Systems and methods for enhanced management of hot melt liquid dispensing systems

Abstract

Systems and methods for enhanced management of hot melt liquid dispensing systems are disclosed. In an exemplary method for determining an operating directive for a hot melt liquid dispensing system having an applicator and a heater, the operating directive is determined based on a filtered applicator parameter value associated with a gun cycle count of the applicator and a filtered heater parameter value associated with a duty cycle value of the heater. The filtered applicator parameter value is determined based on historical applicator parameter values updated from a current applicator parameter value. The filtered heater parameter value is determined based on historical heater parameter values updated from a current heater parameter value.

Description

[0001] Divisional Application Instructions

[0002] This application is a divisional application of Chinese Patent Application No. 202080014929.3, filed on February 26, 2020, entitled "System and Method for Enhanced Management of Hot Melt Liquid Distribution System".

[0003] Cross-referencing of related patent applications

[0004] This application claims priority to U.S. Patent Application No. 62 / 810,380, filed February 26, 2019, which is incorporated herein by reference in its entirety. Technical Field

[0005] This disclosure relates in general to liquid dispensing, and more specifically to enhanced management of hot melt liquid dispensing systems. Background Technology

[0006] Hot melt liquid dispensing systems are used in a variety of applications. For example, such systems can apply hot melt adhesives during the manufacture of disposable hygiene products. Hot melt liquid dispensing systems can also apply hot melt adhesives to assemble various types of packaging, such as paper-based packaging for food and beverages. Hot melt adhesives used in such applications may include moisture-curing hot melt polyurethane adhesives (“hot melt PUR”), which are often used where a stable surface-to-surface bond must be formed. Other conventional hot melt adhesives can be used to bond a variety of similar and dissimilar materials (such as wood, plastics, corrugated films, paper, cardboard raw materials, metals, rigid polyvinyl chloride (PVC), fabrics, leather, etc.) together in a mating relationship. Hot melt adhesives are particularly useful in applications where rapid solidification of the adhesive after melting and dispensing is expected.

[0007] In one exemplary configuration of a hot melt adhesive dispensing system, a solid form of hot melt adhesive is supplied to a melter comprising a heated tank and / or a heated grid to produce molten hot melt adhesive. After heating, the molten adhesive is pumped through a heated hose to an applicator comprising valves and nozzles, sometimes referred to as a dispensing “gun” or gun module. A hot melt adhesive dispensing system may include two or more applicators. Each applicator may include its own heater to further maintain the temperature of the hot melt adhesive before dispensing it. However, operating a hot melt adhesive dispensing system with ideal efficiency presents several challenges. For example, hot melt adhesives can discolor and deteriorate over time. This is especially true when the hot melt adhesive is maintained at the higher temperatures required for application and / or for extended periods. This problem can be exacerbated in systems with relatively low flow rates.

[0008] Degraded hot melt adhesive can tend to adhere to the inner surface of the hose and other components of the hot melt adhesive dispensing system, thereby inhibiting the effective flow of the hot melt adhesive. Degraded hot melt adhesive can also char along with blackened or burned portions of the adhesive. Degraded hot melt adhesive can cause several problems in the dispensing system, including filter and applicator clogging and more frequent cleaning of the hoses delivering the hot melt adhesive to the applicator. Degraded hot melt adhesive can generally lead to increased system maintenance and repairs, as well as reduced operating uptime.

[0009] These and other disadvantages are discussed in this disclosure. Summary of the Invention

[0010] This document discloses a system and method for managing a hot melt liquid dispensing system having an applicator configured to dispense hot melt liquid and a hot melt liquid heater associated with the applicator. In an exemplary method for determining operating instructions for the hot melt liquid dispensing system, a plurality of historical applicator parameter values ​​for a first operating parameter of the applicator and a plurality of historical heater parameter values ​​for a second operating parameter of the hot melt liquid heater are provided. Each of the plurality of historical applicator parameter values ​​is temporally associated with a historical time interval of a historical time block. Each of the plurality of historical heater parameter values ​​is associated with a historical time interval of a historical time block. The current applicator parameter value for the first operating parameter of the applicator and the current heater parameter value for the second operating parameter of the hot melt liquid heater are received. The current applicator parameter value is temporally associated with a current time interval corresponding to a first historical time interval of a historical time block, and the current heater parameter value is associated with the current time interval. Filtered applicator parameter values ​​for the first operating parameter of the applicator are determined based on the current applicator parameter value and the historical applicator parameter values ​​among the plurality of historical applicator parameter values ​​temporally associated with the first historical time interval. Filtered heater parameter values ​​for the second operating parameter associated with the hot melt liquid heater are determined based on the current heater parameter values ​​and historical heater parameter values ​​from a plurality of historical heater parameter values ​​associated with the first historical time interval. Instructions for operating the hot melt liquid distribution system according to the operating parameter values ​​of the third operating parameter of the hot melt liquid distribution system are determined based on the filtered applicator parameter values ​​and the filtered heater parameter values.

[0011] In an exemplary method for predicting the failure of an applicator in a hot-melt liquid dispensing system, multiple applicator parameter values ​​of a first operating parameter of the applicator and multiple heater parameter values ​​of a second operating parameter of the hot-melt liquid heater are provided. Each of the multiple applicator parameter values ​​is temporally associated with a time interval of a first time block, and each of the multiple heater parameter values ​​is associated with an applicator parameter value among the multiple applicator parameter values. A first subset and a second subset of the multiple applicator parameter values ​​are determined. Each applicator parameter value in the first subset of the applicator parameter values ​​indicates that the applicator has no dispensing activity within the time interval associated with the first time block. Each applicator parameter value in the second subset of the applicator parameter values ​​indicates that the applicator has dispensing activity within the time interval associated with the first time block. A first subset and a second subset of the multiple heater parameter values ​​are determined. Each heater parameter value in the first subset of the applicator parameter values ​​is associated with an applicator parameter value of the first subset of the applicator parameter values, and each heater parameter value in the second subset of the heater parameter values ​​is associated with an applicator parameter value of the second subset of the applicator parameter values. The predicted failure time of the applicator is determined based on a first subset and a second subset of the heater parameter values. Attached Figure Description

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

[0013] Figure 1 An exemplary allocation system according to an embodiment of the present disclosure is shown;

[0014] Figure 2 Exemplary system and network configurations according to embodiments of this disclosure are shown;

[0015] Figure 3 An exemplary data flow diagram according to an embodiment of this disclosure is shown;

[0016] Figure 4 An exemplary data flow diagram according to an embodiment of this disclosure is shown;

[0017] Figure 5 An exemplary method flowchart according to an embodiment of this disclosure is shown; and

[0018] Figure 6 An exemplary method flowchart according to an embodiment of the present disclosure is shown.

[0019] Various aspects of this disclosure will now be described in detail with reference to the accompanying drawings, wherein, unless otherwise specified, similar reference numerals always refer to similar elements. Detailed Implementation

[0020] The systems and methods disclosed herein relate to enhanced management of hot melt liquid dispensing systems. Enhanced hot melt liquid dispensing system management can be implemented in dispensing systems used for hot melt adhesives. While primarily referring to hot melt adhesives, the techniques described herein are applicable to any type of hot melt liquid, including non-adhesive liquids.

[0021] Figure 1 An exemplary hot melt adhesive system 10 is shown that can implement the techniques described herein. The hot melt adhesive system 10 includes a dispensing unit 20 comprising an adhesive supply source 22 for receiving and melting solid or semi-solid hot melt adhesive 24a (such as granules), a manifold 26 connected to the adhesive supply source 22, a controller 28, and a user interface 29. The adhesive supply source 22 may be a can-type melter, or a grid and reservoir melter, etc. Upon melting, the solid or semi-solid hot melt adhesive 24a stored in the adhesive supply source 22 transforms into liquid hot melt adhesive 24. The adhesive supply source 22 includes a sidewall 30, a removable cap 31, and a base 32 including one or more adhesive supply source heaters 34 for melting and heating the hot melt adhesive 24a and liquid hot melt adhesive 24 in the adhesive supply source 22. An adhesive supply source outlet 36 adjacent to the base 32 is coupled to a channel 38, which is connected to an inlet 40 of the manifold 26.

[0022] A positive displacement pump 58 (such as a vertically oriented piston pump (as shown) or a gear pump) is coupled to manifold 26 for pumping liquid hot melt adhesive 24 from adhesive supply source 22 into manifold 26, where the liquid hot melt adhesive is split into separate streams. Pump motor 59 drives pump 58. Manifold 26 is mounted to the sidewall 30 of adhesive supply source 22 via spacer 41 and spaced apart from adhesive supply source 22 by a distance 42 sufficient to provide thermal insulation between adhesive supply source 22 and manifold 26. Manifold 26 includes multiple outlet ports 44, which may be equipped with heated hoses 46 attached to one or more adhesive applicators 48, 50 to supply liquid adhesive 24 to applicators 48, 50. Manifold 26 may include a manifold heater 56, which is separate from adhesive supply source heater 34 and can be individually controlled by controller 28. In some embodiments, a single heater may be used to heat both adhesive supply source 22 and manifold 26. Although Figure 1 An adhesive supply source 22 is shown physically close to manifold 26, but other arrangements in which the hot melt adhesive source is physically distant from the manifold are also possible. In such arrangements, more than one pump can be used to move the hot melt adhesive from adhesive supply source 22 toward the final application point.

[0023] Manifold 26 creates multiple flow streams carried by corresponding heated hoses 46 to applicators 48, 50. The hoses 46 are electrically connected to controller 28 via a rope assembly 62 associated with each hose 46. Applicators 48, 50 include one or more adhesive dispensing modules 54 configured to dispense / apply liquid hot melt adhesive 24 to a product (such as a cardboard box, packaging, or other object). The adhesive dispensing module 54 is mounted to an applicator body 51 having an applicator heater 53 and supported on a frame 52. The hot melt adhesive system 10 includes two applicators 48, 50, with one applicator located on each side of the dispensing unit 20, as shown below. Figure 1 As shown, other embodiments of the hot melt adhesive system 10 may use different numbers of applicators, dispensing modules, and other configurations. For example, applicators 48 and 50 may each be configured to have a single adhesive dispensing module 54 or may each be configured to have a pair of adhesive dispensing modules 54. The adhesive dispensing modules 54 of applicators 48 and 50 may be jointly monitored, controlled, and actuated by a common air supply source. Alternatively, the adhesive dispensing modules 54 of applicators 48 and 50 may be independently monitored, controlled, and actuated by separate air supply sources. Applicators 48 and 50 and / or adhesive dispensing modules 54 may be referred to differently as applicators or dispensers.

