenser unit and a liquid containing cartridge having a size and shape for select slide-in reception and/or removal out from an open aperture in the frame when the frame is removed from the dispenser unit, the liquid containing chamber being positionablc within the frame in a forward position in fluid communication with a dispense outlet when the frame is engaged with the dispenser unit.

[Para 28] The frame may include a front aperture having a size and shape relatively smaller than the liquid containing cartridge and relatively larger than the dispense outlet. This permits the liquid containing cartridge to selectively slide into and/or out from the frame. Moreover, the locator pins of the frame may include outwardly extending bolts having a relatively smooth shank portion of a length sufficient for slide in reception in the slotted housing to position a head portion of the bolts to an exterior of the slotted housing. The slotted housing may include a set of externally accessible L-shaped receiving channels relatively wider than a width of the shank portion and relatively smaller than a width of the head portion of the bolts. In this respect, the externally accessible L-shaped receiving channels may also include an enlarged chamfered opening top accessible for drop-in reception of the frame in the slotted housing by way of the locator pins.

[Para 29] In another aspect of these embodiments, the liquid containing cartridge may include an outwardly extending baseplate at least partially relatively larger than the open aperture for flush engagement therewith when the liquid containing cartridge is installed within the frame. Additionally, the liquid containing cartridge may include a pair of liquid containing cartridges, each of which are in fluid communication with a cap having an outlet port selectively couplable with the dispense outlet comprising an inlet of a static mixer outwardly extending from the frame. The liquid containing cartridge may also include at least one rear receiving slot having a size and shape for select engagement with a colleting assembly of the dispenser unit. [Para 30] An adhesive dispensing feedback process as disclosed herein includes steps for activating a drive unit for dispensing a quantity of an adhesive at a desired flow rate, monitoring one or more dispensing characteristics associated with the quantity of the adhesive being dispensed, cross-referencing the one or more dispensing characteristics against a set of operating parameters for each of the one or more dispensing characteristics, and adjusting the desired flow rate of the quantity of adhesive with the drive unit if one or more of the dispensing characteristics fall outside any of the set of operating parameters.

[Para 31] More specifically, to start, a carrier unit having a pair of colleting assemblies coupled therewith are slidably moved into engagement with a respective pair of cartridges positioned in stationary relation to the carrier unit. Here, a pair of piston collets within each of the collcting assemblies may engage with a respective piston head in fluid relation with each of the pair of cartridges in friction-fit engagement therewith. Rotating the screw in a first direction causing forward movement of the colleting assemblies causes liquid to dispense out from within each of the pair of cartridges into a static mixer for forming the adhesive, which is eventually delivered to an outlet tip. When dispensing is to stop, the drive unit may reverse the screw in a second direction, thereby drawing back the piston heads within the liquid containing cartridge by way of the colleting assemblies. This forms a negative pressure at the outlet tip and any excess adhesive is drawn back, thereby effectively stopping “dripping” or “drooling” out the outlet tip. [Para 32] In another aspect of these embodiments, the monitoring step may further include steps for sensing a viscosity of the dispensing adhesive and determining if the viscosity is lower than a threshold value or the viscosity is higher than a threshold value, sensing a current or a voltage of the drive unit in real-time and determining if the current or the voltage is below a threshold value or if the current or the voltage is above a threshold value, measuring an ambient temperature or a temperature of the adhesive, measuring the one or more dispensing characteristics in real-time or in discrete time increments, and/or watching the adhesive with a camera. Reading a temperature of one or more liquid compounds in a liquid dispensing cartridge may help regulate the quality and quantity of the adhesive being dispensed in real-time. Such regulation may involve changing a temperature of the one or more liquid compounds in the liquid dispensing cartridge with a heater or a cooler to help control, e.g.. a viscosity of the adhesive. In response, the adjusting step may include the step of changing a rotating rate of a screw operated by the drive unit to slidably move the carrier unit by the drive unit.

[Para 33] In another embodiment, a selectively removable and/or replaceable protective lens holder as disclosed herein may include a frame having a forwardly positioned receiving channel of a size and shape for select reception of a protective lens e.g., being light permeable) therein when in a first open position. The protective lens holder may be movable to a second position locking the protective lens therein in cooperation with an interior sidewall of a cleaning chamber when slidably engaged therewith. The receiving channel may include a substantially horizontal open slot for selectively inserting and/or removing the protective lens therein when the protective lens holder is in the first position. [Para 34] Additionally, the protective lens holder may further include a handle outwardly extending from the frame opposite the receiving channel and being of a size and shape for hand manipulation outside of an external sidewall of the cleaning chamber. Here, the handle may further include a pair of oppositely facing arcuate recesses enhancing hand manipulation of the protective lens holder outside the external sidewall of the cleaning chamber.

[Para 35] In another embodiment, a debris removal system may include an outlet conduit in fluid communication with a cleaning chamber having debris therein removed from a substrate. A port in the outlet conduit may couple to a pressure sensor in fluid communication therewith for measuring a pressure in the outlet conduit in real-time and a controller coupled with the pressure sensor may be in communication with a laser operable to generate a beam in the cleaning chamber for removing debris from the substrate. Here, the controller is operable to disable the beam in response to a pressure loss measured by the pressure sensor in the outlet conduit. Additionally, an inlet port may selectively receive a pressurized fluid at least partially generating a vacuum in the outlet conduit relative to the cleaning chamber, wherein the inlet port may couple to a pneumatic air pump. A HEPA filter or a carbon filter may also be positioned within the outlet conduit to filter debris therefrom.

[Para 36] In another embodiment, a process for replacing a quick-change cartridge includes sliding a carrier out from engagement of a frame of a dispensing unit, removing a liquid containing cartridge out from within the carrier by way of an access port, inserting a new liquid containing cartridge through the access port, and reinserting the carrier carrying the new liquid containing cartridge into the frame of the dispensing unit. This process may further include moving a set of locking pins outwardly protruding from the carrier through an externally accessible L-shaped channel formed from the frame. Here, the set of outwardly protruding locking pins may be bolts having shank portions movable within the L-shaped channels and head portions relatively larger than and positioned external the L-shaped channels. As such, in one embodiment, the new liquid containing cartridge may be locked in a forward slot of the L-shaped channel upon reinsertion of the carrier into the frame.

[Para 37] This process may further include the step of disengaging the liquid containing cartridge from a slide unit. As such, this may occur by moving an externally accessible slide bracket rearwardly relative to the slide unit, compressing a normally forwardly positioned extension spring within a retraction channel by way of engagement of an inwardly projecting step engaging a washer positioned at one end of the extension spring, and retracting a flaring mandrel of a piston collet out from friction-fit engagement with a piston head associated with the liquid containing cartridge in response to compressing the extension spring. Here, the compressing step may include compressing the extension spring with an intermediary projecting step positioned between coils of the extension spring and the moving step may include terminating rearward movement of the slide bracket with a stop integrated with the frame or positioned within a pull-back channel formed within the slide bracket. Once a new liquid containing cartridge has been engaged with the frame, the reinserting step includes recoupling a slide unit with a piston head associated with the new liquid containing cartridge by tapping a screw, rotating an externally accessible knob, or retracting the piston head into engagement therewith.

[Para 38] In another process disclosed herein, cleaning a surface of a substrate or the like may include enclosing a laser chamber having a Class IM or higher rated laser integrated therewith, positioning the substrate within an ablation chamber coupled with the laser chamber and aligned with the Class IM or higher rated laser, moving a header between a first position exposing an interior of the ablation chamber for placement of the substrate therein and a second position closing the interior of the ablation chamber and forming a Class 1 certified laser operable enclosure in cooperation with the laser chamber, generating a beam with the Class IM or higher rated laser, and contacting at least a portion of the substrate with the beam, thereby cleaning the substrate of debris.

[Para 39] Additionally, this process may include steps for pick-and-placing the substrate within the header and sandwiching the substrate between an upper sealing member and a lower sealing member of the header. Moreover, the substrate may be oriented relative to the beam between an angle of 90° and 180°, such as by way of redirecting at least a portion of the beam off a mirror such that the contacting step includes simultaneously ablating the substrate at two different beam angles. In this embodiment, the mirror may be pivoted in real-time (e.g., about a ball-and-socket joint) to reposition the mirror and the angle at which the beam contacts the substrate. Additionally, or alternatively, the beam may be split by a prism before contacting the substrate.

[Para 40] This process may also include steps for inserting a protective lens between the laser chamber and the ablation chamber generally orthogonal to the beam (e.g., so the beam is directed through the protective lens and into contact with the substrate) and activating a proximity sensor in response to inserting the protective lens or forming the Class 1 certified laser operable enclosure. Here, as part of the inserting step, a front slot of a protective lens holder may be abutted against an interior sidewall, thereby locking the protective lens within the protective lens holder.

[Para 41] Additionally, this process may further include monitoring the Class 1 certified laser operable enclosure in real-time with at least one sensor and terminating the beam in the event the enclosure is no longer Class 1 compliant based on real-time feedback from the at least one sensor (e.g., a pressure sensor or a light sensor). In another aspect, a pressure differential between the cleaning chamber and the outlet port may be measured in real-time, and the beam may be deactivated if the pressure differential between the cleaning chamber and the outlet port falls below a predetermined threshold value. The pressure differential is also important for evacuating debris out from within the cleaning chamber by pressurizing the enclosure and forming a vacuum at an outlet port.

[Para 42] Another process disclosed herein for installing a fastener to a substrate includes cleaning a bonding surface of the fastener and at least a portion of the substrate with a laser, positioning the cleaned bonding surface of the fastener proximate an adhesive dispenser, applying an adhesive to the bonding surface of the fastener with the adhesive dispenser, and bonding the fastener to the substrate along a bondline formed between the bonding surface of the fastener and the substrate. Here, the cleaning step may include operating a Class IM or higher rated laser in a Class 1 certified laser enclosure, such as by opening an ablation chamber coupled with the Class IM or higher rated laser, placing the fastener or the substrate within the ablation chamber, and closing a header of the ablation chamber about the fastener or at least a portion of the substrate to be ablated, thereby forming the Class 1 certified laser enclosure about the fastener or the portion of the substrate to be ablated. Additionally, a beam may be generated with the laser to contact at least a portion of the bonding surface or the substrate with the beam. [Para 43] Moreover, the cleaning step may further include selecting a fastener that includes a one of several nutplates, locating the nutplate relative to an internal bracket inwardly projecting from an inner sidewall within a cleaning chamber so an elastomeric member extending out from a bottom surface of the nutplate bends away from a beam path of the laser, and ablating the bottom surface of the nutplate with the beam. Here, the ablating step may include rotating the bottom surface of the nutplate relative to the beam while the elastomeric member simultaneously remains bent out and away from the beam.

[Para 44] Additionally, the positioning step may include removing the ablated nutplate from the cleaning chamber, sliding the elastomeric member into a slot of a locator block, and aligning the bottom surface of the nutplate proximate an outlet of the adhesive dispenser while simultaneously bending the elastomeric member away from the outlet. Furthermore, the applying step may include the step of rotating the bottom surface of the nutplate relative to the outlet of the adhesive dispenser while simultaneously bending the elastomeric fixture away from the outlet and the rotating step may include adjusting a rotation rate of the bottom surface of the nutplate in response to a desired flow rate of the adhesive, wherein the bonding step includes the step of drawing an elastomeric member through an aperture in the substrate for draw-in bonding of the bonding surface of the fastener to the substrate.

[Para 45] In another process disclosed herein, the process for containing debris within an cleaning chamber may include delivering a pressurized fluid to a debris containment chamber, dispersing the pressurized fluid as an air curtain across an open inner channel within the debris containment chamber, blocking at least some debris within the debris containment chamber from crossing the air curtain, and evacuating at least some of the pressurized fluid out an exit port fluidly coupled with the debris containment chamber simultaneously with at least some debris. [Para 46] Here, the air curtain may include a pair of air curtains, wherein a first air curtain may be positioned substantially orthogonal to the inner channel and a second air curtain may be offset from being orthogonal to the inner channel by between 10 degrees and 90 degrees. As such, the dispersing step may include forming the first air curtain out a slot formed from at least part of the open inner channel of the debris containment chamber and the second air curtain may be formed out a tubular bracket extending within the open inner channel of the debris containment chamber. The system may also monitor a real-time pressure within the debris containment chamber to ensure efficient and effective evacuation of debris therefrom.

[Para 47] Other features and advantages of the present invention will become apparent from the following more detailed description, when taken in conjunction with the accompanying drawings, which illustrate, by way of example, the principles of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS [Para 48] The accompanying drawings illustrate the invention. In such drawings:

[Para 49] FIGURE 1 is an environmental perspective view of a laser ablation containment and debris removal system integrated as part of a portable roller station having a Selective Compliance Assembly Robot Arm (“SCARA”) and an adhesive dispenser;

[Para 50] FIGURE 2 is an enlarged environmental perspective view taken about the square 2 in FIG. 1, more specifically illustrating a Class 4 laser coupled with the laser ablation containment and debris removal system along with the adhesive dispenser integrated with the laser ablation containment and debris removal system;

[Para 51] FIGURE 3 is a perspective view more specifically illustrating the laser ablation containment and debris removal system fully assembled;

[Para 52] FIGURE 4 is an exploded perspective view of the laser ablation containment and debris removal system of FIG. 3, more specifically illustrating a gripper operable by the SCARA sealable within an ablation chamber when operating the Class 4 laser;

[Para 53] FIGURE 5 is an enlarged environmental perspective view illustrating the gripper retaining a nutplate and biasing an elastomeric fixture away from a dispenser applying an adhesive thereunder with the adhesive dispenser;

[Para 54] FIGURE 6 is a top perspective view of the laser ablation containment and debris removal system of FIG. 3 sans an upper umbrella to further illustrate an ablation chamber housing a V-shaped intersection bracket therein;

[Para 55] FIGURE 7 is a bottom perspective view of the laser ablation containment and debris removal system, further illustrating a vacuum pressure sensor and an air inlet port for channeling pressurized air into the ablation chamber to operate one or more air curtains and direct debris out through a vacuum chamber;

[Para 56] FIGURE 8 is a partial cross-sectional view taken about the line 8-8 of FIG. 6, more specifically illustrating a selectively removable protective lens holder separating a laser protection chamber from the ablation chamber, and that the vacuum pressure sensor is coupled with the vacuum chamber;

[Para 57] FIGURE 9 is an enlarged partial cross-sectional view taken about the circle 9 in FIG. 8, further illustrating the V-shaped intersection bracket within the ablation chamber positioned to direct airflow from the ablation chamber into the vacuum chamber fluidly coupled therewith; [Para 58] FIGURE 10 is a partial cross-sectional view taken about the line 10-10 of FIG. 3, more specifically illustrating a pressurized air channel coupled with the ablation chamber;

[Para 59] FIGURE 11 is a cross-sectional view taken about the line 11-11 of FIG. 3, more specifically illustrating an open port of the vacuum pressure sensor coupled with the vacuum chamber;

