Systems and methods for enhanced coating dispensing control

Abstract

Systems and methods for enhanced paint dispensing control are disclosed. The dispensing system is configured to apply a material to the sequence of substrates. The dispensing system applies a first amount of material onto the first substrate according to a first value of the operating parameter. The sensor is used to measure a characteristic of a first amount of material applied on the first substrate. Based on a characteristic of a first amount of material applied on a first substrate, a characteristic of an amount of material is estimated to be out of range after application on a subsequent substrate in a sequence of substrates. In response, the value of the operating parameter is adjusted, and a second amount of material is applied to the second substrate.

Description

[0001] Divisional Application

[0002] This application is a divisional application of Chinese Patent Application No. 201880079642.1, filed on November 2, 2018, entitled “SYSTEM AND METHOD FOR ENHANCED COATING DISPENSING CONTROL.”

[0003] Cross Reference to Related Patent Applications

[0004] This application claims the benefit of U.S. Provisional Patent Application No. 62 / 584,622, filed on November 10, 2017, the disclosure of which is hereby incorporated by reference herein. TECHNICAL FIELD

[0005] The present disclosure relates generally to liquid applications, and more particularly to a system and method for enhanced coating dispensing control. BACKGROUND

[0006] Precision, accuracy, and consistency are important aspects in most any industrial process. This is especially true in many dispensing applications, such as those systems that apply conformal coatings or other fluids to a substrate. Conformal coating generally refers to a process of applying a fluid to selected areas of a substrate, such as a printed circuit board (PCB). Various complex components having inconsistent shapes and arrangements are often attached to the surface of a PCB or other such substrate. The conformal coating process must navigate the irregularities of the substrate and apply the fluid at particular locations, with particular degrees of thickness and other like characteristics. Due to the complex and delicate nature of the PCB or other subject substrate, it is clear that the coating process must be performed within strict tolerances over multiple iterations. Other types of dispensing systems, such as jetting systems, that apply fluids to various types of substrates are similarly demanding.

[0007] However, many current systems struggle to maintain such high standards of precision and accuracy. These and other shortcomings are discussed in the present disclosure. SUMMARY

[0008] Systems and methods for enhanced coating dispensing control are disclosed herein. In one example method, a dispensing system is operated by a controller and has a dispensing device configured to apply a material to a sequence of substrates. Initially, the dispensing system applies a first amount of the material to a first substrate in the sequence of substrates according to a first value of an operating parameter of the dispensing system. A sensor is used to measure a characteristic of the first amount of the material applied to the first substrate. Based on the characteristic of the first amount of the material applied to the first substrate, it is determined that after application to a subsequent substrate in the sequence of substrates, a characteristic of an amount of the material is estimated to be outside a range. In response, the value of the operating parameter is adjusted and a second amount of the liquid is applied to a second substrate in the sequence of substrates. The characteristic of the first amount of the material applied to the first substrate is different than the characteristic of the second amount of the material applied to the second substrate.

[0009] An example dispensing system includes a dispensing device and a sensor arranged to measure a characteristic of an amount of a material applied to a substrate in a sequence of substrates by the dispensing device. The system also includes a controller configured to generate one or more signals to implement the following steps. The dispensing device is operated to apply a first amount of the material to a first substrate in the sequence of substrates according to a first value of an operating parameter of the dispensing system. Information is generated using the sensor regarding a characteristic of the first amount of the material applied to the first substrate. Based on the information regarding the characteristic of the first amount of the material, an estimated value is determined, where the estimated value is a characteristic of an amount of the material after application to a subsequent substrate in the sequence of substrates. The estimated value of the characteristic of the amount of the material after application to the subsequent substrate is compared to a range to determine that the estimated value of the characteristic is outside the range. In response to determining that the estimated value of the characteristic of the amount of the material after application to the subsequent substrate is outside the range, the value of the operating parameter is adjusted to a second value. A second amount of the material from the dispensing device is applied to a second substrate in the sequence of substrates according to the second value of the operating parameter, where the characteristic of the first amount of the material applied to the first substrate is different than the characteristic of the second amount of the material applied to the second substrate. BRIEF DESCRIPTION OF DRAWINGS

[0010] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate implementations and together with the description, explain the principles of the methods and systems: Figure 1 A side view of a coating system according to an implementation of the present disclosure is shown; Figure 2A A coating assembly according to an implementation of the present disclosure is shown; Figure 2B A schematic view of an alternative coating system according to an implementation of the present disclosure is shown; Figure 3A A portion of an inspection station according to an implementation of the present disclosure is shown; Figure 3B A portion of an inspection station according to embodiments of the present disclosure is shown; Figure 4 A data flow diagram according to embodiments of the present disclosure is shown; and Figure 5 A method flow diagram according to embodiments of the present disclosure is shown.

[0011] Aspects of the present disclosure will now be described in detail with reference to the drawings, where like reference numerals are used to refer to like elements throughout and in which: DETAILED DESCRIPTION

[0012] Systems and methods of the present disclosure relate to enhanced control in a paint dispensing process. Enhanced control is implemented in a system having a dispenser that applies fluid to a substrate, an inspection station to measure one or more values of various characteristics of the applied fluid, and / or a curing oven to cure the coated substrate.

[0013] The dispenser and / or other components of the system operate according to one or more operating parameters that affect various characteristics of the applied fluid. One example operating parameter can be fluid pressure of the fluid as it is supplied to the dispenser. As noted, a substrate coated according to these operating parameters can be inspected, such as via a camera, to determine a value of one or more of the paint characteristic values. Based on this value and / or storage of similar past values, a future value of this paint characteristic for a subsequent substrate is predicted. If the predicted value is unacceptable or represents a trend toward an unacceptable value, the operating parameter value can be adjusted for subsequent substrates. For example, the fluid pressure of the fluid can be lowered or raised, as appropriate. Preferably, the system proactively avoids errors or failures due to various paint characteristic values of the fluid exceeding a set tolerance range.

[0014] The disclosed systems and methods can also be used to exhaustively verify the capability of the dispensing portion (e.g., the dispenser) of the system, including any processes performed by the dispensing portion of the system. For example, the disclosed systems and methods can be used to determine a process capability index or process capability ratio, such as Cp or Cpk. pk .

[0015] The teachings disclosed herein can be applied with a wide variety of material dispensing system types, including those that vary in dispensing operation mode, mechanical configuration, valve type, substrate, and / or material. Thus, the teachings presented with reference to a device type, valve type, and / or operation of coating, dispensing, applying, jetting, needle (or similarly styled descriptor), or any other characterization can equally apply to all other types of devices, valves, and / or operations. Of course, this is so unless explicitly stated otherwise or otherwise clearly indicated by context. Similarly, any teachings presented with reference to a type or characterization of material (e.g., paint, fluid, liquid, viscous material, and / or combinations thereof) can equally apply to all other materials unless explicitly stated or otherwise clearly indicated by context. The same is true for any teachings presented with reference to a particular type of substrate, such as printed circuit board (PCB). Thus, the teachings presented with reference to a PCB equally apply to other types of substrates. Likewise, teachings presented with reference to a substrate only can apply to any form of substrate, including a PCB. Again, a clear and explicit statement or a clear context can indicate that the teachings apply only to a particular type of substrate.

[0016] With reference to Figure 1 and Figure 2A A system 100 for applying a fluid (e.g., a paint material, a viscous material, or other type of material) to a series of sequential substrates 114 includes a paint assembly 104, an inspection station 130, and a curing oven 102. The paint assembly 104 selectively applies the fluid to the substrates 114. The coated substrates 114 are then transferred to the inspection station 130 via a conveyor 122 or other form of transport. The inspection station 130 includes one or more sensors that measure a value of one or more characteristics of the fluid on the substrates 114. Data collected by the inspection station 130 is received and processed by a controller 132. Based on the measured values of the paint characteristics, the controller 132 determines or estimates whether a future paint application performed under the same or similar operating parameters will or can produce a substrate paint having a value of one or more characteristics that falls outside of a predetermined tolerance range or other quality metric for the value. If so indicated, the controller 132 alters one or more operating parameters of the paint assembly 104 or other components of the system 100 to prevent a corresponding value of the paint characteristic in a subsequent coated substrate from falling outside of the tolerance range. After inspection, the coated substrates 114 can be transferred to the oven 102 for curing of the paint.

[0017] Of particular note Figure 2AThe coating assembly 104 includes a coating dispenser 108 for selectively applying fluid to the substrate 114. It should be noted that the particular coating assembly 104 and dispenser 108 described and shown herein are merely exemplary, and the present disclosure is not limited thereto. Rather, the dispenser 108 can be implemented in one of a variety of forms, some of which can operate according to different dispensing mechanisms or principles of operation. For example, the dispenser 108 can be implemented in a form configured to apply fluid as droplets or beads, a filament (e.g., a straight or looped line), a swirl or spray pattern / area, or any combination thereof. As another example, the dispenser 108 can be configured with one or more air jets (not shown) to atomize or otherwise impact the fluid as it exits a nozzle of the dispenser 108. Conversely, the dispenser 108 can be configured without any air jets and dispense fluid without atomization or other effects caused by air flow. The operation of the dispenser 108 is discussed below. Figure 2B An exemplary alternative coating system is shown.

[0018] The dispenser 108 is supplied with fluid by a fluid source 106. The dispenser 108 is equipped with a nozzle 134 that operates to dispense a volume of fluid to the substrate 114. In particular, the nozzle 134 includes a valve 136 that can be opened and closed to dispense fluid. As shown, the valve 136 can be opened and closed to dispense fluid by the action of a drive pin 138 moving toward a valve seat 140 within the nozzle 134. When the drive pin 138 moves toward the valve seat 140, intervening fluid is dispensed from an opening 142 at the tip of the nozzle 134. The drive pin 138 is driven by an actuator 144, such as a pneumatic or piezoelectric actuator. The actuator 144 can be mechanically coupled to the drive pin 138, or can be periodically decoupled from the drive pin 138 while in operation. In addition to or alternatively to the above-described arrangement of the valve seat 140, drive pin 138, and actuator 144, fluid can be urged by fluid pressure (e.g., from the fluid source 106) to cause fluid to be dispensed from the nozzle 134. For example, fluid can be expelled from the opening 142 when the valve 136 is open. The operation of the various components of the dispenser 108 and their parameters can be managed and controlled by a controller 132.