[0024] Pump 58 is located external to adhesive supply source 22 and connected to air pressure regulator 70, which receives air from air supply source 61. More specifically, air pressure regulator 70 is mounted to dispensing unit 20 and connected to air supply source 61. In some embodiments, pump 58 may be attached to manifold 26 and heated by manifold heater 56. This arrangement allows for a larger tank opening 60, increasing tank capacity and reducing the time required to heat pump 58. Additionally, flow meter 80 may be attached to manifold 26. Flow meter 80 includes a pair of sensors electrically connected to controller 28 via corresponding cords 63a, 63b associated with each sensor. At least one product detector 90, such as a photoelectric sensor, is also electrically connected to controller 28.

[0025] The distribution unit 20 includes a controller 28 housing power supplies and electronic controls for the hot melt adhesive system 10. The controller 28 may be configured to monitor, store, and set values ​​of various operating parameters of the hot melt adhesive system 10 and its components. For example, the controller 28 may be configured to capture one or more operating parameter values ​​at set time intervals (e.g., every five minutes) and store those captured operating parameter values. Alternatively, the controller 28 may transmit the collected and / or stored operating parameter values ​​to a remote computer system. Thus, the controller 28 may be configured to have one or more processors and a memory configured to store instructions that, when executed by the one or more processors, cause the controller 28 to perform the various operations described herein. The controller 28 may be configured to have a network interface (e.g., wired or wireless) for communicating with a remote computer system, such as to transmit the aforementioned collected and / or stored operating parameter values ​​to the remote computer system.

[0026] The controller 28 can be configured to monitor, store, and set values ​​of operating parameters for the applicators 48, 50, and the adhesive dispensing module 54, including those associated with dispensing hot melt adhesive. Such parameters may include a count of “gun cycles” of the applicators 48, 50, and / or the adhesive dispensing module 54. A gun cycle may refer to a single discrete instance of adhesive dispensing or application, such as the opening and closing cycle of the nozzle valve of the adhesive dispensing module 54. A gun cycle count may refer to a gun cycle of a single adhesive dispensing module 54 of the hot melt adhesive system 10, a gun cycle of a single applicator 48, 50 (and its adhesive dispensing module 54), or multiple (or all) gun cycles comprising the applicators 48, 50. A gun cycle count may refer to an absolute count of gun cycles, a rate of gun cycles, and / or a count of gun cycles over a given time interval. The controller 28 may also monitor, store, and set operating modes of the applicators 48, 50, and the adhesive dispensing module 54, such as an “on” mode, an “off” mode, and a “ready” mode. The applicator 48, 50, or adhesive dispensing module 54 may be in an "on" mode but not in a "ready" mode, such as during an ongoing initialization process or if the associated hot melt adhesive has not yet reached an operating temperature suitable or preferably used for dispensing. The applicator 48, 50, or adhesive dispensing module 54 may be in a ready mode when the associated hot melt adhesive is at a temperature suitable or preferably used for dispensing.

[0027] Relative to the heating characteristics of the hot melt adhesive system 10, the controller 28 is electrically connected to the heaters, including the adhesive supply source heater 34, manifold heater 56, and applicator heater 53, as well as any hose heaters. The controller 28 may also be connected to various temperature sensors in the hot melt adhesive system 10, which may be associated with or included in the adhesive supply source heater 34, manifold heater 56, applicator heater 53, and any hose heaters. The controller 28 individually monitors and adjusts the adhesive supply source heater 34, manifold heater 56, applicator heater 53, and any hose heaters to melt the solid or semi-solid hot melt adhesive 24a received in the adhesive supply source 22 and maintain the temperature of the (melted) hot melt adhesive 24, thereby ensuring the appropriate viscosity of the hot melt adhesive 24 supplied to the applicators 48, 50 and dispensed by the adhesive dispensing module 54. For example, the controller 28 receives temperature information (current temperature value) from the temperature sensors and sends heater control commands to each heater to adjust the temperature (target temperature value). Such heater control commands may increase or decrease the temperature of any or all of the heaters in the hot melt adhesive system 10.

[0028] The current or target temperature can be the operating temperature suitable or preferred for application or dispensing of the hot melt adhesive. The current or target temperature can also be a lower "retreat" temperature. Hot melt adhesives maintained at a retreat temperature experience less scorching and other degradation that would otherwise occur if the hot melt adhesive were held at a higher temperature, such as the operating temperature. Hot melt adhesives held at a retreat temperature may not have the viscosity or other properties preferred for dispensing. Maintaining the hot melt adhesive at a retreat temperature can be useful, for example, when there are brief to moderate intervals in operation. In such or similar situations, the hot melt adhesive can be reduced to a retreat temperature to minimize degradation and discoloration during the intervals, but can be returned to the operating temperature relatively quickly when the dispensing operation resumes.

[0029] In addition to the above, controller 28 can therefore monitor, store, and set various operating parameter values ​​associated with the temperature of the hot melt adhesive within the hot melt adhesive system 10. Besides the current and target temperature values ​​of the adhesive supply source heater 34, manifold heater 56, applicator heater 53, and hose 46, controller 28 can also monitor, store, and set duty cycle information for any or all of the heaters. For example, controller 28 can monitor, store, and set the duty cycle information for the adhesive supply source heater 34. The heater's duty cycle can refer to the percentage or ratio of the time the heater is activated (i.e., heating the associated hot melt adhesive) within a given time interval. Such time intervals for the duty cycle can be consistent with the time intervals at which controller 28 can collect various other operating parameter values ​​of the hot melt liquid adhesive system 10, including gun cycle data. For example, a heater's duty cycle value may be 20% activated within a ten-minute time interval, thus indicating that the heater is activated for two minutes within ten minutes (e.g., cumulatively).

[0030] In one aspect, the duty cycle can be controlled based on a shorter time interval (duty cycle sub-time interval) than the time interval at which the controller 28 collects values ​​of other operating parameters of the hot melt adhesive system 10. For example, the heater temperature can be evaluated every 30 seconds and the duty cycle adjusted accordingly, while the time interval for collecting other operating parameters of the hot melt adhesive system 10 can be a 10-minute time interval. In one aspect, the duty cycle values ​​of multiple shorter duty cycle sub-time intervals within a longer time interval can be averaged, and this average value can be used as a representative duty cycle value for the longer time interval. In another aspect, the duty cycle value of one of the multiple shorter duty cycle sub-time intervals within a longer time interval can be used as a representative duty cycle value for the longer time interval. For example, the duty cycle value of the last duty cycle sub-time interval within a longer time interval can be used as a representative duty cycle value for the longer time interval.

[0031] The heater's duty cycle is typically not a settable operating parameter. Instead, a temperature is typically assigned to the heater, and the heater's duty cycle is adjusted to maintain that temperature for the hot melt adhesive within the heater. The heater's duty cycle can also be based on the operation of the associated applicators 48, 50, and / or adhesive dispensing module 54, such as the count of gun cycles over a time interval. That is, the heater's duty cycle is typically at least in part a function of the operation of the associated applicators 48, 50, and / or adhesive dispensing module 54. For example, an increase in the gun cycle count over a time interval can result in a similar increase in the duty cycle value of the associated heater during that time interval. An increased duty cycle value may be required to maintain the flow of hot melt adhesive to the associated applicators 48, 50, and / or adhesive dispensing module 54 at the dispensing temperature. For example, the duty cycle value of applicator heater 53 over a time interval can be a function of the gun cycle count of applicator 48 (and / or its adhesive dispensing module 54) during that time interval. The time interval for the duty cycle value may deviate in time from the time interval of the gun cycle count associated with the duty cycle value (e.g., afterward). This may be due to a delay in the application of hot melt adhesive supplied by the associated heater by the applicator 48, 50 or adhesive dispensing module 54.

[0032] The duty cycle of the heater can also be affected by the functional status of the associated applicators 48, 50 and / or adhesive dispensing modules 54, such as whether the applicators 48, 50 and / or adhesive dispensing modules 54 operate as expected. For example, an air-leaking applicator 48, 50 and / or adhesive dispensing module 54 may be associated with an increased duty cycle of the corresponding applicator heater 53.

[0033] Figure 2 Exemplary system and network configurations that can be used to implement the techniques described herein are shown. In such configurations, allocation system 220 (e.g., Figure 1 The hot melt adhesive system 10), computer system 230, and client device 240 can communicate with each other via network 210. Communication with the distribution system 120 can be via the controller 222 of the distribution system 220 (e.g., Figure 1 The controller 28) is used to implement this. Network 210 may include one or more wired and / or wireless networks. For example, network 210 may include the Internet, intranet, (wireless) LAN, and / or cellular network.

[0034] As relative to Figure 1 The controller 222 can collect, store, set, and transmit various operating parameter values ​​of the components of the distribution system 220, including any applicator (e.g., Figure 1 Various operating parameter values ​​of the applicators 48, 50 and adhesive dispensing module 54, and any heater components (e.g., Figure 1Various operating parameter values ​​for the adhesive supply source heater 34, manifold heater 56, hose heater, and applicator heater 53. Operating parameters for the dispensing components may include gun cycle count or gun cycle rate over a given time interval, or other indicators of the count. Operating parameters for the heater components may include the duty cycle value of the heater component over a given time interval.

[0035] Computer system 230 may include one or more computing devices, such as various computer servers and network devices. Computer system 230 may include one or more networked computing devices. Computer system 230 may be located remotely from distribution system 220. For example, computer system 230 may include a cloud computing system. In contrast, distribution system 220 may be located at a manufacturing or assembly facility or other type of workshop or factory. Computer system 230 may be associated with a manufacturer of at least a portion of distribution system 220. The owner / operator of distribution system 220 may be an ongoing customer or client of the manufacturer.

[0036] Client device 240 may include computing devices, including desktop computers, laptop computers, tablet computers, or mobile devices (e.g., smartphones). Client device 240 may be configured to have one or more input and output components that enable a user to view and interact with data from computer system 230. For example, a user may use client device 240 to view and approve a proposed operational schedule for allocation system 220 determined by computer system 230. Client device 240 may be located in the same location as allocation system 220 or remotely. Client device 240 may be associated with personnel supervising allocation system 220.

[0037] In operation, the dispensing system 220 can determine historical (i.e., past) and current parameter values ​​of one or more operating parameters associated with the temperature of the hot melt adhesive of the dispensing system 220. For example, the dispensing system 220 can determine one or more historical and current parameter values ​​indicating the duty cycle of the heater associated with the applicator of the dispensing system 220. The dispensing system 220 can also determine historical and current parameter values ​​of one or more operating parameters associated with the applicator of the dispensing system 220. For example, the dispensing system 220 can determine historical and current parameter values ​​indicating the gun cycle count of the applicator of the dispensing system. The dispensing system 220 can transmit the above-mentioned historical and current parameter values ​​to the computer system 230 via the controller 222.

