Control method and high speed fluid injection system
Patent Information
- Application Number
- BR112022016852
- Authority / Receiving Office
- BR · BR
- Patent Type
- Patents
- Current Assignee / Owner
- Publication Date
- 2026-09-15
Smart Images

Figure 00000045_0000 
Figure 00000045_0001 
Figure 00000045_0002
Abstract
Description
1 / 36 METHOD OF CONTROL AND HIGH-SPEED FLUID INJECTION SYSTEM DESCRIPTION OBJECTIVE OF THE INVENTION
[0001] The present invention relates to a control method for a high-speed fluid injection system and a system configured to implement the control method. The invention also has a monitoring system for the system configured to implement the control method. In particular, the present invention allows for automatic, precise, and continuous control of the amount of fluid injected or applied to a plurality of parts. BACKGROUND OF THE INVENTION
[0002] The growing market demand for products and the implementation of more productive processes have opened new fields for improving process efficiency in the container manufacturing sector. Today, the production processes with the greatest potential for improvement in this sector are perhaps those involving the application of fluids to container components, such as bodies and lids. Most of the fluids applied are adhesives, sealants, or varnishes, consisting of dispersions in an organic or aqueous solvent of the solid product to be applied to the component surface.
[0003] In these processes, after the liquid fluid is applied to a component surface, the solvents volatilize and leave a solid product or dry extract on the component surface, which is the name used to refer to the part of the fluid that remains after the solvent is removed. In the case of sealants, for example, the Petition 870240083432, dated 09 / 30 / 2024, page 10 / 63 2 / 36 of the dry extract volume has an effect on the headspace remaining after a container is sealed: an excessive amount of dry extract can prevent proper sealing, while an insufficient amount can cause the container contents to leak or become contaminated. Therefore, the dry extract volume of the sealant applied is considered a critical parameter for ensuring the integrity of the container seal.
[0004] To meet the specific dry extract volume requirements, one must consider, on the one hand, the parameters of the fluid itself, such as density and solvent:solid product ratio; however, attention should be paid primarily to the amount of liquid fluid that is applied to the surface of each part or component.
[0005] To be efficient and profitable, fluid application processes, particularly sealant application processes, in container components such as lids, require large production volumes and high processing capacities. Precision in the amount of fluid applied is fundamental to obtaining lids that meet specifications.
[0006] Generally, stationary or rotary fluid injection machines with one or more injection devices are used in these application processes, with said devices applying quantities of sealing fluid on the order of milligrams to one or more parts that move at high speed on the production line.
[0007] In stationary machines, the injector or injectors are fixed, while the caps move in an indexed manner, remaining in the application station for the time Petition 870240083432, dated 09 / 30 / 2024, page 11 / 63 3 / 36 corresponding to be treated by the injector. In rotary machines, the injectors are mounted to rotate around the machine's axis of rotation, so that they follow the caps during the application process. In these rotary machines, the parts enter the machine via a feeder which transports them, describing a circle in relation to the machine's axis. Each part is treated by an injector as it moves, so that several injectors simultaneously apply the fluid to their respective parts.
[0008] In both stationary and rotary machines, round caps must be distinguished from non-round or molded caps during the injection application process. To distribute the applied fluid, as in the case of sealants, throughout the perimeter of the cap or closing area, for round caps, the cap rotates relative to the injector axis during the application process, while for non-round or molded caps, the injector moves along the perimeter of the cap to deposit the sealant in the closing area. The sealing fluid can thus be spread in the closing area of the cap in one or more layers, depending on the number of turns the cap or injector makes during the application process.
[0009] Given that these application processes are high-speed processes, it is very important that the response speed of the injectors (or injectors) is on the order of milliseconds and that the process capacity remains the same over time in order to maintain an acceptable production rate, since the parts are applied in-line and continuously. In known systems, the trade-off for maintaining a high rate of Petition 870240083432, dated 09 / 30 / 2024, page 12 / 63 4 / 36 production is the imprecision in the amount of fluid applied to each part. In fact, it is a process that can be considered uncontrollable due to obtaining capacity indices far below those desired or considered acceptable for the process to be referred to as under control.
[0010] During the application process, there are factors beyond our control that cause the amount of fluid applied throughout the process to vary considerably. Variations in injector geometry due to wear or misalignment, temperature variations, and variations in the viscosity of the applied fluid are some of the factors that affect the flow rate of the fluid applied by the injector and cause the amount applied to vary during the process.
[0011] Currently, the only widely used control tool in the industry is a manual control method which requires the random weighing of several samples from a batch. This method is usually performed every few hours after the fluid has been applied to a large number of parts (production rates of over 2,000 units / min can be achieved) and if a deviation from the specified quantity is detected, the batch must be discarded, and the operator performing the control must manually adjust the production parameters to correct the deviation. Furthermore, this control method is highly dependent on the experience and skill of each operator to weigh the parts and adjust the process parameters.
[0012] There is therefore a need in the industry to implement effective and efficient methods and systems for the Petition 870240083432, dated 09 / 30 / 2024, page 13 / 63 5 / 36 control of the amount of fluid applied to meet the current demands of the sector.
[0013] Document WO02 / 074516A1 discloses an apparatus and method for proportionally controlling fluid distribution for stacked molds.
[0014] Patent application EP3499194A1 refers to a flow measurement system adapted for measuring a flow rate of sealant applied to a plurality of parts, the flow measurement system comprising a plurality of flow meters, each of the flow meters in fluid communication with a fluid injector, and the plurality of flow meters being configured to generate, process and transmit a signal related to the flow rate of the injected fluid.
[0015] Document US2019 / 070762A1 describes systems and methods for self-tuning PID control of injection molding machines in order to reduce oscillations in the process variables of an injection molding process.
[0016] US patent application 2017 / 168471A1 discloses a remote controller for controlling devices by diverting the feedback signal from the native controller to the remote controller. A remote controller may be provided in any device that employs feedback control from a native controller to add functionality to the device where the native controller is not capable of providing such functionality independently.
[0017] Document US2018 / 056567A1 describes an injection molding system with discretely adjustable variable control to effectively control its operation. DESCRIPTION OF THE INVENTION
[0018] The present invention proposes a solution for the Petition 870240083432, dated 09 / 30 / 2024, page 14 / 63 6 / 36 previous problems by means of a control method for a fluid injection system according to claim 1, a high-speed fluid injection system according to claim 8, and a monitoring system according to claim 14. Dependent claims define preferred embodiments of the invention.
