System and method for remote metering station sensor calibration and verification

Abstract

To calibrate a plurality of fluid sensors of a remote metering system.SOLUTION: The system includes a material supply device including a main pump and a main flow sensor for monitoring an output of the main pump. An application system also includes a remote metering system for receiving a material flowing from the material supply device and applying the material to substrates. The remote metering system includes a first applicator assembly including a first applicator and a first flow sensor for monitoring an output of the first applicator, and a second applicator assembly including a second applicator and a second flow sensor for monitoring an output of the second applicator. The remote metering system further includes a controller in signal communication with the remote metering station and the material supply device. The controller performs first and second calibration operations on the first and second flow sensors, respectively.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] (CROSS REFERENCE TO RELATED APPLICATIONS) This application claims the benefit of U.S. Provisional Patent Application No. 62 / 715,895, filed August 8, 2018, and U.S. Patent Application No. 16 / 529,596, filed August 1, 2019, the disclosures of which are incorporated herein by reference.

[0002] FIELD OF THEINVENTION The present application is directed to a system and method for controlling the operation of an application system for applying material to a substrate. In particular, the present application relates to a system and method for calibrating and verifying the accuracy of sensors in communication with multiple applicators. [Background technology]

[0003] A typical material application system for applying material to a substrate includes a storage device that provides a supply of material to any number of applicators, each capable of applying material to a substrate. However, the storage device and applicators may be spaced apart, in which case the material travels a distance between the storage device and the applicators. When the material stream reaches a remote metering station, the material may be split into multiple separate streams, with each separate stream being directed to a corresponding applicator. Based on the requirements of a particular application operation, it may be desirable for each of the applicators to apply material to the substrate at a different speed and in a different amount.

[0004] Due to the specific requirements that a coating operation may have, any deviation from the coating parameters may create a non-standard or unusable product. This problem, if left uncorrected, may cause significant material waste and economic loss. To ensure consistency of flow rate within each applicator, each applicator may be in communication with a corresponding material flow sensor that monitors the characteristics of the material flow. Because these flow sensors typically must have smaller dimensions to accommodate their desired operating positions, they may have a higher level of error than other types of flow sensors. In addition, these flow sensors may be sensitive to changes in material temperature and viscosity. If uncorrected, these flow sensors may provide inaccurate readings to an operator of the coating system, which may cause the operator to erroneously believe that the applied material pattern meets the required specifications.

[0005] As a result, there is a need for an application system that can calibrate and verify the accuracy of the sensors in communication with each of the material applicators. Summary of the Invention

[0006] One embodiment of the disclosure is a method of calibrating multiple fluid sensors of a remote metering system. The method includes pumping material from a primary pump to a first applicator and receiving a first feedback signal from a primary flow sensor in communication with the primary pump and a second feedback signal from a first flow sensor in communication with the first applicator. The first and second feedback signals are indicative of a flow characteristic of the material through the primary pump and the first applicator, respectively. The method also includes comparing the first and second feedback signals, determining a correction factor for the first flow sensor, and stopping the flow of material to the first applicator. The method further includes pumping material from the primary pump to a second applicator and receiving a third feedback signal from the primary flow sensor and a fourth feedback signal from a second flow sensor in communication with the second applicator. The third and fourth feedback signals are indicative of a flow characteristic of the material through the primary pump and the second applicator, respectively. Additionally, the method includes comparing the third and fourth feedback signals and determining a correction factor for the second flow sensor.

[0007] Another embodiment of the present disclosure is a coating system for applying a material to a substrate. The coating system includes a material supply including a primary pump and a primary flow sensor for monitoring an output of the primary pump. The coating system also includes a remote metering system for receiving the material flowing from the material supply and applying the material to the substrate. The remote metering system includes a first applicator assembly including a first applicator and a first flow sensor for monitoring an output of the first applicator, and a second applicator assembly including a second applicator and a second flow sensor for monitoring an output of the second applicator. The remote metering system further includes a controller in signal communication with the remote metering station and the material supply. The controller is configured to perform a first calibration operation, the controller configured to direct the primary pump to pump the material to the first applicator, receive a first feedback signal from the primary flow sensor and a second feedback signal from the first flow sensor, compare the first and second feedback signals, and determine a correction factor for the first flow sensor. The controller is also configured to stop the flow of material to the first applicator and perform a second calibration operation, and the controller is configured to direct the primary pump to pump material to the second applicator, receive a third feedback signal from the primary flow sensor and a fourth feedback signal from the second flow sensor, compare the third and fourth feedback signals, and determine a correction factor for the second flow sensor.