[0038] Computer system 230 may receive historical and current parameter values ​​from distribution system 220. In some cases, computer system 230 may have stored historical parameter values ​​that were received earlier from distribution system 220. Computer system 230 may process the historical and current parameter values ​​to determine a schedule for distribution system 220. For example, parameter values ​​may be filtered, such as determining a moving average for each operating parameter. The schedule may be determined based on a time trend of the parameter values. This trend may reflect times or time ranges when distribution system 220 is not in active operation for distributing hot melt adhesive, such as when facility personnel are on break or the facility is otherwise closed. The schedule may indicate one or more instructions for operating distribution system 220. The schedule may indicate when one or more heaters of distribution system 220 will operate according to the time and conditions of their operation. For example, the schedule may indicate one or more times when a heater will change from off mode to on mode or from on mode to off mode. The schedule may indicate a target temperature for the heater and the time when the heater will begin heating (or allow cooling) the associated hot melt adhesive to that target temperature. The target temperature may be a distribution temperature or a fallback temperature.

[0039] Computer system 230 can transmit a (proposed) schedule to client device 240, which can be associated with a user responsible for supervising allocation system 220. The user can view the schedule at client device 240 and approve or reject it. If approved, the schedule becomes effective at allocation system 220. If the schedule is rejected, computer system 230 can be notified and an alternative proposed schedule can be determined. The alternative schedule can be transmitted to client device 240 for approval, etc.

[0040] Figure 3 An exemplary data flow diagram 300 according to an embodiment of the present disclosure is shown. In the data flow diagram 300, one or more filtered operation parameters 340 are determined based on one or more current operation parameters 310, one or more historical operation parameters 320, and one or more status parameters 330. The filtered operation parameters 340 can be determined by filtering historical operation parameters 320 based on the current operation parameters 310. For example, the historical operation parameters 320 may include multiple moving averages of the corresponding historical operation parameters 320. The multiple moving averages can be updated based on the corresponding current operation parameters 310 to determine the filtered operation parameters 340. The multiple moving averages of the filtered operation parameters 340 can be determined time-by-time for corresponding time intervals between the current operation parameters 310 and the historical operation parameters 320. One or more instructions 350 can be determined based on the filtered operation parameters 340.

[0041] Current operating parameters 310 may include the allocation system (e.g., Figure 1Hot melt adhesive system 10 or Figure 2 The distribution system 220 operates according to one or more operating parameters. More specifically, the current operating parameter 310 may include one or more parameter values ​​of the current operating parameter 310. Similarly, the historical operating parameter 320 may include one or more operating parameters of the distribution system based on its operation. More specifically, the historical operating parameter 320 may include one or more parameter values ​​of the historical operating parameter 320. Parameter values ​​may correspond to predetermined time intervals. More than one parameter value may be associated with the same time interval, such as both a heater duty cycle parameter value and an applicator gun cycle count parameter value. The duration of the time interval may range from one minute to ten minutes (inclusive). An exemplary time interval duration may be five minutes. Another exemplary time interval duration may be ten minutes.

[0042] The parameter values ​​of historical operating parameter 320 can be relative to historical (i.e., past) time intervals. That is, historical parameter values ​​of historical operating parameter 320 can correspond to time intervals preceding the current time interval. Furthermore, each historical parameter value of historical operating parameter 320 can correspond to historical time intervals of multiple time intervals preceding the current time interval. The parameter values ​​of current operating parameter 310 can be relative to the current time interval. The current parameter value of current operating parameter 310 can correspond to the current time interval. The current time interval can be after the historical time intervals associated with historical operating parameter 320. As used herein and elsewhere in this disclosure, the term "current" should be understood in a broad, general sense rather than its literal meaning. For example, a "current" time interval can be minutes, hours, or days prior to the time that the filtered operating parameter 340 was determined. In some aspects, the current parameter value can refer to a recent or most recent measurement of the operating parameter used to determine the filtered operating parameter 340. For example, the current parameter value can be compared with historical parameter values, because historical parameter values ​​can represent a moving average of the parameter based on previous values ​​of the parameter, while the corresponding current parameter value can include the value of the parameter after those values ​​that constitute the moving average (e.g., subsequently measured or determined).

[0043] In some respects, a current parameter value may refer to multiple parameter values ​​within a predetermined time block. For example, a predetermined time block may be a portion of a day, a day, multiple days, or a week. Similarly, historical parameter values ​​may refer to multiple parameter values ​​within a predetermined time block (e.g., a portion of a day, a day, multiple days, or a week) preceding the current time block. A time block may include multiple time intervals (e.g., five-minute time intervals), where each time interval of the block corresponds to one or more parameter values. For example, a current parameter value may be those parameter values ​​for the corresponding time intervals during the most recent week, and historical parameter values ​​may be or represent (e.g., as a moving average) those parameter values ​​for the corresponding time intervals during the previous week or weeks. Time blocks may be subdivided, such as a week being subdivided into multiple days within a week. A specific current parameter value within a current time block may correspond to a historical parameter value (or its moving average) for the same relative time intervals within those time blocks. For example, the current parameter value within the relative time interval of Tuesday 11:30-11:35 in the current time block (current week) can be correlated with the historical parameter value (or its moving average) within the same relative time interval of Tuesday 11:30-11:35 in a historical time block (previous week or weeks). This will be combined with... Figure 4 The relationship between the current parameter value in the current time block and the historical parameter value in the historical time block is further discussed.

[0044] As described, the historical parameter value of historical operating parameter 320 can be a moving average based on previous historical parameter values ​​of a specific historical operating parameter 320. The moving average of historical parameter values ​​can be for a specific time interval relative to a time block, such as two or more consecutive Wednesday 15:30-15:35 time intervals. Therefore, the moving average of historical parameter values ​​for the Wednesday 15:30-15:35 time interval can be based on parameter values ​​from previous Wednesday 15:30-15:35 time intervals. Moving averages can include simple moving averages, cumulative moving averages, or weighted moving averages. Moving averages can include exponential moving averages, which are also known as exponentially weighted moving averages.

[0045] Current operating parameter 310 may include heater parameter 312 associated with the current temperature of the hot melt adhesive in the dispensing system. Specifically, current operating parameter 310 may include the current parameter value of heater parameter 312. Historical operating parameter 320 may similarly include heater parameter 322 associated with one or more historical temperatures of the hot melt adhesive in the dispensing system. Specifically, historical operating parameter 320 may include one or more historical heater parameter 322 values. Historical heater parameter 322 values ​​may be moving averages of historical heater parameter 322 based on previous heater parameter values ​​of a particular historical heater parameter 322.

[0046] Heater parameters 312 and 322 can be operating parameters of the heaters in the distribution system. Such heaters may include melters (e.g., Figure 1 The heater may include an adhesive supply source 22 with an adhesive supply source heater 34, a heated hose (e.g., a heated hose 46), an applicator heater (e.g., an applicator heater 53), or a manifold heater (e.g., a manifold heater 56). In one embodiment, the heater includes an applicator heater for the applicator. Heater parameters 312, 322 may include the duty cycle of the associated heater. The duty cycle parameter value may indicate a percentage or ratio of the time interval during which the heater is activated. The duty cycle may be controlled by a shorter time interval (duty cycle sub-time interval) than the time interval for collecting other operating parameters 310, 320. For example, the heater duty cycle may be updated in a 30-second duty cycle sub-time interval, while the time interval for collecting other operating parameters 310, 320 may be 5 or 10 minutes. The heater temperature may be checked based on the shorter duty cycle sub-time interval, and the heater duty cycle may be adjusted accordingly to maintain a target temperature. The duty cycle parameter value may indicate an average duty cycle value over the time interval, such as the average duty cycle value of the shorter duty cycle sub-time intervals described above. The average duty cycle can be a weighted average that may be biased toward the end of a time interval (e.g., a duty cycle value biased toward the end of a shorter duty cycle sub-time interval at the end of a longer time interval).

[0047] The duty cycle parameter value can relate to the operation of the associated applicator, such as the gun cycle count of the associated applicator within a certain time interval. The associated applicator can be an applicator that receives hot melt adhesive that has been heated by a heater. For example, the applicator heater ( Figure 1 The applicator heater 53) can be used with an applicator (e.g., Figure 1 The duty cycle of the applicator heater is associated with the applicator (48, 50), and therefore the duty cycle of the applicator heater may be associated with the gun cycle count of the applicator. Alternatively or otherwise, the parameter value of the duty cycle parameter may relate to one or more adhesive dispensing modules of the applicator, including a single adhesive dispensing module of the applicator or all dispensing modules of the applicator.

[0048] Current operating parameters 310 may include applicator parameters 314 associated with the current dispensing or application of hot melt adhesive by the dispensing system. Specifically, current operating parameters 310 may include the current parameter value of applicator parameter 314. Historical operating parameters 320 may similarly include applicator parameters 324 associated with the historical dispensing or application of hot melt adhesive by the dispensing system. Specifically, historical operating parameters 320 may include one or more historical parameter values ​​of applicator parameter 324. Historical applicator parameter 324 values ​​may be moving averages of historical applicator parameter 324 based on previous applicator parameter values ​​for a particular historical applicator parameter 324.

[0049] Applicator parameters 314 and 324 can be the applicator (e.g., Figure 1 Operating parameters of the applicators 48, 50 and / or one or more adhesive dispensing modules (e.g., adhesive dispensing module 54), unless otherwise clearly specified, the one or more adhesive dispensing modules should generally be referred to as the applicator. Applicator parameters 314, 324 may include a count (e.g., quantity) of gun cycles performed by the applicator during a time interval. Thus, each gun cycle parameter value may be temporally associated with a specific time interval. A gun cycle may refer to a single discrete instance of hot melt adhesive dispensing or application, such as the opening and closing cycle of the applicator's nozzle valve. A gun cycle count may refer to the gun cycle of a single applicator (e.g., a single adhesive dispensing module) or may refer to the collective gun cycles of two or more applicators (e.g., the total gun cycles performed by multiple adhesive dispensing modules of the applicator).