[0019] A first inventive aspect provides a control method for a high-speed fluid injection system, comprising: - a plurality of fluid injectors, each fluid injector comprising a movable valve element between a first closed position and a second open position, wherein the second open position of each valve element can be individually controlled to regulate the flow rate injected by each fluid injector; - Fluid supply means configured to supply pressurized fluid to a plurality of fluid injectors; - a plurality of flow meters, wherein each flow meter is connected to a fluid injector, and wherein each flow meter is configured to measure the flow rate of the fluid injected by the fluid injector to which it is connected; - a first control device, configured to receive a flow signal from each fluid injector and control at least the second opening position of each valve element; - a first control loop structure for each fluid injector with feedback on the flow rate injected by the fluid injector, where the first control loop structure is configured to control the flow rate Petition 870240083432, dated 09 / 30 / 2024, page 15 / 63 7 / 36 of the injected fluid acting on the first control device configured to control at least the second opening position of each valve element; where the method comprises the following steps: - To provide an equivalent dynamic model of the high-speed fluid injection system; - Enter a range of reference flow rate values; - Initiate the fluid injection process; - the flow meter connected to the aforementioned fluid injector measuring, for each fluid injector, the value of the injected flow rate, - the first control device comparing, for each fluid injector, the measured flow rate value with the range of reference flow rate values; If the flow rate value is outside the reference flow rate range, the second opening position of the fluid injector valve element is modified; If the flow rate value is within the reference flow rate range, no action will be taken.
[0020] Throughout this document, it will be understood that the quantity of fluid refers to a volume of fluid applied by the injection system or to its mass, these two quantities being linked to each other through the density of the fluid; flow rate should be understood as the temporary variation of the volume of fluid applied by the injectors, and preferably will be the magnitude controlled by the method; in this sense, the value of the volume applied by an injector can be calculated by multiplying the flow rate by the injection time.
[0021] In the technical field of the invention and, therefore, in the context of the invention, it will be understood that a dynamic model Petition 870240083432, dated 09 / 30 / 2024, page 16 / 63 8 / 36 of the system is a set of transfer functions, values, and other similar entities that allow modeling the fluid injection system. More specifically, for a particular application system, and with a specific injector and fluid configuration, the equivalent dynamic model is obtained by evaluating the influence that the second opening position of the valve element, pressure, and temperature have on the flow rate, evaluating this influence in a combined manner for the control factors. The ranges of reference or control values, as well as the rate of increase or decrease of the control factors, are therefore determined in order to obtain the desired flow rate values and be able to act on them in the most optimized way.The fluid properties are also taken into account for the equivalent dynamic model, as they are necessary to translate the flow rate into values of mass or volume of dry extract, or the quantities required depending on each type of application.
[0022] Therefore, for each specific injector and fluid application and configuration system, the system is provided with this equivalent dynamic model, since for certain desired applied product specifications, the range of reference values to be applied for each of the factors, as well as its influence on the flow rate, may vary.
[0023] Technical limitations or aspects, as well as safety and / or energy efficiency considerations, are also taken into account when providing the equivalent dynamic model because, in practice, the reference value ranges may still be restricted technically or for safety reasons. Petition 870240083432, dated 09 / 30 / 2024, page 17 / 63 9 / 36 or energy efficiency.
[0024] Given that it would be necessary to wait for the solvents to completely volatilize in order to obtain the dry extract volume value, unacceptably delaying the control process, the quantity controlled is preferably the flow rate of the fluid injected by each injector; the applied volume can therefore be measured and controlled instantaneously and this flow rate measurement can be translated, if necessary, into a dry product volume through the ratio of solvent and fluid density and the density of the dry extract.
[0025] Fluid should be understood as a substance in liquid phase which, in one embodiment, is a sealing product or fluid. In one embodiment, the sealing product is applied in liquid form and supplied to the injectors in a pressurized manner.
[0026] In one embodiment, the fluid injection system is rotary or stationary.
[0027] In one embodiment, the high-speed fluid injection system is rotary and has a cylindrical configuration with a plurality of injectors distributed along its side or periphery.
[0028] In one embodiment, the flow meters are high-precision flow meters, for example, electromagnetic flow meters. In a particular embodiment, if more than one fluid injector requires a control action, a single control action is performed for each cycle or revolution of the fluid injection system.
[0029] Advantageously, flow feedback control allows controlling the amount of fluid injected. Petition 870240083432, dated 09 / 30 / 2024, page 18 / 63 10 / 36 in a continuous, faster and more precise manner than known control systems in the state of the art. In particular, the individualized control of each injector allows for quick correction of the flow rate injected by one of the injectors without having to interrupt the injection process or modify the conditions of the other injectors, obtaining a faster response speed and greater homogeneity in the amount of fluid applied.
[0030] In a particular embodiment, the fluid supply means further comprise pressure regulating means configured to modify the fluid supply pressure, wherein the fluid injection system comprises a second control device, configured to receive a signal from a range of reference values of the second opening position of each fluid injector, and a narrower, centralized range within said range of reference values of the second opening position, and to control the pressure regulating means; and where the value of the second opening position of at least one fluid injector is outside the pre-established range of values, the method also includes the step of: - Modify the fluid supply pressure.
[0031] Advantageously, pressure control allows regulating the fluid supply pressure either for the injector assembly or individually for each injector and thus modifying, collectively or individually, the flow rate injected by the fluid injectors if one or more of the valve elements are outside a range of values. Petition 870240083432, dated 09 / 30 / 2024, page 19 / 63 11 / 36 of reference, which, in one example, could be the range of values in which the injector response is effective and linear, or nearly linear, and is also within the reference flow rate range. Therefore, if the value of the second opening position is a value that is outside the reference range, then the method involves modifying the pressure so that, in practice, the valve elements are never outside the range.
[0032] In a particular embodiment, if the average value of the second opening position of all fluid injectors is outside the narrower, more centralized range of reference values, the method further comprises the step of: - Modify the fluid supply pressure.
[0033] Advantageously, modifying the supply pressure allows regulating, jointly or individually, the flow rate of the fluid injected by the injectors if the average value of their opening positions is above or below a range, preferably a narrow centralized range of values within the average value of the linear or effective behavior range of the fluid injectors; the control of the valve element can therefore be maintained within the most advantageous range of values.