[Para 60] FIGURE 12 is a cross-sectional view taken about the line 12-12 of FIG. 4, more specifically illustrating the vacuum pressure sensor coupled with the vacuum chamber and a portion of the pressurized air channel;

[Para 61] FIGURE 13 is a cross-sectional view taken about the line 13-13 of FIG. 4, more specifically illustrating the pressurized air channel branching into a pair of conduits for directing pressurized air to an interior of the ablation chamber for generating a pair of air curtains during use;

[Para 62] FIGURE 14 is a cross-sectional view similar to FIG. 13 with the laser ablation containment and debris removal system rotated by about 270 degrees to more specifically illustrate branching of the pressurized air channel into a lower semi-hemispherical conduit and an upper horizontal conduit;

[Para 63] FIGURE 15 is a cross-sectional view taken about the line 15-15 of FIG. 4, more specifically illustrating the lower semi-hemispherical conduit feeding pressurized air to a semihemispherical slit generating a horizontal air curtain across an open interior of the ablation chamber;

[Para 64] FIGURE 16 is a cross-sectional view taken about the line 16-16 of FIG. 4, more specifically illustrating the upper horizontal conduit feeding pressurized air to a vertically facing horizontal slit in the bracket for generating at least a partial vertical air curtain directing debris up and away from the protective lens holder and into the vacuum chamber;

[Para 65] FIGURE 17 is a perspective view more specifically illustrating one embodiment of a protective lens holder as disclosed herein;

[Para 66] FIGURE 18 is a rear perspective view of an adhesive dispenser as disclosed herein;

[Para 67] FIGURE 19 is a partial cut-away top view of the adhesive dispenser taken about the line 19-19 in FIG. 18, further illustrating a pair of cohering assemblies forwardly engaged with a pair of cartridges of a dual cartridge dispensing system; [Para 68] FIGURE 20 is an enlarged partial cut-away top view taken about the circle 20 in FIG. 19, further illustrating that the pair of collcting assemblies each include a spring-biased slide bracket movable to disconnect the pair of colleting assemblies from the pair of cartridges;

[Para 69] FIGURE 21 is a rear perspective view illustrating a quick-change carrier in exploded relation relative to the adhesive dispenser;

[Para 70] FIGURE 22 is an enlarged front perspective view taken about the circle 22 in FIG. 21, more specifically illustrating the quick-change carrier engaged with a dual-cartridge replaceable system;

[Para 71] FIGURE 23 is a rear perspective view of the dual-cartridge replaceable system illustrated in FIGS. 21 and 22 slidably engaged with the quick-change carrier;

[Para 72] FIGURE 24 is a rear perspective view similar to FIG. 23, illustrating slide-out removal of the dual-cartridge replaceable system from the quick-change carrier;

[Para 73] FIGURE 25 is a side view of the adhesive dispenser of FIG. 18;

[Para 74] FIGURE 26 is sectional view taken generally about the line 26-26 in FIG. 25, further illustrating a thread screw in threaded relation with the piston slide carrier;

[Para 75] FIGURE 27 is an environmental perspective view illustrating an adhesive applied underneath a nutplate by way of the adhesive dispenser disclosed herein;

[Para 76] FIGURE 28 is an enlarged perspective view of one of the colleting assemblies, further illustrating an outwardly flaring mandrel positioned within a flaring sleeve that selectively couples to a piston head within the dual-cartridge replaceable system;

[Para 77] FIGURE 29 is a perspective view of an alternative adhesive dispenser, including an externally accessible rotatable knob operable to turn a tapping screw to threadingly engage or disengage one of the piston heads in the dual-cartridge replaceable system;

[Para 78] FIGURE 30 is a perspective view of another adhesive dispenser as disclosed herein, including a thermal enclosure housing the dual-cartridge replaceable system;

[Para 79] FIGURE 31 is a perspective view of the alternative adhesive dispenser similar to FIG. 30, illustrating a cooler and a pair of heating elements that temperature control the dualcartridge replaceable system within the thermal enclosure;

[Para 80] FIGURE 32 is an environmental perspective view of a substrate ablation and debris evacuation system integrated for use with a collaborative robot (“cobot”) as part of a portable roller station; [Para 81] FIGURE 33 is a perspective view of the substrate ablation and debris evacuation system fully assembled;

[Para 82] FIGURE 34 is an alternative perspective view of the substrate ablation and debris evacuation system similar to FIG. 33, rotated to more specifically illustrate an ablation enclosure and a gripper;

[Para 83] FIGURE 35 is a partial exploded perspective view of the substrate ablation and debris evacuation system of FIG. 34;

[Para 84] FIGURE 36 is an environmental perspective view illustrating an ablation enclosure in an open position aligned with a bracket to be ablated on a carrier;

[Para 85] FIGURE 37 is an environmental perspective view similar to FIG. 36, further illustrating an upper sealing member engaging a top surface of the carrier in vacuum sealed relation therewith to enclose the bracket inside;

[Para 86] FIGURE 38 is an environmental perspective view similar to FIGS. 36-37, further illustrating a lower sealing member engaging a bottom surface of the carrier in vacuum sealed relation therewith;

[Para 87] FIGURE 39 is a cross-sectional view taken about the line 39-39 of FIG. 33, more specifically illustrating a fume extractor fluidly coupled with the ablation enclosure;

[Para 88] FIGURE 40 is a partial cross-sectional view taken about the line 40-40 of FIG.

34, more specifically illustrating an air pressure sensor and its open port fluidly coupled with the fume extractor;

[Para 89] FIGURE 41 is a partial cross-sectional view taken about the line 41-41 of FIG.

33, more specifically illustrating the protective lens holder positioned between a laser protective zone and the ablation enclosure in fluid communication with the fume extractor;

[Para 90] FIGURE 42 is a cross-sectional view taken about the line 42-42 of FIG. 33, more specifically illustrating a pair of air curtains positioned above an opening between the ablation enclosure and the fume extractor;

[Para 91] FIGURE 43 is a cross-sectional view taken about the line 43-43 of FIG. 33, more specifically illustrating the air pressure sensor coupled with the fume extractor and an inlet port for receiving pressurized air;

[Para 92] FIGURE 44 is a cross-sectional view taken about the line 44-44 of FIG. 33, more specifically illustrating movement of the pressurized air through an internal channel; [Para 93] FIGURE 45 is a cross-sectional view taken about the line 45-45 of FIG. 36, more specifically illustrating the internal channel branching into a lower conduit and an upper conduit; [Para 94] FIGURE 46 is a cross-sectional view taken about the line 46-46 of FIG. 36, more specifically illustrating the lower conduit channeling pressurized air to a lower semihemispherical slit for generating a lower air curtain across an interior opening of the ablation enclosure and the upper conduit channeling pressurized air to an upper semi-hemispherical slit for generating an upper air curtain across the interior opening of the ablation enclosure; and [Para 95] FIGURE 47 is a cross-sectional view similar to FIG. 46, rotated to further illustrate the flow of pressurized air forming the upper and lower air curtains from the ablation enclosure into the fume extractor through an opening in between.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[Para 96] As shown in the exemplary drawings for purposes of illustration, systems and processes for bonded fastener are illustrated herein with respect to FIGS. 1-47. As will be discussed in more below, the systems and processes disclosed herein may generally be used, e.g., to automate the preparation and installation of bonded fasteners, including cleaning the fastener and/or the substrate prior to application of an adhesive, applying an adhesive to at least a portion of one of the fastener or the substrate, and then affixing the fastener and the substrate along an adhesive bondline. One or more robotic systems may operate independently and/or concurrently with one another to prepare the fastener and/or the substrate for bonding, accurately and consistently apply the adhesive to the fastener and/or the substrate, and then affix the fastener to the substrate with consistent and repeatable results, all of which may be integrated into an adaptable, modular system capable of being deployed in environments, such as existing manufacturing facilities, without the need for personal protective equipment (“PPE”) or the like. [Para 97] The bondable surfaces of the fastener and substrate may be prepared by a laser ablation process where a Class IM or higher laser, such as an Nd:YAG infrared laser operating at a pulsed 1064 nm wavelength, operates within a Class 1 certified laser enclosure to burn off oxide and other contamination from the fastener (e.g., a nutplate or the like) and/or the substrate (e.g. , the flange of an aircraft) by rapidly heating the base surfaces and contamination layers thereon. Typically, the base surfaces of the fastener and/or the substrate, which may be made of metal or the like, have different thermal properties than the contamination layers the laser ablation process is designed to remove therefrom. As such, the heating and/or cooling rate of the base material (material being ablated) and the contamination material (if present) differs based on several different factors such as thermal conductivity, mass, thickness, specific heat capacity, laser parameters, and the surrounding environment. Differences in rapid temperature changes from the laser causes the contamination layers to become brittle and break off the base material, without damaging the base material of the fastener or substrate.

[Para 98] Safety systems may monitor laser operation in real-time to ensure continuous operation within certain parameters deemed safe without the need for operators to use or wear PPE (e.g., laser safety goggles) or build protective laser safety cages. This makes the systems and processes disclosed herein particularly suitable for deployment in environments such as existing manufacturing assembly lines, including as pail of a portable or movable workstation. Moreover, a Dual Check Safety (“DCS”) system may be programmed to prevent laser operation unless sensors confirm the enclosure is properly sealed and operating in a Class 1 certified capacity. Such sensors may include a light sensor monitoring the amount of light escaping the enclosure (if any), proximity sensors ensuring the enclosure is closed, pressure and/or flow sensors that continuously check seals and gauge the efficiency of debris evacuation by a vacuum or fume extractor designed to remove ablated debris during operation. An insufficient seal or drop in air flow below a threshold level may cause the system to disable a safety interlock, thereby deactivating laser operation.

[Para 99] The systems and processes disclosed herein are also designed to reduce variability and increase reliability of the installation processes in a faster and more robust manner than other methods known in the ail, including manual installation. The systems and processes disclosed herein also provide a properly prepared fastener with the correct amount of adhesive to create a repeatable and reliable bondline, which increases efficiency and reduces waste (e.g.. discarded adhesive), thereby also reducing manufacturing and assembly costs in addition to improving deployment flexibility and safety.

[Para 100] In one aspect of the embodiments disclosed herein, a laser ablation containment and debris removal system 50 is generally illustrated in FIGS. 1-14, and 6-16. As best illustrated in FIGS. 1 and 3, the laser ablation containment and debris removal system 50 is generally formed of three sections, a laser protection chamber 52 generally aligned with an ablation chamber 54, and a vacuum chamber 56 in fluid communication with the ablation chamber 54. In this respect, the vacuum chamber 56 is designed to continuously remove debris selectively ablated from substrates in the ablation chamber 54 by a laser 58 (FIGS. 1 and 2) selectively mounted or otherwise integrated into the laser protection chamber 52 opposite the ablation chamber 54. In general operation, the laser 58 emits a beam that travels through the laser protection chamber 52, through a selectively removable and replaceable protective lens holder 60 (FIG. 17) having a protective lens therein (not illustrated in FIG. 17) positioned between the laser protection chamber 52 and the ablation chamber 54, and into the ablation chamber 54 for selectively cleaning a substrate located therein. The protective lens in the holder 60, as discussed in more detail below, is designed to protect the laser 58 from debris ablated from substrates within the ablation chamber 54. The debris removed from the cleaned substrate is then extracted from the ablation chamber 54 by the vacuum chamber 56 fluidly coupled thereto, as also discussed in more detail below.

[Para 101] In one embodiment, to improve the efficiency and accuracy of laser ablating substrates to achieve a consistently higher-quality surface preparation with six sigma reliability during the manufacturing processes, while at the same time reducing surface preparation time and costs, the laser ablation containment and debris removal system 50 may be used in conjunction with a Selective Compliance Assembly Robot Arm (“SCARA”) 62 and/or an adhesive dispenser 64, such as part of a portable roller station 66 as illustrated in FIGS. 1 and 2. Although, of course, any of the laser ablation containment and debris removal system 50, the SCARA 62, and/or the adhesive dispenser 64 may be integrated as part of a stationary or semi- stationary system for use in manufacturing processes that may utilize or integrate the laser ablation containment and debris removal system 50 as disclosed herein. In alternative embodiments, other robotic arms and/or robotic gantry systems known in the art may be used instead of the SCARA 62.

[Para 102] As illustrated in FIG. 1, the SCARA 62 includes an end effector 68 selectively engageable with a coupling 70 of the laser ablation containment and debris removal system 50, which generally extends through an upper umbrella 72 and into the ablation chamber 54 (FIGS. 3 and 4) for coupling with a downwardly presented gripper 74 that generally includes a pair of actuating fingers 76 having a size and shape to selectively pickup and move a substrate requiring cleaning within the ablation chamber 54, such as a nutplate 78 illustrated in FIG. 5. In one embodiment, the gripper 74 may be mechanically or pneumatically driven. Although, in general, the gripper 74 could be replaced with another system able to pick up and move a part to be lascrcd, as disclosed herein.

[Para 103] The ablation chamber 54 is generally formed through cooperation of the umbrella 72 having a sealing ring 80 made from a foam or rubber material generally circumferentially coupled thereto and having a size and shape for select seated reception on an upper rim 82 illustrated in FIG. 4. As such, in operation, the SCARA 62 operates to locate the gripper 74 relative to one of a number of nutplates 78 requiring ablation (e.g., as illustrated in FIG. 5), actuates the fingers 76 to grip one of the nutplates 78 for removal from a nutplate carrier 84, and then transports the selected nutplate 78 above the open upper rim 82 of the laser ablation containment and debris removal system 50. Here, the SCARA 62 descends the gripper 74 holding the selected nutplate 78 into an interior of the ablation chamber 54, which seals when the sealing ring 80 lands on the upper rim 82. To better ensure an airtight seal, or substantially airtight seal, the foam or rubber material of the sealing ring 80 may at least partially compress between the umbrella 72 and the upper rim 82. A similar foam or rubber material may be coupled between the end effector 68 of the SCARA 62 and the coupling 70 upwardly extending from the umbrella 72 to also form an airtight, or substantially airtight, seal therebetween as well. In this respect, the ablation chamber 54 is effectively sealed to ensure that no laser light emits out from within the ablation chamber 54 when ablating the nutplate 78 or another substrate.

[Para 104] Such sealing arrangement allows the laser ablation containment and debris removal system 50 to operate as a Class 1 enclosure, despite use of the Class 4 laser 58. Accordingly, the laser ablation containment and debris removal system 50 may be deployed and operated in manufacturing environments without the need to use laser safety goggles or install protective laser safety cages. This is particularly beneficial in the context of using the laser ablation containment and debris removal system 50 in conjunction with the portable roller station 66 because the laser ablation containment and debris removal system 50 can be effectively deployed in an existing manufacturing environment without the need to conform the manufacturing environment to certain higher class laser safety standards (e.g., requiring operators to wear laser safety goggles and/or require the provision of an additional laser safe enclosure to enclose the SCARA 62). As such, the ablation chamber 54 is a fully integrated Class 1 laser safe enclosure designed to ensure safety by preventing light from the laser 58 from escaping out from within the ablation chamber 54 during operation. [Para 105] In another aspect of these embodiments, the umbrella 72 may slide along an axis 86 (FIGS. 3 and 4) normal to a focal lens of the laser 58 mounted to the laser protection chamber 52 opposite thereof. This can help maintain a desired focal length of the ablated substrate within the ablation chamber 54 relative to the laser 58, based on the geometry of the ablated substrate, while also maintaining a proper seal necessary to operate the laser ablation containment and debris removal system 50 as a Class 1 enclosure.