[0050] Additional or alternative applicator parameters 314, 324 may include the duration of each gun cycle within a time interval, such as the average duration of gun cycles within the time interval. For example, a shorter gun cycle duration may be associated with an applicator configured to dispense small amounts (e.g., “a dot”) of hot melt adhesive at a high frequency during the time interval. Conversely, a longer gun cycle duration may be associated with an applicator configured to dispense larger amounts (e.g., a series) of hot melt adhesive at a lower frequency during the time interval. Additional or alternative applicator parameters 314, 324 may include the amount (e.g., volume) of hot melt adhesive dispensed in each gun cycle, such as the average amount of hot melt adhesive dispensed through gun cycles within the time interval.

[0051] The values ​​of applicator parameters 314 and 324 can be associated with the values ​​of heater parameters 312 and 322. In some cases, the values ​​of heater parameters 312 and 322 at a given time interval can be considered to correspond to the values ​​of applicator parameters 314 and 324 at the same time interval. In other cases, the values ​​of heater parameters 312 and 322 may deviate from the associated values ​​of applicator parameters 314 and 324 in time, such as one or more time intervals following the time interval of the values ​​of applicator parameters 314 and 324. The deviation can be determined to compensate for the delay between changes in the values ​​of applicator parameters 314 and 324 (e.g., gun cycle count) that cause or correspond to changes in the values ​​of heater parameters 312 and 322 (e.g., duty cycle value).

[0052] State parameter 330 may generally indicate the state of the applicator (and / or the dispensing system as a whole), such as the current state. State parameter 330 may also indicate a previous instance of a change in the state of the applicator and / or the state of the dispensing system at a specific time (a state "snapshot"). State parameter 330 may include the open / closed state of the applicator (and / or the dispensing system as a whole). For an applicator in the closed state, state parameter 330 may include the time when the applicator was closed and the time when the applicator was last opened before the current closure. For an applicator in the open state, state parameter 330 may include the time when the applicator was opened and the time when the applicator was last closed before the current opening. The closed state may include a "sleep" state. Other state parameters 330 of the dispensing system may include the "ready" state of the applicator (and / or the dispensing system as a whole). State parameter 330 may include the time when the applicator entered the current ready state and / or the time when the applicator was last in the ready state. The ready state may refer to the state of the applicator in which the hot melt adhesive is at a temperature suitable for or preferably used for dispensing. An unready state can refer to a state in which the hot melt adhesive is in an applicator that is not suitable or preferred for use at a temperature (such as a retreat temperature) for dispensing.

[0053] The filtered operating parameters 340 may include heater parameters 342 and applicator parameters 344. Heater parameter 342 may be similar to heater parameter 312 of the current operating parameters 310 and heater parameter 322 of the historical operating parameters 320. Therefore, heater parameter 342 may refer to the duty cycle of the heater associated with the applicator. The duty cycle value may be relative to a time interval. Additionally, applicator parameter 344 may refer to the applicator's gun cycles. The gun cycle count may be relative to a time interval.

[0054] The filtered operating parameter 340 may be based on the current operating parameter 310, historical operating parameters 320, and / or status parameters 330. In one embodiment, the filtered operating parameter 340 may be an updated version or instance of the historical operating parameter 320, wherein the historical operating parameter 320 has been updated based on the current operating parameter 310. Therefore, determining the filtered operating parameter 340 may include filtering the historical operating parameter 320 based on the current operating parameter 310. Determining the filtered operating parameter 340 may include determining or updating a moving average of the historical operating parameter 320, wherein the current operating parameter 310 is used as an additional (e.g., most recent) data point for updating the moving average. Therefore, the filtered operating parameter 340 may include multiple moving averages of the corresponding parameter values.

[0055] As described, historical operating parameters 320 may include a moving average of the heater parameter values ​​of heater parameter 322. Therefore, determining the filtered heater parameter 342 (specifically, the filtered value of heater parameter 342) may include updating the moving average of historical heater parameter 322 values ​​using the current heater parameter 312 value. For the purpose of updating the moving average, the current heater parameter 312 value may be considered the most recent heater parameter value. Determining the filtered heater parameter 342 value of the filtered operating parameters 340 may be performed according to the following equation (1).

[0056] Equation (1):

[0057] d = f*c + (1-f)*d old

[0058] In equation (1), d represents the updated moving average of the heater parameter values ​​(i.e., the filtered heater parameter 342 values), f represents the filter factor, c represents the current heater parameter 312 value, and d old This represents the historical heater parameter 322 value. The filter factor f can be a number between 0 and 1 and indicates the degree to which more recent heater parameter values ​​are weighted over more distant heater parameter values.

[0059] As described above, the historical operating parameter 320 may include a moving average of the applicator parameter values ​​of the historical applicator parameter 324. Therefore, determining the filtered applicator parameter 344 (specifically, the filtered value of applicator parameter 344) may include updating the moving average of the historical applicator parameter 324 values ​​using the current applicator parameter value 314. The current applicator parameter 314 value can be considered as the most recent applicator parameter value used to determine the updated moving average. Determining the filtered applicator parameter 344 value can also be performed using equation (1), except that d represents the updated moving average of the applicator parameter values ​​(i.e., the filtered applicator parameter 344 values), f represents the filter factor, c represents the current applicator parameter 314 value, and d ola This represents the historical applicator parameter 324 value. The filter factor f used when determining the filtered applicator parameter 344 value may be different from or equal to the filter factor used when determining the filtered heater parameter 342 value.

[0060] In one implementation, the current operating parameters 310, historical operating parameters 320, status parameters 330, and filtered operating parameters 340 may each be organized, in whole or in part, into one or more matrices. Such matrices may represent time blocks comprising multiple time intervals. These time blocks may be further divided into sub-partitions, each sub-partition comprising one or more of the multiple time intervals within the time block. Each element of the matrix may correspond to a time interval among the multiple time intervals. Each element of the matrix may include one or more parameter values ​​temporally associated with the corresponding time interval. For example, each element may include heater parameter values ​​and / or applicator parameter values. One or more parameters in each element may also include an on / off state and / or a ready state (or other status parameters 330).

[0061] Determining the filtered operation parameter 340 value may include the parameter value indicated in the corresponding (according to time interval) element of the matrix based on the current operation parameter 310 value, and performing element-wise and parameter-wise updates on the moving average indicated in the matrix of historical operation parameter 320 values.

[0062] See Figure 4 The current operating parameter 310 value is organized into a current operating parameter matrix 410, the historical operating parameter 320 value is organized into a historical operating parameter matrix 420, and the filtered operating parameter 340 value is organized into a filtered operating parameter matrix 440. The state parameter 330 value can be indicated differently in any of the above matrices. Matrices 410, 420, and 440 each represent a one-week time block. Matrix 410 for the current operating parameter 310 can represent a specific week, such as the current week or the most recent week. Matrices 420 and 440 can represent abstract one-week time blocks because they typically indicate moving averages of parameter values ​​rather than specifically measured parameter values.

[0063] Matrices 410, 420, and 440 are each organized into corresponding columns 418, 428, and 448, each column representing a day of the week. Matrices 410, 420, and 440 are also each organized into corresponding rows 416, 426, and 446, each row representing a time interval within a day (according to a 24-hour clock format). The duration of each time interval is five minutes. Therefore, the first row contains time intervals between 00:00 and 00:05, the second row contains time intervals between 00:05 and 00:10, and so on. Each element in matrices 410, 420, and 440 represents one or more parameter values ​​corresponding to a day of the week and the time interval within that day. The parameter values ​​of the elements are... Figure 4 According to the format [parameters] [一周中的一天][时间间隔]This is represented by the [parameter] field, which indicates "w" for heater parameters, "x" for applicator parameters, "y" for on / off state parameters, and "z" for ready state parameters. Therefore, w Sun1 |x Sun1 |y Sun1 |z Sun1 The first row represents the heater parameter values, applicator parameter values, on / off status parameter values, and ready status parameter values ​​for the time interval between 00:00 and 00:05 on Sunday. The matrix 440 of the filtered operating parameters 340 also uses apostrophes (′) to indicate the updated moving average of the parameter values.

[0064] The matrix 440 containing the filtered operating parameter 340 values ​​can be determined by updating the historical moving average of matrix 420 element-wise and parameter-wise based on the current parameter values ​​indicated in matrix 410. The historical moving average of the parameter represented in a specific element of matrix 420 can be updated based on the current parameter values ​​represented in the corresponding elements of matrix 410. The updated moving average (for that day of the week and that time interval within that day) can be indicated in the corresponding element of matrix 440. The updated moving average can be determined using equation (1).

[0065] For example, the historical moving average of heater parameter values ​​for Sundays during the 23:55-24:00 time interval (as shown in matrix 420 by w) Sun288 (represented by) the current heater parameter values ​​during the current (e.g., most recent) Sunday 23:55-24:00 time interval (also represented by w in matrix 410) Sun288 (Indicated) to update. The updated moving average of heater parameter values ​​for the time interval Sunday 23:55-24:00 is shown in matrix 440 by w Sun288 ′ represents the updated moving average of the heater parameter values, which can be determined according to equation (1), where c is the value of w in matrix 410. Sun288 The value represented by d is the current heater parameter value. old To be in matrix 420 by w Sun288 The moving average of the heater parameter values ​​is represented, and d is the value of the heater parameter in matrix 440 by w. Sun288 ′ represents the updated moving average of the heater parameter values.

[0066] The updated moving average of the applicator parameter values ​​for the time interval Sunday 23:55-24:00 (in matrix 440 by x) Sun288 Similarly, the current applyer parameter value (in the corresponding element of matrix 410) is obtained by using the current (e.g., most recent) Sunday 23:55-24:00 time interval (represented by x). Sun288(This indicates) the historical moving average of the updated applyer parameter values ​​(also represented by x in the corresponding element of matrix 420). Sun288 The updated moving average of the applicator parameter values ​​for the Sunday 23:55-24:00 time interval can also be determined using equation (1). The updated on / off and ready state parameter values ​​for the updated Sunday 23:55-24:00 time interval (represented by y in matrix 440) are determined by y. Sun288 ′ and z Sun288 (represented by ') to reflect the current on / off state and ready state parameter values ​​(represented by y in the corresponding elements of matrix 410 respectively). Sun288 and z Sun288 (This is indicated by the diagram). A similar process can be used to determine each element of the filtered operating parameter matrix 440 (as well as the heater, applicator, and / or their status parameter values).

[0067] When determining the parameter values ​​of an element, the current operation parameter matrix 410 can be determined on a scrolling basis. For example, the elements of matrix 410 can be updated in real time or almost in real time. Alternatively, matrix 410 and its elements can be determined simultaneously. Similarly, a filtered operation parameter matrix 440 can be determined on a scrolling basis. For example, the elements of matrix 440 can be determined when determining the corresponding elements of the current operation parameter matrix 410. Alternatively, matrix 440 and its elements can be determined simultaneously, such as after determining all elements of the current operation parameter matrix 410.

