Air Pressure Control in Hot Melt Liquid Dispensing Systems

Abstract

Systems and methods for controlling air pressure in a hot melt liquid dispensing system are described. An example hot melt liquid dispensing system includes a pump that pumps hot melt liquid to an applicator. The hot melt liquid dispensing system also includes an air flow path that supplies pressurized air to the pump and an electronic pressure sensor associated with the air flow path. The hot melt liquid dispensing system also includes a controller that receives an electronic signal from the electronic pressure sensor indicating air pressure in the air flow path and causes adjustments to the air pressure in the air flow path based on the electronic signal from the electronic pressure sensor.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to U.S. Provisional Application No. 62 / 903,575, filed on September 20, 2019, the entire contents of which are incorporated herein by reference. Technical Field

[0003] The present disclosure relates generally to liquid dispensing and, more particularly, to air pressure control in hot melt liquid dispensing systems. Background Art

[0004] Hot melt liquid dispensing systems can be used in a variety of applications. For example, such systems can apply hot melt adhesives during the manufacturing process of disposable hygiene products. As another example, hot melt liquid dispensing systems can apply hot melt adhesives to assemble and / or seal various types of packaging, such as paper-based packaging for food and beverages.

[0005] In the example configuration of hot melt liquid dispensing system, the hot melt adhesive (or other types of hot melt material) in solid form is supplied to the melter of the reservoir and / or the grid of heating, to produce the hot melt adhesive of melting.After heating, the molten adhesive can be pumped to an applicator by a heated hose, and the applicator is sometimes referred to as dispensing " gun " or gun module, and the applicator comprises a valve and a nozzle. The molten adhesive that the applicator will provide is usually assigned to required surface or base material as a series of points or lines then. In many applications, adhesive should be applied with accurate positioning, time and volume. For example, the adhesive volume not distributed may cause bonding invalid, and the adhesive volume is too much and not only may cause material waste, and in case adhesive is applied to the surface, may also cause undesirable flow.

[0006] In some hot melt liquid dispensing systems, molten adhesive is forced to the applicator via a pump driven and / or controlled by a supply of pressurized air. Because the pump affects the pressure and flow of molten adhesive supplied to the applicator, careful control of the pressure of the air supplied to the pump is often beneficial. However, achieving improved air pressure control in hot melt liquid dispensing systems remains challenging. For example, systems that rely on manual, mechanical adjustment of air pressure can have numerous drawbacks. For example, this approach is subject to human error or operator inattention. Operators may make unauthorized changes to the air pressure or may not have received adequate training. Systems that rely on manual, mechanical pressure adjustment can also lack repeatability—even the most diligent operator cannot consistently set the air pressure to the same value with the utmost precision and accuracy. Furthermore, the location of hot melt liquid dispensing systems within production facilities can make physical access to the air pressure adjustment mechanism difficult or even dangerous due to the high-temperature components and materials present in this area.

[0007] These and other shortcomings are addressed in the present disclosure. Summary of the Invention

[0008] Disclosed herein are systems and methods for air pressure control in hot melt liquid dispensing systems.

[0009] An exemplary hot melt liquid dispensing system includes a pump configured to pump hot melt liquid to an applicator. The hot melt liquid dispensing system also includes an air flow path configured to supply pressurized air to the pump and an electronic pressure sensor associated with the air flow path. The hot melt liquid dispensing system also includes a controller configured to receive an electronic signal from the electronic pressure sensor indicating air pressure in the air flow path and cause an adjustment to the air pressure in the air flow path based on the electronic signal from the electronic pressure sensor.

[0010] In an example method for controlling air pressure in a hot melt liquid dispensing system, an electronic signal is received from an electronic pressure sensor associated with an air flow path configured to supply pressurized air to a pump of the hot melt liquid dispensing system. The electronic signal indicates air pressure in the air flow path. Based on the electronic signal from the electronic pressure sensor, an adjustment of the air pressure in the air flow path is caused.

[0011] An example controller includes one or more processors and a memory storing instructions that, when executed by the one or more processors, cause the controller to: receive an electronic signal from an electronic pressure sensor, the electronic signal indicating air pressure in an air flow path configured to supply pressurized air to a pump of a hot melt liquid dispensing system. The instructions, when executed by the one or more processors, further cause the controller to cause an adjustment of the air pressure in the air flow path based on the electronic signal from the electronic pressure sensor. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments and, together with the description, serve to explain the principles of the methods and systems:

[0013] Figure 1A shows a perspective view of an adhesive dispensing apparatus according to one embodiment of the present disclosure;

[0014] Figure 1B Shown Figure 1A an alternate perspective view of the adhesive dispensing apparatus shown;

[0015] Figure 1C Shown Figure 1A Another alternative perspective view of the adhesive dispensing apparatus is shown;

[0016] Figure 2 Shown Figure 1A The adhesive dispensing apparatus shown is along Figure 1A A cross-sectional view taken along line 2-2 is shown;

[0017] Figure 3 Pictured Figure 1A The adhesive dispensing apparatus shown in FIG. Figure 1A An alternative cross-sectional view taken along line 3-3 shown in FIG;

[0018] Figure 4 Shown Figure 1A An alternative perspective view of the adhesive dispensing device shown in , with some of the outer cover portions hidden;

[0019] Figure 5 A schematic diagram illustrating a configuration of a hot melt liquid dispensing system according to one embodiment of the present disclosure; and

[0020] Figure 6 A method flow chart according to an embodiment of the present disclosure is illustrated.