[0019] The coating assembly 104 can be configured with one or more flow meters 146 that can each be configured to measure the flow rate, velocity, and / or fluid pressure of fluid flowing through an associated structure. For example, the flow meters 146 can be integrated with or positioned in association with the fluid source 106, a channel (not labeled) leading from the fluid source 106 to the dispenser 108, and / or the nozzle 134 of the dispenser 108. Data measured by the flow meters 146 can be communicated to the controller 132, which can use the data to determine whether a tolerance range can be exceeded and to determine which operating parameter to adjust and to what extent.

[0020] The coating assembly 104 may be configured to allow the dispenser 108 to have three degrees of freedom of movement in three dimensions (such as X, Y, and Z coordinates), with the reference frame being the planar surface of the substrate 114 or the surface on which the substrate 114 rests. In some cases, the dispenser 108 may be configured to tilt the nozzle 134 relative to the vertical axis of the nozzle 134 (i.e., the axis of the nozzle 134 parallel to the Z-axis when the nozzle 134 is stationary). The surface supporting the substrate 114 may be configured to move relative to the dispenser 108, in addition to or as an alternative to the movement of the dispenser 108 relative to the substrate 114.

[0021] Figure 2B Showing completely or partially except Figure 2A A coating system 10, which may be used in conjunction with system 100, either in addition to or wholly or partially as a replacement for the coating component 104 shown. Coating system 10 can be used to apply liquid coating materials, such as conformal coating materials, to a series of substrates, such as representative substrate 12. While the operation of representative coating system 10 will be described herein, those skilled in the art will understand that a wide variety of other coating systems can be used to accomplish the following methods. Coating system 10 may be, for example, a conformal coating applicator such as the SC-105, SC-205, or SC-400, commercially available from Asymtek, Carlsbad, California.

[0022] In a representative embodiment, the coating system 10 includes a multi-axis electromechanical positioner or robot 14 and a conformal coating applicator 16 coupled to the robot 14. For example, the applicator 16 may be suspended from the robot 14 above the substrate 12. In one embodiment, the robot 14 is adapted to move the applicator 16 in directions defined in the XYZ Cartesian coordinate system to provide three degrees of freedom. The robot 14 includes a drive coupled in a known manner to an independently controllable motor (not shown). The applicator 16 is manipulated by the robot 14 relative to the substrate 12 for applying a quantity of liquid coating material to a selected area of ​​the substrate 12.

[0023] A programmable controller 18 coordinates movement and actuation of the coating system 10. The controller 18 can be a programmable logic controller (PLC), a microprocessor-based controller, a personal computer, or another conventional control device capable of performing the functions described herein, as will be understood by those of ordinary skill in the art. For example, the controller 18 can execute various flow control routines and fan width control routines. A human-machine interface (HMI) device 19 is operatively connected to the controller 18 in a known manner. The HMI device 19 can include input devices and controls, such as a keypad, buttons, control knobs, a touch screen, and the like, as well as output devices, such as a display and other visual indicators, which are used by an operator to control operation of the controller 18, and thus operation of the coating system 10. The HMI device 19 can also include an audio output device, such as a speaker, through which audio alerts can be communicated to the operator.

[0024] The substrates 12 (e.g., printed circuit boards having semiconductor dies and other components attached) are supported in operable relation to the applicators 16 in a known manner, and liquid coating material is applied from the applicators 16 onto selected areas on each of the substrates 12. Depending on the dispensing application, a series of substrates 12 can be coated in batch mode. Alternatively, the substrates 12 can be transported continuously past the applicators 16 on an automated conveyor 20. The conveyor 20 has a conventional design, and in addition can have a width that can be adjusted to accommodate different sizes of substrates 12. The conveyor 20 receives command signals from a conveyor controller 22, which can also include pneumatically operated lift and lock mechanisms (not shown).

[0025] The applicators 16 are electrically coupled to an applicator controller 24, which provides command signals that control operation of the applicators 16. A motion controller 26 is electrically coupled to the robot 14 by a communication link 21. The solenoids 34 are electrically coupled to the motion controller 26 by a communication link 23. The conveyor controller 22 and the motion controller 26 are also electrically coupled to the controller 18 by respective communication links 25, 27. The motion controller 26 is electrically coupled to the conveyor controller 22 by a communication link 29. Thus, the programmable control system for the coating system 10 includes the controller 18, the applicator controller 24, the motion controller 26, and optionally the conveyor controller 22 as interconnected components that communicate with one another.

[0026] The motion controller 26 provides command signals to the robot 14 by the communication link 21. The robot 14 uses the command signals to control the position and / or velocity of the applicators 16. Generally, the robot 14 includes electric motors, such as servo motors or stepper motors, that drive motion of the different axes of the robot 14.

[0027] Coater 16 includes a body 30 suspended from robot 14, a nozzle 31 mounted to one end of body 30, and a flow control mechanism (not shown) disposed within body 30. The flow control mechanism within body 30 can include an air actuated needle, an air piston, and a valve seat that cooperate to form a dispensing valve (not shown) that is operable to control the flow of conformal coating material dispensed from coater 16. A pressurized fluid supply 32 and a solenoid 34 cooperate to supply pressurized fluid in a known manner to regulate actuation of the dispensing valve within body 30. Specifically, solenoid 34 controls the air pressure in a conduit 33 connecting pressurized fluid supply 32 with coater 16 to move the air piston and, in turn, the needle relative to the valve seat to provide an open position for the dispensing valve in which liquid coating material is dispensed from coater 16 onto substrate 12. Solenoid 34 can exhaust the air pressure acting on the air piston to allow the needle to return to a closed position in which the needle contacts the valve seat to interrupt dispensing.

[0028] Coating system 10 can include a fan width sensor 62 that can be disposed, for example, on robot 14 or coater 16. In some aspects, fan width sensor 62 can also be a separate module that is independent of robot 14 and coater 16. Fan width sensor 62 can be configured to determine various characteristics (e.g., width or shape) of the fan of material dispensed from coater 16. As used herein, the fan of material refers to the shape of material stream 42 from coater 16 and its dimensions. For example, coater 16 can dispense material in a conical spray at a known distance between coater 16 and substrate 12, whereby the conical spray will produce a circular coating area on substrate 12 having a certain diameter. As coater 16 moves along substrate 12, the conical spray of material will produce a coating swath on substrate 12 having a width corresponding to the particular diameter of the conical spray. Fan width sensor 62 can be communicatively connected with motion controller 26 and / or controller 18. For example, data points indicative of the fan of material and determined by fan width sensor 62 can be transmitted to controller 18 and stored in memory 44 therein.

[0029] In one aspect, the fan width sensor 62 can include a camera and a light source or laser source, with the material stream 42 positioned between the camera and the light source or laser source to determine various characteristics of the material stream 42 (e.g., width or shape). The camera can be configured to capture images of the fluid pattern of the stream 42 as it is dispensed from the applicator 16. The images captured by the camera can be still images or images that include a video stream. The camera can relay the images of the fluid pattern to the controller 18, which can use the images to perform other processing steps, such as a fan width control routine. The light source or laser source can be configured to emit light or laser light through the fluid pattern of the stream 42. For example, the light source or laser source can be located directly in front of the camera on the other side of the applicator 16 and in the same horizontal plane as the camera. The light source or laser source can provide illumination of the fluid pattern of the stream 42 to improve the image quality of the images captured by the camera. A fan width sensor 62 so configured can allow for determination of the fan width or other characteristics of the stream 42 and possible real-time adjustments in coating the substrate.

[0030] The coating system 10 includes a pressurized liquid supply 38 that operates in a known manner under the command of the controller 18 to generate a continuous stream or supply of pressurized liquid coating material. For example, the pressurized liquid supply 38 can include a diaphragm or piston pump that siphons an amount of liquid coating material from a reservoir and then pumps the stream of liquid coating material from the reservoir through a fluid path to the applicator 16 under pressure. The pressurized liquid supply 38 is electrically connected by a communication link 39 with the controller 18, which can adjust operating parameters such as the temperature and pressure of the liquid coating material by transmitting appropriate control signals to the pressurized liquid supply 38 through the communication link 39.

[0031] The pressurized liquid supply 38 is optionally configured with one or more conventional heating elements 38a that are electrically coupled with a conventional temperature controller 60 that is electrically coupled with the controller 18. The configuration and operation of conventional heating elements such as the heating elements 38a and temperature controllers such as the temperature controller 60 are understood by those of ordinary skill in the art. In alternative embodiments, the applicator 16 can include a heating element (not shown), or a heating element (not shown) can be provided in one of the conduits 51, 53, 55. Regardless of the specific location of the heating element in the flow path between the pressurized liquid supply 38 and the nozzle 31, the liquid coating material can be heated in that flow path prior to application to the substrate 12.

[0032] The applicator 16 includes a liquid inlet 36 coupled in fluid communication with a pressurized liquid supply 38. Liquid coating material is supplied from the pressurized liquid supply 38 through the liquid inlet 36 to the applicator 16 for regulated dispensing from a dispensing orifice (not shown) in the nozzle 31. The body 30 has a fluid inlet 40 coupled with the pressurized fluid supply 32 and an internal passage (not shown) that directs pressurized fluid to an outlet in the vicinity of the dispensing orifice in the nozzle 31, where the pressurized fluid is discharged to interact with and manipulate a stream 42 of liquid coating material sprayed from the applicator 16. A fluid regulator 43, in communication with the motion controller 26 through a communication link 45, controls the flow of pressurized fluid from the pressurized fluid supply 32 to the fluid inlet 40. Representative applicators similar to the applicator 16 are described in U.S. Patent No. 7,028,867, the disclosure of which is hereby incorporated by reference in its entirety.

[0033] The coating system 10 is operated in accordance with instructions stored in a memory 44 associated with the controller 18 and / or in a library of operation cycles or sequences stored in other computers. The operation sequences are called and placed in a particular operation program executing on the controller 18 as needed. The operation sequences can be adjusted to accommodate different environmental conditions, different types of substrates 12, or different types of conformal coating materials. During operation, the controller 18 can transfer the entire operation program as an electrical signal through the communication link 25 to the motion controller 26 for execution at the motion controller 26. Alternatively, the controller 18 can transfer one or more instructions in a batch of instructions and data as electrical signals through the communication link 25 to the motion controller 26 for subsequent execution. An operator can input parameters at the HMI device 19, such as the type of substrate 12, an identifier for the substrate 12, a description of the substrate 12, the type of liquid coating material, the liquid pressure, the auxiliary air pressure, the speed of the applicator 16, the distance between the substrate 12 and the applicator 16, and the like. The inputted parameters are stored in the memory 44 of the controller 18 for future use in the operation sequences. Each substrate 12 is matched by the controller 18 with a coating program that determines which particular parts and areas of the substrate 12 are to be coated with the liquid coating material. Typically, the liquid coating material is applied only to selected areas and / or parts on the substrate 12.