[0068] Return to Figure 3 The filtered operating parameters 340 can be used to determine one or more instructions 350. Instructions 350 can be relative to one or more operating parameters of the dispensing system. For example, instructions 350 can relate to the applicator heater or other heaters of the dispensing system. Such instructions 350 can cause the applicator heater to raise its target temperature, lower its target temperature, and / or set a target temperature. Instructions 350 can set the heater to a fallback temperature. Instructions 350 can cause the heater to turn off, turn on, enter a sleep mode, or "wake up" from a sleep mode. Instructions can cause the dispensing system to turn off, turn on, enter a sleep mode, or "wake up" from a sleep mode. Instructions 350 can indicate the time when the aforementioned actions will be performed or begin to take effect.

[0069] Instruction 350 may indicate multiple instructions to be implemented within a certain time period. These multiple instructions may include a schedule, according to which the dispensing system and its components operate. The schedule may indicate the dates and times when the various instructions are to take effect. For example, the schedule may indicate the first opening time of the heater for weekdays and different second opening times for weekends. These opening times can be optimized so that the hot melt adhesive is at the ready temperature when the dispensing system's production operation begins later (rather than obviously before). As another example, the schedule may indicate the time and temperature at which the dispensing system enters a rollback mode, and the time it takes for the dispensing system to enter normal mode and raise the temperature of the hot melt adhesive at the applicator to the dispensing temperature.

[0070] Instruction 350 may be implemented electronically or digitally. For example, instruction 350 may include digital data that can be transmitted from a remote computer system (e.g., Figure 2 Computer system 230) determines and via network (e.g., Figure 2 The network 210 transmits data to the controller of the distribution system. The controller can receive and process instructions 350 to implement instructions 350. Instructions 350 may include electrical control signals from the controller to one or more components of the distribution system, such as the applicator heater. The controller can implement instructions without local user intervention.

[0071] Figure 5 The diagram illustrates methods for determining the operation of a hot melt liquid distribution system (e.g., Figure 1 A flowchart of a method 500 for one or more instructions to a hot melt adhesive system 10. In an exemplary embodiment, method 500 may include compiling a record of historical applicator parameter values ​​(each value associated with a time interval) of the applicator (e.g., gun cycle count) and a record of associated historical heater parameter values ​​(each value also associated with a time interval) of the heater (e.g., duty cycle value). The historical applicator parameter values ​​associated with each time interval may be filtered based on the current applicator parameter values ​​corresponding to that time interval (e.g., updated to a moving average). Similarly, the historical heater parameter values ​​associated with each time interval may be filtered based on the current applicator parameter values ​​corresponding to that time interval (e.g., updated to a moving average). Based on the filtered applicator parameter values ​​and heater parameter values, instructions for operating the hot melt liquid dispensing system and / or its components may be determined. For example, instructions may cause the hot melt liquid heater to raise or lower the temperature of the hot melt liquid to be supplied to the applicator at a specified time. The specified time may correspond to a period of temporary suspension of active operation of the hot melt liquid dispensing system.

[0072] At step 502, an applicator for the hot melt liquid dispensing system (e.g., Figure 1The first operating parameters of the applicators 48, 50 and / or adhesive dispensing module 54) contain multiple historical applicator parameter values. These historical applicator parameter values ​​can be compared with... Figure 3 The historical applyer parameter 324 values ​​are the same or similar. Historical applyer parameter values ​​may include the gun cycle count of the applyer within a certain time interval. Each of the multiple historical applyer parameter values ​​may be temporally associated with a historical time interval of a historical time block. For example, multiple historical applyer parameter values ​​may be implemented as a matrix of historical parameter values ​​(e.g., Figure 4 A matrix (420) is constructed, where each element of the matrix represents a historical applyer parameter value and the time interval associated with that historical applyer parameter value. The matrix may represent a historical time block spanning one week and may be further divided into days of the week corresponding to the columns of the matrix. For example, the time interval may include a duration of five minutes.

[0073] At step 504, a hot melt liquid heater (e.g., for example, can be provided for the hot melt liquid distribution system) can be provided. Figure 2 The second operating parameter of the applicator heater 53) contains multiple historical heater parameter values. These historical heater parameter values ​​can be compared with... Figure 3 The historical heater parameter values ​​are the same or similar. Historical heater parameter values ​​may include the duty cycle of the molten liquid heater. Each of the multiple historical heater parameter values ​​may be associated with a historical applicator parameter value in time. For example, a historical heater parameter value may be associated with a historical time interval that is the same as the associated historical applicator parameter value. Alternatively, a historical heater parameter value may be associated with a historical time interval that deviates from the associated historical applicator parameter value. Multiple historical heater parameter values ​​may be represented in a matrix of historical parameter values ​​along with multiple historical applicator parameter values. For example, historical heater parameter values ​​and their associated historical applicator parameter values ​​may be represented in the same elements of the matrix.

[0074] Historical applicator parameter values ​​associated with a specific historical time interval (e.g., a time interval between days of the week) may include moving averages of previous historical applicator parameter values ​​(of a first operating parameter of the applicator), each of which is associated with a corresponding historical time interval of a previous historical time block (e.g., the previous few days and / or weeks). Similarly, historical heater parameter values ​​associated with a specific historical time interval may include moving averages of previous historical heater parameter values ​​(of a second operating parameter of the molten liquid heater), each of which is associated with a corresponding historical time interval of a previous historical time block.

[0075] At step 506, the current applicator parameter value of the first operating parameter of the applicator can be received. The current applicator parameter value can be compared with... Figure 3 The current applicator parameter 314 value is the same as or similar to the current applicator parameter value. The current applicator parameter value can be associated with the current time interval. The current applicator parameter value can include the gun cycle count of the applicator during the current time interval. The current applicator parameter value can be associated with the current time interval of a first historical time interval corresponding to a historical time block. For example, the current applicator parameter value can be associated with the current time interval of Saturday 00:05-00:10, and this current time interval can correspond to... Figure 4 The historical time interval is represented in the element at the intersection of the "Saturday" column and the "00:10" row in the historical operation parameter matrix 420. By extension, the current applicator parameter value can be associated with a historical applicator parameter value that is temporally associated with the corresponding first historical time interval. The current applicator parameter value can be one of multiple current applicator parameter values, each temporally associated with a corresponding current time interval, such as in... Figure 4 The current operation parameter matrix 410 represents this.

[0076] At step 508, the current heater parameter value of the second operating parameter of the hot melt liquid heater can be received. The current heater parameter value can be compared with... Figure 3 The current heater parameter 312 value is the same as or similar to the current heater parameter value. The current heater parameter value may include the duty cycle value of the hot melt liquid heater. The current heater parameter value may be associated with the current applicator parameter value. For example, the current heater parameter value may be associated in time with a current time interval mentioned relative to the current applicator value. In one aspect, both the current heater parameter value and the current applicator parameter value may correspond to the same time interval. In other aspects, the current heater parameter value may correspond to a time interval that deviates in time from the time interval corresponding to the current applicator parameter value.

[0077] By associating with the current applicator parameter value, the current heater parameter value can be associated with historical applicator parameter values. For example, both the current applicator parameter value and the current heater parameter value can be associated with the same current time interval in time, and both historical applicator parameter values ​​and historical heater parameter values ​​can be associated with historical time intervals corresponding to that current time interval in time. The current heater parameter value can be one of multiple current heater parameter values, each associated in time with a corresponding current time interval, such as in... Figure 4 The current operation parameter matrix 410 represents this.

[0078] At step 510, a filtered applicator parameter value for the first operating parameter of the applicator can be determined based on the current applicator parameter value and historical applicator parameter values ​​from a plurality of historical applicator parameter values ​​(e.g., Figure 3The filtered applicator parameter 344 value. The historical applicator parameter value used as the basis for determining the filtered applicator parameter value can be associated in time with a first historical time interval corresponding to a historical time block of the current time interval (refer to step 506). That is, both the current applicator parameter value and the historical applicator parameter value can be associated in time with the corresponding time interval. In one example, the historical applicator parameter value may include a moving average of the applicator's first operating parameter. Therefore, determining the filtered applicator parameter value may include updating the moving average indicated by the historical applicator parameter value, where the current applicator parameter value is used as a later or more recent data point for the applicator's first operating parameter.

[0079] At step 512, filtered heater parameter values ​​for the second operating parameters of the hot melt liquid heater can be determined based on the current heater parameter values ​​and historical heater parameter values ​​from a plurality of historical heater parameter values ​​(e.g., Figure 3 The filtered heater parameter 342 value). The historical heater parameter values ​​used to determine the filtered heater parameter values ​​can be associated with the first historical time interval mentioned above relative to the filtered applicator parameter values. For example, the historical heater parameter values ​​used as the basis for determining the filtered heater parameter values ​​can be associated with the historical applicator parameter values ​​used to determine the filtered applicator parameter values. Specifically, the historical heater parameter values ​​used to determine the filtered heater parameter values ​​can be associated with the historical applicator parameter values ​​that are temporally associated with the first historical time interval of the historical time block. For example, the historical heater parameter values ​​used to determine the filtered heater parameter values ​​can be temporally associated with the historical time interval corresponding to the current time interval.

[0080] The filtered applicator parameter values ​​and the filtered heater parameter values ​​can be found in Figure 4 The filtered operating parameter matrix 440 represents the parameters. The filtered applicator parameter values ​​and the filtered heater parameter values ​​can be associated with the same time interval. For example, the filtered applicator parameter values ​​can be represented in matrix 440 by X... Sat1 ′ represents, and the filtered heater parameter values ​​can be obtained from W in matrix 440. Sat1 The '' indicates that they are all time-related to the time interval of Saturday 00:00-00:05. The filtered applicator parameter values ​​can be based on X. Sat1 The current applicator parameter values ​​in the current operating parameter matrix 410, representing the time interval from 00:00 to 00:05 on the current Saturday, and also represented by X Sat1 The historical applicator parameter values ​​for the historical Saturday 00:00-00:05 time interval, represented in the historical operation parameter matrix 420, are used to determine the parameters. The filtered heater parameter values ​​can be based on W... Sat1The current heater parameter values ​​in the current operating parameter matrix 410 for the current Saturday 00:00-00:05 time interval are represented by W. Sat1 The historical heater parameter values ​​for the historical Saturday 00:00-00:05 time interval in the historical operating parameter matrix 420 are used to determine this. A corresponding process can be performed to determine additional elements of the filtered operating parameter matrix 440 (i.e., additional filtered applicator parameter values ​​and / or additional filtered heater parameter values).