[0021] Various aspects of the disclosure will now be described in detail with reference to the drawings, wherein like reference numerals refer to like elements throughout unless otherwise specified. DETAILED DESCRIPTION

[0022] The systems and methods of the present disclosure relate to air pressure control in hot melt liquid dispensing systems.

[0023] refer to Figures 1A-4 , shows an adhesive dispensing apparatus 10 according to one embodiment of the present invention. The adhesive dispensing apparatus 10 includes a melting module 12 and a control module 14, which is electrically and / or physically coupled to the melting module 12. The melting module 12 is configured to include components associated with receiving solid adhesive and melting the solid adhesive, while the control module 14 is configured to include electronic components for controlling the operation of the melting module 12, wherein each of the melting module 12 and the control module 14 will be described in further detail below. Each of the melting module 12 and the control module 14 can be mounted to and supported by a base 18. The base 18 can include a metal body and be configured to releasably couple to each of the melting module 12 and the control module 14, such as by fasteners that can include bolts, screws, etc., but it is contemplated that in other embodiments, the melting module 12 and the control module 14 can alternatively be coupled to the base 18.

[0024] When the melting module 12 and the control module 14 are coupled to the base 18, a thermal gap 32 can be defined between the melting module 12 and the control module 14. The thermal gap 32 can be configured to minimize and / or substantially eliminate heat transfer from the melting module 12 to the control module 14, thereby preventing heat generated by the melting module 12 from damaging electronic components contained in the control module 14. The thermal gap 32 can include a space between the melting module 12 and the control module 14. Additionally, it is contemplated that the thermal gap 32 can further include a material configured to prevent heat transfer, such as various types of insulators, although any particular type of material or structure is not required.

[0025] like Figure 1C As shown, the adhesive dispensing apparatus 10 can define a particular footprint F. The lower end of the base 18 can define the footprint F, which can be defined as the cross-sectional shape and area defined by the lower end of the base 18. Additionally or alternatively, the footprint F can be defined by the common lower end of the melting module 12 and the control module 14.

[0026] The adhesive dispensing apparatus 10 may include a melt module cover 26 and a control module cover 30, each configured to provide selective access to the melt module 12 and the control module 14, respectively. The melt module cover 26 is configured to house components of the melt module 12 and at least partially insulate the melt module 12 from the surrounding environment, while the control module cover 30 is configured to house components of the control module 14 and isolate the control module 14 from the melt module 12 and the surrounding environment. The control module cover 30 includes a top cover 31 that is removable separately from the rest of the control module cover 30. In particular, the aforementioned thermal gap 32 may be defined between the melt module cover 26 and the control module cover 30.

[0027] The control module 14 may include a controller 36 disposed within the controller housing 15. The controller 36 may include any suitable computing device configured to host software applications for monitoring and controlling the various operations of the adhesive dispensing device 10 as described herein. It should be understood that the controller 36 may include any suitable integrated circuit. Specifically, the controller 36 may include a memory and perform signal communication with the human-machine interface (HMI) device 34. The memory may be volatile (such as certain types of RAM), non-volatile (such as ROM, flash memory, etc.), or a combination thereof. The controller 36 may include additional storage (e.g., removable storage and / or non-removable storage), including but not limited to magnetic tape, flash memory, smart cards, CD-ROMs, digital versatile disks (DVDs) or other optical storage, magnetic tape, disk storage or other magnetic storage devices, universal serial bus (USB) compatible memory, or any other medium that can be used to store information and can be accessed by the controller 36. The memory of the controller 36 may be configured to store and call various metering operations to be performed by the adhesive dispensing device 10 as needed. The control module 14 may also include an electrical connector 44 extending through the control module cover 30 that may be configured to establish a connection with the applicator and / or heated hose to transmit power to the applicator and / or hose and exchange communication signals.

[0028] As described above, the control module 14 may include an HMI device 34 that communicates signals with the controller 36. In the depicted embodiment, the HMI device 34 may include a display, such as an OLED screen. However, additionally or alternatively, it is contemplated that the HMI device 34 may also include various forms of input, the input providing the ability to control the controller 36 via, for example, buttons, soft keys, a mouse, voice actuation control, a touch screen, the movement of the controller 36, visual prompts (e.g., moving a hand in front of a camera on the controller 36), etc. The HMI device 34 may provide output via a graphical user interface (comprising visual information) via a display, such as a visual indication of the current situation in the adhesive dispensing device 10, and the acceptable ranges of these parameters. Other outputs may include audio information (e.g., by a speaker), mechanically (e.g., by a vibration mechanism), or a combination thereof. In various configurations, the HMI device 34 may include a display, a touch screen, a keyboard, a mouse, a motion detector, a speaker, a microphone, a camera, or any combination thereof. The HMI device 34 may also include any suitable device for inputting biometric information, such as fingerprint information, retinal information, voice information, and / or facial feature information, for example, to require specific biometric information to access the controller 36. In addition to the HMI device 34, the control module 14 may include a pressure dial 40 for easily displaying pressure readings, such as barometric pressure readings.