[0034] The use of a narrower and more centralized range within the reference value range of the second opening position allows the second control device better control, since there is more room for maneuver in both directions, i.e., for opening to a greater and lesser extent.
[0035] In a particular embodiment, the fluid supply means also comprise regulating means. Petition 870240083432, dated 09 / 30 / 2024, page 20 / 63 12 / 36 temperature settings configured to modify the fluid supply temperature, and wherein the fluid injection system comprises a third control device; wherein the third control device is further configured to receive a signal from the fluid supply pressure, a range of reference values for the fluid supply pressure, and to control the means of temperature regulation; If the fluid supply pressure value is outside the reference pressure range, the method also includes the step of: - modify the fluid supply temperature by initially increasing the temperature.
[0036] Advantageously, temperature control allows for the regulation, either jointly or individually, of the fluid injection flow rate if the pressure is above or below the reference range, thus maintaining pressure control within the most advantageous range of values. In this sense, if the supply pressure value is outside the reference range, then the method consists of modifying the temperature, so that in practice the supply pressure will never be outside the range.
[0037] In a particular embodiment, if the value of the fluid supply pressure is outside a second range of reference values that is narrower than the first range of pressure values, the method further comprises the step of: - modify the fluid supply temperature by a second increase that is less than the first increase of Petition 870240083432, dated 09 / 30 / 2024, page 21 / 63 13 / 36 temperature.
[0038] In a particular embodiment, the second range of reference values is centered on a value different from the first range of reference values.
[0039] Advantageously, establishing a narrower range of values allows for more precise control actions to maintain the pressure value close to the reference value.
[0040] In a particular embodiment, the valve element of the fluid injectors is a needle configured to be moved longitudinally, blocking a nozzle of the fluid injector, and wherein the control method further comprises the step of: — Initialize each fluid injector using the following steps: Move the limit switch to the closed position of the needle, so that the needle has no room for movement; move the adjustable limit switch to the open position until fluid injection begins with the needle open; move the limit switch to the open position until it reaches the midpoint of the control range determined for the second open position.
[0041] Advantageously, the needle-shaped valve element allows regulating a range of injection flow rates by means of the amplitude of the needle's longitudinal movement within its range of motion or stroke. This range of motion is fixed by an adjustable limit stop or stop. Also advantageously, in this embodiment, the method allows Petition 870240083432, dated 09 / 30 / 2024, page 22 / 63 14 / 36 determine the final positions of the needle stroke which are used to determine the range of reference values for the needle end-of-stroke position, where the needle has an effective and linear or near-linear influence on the injected flow rate.
[0042] In a particular embodiment, the first control device is further configured to maintain the opening position within the average value of the opening position reference range.
[0043] Therefore, by being equidistant from the extreme values of the valve element position, better control capability is provided, since there is freedom of movement in both directions, that is, both for opening to a greater extent, i.e., greater flow, and for opening to a smaller extent, i.e., less flow.
[0044] In a particular embodiment, the method comprises the use of a low-pass filter to filter the flow meter measurements. In one embodiment, the low-pass filter for filtering the flow meter measurements is a weighted moving average filter.
[0045] Advantageously, the incorporation of a low-pass filter, and particularly a weighted moving average filter, makes it possible to eliminate flow measurement interference and improve the stability of the control method.
[0046] In a second inventive aspect, the invention provides a high-speed fluid injection system configured to implement a control method according to the first inventive aspect, comprising: - a plurality of fluid injectors, each fluid injector comprising a movable valve element between Petition 870240083432, dated 09 / 30 / 2024, page 23 / 63 15 / 36 a first closed position and a second open position, wherein the second open position of each valve element can be individually controlled to regulate the flow rate injected by each fluid injector; - Fluid supply means configured to supply pressurized fluid to a plurality of fluid injectors; - a plurality of flow meters, wherein each flow meter is connected to a fluid injector, and wherein each flow meter is configured to measure the flow rate of the fluid injected by the fluid injector to which it is connected; - a first control device, configured to receive a flow signal from each fluid injector and to control at least the second opening position of each valve element; - a first control repetition structure with feedback of the flow rate injected by each fluid injector, wherein the first control repetition structure is configured to control the flow rate of the fluid injected by the fluid injector acting on the first control device configured to control at least the second opening position of each valve element.
[0047] Advantageously, the fluid injection system comprises the elements necessary to implement the control method of the first inventive aspect.
[0048] In one embodiment, the fluid injection system (Ll) is rotary or stationary.
[0049] In a particular embodiment, the fluid supply means comprise pressure regulating means configured to modify the supply pressure. Petition 870240083432, dated 09 / 30 / 2024, page 24 / 63 16 / 36 fluid, wherein the injection system comprises a second control device configured to control the fluid supply pressure and wherein the system further comprises a second control repeater structure, wherein the second control repeater structure is configured to control at least the fluid supply pressure.
[0050] Advantageously, pressure regulating means transform a pressure control signal into a physical pressure variation in the fluid supply means. In one particular embodiment, the pressure regulating means act by means of constriction of a valve and in another embodiment by means of supplying a compressed fluid. Also advantageously, the second control device allows regulating the injected flow rate by regulating a parameter different from the parameter regulated by the first control device.
[0051] In one embodiment, the second control device is physically attached to the first control device.
[0052] In a particular embodiment, the fluid supply means further comprise temperature regulation means configured to modify the fluid supply temperature, wherein the injection system comprises a third control device configured to control the fluid temperature by means of a signal to control the fluid temperature, and wherein the system further comprises a third control repetition structure, wherein the third control repetition structure is configured to control at least the fluid temperature. Petition 870240083432, dated 09 / 30 / 2024, page 25 / 63 17 / 36
[0053] Advantageously, temperature control means transform a temperature control signal into a physical variation in the temperature of the fluid in the fluid supply media.
[0054] In one embodiment, the third control device is physically attached to the first and second control devices.
[0055] In one embodiment, the flow meters and control devices are arranged on a platform separate from the platform or support that contains the injectors. Both platforms may move together or remain static, depending on whether the application system is rotary or stationary.
[0056] In one embodiment, one or more of the control devices are located outside the platform containing the flow meters, and two or more of the components comprising the high-speed fluid injection system communicate with each other wirelessly.
[0057] In a particular embodiment, the first control device comprises a proportional, integral and / or derivative controller.