[Para 106] Additionally, the combination of the umbrella 72, the sealing ring 80, and the upper rim 82 are versatile from the standpoint that the geometry of each may be changed depending on the desired size and/or shape of the part or substrate to be ablated in the laser ablation containment and debris removal system 50. For example, in the embodiments disclosed herein, each of the umbrella 72, the sealing ring 80, and the upper rim 82 are generally depicted as cylindrical. Although, in other embodiments, each of the umbrella 72, the sealing ring 80, and the upper rim 82 may be made of a different geometric shape (e.g. , square, rectangular, triangular, etc.), depending on the application. Moreover, the depth of the ablation chamber 54 formed by inter-engagement of the umbrella 72 with the sealing ring 80 and the upper rim 82 may also vary depending on the size and shape of the ablated part. In this respect, e.g., larger parts may require a larger depth, while smaller parts such as the nutplates 78 disclosed herein, may require a relatively smaller depth. Moreover, the gripper 74 and/or the actuating fingers 76 therein operated by the SCARA 62 may also vary in size and shape (e.g., to accommodate pails differing in size and/or surface area), depending on the desired application. Again, larger parts to be cleaned by the laser ablation containment and debris removal system 50 may require the use of a relatively larger gripper and/or actuating fingers, while smaller parts may require the use of a relatively smaller gripper and/or relatively smaller actuating fingers. In one embodiment, the gripper 74 may be of a size and/or shape to handle scalable materials and remain controllable by the SCARA 62 using input/output (“I/O”) command controls. Additionally, a secondary and relatively larger umbrella could nest over the upper rim 82 to accommodate more room thereunder for larger parts.

[Para 107] In another aspect of the embodiments disclosed herein, pails within the ablation chamber 54 may be generally oriented relative to the laser 58 at an angular orientation between 90° and 180° relative to the focal lens thereof. In these embodiments, the laser ablation containment and debris removal system 50 is still able to operate as a Class 1 enclosure because light from the Class 4 laser 58 remains confined therein during operation, as described above. This provides more flexibility, again, as the laser ablation containment and debris removal system 50 may be deployed in manufacturing environments without the need for enhanced safety protocols commonly associated with higher class laser operation (e.g., Class IM and higher). Further integration with the SCARA 62 and the ability to position parts requiring cleaning within the ablation chamber 54 without the emission of any substantial amount of laser light therefrom ensures repeatable and accurate laser operation while simultaneously maintaining safety.

[Para 108] FIGS. 3 and 4 more specifically illustrate a slot 88 formed within a sidewall 90 of the laser ablation containment and debris removal system 50 effectively forming a natural transition between the laser protection chamber 52 and the ablation chamber 54. The slot 88 is of a size and shape to selectively receive and retain the protective lens holder 60 therein, e.g., as generally illustrated in FIG. 2 and more specifically illustrated in FIG. 17. In one embodiment, the protective lens holder 60 is positioned within the laser protection chamber 52 generally orthogonal to the direction of light emitted by the laser 58 below. As such, a beam of the laser 58 travels up through the protective lens in the holder 60 and into the ablation chamber 54 for contact with a substrate needing cleaning, such as the aforementioned nutplate 78. During ablation, debris ablated from the surface of the substrate enters the ablation chamber 54. While all the debris is preferably immediately evacuated out from the ablation chamber 54 through the vacuum chamber 56, it is expected that some debris will remain therein for travel back toward the laser 58. In this respect, the protective lens holder 60 serves as an intermediary to stop projecting debris remaining within the ablation chamber 54 from contacting or otherwise degrading the output lens of the laser 58. Instead, over time, debris collects or otherwise damages the protective lens in the holder 60 instead. As such, it is possible to periodically selectively remove the protective lens holder 60 from the laser protection chamber 52 out from within the slot 88 in the sidewall 94. Once removed, the protective lens in the holder 60 can be cleaned and/or selectively replaced, e.g., by swapping out an entirely new protective lens holder 60; or just replacing the protective lens therein, as discussed in more detail below.

[Para 109] The protective lens holder 60 ensures that the laser 58 remains substantially undamaged from debris within the ablation chamber 54 during operation, while also enabling quick and easy replacement of the protective lens holder 60 after extensive use of the laser ablation containment and debris removal system 50 disclosed herein. As such, the protective lens holder 60 is able to protect the relatively more expensive laser focusing lens of the laser 58 from debris and other particulates within the ablation chamber 54.

[Para 110] Another feature of the laser ablation containment and debris removal system 50 disclosed herein is a bracket 92 inwardly projecting from an inner sidewall 94 within an interior of the ablation chamber 54, as best illustrated in FIG. 6 and further illustrated in FIG. 7. The bracket 92 cooperates with the inner sidewall 94 to form a space or gap 96 in between for select slide in reception of an elastomeric fixture 98, such as one that may be pre-installed with any of the nutplates 78 illustrated in FIG. 5. As such, the SCARA 62 may selectively reposition the nutplate 78 within the interior the ablation chamber 54 such that a lower portion 100 of the elastomeric fixture 98 seats within a V-shaped intersection 102 (FIG. 6) of the bracket 92. The SCARA 62 may then selectively horizontally reposition the nutplate 78 whereby the lower portion 100 of the elastomeric fixture 98 moves within the gap 96 into engagement with the V- shaped intersection 102 such that the lower portion 100 is bent out from within the path of the laser 58, similar to the position illustrated in FIG. 5 when applying an adhesive to the bottom surface of the nutplate 78 from a tip 104 of the adhesive dispenser 64. In a similar fashion, doing so moves a bottom portion of the nutplate 78 into a clear path with a beam of the laser 58, so the nutplate 78 can be cleaned without interference with the elastomeric fixture 98. Moreover, the SCARA 62 may also operate the gripper 74 to rotate the nutplate 78 by approximately 360 degrees so the incoming beam from the laser 58 is able to ablate the entire bottom surface thereof. Of course, the lower portion 100 of the elastomeric fixture 98 remains substantially bent out and away from the incoming beam during the entire rotation through engagement with the V- shaped intersection 102 of the inwardly projecting bracket 92, as mentioned above with respect to the position in FIG. 5.

[Para 111] The ablation chamber 54 may also include one or more sensors positioned therein for purposes of real-time monitoring, such as to ensure the ablation chamber 54 remains adequately sealed to ensure that little or no laser light emits out from within. Such sensors may include a pressure sensor ensuring that the ablation chamber 54 is pressurized upon activation of the laser 58, proximity sensors ensuring the sealing ring 80 seats on the upper rim 82, a light sensor capable of measuring the amount of light escaping the ablation chamber 54 during use, or another sensor known in the art able to check and/or verify the quality of the seal between the sealing ring 80 and the upper rim 82. Each of these one or more sensors integrated with the laser ablation containment and debris removal system 50 may be used alone or in combination with one another to enhance safety before, during, and/or after operation of the laser ablation containment and debris removal system 50.

[Para 112] In another aspect of these embodiments, FIG. 8 is partial cross-sectional view more specifically illustrating an internal configuration of the respective laser protection chamber 52, the ablation chamber 54, and the vacuum chamber 56, and FIG. 9 is an enlarged partial cross- sectional view taken about the circle 9 in FIG. 8. More specifically, FIG. 8 generally illustrates the location of the protective lens holder 60 between the laser protection chamber 52 and the ablation chamber 54 to effectively seal the laser 58 therefrom. Moreover, FIG. 8 also illustrates that the ablation chamber 54 is in fluid communication with the vacuum chamber 56 for purposes of evacuating or extracting debris out from within the ablation chamber 54 during the ablation process. In this respect, the vacuum chamber 56 may include a pressure sensor 106 having an open port 108 exposed to and able to monitor the vacuum pressure in the vacuum chamber 56 in real-time. The air pressure sensor 106 provides feedback to the ablation containment and debris removal system 50 to ensure an adequate seal of the ablation chamber 54 before operating the laser 58, otherwise the laser ablation containment and debris removal system 50 will not initiate the laser 58. The air pressure sensor 106 also provides real-time feedback during operation, whereby the laser ablation containment and debris removal system 50 will proactively turn off the laser 58 in the event of a predetermined pressure loss or low pressure reading in the vacuum chamber 56 during operation. Maintaining adequate pressure within the laser ablation containment and debris removal system 50 further ensures there is an adequate vacuum within the chamber 26 during operation, e.g., to efficiently remove debris from the ablation chamber 54.

[Para 113] Also illustrated in the bottom perspective view of FIG. 7 is an inlet port 110 that selectively receives pressurized fluid (e.g.. from a pneumatic system) such as compressed or pressurized air for use in the ablation chamber 54 to assist creating the aforementioned vacuum. In this respect, FIG. 10 is a partial cross-sectional view illustrating that the inlet port 110 is fluidly coupled with a discrete pressurized air channel 112 formed between the vacuum chamber 56 and the ablation chamber 54. The vacuum pressure sensor 106 may ensure there is sufficient airflow within the channel 112 to generate a proper vacuum between the inlet port 110 and an exit port 114 (FTG. 11 ) of the vacuum chamber 56 sufficient to efficiently draw debris out from within the ablation chamber 54 during operation thereof.

[Para 114] Moreover, FIG. 13 more specifically illustrates a cross-sectional view of the laser ablation containment and debris removal system 50 wherein the channel 112 carrying incoming pressurized air eventually splits into a lower conduit 116 and an upper conduit 118 at a branch 120 thereof. In this respect, FIG. 14 is an alternative cross-sectional view illustrating splitting the pressurized air channel 112 at the branch 120 to divert incoming pressurized air into the lower conduit 116 and into the upper conduit 118 immediately.

[Para 115] FIG. 15 illustrates that the lower conduit 116 is generally semi-hemispherical and tracks an outer surface geometry 122 of the ablation chamber 54. The lower conduit 116 is in fluid communication with a semi-hemispherical slit 124 that opens into an interior 126 of the ablation chamber 54. As such, the pressurized air flows out through the semi-hemispherical slit 124 across an opening in the ablation chamber 54 thereby generating a generally horizontal air knife or curtain 128 designed to substantially reduce slag and/or block ablated debris from traveling down into the laser protection chamber 52. Moreover, the directional arrows in FIG. 15 illustrate that pressurized air flowing out from the semi-hemispherical slit 124 as the horizontal air curtain 128 is directed into the vacuum chamber 56. As such, any debris caught in this horizontal air curtain 128 is immediately removed from the laser ablation containment and debris removal system 50. The air curtain 128 thus provides a layer of constantly flowing pressurized air that substantially prevents debris from traveling back into the laser protection chamber 52 where the protective lens holder 60 is located.

[Para 116] Moreover, FIG. 16 further illustrates that pressurized air directed into the upper conduit 118 travels into a hollow portion of the bracket 92. Here, FIG. 16 illustrates that the bracket 92 includes a horizontal slit 130 therein that creates an upwardly projecting air curtain 132. Given the proximity of the ablated surface immediately above the horizontal slit 130, ablated debris from the subject substrate is immediately pushed upwardly by the air curtain 132, and naturally away from ablated substrate, the horizontal air curtain 128, and the laser protection chamber 52. As such, this reduces the concentration of debris that may have a tendency to move toward the horizontal air curtain 128 and the ablated substrate. Of course, the horizontal slit 130 and the related curtain 132 could be somewhat oriented to push pressurized air toward the vacuum chamber 56, or the horizontal slit 130 and the related curtain 132 may be generally vertically aligned to maximize pushing ablated debris up and away from the horizontal air curtain 128, thereby essentially acting as another barrier to the protective lens holder 60. The vertical air curtain 132 also acts to push air toward the vacuum chamber 56 and away from the blasted surface of the substrate to prevent debris from settling on the freshly blasted surface. This further assists moving debris into the vacuum chamber 56 for removal from the laser ablation containment and debris removal system 50 during operation.

[Para 117] Alternatively, the horizontal air curtain 128 and/or the vertical air curtain 132 may be angled anywhere between being horizontal and/or vertical, depending on the structure of the laser ablation containment and debris removal system 50 and/or the ablated part. For example, the vertical air curtain 132 may be offset by forty-five degrees to more efficiently prevent ablated debris from settling back along an ablated substrate positioned within the ablation chamber 54. Moreover, either one of the curtains 128, 132 may also be positioned in an offset position relative to either of the vertical or horizontal planes to more efficiently direct pressurized airflow into the vacuum chamber 56. In any of these embodiments, the vacuum chamber 56 may further include one or more HEPA filters and/or one or more carbon filters to collect dangerous or hazardous fumes and/or particles at the exit port 114 or elsewhere, as needed.

[Para 118] FIG. 17 more specifically illustrates one embodiment of the protective lens holder 60 having a handle 134 formed from a pair of oppositely facing arcuate recesses 136 convenient for hand grasping so the protective lens holder 60 may be more easily inserted and removed out from within the slot 88. Moreover, the protective lens holder 60 also includes a generally circular opening 138 having a receiving channel 140 therein accessible by way of a front slot 142 having a size and shape to selectively receive and retain (e. ., in friction fit relation) a protective lens 143 or the like therein. In this respect, the receiving channel 140 effectively retains the protective lens 143 in a position within the laser ablation containment and debris removal system 50 to permit the beam emitted by the laser 58 to transmit therethrough, whether orthogonal thereto or otherwise. At the same time, by virtue of being positioned between the laser protection chamber 52 and the ablation chamber 54, the protective lens 143 effectively prevents ablated debris from traveling back to the laser 58.

[Para 119] The protective lens holder 60 can be easily accessed by selectively grasping the outwardly extending handle 134 and pulling on the arcuate recesses 136 to retract the protective lens holder 60 out from engagement with the slot 88. In one embodiment, the entire assembly of the protective lens holder 60, namely including the handle 134, the receiving channel 244, and the protective lens 143 therein may simply be discarded and replaced by a new protective lens holder 60 having a clean or undamaged protective lens 143 therein. In an alternative embodiment, once removed, the protective lens 143 may slide out from within the receiving channel 140 through the front slot 142 for cleaning when excessively contaminated (e.g., to remove debris that may build-up over time) or replacement (e.g., if scratched or damaged). Thereafter, the cleaned or replacement protective lens 143 may be reinserted into the receiving channel 140 by way of the front slot 142, and then the assembly of the protective lens holder 60 may be reinserted back into the slot 88 for further use in the laser ablation containment and debris removal system 50. Once inserted back into the slot 88, the protective lens 143 may effectively be wedged between an inner side wall and the receiving channel 140 for secure retention therein. Moreover, insertion of the protective lens holder 60 within the slot 88 may activate a proximity sensor or the like to ensure the protective lens holder 60 and the protective lens 143 are in position before and during operating the laser 58.