[0029] In addition, the controller 36 can communicate with the remote device 38 ( Figure 1A 10 , the remote device 38 is isolated from the control module 14. In one embodiment, the remote device 38 may include a display module 14, such as an OLED display, that is separate from the control device, although various types of conventional displays are contemplated. Alternatively, the remote device 38 may include an external computing device, examples of which include a processor, a desktop computing device, a server computing device, or a portable computing device, such as a laptop, tablet, or smart phone. Thus, the remote device 38 may provide an operator with the ability to interact with and control the controller 36 at a distance from the adhesive dispensing device 10. The remote device 38 may be used as part of a cloud control system 10 for the adhesive dispensing device. The remote device 38 may include a PLC (programmable logic controller) or a factory computer.

[0030] The melting module 12 will be described in more detail. The melting module 12 includes a melter subassembly 75 that is configured to receive solid or semi-solid adhesive material pellets, either manually filled by opening the cover assembly 50 or received by an automatic filling mechanism. The melter subassembly 75 can heat the pellets to a specified temperature to form a molten adhesive. The melting module 12 can also include a pump 150 that is configured to pressurize the molten adhesive and distribute it to one or more downstream applicators 144 (in the Figure 1B Schematically shown in FIG). The applicator 144 may also be referred to as a dispensing gun. As used herein, the applicator 144 may refer to a coater module configured with a coater group.

[0031] The melting module 12 may include a manifold 140 configured to receive pressurized molten adhesive from a pump 150 and distribute the adhesive to one or more outputs 54 external to the manifold 140. Portions of the manifold 140 and the pump 150 may be integrated into a single structural component (e.g., a manifold block). For example, a portion of the fluid cavity 158 of the pump 150 may extend into such a common structural component to supply pressurized molten adhesive to portions of the manifold 140. The manifold 140 may be configured with one or more heaters 148 (e.g., heating elements) to maintain the adhesive flowing through the manifold 140 at a specified temperature. The heaters 148 may also be used to remelt any adhesive material that has cooled within the manifold 140.

[0032] The manifold 140 may include an external manifold cover 142 having an opening for the output 54. The manifold cover 142 may be integral with the manifold 140 or may be capable of being attached and detached separately. A heated hose 146 may be connected to the output 54 to receive pressurized molten adhesive from the manifold 140 and transport the adhesive to the applicator 144 for dispensing. The applicator 144 and the heated hose 146 may each be configured with one or more heaters to maintain the adhesive at a specified temperature. The heater of the applicator 144 and the heated hose 146 may also be used to remelt any adhesive material that has cooled within the component. The heater of the applicator 144 and the heated hose 146 as well as the heater 148 of the manifold 140 may communicate signals with the controller 36 to transmit status information (e.g., temperature readings) to the controller 36 and receive control signals from the controller 36. When not connected to the applicator 144, each of the multiple outputs 54 may be sealed using a plug.

[0033] Melting module 12 can include a melter subassembly 75 that can define a receiving space 94 configured to receive solid material, including melted adhesive. A top wall of melter subassembly 75 can define an opening 86 in communication with receiving space 94, such that when lid assembly 50 is pivoted to an open position, material can be manually deposited into receiving space 94 through opening 86, but when lid assembly 50 is in a closed position, lid assembly 50 can prevent adhesive from being introduced into receiving space 94 through opening 86. Receiving space 94 can be defined by a specific volume designed for a particular adhesive operation. For example, receiving space 94 can be configured to receive 4 kg of adhesive, although other sizes are contemplated.

[0034] The melter subassembly 75 may also include a level sensor 98 disposed within the receiving space 94. Specifically, the level sensor 98 may be attached to an inner surface of one of the side walls of the melter subassembly 75 and may be in signal communication with the control module 14. The level sensor 98 may include a capacitive level sensor, although other types of level sensors are also contemplated. In operation, the level sensor 98 may monitor the material level within the receiving space 94 and send a signal indicating the adhesive level to the controller 36.

[0035] The melter subassembly 75 may also include a heater 114 configured to melt the adhesive. Although described as being attached to and extending at least partially through the base of the melter subassembly 75, the heater 114 may alternatively or additionally be attached to any portion of the melter subassembly 75. It should be understood that the heater 114 may include any type of known heating device configured to melt the adhesive within the melter assembly. The melter subassembly 75 may also include a plurality of fins 118 extending upward from the base and into the receiving space 94, wherein the fins 118 are configured to be heated by the heater 114 and provide increased surface area for heating and melting the adhesive. Although a specific number, arrangement, and configuration of the fins 118 are shown, it is contemplated that the fins 118 may be alternatively configured as desired. Additionally, an outlet 122 may be defined in the base and in fluid communication with the receiving space 94, wherein the melted adhesive is configured to flow through the outlet 122 and exit the receiving space 94. Cage 130 may be positioned proximate outlet 122 , wherein cage 130 is configured to act as a filter to prevent unmelted adhesive clumps of a certain size from reaching outlet 122 , as such adhesive clumps may congeal around outlet 122 and block outlet 122 .