[0058] Advantageously, a PID controller allows establishing a stable and efficient feedback flow control repetition structure.
[0059] In a particular embodiment, the valve element of fluid injectors is a needle configured to be moved longitudinally, blocking a fluid injector nozzle.
[0060] Advantageously, a needle-shaped valve element allows for very precise adjustment of both the Petition 870240083432, dated 09 / 30 / 2024, page 26 / 63 18 / 36 opening as the closing of fluid injectors, and effectively modify the flow rate as a function of the movement it performs.
[0061] In a particular embodiment, the pressure regulating means comprise a pressure regulating valve disposed at an inlet or outlet of the fluid supply means.
[0062] Advantageously, a pressure regulating valve allows for easy and effective control of fluid supply pressure.
[0063] In a particular embodiment, the temperature regulation means configured to regulate the fluid temperature comprise heated hoses and / or thermostated tanks.
[0064] Advantageously, heated hoses allow the fluid temperature to be maintained as the fluid passes through the conduit; also advantageously, thermostated tanks allow the fluid temperature to be maintained around a reference value.
[0065] In a third inventive aspect, the invention provides a monitoring system for an injection system according to the second inventive aspect, comprising a real-time monitoring device configured to transmit at least the quantities measured by the injection system.
[0066] Advantageously, the monitoring system allows the values and magnitudes of the control system to be displayed to an operator, so that the operator can receive information about the fluid injection process at all times.
[0067] In a particular embodiment, the system comprises Petition 870240083432, dated 09 / 30 / 2024, page 27 / 63 19 / 36 also a communication port for bidirectional transmission between the real-time monitoring device and the display media to show the transmitted data to an operator, and the encapsulation and decapsulation of the transmitted data between the real-time monitoring device and the display media.
[0068] Advantageously, the communication port allows for secure bidirectional communication; in particular, it allows an operator to enter reference values, as well as view adjustment parameters and results.
[0069] In a particular embodiment, the real-time monitoring device is also configured for block transmission of data recorded by the injection system.
[0070] Advantageously, the transmission of the set of values measured by the system allows the data to be used in a subsequent analysis performed by an external element, such as a computer.
[0071] All the features and / or steps of the method described in this specification (including the claims, description and drawings) may be combined in any combination, except for combinations of such features that are mutually exclusive. DESCRIPTION OF THE DRAWINGS
[0072] These and other features and advantages of the invention will become more evident based on the following detailed description of a preferred embodiment given only by way of illustrative and non-limiting example with reference to the accompanying figures. Petition 870240083432, dated 09 / 30 / 2024, page 28 / 63 20 / 36 Figure 1a This figure shows one embodiment of the control method with a flow feedback loop structure. Figure 1b This figure shows one embodiment of the control method with pressure control. Figure 1c This figure shows one embodiment of the control method with temperature control. Figure 2 This figure illustrates one embodiment of the rotary high-speed fluid injection system. Figure 3 This figure shows one mode of the monitoring system. Figure 4 This figure shows one embodiment of the stationary high-speed fluid injection system. Figure 5 This figure shows one embodiment of the stationary high-speed fluid injection system with pressure and temperature control. Figure 6a This figure shows another embodiment of the control method with a pressure flow feedback loop structure. Figure 6b This figure shows one embodiment of the control method from the previous figure with temperature control. Figure 7a This figure illustrates another embodiment of the stationary high-velocity fluid injection system. Figure 7b This figure shows one embodiment of the stationary fluid injection system from the previous figure with additional temperature control. Figure 8 This figure shows a graph of the flow rate evolution based on the second opening position of the valve element for a given configuration. Figure 9 This figure shows the process capability of Petition 870240083432, dated 09 / 30 / 2024, page 29 / 63 21 / 36 fluid application with a traditional system. Figure 10 This figure shows the capability of the fluid application process with the method and system of the simplest embodiment of the invention. DETAILED DESCRIPTION OF THE INVENTION A method for controlling flow rate by controlling the second opening position of the valve element (V), pressure (P), and temperature (T).
[0073] The present invention provides a precise and continuous control method for controlling the amount of fluid injected by a high-speed fluid injection system (1), using the flow rate (Q) of the injected fluid as the control variable.
[0074] In the simplest embodiment of the invention, this is achieved by means of a rotary system (1) as shown in Figure 2, comprising a control device (6), a plurality of adjustable fluid injectors (2) with their respective flow meters (5) and fluid feed means (4) supplying pressurized fluid, wherein the flow values (Q) measured by the flow meters (5) are compared with a given range of reference flow values (QA-QB), and if the flow value (Q) is outside the range of reference values (QA-QB), the control device (6) emits a control signal to the out-of-specification fluid injectors (2) to modify the final position (V) of the needle stroke (3) which has an effect on the flow rate (Q) of the injected fluid. The first control repeating structure (L1) is thus configured.
[0075] In the embodiment shown in Figure 2, the rotary fluid injection system (1) comprises eight injectors Petition 870240083432, dated 09 / 30 / 2024, page 30 / 63 22 / 36 of fluid (2) with needles (3) as valve elements to restrict fluid passage. In a particular example, the fluid feed means (4) are a pressurized tank supplying pressurized fluid.
[0076] The preferred type of injectors (2) comprises a needle valve (3) that deposits the fluid into the application area when it opens; the injector (2) is closed by means of this needle (3) which closes against a nozzle with a small diameter opening (generally between 0.4 mm and 2.0 mm) when it moves downwards. The needle (3), which normally blocks the nozzle opening, moves (or is raised) when the fluid is to be applied as a result of an actuator which may be, for example, a solenoid or pneumatic valve. The injector receives an opening signal when a part is detected in the application area and remains open for the specific period of time required to ensure correct fluid application.
[0077] The maximum height to which the needle (3) is raised upon receiving the opening signal is modified by means of the movement of a stop that limits the longitudinal movement of the needle, so that the stroke of the needle (3) can be regulated. The free distance between the tip of the needle (3) and the nozzle therefore depends on the length of the needle stroke and, consequently, on the effective section of the nozzle which regulates the amount of fluid that is injected.