[0034] An "air over fluid" (A / F) regulator 50 and a flow meter 52 are located in the flow path of the liquid coating material from the pressurized liquid supply 38 to the liquid inlet 36 of the applicator 16. Thus, the liquid coating material is constrained to flow through the A / F regulator 50 and the flow meter 52 as it is carried from the pressurized liquid supply 38 to the applicator 16. The liquid input of the A / F regulator 50 is coupled with the liquid outlet of the pressurized liquid supply 38 by a conduit 51. Similarly, the A / F regulator 50 has a liquid outlet that is coupled with the liquid input of the flow meter 52 by a conduit 53, which in turn has a liquid outlet that is coupled with the liquid inlet 36 of the applicator 16 by a conduit 55.

[0035] The A / F regulator 50 controls the fluid pressure of the pressurized liquid material as it is carried in the fluid path to the applicator 16. The controller 18 is electrically coupled with the regulator 54 by a communication link 57. In one embodiment, the regulator 54 can be an "electrical to pressure" (E / P) regulator that receives a control voltage from the motion controller 26 and includes a transducer that converts the control voltage to a fluid pressure. Alternatively, the regulator 54 can receive a control current or a serial communication signal instead of a control voltage for conversion to a fluid pressure. The regulator 54 delivers pressurized fluid to the A / F regulator 50 for controlling the fluid pressure of the liquid coating material flowing through the A / F regulator 50.

[0036] The A / F regulator 50 is positioned in the conduit 35 that defines the fluid path between the pressurized liquid supply 38 and the flow meter 52. In an alternative embodiment, the flow meter 52 can be positioned in the fluid path between the pressurized liquid supply 38 and the A / F regulator 50 such that the flow meter 52 is upstream of the A / F regulator 50. With this alternative arrangement, the A / F regulator 50 would alter the pressure of the liquid coating material after it flows through the flow meter 52.

[0037] The controller 18 is electrically coupled with the flow meter 52 by a communication link 59. In response to the flow of liquid coating material from the conduit 53 to the conduit 55, the flow meter 52 generates counts or strings of electrical pulses, each count or electrical pulse representing a fixed volume of liquid coating material that flows through or past the flow meter 52. Alternatively, the strings of electrical pulses from the flow meter 52 can be transmitted from the flow meter to the motion controller 26, which then relays them to the controller 18. In one embodiment, the flow meter 52 can include a gear meter that rotates in response to the flow through the gear meter and generates electrical pulses with an encoder for a fixed amount of rotation that represents a known volume, which are transmitted as electrical signals in a signal stream to the controller 18. For example, the gear meter can generate a pulse for every 0.04 cubic centimeters of liquid coating material that flows through the flow meter 52. In another embodiment, the flow meter 52 can include a thermal mass flow meter.

[0038] In use, when the substrate 12 is properly positioned relative to the applicator 16, the controller 18 obtains an application program for the substrate 12. The application program determines which parts and / or areas of the substrate 12 are to be coated with a liquid coating material, which is typically applied in a swath. For example, the substrate 12 can have twenty-five separate parts or areas that are to be coated with a swath of liquid coating material. The controller 18 retrieves the sequence of operations from the memory 44 of the controller 18 and, in turn, transmits control signals representing the sequence of operations to the motion controller 26 over the communication link 25. The motion controller 26 sends command signals to the robot 14 over the communication link 21 that instruct the robot 14 to move the applicator 16 relative to the substrate 12 at a specified speed to a desired position. The motion controller 26 controls the motion of the robot 14 to move the applicator 16 in a plane (e.g., X and Y directions) across the substrate 12, so that during this motion, the dispensing valve in the applicator 16 is opened and closed as needed to apply the liquid coating material to the desired parts and areas of the substrate 12.

[0039] Specifically, at any particular position on the substrate 12, the motion controller 26 also provides a command signal to the solenoid 34 to cause the solenoid to change state to open the dispensing valve, which results in the discharge of liquid coating material from the nozzle 31. At the same time, the motion controller 26 provides a command signal to the robot 14 to initiate motion of the applicator 16 relative to the substrate 12. The liquid coating material stream 42 can optionally be manipulated by an auxiliary fluid, such as air, that affects the shaping of the stream 42 that is discharged from the applicator 16. After a predetermined time has elapsed, the motion controller 26 then changes the state of the valve command signal to cause the solenoid 34 to return to its initial state. This action closes the dispensing valve to interrupt the discharge of liquid coating material from the nozzle 31 of the applicator 16. The motion controller 26 can cause the dispensing valve of the applicator 16 to open and close the dispensing valve multiple times (e.g., twenty-five times) during the course of the application program, so that multiple parts and areas of the substrate 12 receive an amount of liquid coating material.

[0040] During the application program or in preparation for executing the application program, the controller 18 provides an electrical signal to the motion controller 26 that prompts the motion controller 26 to provide a command signal to the regulator 54. The regulator 54 controls the air pressure supplied to the A / F regulator 50 to select a liquid pressure for the pressurized liquid coating material that flows from the pressurized liquid supply 38 to the applicator 16. The selected value of the liquid pressure depends on the desired flow rate of the liquid coating material, depending on the dispensing application. The flow rate of the liquid coating material is affected by the liquid pressure, the diameter of the discharge orifice in the dispensing nozzle 31, the material viscosity, etc., among other factors.

[0041] Again, the reader is reminded that any teachings with respect to, for example, a particular device type, mode of operation, or material can equally apply to all other types of device, modes of operation, and materials, unless explicitly stated otherwise and / or clear from the context. Thus, any teachings with respect to each of the systems of Figure 2A and Figure 2B may equally apply to each other. Likewise, any other teachings herein with respect to one of the systems of Figure 2A and Figure 2B may also apply to the other.

[0042] Returning attention to Figure 1 and Figure 2A , after the operation of dispensing fluid to the substrate 114 is complete, the coated substrate 114 is transported (e.g., via the conveyor 122) to the inspection station 130. Using one or more sensors, the inspection station 130 can measure and / or determine values of characteristics of the fluid applied to the substrate 114 (which can be referred to herein as “coating characteristics”). For example, the inspection station 130 can measure placement of the fluid relative to the substrate 114 and / or relative to other portions of the fluid on the substrate 114. In a related example, the inspection station 130 can measure shape and other related characteristics of the coating material formation. The inspection station 130 can measure, for example, the size and proportions of the fluid formation placed between two rows of components.

[0043] As yet another example of coating characteristics, the inspection station 130 can measure thickness of the fluid applied to the substrate 114 or portions thereof. In any of the above examples, the measured values of coating characteristics can represent only a subset of the fluid applied to the substrate 114. For example, one value of a coating characteristic can refer to the fluid applied to a first subset of the substrate 114, and a second value of the coating characteristic can refer to the fluid applied to a second subset of the substrate 114. This can be the case, for example, if one region of the substrate 114 is used to receive one thickness of fluid, and a second region of the substrate 114 is used to receive a second, different thickness of fluid. The subset of fluid on the substrate 114 can also be defined by discrete (i.e., non-contiguous) formations of fluid. The thickness of the fluid can be measured by a sensor such as a wet film gauge, an ultrasonic gauge, a laser sensor, and / or a sensor using eddy currents (not shown).

[0044] In one embodiment, the inspection station 130 can measure a value of a coating property of the fluid applied to a predetermined location on the substrate 114. For example, a location on the substrate 114 can be designated as a "sample area." The sample area can be located on a region of the substrate 114 that is free of any functional components and preferably is flat. This can be used to isolate the target coating property of the fluid from other variables that can be introduced at other locations on the substrate 114 in other ways. For example, the vertical aspect of a component can make it difficult to accurately measure some coating properties of the fluid applied to a region with a vertical component, such as fluid thickness. In addition, misalignment or misregistration of a component can cause the associated fluid formation to appear as if the fluid was incorrectly placed with respect to the component, when in fact the formation is correct with respect to placement as the entire substrate 114. The misaligned or misregistered component alone causes a false positive with respect to placement of the fluid formation. The sample area on the substrate 114 can be visually marked on the substrate 114 to visually identify the target area for application of the sample fluid.

[0045] The application of the sample fluid on the designated sample area and the subsequent measurement can not be performed for each coated substrate 114. Rather, it can be performed at predetermined intervals with respect to a number of coated substrates 114 (e.g., every 50 substrates), a number of inspections (e.g., every ten inspections of the substrate 114), or elapsed time (e.g., every hour). The application of the fluid to the sample area and its measurement can also be responsive to an operator input. It should be noted that the sample area can be adapted to applications of multiple fluid formations, such as multiple dots or beads of fluid.

[0046] The value of the property of the fluid on the substrate 114 can be communicated to and stored at the controller 132 for processing. In addition, subsequent substrates 114 in a series of substrates 114 are coated by the coating assembly 104 and communicated to the inspection station 130, which likewise can measure the value of the coating property of each sequential substrate 114 and communicate the data to the controller 132.

[0047] In short, controller 132 may be configured with a processor, memory (volatile and / or non-volatile), and various communication interfaces. The memory may, for example, store instructions that, when executed by the processor, cause the processor to perform various operations indicated in the instructions. Examples of such operations will be provided herein. Controller 132 may communicate with various components of system 100, including coating assembly 104, dispenser 108, conveyor 122, inspection station 130, curing oven 102, and any of their sub-components. Controller 132 manages the cooperative operation of the various components of system 100. Operating parameters of the various components, according to their operation, may be set and / or adjusted by controller 132. Therefore, controller 132 may maintain operating parameter values ​​for many components of system 100. This may be advantageous for performing those parts of the disclosed technology, where controller 132 adjusts the values ​​of the component operating parameters in response to determining or estimating tolerance values ​​that will or may exceed the coating properties.