[Para 120] As such, the laser ablation containment and debris removal system 50 as disclosed herein cooperates with the SCARA 62 and the Class 4 laser 58 to achieve superior surface preparation of the nutplate 78 or the like using a Class 1 rated enclosure that includes the laser protection chamber 52 (with the laser 58 coupled thereto) and the ablation chamber 54 in fluid communication with the vacuum chamber 56 where debris and other fumes are evacuated during operation. The one or more air curtains 128, 132 reduce slag and keep blasted debris material from settling back on the cleaned substrate and/or the protective lens in the holder 60, and help facilitate directional air flow into the vacuum chamber 56. The SCARA 62 ensures that the ablation chamber 54 remains appropriately sealed such that there is little or no access to laser light by users or those close by during operation. Of course, the ablation chamber 54 can be modified to include the ability to laser different surfaces at different angles, with different lengths and diameters, and can be manufactured using various methods, including 3D printing and investment casting.

[Para 121] Once the nutplate 78 has been ablated using the laser ablation containment and debris removal system 50, the next step is to apply an adhesive thereon, such as by way of the adhesive dispenser 64 illustrated with respect to FIGS. 1-2, 18-19, 21, and 25-26. As briefly mentioned above, the adhesive dispenser 64 solves a problem in the art of accurate and repeatable volumetric dispensing of a controlled amount of adhesive on the order of less than about 0.1 gram (“g”) while at the same time controlling the inherent “drip” or “drool” of adhesive at the location where the adhesive is dispensed. In this respect, in one embodiment, the adhesive dispenser 64 may be integrated as part of the laser ablation containment and debris removal system 50, as discussed in detail above, such as by way of being used in conjunction with the SCARA 62 as a part of the portable roller station 66 illustrated in FIGS. 1 and 2. Although, of course, the adhesive dispenser 64 may be integrated as part of a stationary or semi- stationary system for use in manufacturing processes that may utilize or integrate the dispenser 64 as disclosed herein.

[Para 122] As briefly mentioned above, the SCARA 62 works in conjunction with the downwardly presented gripper 74 and the outstretched actuating fingers 76 to automate the process for selectively picking-up and moving substrates for receiving an adhesive 144 (FIG. 27) thereto, such as along a bottom surface 146 of the nutplate 78. In one embodiment, the SCARA 62 operates to locate the gripper 74 relative to one of a number of the nutplates 78 on a carrier 84 (e.g., as illustrated in FIG. 5), actuates the fingers 76 to grip one of the nutplates 78 for removal from the carrier 84, and then transports the selected nutplate 78 within the laser ablation containment and debris removal system 50 for application of the adhesive 144 by the adhesive dispenser 64.

[Para 123] To apply the adhesive 144, and as illustrated best in FIG. 5, the SCARA 62 selectively repositions the nutplate 78 so that the lower portion 100 of the elastomeric fixture 98 extending through the nutplate 78 slides within a slot 148 of a locator block 150 generally offset from a needle 152 of the adhesive dispenser 64. The SCARA 62 may then selectively horizontally reposition the nutplate 78 so the elastomeric fixture 98 bends about the lower portion 100 as illustrated in FIG. 5, namely at least where the bottom surface 146 of the nutplate 78 aligns over the tip 104 of the needle 152 where the adhesive 144 dispenses without interference from the elastomeric fixture 98. Moreover, the SCARA 62 may also operate the gripper 74 to rotate the nutplate 78 by approximately 360 degrees so the adhesive 144 dispensed from the tip 104 is consistently circumferentially applied thereto. The adhesive dispenser 64, as discussed in more detail below, ensures that the bead of the applied adhesive 144 is substantially consistently applied to the bottom surface 146, as illustrated in FIG. 27. Of course, the lower portion 100 of the elastomeric fixture 98 remains substantially bent out and away from the tip 104 and rotates within the slot 148 of the locator block 150 during circumferential application of the adhesive 144 thereto.

[Para 124] FIG. 18 more specifically illustrates one embodiment of the adhesive dispenser 64 as disclosed herein, including that the tip 104 of the dispensing needle 152 is generally located at a forward position and fluidly coupled with an adhesive static mixer 154 that selectively receives fluid from a pair of liquid containing cartridges 156, 158 during operation. The needle 152 may be held in the forward position by a cradle 160 substantially coaxially aligned with each of the tip 104 and the adhesive static mixer 154. The cradle 160 may couple to an extension 162, which is illustrated in FIG. 19 extending generally perpendicular to the axial orientation of the needle 104 for offset coupling thereto to a front end 164 of a support bracket 166. The support bracket 166 is selectively slidably positionable relative to a housing 168 of the adhesive dispenser 64 by way of an elongated channel 170 formed along its length thereof. Here, the elongated channel 170 has a size and shape for select pass through reception of a shank portion of a pair of bolts 172 that selectively threadingly engage a respective pair of apertures formed in the housing 168. Each of the bolts 172 have a head 174 relatively larger than the elongated channel 170 such that, when the bolts 172 are threadingly engaged with the housing 168, the respective heads 174 cooperate with the housing 168 to sandwich the support bracket 166 in flush locking engagement in between.

[Para 125] The location of the front end 164 may be selectively adjusted by at least partially unthreading each of the bolts 172 from the housing 168 to release or free the support bracket 166 from its sandwiched friction-fit engagement between the heads 174 of the bolts 172 and the housing 168. Here, the support bracket 166 remains coupled to the housing 168 by the bolts 172, yet slidable relative thereto by way of the shank of each of bolts 172 continuing to remain or reside within the elongated channel 170 and at least partially engaged with the threaded apertures in the housing 168. As such, the positioning of the support bracket 166 relative to the housing 168 effectively determines the distance the cradled needle 152 (and ultimately the tip 104 extending therefrom) is positioned relative to the housing 168. Once the desired positioning of the cradle 160 cupping the needle 152 is set, each of the bolts 172 may be retightened to hold or retain the support bracket 166 against the housing 168.

[Para 126] The top view in FIG. 19 and the perspective views of FIGS. 21-24 best illustrate that the adhesive dispenser 64 is designed to work with a dual-cartridge replacement system 176 that generally includes the pair of cartridges 156, 1 8 (e.g., a standard two-part adhesive cartridge known in the art) that terminate in fluid relation with a dual-cartridge cap 178 (FIG. 19) that fluidly couples with the adhesive static mixer 154 for delivering the adhesive 144 therethrough to the tip 104 by way of the needle 152, as will be discussed in more detail below. In one embodiment, e.g., the needle 152 may threadingly engage one end of the adhesive static mixer 154, and the dual-cartridge cap 178 may be integrally formed with each of the cartridges 156, 158 as is known in the art and configured for snap-fit fluid coupling with the adhesive static mixer 154 at an end opposite where the needle 152 threadingly engages the adhesive static mixer 154. In alternative embodiments, each of the needle 152, the adhesive static mixer 154, the pair cartridges 156, 158, and/or the dual-cartridge cap 178 may be separately manufactured and assembled in a manner that ensures that the liquid compounds within each of the cartridges 156, 158 are able to dispense therefrom into the dual cartridge cap 178 and then intermixed within the adhesive static mixer 154 for travel out through the tip 104 by way of the needle 152 as the adhesive 144. In alternative embodiments, the dual-cartridge replacement system 176 may be of a unitary construction, including being manufactured by way of 3D printing or the like.

[Para 127] As best illustrated in the perspective views of FIGS. 21-24, the dual-cartridge replacement system 176 selectively slidably engages with a quick-change carrier 180 designed for slotted reception in the housing 168 of the adhesive dispenser 64. FIGS. 22-24 illustrate that the quick-change carrier 180 includes a plurality of outwardly extending bolts 182 having a respective shank portion 184 relatively smaller in diameter than a corresponding head portion 184. As such, each of the shank portions 184 have a diameter sized for slotted engagement within a respective set of receiving channels 188 formed from a pair of receiving rails 190 of the housing 168, while the respective head portions 186 are too large to fit therein. The receiving channels 188 may include a generally enlarged chamfered opening formed from the receiving rails 190, which are designed to provide additional clearance for initially more easily locating each of the shank portions 184 in the respective receiving channels 188. The receiving channels 188 then taper inwardly to a width somewhat larger than the diameter of the shank portion 184 for better securement therein. The length of the shank portion 184 between a frame 192 of the quick-change carrier 180 and the head portion 184 is approximately the width of the receiving rails 190 in the housing 168 to further prevent side-to-side movement of the quick-change carrier 180 when engaged with the housing 168. After the quick-change carrier 180 fully descends into the receiving channels 188, each of the shank portions 184 are able to forwardly engage a respective set of locking slots 194 that turn forward at approximately 90 degrees relative to the receiving channels 188. The quick-change carrier 180 remains forwardly engaged within the locking slots 194 in operation by way of, e.g., a pair of cohering assemblies 196, 198, as discussed in more detail below.

[Para 128] In one embodiment, the quick-change carrier 180 may include a generally open frame structure as best illustrated in FIGS. 21-24. In an alternative embodiment, the quick- change carrier 180 may be housed within a thermal enclosure 200 (FIGS. 30 and 31) temperature controlled by way of a cooler 202 (FIG. 30) and/or one or more heating elements 204 (FIG. 31) positioned within the thermal enclosure 200. Here, the adhesive dispenser 64 is able to control the temperature of the liquid compounds within the cartridges 156, 158 of the dual-cartridge replaceable system 176 based on feedback from one or more temperature sensors located within the enclosure. For example, a single temperature sensor may continuously read the overall temperature within the quick-change earner 180 or, alternatively, a pair of temperature sensors may individually continuously read the temperature of each of the cartridges 156, 158 individually. In this latter embodiment, the adhesive dispenser 64 may individually control the temperature of each of the cartridges 156, 158 and the liquid compounds therein within a certain temperature range or differential. As such, the adhesive dispenser 64 can control the temperature of compounds within the cartridges 156, 158 that dispense therefrom. This feature provides greater control over the amount of fluid dispensed from each of the cartridges 156, 158, to further control the viscosity of the adhesive 144 dispensed from the tip 104 of the needle 152. [Para 129] FIGS. 22 and 23 best illustrate the dual-cartridge replacement system 176 in full engagement with the quick-change carrier 180. Here, the frame 192 of the quick-change carrier 180 may include a front aperture 206 having a size and shape to permit the adhesive static mixer 154 to extend therethrough. Similarly, as best illustrated in FIG. 24, the frame 192 may also include a relatively larger rear aperture 208 having a size and shape to generally accommodate slide through reception of each of the cartridges 156, 158. At the same time, the dual-cartridge replacement system 176 may also include an outwardly extending baseplate 210 relatively larger than the rear aperture 208 in the frame 192 to prevent the dual-cartridge replacement system 176 from sliding all the way out from the frame 192. In this respect, as best illustrated in FIG. 23, the baseplate 210 has a surface area that selectively engages the frame 192 in flush relationship when the cohering assemblies 196, 198 forwardly engage the quick-change carrier 180 within the locking slots 194 of the housing 168, as discussed above in detail.

[Para 130] Moreover, when the frame 192 carrying the dual-cartridge replacement system 176 has been removed out from engagement with the housing 168 (e.g., as illustrated in FIG. 21), the dual-cartridge replacement system 176 may easily be replaced by simply sliding the dual-cartridge replacement system 176 out from engagement with the frame 192 by way of the rear aperture 208, as generally illustrated in FIG. 24. After removal, a new (fresh/filled) dualcartridge replacement system 176 may then be reinserted through each of the rear aperture 208 and the front aperture 206 (to the extent it extends therefrom) until located in the position generally illustrated in FIGS. 21-23. Thereafter, the quick-change carrier 180 carrying the new dual-cartridge replacement system 176 may be reengaged with the housing 168 quickly and easily by simply sliding the shank portions 184 of the bolts 182 extending out from the frame 192 back into the respective receiving channels 188 and into the corresponding locking slots 194. Thereafter, the adhesive dispenser 64 may be operated to dispense the adhesive 144 out from the tip 104 of the needle 152 in accordance with the embodiments disclosed herein.

[Para 131] Once the shank portions 184 fully seat within each of the receiving channels 188, the quick-change carrier 180 may be pushed forward by a drive unit 212 to assist positioning the shank portions 184 into the respective locking slots 194 in preparation for operating the adhesive dispenser 64. Here, the drive unit 212 operates a forwardly extending thread screw 214 threadingly engaged with a piston slide carrier 216 having the pair of colleting assemblies 196, 198 rigidly coupled thereto. In operation, the drive unit 212 controls the forward and rearward motion of the piston slide carrier 216 by turning the thread screw 214 either clockwise or counterclockwise. For example, in one embodiment, operating the thread screw 214 to turn clockwise causes the piston slide carrier 216 to move forward within the housing 168 to draw each of the colleting assemblies 196, 198 into engagement with each of the cartridges 156, 158. Conversely, operating the thread screw 214 to turn counterclockwise causes the piston slide carriers 118 to move rearward within the housing 168 to draw each of the colleting assemblies 196, 198 out from engagement with each of the cartridges 156, 158.

[Para 132] An upstanding collet clamp 218 (best illustrated in FIG. 18 and the side view of FIG. 25) rigidly coupled to the piston slide carrier 216 selectively clamps each of the colleting assemblies 196, 198 therein. As such, movement of the piston slide carrier 216 driven by the drive unit 212, as described above with respect to the thread screw 214, causes commensurate movement of the colleting assemblies 196, 198. As illustrated in the enlarged partial cut-away top view of FIG. 20, each of the colleting assemblies 196, 198 include an internal piston collet 220 threaded therein. Each piston collet 220 terminates in an outwardly flaring mandrel 222 held within a flaring sleeve 224, as best illustrated in FIG. 28. The piston collet 220 of the colleting assemblies 196, 198 couples with a piston head 226 by way of forward movement of the relatively thin-walled flaring sleeve 224 and the outwardly flaring mandrel 222 of the piston collet 220 into a relatively smaller recess 228 formed within the piston head 226 for friction-fit engagement therewith. Here, the relatively thin-walled flaring sleeve 224 has the ability to positively attach to the piston head 226. Alternatively, attachment to the piston head 226 may be accomplished by a tapping screw 230 (FIG. 29) that threads into the piston head 226, such as by way of rotating an externally accessible knob 232. In another alternative embodiment, the piston head 226 may be modified so that a built-in feature may “grab” the piston head 226 from behind. Each piston head 226 is of a size and shape to generally extend within the interior of one of the respective cartridges 156, 158 to push liquid compound out from within each of the respective cartridges 156, 158 and into the aforementioned dual-cartridge cap 178. Each of the piston heads 226 may be the same size or a different size, depending on the size of the corresponding cartridge 156, 158 and/or the liquid compound to be dispensed therefrom to make the adhesive 144.