[0008] The foregoing summary, as well as the following detailed description, will be better understood when read in conjunction with the appended drawings, which illustrate exemplary embodiments of the present disclosure, but it should be understood that the application is not limited to the precise arrangements and instrumentalities shown. [Brief description of the drawings]

[0009] [Figure 1] FIG. 1 is a schematic diagram of a coating system according to one embodiment of the present disclosure. [Diagram 2]2 is a schematic diagram of the application system shown in FIG. 1 with the controller performing a first calibration operation on the first flow sensor. [Diagram 3] 2 is a schematic diagram of the application system shown in FIG. 1, the controller performing a second calibration operation on a second flow sensor. [Figure 4] 2 is a schematic diagram of the application system shown in FIG. 1 , the controller performing a third calibration operation on a third flow sensor. [Diagram 5] 2 is a schematic diagram of the application system shown in FIG. 1, in which a controller performs monitoring operations on the flow sensors of each applicator. [Figure 6-1] 1 illustrates a process flow diagram of a method and system for calibrating multiple fluid sensors in a dispensing system. [Figure 6-2] 1 illustrates a process flow diagram of a method and system for calibrating multiple fluid sensors in a dispensing system. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0010] An embodiment of the present invention includes an application system 10 for dispensing material from multiple applicators. With reference to FIG. 1, application system 10 includes a material supply 15 having a storage device 20 for storing a supply of material. In one embodiment, material supply 15 is a melter suitable for heating and pumping any conventional hot melt adhesive, as well as the material being a hot melt adhesive. Storage device 20 may be a conventional storage tank within material supply 15 or a remote hopper, such as a container, capable of storing unmolten hot melt adhesive particles. Additionally, the material may alternatively be other heated or unheated materials, such as lotions, fragrances, and odor control products.

[0011] The material supply apparatus 15 also includes a main pump 24 for pumping the material. In one embodiment, the main pump 24 may be a conventional gear pump having a dedicated drive motor for driving gears, although other types of pumps, such as a gerotor pump or a piston pump, are contemplated. The material supply apparatus 15 also includes a main flow sensor 28 in fluid communication with the main pump 24, the main flow sensor 28 configured to monitor the output of material from the main pump 24. The main flow sensor 28 may be a gear type flow meter, although other types of flow sensors, such as a turbine, vortex, or hot wire anemometer sensor, are contemplated. The main flow sensor 28 may be in wireless and / or wired communication with the controller 32, as described in more detail below, via signal connection 36a, such that the main flow sensor 28 may provide a feedback signal to the controller 32 via signal connection 36a indicative of some characteristic of the output of the main pump 24. For example, the feedback signal from the main flow sensor 28 may be proportional to the volumetric flow rate of the output of the main pump 24. Alternatively, the feedback signal from the primary flow sensor 28 may be proportional to the mass flow rate of the output of the primary pump 24. However, it is contemplated that the primary flow sensor 28 may measure any other characteristic of the output. For example, the feedback signal from the primary flow sensor 28 may include a number of pulses, each indicative of a constant predetermined amount of flow output by the primary pump 24. Additionally, the feedback signal from the primary flow sensor 28 may include an electrical signal, such as voltage or amperes, that corresponds to a known flow rate.