[0078] In practice, for each injector configuration in which the needle type and nozzle type can be varied, the range of the needle stroke in which the needle elevation has an effective influence on the flow rate of the applied fluid and in which the response is linear or nearly linear must be determined. Petition 870240083432, dated 09 / 30 / 2024, page 31 / 63 23 / 36
[0079] The mechanisms used to adjust the needle end-of-stroke in these injectors include movable stops that are adjusted manually or by means of motors such as, for example, stepped motors arranged in the injectors themselves (2). The motors allow adjustment of the maximum needle lift to be controlled remotely.
[0080] For many needle-nozzle configurations, the variation in the needle stroke (3) only influences the injected flow rate (Q) in the range of 0 to 1.50 mm; beyond this range, the needle elevation (3) has no influence on the amount of fluid applied. The most common injectors in the industry would have a stroke equivalent to about ten passes, giving rise to the range of [25, 35] within which the injector (2) can be effectively controlled.
[0081] Figure 8 shows the graph of the flow rate (Q) evolution based on the second opening position (V) of the valve element (3) for the case in which the injector (2) is a solenoid-operated needle injector, with the solenoid itself being the end of the stroke. This type of injector is the most widely used in industry.
[0082] It can be observed in the aforementioned graph that, with the end of the course at the lowest point, there is no flow (Q=0). Then, after the needle is raised to a certain point (Vi), the flow is still not obtained (Q=0), since the needle has not been raised sufficiently.
[0083] Subsequently, after passing the elevation point Vi, the flow rate (Q^0) begins to flow, that is, it is the position of the needle (V) where it already has an influence on the flow rate (Q). In this area, the flow is still uncertain and unstable, as can be seen in Figure 8. Petition 870240083432, dated 09 / 30 / 2024, page 32 / 63 24 / 36
[0084] By raising the needle (V) even further, the area where the response is effective is reached, that is, it has an influence on the flow rate (Q), and is almost linear. It is verified that the flow rate range QA-QB, corresponding to the flow rate specifications for the particular application process, is within this response area, and the range of reference values VA-VB that corresponds to or is within the QA-QB response area is selected.
[0085] In a particular case, a narrower and more centralized range of VC-VD reference values within the VA-VB reference value range is selected.
[0086] At very high needle lift position values (V), the flow rate (Q) is stabilized and even drops because, as the solenoid itself is at the end of its stroke, it will no longer be able to exert any influence to lift the needle when it is too far from it. In this area, the system is saturated or provides no response.
[0087] In this sense, the system is unstable for values below the effective and almost linear response area, and the system is saturated for values above it. Therefore, the VA-VB range is selected within this area as the effective value control range. The slope of the curve within the VA-VB area determines the instructions or speed that apply when the needle position (V) is actuated to obtain a desired variation in flow rate (Q). When the equivalent dynamic model is obtained, the evaluation of the influence of pressure (P) and temperature (T) on flow rate (Q) is also performed similarly with the same objective, determining the reference value ranges, as well as the instructions to increase and decrease these control parameters. Petition 870240083432, dated 09 / 30 / 2024, page 33 / 63 25 / 36
[0088] The sealing fluid is supplied to the injectors by means of a pump or pressurized tank (4), so that the injectors (2) receive a constant supply of fluid at a pressure higher than atmospheric pressure.
[0089] Generally, the amount of fluid injected can be expressed in the form of injected flow rate (Q), which is a function of the fluid exit velocity at the injector outlet (2); the fluid exit velocity depends, among other factors, on: - Supply pressure (P): the higher the pressure, the higher the outlet velocity. - The effective cross-section and internal geometry of the nozzle: the larger the effective cross-section of the outlet opening and the larger the internal volume of the nozzle, the greater the velocity. - Needle height (V): the higher the needle or stroke, the greater the speed. - Fluid viscosity: the lower the fluid viscosity, the higher the exit velocity. For an injection process with a fixed injector opening time, the fluid outlet velocity must be modified to regulate the amount to be applied. In a controlled process, the fluid viscosity and nozzle configuration are fixed parameters, and therefore, the needle height (V), pressure (P), and temperature (T) are regulated to adjust the amount of fluid to be applied. An increase in pressure (P) and / or needle height (V) and / or temperature (T) will increase the amount of fluid applied, while a reduction in pressure (P) and / or reduction in needle stroke (V) and / or temperature (T) will cause a reduction in the injected flow rate. In practice, viscosity is not always fixed, since... Petition 870240083432, dated 09 / 30 / 2024, page 34 / 63 26 / 36 Fluid composition may vary between batches and products and, in addition, the temperature (T) of the fluid affects the viscosity of most fluids. Furthermore, injector components (2), such as the nozzle, may wear out over time and affect the fluid exit velocity.
[0090] Figure 1a shows a diagram of the simplest embodiment of the first control repetition structure (L1) of the system (1); this embodiment comprises a first control repetition structure (L1) of the injected flow rate with feedback of the flow rate (Q). This repetition structure (L1) is implemented by means of a plurality of PID controllers, one for each fluid injector (2), and represented as part of the first control device (6).
[0091] A flow rate (Q) signal from the corresponding flow meter (5) is fed to each controller (6) of the plurality of PID controllers, and this signal is compared with the determined range of reference flow rate values (QA-QB), and if the flow rate (Q) value is below the range of reference values (QA-QB), the controller (6) sends a signal to activate the injector mechanism (2) which moves the needle end stop (3) the required distance, thus increasing the needle stroke. For the particular case in which the injector mechanism (2) is a stepped motor, the controller (6) sends a signal to activate the stepped motor of the injector (2) which moves the needle end stop (3) the distance equivalent to one step of the motor.
[0092] In contrast, if the flow measurement is above the reference range (Qa-Qb), the controller (6) sends a signal to close the needle limit switch (3) or to Petition 870240083432, dated 09 / 30 / 2024, page 35 / 63 27 / 36 bring it closer to the injector nozzle (2), reducing the needle stroke.
[0093] The stepped values of the needle (2) movement (V) are not absolute, therefore it is necessary to establish the stepped values between which the needle (3) allows fluid to exit and from which the flow rate no longer increases in order to obtain the system control band. Within this control band, the value of the needle (3) elevation (V), being in the intermediate position of the range, is prioritized by the controller (6), provided the process allows it. Therefore, it is less likely that a control action will take the needle (3) to the limit of the control range.
[0094] For both the one shown in Figure 1a and any of the described embodiments, the PID controllers can be physical devices arranged in communication with the injector actuator (2), or virtual devices implemented by one or more control devices (6), for example, by means of a computer or programmable logic controller which implements eight control repetition structures with their respective inputs and outputs.