[0036] The passage 126 can extend from the outlet 122 to the pump 150 to supply the pump 150 with molten adhesive from the melter subassembly 75. The pump 150 can be a double-acting piston pump, but other types of pumps are also contemplated. The pump 150 can be actuated based on a pressurized air supply. The pump 150 can be operated to discharge the molten adhesive from one or more outputs 54 through the manifold 140. The pump 150 can be controlled by the controller 36 of the control module 14 to deliver a desired flow of molten adhesive through the outputs 54. The controller 36 can regulate the air supply (e.g., air pressure) to the pump 150 to at least partially achieve the desired operation of the pump 150.

[0037] Special attention Figure 4 , which shows a view of the adhesive dispensing apparatus 10 with various covers hidden, including a pressure control assembly 159 associated with air pressure control. The pressure control assembly 159 is typically (but not exclusively) housed in the space 33 defined between the top cover 31 of the control module cover 30 and the controller housing 15 (see FIG. Figure 2 ). The pressure control assembly 159 includes the regulator 172, the pressure control plate 174, the manual adjustment mechanism 160, the pressure dial 40, and various air lines (e.g., pipes or hoses) and electrical connections. It should be noted that not all electrical connections or air lines must be shown in the accompanying drawings (including the accompanying drawings). Figure 4 ) is shown in ).

[0038] Typically, regulator 172 can receive pressurized air from an external air source via input air line 162. An air filter (not shown) can be connected to the external inlet of input air line 162. The external air source can include a station air source. Regulator 172 can adjust the pressure (and / or other parameters) of the unregulated input air supply as needed and output the regulated air supply to pump air valve 168 via air line 164, pressure relief valve 170, and air line 166. Pump air valve 168 can cause actuation of pump 150. For example, in the case of a pneumatic double-acting piston pump, pump air valve 168 can direct air to the upper or lower portion of the associated cylinder to cause the piston to stroke. When the pressurized air supply is removed, such as when pump 150 is shut down, pressure relief valve 170 can allow the pressurized molten adhesive within pump 150 and manifold 140 to be bypassed back to melter subassembly 75.

[0039] As noted, the pressure control assembly 159 (or portions thereof) may generally be configured to control the pressure and / or other parameters of the pressurized air supplied to the pump 150 to cause actuation of the pump 150. The pressure control assembly 159 may be configured for automatic air pressure control via the controller 36 and / or the remote device 38. Air pressure control may additionally or alternatively be based on user input, such as user input received via the HMI device 34 or the remote device 38.

[0040] The pressure control assembly 159 can regulate the pressure of the air supplied to the pump 150 based on pressure sensor readings from one or more pressure sensors (such as pressure sensor 180) located in the air supply flow path. The one or more pressure sensors may include an electronic pressure sensor configured to output an electrical pressure signal (e.g., digital or analog), such as a digital pressure transducer sensor or a pressure-to-current (or voltage) transducer. Although in Figure 4 While not shown in the figure, the connections to the air flow path are shown, and the pressure control board 174 includes, for example, an onboard digital pressure sensor 176. The digital pressure readings may be sent to the controller 36, the pressure control board 174, and / or the regulator 172 for use in controlling the process.

[0041] The pressure of the air supply can be controlled based on a pressure measurement of the unregulated (e.g., upstream) air supply in the air flow path, such as a measurement from a pressure sensor (not shown) in the input air line 162 before the regulator 172. Additionally or alternatively, pressure control can be based on a pressure measurement in the air flow path downstream of the pressure regulating element (e.g., regulator 172). For example, pressure control can be based on a pressure measurement from a pressure sensor 180 in air line 164 and / or a pressure sensor (not shown) in air line 166. Downstream and / or upstream air pressure measurements can also be made by one or more sensors at or in the regulator 172. Downstream pressure measurements can be used to establish closed-loop control of air pressure.

[0042] Regulator 172 can control the pressure of the air supplied to pump 150 (e.g., pump air valve 168) via pressure transducer 178. Pressure transducer 178 can be configured to receive an electronic signal (e.g., analog or digital) and provide a proportional (e.g., linear) pneumatic output to the air flow path. Pressure transducer 178 can include a current-to-pressure transducer, a voltage-to-pressure transducer, or a similar device that converts an electronic signal into pressure. Although described as part of regulator 172, pressure transducer 178 can generally be located elsewhere in pressure control assembly 159 or adhesive dispensing device 10.

[0043] The regulator 172 may be configured to selectively enable or disable the downstream air supply to the pump 150. For example, the regulator 172 may be configured with a solenoid valve operable to selectively open or close the output air flow from the regulator 172.

[0044] The pressure control assembly 159 also includes a manual adjustment mechanism 160 and a pressure dial 40. The manual adjustment mechanism 160 provides an alternative method of regulating the pressure of the air supply to the pump 150. The operator can manipulate the manual adjustment mechanism 160 using a hex tool, a screwdriver, or the like to manually adjust the air pressure. The operator can observe the pressure dial 40 while doing so. However, it is noted that this manual adjustment method may present challenges in making accurate, precise, and repeatable adjustments. Physical access to the manual adjustment mechanism 160 and / or hazardous exposure to nearby heated components may also hinder such manual pressure control.