[0012] The controller 32 may include any suitable computing device configured to execute software applications for monitoring and controlling various operations of the application system 10 described herein. It will be understood that the controller 32 may be a processor, a desktop computing device, a server computing device, or a portable computing device such as a laptop, tablet, or smartphone. In particular, the controller 32 may include a memory (not shown) and a human machine interface (HIM) (not shown). The memory may be volatile (e.g., some types of RAM, etc.), non-volatile (e.g., ROM, flash memory, etc.), or a combination thereof. The controller 32 may include additional storage devices (e.g., removable storage devices and / or non-removable storage devices), examples of which include, but are not limited to, flash memory, smart cards, CD-ROMs, digital versatile disks (DVDs) or other optical storage devices, magnetic tape, magnetic disk storage devices or other magnetic storage devices, universal serial bus (USB) compatible memory, or any other medium that can be used to store information and that can be accessed by the controller 32. The HMI device may include inputs that provide the ability to interact with the controller 32, for example, via buttons, soft keys, a mouse, voice-activated control, a touch screen, movement of the controller 32, visual cues (e.g., moving a hand in front of a camera on the controller 32), and the like. The HMI device may provide outputs, including visual information, via a graphical user interface, such as a visual indication of the current flow characteristics of various portions of the application system 10 via a display as well as the acceptable ranges of these parameters. Other outputs may include auditory information (e.g., via a speaker), mechanically provided information (e.g., via a vibration mechanism), visual information (e.g., via a light tower), or combinations thereof. In various configurations, the HMI device may include a display, a touch screen, a keyboard, a mouse, a motion detector, a speaker, a microphone, a camera, or any combination thereof.The HMI device may further include any suitable device for inputting biometric information, such as, for example, fingerprint information, retinal information, voice information, and / or facial characteristic information, for example, since certain biometric information is required for purposes of accessing the controller 32.

[0013] The material supply device 15 may be connected to a hose 40 that provides a path of material from the material supply device 15 to a remote metering system 50. The hose 40 allows the material supply device 15 and the remote metering system 50 to be spaced apart any desired distance on a manufacturing site. The remote metering system 50 is configured to receive material flowing from the material supply device 15 through the hose 40 and apply the material to a single substrate or to multiple substrates at once, depending on the particular configuration of the application system 10. The remote metering system 50 may have a remote metering stand 54 that receives material output via the hose 40. The remote metering stand 54 may include a manifold having an input, multiple outputs, and a system of passages for dividing the flow among the multiple outputs. The remote metering stand 54 may include a diverter for selectively changing the division of the material flow among the multiple outputs, although the division of the material flow may be constant. The remote weigh stand 54 may be constructed as an assembly of individual parts such that the size, shape, and / or configuration of the remote weigh stand 54 may be modified, as desired, by the operator of the application system 10 to suit a particular material application operation. The components of the remote weigh stand 54 may be in wireless and / or wired communication with the controller via signal connection 36b.

[0014] The remote metering stand 54 may be configured such that multiple applicator assemblies may be mounted thereon. In one embodiment, each applicator assembly may include a corresponding remote metering stand (RMS) pump, a supply hose, an applicator flow sensor, and an applicator. However, this list is not meant to be exhaustive, and each applicator assembly may include more or fewer components as required for a particular application operation. In the illustrated embodiment, the remote metering system 50 includes three applicator assemblies: a first applicator assembly 56a, a second applicator assembly 56b, and a third applicator assembly 56c. The first applicator assembly 56a may include a first RMS pump 58a, a first supply hose 62a for transporting a first portion of the material flow from the first RMS pump 58a, and a first applicator 70a for receiving a first portion of the material flow from the first supply hose 62a and applying the first portion to a substrate. The first applicator assembly 56a may also include a first flow sensor 66a for monitoring the flow of material provided to the first applicator 70a. The first flow sensor 66a may be in wired and / or wireless communication with the controller 32 via signal connection 36c, such that the first flow sensor 66a may provide a feedback signal to the controller 32 indicative of some characteristic of the flow of material provided to the first applicator 70a. For example, the feedback signal from the first flow sensor 66a may be proportional to a volumetric flow rate of the flow of material provided to the first applicator 70a. Alternatively, the feedback signal from the first flow sensor 66a may be proportional to a mass flow rate of the flow of material provided to the first applicator 70a. However, it is contemplated that the first flow sensor 66a may measure any other characteristic of the flow of material.