[0048] like Figure 1 As shown, controller 132 is coupled to inspection station 130. However, this disclosure is not limited thereto. Controller 132 may be connected to or integrated with any component of system 100. Alternatively, controller 132 may be a stand-alone unit. Controller 132 may be further configured with a display for providing visual output to an operator and one or more input devices (e.g., a keyboard and mouse) for the operator to provide input to controller 132. For example, if controller 132 determines or estimates that fluid characteristics will exceed or may exceed a threshold, the operator may interact with controller 132 to provide manual intervention in the operation of dispenser 108.

[0049] As previously described, controller 132 communicates with inspection station 130 and can receive and store data transmitted from inspection station 130, including data indicating values ​​of coating properties. Controller 132 can iteratively receive and store data from inspection station 130 reflecting the corresponding values ​​of coating properties for each of the sequentially inspected coated substrates 114. This data body can represent a “time” sequence of values ​​of coating properties for a group of sequentially inspected substrates 114. However, it should be noted that the group of sequentially inspected substrates 114 does not need to represent all substrates 114 coated within a corresponding time period. Instead, some substrates 114 may be coated, but not inspected during the interim time between inspections of two other coated substrates 114. The “time” aspect of the time sequence can refer to the coated substrates 114 inspected in a series of sequentially inspected coated substrates 114 (or only coated substrates 114, whether or not they are inspected). But the “time” aspect of the time sequence can also be considered in its typical sense (i.e., the elapsed time).

[0050] Using this data reflecting respective values of a coating property of the fluid on two or more substrates 114, the controller 132 can analyze the data to determine or estimate whether a future value of the coating property will, or is likely to, exceed a tolerance value for the coating property (e.g., fall outside a threshold range) in a subsequent iteration of applying the fluid to another substrate 114. If the controller 132 determines that a future value of the coating property will exceed or is likely to exceed the tolerance, the controller 132 can also determine or estimate when the tolerance will be exceeded or is likely to be exceeded.

[0051] Various predictive and statistical modeling, trend estimation, and / or time series forecasting techniques can be applied to the coating property value data received from the inspection station 130. For example, a linear regression technique can be applied to a linear representation of a time series of coating property values, as obtained on a series of inspected coated substrates 114. In other words, the values of the coating property can form the Y-axis of a line graph, and the series of sequentially coated substrates 114 can form the X-axis of the line graph. For example, the data points on the X-axis can be for a first coated substrate 114, a second coated substrate 114, a third coated substrate 114, etc., respectively. Each of the pairs of coating property value: coated substrate can be represented as a data point on the line graph. A linear regression process or the like can determine a trend line for these data points. Values that exceed the coating property tolerance can be cross-referenced in the trend line to determine a corresponding number (or other metric) of coated substrates 114 that will exceed or are likely to exceed the tolerance. It should be noted that references herein to when the tolerance will be exceeded or is likely to be exceeded can refer to a timing time or another metric, unless explicitly stated otherwise or otherwise clearly indicated by context. Examples of other metrics than a timing time can include a number of coated substrates or a number of coated substrates inspected. Of course, one can be inferred from the other if the coating and / or inspection rates (relative to time) are known.

[0052] If the controller 132 determines or estimates that the coating property will exceed or can exceed the tolerance value, the controller 132 can adjust one or more operating parameters of components of the system 100. For example, the operating parameters of the dispenser 108 can be adjusted. Examples of operating parameters of the dispenser 108 that can be adjusted by the controller 132 include 1) the fluid pressure at which the fluid is provided to the nozzle 134, 2) the air pressure at which one or more air jets apply air to the fluid as it exits the nozzle 134, 3) the timing between coating applications, 4) the position of the dispenser 108 and / or nozzle 134 (e.g., the vertical distance between the nozzle 134 and the substrate 114), 5) the actuation timing of the actuator 144 and / or drive pin 138, 6) the flow rate of the fluid supplied to the nozzle 134 (i.e., the volume per unit of time), and / or 7) the speed and / or rate at which the valve 136 is opened and closed. As an operating parameter of the coating assembly 104, the fluid (or properties thereof) supplied by the fluid source 106 can be changed, such as with respect to the viscosity of the fluid. Other operating parameters that can be adjusted include the speed at which the conveyor 122 transports the substrate 114 or the general rate at which the coating process of the coating assembly 104 and / or the coating and inspection processes together are performed. Additional examples of adjustable operating parameters include the intensity of heat applied in the curing oven 102 or the length of time that a coated substrate 114 is held in the curing oven 102.

[0053] The adjustment of the operating parameter preferably will result in a new value that slows or stops the trend of the coating property value toward the limit of the tolerance value. It is also preferred that the new value to which the operating parameter is adjusted reverses the trend toward the limit of the tolerance value and begins to cause the value of the coating property to move toward the target value. Even more preferably, the new operating parameter value causes the value of the coating property to be within the tolerance range at the next inspection.

[0054] After the coated substrate 114 is inspected at the inspection station 130, the coated substrate 114 is moved, such as by the conveyor 122, to the curing oven 102 to cure the fluid. The curing oven 102 has an interior volume 110 and one or more heating zones 112. Each heating zone 112 receives a coated substrate 114 and heats the environment within the heating zone 112 to a predetermined temperature. The substrate 114 can be moved on a conveyor belt, such as the conveyor 122. However, it should be noted that the conveyor 122 need not include a single conveyor belt, but can be formed of a series of conveyor belts. In one embodiment, each heating zone 112 can be an enclosure that is separated from the rest of the oven by a physical boundary or partition. In another embodiment, each heating zone 112 can be a region of the oven 102 that is not physically separated from the rest of the oven. In some embodiments, the heating zone 112 can be defined by the interior volume 110 of the curing oven 102 such that the heating zone 112 is in fluid communication with the interior volume 110.

[0055] The temperature in each heating zone 112 can be fixed, or it can be adjusted during the heating process. The transition between one heating zone and an adjacent heating zone can be gradual, and can include a temperature gradient ranging from the temperature of a first heating zone 112 to the temperature of a second heating zone 112. In some embodiments, a portion of the interior volume 110 defining a first heating zone 112 can also define a second heating zone 112, such that the heating zones 112 overlap.

[0056] The system 100 can include one or more vents. A first vent 116 can be connected to the curing oven 102 to allow gases, such as evaporated solvent, to move from the interior of the curing oven 102 to the environment outside of the curing oven 102. A second vent 117 can be connected to the coating assembly 104. The second vent 117 can allow gases to flow from within the coating assembly 104 to the environment outside of the coating assembly 104. One or more of the first vent 116 and the second vent 117 can be configured with a regulator 118 (shown schematically in connection with the first vent 116) that can be adjusted to change the rate at which evaporated solvent or other gases can flow from within the volume 110 of the curing oven 102 and / or from within the coating assembly 104 to the environment outside of the curing oven 102 and / or the coating assembly 104, respectively. The regulator 118 can include a damper, a gate, a valve, or another suitable device that can be adjusted to allow or block the passage of evaporated solvent or other gases. One or more of the first vent 116 and the second vent 117 can be configured with a fan 120 that, when operated, can create a negative pressure within the volume 110 of the curing oven 102 and / or the interior of the coating assembly 104, as appropriate. In addition to or alternatively, other types of curing systems, such as a UV curing system, a batch oven curing system, or an air temperature curing system, can be implemented in the system 100.

[0057] In alternative embodiments, the inspection station 130 can be configured to receive the substrate 114 after the coating on the substrate 114 is cured for inspection. For example, the arrangement of the coating assembly 104, the inspection station 130, and the curing oven 102 as shown can be changed such that the curing oven 102 is positioned between the coating assembly 104 and the inspection station 130. Thus, the coating assembly 104 can apply the fluid to the substrate 114, and the coated substrate 114 can be passed to the curing oven 102, where the fluid on the substrate 114 is cured. The coated and cured substrate 114 can then be passed to the inspection station 130. The inspection station 130 can measure various coating properties of the cured fluid in the same or similar manner as when the uncured fluid is inspected directly after the fluid is applied to the substrate 114. The coating properties of the cured fluid can include the same or similar coating properties as those discussed above with respect to the uncured fluid. Figure 1

[0058] ​In another alternative embodiment, the inspection station 130 or portions thereof (e.g., the components shown in Figure 3A and Figure 3B , can be integrated with the coating assembly 104. In such an embodiment, the housing 131 of the inspection station 130 can be omitted. Thus, the coated substrate 114 can be transferred directly to the curing oven 102 after the coated substrate 114, and the coated substrate 114 can be inspected by the integrated inspection station 130, if applicable. In this embodiment, the coating assembly can be configured with two movable arms: one for moving and positioning the dispenser 108, and the other for moving and positioning at least some of the components of the inspection station 130. For example, the camera and / or light source (e.g., UV light source and / or white light source) can be fixed to one of the movable arms. In operation, the dispenser 108 can be positioned and selectively repositioned above the substrate 114 while fluid is applied to the substrate 114, and the other arm holding the inspection components can be positioned alongside. After the coating operation is complete, the dispenser 108 can be moved aside, and the inspection components can be positioned and selectively repositioned above the substrate 114 to inspect the fluid thereon. In another example, both the dispenser 108 and the inspection components can be attached to a single movable arm. In this case, the movable arm can be positioned and selectively repositioned depending on whether a coating operation or an inspection operation is being performed.

[0059] To position the dispenser 108 and / or the inspection components during the respective operations, the movable arm can move above the X-axis, Y-axis, and Z-axis of the substrate 114 while the substrate 114 remains stationary. Alternatively, one or more of the movement axes can be performed by the movable arm, and the substrate 114 can move above one or more of the remaining movement axes. For example, the movable arm can move above the X-axis and Z-axis (i.e., one direction parallel to the planar surface of the substrate 114 and one direction perpendicular to the planar surface of the substrate 114), and the substrate 114 can move above the remaining Y-axis. Additionally or alternatively, the inspection components can be fixed to a static support.

[0060] With continued reference to Figure 1 and Figure 2A , Figure 3A an example configuration of an inspection system 300 is shown, and Figure 3B a camera subsystem 316 associated with the inspection system 300 is shown. The inspection station 130 and other related components of the system 100 can be configured in the same or similar manner as shown in Figure 3A and Figure 3B .