[0045] Figure 5 The diagram shows a method for hot melt liquid dispensing system (e.g., Figures 1A to 4 Schematic diagram 500 of an example air pressure control configuration for adhesive dispensing apparatus 10 and / or associated systems and devices. In the example configuration, pressurized air flow path 520 is provided from air source 502 to pump 510. Air flow path 520 passes through pressure control assembly 504 (e.g., Figure 4504) to control the pressure of the air flow path 520 to the pump 510. The portion of the air flow path 520 after the pressure control assembly 504 will be referred to as the downstream (or regulated) air flow path 520b and the portion of the air flow path 520 before the pressure control assembly 504 will be referred to as the upstream (or unregulated) air flow path 520a.

[0046] An electronic pressure sensor 508 is positioned in the downstream air flow path 520b to make pressure measurements and transmit these pressure measurements to the system controller 512 and / or the remote controller 514. The system controller 512 and / or the remote controller 514 can cause the pressure control assembly 504 to adjust the pressure of the air flow path 520 based on the downstream pressure measurements from the electronic pressure sensor 508. For example, the transducer 506 of the pressure control assembly 504 can cause an adjustment to the air pressure of the downstream air flow path 520, e.g., based on an electronic signal sent to the transducer 506.

[0047] The air source 502 may include a pressurized external air source, such as a station air source. The air source 502 may be received via an input air line of a distribution system. The upstream air flow path 520a may be received at a pressure control assembly 504. The pressure control assembly 504 may include a regulator device (e.g., Figure 4 The regulator 172 is configured to adjust the air pressure of the air flow path 520 to achieve a desired air pressure in the downstream air flow path 520b. The regulator may include a transducer 506 (e.g., Figure 4 506) can be used to adjust the air pressure in the air flow path 520. The transducer 506 can be configured to cause the adjustment of the air pressure based on an electronic signal transmitted to the transducer 506, such as from the system controller 512, the remote controller 514, or another component of the pressure control assembly 504. The transducer 506 can include a current-to-pressure transducer, a voltage-to-pressure transducer, a pressure sensor, or a similar type of sensor.

[0048] The system controller 512 and / or the remote controller 514 can receive one or more pressure measurements from the electronic pressure sensor 508. The one or more pressure measurements can be received as an electronic signal (analog or digital) generated by the electronic pressure sensor 508. The electronic signal from the electronic pressure sensor 508 can indicate the air pressure in the air flow path 520b. The electronic pressure sensor 508 can include a digital pressure transducer or a pressure-to-current (or voltage) transducer. Based on the air pressure set point (e.g., a set point range) and one or more pressure measurements from the electronic pressure sensor 508, the system controller 512 and / or the remote controller 514 can determine adjustments to the pressure entering the upstream air flow path 520a. For example, the current pressure measurement can be compared to the air pressure set point or set point range to determine the necessary adjustments, if any. Other control algorithms or techniques can be used, such as a closed-loop controller (e.g., a PID controller). The system controller 512 and / or the remote controller 514 can send an electronic signal to the pressure control assembly 504 (e.g., the transducer 506) to implement the pressure adjustment. The pressure is preferably adjusted so that the air pressure of the downstream air flow path 520b reaches the pressure set point or is within the pressure set point range.

[0049] The system controller 512 can communicate with the adhesive dispensing equipment of the dispensing system (e.g., Figure 2 and Figure 3 The system controller 512 may be integrated or connected to, but not limited to, a controller 36 of the facility. For example, the system controller 512 may include a PLC or other computing or logic device at the facility. A remote controller 514 (e.g., Figure 1A The remote controller 514 may be located external to the dispensing system. For example, the remote controller 514 may include a cloud-based or server-based controller. The remote controller 514 may include a remote personal computing device (e.g., a laptop, tablet, smartphone, or desktop computer) that communicates with the dispensing system via a cloud-based or server-based system. The remote controller 514 may include a PLC or other similar device at the facility. The various control logic, user interfaces, and other functions described herein may be implemented in varying combinations and to varying degrees by either or both of the system controller 512 and the remote controllers 514 and 514.

[0050] The system controller 512 and the remote controller 514 can provide respective user interfaces 526, 527 (e.g., graphical user interfaces) to facilitate interaction between an operator (locally or remotely) and the distribution system. For example, the user interface can enable the operator to input a gas pressure set point. By inputting the gas pressure set point through the user interface, the operator can enter the set point with a precise numerical value, rather than using the imprecise trial and error method of a mechanical adjustment mechanism and an analog pressure dial. As another example, the user interface can display the current gas pressure reading to the operator. The user interface can also display one or more past gas pressure readings. In this regard, the user interface provides higher precision and accuracy in displaying the current gas pressure reading than an analog pressure dial. The electronic pressure sensor 508 further enhances this advantage, providing more accurate and precise pressure measurements than a corresponding analog pressure sensor.

[0051] In addition, the interactive user interface on the remote controller 514 (and / or the system controller 512 in some configurations) can enable a remote operator to monitor and control the air pressure parameters (and other system parameters) of the distribution system. As described above, it may be difficult or even dangerous for an operator to physically access the manual air pressure adjustment mechanism. However, remote control via the system controller 512 and / or the remote controller 514 can largely eliminate these challenges. This arrangement can also achieve centralized control of multiple distribution systems configured in this way. Remote or off-site operators can monitor and control multiple distribution systems simultaneously through their respective remote user interfaces without having to repeatedly move from distribution system to distribution system on the production floor.