[0015] The second applicator assembly 56b may include a second RMS pump 58b, a second supply hose 62b for transporting a second portion of the material flow from the second RMS pump 58b, and a second applicator 70b for receiving the second portion of the material flow from the second supply hose 62b and applying the second portion to a substrate. The second applicator assembly 56b may also include a second flow sensor 66b for monitoring the flow of material provided to the second applicator 70b. The second flow sensor 66b may be in wired and / or wireless communication with the controller 32 via signal connection 36d, such that the second flow sensor 66b may provide a feedback signal to the controller 32 indicative of some characteristic of the flow of material provided to the first applicator 70a. For example, the feedback signal from the second flow sensor 66b may be proportional to a volumetric flow rate of the material flow provided to the second applicator 70b. Alternatively, the feedback signal from the second flow sensor 66b may be proportional to the mass flow rate of the material flow provided to the second applicator 70b, however, it is contemplated that the second flow sensor 66b may measure any other characteristic of the material flow.

[0016] Further, the third applicator assembly 56c may include a third RMS pump 58c, a third supply hose 62c for transporting a third portion of the material flow from the third RMS pump 58c, and a third applicator 70c for receiving the third portion of the material flow from the third supply hose 62c and applying the third portion to the substrate. The third applicator assembly 56c may also include a third flow sensor 66c for monitoring the output of the third applicator 70c. The third flow sensor 66c may be in wired and / or wireless communication with the controller 32 via signal connection 36e, such that the third flow sensor 66c may provide a feedback signal to the controller 32 indicative of some characteristic of the material flow provided to the third applicator 70c. For example, the feedback signal from the third flow sensor 66c may be proportional to a volumetric flow rate of the material flow provided to the third applicator 70c. Alternatively, the feedback signal from the third flow sensor 66c may be proportional to the mass flow rate of the material flow provided to the third applicator 70c, however, it is contemplated that the third flow sensor 66c may measure any other characteristic of the material flow.

[0017] Although the first, second, and third applicator assemblies 56a-56c are shown and described as being substantially the same, they may vary depending on the requirements of a particular dispensing operation. Also, although only three applicator assemblies 56a-56c are shown as being included in the remote metering system 50, the remote metering system 50 may include more or fewer applicator assemblies, as desired. For example, the remote metering system 50 may include one applicator assembly, two applicator assemblies, or more than three applicator assemblies.

[0018] Each of the RMS pumps 58a-c may be a gear pump or any other type of pump conventionally utilized to pump flowable materials. Although illustrated as being connected to the applicators 70a-c via the supply hoses 62a-c, in other embodiments, the RMS pumps 58a-c may be directly connected to the applicators 70a-c. Each of the flow sensors 66a-c may enable the flow sensors 66a-c to have a low profile, thereby allowing them to be in close proximity to or integral with the respective applicators 70a-c. However, the flow sensors 66a-c may also be gear flow meters or any type of flow meter conventionally used to measure the flow of a fluid, each outputting a number of signals indicative of a predetermined amount of material. Additionally, each of the applicators 70a-c may include a non-contact, contact, time-constrained dispensing, jetting, etc., dispenser for applying material to a substrate.

[0019] During operation, the controller 32 is configured to control the operation of the components of the application system 10. The controller 32 may perform this function autonomously, via user input, or via a combination of the two. Because the application system 10 may apply material to substrates at high speeds, e.g., at rates of over a thousand product substrate segments per minute, any deviation from the intended material flow dispense amount or rate can be very detrimental and may result in a non-standard or unsalable product. To prevent this, it is essential that the flow sensors 66a-66c are operated with a high level of precision and accuracy. To ensure the accuracy of the flow sensors 66a-66c, it is desirable to perform a calibration operation on the flow sensors 66a-66c prior to commencing a dispensing operation. It is further highly desirable that this calibration operation be automated to the greatest extent practical.