[0095] Figure 1b shows an improvement on the previous embodiment of the first control repetition structure (L1), in which the system (1) comprises a second control repetition structure (L2) to regulate the pressure (P) of the system (1). In this embodiment, the system (1) comprises a second control device (6.1) which is fed with the set of values of the second opening position (V) of the needles (3) of all injectors (2). If the second control device (6.1) detects that one of the values of the second position (V) of the needles (3) is outside the range of Petition 870240083432, dated 09 / 30 / 2024, pp. 36 / 63 28 / 36 control of reference values Va - Vb, the control device (6.1) sends a control signal to the pressure regulating means (7) to modify the fluid supply pressure (P); this variation results in a variation in the fluid outlet velocity of the injectors (2), which is equivalent to modifying the injection flow rate (Q).
[0096] A flow control (Q) is thus implemented for cases in which the regulation of the injectors (2) is not possible.
[0097] Another capability of the second control repetition structure (L2) is to determine if the average of the values of the second opening position (V) is outside a narrower centralized range of reference values Vc — Vd within the value of the opening position (V). If this condition is met, the second control device (6.1) sends a signal to modify the fluid supply pressure (P) and force a correction of the opening positions (V) in order to bring the average closer to the average value of the range.
[0098] The second control device (6.1) can be implemented by means of an industrial computer, a programmable logic controller or a similar device. In an embodiment not shown, the physical device corresponding to the second control device (6.1) is the same as the physical device in which the first control device (6) is implemented. In turn, the pressure regulation means (7) are conventional means for regulating fluid pressure, such as controlled valves.
[0099] Figure 1c shows another embodiment in which a third control repetition structure (L3) is added. Petition 870240083432, dated 09 / 30 / 2024, page 37 / 63 29 / 36 to the mode shown in Figure 1b. In this mode, the system (1) includes a third control device (6.2) which is fed with a supply pressure value (P). If the supply pressure (P) is outside a range of reference pressure values (Pa - Pb), the third control device (6.2) sends a control signal to the temperature regulating medium (9) to modify the temperature (T). A variation in temperature (T) will affect the viscosity of the fluid, whose velocity, in turn, will be modified; the third control repeater structure (L3) therefore allows modifying the injected flow rate (Q).
[0100] The third control device (6.2) can be implemented by means of an industrial computer, a programmable logic controller or a similar device. In an embodiment not shown, the physical device corresponding to the third control device (6.2) is the same as the physical device in which the first control device (6) and the second control device (6.1) are implemented. In turn, the temperature regulating means (9) are conventional temperature regulation means, such as heated hoses or thermostated tanks.
[0101] Figure 3 shows one embodiment of the monitoring system (10). The purpose of this monitoring system (10) is to record operating data of the system control method (1) and securely send said data to a user so that this information can be processed. In addition to the real-time presentation of information related to control variables, such as the position (V) of each needle (3), pressure (P) and temperature Petition 870240083432, dated 09 / 30 / 2024, page 38 / 63 30 / 36 supply (T), fault alarms, etc., the monitoring system (10) allows the user to modify the reference values of any of the variables or manually cancel some or all of the control repetition structures. In this sense, the monitoring system (10) includes a communication port to ensure secure bidirectional communication.
[0102] Unlike the embodiment shown in Figure 2 in which the fluid injection system (1) was a rotary system, the fluid injection system (1) in Figure 4 is stationary. In this embodiment, the system comprises one or more fixed injectors (2) and the caps are those that move in an indexed manner, remaining in the application station for the time corresponding to being treated by the injector (2). The system comprises a first control repeater structure (L1) configured to control the flow rate of the injected fluid acting on the first control device (6) configured to control at least the second opening position (V) of each valve element.
[0103] Figure 5 shows an embodiment that is improved over that shown in Figure 4, in which a second control repeater structure (L2) configured to control at least the fluid supply pressure and a third control repeater structure (L3) configured to control the fluid supply temperature are included.
[0104] With the exception of those incompatible or mutually exclusive modalities, all the particularities indicated above for the rotary injection system are applicable to this stationary injection system. Petition 870240083432, dated 09 / 30 / 2024, page 39 / 63 31 / 36 A control method for controlling flow rate by controlling pressure (P) and temperature (T).
[0105] The invention also provides a precise and continuous control method for controlling the amount of fluid injected by a high-speed fluid injection system (1), when the flow rate (Q) of the injected fluid cannot be controlled remotely by means of fluid injectors (2), i.e., when the flow rate (Q) cannot be controlled by means of controlling the second opening position of the valve element (V) of the fluid injectors (2) remotely.
[0106] In the simplest embodiment of the invention, this is achieved by means of a system (1A) as shown in Figure 7a, comprising a control device (6.1), a plurality of non-regulatable fluid injectors (2) with their respective flow meters (5) and fluid feed means (4) supplying pressurized fluid, wherein the flow values (Q) measured by the flow meters (5) are compared with a given range of reference flow values (QA-QB), and if the flow value (Q) is outside the range of reference values (QA-QB), the control device (6.1) sends a control signal to the pressure regulating means (7) to modify the fluid supply pressure to the fluid injectors (2), which has an effect on the flow rate (Q) of the injected fluid. The first control repeating structure (L1*) is thus configured.
[0107] Figure 7b shows an improvement on the previous modality, in which a second control repetition structure (L2*) is added to the modality shown in Figure Petition 870240083432, dated 09 / 30 / 2024, page 40 / 63 32 / 36 6a. In this embodiment, the system (1A) includes a second control device (6.2) which is fed with a supply pressure value (P). If the supply pressure (P) is outside a certain range of reference pressure values (Pa - Pb), the second control device (6.2) sends a control signal to the temperature regulating medium (9) to modify the temperature (T). A variation in temperature (T) will affect the viscosity of the fluid, whose velocity, in turn, will be modified; the second control repeater structure (L2*) therefore allows modifying the injected flow rate (Q). The configuration of this second control repeater structure (L2*) is shown in Figure 7b.
[0108] Similarly, all the particulars indicated in the previous embodiments for the control method for controlling the flow rate by controlling the second opening position of the valve element (V), pressure (P) and temperature (T) are applicable to the present control method for controlling the flow rate by controlling pressure (P) and temperature (T), except for those embodiments that are incompatible or mutually exclusive. Results of experimental data - Control method for high-speed flow control by means of controlling the second opening position of the valve element (V) and pressure (P).