[0061] The inspection system 300 can include an illumination subsystem 304 having an ultraviolet (UV) light source 308 that directs UV light to the substrate 114 (in Figure 3AThe inspection system 300 includes a fluid 302 labeled "PCB under inspection". The fluid 302 may include a tracer that fluoresces in the presence of UV light. The illumination subsystem 304 may also include an optional white light source 312 that directs white light onto the fluid 302 on the substrate 114. Figure 3B (As shown in detail below), the camera subsystem includes a camera 340. The camera 340 has a lens 344 positioned above the substrate 114 for capturing one or more images of the illuminated substrate 114 when light is emitted onto it. Specifically, the camera 340 can be angled or positioned perpendicular to the facing surface 114a of the substrate 114. When positioned perpendicular to the facing surface 114a, as... Figure 3B As shown, the inspection system 300 may include an angled reflector 348. Although in Figure 3A Depicted as being located above substrate 114 and in Figure 3B The image is depicted as perpendicular to the substrate 114, but the camera 340 may be angled relative to the facing surface 114a of the substrate 114, for example, at a 45° angle, such that the lens 344 captures one or more edge images of the outer edge 114b of the illuminated substrate 114. The images from the camera 340 are transmitted to an image processing computer 334, which may be integrated with or operate in cooperation with the controller 132, for determining whether the substrate 114 is properly coated. Alternatively, the image processing computer 334 may be separate from but electronically communicate with the controller 132. The image processing computer or other applicable components of the system 100 may apply various image processing techniques, such as target recognition, pattern recognition, or feature (line, angle, point of interest, etc.) evaluation, to determine values ​​for various coating properties.

[0062] The inspection system 300 may also include a plate holder subsystem 338 configured to support the substrate 114 during inspection. The plate holder subsystem 338 may be configured to hold the substrate 114 around one or more of its edges during inspection. In another embodiment, the plate holder subsystem 338 may include support pins (not shown) for holding the substrate 114 during inspection. To adjust the position of the camera subsystem 316, the camera subsystem 316 may be connected to an XY-axis motor 320. The XY-axis motor 320 is configured to move the camera subsystem 316 relative to the substrate 114 upon receiving instructions from the motion controller 332 and / or the image processing computer 334. Like the image processing computer 334, the motion controller 332 may be integrated with the controller 132, or alternatively, may operate separately from but cooperatively with the controller 132. While one type of inspection apparatus has been described, the inspection system 300 may include various other types of inspection apparatus, such as laser sensors, to measure the coating thickness on the substrate, as needed.

[0063] Figure 4 A data flow diagram 400 is shown that at least partially represents an enhanced paint dispensing control process according to an embodiment of the present disclosure. Although references are made to paint materials, coating operations, paint systems, and other paint-related terms, the present disclosure is not limited thereto. The various components of diagram 400 and their descriptions are equally applicable to all types of equipment (e.g., needle dispensers), operations (e.g., spraying operations), and materials (e.g., viscous materials).

[0064] By way of introduction, coating systems (e.g., Figure 1 System 100 typically performs coating operations based on corresponding values ​​of various operating parameters of the coating system. An immediate coating operation 406 is performed to apply fluid to a substrate (e.g., substrate 114) based on the current operating parameter value 404. Operating parameters are parameters that affect the coating's properties. The current value of the operating parameter is preferably within an acceptable tolerance range 402, but not necessarily. The fluid on the substrate is then examined to determine coating characteristic values ​​408 for the fluid properties. The sum of coating characteristic values ​​410 is updated based on the immediate coating characteristic value 408. The sum of coating characteristic values ​​410 is analyzed to determine and / or estimate one or more future predicted coating characteristic values ​​412 for the fluid on subsequent coating substrates. Based on the predicted coating characteristic values ​​412, the operating parameter value 404 is adjusted, if necessary, to preferably prevent the coating characteristic values ​​of subsequent substrates from falling outside the tolerance range 402, thereby avoiding failures or defects in subsequent substrates.

[0065] Tolerance range 402 can refer to a range of values ​​that the substrate manufacturer or its customer considers acceptable. The value of tolerance range 402 may correspond to a specific coating characteristic of the fluid applied to the substrate. Various types of coating characteristics will be described below with reference to coating characteristic value 408. Tolerance range 402 may include upper and lower limits. Although in some cases, tolerance range 402 may actually or in fact include only one of the upper or lower limits.

[0066] In some implementations, tolerance range 402 may include multiple sets of tolerance ranges, one set being within another. Two ranges may indicate, for example, a low-level warning and a high-level warning. Multiple ranges can be used to compare the predicted paint characteristic value 412 with tolerance range 402 and / or determine adjustments to the operating parameter value 404. In the example, a predicted paint characteristic value 412 exceeding the outermost tolerance range may result in a larger adjustment to the operating parameter value 404, while a predicted paint characteristic value exceeding an inner tolerance range but within an outer tolerance range may result in a smaller adjustment to the operating parameter value 404.

[0067] Operating parameter value 404 may represent the following: operating parameters related to the coating system, components of the coating system, or any other variable related to the operation of the coating system but not strictly part of the coating system itself. Operating parameters can be any parameter that can substantially affect the coating operation and / or the fluid applied to the substrate, such as coating characteristic value 408.

[0068] Operating parameters may include the paint dispenser (e.g., Figure 1 Operating parameters of the distributor 108 may include, for example, the fluid pressure or flow rate of the fluid supplied from the fluid source and / or to the nozzle of the coating distributor. Another operating parameter of the coating distributor may include the rate at which the coating distributor applies various formations (e.g., dots) of fluid to the substrate or the speed at which the distributor moves relative to the substrate during the coating operation. Operating parameters of the coating distributor may also include any parameters related to the fluid dispensing itself, such as the velocity of the fluid exiting the nozzle, and the size, shape, or orientation of the fluid as it travels between the nozzle and the substrate. Operating parameters of the coating distributor may relate to the positioning of the coating distributor, such as the distance between the nozzle and the substrate.

[0069] Another example associated with a paint dispenser includes operating parameters related to the fluid source, such as the flow rate and / or pressure of the fluid supplied. Another exemplary operating parameter may relate to the actuator and / or drive pin / seat arrangement, such as the actuation frequency or speed, or the impact force of the drive pin on the seat. Yet another exemplary operating parameter may relate to the airflow (e.g., from an air jet) that the fluid experiences as it is dispensed from the nozzle, including air pressure or the directionality of the air.

[0070] Other example operational parameters can relate to the overall speed at which a series of substrates are moved through and coated by the paint dispenser. More generally, the operational parameter can refer to the speed or rate at which the entire paint system processes a series of substrates. This can include the speed at which one or more conveyors or other devices move the substrates through the paint system. For example, if the paint property value 408 remains stable over multiple iterations, the operational parameter relating to the speed of operation can be increased. Another example of an operational parameter relates to properties of the fluid itself, such as its viscosity and / or temperature.

[0071] The coating operation 406 can be performed in accordance with the operational parameter value 404. In particular, a volume of fluid is applied to at least some regions of the substrate by the paint dispenser. The regions of the substrate to which the fluid can be applied include any electrical or other components positioned on the substrate, regions of the substrate that do not have components (e.g., between two components), or any combination of the two, including regions that overlap the boundaries between component and non-component sub-regions.

[0072] Furthermore and as noted above, the fluid can be applied to a "sample region" of the substrate that does not have any components or functional aspects (other than those primarily implemented for further use of the sample region). The sample region can serve as a surface (e.g., in various formations, such as droplets or lines) to which one or more volumes of fluid are applied. The fluid applied to the sample region can primarily serve as a test subject for measuring one or more properties of the fluid in isolation from other variables that can affect the measurement of the properties. For example, the three-dimensional and complex nature of many components can hinder the measurement of fluid thickness. Other faults related to the substrate introduced in earlier processes can also interfere with certain measurements. For example, components mounted on the substrate can be misaligned, resulting in fluid applied on the substrate that appears incorrectly positioned relative to what should be properly aligned. The sample region can be indicated by a dot or other marker. The dot or other marker can serve as a frame of reference to determine the true paint property values of the fluid, particularly with respect to positioning relative to the overlay region. Furthermore, the sample region can be flat such that, for example, fluid thickness can be more accurately measured.

[0073] In some embodiments, the substrate subjected to the coating operation 406 can also undergo a curing operation 407 prior to inspecting the fluid on the substrate and determining and / or measuring the paint property values 408. In this case, a curing oven (e.g., the curing oven 102 of Figure 1 Thus, unless explicitly stated otherwise or otherwise clear from context, "coated substrate" and the like can be understood to also include substrates that are coated and cured.

[0074] After coating operation 406 (and optionally curing operation 407) is completed, values ​​of coating properties related to at least some portions of the fluid applied to the substrate are determined (i.e., coating property values ​​408). Coating property values ​​408 may be determined by a camera or other sensors (e.g., Figure 3A and Figure 3B The camera component 316 is determined. The sensor can be an inspection station (e.g., Figure 1 The inspection station (130) is a separate part from the coating assembly, and therefore, the coated substrate may need to be transported to the inspection station. Alternatively, the inspection station may be at least partially integrated with the coating assembly or other components of the coating system (e.g., a curing oven).

[0075] Even if the coating properties are of the same "type", a coating property can refer to a fluid covering one portion of the substrate, while another coating property can refer to a fluid covering a different second portion of the substrate. In the example, the coating properties of both portions can indicate the coating thickness at their respective portions of the substrate.

[0076] For example, coating characteristics can refer to the location of a fluid or a portion thereof (i.e., the area covered by the coating) relative to the entire substrate or relative to one or more designated parts or other landmarks on the substrate. A portion of the substrate may include the “sample area” and / or its target points as described above. As noted, the fluid may be applied to the substrate as discrete formations such as dots or beads, lines (straight or circular), or area coatings (i.e., “vortex” patterns). Thus, the location of the fluid can refer to a specific fluid formation on the substrate.

[0077] Coating characteristics can refer to the location of the coating and / or coating formation relative to a specified area of ​​the substrate where the coating is intended to be applied. For example, a value for such a coating characteristic may indicate the percentage of coverage and / or lack thereof in that area. Alternatively, a value for such a coating characteristic may indicate the percentage of the coating formation that exceeds its intended coverage area and / or is within the intended coverage area. These percentage values ​​may also be indicated by other quantitative measures rather than percentages.