[0020] During steady state operation, the controller 32 may direct the main pump 24 to pump material from the storage device 20 through the hose 40 to the remote metering system 50. The remote metering stand 54 may then split the flow into three separate flows, each delivered to a corresponding one of the applicator assemblies 56a-56c, each applying the material to the intended substrate. However, prior to steady state operation, the controller 32 may calibrate the flow sensors 66a-66c, so that an operator of the application system 10 can be confident that the readings received from the flow sensors 66a-66c have the highest accuracy. To accomplish this, the controller 32 may direct the components of the application system 10 to perform a system-wide calibration operation, which involves several separate calibration operations.

[0021] Initially, the controller 32 may instruct the application system 10 to perform a first calibration operation (shown in FIG. 2), in which the controller 32 instructs the primary pump 24 to pump material from the storage device 20 to the remote metering system 50, and the remote metering stand 54 directs the flow of material only to the first applicator 70a. This first calibration operation is intended to calibrate the first flow sensor 66a of the first applicator assembly 56a. During this calibration operation, the first RMS pump 58a may not operate so that the flow of material seen by the primary flow sensor 28 most accurately reflects the flow of material seen by the first flow sensor 66a. While the flow of material is directed only to the first applicator 70a, the primary flow sensor 28 is configured to monitor a characteristic of the flow of material exiting the primary pump 24 and transmit a first feedback signal indicative of the characteristic to the controller 32 via the signal connection 36a. Concurrently, the first flow sensor 66a is configured to monitor a characteristic of the flow of material to the first applicator 70a and transmit a second feedback signal indicative of the characteristic to the controller 32 via signal connection 36c. For example, the characteristic may be a mass flow rate, a volumetric flow rate, etc.

[0022] The controller 32 is configured to receive a first feedback signal from the primary flow sensor 28 and a second feedback signal from the first flow sensor 66a, and compare the first and second feedback signals. Ideally, the first and second feedback signals represent the same material flow characteristics. However, during operation, the first and second feedback signals may differ, which may indicate either a defect in the first flow sensor 66a, a need for its calibration, or other problems with it. Therefore, to ensure that the first flow sensor 66a provides accurate readings, the controller 32 may determine a correction factor for the first flow sensor 66a based on the difference between the first and second feedback signals to correct for deviations in the feedback received from the first flow sensor 66a. The correction factor may be determined according to a look-up table, a calculation, or other such means. This correction factor can be automatically applied to future feedback signals received by the controller 32 from the first flow sensor 66a, thereby enabling the controller 32, and likewise the operator of the application system 10, to most accurately monitor the flow characteristics of the material flowing through the first applicator assembly 56a.

[0023] Once the first correction factor is determined, the controller 32 may stop the flow of material to the first applicator 70a and then instruct the application system 10 to perform a second calibration operation (shown in FIG. 3). During the second calibration operation, the controller 32 instructs the primary pump 24 to again pump material from the storage device 20 to the remote metering system 50. However, in the second calibration operation, the remote metering stand 54 directs the flow of material only to the second applicator 70b. The second calibration operation is intended to calibrate the second flow sensor 66b of the second applicator assembly 56b. During this calibration operation, the second RMS pump 58b may not be operated so that the material flow seen by the primary flow sensor 28 most accurately reflects the material flow seen by the second flow sensor 66b. Although material flow is directed only to the second applicator 70b, the primary flow sensor 28 is configured to monitor a characteristic of the flow of material exiting the primary pump 24 and to transmit a third feedback signal indicative of the characteristic to the controller 32 via signal connection 36a. Concurrently, the second flow sensor 66b is configured to monitor a characteristic of the flow of material to the second applicator 70b and to transmit a fourth feedback signal indicative of the characteristic to the controller 32 via signal connection 36d. For example, the characteristic may be a mass flow rate, a volumetric flow rate, etc.