[Para 133] More specifically, in operation, the drive unit 212 activates the thread screw 214 to drive the piston slide carrier 216 forward such that the collating assemblies 196, 198 rigidly attached thereto each extend a respective piston collet 220 and the corresponding piston head 226 coupled thereto into the respective cartridges 156, 158. As such, in response, a determined amount of liquid compound within each of the cartridges 156, 158 pushes out into the dualcartridge cap 178, and eventually into the adhesive static mixer 154 where the compounds from each of the cartridges 156, 158 are adequately mixed to form the adhesive 144, which is eventually dispensed out from the dual-cartridge replacement system 176 by way of the tip 104 at the end of the needle 152.

[Para 134] The drive unit 212 may include one or more sensors that provide real-time feedback regarding the viscosity of the adhesive 144 dispensed from the tip 104 of the needle 152. In one embodiment, the sensor is a force-feedback sensor that monitors the change in current and/or voltage within the drive motor of the drive unit 212. In response to information from the forcc-fccdback sensor, the drive unit 212 adjusts the rate the thread screw 214 operates to displace the liquid compound out from within the respective cartridges 156, 158. For example, a higher current and/or voltage is an indicator the adhesive 144 has a relatively higher viscosity, i.e., the adhesive 144 is curing more than desired before being dispensed from the tip 104. Here, the drive unit 212 may adjust the rate the thread screw 214 operates to dispense the adhesive 144 by increasing the drive rate into the cartridges 156, 158. At the same time, the drive unit 212 may communicate with the SCARA 62 to ensure the nutplate 78 is being rotated at an adequate speed to ensure the increased rate of the adhesive 144 flow being dispensed from the tip 104 is still applied evenly circumferentially along the bottom surface 146 of the nutplate 78 as illustrated in FIG. 27. Of course, the same is true in the reverse, namely when the forcefeedback sensor determines that the viscosity of the adhesive 144 is lower than desired, the drive unit 212 may decrease the rate the thread screw 214 operates to dispense the adhesive 144 by decreasing the drive rate into the cartridges 156, 158. Similarly, e.g., at the same time, the drive unit 212 may communicate with the SCARA 62 to ensure the nutplate 78 is being rotated at an adequate speed to ensure the decreased rate of the adhesive 144 being dispensed from the tip 104 is still applied evenly circumferentially along the bottom surface 146 of the nutplate 78 as illustrated in FIG. 27. As such, the force-feedback sensor is able to monitor electronic feedback to take into account changes in the viscosity of the adhesive 144 to control the dispensed volume of the adhesive 144.

[Para 135] In alternative embodiments, the drive unit 212 may include additional, or alternative sensors, that provide alternative and/or additional feedback. For example, in one embodiment, a temperature sensor may also provide feedback regarding ambient and adhesive temperatures so the drive unit 212 can better calculate the viscosity of the adhesive 144 based on cure rates within the dual-cartridge replacement system 176. For example, in some embodiments, higher temperatures may cause the mixture of liquid compounds within the adhesive static mixer 154 to cure faster than at lower temperatures, and vice versa. As such, the drive unit 212 may adjust the rate at which the thread screw 214 operates to ensure the adhesive 144 dispensed from the tip 104 continues to have a consistent viscosity. Additionally, in other embodiments, other sensors known in the art for assisting in determining the viscosity of the adhesive 144 may also be integrated with the drive unit 212. The feedback system, whether taking measurements in real-time or periodically, can refine and adjust the drive motor, as needed, to dispense the adhesive 144 with greater accuracy and repeatability.

[Para 136] In alternative embodiments, the adhesive dispenser 64 may include additional “smart” features such as a timer system and/or a vision system to provide additional feedback regarding the physical state of the adhesive 144 being dispensed from the tip 104. Such information could be used to further increase the reliability and repeatability of the adhesive dispenser 64 as disclosed herein, namely applying the adhesive 144 on to small parts (e.g., for aircraft and the like) in a repeatable and reliable manner.

[Para 137] After the adhesive 144 is applied fully circumferentially along the bottom surface 146 of the nutplate 78, the drive unit 212 discontinues forward movement of the piston slide carrier 216 to stop the flow of the adhesive 144 out from the tip 104 of the needle 152 while the SCARA 62 selects another nutplate requiring application of the adhesive 144. Although, simply discontinuing forward movement of the thread screw 214 may not necessarily result in the complete discontinuation of the adhesive 144 dispensing from the tip 104, i.e., this is the so- called “drip” or “drool” issue known in the art resultant from residual pressure within the dispensing system. As such, to correct this issue, the drive unit 212 not only discontinues forward movement of the thread screw 214, but also immediately reverses the thread screw 214 by a predetermined distance to draw each of the piston heads 226 rearwardly within the cartridges 156, 158 to generate a back pressure or vacuum therein to discontinue or halt any potential forward movement of the adhesive 144 remaining within the adhesive static mixer 154, the needle 152, and ultimately at the tip 104. The drive unit 212 is able to accomplish such retraction by way of rigid engagement of the piston collet 220 with the respective recesses 216 in the respective piston heads 226. This way, the drive unit 212 is able to operate the thread screw 214 to prevent the so-called “drip” or “drool”. For example, in one embodiment, the respective piston heads 226 may retract within the cartridges 156, 158 by way of the tapping screw 230 threaded into the piston heads 226, thereby causing the adhesive 144 to “pull back” as well to reduce or stop the “drip” or “drool” at the tip 104. The amount of retraction may depend on a variety of factors, including the type of the adhesive 144 and feedback received by the drive unit 212 from the one or more sensors integrated with the automatic adhesive dispenser 64. As an example, the drive unit 212 may determine that the thread screw 214 needs to be retracted by a greater distance when the adhesive 144 has a relatively lower viscosity, and vice versa, when measured in real-time by the force feedback sensor.

[Para 138] When the dual-cartridge replacement system 176 needs replacement, the piston collet 220 disengages each of the piston heads 226 so that the colleting assemblies 196, 198 no longer rigidly couple with the cartridges 156, 158. Such disengagement is accomplished by way of operating a slide bracket 234 internally located within each of the colleting assemblies 196, 198 by way of one or both of a pair of flanges 236 (FIGS. 18 and 19) outwardly extending from the colleting assemblies 196, 198. During normal operation, an inwardly projecting step 238 of the slide bracket 234 interfaces with a washer 240 spring-biased in a forward position by a spring 242 positioned within a retraction channel 244. Pulling each of the flanges 236 rearwardly toward the drive unit 212 causes the slide bracket 234 to move relative to the colleting assemblies 196, 198 such that the inwardly projecting step 238 contacts the washer 240 to compress the spring 242 within the retraction channel 244. In this respect, an intermediary inwardly projecting step 246 (FIG. 28) may extend in between coils of the spring 242 to assist in compression of the spring 242. As such, the slide brackets 234 are able to move relative to the colleting assemblies 196, 198 by a predetermined distance set as the length of one or more pullback channels 248 positioned along the length of the slide bracket 234 having a slide pin 250 positioned therein. Rearward movement of the slide bracket 234 may also terminate where the flanges 236 are formed by way of a step or stop 252. Such retraction causes the piston collet 220 to withdraw out from within their respective recesses 228, thereby decoupling each of the colleting assemblies 196, 198 from the cartridges 156, 158 of the dual-cartridge replacement system 176. In this manner, physical attachment to the piston heads 226 within the dualcartridge replacement system 176 can be rapidly disconnected from the colleting assemblies 196, 198 by way of the release mechanism operated by the slide bracket 234. Once disconnected, the dual-cartridge replacement system 176 can be changed cleanly and simply by removing the quick-change carrier 180 out from the housing 168 so the dual-cartridge replacement system 176 carried thereby can be removed and replaced, as discussed in detail above.

[Para 139] Another feature of the adhesive dispenser 64 is an adhesive purging system that automatically dispenses the adhesive 144 into a waste location as the adhesive “working life” expires. [Para 140] To this end, the adhesive dispenser 64 is able to solve the problem of accurate and repeatable volumetric dispensing of adhesives, such as from a two part cartridge, through use of one or more sensors that measure the viscosity of the adhesive in real-time to control the amount dispensed onto the part, such as the bottom surface 146 of the nutplate 78 illustrated in FIG. 27. Moreover, the adhesive dispenser 64 also includes a “pull back” colleting feature that enables the dispenser 64 to rearwardly retract the piston heads 226 within the cartridges 156, 158 to control the inherent “drip” and/or ’’drool” of the adhesive 144 at the location of dispensed material, resulting from the residual pressure within the dispensing system.

[Para 141] In another aspect of the systems and processes disclosed herein, a substrate ablation and debris evacuation system 254 (illustrated in FIGS. 32-47) may be integrated as another step or station in conjunction with the laser ablation containment and debris removal system 50 and/or the adhesive dispenser 64, for providing a more flexible, efficient, and consistent process for cleaning and adhesively securing parts to a substrate. More specifically as illustrated in FIG. 32, a collaborative robot (“cobot”) 256 couples to the substrate ablation and debris evacuation system 254 by way of a mount 258 that selectively engages a housing 260 containing an infrared laser 262 (e.g., a Class 4 rated laser) therein, as best illustrated in FIG. 32. The infrared laser 262 generates a laser beam that transmits infrared light through the mount 258, through a laser protective zone 264, and into a Class 1 rated ablation enclosure 266 to ablate a part or substrate therein. In the embodiments disclosed herein, the infrared laser 262 may be used to ablate a substrate, such as a bracket 268 (e.g., as illustrated in FIGS. 36-38), to prepare the bracket 268 for installation of a nutplate 78 or the like thereon by way of the adhesive 144. Or course, the infrared laser 262 may be used to ablate other substrates, such as an airplane wing (or other surface of an airplane or vehicle), pursuant to the embodiments disclosed herein. The mount 258 is thus designed to affix the infrared laser 262 in a position to cooperate with the laser protective zone 264 and the ablation enclosure 266 to prepare the bracket 268 to adhesively receive the nutplate 78 by way of removing debris therefrom (e.g., primers or the like) without causing damage to the material composition of the ablated bracket 268. To this end, the mount 258, the housing 260, the laser protective zone 264, and the ablation enclosure 266 cooperate to operate the Class 4 infrared laser 262 within a Class 1 rated enclosure. Accordingly, the infrared laser 262 can be operated in a safer manner that eliminates the need for the operator to wear safety goggles and/or otherwise require the provision of an additional laser safe enclosure. [Para 142] FIGS. 33-35 more specifically illustrate the mount 258 mounted to a top or upper portion of the laser protective zone 264 having a generally cone-shaped or frustoconical configuration. The laser protective zone 264 and the ablation enclosure 266 are generally separately defined by another of the selectively removable and replaceable protective lens holder 60’ (FIG. 17) positioned in between, e.g., as best illustrated in FIGS. 33 and 34. The protective lens holder 60’ entirely or substantially seals the laser protective zone 264 from the ablation enclosure 266 so the laser lens within the housing 260 is not subject to dispersing debris and/or other particulate matter blasted off the subject bracket 268 during ablation.

[Para 143] Moreover, the substrate ablation and debris evacuation system 254 may further include a fume extractor 270 in fluid communication with the ablation enclosure 266, e.g., as best illustrated in the cross-sectional views of FIGS. 39 and 42. In this respect, the fume extractor 270 is designed to continuously remove debris selectively ablated from the bracket 268 in the ablation enclosure 266 by the infrared laser 262 (FIG. 32). In general operation, the infrared laser 262 emits a beam that travels through the laser protective zone 264, through the selectively removable and replaceable protective lens holder 60’ positioned between the laser protective zone 264 and the ablation enclosure 266, and into the ablation enclosure 266 for selectively cleaning the bracket 268 encapsulated therein. The debris ablated from the bracket 268 within the ablation enclosure 266 is then removed therefrom by a vacuum generated within the substrate ablation and debris evacuation system 254 to fluidly extract or remove debris out from within the ablation enclosure 266, as discussed in more detail below.

[Para 144] As with the laser ablation containment and debris removal system 50 and the adhesive dispenser 64, the substrate ablation and debris evacuation system 254 may also be used as part of a portable roller station 66’, e.g., as illustrated in FIG. 32. Although, of course, the substrate ablation and debris evacuation system 254, the cobot 256, and the related components such as the mount 258, the housing 260, the infrared laser 262, the laser protective zone 264, the ablation enclosure 266, and/or the fume extractor 270 may be integrated as part of a stationary or semi- stationary system for use in manufacturing processes that may more permanently utilize or integrate the substrate ablation and debris evacuation system 254 as disclosed herein. In additional alternative embodiments, any robotic arm known in the art could be used in place of the cobot 256. [Para 145] As best illustrated in FIGS. 33-35, the ablation enclosure 266 includes a relatively rigid base 272 having a lower scaling member 274 coupled to an upper surface 276 thereof (best illustrated in FIG. 44) that cooperates with an upper sealing member 278 extending outwardly from one end of the laser protective zone 264 generally opposite the mount 258. In one embodiment, the base 272 with the lower sealing member 274 coupled thereto is selectively movable relative to the upper sealing member 278 by way of being coupled to a linear actuator or pneumatic piston 280. Here, the piston 280 may move the base 272 between an open position (FIGS. 33-34 and 36-37) and a closed position (FIG. 38). To provide additional stability during movement between the open and closed positions, the base 272 may include a pair of upwardly extending guideposts 282 that selectively slide within a respective pair of slide channels 284 (FIGS. 45 and 47) formed from a pair of feet 286 outwardly extending from an outer surface 288 (FIG. 36) thereof. The pair of guideposts 282 effectively prevent the base 272 from rotating relative to the laser protective zone 264 during pneumatic movement thereof.

[Para 146] The lower sealing member 274 includes an upstanding circumferential sidewall 290 that terminates in an upper rim 292 forming an interior cavity 294 therein. The upper rim 292 is a generally flat surface designed for flush engagement with a bottom surface 296 of a carrier 298 (FIGS. 36-38) having one or more of the brackets 268 coupled thereto. Similarly, the upper sealing member 278 includes a downwardly projecting circumferential sidewall 300 that terminates in a lower rim 302 forming an interior cavity 304 (FIG. 35) therein. The lower rim 302 is a generally flat surface designed for flush engagement with a top surface 306 of the carrier 298 having the one or more of the brackets 268 coupled thereto. Moreover, each of the interior cavities 294, 304 are generally wider and/or have a depth sufficient to fully encircle and enclose the subject bracket 268, or other part as may be used in connection with the substrate ablation and debris evacuation system 254, when landing on the respective bottom surface 296 and the top surface 306 of the carrier 298. Each of the lower sealing member 274 and/or the upper sealing member 278 may be made from a foam or rubber material at least somewhat compressible so that, when seated on the respective surfaces 296, 306, the subject bracket 268 or other part is vacuum sealed therein. Although, in other embodiments, the lower sealing member 274 and/or the upper sealing member 278 may be made from other materials so long as the lower sealing member 274 and the upper sealing member 278 are able to create the vacuum seal disclosed herein. Compressing the sealing members 274, 278 against the surfaces 296, 306 ensures that no laser light emits from within the ablation enclosure 266 when operating the infrared laser 262.