[0081] At step 514, the command can be determined based on the filtered applicator parameter values ​​and the filtered heater parameter values ​​(e.g., Figure 3 The determined instructions may include instructions for operating the hot melt liquid dispensing system (or its components) according to the operating parameter value of a third operating parameter of the hot melt liquid adhesive system. For example, the instructions may be used to operate the hot melt liquid heater. Additionally, the third operating parameter may include operating parameters of the hot melt liquid heater. The operating parameter value of the third operating parameter may include a target temperature of the hot melt liquid heater, such as a predetermined dispensing temperature or a predetermined retreat temperature. The determined instructions may include instructions for stopping the hot melt liquid heater from applying heat to the hot melt liquid, instructions for starting the hot melt liquid heater from applying heat to the hot melt liquid, or instructions for putting the hot melt liquid heater into at least one of an on mode, a off mode, or a ready mode. The determined instructions may include instructions for putting the hot melt liquid dispensing system into an operating mode, which includes at least one of an on mode, a off mode, or a ready mode.

[0082] At least a portion of method 500 may be generated by a computer system (such as...) remote from the hot melt liquid dispensing system. Figure 2 The computer system 230 executes the commands. For example, the remote computer system may provide multiple historical applicator parameter values ​​and / or multiple historical heater parameter values. The remote computer system may store such parameter values ​​and provide them from a storage device. As another example, the remote computer system may receive current applicator parameter values ​​and / or current heater parameter values, such as from the controller of the hot melt liquid dispensing system. Using the multiple historical applicator parameter values ​​and multiple historical heater parameter values ​​provided from the storage device, and the current applicator parameter values ​​and current heater parameter values ​​received from the hot melt liquid dispensing system, the remote computer system may determine filtered applicator parameter values ​​and filtered heater parameter values. Additionally, the remote computer system may determine instructions for operating the hot melt liquid dispensing system. The remote computer system may transmit the instructions to the controller of the hot melt liquid dispensing system to implement the instructions. The instructions may include control signals generated by the controller.

[0083] This paper also discloses methods for predicting hot melt liquid distribution systems (e.g., Figure 1The applicator of the hot melt adhesive system 10) (e.g., Figure 1 The technique for determining the failure time of the applicator 48, 50 / or adhesive dispensing module 54. Such failures may specifically be associated with air leaks at or by the applicator, observed to be related to the associated heater (e.g., Figure 1 The increase in the duty cycle of the applicator heater 53 is related to this. "Failure" is not limited to complete failure of operability, but can also include those states in which the applicator's performance deteriorates unacceptably. For example, an applicator performance that drops below a threshold or outside a threshold range can be considered an applicator failure. The applicator's performance can be measured based on the operating parameters of another component, including the heater's duty cycle.

[0084] The predicted failure time of the applicator can be at least partially based on information about... Figure 3 The predicted failure time can be determined based on the data provided. For example, the predicted failure time can be determined based on the current operating parameter 310 value (including the current heater parameter 312 value (e.g., current duty cycle) and the current applicator parameter 314 value (e.g., current gun cycle count)). The predicted failure time can also be determined based on historical operating parameter 320 values ​​(including historical heater parameter 322 values ​​(e.g., historical duty cycle) and historical applicator parameter 324 values ​​(e.g., historical gun cycle count)). The predicted failure time can also be further determined based on status parameters 330 (such as the current or historical open, closed, or ready state of the applicator, heater, or the overall hot melt liquid distribution system).

[0085] In an exemplary embodiment, the heater's duty cycle value can be determined for time intervals during which the applicator does not perform gun cycles. The heater's duty cycle value can also be determined for time intervals during which the applicator performs multiple gun cycles. The duty cycle value during time intervals without gun cycles can be compared with the duty cycle value during time intervals with multiple gun cycles to determine the predicted failure time. The average gun cycle count for those time intervals with multiple gun cycles can be determined and can also be used to determine the predicted failure time. The duty cycle value for time intervals without gun cycles, the duty cycle value for time intervals with multiple gun cycles, and the gun cycle count for time intervals with multiple gun cycles can be averaged over time intervals of a day or other time blocks. The relationship between the three averages can be used to determine the predicted failure time.

[0086] Similar analyses of gun cycle counts and duty cycle values ​​can be performed relative to the time interval of the next day. Duty cycle values ​​for the time interval of the next day without gun cycles, duty cycle values ​​for the time interval of the next day with multiple gun cycles, and gun cycle counts for the time interval of the next day with multiple gun cycles can also be averaged. The relationship between the three averages of the next day can be compared to a similar relationship between the three averages of the initial day. This comparison can also serve as a further basis for determining the predicted failure time. Similar duty cycle / gun cycle relationships for additional multiple days can also be determined and analyzed by combining the duty cycle / gun cycle relationships of the first day and the second day. For example, the duty cycle / gun cycle relationship for each day can be plotted on a graph, and trends indicating predicted failure times can be identified. Trends can be identified by fitting a curve (e.g., a mathematical function) to the data points plotted on the graph.

[0087] Figure 6 A method for predicting hot melt liquid distribution systems (e.g., Figure 1 The applicator of the hot melt adhesive system 10) (e.g., Figure 1 A flowchart of a method 600 for determining the failure time of the applicators 48, 50 and / or adhesive dispensing module 54, wherein the hot melt liquid dispensing system has a heater (e.g., ...) associated with the applicator. Figure 1 The applicator heater 53). At step 602, first operating parameters of the applicator can be provided (e.g., Figure 3 The applicator parameter values ​​(applicator parameters 314, 324) are multiple applicator parameter values. Each of the multiple applicator parameter values ​​may be temporally associated with a time interval of a first time block. The first operating parameter of the applicator may be a count of gun cycles performed by the applicator within a certain time interval (e.g., the applicator's speed and / or response time during that time interval). Therefore, the applicator parameter values ​​may include a gun cycle count for a time interval associated with the time. The applicator parameter values ​​may indicate a gun cycle count of zero, one, or more gun cycles.

[0088] The first time block may include the first day or a portion thereof. The time interval of the first day or other time blocks need not include every possible time interval within the same day or other time block. For example, the time interval of the first time block may be limited to those time intervals during which at least one of the applicator, heater, or hot melt dispensing system is turned on. Alternatively, the time interval of the first time block may be limited to those time intervals during which at least one of the applicator, heater, or hot melt dispensing system is in a ready state. The time interval may have a duration ranging from one minute to ten minutes, including endpoints. For example, the time interval may have a duration of five minutes or ten minutes.

[0089] At step 604, a second operating parameter for the heater can be provided (e.g., Figure 3 Multiple heater parameter values ​​(312, 322) are used. In some embodiments, step 604 may be optional, and method 600 may alternatively proceed to step 606. Each heater parameter value among the multiple applicator parameter values ​​may be associated with an applicator parameter value among the multiple applicator parameter values. Each heater parameter value may also be associated temporally with a time interval of a first time block. A second operating parameter of the heater may include the heater's duty cycle within a time interval. Both the heater parameter value and the associated applicator parameter value may be associated temporally with the same time interval of the first time block. Alternatively, the heater parameter value may be associated temporally with a time interval that deviates from the time interval of the temporally associated applicator parameter value, such as to compensate for the delay effect on the heater's duty cycle caused by changes in the applicator's gun cycle.

[0090] At step 606, a first subset of the multiple applicator parameter values ​​may be determined. This first subset of applicator parameter values ​​(and the second subset discussed below) may be determined based on: applicator dispensing activity during a corresponding time interval, specifically the applicator gun cycle count during the corresponding time interval, and more specifically, whether a given applicator parameter value indicates no gun cycle during the time-related time interval (e.g., zero gun cycle count) or the presence of one or more gun cycles during the time-related time interval (e.g., non-zero or multiple gun cycle counts). The first subset of applicator parameter values ​​may include those applicator parameter values ​​that indicate no dispensing activity (i.e., zero gun cycle count) during the time-related time interval.

[0091] At step 608, a second subset of the applicator parameter values ​​may be determined from among the plurality of applicator parameter values. The second subset of applicator parameter values ​​may include those applicator parameter values ​​indicating application activity during a time-related time interval. The second subset of applicator parameter values ​​may include those applicator parameter values ​​that exceed a threshold applicator parameter value or fall within a threshold range of a threshold applicator parameter value. For example, the second subset of applicator parameter values ​​may include those applicator parameter values ​​indicating a gun cycle count exceeding a threshold gun cycle count or falling within a threshold range of gun cycle counts. The threshold gun cycle count may be zero, so the second subset of applicator parameter values ​​may include all applicator parameter values ​​indicating a non-zero gun cycle count. Alternatively, the threshold gun cycle count may be greater than zero, so it is possible that some applicator parameter values ​​may not be included in either the first or second subset of the applicator parameter values.

[0092] At step 610, a first subset of heater parameter values ​​from a plurality of heater parameter values ​​may be determined, wherein each heater parameter value in the first subset of heater parameter values ​​(e.g., a duty cycle value of the heater for a given time interval) is associated with an applicator parameter value in the first subset of applicator parameter values. Thus, each heater parameter value in the first subset of heater parameter values ​​may be associated with an applicator parameter value that indicates no applicator dispensing activity (e.g., zero-gun cycle count) during a time interval associated with the applicator parameter value. For example, each heater parameter value in the first subset of heater parameter values ​​may be associated temporally with a time interval during which no applicator dispensing activity occurred. In some embodiments, step 610 may be optional, and method 600 may alternatively proceed to steps 614a and / or 614b.

[0093] At step 612, a second subset of heater parameter values ​​from a plurality of heater parameter values ​​may be determined, wherein each heater parameter value in the second subset of heater parameter values ​​(e.g., a duty cycle value of the heater for a given time interval) is associated with an applicator parameter value in the second subset of applicator parameter values. Thus, each heater parameter value in the second subset of heater parameter values ​​may be associated with an applicator parameter value in the second subset of applicator parameter values ​​that indicates a dispensing activity (e.g., a non-zero or multi-gun cycle count) during the time interval associated with the applicator parameter value. For example, each heater parameter value in the second subset of heater parameter values ​​may be associated temporally with a time interval during which applicator dispensing activity occurs. In some embodiments, step 612 may be optional, and method 600 may alternatively proceed to steps 614a and / or 614b.