[0024] The controller 32 is configured to receive a third feedback signal from the primary flow sensor 28 and a fourth feedback signal from the second flow sensor 66b, and compare the third and fourth feedback signals. Ideally, the third and fourth feedback signals represent the same material flow characteristics. However, during operation, the third and fourth feedback signals may differ, which may indicate a defect in or other problem with the second flow sensor 66b. Therefore, to ensure that the second flow sensor 66b provides an accurate reading, the controller 32 may determine a correction factor for the second flow sensor 66b based on the difference between the third and fourth feedback signals to correct for deviations in the feedback received from the second flow sensor 66b. The correction factor may be determined according to a look-up table, a calculation, or other such means. This correction factor can be automatically applied by the controller 32 to future feedback signals received from the second flow sensor 66b, thus enabling the controller 32, and likewise the operator of the application system 10, to most accurately monitor the flow characteristics of the material flowing through the second applicator assembly 56b.

[0025] In an applicator system including a third applicator assembly 56c, once the second correction factor is determined, the controller 32 may stop the flow of material to the second applicator 70b and then instruct the application system 10 to perform a third calibration operation (shown in FIG. 4). During the third calibration operation, the controller 32 instructs the primary pump 24 to pump material from the storage device 20 to the remote metering system 50, and the remote metering stand 54 directs the flow of material only to the third applicator 70c. The third calibration operation is intended to calibrate the third flow sensor 66c of the third applicator assembly 56c. During this calibration operation, the third RMS pump 58c may not be operated so that the material flow experienced by the primary flow sensor 28 most accurately reflects the material flow experienced by the third flow sensor 66c. When material flow is directed only to the third applicator 70c, the primary flow sensor 28 is configured to monitor a characteristic of the flow of material exiting the primary pump 24 and transmit a fifth feedback signal indicative of the characteristic via signal connection 36a. Concurrently, the third flow sensor 66c is configured to monitor a characteristic of the flow of material to the third applicator 70c and transmit a sixth feedback signal indicative of the characteristic via signal connection 36e. For example, the characteristic may be mass flow rate, volumetric flow rate, etc.

[0026] The controller 32 is configured to receive a fifth feedback signal from the primary flow sensor 28 and a sixth feedback signal from the third flow sensor 66c, and compare the fifth and sixth feedback signals. Ideally, the fifth and sixth feedback signals represent the same material flow characteristics. However, during operation, the fifth and sixth feedback signals may differ, which may indicate a defect in or other problem with the third flow sensor 66c. Therefore, to ensure that the third flow sensor 66c provides an accurate reading, the controller 32 may determine a correction factor for the third flow sensor 66c based on the difference between the fifth and sixth feedback signals to correct for deviations in the feedback received from the third flow sensor 66c. The correction factor may be determined according to a look-up table, a calculation, or other such means. This correction factor can be automatically applied by the controller 32 to future feedback signals received from the third flow sensor 66c, thus enabling the controller 32, and likewise the operator of the application system 10, to most accurately monitor the flow characteristics of the material flowing through the third applicator assembly 56c.

[0027] Although the system-wide calibration operation is described as including three calibration operations, the present disclosure is not intended to be so limited. For example, in another embodiment, the application system 10 may include four or more applicator assemblies, and thus the calibration operations performed by the controller 32 may include four or more separate calibration operations. Alternatively, the controller 32 may be configured to perform calibration operations that do not perform separate calibration operations on each applicator assembly, such that the application system 10 performs fewer calibration operations than it has applicator assemblies. Additionally, the controller 32 may be configured to repeat the calibration operations over time. For example, the controller 32 may repeat the calibration operations at predetermined milestones, such as upon starting the application system 10 after a period of inactivity, upon starting a new dispensing operation, upon dispensing new material, etc. Alternatively, the calibration operations may be repeated at predetermined intervals, such as after applying material to a set number of substrates, after a set volume or mass of material has been dispensed, etc. An operator of the application system may also instruct the controller 32 to perform calibration operations on demand.

[0028] After the calibration operation has been performed, the controller 32 may direct the components of the application system 10 to engage in normal steady-state operation (as shown in FIG. 5). During steady-state operation, material is pumped from the storage device 20 to the remote metering system 50 by the main pump 24, and the remote metering stand 54 divides the flow of material into separate flow portions. In the illustrated embodiment, the remote metering stand 54 may divide the flow of material into a first portion provided to the first applicator 70a, a second portion provided to the second applicator 70b, and a third portion provided to the third applicator 70c. However, during operation, the number of flow portions may vary with the number of applicator assemblies included in the application system 10, as discussed above. Each of the first, second, and third flow portions may have specific characteristics based on the intended dispensing operation to be performed by the applicator 70a-70c to which the particular flow portion is directed. These characteristics may be altered by remote weigh stand 54 upon automatic and / or manual instruction from controller 32 .