[Para 147] Accordingly, in one embodiment, the depth of the respective interior cavities 294, 304 may be selected to provide compatibility for use with subject parts that vary in size, such as the brackets 268 illustrated in FIGS. 36-38. In the embodiments illustrated in FIGS. 36-38, the upper rim 292 of the lower sealing member 274 lands on the bottom surface 296 of the carrier 298 to form a circumferential seal underneath the bracket 268 and the lower rim 302 of the upper sealing member 278 lands on the top surface 306 of the carrier 298 to form a circumferential seal over the bracket 268, including over a substrate 308 and an upwardly extending flange 310. Here, the sealing members 274, 278 sandwich the carrier 298 in between and effectively seal the bracket 268 therein. This seal helps prevent light from the infrared laser 262 from escaping the ablation enclosure 266 along with generating a vacuum therein. Of course, in alternative embodiments, each of the sealing members 274, 278 may vary in size and/or be selectively removable and/or replaceable, e.g., in the event the sealing members 274, 278 wear out over time or the need arises where a different size sealing member 274, 278 is needed for part compatibility.

[Para 148] In operation as illustrated in FIGS. 36-38, the cobot 256 first operates to locate the ablation enclosure 266 such that the upper sealing member 278 is positioned over one of the brackets 268 in the carrier 298 requiring ablation, e.g., as illustrated in FIG. 36. The cobot 256 then lowers the assembly so the lower rim 302 of the upper sealing member 278 lands on the top surface 306 of the carrier 298, thereby enclosing the bracket 268 therein, including the substrate 308 and the upwardly extending flange 310. The upper sealing member 278 generally forms an airtight seal with the top surface 306, as illustrated in FIG. 37. In some embodiments, this seal may be enough to form the Class 1 enclosure, e.g., when ablating surfaces that are too large to be sandwiched, such as the wing or other surface of an airplane. In another embodiment, the cobot 256 may activate the piston 280 to draw the upper rim 292 of the lower sealing member 274 up into engagement with the bottom surface 296 of the carrier 298 as illustrated in FIG. 38. When in this position, the lower sealing member 274 and the upper sealing member 278 work together to create an airtight, or substantially airtight seal, with the carrier 298 sandwiched in between. Here, the ablation enclosure 266 is effectively sealed to prevent, or substantially prevent, light emitted by the infrared laser 262 from escaping the ablation enclosure 266. As such, the Class 4 infrared laser 262 operates within a Class 1 rated enclosure within the substrate ablation and debris evacuation system 254. Here, the infrared laser 262 is considered safe to operate in a manufacturing environment without the need for additional safety precautions such as safety goggles or laser safe cages, as discussed above. This is particularly beneficial in the context of using the substrate ablation and debris evacuation system 254 in conjunction with the portable roller station 66’ because the substrate ablation and debris evacuation system 254 can effectively be deployed anywhere, including in an existing manufacturing environment, without the need to conform the production environment to certain higher class laser safety standards (e.g., requiring operators to wear laser safety goggles or constructing laser safe cages to enclose the cobot 256 and its assembly). As such, the ablation enclosure 266 is a fully integrated Class 1 laser safe enclosure designed to ensure safety by preventing light from the infrared laser 262 from escaping out from within the ablation enclosure 266 during operation.

[Para 149] The lower sealing member 274 and the upper sealing member 278 are versatile from the standpoint that the geometry of each may change depending on the desired size and/or shape of the bracket, part, or substrate to be ablated in the substrate ablation and debris evacuation system 254. For example, in some embodiments disclosed herein, each of the lower sealing member 274 and the upper sealing member 278 are generally depicted as cylindrical, and the upper sealing member 278 generally attaches to the laser protective zone 264 having a cone shape. In other embodiments, each of the lower sealing member 274 and the upper sealing member 278 may be made of a different geometric shape (e.g., square, rectangular, triangular, etc.), depending on the application. Moreover, the depth of the ablation enclosure 266 formed by the generally hollow interior cavities 294, 304 of the lower sealing member 274 and the upper sealing member 278, or just the hollow interior cavity 294 of the upper sealing member 278 in embodiments where the lower sealing member 274 is not needed, may also vary depending on the size and shape of the ablated part or surface. In this respect, e.g., larger parts may require a deeper depth, while smaller parts such as the brackets 268 disclosed herein, may require a relatively shallower depth. Additionally, the size of the opening between the lower sealing member 274 and the upper sealing member 278 may also vary in height based on the length of the piston 280 and the supporting guideposts 282, e.g., to accommodate larger or smaller parts therein. [Para 150] In another aspect of the embodiments disclosed herein, the surface or surfaces to be cleaned within the ablation enclosure 266 may generally be oriented at an angle between 90° and 180° relative to the focal lens of the infrared laser 262. For example, in the embodiment illustrated in FIGS. 36-38, the substrate 308 is at an angle of approximately 90° relative to the focal lens of the infrared laser 262 by way of its surface plane sitting generally orthogonal to the ablating beam. Alternatively, the laser protective zone 264 may be adapted internally so the emitted beam better ablates the surface or surfaces to be cleaned. For example, in one embodiment, to prepare surfaces not normal or orthogonal to the focal lens of the infrared laser 262, the housing 260 may couple to the mount 258 at an angle to offset the beam angle so that the infrared laser 262 is not concentric or otherwise centered within the laser protective zone 264. Here, and even in embodiments where the laser beam is concentric within the laser protective zone 264, adding one or more adaptable fixtures such a mirror 311 (FIG. 39) within the laser protective zone 264 can be used to redirect the beam path to ablate surfaces that are upwards of 180° offset relative to the focal lens of the infrared laser 262. Moreover, locating one or more prisms 313 within the interior of the laser protective zone 264 may split the beam into multiple beams for ablating multiple surfaces simultaneously. In this embodiment, these internally located mirrors 311 and/or the prisms 313 may permit simultaneously ablating the substrate 308 generally orthogonal to the beam path and the upwardly extending flange 310 offset from the beam path by about 180°. Of course, the prisms 313 may be used alone or in combination with one or more of the mirrors 311 mentioned above, depending on the application. The mirrors 311 and/or the prisms 313 may be mounted to a pivot 315 (e.g., a single or multi-plane pivot similar to a ball-and-socket joint) and repositionable in real-time within the laser protective zone 264 during the ablation process. Modifying the laser protective zone 264 to include the mirrors 311 and/or the prisms 313 helps prepare and clean hard-to-reach surfaces that may not be readily within a straight beam path.

[Para 151] Additionally, the laser protective zone 264 may further be modified to include external mounts or brackets to help maintain alignment of the infrared laser 262 normal to the subject workpiece, such as the bracket 268. Additionally, the length and diameter of the laser protective zone 264 can vary to accommodate the required lasering area and different focal lengths. These, and other adaptations as disclosed herein enhance the versatility and functionality of the laser protective zone 264, making it more efficient and effective for a range of applications.

[Para 152] As illustrated in FIG. 35 and the cross-sectional view of FIG. 39, the laser protective zone 264 includes a slot 312 formed within a sidewall thereof for select reception and retainment of the protective lens holder 60’ therein. This forms a natural transition between where the laser protective zone 264 ends and the ablation enclosure 266 begins. The beam of the infrared laser 262 travels through the protective lens holder 60’ and into the ablation enclosure 266 for contact with a part needing cleaning, such as the aforementioned bracket 268. During ablation, debris ablated from the surface of the bracket 268 (e.g., the substrate 308 or the upwardly extending flange 310) enters the ablation enclosure 266. While all the debris is preferably immediately evacuated out from the ablation enclosure 266 through the fume extractor 270, it is expected that some debris will remain therein and may have a tendency to travel back toward the infrared laser 262. In this respect, the protective lens holder 60’ serves as an intermediary to stop projecting debris remaining within the ablation enclosure 266 from contacting or otherwise degrading the output lens of the infrared laser 262, similar to the lens 60 discussed above. Over time, debris collects or otherwise damages the protective lens 143 within the protective lens holder 60’ instead of the relatively more expensive laser lens. Given that the protective lens holder 60’ is selectively removable and replaceable within the slot 312, it is possible to periodically change out the protective lens 143 for cleaning and replacement if the protective lens 143 is damaged or includes excessive debris thereon.

[Para 153] In one embodiment, the protective lens holder 60’ may have the same or a similar construction as the protective lens holder 60 disclosed above and illustrated with respect to FIG. 17 for protecting the laser 58. For example, the protective lens holder 60’ may also include the handle 134 formed from the pair of oppositely facing arcuate recesses 136 convenient for hand grasping so the protective lens holder 60’ may be more easily inserted and/or removed out from within the slot 312. Moreover, the protective lens holder 60’ may also similarly include the generally circular opening 138 having the receiving channel 140 therein accessible by way of the front slot 142 having a size and shape to selectively receive and retain (e.g., in friction fit relation) the protective lens 143 or the like therein. In this respect, similar to the above, the receiving channel 140 retains the protective lens 143 in a position within the substrate ablation and debris evacuation system 254 to permit the beam emitted by the infrared laser 262 to transmit therethrough, whether orthogonal thereto or otherwise. At the same time, by virtue of being positioned between the laser protective zone 264 and the ablation enclosure 266, the protective lens 143 effectively prevents ablated debris from traveling back to the infrared laser 262.

[Para 154] The protective lens 143 can be easily accessed by selectively grasping the outwardly extending handle 134 and pulling on the arcuate recesses 136 to retract the protective lens holder 60’ out from engagement with the slot 312. In one embodiment, the entire assembly of the protective lens holder 60’, namely including the handle 134, the receiving channel 140, and the protective lens 143 therein may simply be discarded and replaced by a new protective lens holder 60’ having a clean or undamaged protective lens 143 therein. In an alternative embodiment, once removed, the protective lens 143 may slide out from within the receiving channel 140 through the front slot 142 for cleaning (e.g., to remove debris that may build-up over time) or replacement (e.g., if scratched or damaged). Thereafter, the cleaned or replacement protective lens 143 may be reinserted into the receiving channel 140 by way of the front slot 142, and then the assembly of the protective lens holder 60’ may be reinserted back into the slot 312 for further use in the substrate ablation and debris evacuation system 254. Once inserted back into the slot 312, the protective lens 143 may effectively be wedged between an inner sidewall and the receiving channel 140 for secure retention therein. Moreover, insertion of the protective lens holder 60’ within the slot 312 may activate a proximity sensor or the like to ensure the protective lens holder 60’ is in position before and during operating the infrared laser 262.

[Para 155] In operation, when the enclosure 266 is in sealing relation with the carrier 298, e.g., as illustrated in FIG. 38, the substrate ablation and debris evacuation system 254 is able to pressurize the enclosure 266 and the corresponding fume extractor 270 fluidly coupled therewith (FIG. 42) to generate a vacuum therein to draw out debris through the fume extractor 270 during operation. Here, an air pressure sensor 314 may include an open port 316 (FIGS. 40 and 43-44) fluidly coupled with the fume extractor 270 to measure real-time pressure within the ablation enclosure 266 and the fume extractor 270 to ensure that one or both of the lower sealing member 274 and the upper sealing member 278 form an airtight seal with, e.g., the carrier 298. Presence of this pressure differential verifies closure and sealing of the ablation enclosure 266, ensuring continued operation of the Class 4 infrared laser 262 in a Class 1 enclosure, along with ensuring that debris ablated from the subject workpiece is efficiently removed from the ablation enclosure 266 during operation thereof. Such pressurization may be accomplished through use of a pneumatic system that utilizes compressed air.

[Para 156] In another aspect of the embodiments disclosed herein, the substrate ablation and debris evacuation system 254 may further include a gripper 318 that generally includes a pair of fingers 320 operated by, e.g., an air solenoid 322 or similar pneumatic or electric actuator to facilitate handling scalable materials, such as an elastomeric fixture 98 illustrated in FIGS. 5-7. Here, the fingers 320 are pneumatically operated by the air solenoid 322 to compress upon one end of the elastomeric fixture 98 in gripped relation therewith. Accordingly, the cobot 256 may then pull the elastomeric fixture 98 downwardly to draw the nutplate 78 attached thereto, and having the adhesive 144 underneath, into engagement with the substrate 308. In these embodiments, the gripper 318 and/or the aforementioned pneumatic sealing system may be integrated with and controlled by a robotic system utilizing input-output (“I/O”) commands.

[Para 157] The gripper 318 and/or the actuating fingers 320 therein operated by the cobot 256 may also vary in size and shape (e.g., to accommodate parts differing in size/shape), depending on the desired application. Again, larger parts to be cleaned by the substrate ablation and debris evacuation system 254 may require the use of a relatively larger gripper and/or relatively larger actuating fingers, while smaller parts may require the use of a relatively smaller gripper and/or relatively smaller actuating fingers. In one embodiment, the gripper 318 may be of a size and/or shape to handle scalable materials such as the aforementioned elastomeric fixture 98 and remain controllable by the cobot 256 using input/output (“I/O”) command controls.

[Para 158] In another aspect of these embodiments, FIGS. 39 and 41-42 are cross-sectional views more specifically illustrating an internal configuration of the respective laser protective zone 264, the ablation enclosure 266, and the fume extractor 270. More specifically, FIGS. 39 and 42 generally illustrate the location of the protective lens holder 60’ between the laser protective zone 264 and the ablation enclosure 266 to effectively seal the infrared laser 262 therefrom. Moreover, FIGS. 39 and 42 also illustrate that the ablation enclosure 266 is in fluid communication with the fume extractor 270, such as through an opening 324 therebetween, for purposes of evacuating or extracting debris out from within the ablation enclosure 266 during the ablation process. As briefly mentioned above, and as illustrated in FIG. 40, the fume extractor 270 may include the air pressure sensor 314 and the open port 316 may be exposed to and able to monitor the vacuum pressure in the fume extractor 270 in real-time. The air pressure sensor 314 provides feedback to the substrate ablation and debris evacuation system 254 to ensure a complete seal of the ablation enclosure 266 before operating the infrared laser 262. The air pressure sensor 314 may also help ensure that the vacuum within the fume extractor 270 is adequate during operation, e.g., to ensure efficient removal of debris from the ablation enclosure 266 during use of the substrate ablation and debris evacuation system 254.