[0078] In addition or alternatively, the location of the fluid can refer to a portion of the fluid formation. For example, a correctly applied area coating formation can cover the area between two rows of components, but not intrude onto either of the components. However, the area coating formation can include a first section that is correctly applied, covering a portion of the designated area without being additionally applied to any of the components. The area coating formation can also include a second section that is incorrectly applied, deviating from its intended location and not fully covering its intended area between rows of components. Furthermore, the second section also covers some of the components. Thus, the location of the fluid can refer to this faulty portion of the area coating formation, rather than the location of the entire area coating formation.

[0079] In addition or alternatively, the location of the fluid formation can be represented by a single location, such as a center point of the fluid formation. Thus, the overall location of the fluid location is the same as the location of the corresponding single location. In addition or alternatively, the location of the fluid formation can be relative to another fluid formation or portion of the fluid. For example, a pair of fluid points can be intended to be placed a certain distance apart. Thus, the location of the first point can be a frame of reference for indicating the location of the second point.

[0080] As another example, the coating characteristic can refer to one or more dimensions or shapes of the fluid formation (or portion of the fluid). The dimensions of the fluid formation can include a width, a length, a diameter, or other distance between two points in the fluid formation. The shape of the fluid can include a circular shape, a point, an oval, a linear or elliptical shape, or an elongated shape. The shape of the fluid formation can refer to the relative proportions and angles of the width, length, or other dimensions of the fluid formation, as well as any contours or other features that define the perimeter of the fluid formation. The shape can be classified according to one or more predefined shapes or characteristics, such as circular, oval, or elongated.

[0081] As yet another example, the coating characteristic can indicate that the fluid formation or other portion of the fluid is intended to be applied as a "sample." This coating characteristic can be determined by the location of the fluid formation or other portion of the fluid in a designated sample area of the substrate.

[0082] Another example of a coating characteristic can include the thickness of the fluid, the fluid formation, or a portion of the fluid on the substrate. Here, the thickness can be defined as the distance between a point on the substrate and a vertically corresponding point on the fluid. Vertically refers to a direction that is perpendicular to the planar surface of the substrate. In some examples, the thickness at a point or subset of points within the fluid formation can represent the thickness of the fluid formation. In other examples, the thickness of the fluid formation can be a minimum thickness value or a maximum thickness value over various measurement points of the fluid formation. Other coating characteristics include the volume of material, the flow of material on the substrate, UV reflectivity, and refractive index.

[0083] Other examples of coating properties can include application attributes of the fluid itself, such as electrical insulation, resistance to mechanical stress, vibration dampening, moisture permeability, and thermal insulation.

[0084] Additionally or alternatively, the coating property can include a composite of two or more of any of the coating properties described herein. For example, the coating property can include a composite coating property that reflects a location and a coating thickness of the fluid to be applied at the location.

[0085] The determined or measured coating property value 408 can be added to a sum of coating property values 410. The sum of coating property values 410 can include previously measured and / or determined and / or associated with a coated substrate that was previously coated and / or inspected prior to the instant coated substrate associated with the instant coating property value 408. It should be noted that it is not required that all of a series of sequentially coated substrates be inspected. Rather, only a subset, such as every fifth coated substrate in the series of sequentially coated substrates, can be inspected.

[0086] In an example, the coating property values of the sum of coating property values 410 can be ordered and / or structured to facilitate determination of a predicted coating property value 412. The coating property values can each be associated with a corresponding coated substrate in the series of sequentially substrates. Thus, the coating property values of the sum of coating property values 410 can be ordered according to the order of the series of sequentially coated substrates. Additionally or alternatively, the coating property value 408 and other coating property values can be associated with a time or incorporate a time stamp by which the values of the sum of coating property values 410 can be ordered. The sum of coating property values 410 can be organized as a time series of coating property values. The time series can be represented on a two-axis plot, where one axis represents time (or a similar metric) and the other axis represents the coating property values. As described above, the “time” aspect of the time series can refer to chronological time or the order of the coated substrates (or just the coated substrates, whether or not inspected) in the series of sequentially coated substrates 114 that are inspected.

[0087] In another example, the sum of coating property values 410 can neither indicate time, the associated coated substrate, nor any other indication of relative order between the coating property values. In such a case (or other cases), the coating property values of the sum of coating property values 410 can be unordered and / or cannot be ordered.

[0088] The sum of coating property values 410 can form at least one basis for determining and / or estimating a predicted coating property value 412. The predicted coating property value 412 can include one or more (predicted) coating property values of a fluid to be applied to a substrate at a future time. The aforementioned terms "future" and the like can refer to a timing or order within the series of sequentially coated substrates.

[0089] The predicted coating property value 412 can be considered "predicted" if determined and / or estimated at a predetermined confidence level, such as 90%, 95%, or 99% confidence. Thus, the predicted coating property value 412 is not necessarily an absolute guarantee. Additionally or alternatively, other indicators of confidence or similar concepts can be used. Thus, the confidence level or other similar metric can be used as a threshold requirement for a predicted coating property value to be considered valid. Additionally or alternatively, the confidence level or other metric can be used in other portions of the process. For example, the confidence level or other metric can be one factor that can determine new operating parameter values 404 for subsequent iterations of the process. In this example, a high confidence level can warrant greater adjustments to the operating parameter values 404, while a lower confidence level can result in more conservative or smaller adjustments to the operating parameter values 404.

[0090] The predicted coating property value 412 can be associated with a future substrate that will be coated and / or inspected immediately after the immediate coated substrate in the series of sequentially coated substrates. Additionally or alternatively, the predicted coating property value 412 can be associated with a future substrate that is not immediately after the immediate coated substrate in the series of sequentially coated substrates. Rather, there can be intervening coated and / or inspected substrates between the immediate coated substrate and the future coated substrate that are associated with the predicted coating property value 412.

[0091] The predicted coating property value 412 can be similar to the coating property values of the sum of coating property values 410 and the coating property values 408. That is, each of the aforementioned values refer to the same underlying coating property. For example, the coating property values 408, the summed coating property values 410, and the predicted coating property value 412 can all refer to coating thickness.

[0092] The predicted coating property value 412 can be determined via one or more prediction techniques applied to the sum of coating property values 410 or a portion thereof. For example, it should be recalled that the sum of coating property values 410 can form a time series with respect to a coating substrate order, a timing, or other timing metric. The time series can be represented as various data points on a line graph. Linear regression and / or curve / line matching techniques can be used to determine a trend line or other functional representation. The trend line and / or function can be used to determine the predicted coating property value 412. Other techniques for time series forecasting can also be used.

[0093] In some embodiments, various techniques can be applied to the sum of coating property values 410 to smooth the time series representation and / or to apply a weighting to the most recent data points in the time series. For example, a moving average technique such as a simple moving average, a cumulative rolling average, a weighted moving average, and / or an exponential moving average can be used. Another example technique is an autoregressive moving average (ARMA).

[0094] In alternative embodiments, a particular coating property value can be identified, and a prediction technique can be used to predict the number of substrates (or other timing metric) that can be coated before the identified coating property value is exceeded. For example, the identified coating property value can be a tolerance range 402 value. The operating parameter values 404 can be adjusted according to the prediction rather than the predicted coating property value 412.

[0095] The predicted coating property values 412 can include two or more predicted coating property values. The multiple predicted coating property values 412 can all be values of the same coating property, but each predicted coating property value can refer to a predicted coating property value associated with a separately coated substrate. For example, the multiple predicted coating property values 412 can refer to coating property values of substrates immediately following (e.g., first, second, third, etc. substrates after the immediately coated substrate). In another example, the multiple predicted coating property values can refer to subsequently coated substrates that are at some predetermined interval from each other. For example, a first predicted coating property value can predict a coating thickness on a coated substrate that is the fifth coated substrate after the immediately coated substrate. A second predicted coating property value can predict a coating thickness on a coated substrate that is the tenth coated substrate after the immediately coated substrate, etc. The predicted coating property values 412 can include a predetermined or operator-entered number of predicted coating property values that can reflect how far the operator wants the system to project in terms of adjusting its operating parameters. In addition to or alternatively, the operator can indicate an interval between coated substrates to which the predicted coating property values 412 refer.

[0096] The operation parameter value 404 can be adjusted (e.g., re-determined) to a new value based on the predicted coating property value 412. For example, the predicted coating property value 412 can be compared to one or more of the outer values of the tolerance range 402. The adjustment to the operation parameter value 404 can be based on this comparison and / or other factors. Generally, if the predicted coating property value 412 is outside of the tolerance range 402, the operation parameter value 404 can be adjusted, preferably to a value that is expected to result in a coating property value in a subsequently coated substrate (e.g., in a further iteration of the process) that falls back within the tolerance range 402 or at least moves toward a value within the tolerance range 402. If the predicted coating property value 412 is within the tolerance range 402, but closer to an outer limit of the tolerance range 402 than previously, the operation parameter value 404 can also be adjusted, such as to move the coating property value away from the outer limit of the tolerance range 402. In some cases, the operation parameter value 404 can not be adjusted. For example, if the predicted coating property value 412 is the same as or within some acceptable variance (such as a 10% variance) of the current coating property value, the operation parameter value 404 can not be adjusted. Another case in which the operation parameter value 404 can not be adjusted is when the predicted coating property value 412 is not the same as the current coating property value 408, but the predicted coating property value 412 is not outside of the tolerance range 402. As suggested by the above examples, the determination of the adjustment to the operation parameter value 404 can be based on the current coating property value 408.

[0097] The adjustment need not be limited to a single operation parameter. Rather, in some cases, multiple operation parameter values 404 can be adjusted to achieve the same or similar effect and / or under the same or similar criteria as if only a single operation parameter were adjusted.

[0098] It can generally be contemplated that the iteration of the process is performed with respect to a single coating property. For example, the process can involve the coating thickness at one particular location on a coated substrate. In other cases, however, the process can separately track the values of multiple coating properties (e.g., one for coating thickness and another for coating location) over several iterations. Predictions can be determined for the values of both of the coating properties, and the operation parameter can be adjusted independently based on the predicted value for each coating property.