[0094] The first and / or second subsets of applicator parameter values ​​and / or the first and / or second subsets of heater parameter values ​​may also be limited to those parameter values ​​that are temporally associated with time intervals during which at least one of the heater, applicator, or hot melt liquid dispensing system (as applicable) is in a ready state. The first and / or second subsets of applicator parameter values ​​and / or the first and / or second subsets of heater parameter values ​​may additionally or alternatively be limited to those parameter values ​​that are temporally associated with time intervals during which the hot melt liquid to be supplied to the applicator is at a temperature suitable or preferably used for dispensing. For example, the first subset of applicator parameter values ​​and the first subset of heater parameter values ​​may be limited to parameter values ​​that are temporally associated with time intervals during which the hot melt liquid dispensing system is shut down, even if no dispensing activity occurs during those time intervals.

[0095] Method 600 may include one or both of steps 614a and 614b. At steps 614a and / or 614b, a predicted failure time of the applicator may be determined. The predicted failure time indicated in steps 614a and 614b may refer to the same predicted failure time. In step 614a, the predicted failure time of the applicator may be determined based on a first subset and a second subset of the applicator parameter values. In step 614b, the predicted failure time of the applicator may be determined based on a first subset and a second subset of the heater parameter values. Where method 600 includes both steps 614a and 614b, the predicted failure time of the applicator may be determined based on a first subset of the applicator parameter values, a second subset of the applicator parameter values, a first subset of the heater parameter values, and a second subset of the heater parameter values. Alternatively (not shown), the predicted failure time of the applicator may be determined based on a first subset and a second subset of the heater parameter values. That is, in this case, method 600 may include step 614b but not step 614a.

[0096] For example, the predicted failure time of the applicator can be determined based on one or more heater parameter values ​​(e.g., duty cycle values) each associated in time with a time interval during which no applicator dispensing activity occurred (zero-gun cycle count), and one or more heater parameter values ​​(e.g., duty cycle values) each associated in time with a time interval during which applicator dispensing activity actually occurred (non-zero or multi-gun cycle count). Determining the predicted failure time may include comparing one or more heater parameter values ​​from a first subset of heater parameter values ​​with one or more heater parameter values ​​from a second subset of heater parameter values.

[0097] The predicted failure time can also be based on the average of duty cycle values ​​associated with time intervals during which no gun cycles occur, and the average of duty cycle values ​​associated with time intervals during which one or more gun cycles occur. The first time block may include one day, such that the two duty cycle averages are daily averages. When determining the predicted failure time, the two duty cycle averages can be compared with each other. Therefore, determining the predicted failure time may also include comparing the average of a first subset of heater parameter values ​​with the average of a second subset of heater parameter values.

[0098] The predicted failure time of the applicator can also be based on non-zero gun cycle counts, such as the average of non-zero gun cycle counts occurring during two or more time intervals in the first time block. For example, the predicted failure time can be based on the average duty cycle values ​​associated with time intervals during which no gun cycle occurred, the average duty cycle values ​​associated with time intervals during which one or more gun cycles occurred, and the average gun cycle counts associated with time intervals during which one or more gun cycles occurred. Therefore, the predicted failure time of the applicator can be based on the average duty cycle values ​​of a first subset of heater parameter values, the average duty cycle values ​​of a second subset of heater parameter values, and the average gun cycle counts of a second subset of applicator parameter values.

[0099] The predicted failure time of the applicator can be based on the relationship between the average duty cycle of a first subset of heater parameter values, the average duty cycle of a second subset of heater parameter values, and the average gun cycle count of a second subset of applicator parameter values ​​(i.e., a first parameter relationship associated with a first time block). The first parameter relationship can reflect the difference between the average duty cycle of the second subset of heater parameter values ​​and the average duty cycle of the first subset of heater parameter values. The first parameter relationship can also include the relationship between the average gun cycle count (e.g., non-zero or multi-gun cycle count) of the second subset of applicator parameter values ​​and the aforementioned difference between the average duty cycle of the second subset of heater parameter values ​​and the average duty cycle of the first subset of heater parameter values. For example, the first parameter relationship can be reflected in the following equation (2).

[0100] Equation (2):

[0101]

[0102] In equation (2), R can be a value representing the first parameter relationship (or another similar relationship associated with another time block). R can represent a slope or other relationship applicable to a graph that includes a y-axis indicating the increasing duty cycle value of the applicator in a "failed" state and an x-axis indicating the increasing duty cycle value of the applicator not in a failed state. A g A can represent the average duty cycle value of a second subset of heater parameter values ​​(correlated with the non-zero gun cycle count time interval in time), and A0 can represent the average duty cycle value of a first subset of heater parameter values ​​(correlated with the zero (0) gun cycle count time interval in time). g can represent the average gun cycle count (e.g., non-zero or multi-gun cycle count) of the second subset of applicator parameter values.

[0103] The predicted failure time of the applicator can also be determined based on additional applicator parameter values ​​and heater parameter values ​​that are temporally associated with time intervals of one or more additional time blocks (such as an additional day or more days). For example, method 600 may also include a second plurality of applicator parameter values ​​(e.g., gun cycle count) providing a first operating parameter of the applicator, and a second plurality of heater parameter values ​​(e.g., duty cycle value) providing a second operating parameter of the heater. The second plurality of applicator parameter values ​​may be similar to the first plurality of applicator parameter values ​​in some respects, except that at least each of the second plurality of applicator parameter values ​​may be temporally associated with time intervals of the second time block. For example, the first time block may be the first day and the second time block may be the second day. The first time block and the second time block may not overlap.

[0104] Similarly, the second plurality of heater parameter values ​​may be similar to the first plurality of heater parameter values ​​in some respects, except that at least each of the second plurality of heater parameter values ​​may be associated with an applicator parameter value in the second plurality of applicator parameter values. Each of the second plurality of heater parameter values ​​may also be associated temporally with a time interval of a second time block, such as the same time interval as the applicator parameter value associated with the heater parameter value.

[0105] Method 600 may further include determining a third and fourth subset of the applicator parameter values ​​for the second plurality of applicator parameter values. Similar in some respects to the first subset of applicator parameter values ​​(associated with the first time block), each applicator parameter value in the third subset of applicator parameter values ​​may indicate that no applicator application activity occurred during a time interval associated with the second time block. Therefore, each applicator parameter value in the third subset of applicator parameter values ​​may indicate a zero gun cycle count. Similar in some respects to the second subset of applicator parameter values ​​(associated with the first time block), each applicator parameter value in the fourth subset of applicator parameter values ​​may indicate that applicator application activity did occur during a time interval associated with the second time block. Therefore, each applicator parameter value in the fourth subset of applicator parameter values ​​may indicate a non-zero or multiple gun cycle count.

[0106] Method 600 may further include determining a third and fourth subset of heater parameter values ​​of the second plurality of heater parameter values. Similar in some respects to the first subset of heater parameter values ​​(associated with the first time block), each heater parameter value in the third subset of heater parameter values ​​may be associated with an applicator parameter value in the third subset of applicator parameter values. Thus, each heater parameter value in the third subset of heater parameter values ​​may be associated with a zero-gun cycle count, such as a time interval during which no applicator activity occurred. Similar in some respects to the second subset of heater parameter values ​​(associated with the first time block), each heater parameter value in the fourth subset of heater parameter values ​​may be associated with an applicator parameter value in the fourth subset of applicator parameter values. Thus, each heater parameter value in the fourth subset of heater parameter values ​​may be associated with a non-zero or multi-gun cycle count, such as a time interval during which applicator applicator activity occurred.

[0107] In method 600, the predicted failure time of the applicator may also be based on a third subset and a fourth subset of the heater parameter values. For example, the predicted failure time of the applicator may be based on the heater duty cycle value associated temporally with the time interval of a second time block in which no applicator dispensing activity occurs (e.g., zero gun cycle count), and the heater duty cycle value associated temporally with the time interval of a second time block during which applicator dispensing activity does occur (e.g., non-zero or multi-gun cycle count).

[0108] The predicted failure time can also be based on the average duty cycle of a third subset of heater parameter values, the average duty cycle of a fourth subset of heater parameter values, and the average gun cycle count of a fourth subset of applicator parameter values. Specifically, the predicted failure time of the applicator can be based on the relationship between the average duty cycle of the third subset of heater parameter values, the average duty cycle of the fourth subset of heater parameter values, and the average gun cycle count of a fourth subset of applicator parameter values ​​(i.e., a second parameter relationship associated with the second time block). Similar to the first parameter relationship associated with the first time block, the second parameter relationship can reflect the difference between the average duty cycle of the fourth subset of heater parameter values ​​and the average duty cycle of the third subset of heater parameter values. Also similar to the first parameter relationship, the second parameter relationship can also include the relationship between the average gun cycle count (e.g., non-zero or multi-gun cycle count) of the fourth subset of applicator parameter values ​​and the aforementioned difference between the average duty cycle of the fourth subset of heater parameter values ​​and the average duty cycle of the third subset of heater parameter values. Again, similar to the first parameter relationship, the second parameter relationship can be expressed in equation (2).

[0109] Determining the predicted failure time of the applicator may include comparing a first parameter relationship associated with a first time block (e.g., day 1) and a second parameter relationship associated with a second time block (e.g., day 2). Comparing the first and second parameter relationships may include determining a trend (e.g., a statistical trend) between the first and second parameter relationships. This trend may be relative to the gun cycle count and the heater duty cycle value associated with the gun cycle count. Determining the predicted failure time of the applicator may also include fitting a curve (e.g., a mathematical function) to the trend, such as when plotting the first and second parameter relationships on a graph.

[0110] Determining the predicted failure time of the applicator can also be based on one or more other parameter relationships besides the first and second parameter relationships. Each of the one or more other parameter relationships can be associated with a different time block (e.g., a day) than the first and second time blocks. Each of the one or more other parameter relationships can be based on a corresponding plurality of applicator parameter values ​​and heater parameter values ​​that are temporally associated with the corresponding other time block. In some aspects, each of the one or more other parameter relationships can be determined in a manner similar to that in which the first and second parameter relationships can be determined.

[0111] Therefore, determining the predicted failure time of the applicator may also include performing a comparison between a first parameter relationship, a second parameter relationship, and one or more other parameter relationships. This comparison may include determining a trend (e.g., a statistical trend) among the first parameter relationship, the second parameter relationship, and one or more other parameter relationships. The comparison may also include determining a curve to fit the trend, such as when the first parameter relationship, the second parameter relationship, and one or more other parameter relationships are plotted graphically.

[0112] Those skilled in the art will understand that the systems and methods disclosed herein can be implemented via a computing device, which may include, but is not limited to, one or more processors, system memory, and a system bus that connects the various system components, including the processors, to the system memory. In the case of a multiprocessor system, parallel computing can be utilized.