[Para 159] Alternatively, or in addition to, the ablation enclosure 266 may also include one or more sensors position therein for purposes of real-time monitoring, such as to ensure that the ablation enclosure 266 remains adequately sealed so light from the infrared laser 262 does not escape during use. This helps ensure the substrate ablation and debris evacuation system 254 continues to operate as a Class 1 enclosure, despite utilizing a Class 4 laser. Such sensors may include a pressure sensor comparable to that of the air pressure sensor 314 to further ensure that the ablation enclosure 266 remains pressurized upon activation of the infrared laser 262. In another embodiment, the ablation enclosure 266 may include one or more proximity sensors to help ensure that the lower sealing member 274 properly seats on the bottom surface 296 of the carrier 298 and/or that the upper sealing member 278 properly seats on the top surface 306 of the carrier 298. In another embodiment, the ablation enclosure 266 may include a light sensor capable of measuring the relative amount of light escaping the ablation enclosure 266 during use. In this embodiment, a light curtain may be used to shield the sensor from inaccurate readings due to external ambient light in production environments. Additionally, other sensors known in the art may be used so long as they are able to check and/or verify the quality of the seal between the sealing members 274, 278 and the carrier 298, and provide real-time feedback so the substrate ablation and debris evacuation system 254 can turn off the infrared laser 262 in the event the enclosure is no longer Class 1 compliant. Each of these one or more sensors integrated with the substrate ablation and debris evacuation system 254 may be used alone or in combination with one another to enhance safety before, during, and/or after operation of the substrate ablation and debris evacuation system 254.

[Para 160] As best illustrated in FIGS. 42-44, an inlet port 326 formed generally between the laser protective zone 264 and the fume extractor 270 selectively receives pressurized fluid such as compressed or pressurized air from a pneumatic system. More specifically, FIGS. 42 and 44 illustrate that the inlet port 326 is fluidly coupled with a channel 328 that carries the incoming pressurized air down between the fume extractor 270 and the ablation enclosure 266. The pressurized air is used to create the forementioned vacuum to evacuate debris out through the fume extractor 270. As such, the aforementioned air pressure sensor 314 in the fume extractor 270 may ensure there is sufficient airflow within the channel 328 to generate a proper vacuum between the inlet port 326 and an exit port 330 (FIGS. 33-35 and 40-42) of the fume extractor 270 to draw debris out from within the ablation enclosure 266 during operation thereof.

[Para 161] FIGS. 45 and 46 illustrate that the pressurized air channel 328 eventually splits into a lower conduit 332 and an upper conduit 334 at a branch 336 thereof. From here, FIGS. 45-47 best illustrate that the lower conduit 332 is generally semi-hemispherical and tracks a curved interior surface 338 of the ablation enclosure 266. The lower conduit 332 is in fluid communication with a lower semi-hemispherical slit 340 that opens into an interior opening 342 of the ablation enclosure 266. As such, pressurized air flows out through the lower semihemispherical slit 340 across the interior opening 342 to generate a lower air knife or air curtain 344 (as indicated by a set of directional arrows therein) designed to substantially reduce slag and/or block ablated debris from traveling into the laser protective zone 264. The lower semihemispherical slit 340 is located somewhat above the interior opening 324 between the ablation enclosure 266 and the fume extractor 270 such that pressurized air flowing out from the lower semi-hemispherical slit 340 as the lower air curtain 344 provides somewhat of a downward pressure into the opening 324 for eventual extraction out through the fume extractor 270. As such, this lower air curtain 344 provides an initial shield to redirect or oppose upwardly projected ablated debris from traveling toward the protective lens holder 60’ and the laser protective zone 264 by way of providing a first layer of constantly flowing pressurized air across the interior opening 342.

[Para 162] Moreover, FIGS. 45-47 also illustrate that the upper conduit 334 is generally semi-hemispherical and also tracks the curved interior surface 338 of the ablation enclosure 266 commensurate with the lower conduit 332. Here, the upper conduit 334 is in fluid communication with an upper semi-hemispherical slit 346 that opens into the interior opening 342 of the ablation enclosure 266. As such, pressurized air flows out through the upper semihemispherical slit 346 across the interior opening 342 in the ablation enclosure 266 to generate a second upper air knife or air curtain 348 designed to reduce whatever leftover slag and/or ablated debris may escape or otherwise travel around the lower air curtain 344. By virtue of being located above the lower semi-hemispherical slit 340, pressurized air emitted from the upper semi-hemispherical slit 346 applies an additional downward pressure to counteract any upwardly moving ablated debris. As such, the upper scmi-hcmisphcrical slit 346 and the upper air curtain 348 provide a second shield designed to move debris and other particulate away from the laser protective zone 264 and into the fume extractor 270 through the opening 324 in fluid communication with the ablation enclosure 266.

[Para 163] The fume extractor 270 is fully enclosed with the ablation enclosure 266 when each of the sealing members 274, 278 land on the respective surfaces 296, 306 of the carrier 298 and facilitates efficient removal of contaminants by way of a tight vacuum seal therewith that prevents exposing users to hazardous airborne particles. As such, the vacuum generated within the fume extractor 270 extracts fumes and other particles lasered within the ablation enclosure 266. In one embodiment, the fume extractor 270 may have one or more HEPA filters and/or one or more carbon filters to collect these dangerous or hazardous fumes and/or particles at the exit port 330 or elsewhere, as needed. The air pressure sensor 314 takes real-time pressure readings from within the fume extractor 270 to provide feedback to the substrate ablation and debris evacuation system 254 regarding the quality of the vacuum therein to ensure the ablation enclosure 266 continues to remain sealed for safety purposes. If the pressure drops below a predetermined threshold, the substrate ablation and debris evacuation system 254 may shut off the infrared laser 262 in real-time to discontinue the ablating process.

[Para 164] The laser protective zone 264, the ablation enclosure 266, and/or the fume extractor 270 can be fabricated through various manufacturing processes, such as 3D printing using FDM, 3D printing using SLA Resin, 3D printing using SLS, investment casting with a wax core for the internal passages (e. ., the channel 328), or machining. The shape of the substrate ablation and debris evacuation system 254 is not necessarily limited to a conical shape and can be designed as a box or any other shape, as needed.

[Para 165] Additionally, the substrate ablation and debris evacuation system 254 can also be used with alternative methods for surface preparation/activation, such as dry ice, plasma, and media blasting. These alternative processes provide additional flexibility in choosing the most suitable method for ablating surfaces, depending on the specific manufacturing, assembly, or repair needs.

[Para 166] As such, in general, the substrate ablation and debris evacuation system 254 is equipped to use the Class 4 infrared laser 262 in a Class 1 laser safe enclosure that includes the laser protective zone 264 generally aligned to emit a beam through the protective lens holder 60’ and into the ablation enclosure 266 fluidly coupled with the fume extractor 270 where debris and other fumes are evacuated from the substrate ablation and debris evacuation system 254 during operation. One or more air curtains 344, 348 help reduce slag and keep blasted debris material from settling back on the cleaned substrate and/or the protective lens 143 within the protective lens holder 60’, and help facilitate directional air flow into the fume extractor 270. The cobot 256 ensures that the dual-piece ablation enclosure 266 remains appropriately sealed whereby little or no laser light emits therefrom during operation. Of course, the ablation enclosure 266 can be modified to include the ability to laser different surfaces at different angles, with different lengths and diameters, and can be manufactured using various methods, including 3D printing and investment casting as mentioned above.

[Para 167] Although several embodiments have been described in detail for purposes of illustration, various modifications may be made without departing from the scope and spirit of the invention. Accordingly, the invention is not to be limited, except as by the appended claims.

Claims

What is claimed is:

[Claim 1] A laser ablation containment system, comprising: a laser chamber having a Class IM or higher rated laser integrated therewith; a cleaning chamber coupled with the laser chamber and aligned therewith to selectively receive a beam generated by the Class IM or higher rated laser, the cleaning chamber including a header selectively movable between a first position exposing an interior of the cleaning chamber for placement of a substrate therein and a second position securely closing the interior of the cleaning chamber to form a Class 1 certified laser operable enclosure in cooperation with the laser chamber.

[Claim 2] The system of claim 1, wherein the laser chamber and the cleaning chamber are integrated as part of a portable roller station.

[Claim 3] The system of claim 1, wherein the cleaning chamber and the laser chamber are coupled with a robotic arm movable to selectively position the header against the substrate to form the enclosure therewith.

[Claim 4] The system of claim 1, wherein the cleaning chamber is in fluid communication with a debris removal chamber.

[Claim 5] The system of claim 1, including a gripper having a pair of actuating fingers positioned underneath an umbrella and operable to selectively pick-and-place the substrate within the enclosure formed by sealing engagement of the umbrella with a sealing rim.

[Claim 6] The system of claim 5, wherein the umbrella is slidable along an axis normal to a focal lens of the Class IM or higher rated laser mounted within the laser chamber.

[Claim 7] The system of claim 5, including a proximity sensor positioned to identify when umbrella is seated on the sealing rim.

[Claim 8] The system of claim 1 , wherein the header includes an outwardly projecting compressible liner forming at least part of an outer perimeter of the enclosure.

[Claim 9] The system of claim 1, including at least one sensor measuring pressure or light within the enclosure.

[Claim 10] The system of claim 1, including a selectively removable and replaceable protective lens selectively positionable within a slot substantially sealing off the laser chamber from the cleaning chamber.

[Claim 11] The system of claim 10, wherein the protective lens is carried by a lens holder having a front channel providing access to the protective lens when removed from the slot, the front channel being flush with an inner sidewall of the cleaning chamber when in the slot, thereby locking the protective lens therein.

[Claim 12] The system of claim 1, wherein the header comprises a clamp having a base with a lower sealing member upwardly extending therefrom that cooperates with an upper sealing member to form the enclosure in between when the header is in the second position.

[Claim 13] The system of claim 12, wherein the lower sealing member comprises a foam or rubber material and is movable relative to the upper sealing member comprising a foam or rubber material by a linear actuator or a pneumatic piston.

[Claim 14] The system of claim 1, wherein the laser chamber is offset relative to the cleaning chamber by an angle between 90° and 180°.

[Claim 15] The system of claim 1, including a mirror or a prism located within one of the laser chamber or the cleaning chamber and positioned to receive and redirect the beam by up to an offset of 180°.

[Claim 16] The system of claim 15, wherein at least one of the mirror or the prism is mounted to a pivot and rcpositionablc in real-time within one of the laser chamber or the cleaning chamber.

[Claim 17] The system of claim 16, wherein the pivot comprises a single plane pivot, a multiplane pivot, or a ball-and-socket pivot.

[Claim 18] The system of claim 1, including a bracket inwardly projecting from an inner sidewall of the cleaning chamber forming a gap in between for select seated reception of an elastomeric fixture downwardly protruding from a nutplate.

[Claim 19] The system of claim 1, wherein the Class IM or higher rated laser comprises a Class 4 laser.

[Claim 20] A debris containment system, comprising: a conduit for delivering a pressurized fluid to a cleaning chamber; and an outlet coupled with the conduit and positioned to direct the pressurized fluid substantially across an interior channel of the cleaning chamber as an air curtain thereacross substantially preventing debris on one side of the interior channel of the cleaning chamber from crossing the air curtain to another side of the interior channel of the cleaning chamber.

[Claim 21] The system of claim 20, wherein the interior channel comprises a cylindrical channel and the outlet comprises a semi-hemispherical slot formed from an interior sidewall of the cleaning chamber.

[Claim 22] The system of claim 21, wherein the semi-hemispherical slot forwardly faces the interior channel and the air curtain extends generally horizontally across the interior channel of the cleaning chamber.

[Claim 23] The system of claim 20, wherein the conduit comprises a first conduit and a second conduit and the outlet comprises a first outlet and a second outlet, wherein each of the first and second outlets open to the interior channel producing a first air curtain and a second air curtain offset from the first air curtain.

[Claim 24] The system of claim 23, wherein the first air curtain and the second air curtain extend across the interior channel of the cleaning chamber at different angles relative to one another.

[Claim 25] The system of claim 23, wherein the first conduit comprises an upper conduit and the second conduit comprises a lower conduit, wherein each of the upper conduit and the lower conduit includes a respective slot having a width approximately half of a perimeter of the interior channel of the cleaning chamber.

[Claim 26] The system of claim 20, wherein the air curtain extends generally horizontally across the interior channel and toward a debris removal chamber in fluid communication therewith.

[Claim 27] The system of claim 26, including at least one of a HEPA filter or a carbon filter positioned within the debris removal chamber to absorb debris.

[Claim 28] The system of claim 26, including an air pressure sensor positioned within one of the cleaning chamber or the debris removal chamber.

[Claim 29] The system of claim 20, wherein the outlet is positioned at an angle relative to the interior channel wherein the air curtain extends across the interior channel at an angle relative thereto.

[Claim 30] The system of claim 20, wherein the outlet comprises a generally elongated slot formed from a tubular bracket extending within the interior channel of the cleaning chamber.

[Claim 31] The system of claim 30, wherein the elongated slot positions the air curtain to flow at least partially vertically within the interior channel of the cleaning chamber.

[Claim 32] The system of claim 31 , wherein the at least partially vertical flow of the air curtain opposes movement of debris toward a laser chamber coupled to the cleaning chamber.

[Claim 33] An adhesive dispenser system, comprising: a frame having a drive unit mounted thereto; and a screw threadingly operated by the drive unit and engaged with a carrier unit slidable relative to the frame and having at least one colleting assembly rigidly coupled thereto; wherein the at least one colleting assembly includes a piston collet selectively slidably engageable with a piston head and operable to dispense liquid from a cartridge when the drive unit operates the screw in a first direction and to reduce liquid “drip” when the drive unit operates the screw in a second direction opposite the first direction.

[Claim 34] The system of claim 33, wherein the drive unit is operable to move the screw at a rate to dispense liquid in increments of less than 0.1 gram (“g”).

[Claim 35] The system of claim 33, wherein the adhesive dispenser system is coupled to a portable roller station.

[Claim 36] The system of claim 33, including a support bracket having an extension sized to receive a dispensing needle in spaced apart relation relative to the frame, the support bracket is selectively adjustable relative to the frame by an elongated channel lockable to the frame by a positioning pin located therein.

[Claim 37] The system of claim 33, wherein the piston collet terminates in an outwardly flaring mandrel sized for friction fit engagement with the piston head.

[Claim 38] The system of claim 33, wherein the at least one colleting assembly comprises a pair of colleting assemblies, each of which includes a respective piston collet selectively slidably engageable with a respective piston head operable to dispense adhesive from a dual-cartridge assembly.

[Claim 39] The system of claim 38, wherein the respective piston heads comprise a different size relative to one another.

[Claim 40] The system of claim 33, including at least one feedback sensor coupled to the drive unit for providing real-time sensing feedback regarding adhesive viscosity.

[Claim 41] The system of claim 40, wherein the at least one feedback sensor comprises a force-feedback sensor measuring a current or a voltage of the drive unit in real-time.

[Claim 42] The system of claim 33, including a camera positioned to photograph adhesive dispensed from the cartridge.

[Claim 43] The system of claim 33, including a quick release mechanism for one-step disengagement of the piston collet from the cartridge.