[0109] The results of the experimental data explained below and shown in figures 9 and 10 correspond to the embodiment of the invention by means of a rotary system (1) as shown in Figure 5 without temperature control, i.e., only by means of the second control. Petition 870240083432, dated 09 / 30 / 2024, page 41 / 63 33 / 36 valve element opening position (V) and pressure (P). Figure 1b shows the control repeater structures of this system mode (1).
[0110] The tests were carried out on a water-based sealant application machine for metal packaging lids. The application machine is a rotary type machine with 8 adjustable fluid injectors (application guns) that applies water-based sealant at 2100 lids per minute, with an application time per lid of 50ms.
[0111] The dry weight specification of the applied water-based sealant is 19 mg at the lower limit and 29 mg at the upper limit.
[0112] As shown in figures 5 and 1b, the application equipment consists of a control device (6), eight adjustable fluid injectors (2) with their respective flow meters (5), and a pressurized tank (4) supplying pressurized fluid (water-based sealant), wherein the flow values (Q) measured by the flow meters (5) are compared with a given range of reference flow values (QA-QB), and if the flow value (Q) is outside the range of reference values (QA-QB), the control device (6) sends a control signal to the out-of-specification fluid injectors (2) to modify the final position (V) of the needle stroke (3) which has an effect on the flow rate (Q) of the injected fluid. The first control repetition structure (L1) is thus configured.
[0113] In addition to the first control repetition structure (L1), this system mode (1) comprises a second control repetition structure (L2) to regulate Petition 870240083432, dated 09 / 30 / 2024, pp. 42 / 63 34 / 36 the system pressure (P) (1). In this embodiment, the system (1) comprises a second control device (6.1) which is fed with the set of values of the second opening position (V) of the needles (3) of all injectors (2). If the second control device (6.1) detects that one of the values of the second position (V) of the needles (3) is outside the control range of the reference values Va - Vb, the control device (6.1) sends a control signal to the pressure regulating means (7) to modify the fluid supply pressure (P); this variation results in a variation in the fluid outlet velocity of the injectors (2), which is equivalent to modifying the injection flow rate (Q).
[0114] With this method, a flow control (Q) is thus implemented for cases in which the regulation of the injectors (2), i.e., the regulation of the final position (V) of the needle stroke (3), is not possible.
[0115] The results show the capability analysis of the high-speed application process with traditional control versus the application process using the detailed embodiment of the control method and system of the present invention.
[0116] In figures 9 and 10, the following parameters are used: LSL = Lower Specification Limit (dry weight specification of the applied water-based sealant) USL = Upper Specification Limit (dry weight specification of the applied water-based sealant) Sample N = sample number PPM = Defective Parts per Million Pp, PpL, PpU, Ppk and Cpm = Overall capacity indices Petition 870240083432, dated 09 / 30 / 2024, pp. 43 / 63 35 / 36 of the process Cp, CpL, CpU and Cpk = Potential process capability indices.
[0117] More specifically: - Cp or Pp = (USL - LSL) / 6*StDev ^ >1 means: The process is narrower than the established limits. - CPU or PPU = (USL - Target) / 3 * StDev ^ <1 means: The upper limit is exceeded - CPL or PPL = (Target - LSL) / 3 * StDev ^ <1 means: The lower limit is exceeded - Cpk or Ppk = min{CPU,CPL} ^ <1 means: The process violates at least one of the limits.
[0118] Furthermore, following the industry's Six Sigma standards (Six Sigma comes from statistics, specifically from the area of statistical quality control, which assesses process capability): - Ppk < 1 Process out of control, not centralized and out of specification - PpK > 2 World-class process with six sigma quality.
[0119] Thus, figure 9 shows the capability analysis of the high-speed application process with traditional control and figure 10 shows the capability analysis of the high-speed application process using the control method and the system of the aforementioned modality.
[0120] As shown in Figure 9, the long-term capability index Ppk for the application process is 0.72. This Ppk index indicates that the process is out of control, resulting in a high rate of defective (out-of-specification) parts with a PPM of 23,412.20, which Petition 870240083432, dated 09 / 30 / 2024, pp. 44 / 63 36 / 36 means that for every million caps applied, more than 23,000 caps are defective.
[0121] However, as can be seen in Figure 10, by applying the control method and system of the aforementioned embodiment of the present invention, it is possible to considerably improve the capability of the application process by significantly reducing the variability of applied weights (fluids), increasing the Ppk to 3.28 and decreasing the rate of defective parts to 0. Petition 870240083432, dated 09 / 30 / 2024, pages 45 / 63
Claims
1 / 8 CLAIMS 1. A method for controlling the amount of fluid applied to a container component surface by a high-speed fluid injection system (1), the method CHARACTERIZED in that the injection system (1) comprises: - a plurality of fluid injectors (2) configured to apply fluid to a container component surface, each fluid injector (2) comprising a valve element (3) movable between a first closed position and a second open position (V), wherein the second open position (V) of each valve element (3) can be individually controlled to regulate the flow rate (Q) injected by each fluid injector (2); - fluid supply means (4) configured to supply pressurized fluid to the plurality of fluid injectors (2);- a plurality of flow meters (5), wherein each flow meter (5) is connected to a fluid injector (2), and wherein each flow meter (5) is configured to measure the flow rate (Q) of the fluid injected by the fluid injector (2) to which it is connected; - a first control device (6), configured to receive a signal of the flow rate (Q) from each fluid injector (2) and to control at least the second opening position (V) of each valve element (3); - a first control repetition structure (L1) for each fluid injector (2) with feedback of the flow rate (Q) injected by the fluid injector (2), wherein the first control repetition structure (L1) is configured for Petition 870260080846, dated 11 / 08 / 2026, page. 9 / 24 2 / 8 control the flow rate (Q) of the injected fluid by acting on the first control device (6) configured to control at least the second opening position (V) of each valve element (3);wherein the method comprises the steps of: - providing an equivalent dynamic model of the high-speed fluid injection system (1); - entering a range of reference flow values (QA - Qb); - initiating the fluid injection process; - the flow meter (5) connected to said fluid injector (2) measuring, for each fluid injector (2), the injected flow value (Q); - the first control device (6) comparing, for each fluid injector (2), the measured flow value (Q) with the range of reference flow values (Qa - Qb); if the flow value (Q) is outside the range of reference flow values (QA - QB), the second opening position (V) of the valve element (3) of the fluid injector (2) is modified; If the flow rate (Q) value is within the reference flow rate range (QA - QB), no action will be taken.