[0052] Due to the electronic nature of the pressure adjustments by the transducer 506 and the pressure measurements from the electronic pressure sensor 508, the system controller 512 and / or the remote controller 514 can effectively create and store a record of such pressure adjustments (e.g., electronic control signals to the transducer 506) and measurements (e.g., electronic signals from the electronic pressure sensor 508). A record of the air pressure set points can also be created and stored. The pressure adjustments, pressure measurements, and / or pressure set point records can be displayed on the user interface of the system controller 512 and / or the remote controller 514 for efficient operator review.

[0053] The records can also be used for various types of data analysis and control algorithms. For example, analysis of pressure adjustment records and pressure measurement records can reveal trends in the relationship between pressure adjustments and corresponding pressure measurements. This trend may indicate a system malfunction, such as a loose or leaking air hose. These records can also be used for quality control. For example, an incorrectly entered air pressure set point or a pressure measurement exceeding a threshold value may be traced back to a failed product batch. In addition, product quality control indicators can be analyzed with corresponding pressure set point, pressure adjustment, and / or pressure measurement records to identify any relevant relationships. For example, a pressure set point that has historically been associated with a high-quality product batch can be identified and reused for the same or similar operation. As described above, this identified pressure set point can be easily input through the user interface and implemented by the electronically controlled transducer 506. The above records can be implemented as logs 524 and 525 on the system controller 512 and remote controller 514, respectively.

[0054] Figure 6 A method flow chart is shown for a method 600 for controlling air pressure in a hot melt liquid dispensing system ("dispensing system"), such as a Figures 1A-4 The adhesive dispensing apparatus 10 and associated systems and components are described. Method 600 may be performed at least in part by a controller associated with the dispensing system. The controller may be a local controller or a remote controller. The dispensing system may include a pump configured to pump hot melt liquid to an applicator associated with the dispensing system. The hot melt liquid may be received from a melter of the dispensing apparatus.

[0055] The distribution system can include an air flow path configured to supply pressurized air to the pump. The air flow path can originate from an input air line that receives air from an external air source (e.g., a station air source). The air flow path can include various air lines of the distribution system and terminate at the pump. For example, the air flow path can terminate at an air valve of the pump. The pump can be pneumatically driven by pressurized air from the air flow path.

[0056] The distribution system may include an electronic pressure sensor associated with the air flow path. The electronic pressure sensor may be configured to measure the air pressure in the air flow path. The electronic pressure sensor may be configured to transmit an electronic signal indicative of the air pressure measured in the air flow path. The electronic pressure sensor may include a pressure-to-current transducer or a pressure-to-voltage transducer. The distribution system may include a pressure control assembly configured to control the pressure in the air flow path. For example, the pressure control assembly may be configured to increase or decrease the air pressure in a portion of the air flow path downstream of the pressure control assembly. The pressure control assembly may include a transducer operable to regulate the pressure in the air flow path. The transducer may include a current-to-pressure transducer or a voltage-to-pressure transducer. The transducer may be operable to regulate the air pressure based on an electronic signal transmitted to and received by the transducer.

[0057] At step 602, an air pressure set point for an air flow path is received, for example, by a controller of a distribution system. The pressure set point may be received via a user interface associated with the distribution system. For example, an operator may enter the pressure set point into the user interface. The user interface may be local to the distribution system. Additionally or alternatively, the pressure set point may be received from a remote device, such as a remote controller. The pressure set point may be received via the user interface of the remote device. The pressure set point may include a pressure set point range. In some embodiments, the pressure set point may already be set or received at the distribution system, in which case method 600 may begin at step 604.

[0058] At step 604, an electronic signal is received from an electronic pressure sensor associated with the air flow path. The electronic signal may indicate the air pressure in the air flow path. For example, the electronic signal may be received by a controller. The electronic signal may include a current or voltage signal generated based on the pressure applied to the electronic pressure sensor. The measured air pressure in the air flow path may be displayed to an operator or other interested party. For example, the air pressure may be displayed on a user interface associated with the distribution system, including a local or remote user interface.

[0059] At step 606, the air pressure in the air flow path is adjusted based on the electronic signal from the electronic pressure sensor. Additionally or alternatively, the adjustment of the air pressure can be based on an air pressure set point. For example, the adjustment can be based on a comparison of the measured air pressure in the air flow path with the pressure set point. Other control techniques can be used, such as closed-loop control (e.g., a PID controller).

[0060] The transducer of the pressure control assembly can be used to adjust the air pressure in the air flow path. The air pressure can be adjusted by transmitting an electronic control signal to the transducer. The transducer can change the pressure in the air flow path based on the received electronic control signal. The transducer can include a voltage-pressure transducer or a current-pressure transducer. Therefore, the electronic control signal can include a voltage signal or a current signal. The electronic pressure sensor can be positioned in the air flow path downstream of the transducer. Therefore, the air pressure measured by the electronic pressure sensor can be a regulated air flow (as opposed to the air flow initially received from the external air source).