[Claim 44] The system of claim 43, wherein the quick release mechanism comprises a slide bracket having a step operable to compress a spring from a first normal extended position to a second compressed position withdrawing the piston collet out from engagement with the piston head.

[Claim 45] The system of claim 44, wherein the slide bracket includes a pull back channel having a slide pin therein confining movement of the slide bracket relative to the carrier unit by a predetermined distance.

[Claim 46] The system of claim 44, including a stop coupled with the carrier unit and positioned to terminate rearward movement of the slide bracket relative to the carrier unit by a predetermined distance.

[Claim 47] The system of claim 33, wherein the frame includes a thermal enclosure having a cooling element or a heating element proximate a quick-change carrier therein.

[Claim 48] A quick change cartridge system, comprising: a frame having a set of outwardly extending locator pins having a size and shape for select slide-fit engagement with a slotted housing of a dispenser unit; and a liquid containing cartridge having a size and shape for select slide-in reception and/or removal out from an open aperture in the frame when the frame is removed from the dispenser unit, the liquid containing chamber being positionable within the frame in a forward position in fluid communication with a dispense outlet when the frame is engaged with the dispenser unit.

[Claim 49] The system of claim 48, wherein the frame includes a front aperture having a size and shape relatively smaller than the liquid containing cartridge and relatively larger than the dispense outlet.

[Claim 50] The system of claim 48, wherein the locator pins comprise bolts outwardly extending from the frame and having a relatively smooth shank portion of a length sufficient for slide in reception in the slotted housing and to position a head portion of the bolts to an exterior of the slotted housing.

[Claim 51] The system of claim 50, wherein the slotted housing includes a set of externally accessible L-shaped receiving channels relatively wider than a width of the shank portion and relatively smaller than a width of the head portion of the bolts.

[Claim 52] The system of claim 51, wherein the externally accessible L-shapcd receiving channels include an enlarged chamfered opening top accessible for drop-in reception of the frame in the slotted housing.

[Claim 53] The system of claim 48, wherein the liquid containing cartridge includes an outwardly extending baseplate at least partially relatively larger than the open aperture for flush engagement therewith when the liquid containing cartridge is installed within the frame.

[Claim 54] The system of claim 48, wherein the liquid containing cartridge includes a pair of liquid containing cartridges, each of which are in fluid communication with a cap having an outlet port selectively couplable with the dispense outlet comprising an inlet of a static mixer outwardly extending from the frame.

[Claim 55] The system of claim 48, wherein the liquid containing cartridge includes at least one rear receiving slot having a size and shape for select engagement with a colleting assembly of the dispenser unit.

[Claim 56] An adhesive dispensing feedback process, comprising the steps of: activating a drive unit for dispensing a quantity of an adhesive at a desired flow rate; monitoring one or more dispensing characteristics associated with the quantity of the adhesive being dispensed; cross-referencing the one or more dispensing characteristics against a set of operating parameters for each of the one or more dispensing characteristics; and adjusting the desired flow rate of the quantity of adhesive with the drive unit if one or more of the dispensing characteristics fall outside any of the set of operating parameters.

[Claim 57] The process of claim 56, including the steps of: reversing the drive unit; drawing back a piston head within a liquid containing cartridge operable by the drive unit to dispense the adhesive from an outlet tip; and forming a negative pressure at the outlet tip to stop dispensing adhesive and control drip at the outlet tip.

[Claim 58] The process of claim 56, including the step of reading a temperature of one or more liquid compounds in a liquid dispensing cartridge.

[Claim 59] The process of claim 58, including the step of changing a temperature of the one or more liquid compounds in the liquid dispensing cartridge with a heater or a cooler.

[Claim 60] The process of claim 56, including the step of controlling a viscosity of the adhesive.

[Claim 61] The process of claim 56, including the steps of: slidably moving a carrier unit having a pair of colleting assemblies coupled therewith into engagement with a respective pair of cartridges positioned in stationary relation to the carrier unit; and dispensing liquid out from within each of the pair of cartridges into a static mixer for forming the adhesive.

[Claim 62] The process of claim 61, including the step of engaging a piston collet within each of the colleting assemblies with a respective piston head in fluid relation with each of the pair of cartridges.

[Claim 63] The process of claim 61, wherein the adjusting step includes the step of changing a rotating rate of a thread screw operated to slidably move the carrier unit by the drive unit.

[Claim 64] The process of claim 56, wherein the monitoring step includes the step of sensing a viscosity of the dispensing adhesive and determining if the viscosity is lower than a threshold value or the viscosity is higher than a threshold value.

[Claim 65] The process of claim 56, wherein the monitoring step includes the step of sensing a current or a voltage of the drive unit in real-time and determining if the current or the voltage is below a threshold value or if the current or the voltage is above a threshold value.

[Claim 66] The process of claim 56, wherein the monitoring step includes the step of measuring an ambient temperature or a temperature of the adhesive.

[Claim 67] The process of claim 56, wherein the monitoring step includes measuring the one or more dispensing characteristics in real-time or in discrete time increments.

[Claim 68] The process of claim 56, wherein the monitoring step includes the step of watching the adhesive with a camera.

[Claim 69] A protective lens holder, comprising: a frame having a forwardly positioned receiving channel of a size and shape for select reception of a protective lens therein when in a first open position and movable to a second position locking the protective lens therein in cooperation with an interior sidewall of a cleaning chamber when slidably engaged therewith; and a handle outwardly extending from the frame opposite the receiving channel and being of a size and shape for hand manipulation outside of an external sidewall of the cleaning chamber.

[Claim 70] The protective lens holder of claim 69, wherein the protective lens is selectively replaceable and the protective lens holder is selectively reusable with the cleaning chamber.

[Claim 71] The protective lens holder of claim 69, wherein the receiving channel includes a substantially horizontal open slot for selectively inserting and removing the protective lens therein when in the first open position.

[Claim 72] The protective lens holder of claim 69, wherein the handle includes a pair of oppositely facing arcuate recesses enhancing hand manipulation of the protective lens holder outside the external sidewall of the cleaning chamber.

[Claim 73] The protective lens holder of claim 69, wherein the protective lens comprises a light permeable protective lens.

[Claim 74] A debris removal system, comprising: an outlet conduit in fluid communication with a cleaning chamber having debris therein removed from a substrate; a port in the outlet conduit coupled to a pressure sensor in fluid communication therewith for measuring a pressure in the outlet conduit in real-time; and a controller coupled with the pressure sensor and in communication with a laser operable to generate a beam in the cleaning chamber for removing debris from the substrate, the controller operable to disable the beam in response to a pressure loss measured by the pressure sensor in the outlet conduit.

[Claim 75] The system of claim 74, including an inlet port that selectively receives a pressurized fluid at least partially generating a vacuum in the outlet conduit relative to the cleaning chamber.

[Claim 76] The system of claim 75, wherein the inlet port couples to a pneumatic air pump.

[Claim 77] The system of claim 75, including a HEP A filter or a carbon filter positioned within the outlet conduit to filter debris.

[Claim 78] A process for replacing a quick-change cartridge, including the steps of: sliding a carrier out from engagement of a frame of a dispensing unit; removing a liquid containing cartridge out from within the carrier by way of an access port; inserting a new liquid containing cartridge into the carrier through the access port; and reinserting the carrier carrying the new liquid containing cartridge into the frame of the dispensing unit.

[Claim 79] The process of claim 78, including the step of disengaging the liquid containing cartridge from a slide unit of the dispensing unit.

[Claim 80] The process of claim 79, wherein the disengaging step further includes the steps of: moving an externally accessible slide bracket rearwardly relative to the slide unit; compressing a normally forwardly positioned extension spring within a retraction channel by way of engagement of an inwardly projecting step engaging a washer positioned at one end of the extension spring; and retracting a flaring mandrel of a piston collet out from friction-fit engagement with a piston head associated with the liquid containing cartridge in response to compressing the extension spring.

[Claim 81] The process of claim 80, wherein the compressing step includes the step of compressing the extension spring with an intermediary projecting step positioned between coils of the extension spring.

[Claim 82] The process of claim 80, wherein the moving step includes the step of terminating rearward movement of the slide bracket with a stop integrated with the frame or positioned within a pull-back channel formed within the slide bracket.

[Claim 83] The process of claim 78, including the step of moving a set of locking pins outwardly protruding from the earner through an externally accessible L-shaped channel formed from the frame.

[Claim 84] The process of claim 83, wherein the set of outwardly protruding locking pins comprise a bolt having a shank portion movable within the L-shaped channel and a head portion relatively larger than and positioned external the L-shaped channel.

[Claim 85] The process of claim 83, including the step of locking the new liquid containing cartridge into a forward slot of the L-shaped channel.

[Claim 86] The process of claim 78, wherein the reinserting step includes recoupling a slide unit with a piston head associated with the new liquid containing cartridge by tapping a screw, rotating an externally accessible knob, or retracting the piston head into engagement therewith.

[Claim 87] A process for cleaning a surface, comprising the steps of: enclosing a laser chamber having a Class IM or higher rated laser integrated therewith; positioning a substrate within an ablation chamber coupled with the laser chamber and aligned with the Class IM or higher rated laser; moving a header between a first position exposing an interior of the ablation chamber for placement of the substrate therein and a second position closing the interior of the ablation chamber and forming a Class 1 certified laser operable enclosure in cooperation with the laser chamber; generating a beam with the Class IM or higher rated laser; and contacting at least a portion of the substrate with the beam, thereby cleaning the substrate of debris.

[Claim 88] The process of claim 87, including the step of pick-and-placing the substrate within the header.

[Claim 89] The process of claim 87, including the step of orienting the substrate relative to the beam between an angle between 90° and 180°.

[Claim 90] The process of claim 87, including the step of inserting a protective lens between the laser chamber and the ablation chamber and generally orthogonal to the beam.

[Claim 91] The process of claim 90, wherein the generating step includes the step of sending the beam through the protective lens and into contact with the substrate.

[Claim 92] The process of claim 90, including the step of activating a proximity sensor in response to inserting the protective lens or forming the Class 1 certified laser operable enclosure.

[Claim 93] The process of claim 90, including the step of abutting a front slot of a protective lens holder against an interior sidewall thereby locking the protective lens within the protective lens holder.

[Claim 94] The process of claim 87, including the step of sandwiching the substrate between an upper sealing member and a lower sealing member of the header.

[Claim 95] The process of claim 87, including the step of redirecting at least a portion of the beam off a mirror, wherein the contacting step includes simultaneously ablating the substrate at two different beam angles.

[Claim 96] The process of claim 95, including the step of pivoting the mirror about at least one plane.

[Claim 97] The process of claim 96, wherein the pivoting step includes repositioning the mirror about a ball-and-socket joint.

[Claim 98] The process of claim 87, including the step of splitting the beam with a prism before contacting the substrate.

[Claim 99] The process of claim 87, including the step of evacuating debris out from within the cleaning chamber.

[Claim 100] The process of claim 99, wherein the evacuating step includes steps for pressurizing the enclosure and forming a vacuum at an outlet port evacuating the ablated debris.

[Claim 101] The process of claim 100, including the steps of measuring a pressure differential between the cleaning chamber and the outlet port and deactivating the beam if a pressure differential between the cleaning chamber and the outlet port falls below a threshold value.

[Claim 102] The process of claim 87, including the steps of monitoring the Class 1 certified laser operable enclosure in real-time with at least one sensor and terminating the beam in the event the enclosure is no longer Class 1 compliant based on real-time feedback from the at least one sensor.

[Claim 103] The process of claim 102, wherein the sensor comprises a pressure sensor or a light sensor.

[Claim 104] A process for installing a fastener to a substrate, comprising the steps of: cleaning a bonding surface of the fastener and at least a portion of the substrate with a laser; positioning the cleaned bonding surface of the fastener proximate an adhesive dispenser; applying an adhesive to the bonding surface of the fastener with the adhesive dispenser; and bonding the fastener to the substrate along a bondline formed between the bonding surface of the fastener and the substrate.

[Claim 105] The process of claim 104, wherein the cleaning step includes operating a Class IM or higher rated laser in a Class 1 certified laser enclosure.

[Claim 106] The process of claim 105, wherein the cleaning step includes the steps of: opening an ablation chamber coupled with the Class IM or higher rated laser; placing the fastener or the substrate within the ablation chamber; and closing a header of the ablation chamber about the fastener or at least a portion of the substrate to be ablated, thereby forming the Class 1 certified laser enclosure about the fastener or the portion of the substrate to be ablated.

[Claim 107] The process of claim 104, including the steps of generating a beam with the laser and contacting at least a portion of the bonding surface or the substrate with the beam.

[Claim 108] The process of claim 104, wherein the cleaning step includes steps for: selecting the fastener comprising a nutplate; locating the nutplate relative to an internal bracket inwardly projecting from an inner sidewall within a cleaning chamber so an elastomeric member extending out from a bottom surface of the nutplate bends away from a beam path of the laser; and ablating the bottom surface of the nutplate with the beam.

[Claim 109] The process of claim 108, wherein the ablating step includes the step of rotating the bottom surface of the nutplate relative to the beam while the elastomeric member simultaneously remains bent out and away from the beam.

[Claim 110] The process of claim 108, wherein the positioning step includes steps for: removing the ablated nutplate from the cleaning chamber; sliding the elastomeric member into a slot of a locator block; and aligning the bottom surface of the nutplate proximate an outlet of the adhesive dispenser while simultaneously bending the elastomeric member away from the outlet.

[Claim 111] The process of claim 110, wherein the applying step includes the step of rotating the bottom surface of the nutplate relative to the outlet of the adhesive dispenser while simultaneously bending the elastomeric fixture away from the outlet.

[Claim 112] The process of claim 111, wherein the rotating step includes adjusting a rotation rate of the bottom surface of the nutplate in response to a desired flow rate of the adhesive.

[Claim 113] The process of claim 108, wherein the bonding step includes the step of drawing an elastomeric member through an aperture in the substrate for draw-in bonding of the bonding surface of the fastener to the substrate.

[Claim 114] A process for containing debris, comprising the steps of: delivering a pressurized fluid to a debris containment chamber; dispersing the pressurized fluid as an air curtain across an open inner channel within the debris containment chamber; blocking at least some debris within the debris containment chamber from crossing the air curtain; and evacuating at least some of the pressurized fluid out an exit port fluidly coupled with the debris containment chamber simultaneously with at least some debris.

[Claim 115] The process of claim 114, wherein the air curtain comprises a pair of air curtains, a first air curtain positioned substantially orthogonal to the inner channel and a second air curtain offset from being orthogonal to the inner channel by between 10 degrees and 90 degrees.

[Claim 116] The process of claim 115, wherein the dispersing step includes forming the first air curtain out a slot formed from at least pail of the open inner channel of the debris containment chamber.

[Claim 117] The process of claim 115, wherein the dispersing step includes forming the second air curtain out a tubular bracket extending within the open inner channel of the debris containment chamber.

[Claim 118] The process of claim 114, including the step of monitoring a real-time pressure within the debris containment chamber.