2. Control method for a fluid injection system (1), according to claim 1, CHARACTERIZED in that the fluid injection system (1) is rotary or stationary.
3. Control method for a fluid injection system (1), according to claim 2, CHARACTERIZED in that: Petition 870260080846, dated 11 / 08 / 2026, page 10 / 24 3 / 8 wherein the fluid supply means (4) further comprise pressure regulating means (7) configured to modify the fluid supply pressure (P), wherein the fluid injection system (1) comprises a second control device (6.1), configured to receive a signal from a range of reference values of the second opening position (VA - VB) of each fluid injector (2), and a narrower and more centralized range (Vc — Vd) within the said range of reference values of the second opening position (Va - Vb), and to control the pressure regulation means (7); and wherein if the value of the second opening position (V) of at least one fluid injector (2) is outside the range of reference values of the second opening position (Va - Vb), the method further comprises the step of: - modifying the fluid supply pressure (P).
4. Control method for a fluid injection system (1), according to claim 3, CHARACTERIZED in that if the average value of the second opening position (V) of all fluid injectors (2) is outside the narrower and more centralized range of reference values (Vc — Vd), the method further comprises the step of: - modifying the fluid supply pressure (P).
5. Control method for a fluid injection system (1) according to claim 3 or 4, CHARACTERIZED in that: wherein the fluid supply means (4) further comprise temperature regulation means (9) configured to modify the fluid supply temperature (T), and wherein the fluid injection system (1) comprises a third control device (6.2); wherein the third control device (6.2) is further configured to receive a signal from the fluid supply pressure (P), a range of reference values of the fluid supply pressure (PA - PB), and to control the temperature regulation means (9); whereby, if the value of the fluid supply pressure (P) is outside the range of reference pressure values (PA - PB), the method further comprises the step of: - modifying the fluid supply temperature (T) by first increasing the temperature (T).
6. Control method for a fluid injection system (1), according to any one of claims 1 to 5, CHARACTERIZED in that the valve element (3) of the fluid injectors (2) is a needle configured to be moved longitudinally, blocking a nozzle of the fluid injector (2), and in which the second opening position (V) of the valve element (3) is determined by an adjustable limit switch and in which the control method further comprises the step of: - initializing each fluid injector (2) by means of the steps of: moving the limit switch to the closed position of the needle, so that the needle has no margin of movement, moving the adjustable limit switch to the open position until fluid injection begins with the needle open (Q Φ 0), moving the limit switch to the open position until reaching the midpoint of the control range determined for the second opening position (V). Petition 870260080846, dated 11 / 08 / 2026, page 12 / 24 5 / 8 7. Control method for a fluid injection system (1), according to any one of claims 1 to 6, CHARACTERIZED in that it comprises the use of a low-pass filter to filter the measurement of the flow meters (5).
8. High-speed fluid injection system (1) configured to implement a control method for controlling the amount of fluid applied to a container component surface as defined in any one of claims 1 to 7, CHARACTERIZED in that it comprises: - a plurality of fluid injectors (2) configured to apply fluid to a container component surface, each fluid injector (2) comprising a valve element (3) movable between a first closed position and a second open position (V), wherein the second open position (V) of each valve element (3) can be individually controlled to regulate the flow rate (Q) injected by each fluid injector (2); - fluid supply means (4) configured to supply pressurized fluid to the plurality of fluid injectors (2);- a plurality of flow meters (5), wherein each flow meter (5) is connected to a fluid injector (2), and wherein each flow meter (5) is configured to measure the flow rate (Q) of the fluid injected by the fluid injector (2) to which it is connected; - a first control device (6), configured to receive a flow rate (Q) signal from each fluid injector (2) and control at least the second opening position (V) of each valve element (3); - a first control repetition structure (L1) with feedback of the flow rate (Q) injected by each fluid injector (2), wherein the first control repetition structure (L1) is configured to control the flow rate (Q) of the fluid injected by the fluid injector (2) acting on the first control device (6) configured to control at least the second opening position (V) of each valve element (3).; 9. High-speed fluid injection system (1), according to claim 8, CHARACTERIZED in that the fluid injection system (1) is rotary or stationary.
10. High-speed fluid injection system (1), according to claim 9, CHARACTERIZED in that the fluid supply means (4) comprise pressure regulating means (7) configured to modify the fluid supply pressure (P), wherein the injection system (1) comprises a second control device (6.1) configured to control the fluid supply pressure (P), and wherein the system (1) further comprises a second control repeating structure (L2), wherein the second control repeating structure (L2) is configured to control at least the fluid supply pressure (P).
11. High-speed fluid injection system (1), according to any one of claims 8 to 10, CHARACTERIZED in that the fluid feed means (4) further comprise temperature regulation means (9) configured to modify the fluid supply temperature (T), wherein the injection system (1) comprises a third control device (6.2) configured to control the fluid temperature (T) by means of a signal to control the fluid temperature (T), and wherein the system (1) further comprises a third control repeater structure (L3), wherein the third control repeater structure (L3) is configured to control at least the fluid temperature (T).
12. High-speed fluid injection system (1), according to any one of claims 8 to 11, CHARACTERIZED in that the first control device (6) comprises a proportional, integral and / or derivative controller.
13. High-speed fluid injection system (1), according to any one of claims 8 to 12, CHARACTERIZED in that the valve element (3) of the fluid injectors (2) is a needle configured to be moved longitudinally, blocking a nozzle of the fluid injector (2).
14. High-speed fluid injection system (1), according to any one of claims 8 to 13, CHARACTERIZED in that it comprises a monitoring system (10) comprising a real-time monitoring device of the injection system (1).
15. High-speed fluid injection system (1), according to claim 14, CHARACTERIZED in that the monitoring system (10) further comprises a communication port for bidirectional transmission between the real-time monitoring device and the display means to show the transmitted data to an operator, Petition 870260080846, dated 11 / 08 / 2026, p. 15 / 24 8 / 8 and the encapsulation and decapsulation of transmitted data between the real-time monitoring device and the display means. Petition 870260080846, dated 11 / 08 / 2026, p. 16 / 24