[0099] Rather than independently adjusting the operating parameter values as the multiple coating property values are tracked, the value of a single operating parameter can be adjusted based on the predicted values of two or more coating properties. The adjustment of the single operating parameter value 404 can be performed according to one or more criteria. For example, the single operating parameter value 404 can be adjusted to benefit both coating properties equally, such as moving both coating property values from their respective tolerance range outer limits by a proportionally equal amount. In another example, the single operating parameter can be adjusted to benefit each coating property according to its proportional distance toward its respective tolerance range outer limit. In another example, the operating parameter can be adjusted to affect the single coating property that is most "toward" its tolerance range outer limit, which can reflect the coating property that is more likely to move outside of its respective tolerance range 402 first. In yet another example, the operating parameter value 404 can be adjusted to best benefit (e.g., move "away" from the tolerance limit) both coating properties in the sum. In another example, the operating parameter value 404 can be adjusted based on only one of the coating properties, with a concomitant benefit or detriment to the other coating parameter. In an alternative form of this example, the adjustment of the operating parameter can be with respect to only one coating property until the other coating property is predicted to be outside of its tolerance range 402. In this case, the operating parameter can be adjusted to affect the other coating property completely or partially.

[0100] After the operating parameter value 404 is adjusted (or not adjusted) based on the predicted coating property values 412, this iteration of the process can be considered complete. Another iteration of the process can be performed with respect to a later coated substrate in the series. The subsequent coated substrate that is subject to the next iteration of the process can be the coated substrate immediately after the coated substrate in the previous iteration. Alternatively, the new coated substrate that is subject to the new iteration of the process can be a later substrate that has a certain interval (either in chronological time or number of coated substrates) between it and the previously examined coated substrate.

[0101] Figure 5 A flowchart illustrating a method 500 of performing a coating operation using enhanced coating control is shown. The method begins at step 502. At step 504, a dispenser (e.g., the dispenser 108 of Figure 1 ) can perform a coating operation to apply a fluid to at least some portions of a substrate (e.g., the substrate 114 of Figure 1 ) according to values of operating parameters of the dispenser. In particular, the dispenser can include a nozzle having a valve that can be selectively opened and closed to dispense the fluid (e.g., the coating operation 406 of Figure 4 ). As some examples, the fluid can be applied as a dot, a line, or a spray area. The substrate can be part of a series of subsequent substrates, such as a first substrate of the series.

[0102] Readers are reminded once again that references to dispensers, coating operations, fluids, and other terms used in describing method 500 should be interpreted broadly and may cover any type of equipment, dispensing operation, and / or material type, unless explicitly stated or the context clearly indicates otherwise.

[0103] The values ​​can be determined based on one or more properties that affect the fluid applied to the substrate (e.g., Figure 4 The operating parameter values ​​(e.g., coating property value 408) Figure 4 The coating operation is performed using operating parameter values ​​(404). Operating parameters may include, for example, the fluid pressure when it is supplied to the nozzle and / or from the fluid supply source to the distributor. As another example, operating parameters may include nozzle operating parameters, such as the rate at which the valve opens or closes.

[0104] Coating characteristics may include, for example, the thickness of the fluid applied to the substrate, a portion of the substrate, and / or the formation of the fluid (e.g., dots, lines, or spray areas). Coating characteristics may also refer to aspects of fluid coverage. This may include the location of the coating on the substrate and / or the size of the coated area, such as the size and / or shape of the fluid formation. For example, the coating formation may extend beyond the target area where the coating formation is to be applied, but not beyond that target area. Other examples of coating characteristics are described in more detail herein.

[0105] At step 506, it may be done, for example, by passing through a checkpoint (e.g., Figure 1 Inspection station 130 is used to measure the values ​​of the aforementioned coating characteristics on the coated substrate. The inspection station or other components may use one or more sensors, such as a camera, to measure the coating characteristic values. The inspection station can measure the coating characteristic values ​​immediately after the substrate is coated, such as... Figure 1 As shown. In other specific embodiments, the inspection station may be located within the coating system to measure coating properties after fluid curing on the substrate. For example, a curing oven (e.g., Figure 1 The curing oven 102 can be positioned between the distributor and the inspection station.

[0106] At step 508, predicted values ​​of coating property values ​​can be determined / estimated (e.g., Figure 4 The predicted coating property value (412) may refer to a predicted value of the coating property of a fluid that is subsequently applied to a substrate following an immediate substrate in a series of sequential substrates. A subsequent substrate may be a substrate immediately following an immediate substrate, or a substrate with multiple intervening substrates between it and the immediate substrate. For example, a subsequent substrate may be the 10th substrate that is coated and / or inspected after the immediate substrate. In one embodiment, multiple predicted coating property values ​​may be determined / estimated for multiple subsequent substrates.

[0107] The predicted coating property value can be determined based on the instant coating property value. Additionally or alternatively, such as for a previously inspected coated substrate of the series of substrates, the predicted coating property value can be based on a sum of past coating property values (e.g., a sum of coating property values 410). The instant coating property value can now be added to the sum. The sum of coating property values can be organized as a time series. One or more of various forecasting and / or prediction techniques can be applied to the time series to determine the predicted coating property value. Figure 4

[0108] The determined coating property value can have an associated confidence level or other measure indicative of the statistical certainty of the prediction. The confidence level or other measure can act as a threshold at which the prediction is considered valid. Additionally or alternatively, the confidence level or other similar measure can be a factor by which the operating parameters can be adjusted in step 514.

[0109] At step 510, the predicted coating property value from step 508 can be compared to a tolerance range of values (e.g., a tolerance range of values 402). At step 512, if the predicted coating property value is outside of the tolerance range of values, the method can proceed to step 514. The comparison can be performed with a margin of a specified percentage of the values of the predicted coating property value and / or the tolerance range of values, such as 10%. In reference to“about,” the predicted coating property value and / or the values of the tolerance range of values should be understood to mean the value plus or minus 10%. Other similar uses of“about” should be considered likewise. Figure 4

[0110] In embodiments in which a plurality of predicted coating property values are determined for a plurality of subsequent substrates, the comparison can be performed for each of the plurality of predicted coating property values. Steps 512 and subsequent steps can be performed sequentially for each of the plurality of predicted coating property values.

[0111] At step 512, if the predicted coating property value is not outside of the tolerance range of values, the method 500 can proceed to step 516.

[0112] At step 516, if the instant substrate is a final substrate or the method 500 is otherwise indicated to terminate, the method 500 can end at step 518.

[0113] ​​Additionally, at step 516, if the instant substrate is not the final substrate in the series of sequential substrates and there are no other indications to terminate method 500, method 500 can return to step 504 without adjusting the value of the operating parameter. After returning to step 504, a new iteration of method 500 can be performed (specifically, steps 504-516), in which a new coating operation is performed on a subsequent substrate in the series of sequential substrates. The subsequent substrate need not be the substrate immediately after the substrate of the previous iteration, but can be some interval of substrates after the substrate of the previous iteration. The value of the operating parameter in this next iteration of method 500 can be the same as the value of the operating parameter used in the previous iteration.

[0114] If the predicted value of the coating property value at step 512 is outside the tolerance range of values (i.e., represents an unacceptable predicted value), the value of the operating parameter can be adjusted at step 514. For example, the value of the operating parameter can be adjusted such that the coating property value in a subsequent iteration of method 500 is (or is expected to be) within the tolerance range of values, or at least closer to being within the tolerance range of values. In some implementations, the value of multiple operating parameters can be adjusted to affect the coating property value in a subsequent iteration of method 500.

[0115] After adjusting the value of the operating parameter, method 500 can return to step 504. In this next iteration, at step 504, the coating operation can be performed using the adjusted value of the operating parameter. In this next iteration, method 500 can proceed to step 504 and so on.

[0116] It will be appreciated by those skilled in the art that the systems and methods disclosed herein can be implemented via a computing device, which can include, but is not limited to, one or more processors, system memory, and a system bus coupling the various system components including the processor(s) to the system memory. In the case of multiple processors, the system can utilize parallel computing.

[0117] For purposes of illustration, the application and other executable program components such as operating systems are shown herein as discrete blocks, although it is understood that such programs and components can reside at various times in different storage components of the computing device, and that the data is likely to be processed by different data processors of the computer. The specific design of the service software can be stored or transmitted across some form of computer readable media. Any of the methods disclosed herein can be performed by computer readable instructions embodied on a computer readable medium. Computer readable media can be any available media that can be accessed by a computer. By way of example, and not limitation, computer readable media can comprise "computer storage media" and "communications media." "Computer storage media" includes volatile and non-volatile, removable and non-removable media implemented in any method or technology for storage of information such as computer readable instructions, data structures, program modules or other data. Exemplary computer storage media includes, but is not limited to, RAM, ROM, EEPROM, flash memory or other memory technology, CD-ROM, digital versatile disks (DVD) or other optical storage, magnetic cassettes, magnetic tape, magnetic disk storage or other magnetic storage devices, or any other medium which can be used to store the desired information and which can be accessed by the computer. Application programs and / or the like and / or storage media can be implemented at least partially on remote systems.

[0118] As used in the specification and the appended claims, the singular forms "a," "an" and "the" include plural referents unless the context clearly dictates otherwise. Ranges can be expressed herein as "about" one particular value and / or "about" another particular value. When such a range is recited, another embodiment includes from the one particular value and / or to the other particular value. Similarly, when values are expressed as approximations by use of the antecedent "about," it will be understood that the particular value forms another embodiment. It will be further understood that the endpoints of the ranges are significant, and that the ranges are only indicative, and that the endpoints are included in the range, but not the reverse.

[0119] Unless otherwise indicated herein, the description herein of ranges of values is intended to serve as a shorthand method of referring individually to each separate value falling within the range. Each individual value is incorporated herein in the specification as if it were individually recited herein.

[0120] Throughout the specification and claims, the word "comprise" and variations such as "comprising," and "comprises" will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps. "Exemplary" means "an example of" and is not intended to convey an indication of a preferred or ideal embodiment. "Such as" is not used in a restrictive sense, but for illustrative purposes.

[0121] Disclosed are components that can be used to perform the disclosed methods and systems. These and other components are disclosed herein, and it is understood that when combinations, subsets, interactions, groups, etc. of these components are disclosed that while specific reference of each various individual and collective combinations and permutation of these can not be explicitly disclosed, every combination and permutation of the various components is specifically contemplated and described herein. This applies to all aspects of this application including, but not limited to steps in disclosed methods. Thus, if there are a variety of additional steps that can be performed or incorporated, it is understood that each of these additional steps can be performed with any specific embodiment or combination of embodiments of the disclosed methods.