[0113] For illustrative purposes, applications and other executable program components such as operating systems are shown herein as discrete blocks; however, it should be understood that such programs and components reside in different storage components of a computing device at different times and are executed by the computer's data processor. Specific implementations of service software may be stored or transmitted across some form of computer-readable medium. Any method disclosed in this invention can be executed by computer-readable instructions embodied on a computer-readable medium. A computer-readable medium can be any available medium accessible to a computer. By way of example and not intended to be limiting, a computer-readable medium may include "computer storage medium" and "communication medium." "Computer storage medium" includes volatile and non-volatile, removable and non-removable media implemented in any method or technique 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 memory technologies, CD-ROM, digital versatile optical disc (DVD) or other optical storage devices, magnetic cartridges, magnetic tape, disk storage devices or other magnetic storage devices, or any other medium that can be used to store desired information and is accessible by a computer. Applications and / or storage media may be implemented at least partially at a remote system.

[0114] As used herein and in the appended claims, the singular forms “a,” “an,” and “the” include multiple referents unless the content expressly indicates otherwise. A range may be expressed herein as “about” a particular value and / or “about” another particular value. When such a range is expressed, another embodiment includes from one particular value and / or to another particular value. Similarly, when a value is expressed as an approximation using the antecedent “about,” it should be understood that the particular value forms another embodiment. It should also be understood that each endpoint in the range is significant with respect to the other endpoints and is independent of the other endpoints.

[0115] Unless otherwise specified herein, the descriptions of ranges of values ​​herein are intended only as a shorthand for individually referring to each independent value falling within that range, and each independent value is incorporated into this specification as if listed separately herein.

[0116] Throughout this specification and claims, the word “comprising” and variations thereof, such as “comprising” and “including,” mean “including, but not limited to,” and are not intended to exclude, for example, other components, integers, or steps. “Exemplary” means “an example of…” and is not intended to convey indications of preferred or ideal embodiments. “Like” is not used in a limiting sense but is for illustrative purposes.

[0117] This invention discloses components that can be used to perform the disclosed methods and systems. These and other components are disclosed herein, and it should be understood that while specific references to combinations, subsets, interactions, groups, etc., of each of these components may not be explicitly disclosed when disclosing combinations, subsets, interactions, groups, etc., of these components, each of these methods and systems is specifically contemplated and described herein. This applies to all aspects of this patent application, including but not limited to the steps in the disclosed methods. Therefore, if multiple additional steps are available, it should be understood that each of these additional steps can be performed using any particular embodiment or combination of embodiments of the methods disclosed herein.

[0118] Unless otherwise expressly stated, it is not intended that any method described herein require the steps of the method to be performed in a particular order. Therefore, if a method claim does not actually state that the order of its steps will be followed, or if the claims or description do not specifically state that the steps will be limited to a particular order, it is not intended to infer the order in any way. This provides for any possible non-explicit basis for the description, including: logical problems concerning the arrangement of steps or operational procedures; simple meanings derived from grammatical structures or punctuation; and the number or type of embodiments described in the description.

[0119] It will be apparent to those skilled in the art that various modifications and variations can be made without departing from the scope or spirit of the invention. Other embodiments will be apparent to those skilled in the art in light of the specification and the practices disclosed herein. It is intended that the specification and examples be considered merely exemplary, wherein the true scope and spirit are indicated by the following claims.

Claims

1. A method for predicting the failure of an applicator in a hot melt liquid dispensing system, the applicator being configured to dispense hot melt liquid, and the hot melt liquid dispensing system further having a hot melt liquid heater associated with the applicator, the method comprising: Provides a plurality of applicator parameter values ​​for a first operating parameter of the applicator, each of the plurality of applicator parameter values ​​being temporally associated with a time interval of a first time block; A first subset of the multiple applicator parameter values ​​is determined, each applicator parameter value in the first subset indicating that the applicator did not assign activity within the time interval associated with the time of the first time block; A second subset of the multiple applicator parameter values ​​is determined, each applicator parameter value in the second subset indicating the applicator's distribution activity within a time interval associated with the time of the first time block; as well as The predicted failure time of the applicator is determined based on a first subset and a second subset of the applicator parameter values.

2. The method of claim 1, wherein the first operating parameter of the applicator includes a gun cycle count of the applicator during a time-correlated time interval.

3. The method of claim 2, wherein determining the first subset of the applicator parameter values ​​comprises: Each applicator parameter value in the first subset of the applicator parameter values ​​indicates a gun cycle count that is zero during the time-related time interval.

4. The method of claim 3, wherein determining the second subset of the applicator parameter values ​​comprises: Each applicator parameter value in the second subset of the applicator parameter values ​​indicates the gun cycle count that exceeds the threshold gun cycle count during the time-correlated time interval.

5. The method of claim 2, wherein the predicted failure time of the applicator is further based on the gun cycle count for each applicator parameter value in a first subset of the applicator parameter values.

6. The method of claim 1, wherein the hot melt liquid dispensing system further comprises a hot melt liquid heater associated with the applicator, the method further comprising: Provides a plurality of heater parameter values ​​for the second operating parameters of the hot melt liquid heater, each of the plurality of heater parameter values ​​being associated with one of the plurality of applicator parameter values; A first subset of heater parameter values ​​is determined from the plurality of heater parameter values, each heater parameter value in the first subset of heater parameter values ​​being associated with an applicator parameter value in the first subset of applicator parameter values; as well as A second subset of the plurality of heater parameter values ​​is determined, wherein each heater parameter value in the second subset of the heater parameter values ​​is associated with an applicator parameter value in the second subset of the applicator parameter values. The predicted failure time of the applicator is also based on a second subset of the heater parameter values.

7. The method of claim 6, wherein the second operating parameter of the hot melt liquid heater includes the duty cycle of the hot melt liquid heater during a time-correlated time interval.

8. The method of claim 7, wherein determining the predicted failure time of the applicator comprises: One or more heater parameter values ​​from a first subset of the heater parameter values ​​are compared with one or more heater parameter values ​​from a second subset of the heater parameter values.

9. The method of claim 8, wherein comparing one or more heater parameter values ​​of a first subset of the heater parameter values ​​with one or more heater parameter values ​​of a second subset of the heater parameter values ​​comprises: The average value of a first subset of the heater parameter values ​​is compared with the average value of a second subset of the heater parameter values.

10. The method of claim 7, wherein the predicted failure time of the applicator is further based on the average duty cycle of a first subset of the heater parameter values, the average duty cycle of a second subset of the heater parameter values, and the average gun cycle count of a second subset of the applicator parameter values.

11. The method of claim 7, wherein the method further comprises: Provides a second plurality of applicator parameter values ​​for the first operating parameter of the applicator, each of the second plurality of applicator parameter values ​​being temporally associated with a time interval of a second time block; Provides a second plurality of heater parameter values ​​for the second operating parameters of the hot melt liquid heater, each of the plurality of heater parameter values ​​being associated with one of the second plurality of applicator parameter values; A third subset of the second plurality of applicator parameter values ​​is determined, each applicator parameter value in the third subset indicating that the applicator did not assign activity within the time interval associated with the time of the second time block; Determine a fourth subset of the second plurality of applicator parameter values, each applicator parameter value in the fourth subset indicating the applicator's distribution activity within a time interval associated with the time of the second time block; Determine a third subset of heater parameter values ​​from the second plurality of heater parameter values, wherein each heater parameter value in the third subset of heater parameter values ​​is associated with an applicator parameter value in the third subset of applicator parameter values; as well as A fourth subset of heater parameter values ​​is determined from the second plurality of heater parameter values, wherein each heater parameter value in the fourth subset of heater parameter values ​​is associated with an applicator parameter value in the fourth subset of applicator parameter values. The predicted failure time of the applicator is also based on a third subset and a fourth subset of the heater parameter values.

12. The method of claim 11, wherein the first time block comprises the first day, and the second time block comprises the second day following the first day.

13. The method of claim 11, wherein the time interval of the first time block has a duration in the range of one minute to ten minutes, including end values.

14. The method of claim 11, wherein the predicted failure time of the applicator is further based on the average duty cycle of a third subset of the heater parameter values, the average duty cycle of a fourth subset of the heater parameter values, and the average gun cycle count of a fourth subset of the applicator parameter values.

15. The method of claim 14, wherein determining the predicted failure time of the applicator comprises: The first parameter relationship associated with the first time block and the second parameter relationship associated with the second time block are compared. Wherein, the first parameter is related to the average duty cycle value of a first subset of the heater parameter values, the average duty cycle value of a second subset of the heater parameter values, and the average gun cycle count of a second subset of the applicator parameter values, and The second parameter is related to the average duty cycle of the third subset of the heater parameter values, the average duty cycle of the fourth subset of the heater parameter values, and the average gun cycle count of the fourth subset of the applicator parameter values.

16. The method of claim 15, wherein: The first parameter relationship reflects the difference between the average duty cycle value of the second subset of the heater parameter values ​​and the average duty cycle value of the first subset of the heater parameter values, and The second parameter relationship reflects the difference between the average duty cycle of the fourth subset of the heater parameter values ​​and the average duty cycle of the third subset of the heater parameter values.

17. The method of claim 16, wherein: The first parameter relationship also includes the relationship between the average gun cycle count of the second subset of the applicator parameter values ​​and the difference between the average duty cycle value of the second subset of the heater parameter values ​​and the average duty cycle value of the first subset of the heater parameter values, and The second parameter relationship also includes the relationship between the average gun cycle count of the fourth subset of the applicator parameter values ​​and the difference between the average duty cycle of the fourth subset of the heater parameter values ​​and the average duty cycle of the third subset of the heater parameter values.

18. The method of claim 17, wherein determining the predicted failure time of the applicator comprises: The first parameter relationship, the second parameter relationship, and each of them are compared with one or more other parameter relationships that are temporally associated with time blocks other than the first time block and the second time block.

19. The method of claim 18, wherein determining the predicted failure time of the applicator comprises: Determine the statistical trend among the first parameter relationship, the second parameter relationship, and the one or more other parameter relationships.

20. The method of claim 19, wherein determining the statistical trend comprises: Determine the mathematical function used to fit the statistical trend.

21. The method of claim 6, wherein the time interval of the first time block includes the time interval during which at least one of the applicator, the hot melt liquid heater, or the hot melt liquid distribution system is in a ready state.

22. The method of claim 6, wherein one of the plurality of heater parameter values ​​is associated with a time interval, the time interval being the same as the time interval associated with the applicator parameter value, which is associated with the heater parameter value.

23. The method of claim 6, wherein one of the plurality of heater parameter values ​​is associated in time with a time interval that deviates from the time interval associated in time with the applicator parameter value associated with the heater parameter value.

24. The method of claim 6, wherein the predicted failure time of the applicator relates to an air leak associated with the applicator.

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