[0061] The pressure adjustment and / or electronic control signal to the transducer can be displayed on a user interface. One or more of the pressure setpoint, the measured air pressure in the air flow path, the electronic signal from the electronic pressure sensor indicating the measured air pressure, the pressure adjustment, or the electronic control signal to the transducer can be recorded and stored. For example, the controller can record such data in a log stored by the controller. The log can be used for various analyses, such as diagnostic, quality control, or process control analysis.

[0062] Those skilled in the art will appreciate that the systems and methods disclosed herein can be implemented by a computing device that may include, but is not limited to, one or more processors, a system memory, and a system bus that connects various system components, including the processor to the system memory. For example, a computing device (e.g., a controller) may include one or more processors and a memory that stores instructions that, when executed by the one or more processors, implement one or more of the various methods and techniques described herein.

[0063] For illustrative purposes, applications and other executable program components (e.g., operating systems) are shown herein as discrete blocks, although it should be recognized that such programs and components reside at different times in different storage components of a computing device and are executed by the computer's data processor. The implementation of the service software can be stored on a form of computer-readable medium or transmitted via some form of computer-readable medium. Any of the disclosed methods can be executed by computer-readable instructions embodied on a computer-readable medium. A computer-readable medium can be any available medium that a computer can access. By way of example and not limitation, computer-readable media may include "computer storage media" and "communication media." "Computer storage media" includes volatile and non-volatile, removable and non-removable media implemented in any method or technology for storing information such as computer-readable instructions, data structures, program modules, or other data. Exemplary computer storage media include, but are not limited to, RAM, ROM, EEPROM, flash memory or other storage technology, CD-ROM, digital versatile disk (DVD) or other optical storage, magnetic tape, magnetic tape, disk storage or other magnetic storage devices, or any other medium that can be used to store the required information and can be accessed by a computer. Applications, etc. and / or storage media can be implemented at least in part at a remote system.

[0064] As used in the specification and the appended claims, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise. Ranges may be expressed herein as from "about" one particular value, and / or "approximately" another particular value. When such a range is expressed, another embodiment includes from the from particular value and / or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent "about," it will be understood that the particular value forms another embodiment. It will be further understood that the endpoints of each of the ranges are significant both in relation to the other endpoint, and independently of the other endpoint.

[0065] Unless expressly stated otherwise, any method described herein is not intended to be construed as requiring that its steps be performed in a specific order. Therefore, if a method claim does not actually recite the order in which its steps are to be followed, or if the claim or description does not otherwise specifically state that the steps are to be restricted to a particular order, then that order is by no means to be inferred in any respect. This applies to any possible non-express basis for interpretation, including: logical issues relating to the arrangement of steps or operational flow; plain meaning derived from grammatical organization or punctuation; or the number or type of embodiments described in the specification.

[0066] It will be apparent to those skilled in the art that various modifications and variations may be made without departing from the scope or spirit of the present invention. Other embodiments will be apparent to those skilled in the art through consideration of the specification and practice disclosed herein. It is intended that the specification and examples be considered as exemplary only, with the true scope and spirit being indicated by the appended claims.

Claims

1. A hot melt liquid dispensing system comprising: a pump configured to pump the hot melt liquid to the applicator; an air flow path configured to supply pressurized air to the pump; an electronic pressure sensor associated with the air flow path; a pressure control assembly comprising a transducer, the pressure control assembly being configured to control air pressure in an air flow path supplied to the pump, wherein the transducer is configured to cause adjustment of the air pressure in the air flow path, wherein the transducer is configured to provide a pneumatic output to the air flow path that is proportional to an electronic signal transmitted to the transducer, whereby the transducer is configured to output the adjusted air via the air flow path to the pump, and wherein the transducer comprises at least one of a current-to-pressure transducer or a voltage-to-pressure transducer; pressure relief valve; and A controller configured to: receiving an electronic signal from the electronic pressure sensor, wherein the electronic signal is indicative of air pressure in the air flow path, causing an adjustment to the air pressure in the air flow path based on the electronic signal from the electronic pressure sensor by transmitting the electronic signal to the pressure control assembly, wherein the controller causes the adjustment to the air pressure in the air flow path by transmitting the electronic signal to the transducer, wherein the electronic pressure sensor is positioned downstream of the transducer in the air flow path, wherein the regulator of the pressure control assembly is configured to adjust the pressure of an unregulated input air supply and output a regulated air supply to the pump via a first air line and a second air line, wherein the regulator and the transducer are both spaced apart from the pump, wherein the first air line is configured to fluidly connect the regulator to the pressure relief valve, and Wherein, the second air line is configured to fluidly connect the regulator to the pump.

2. The hot melt liquid dispensing system of claim 1, wherein: The pneumatic output to the air flow path is linearly proportional to the electronic signal transmitted to the transducer.

3. The hot melt liquid dispensing system of claim 1, wherein: The regulator of the pressure control assembly is configured to output a regulated air supply to a pump air valve via the first air line and the second air line.

4. The hot melt liquid dispensing system of claim 1, wherein: The controller is further configured to store at least one of the air pressure in the air flow path or an adjustment to the air pressure.

5. The hot melt liquid dispensing system of claim 1, wherein: The electronic pressure sensor includes at least one of a pressure-current transducer and a pressure-voltage transducer.