[0122] Unless specifically stated otherwise, it is not intended that any method described herein require the steps of the method be performed in a specific order. Hence, if a method claim does not actually recite an order to be followed by its steps or it is not otherwise specifically stated in the claims or description that the steps are to be limited to a specific order, it is not intended that any aspect of the method be inferred as being ordered. This applies to any aspect of the method, including the steps of any of the methods. This applies equally to the description and drawings, which are also to be construed in the exact same manner. This provides an explicit definition of the scope of the claims.

[0123] It will be apparent to those skilled in the art that various modifications and variations can be made in the present application without departing from the scope or spirit of the application. Other embodiments will be apparent to those skilled in the art from consideration of the specification and practice of the application disclosed herein. It is intended that the specification and examples be considered as exemplary only, with the true scope and spirit of the application being indicated by the following claims.

Claims

1. A method for controlling a dispensing system, the dispensing system being operated by a controller and having a dispensing device configured to apply a liquid or viscous material to a sequence of substrates moving through the dispensing system, the method comprising: Operate the dispensing device to apply a first amount of material to the first substrate in the substrate sequence according to a first value of the operating parameters of the dispensing system; The coating properties of the first amount of material applied to the first substrate are measured using a sensor in order to obtain a measured value of the coating properties of the first amount of material applied to the first substrate. Based on the measured values ​​of the coating properties of the first amount of material applied to the first substrate, it is determined whether the predicted coating property values ​​of a certain amount of material to be applied to subsequent substrates in the substrate sequence are estimated to be out of tolerance. In response to the determination that a predicted coating characteristic value of the predetermined amount of material to be applied to the subsequent substrate is estimated to be outside the tolerance range and the predicted coating characteristic value has a predetermined threshold confidence level, the value of the operating parameter is adjusted to a second value, the predetermined threshold confidence level defining the requirements that the predicted coating characteristic value must meet to be considered valid; and According to the second value of the operating parameters, a second amount of material is applied from the dispensing device to the subsequent substrates in the substrate sequence. The coating properties of the first amount of material applied to the first substrate are different from the coating properties of the second amount of material applied to the subsequent substrate; The adjustment of the operating parameter value to the second value is based on one or more coating properties of a certain amount of material applied to one or more corresponding substrates in the substrate sequence prior to the first substrate; and In this case, adjusting the value of the operating parameter to the second value restricts the coating characteristic value of the subsequent substrate from falling outside the tolerance range.

2. The method according to claim 1, wherein, The coating characteristics of the first amount of material applied to the first substrate include at least one of the location of the coating material formation on the first substrate, the size of the coating material formation on the first substrate, the shape of the coating material formation on the first substrate, and the thickness of the coating material formation on the first substrate.

3. The method according to claim 2, wherein, The operating parameters are associated with at least one of the following: the fluid pressure of the material supplied to the nozzle of the dispensing device, the flow rate of the material supplied to the nozzle, the dispensing rate of the material from the nozzle, the rate of coating the substrate sequence, and the air pressure of the atomizing air jet of the dispensing device.

4. The method according to claim 1, wherein, The coating properties of the first amount of material are measured at a designated non-functional sample area on the first substrate where there are no functional components; and wherein the coating properties of the first amount of material applied to the first substrate include at least one of the location of the coating material formation on the first substrate, the size of the coating material formation on the first substrate, the shape of the coating material formation on the first substrate, and the thickness of the coating material formation on the first substrate.

5. The method according to claim 4, wherein, The designated non-functional sample area of ​​the first substrate includes a target location, which is visually marked on the first substrate to visually identify the target area for application, and the coating characteristics of the first amount of material include the position of the first amount of material on the first substrate relative to the target location.

6. The method according to claim 1, wherein, The subsequent substrates are two or more substrates in the substrate sequence following the first substrate; and wherein the coating characteristics of the first amount of material applied to the first substrate include at least one of the position of the coating material formation on the first substrate, the size of the coating material formation on the first substrate, the shape of the coating material formation on the first substrate, and the thickness of the coating material formation on the first substrate.

7. The method according to claim 1, wherein, The coating characteristics of the first amount of material applied to the first substrate include at least two of the location of the coating material formation on the first substrate, the size of the coating material formation on the first substrate, the shape of the coating material formation on the first substrate, and the thickness of the coating material formation on the first substrate.

8. The method according to claim 7, wherein, The operating parameters are associated with at least one of the following: the fluid pressure of the material supplied to the nozzle of the dispensing device, the flow rate of the material supplied to the nozzle, the dispensing rate of the material from the nozzle, the rate of coating the substrate sequence, and the air pressure of the atomizing air jet of the dispensing device.

9. The method according to claim 1, wherein, The operating parameters are associated with at least one of the following: the fluid pressure of the material supplied to the nozzle of the dispensing device, the flow rate of the material supplied to the nozzle, the dispensing rate of the material from the nozzle, the rate of coating the substrate sequence, and the air pressure of the atomizing air jet of the dispensing device.

10. The method according to claim 9, wherein, The characteristics of one or more coatings, which are a certain amount of material applied to one or more substrates prior to the first substrate, are represented as time series data, and wherein adjusting the value of the operating parameter to the second value is further based on the time series data.

11. The method of claim 10, further comprising: The smoothing function is applied to the time series data, wherein the smoothing function includes at least one of the following: simple moving average function, cumulative rolling average function, weighted moving average function, exponential moving average function, and autoregressive moving average function.

12. The method according to claim 1, wherein, The dispensing device applies the first amount of material according to a first value of a second operating parameter of the dispensing system, wherein the method further includes: In response to the determination that the coating properties of a certain amount of material to be applied to the subsequent substrate are estimated to be outside the tolerance range, the value of the second operating parameter is adjusted to a second value, wherein the second amount of material is further applied to the subsequent substrate according to the second value of the second operating parameter. The second operating parameter is associated with at least one of the following: the fluid pressure of the material supplied to the nozzle of the dispensing device, the flow rate of the material supplied to the nozzle, the dispensing rate of the material from the nozzle, the rate of coating the substrate sequence, and the air pressure of the atomizing air jet of the dispensing device.

13. The method according to claim 1, further comprising: Determine the level of confidence in the statistical certainty of the forecast associated with the adjusted value.

14. The method according to claim 13, in, The one or more properties of a certain amount of material applied to one or more substrates prior to the first substrate are represented as time series data; and The adjustment of the value of the operation parameter to the second value is based on the time series data.

15. The method according to claim 1, further comprising: A curing oven is used to cure a certain amount of material applied to the substrates in the substrate sequence.

16. The method according to claim 1, wherein, When measuring the coating properties of the first amount of material, the first amount of material is cured on the first substrate.

17. The method according to claim 1, further comprising: A curing oven is used to cure a certain amount of material applied to the substrates in the substrate sequence. Before measuring the coating properties, a certain amount of material is cured on the substrate.

18. A dispensing system for applying a liquid or viscous material to a substrate, the substrate moving through the dispensing system, the dispensing system comprising: Dispensing device; Sensors, the sensors being arranged to measure the coating properties of a certain amount of material applied by the dispensing device to a sequence of substrates moving through the dispensing system on the substrates; and A controller, configured to generate one or more signals for: Operate the dispensing device to apply a first amount of material to the first substrate in the substrate sequence according to a first value of the operating parameters of the dispensing system; The sensor is used to measure the coating properties of the first amount of material applied to the first substrate in order to obtain a measured value of the coating properties of the first amount of material applied to the first substrate. Based on the measured values ​​of the coating properties of the first amount of material applied to the first substrate, it is determined whether the predicted coating property values ​​of a certain amount of material to be applied to subsequent substrates in the substrate sequence are estimated to be out of tolerance. In response to the determination that the predicted coating characteristic value of the amount of material to be applied to the subsequent substrate is estimated to be outside the tolerance range and the predicted coating characteristic value has a predetermined threshold confidence level, the value of the operating parameter is adjusted to a second value, the predetermined threshold confidence level defining the requirement that the predicted coating characteristic value of the amount of material is considered valid and to be met; According to the second value of the operating parameters, a second amount of material is applied from the dispensing device to the subsequent substrates in the substrate sequence. The coating properties of the first amount of material applied to the first substrate are different from the coating properties of the second amount of material applied to the subsequent substrate; The adjustment of the operating parameter value to the second value is based on one or more coating properties of a certain amount of material applied to one or more corresponding substrates in the substrate sequence prior to the first substrate; and In this case, adjusting the value of the operating parameter to the second value restricts the coating characteristic value of the subsequent substrate from falling outside the tolerance range.

19. The distribution system according to claim 18, further comprising: A distribution component, the distribution component including the distribution device; and An inspection station, comprising the sensor, is configured to receive one of the substrates in the substrate sequence after a certain amount of material has been applied to it.

20. The dispensing device according to claim 19, wherein, The dispensing system is configured to apply a certain amount of material in at least one of the following forms: beads, lines, or spray patterns.

21. The distribution system according to claim 19, wherein, The checkpoint is separate from the distribution component.

22. The distribution system according to claim 19, further comprising: A curing oven configured to cure a certain amount of material applied to substrates in the substrate sequence.

23. The distribution system according to claim 22, wherein, The curing oven is located between the dispensing device and the inspection station, and wherein the first amount of material on the first substrate is cured.

24. The distribution system according to claim 18, wherein, The sensor includes a camera configured to capture images of a certain amount of material applied to the substrates in the substrate sequence.

25. The distribution system according to claim 18, wherein, The dispensing device and the sensor are integrated into a common component.

26. The distribution system according to claim 25, wherein, The shared component includes a movable arm, and at least one of the dispensing device and the sensor is attached to the movable arm.

27. The distribution system according to claim 18, further comprising: Movable arm; and A sensor assembly attached to the movable arm, wherein the sensor assembly includes the sensor and an ultraviolet light source, and wherein the sensor includes a camera configured to capture an image of a certain amount of material applied to a substrate in the substrate sequence.

28. The dispensing system of claim 18 further includes a curing oven configured and / or operable to cure a quantity of material applied to substrates in the substrate sequence.

29. The distribution system according to claim 18, in, The one or more properties of a certain amount of material applied to one or more substrates prior to the first substrate are represented as time-series data; and The adjustment of the value of the operation parameter to the second value is based on the time series data.

30. The dispensing system of claim 18 further includes the use of a curing oven to cure a quantity of material applied to the substrates in the substrate sequence.

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