6. The hot melt liquid dispensing system of claim 1, wherein: The controller is further configured to receive an air pressure set point and to adjust the air pressure in the air flow path further based on the air pressure set point.

7. The hot melt liquid dispensing system of claim 6, wherein: The air pressure set point is received via a user interface associated with the hot melt liquid dispensing system, and the controller is configured to identify a relevant relationship by analyzing the quality control indicator with the corresponding pressure set point record, the corresponding pressure adjustment record and / or the corresponding pressure measurement value record.

8. The hot melt liquid dispensing system of claim 7, wherein: The user interface includes a user interface of a remote control device.

9. The hot melt liquid dispensing system of claim 7, wherein: The controller is further configured to cause a display of the air pressure in the air flow path via the user interface.

10. A method for controlling air pressure in a hot melt liquid dispensing system, the method comprising: receiving an electronic signal from an electronic pressure sensor, wherein the electronic signal is indicative of air pressure in an air flow path configured to supply pressurized air to a pump of the hot melt liquid dispensing system; as well as causing an adjustment of the air pressure in the air flow path based on the electronic signal from the electronic pressure sensor by transmitting an electronic signal to a pressure control assembly, wherein the pressure control assembly includes a transducer and is configured to control the air pressure in the air flow path supplied to the pump, wherein causing the adjustment of the air pressure in the air flow path includes transmitting the electronic signal to the transducer, the transducer being configured to cause the adjustment of the air pressure in the air flow path, wherein the transducer provides a pneumatic output to the air flow path that is proportional to the electronic signal transmitted to the transducer, whereby the transducer outputs the adjusted air via the air flow path to the pump, and wherein the transducer includes at least one of a current-to-pressure transducer or a voltage-to-pressure transducer. wherein the electronic pressure sensor is positioned downstream of the transducer in the air flow path, wherein the regulator of the pressure control assembly is configured to adjust the pressure of an unregulated input air supply and output a regulated air supply to the pump via a first air line and a second air line, wherein the regulator and the transducer are both spaced apart from the pump, wherein the first air line is configured to fluidly connect the regulator to a pressure relief valve, and Wherein, the second air line is configured to fluidly connect the regulator to the pump.

11. The method according to claim 10, wherein: The pneumatic output to the air flow path is linearly proportional to the electronic signal transmitted to the transducer.

12. The method of claim 10, further comprising storing at least one of the air pressure in the air flow path or an adjustment to the air pressure.

13. The method according to claim 10, further comprising: receiving an air pressure set point, wherein adjusting the air pressure in the air flow path is further performed based on the air pressure set point; and The relevant relationship is identified by analyzing the quality control indicator with the corresponding pressure set point record, the corresponding pressure adjustment record, and / or the corresponding pressure measurement value record.

14. The method according to claim 13, wherein The air pressure set point is received via a user interface associated with the hot melt liquid dispensing system.

15. The method of claim 14, further comprising causing a display of the air pressure in the air flow path via the user interface.

16. A hot melt liquid dispensing system comprising: Pressure relief valve; as well as A controller, the controller comprising: one or more processors; and a memory storing instructions that, when executed by the one or more processors, cause the controller to: receiving an electronic signal from an electronic pressure sensor, wherein the electronic signal is indicative of air pressure in an air flow path configured to supply pressurized air to a pump of a hot melt liquid dispensing system; and causing an adjustment of the air pressure in the air flow path based on the electronic signal from the electronic pressure sensor by transmitting an electronic signal to a pressure control assembly, wherein the pressure control assembly includes a transducer and is configured to control the air pressure of the air flow path supplied to the pump, wherein the controller causes the adjustment of the air pressure by transmitting an electronic signal to the transducer, the transducer being configured to cause the adjustment of the air pressure in the air flow path, wherein the transducer is configured to provide a pneumatic output to the air flow path that is proportional to the electronic signal transmitted to the transducer, whereby the transducer outputs the adjusted air to the pump via the air flow path, and wherein the transducer comprises at least one of a current-to-pressure transducer or a voltage-to-pressure transducer, wherein the electronic pressure sensor is positioned downstream of the transducer in the air flow path, wherein the regulator of the pressure control assembly is configured to adjust the pressure of an unregulated input air supply and output a regulated air supply to the pump via a first air line and a second air line, wherein the regulator and the transducer are both spaced apart from the pump, wherein the first air line is configured to fluidly connect the regulator to the pressure relief valve, and Wherein, the second air line is configured to fluidly connect the regulator to the pump.

17. The hot melt liquid dispensing system of claim 16, wherein: The pneumatic output to the air flow path is linearly proportional to the electronic signal transmitted to the transducer.

18. The hot melt liquid dispensing system of claim 16, wherein: The instructions, when executed by the one or more processors, further cause the controller to: An air pressure set point is received, wherein adjusting the air pressure in the air flow path is further performed based on the air pressure set point.

19. The hot melt liquid dispensing system of claim 18, wherein: receiving the air pressure set point via a user interface associated with the hot melt liquid dispensing system, and the instructions, when executed by the one or more processors, further cause the controller to: causing a display of the air pressure in the air flow path via the user interface; and The relevant relationship is identified by analyzing the quality control indicator with the corresponding pressure set point record, the corresponding pressure adjustment record, and / or the corresponding pressure measurement value record.

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