[0029] During steady state operation, each RMS pump 58a-58c of each applicator assembly 56a-56c may meter the portion of the material flow provided to its corresponding applicator assembly. Thus, the rate at which material flows through each of the applicator assemblies 56a-56c is not limited to the rate at which the material enters the applicator assembly 56a-56c after being pumped by the primary pump 24. During operation, the first RMS pump 58a may pump a first portion of the material flow through the first applicator assembly 56a at a first rate, the second RMS pump 58b may pump a second portion of the material flow through the second applicator assembly 56b at a second rate, and the third RMS pump 58c may pump a third portion of the material flow through the third applicator assembly 56c at a third rate. The first, second, and third rates may be the same or different as desired, depending on the requirements of each individual dispensing operation. Furthermore, the pump displacement (power per revolution) of each of the RMS pumps 58a-58c may be the same or different, as desired.

[0030] To ensure that the first, second, and third rates maintain consistent flow throughout the application process, the controller 32 may perform a monitoring operation. During the monitoring operation, the controller 32 may be configured to instruct the primary pump 24 to pump a first portion of the material flow to the first applicator 70a and a second portion of the material flow to the second applicator 70b. The controller 32 may also be configured to pump a third portion of the material flow to the third applicator 70c. During this time, the flow sensors 66a-66c may provide the controller 32 with feedback signals indicative of characteristics of the respective portions of the material flow at discrete times. Thus, the controller 32 is configured to receive a feedback signal indicative of a characteristic of the first portion of the material flow from the first flow sensor 66a, a feedback signal indicative of a characteristic of the second portion of the material flow from the second flow sensor 66b, and / or a feedback signal indicative of a characteristic of the third portion of the material flow from the third flow sensor 66c. Each of these feedback signals may be modulated by the correction factors described above (labeled as CF1, CF2, CF3 in FIG. 5).

[0031] Upon receiving these feedback signals, the controller 32 may compare them and the characteristics they represent to the intended characteristics of any of the first, second, and / or third portions of the material flow. If any of the flow characteristics differ from the intended characteristics for a particular flow portion, the controller 32 may adjust the operation of the pump corresponding to that flow portion. For example, if the feedback signal from the first flow sensor 66a indicates flow characteristics that do not match the intended characteristics of the first portion of the fluid flow, the controller 32 may adjust the operation of the first RMS pump 58a. Similarly, if the feedback signal from the second flow sensor 66b indicates flow characteristics that do not match the intended characteristics of the second portion of the fluid flow, the controller 32 may adjust the operation of the second RMS pump 58b. Additionally, if the feedback signal from the third flow sensor 66c indicates flow characteristics that do not match the intended characteristics of the third portion of the fluid flow, the controller 32 may adjust the operation of the third RMS pump 58c. Alternatively, the controller 32 may adjust operation of a pump corresponding to a particular flow portion if the flow characteristics for that portion deviate from the intended characteristics by more than a threshold amount, which may be selected by an operator of the application system 10 or may be determined by the controller 32. Additionally, the controller 32 may sum the feedback signals from the flow sensors 66a-66c and compare the summed signal to the feedback signal received from the primary flow sensor 28. This may be done continuously and in real-time to verify system integrity, which may be especially beneficial given the high value of high speed production.

[0032] In addition to, or alternatively to, the controller 32 adjusting the operation of the RMS pumps 58a-58c, the controller 32 or associated components may generate an alert when one of the feedback signals indicates characteristics that are outside of or exceed a set deviation from the intended characteristics for that particular flow portion, since a deviation of a certain magnitude may indicate a problem more serious than an incorrect pump speed, such as a break or other defect in the application system 10, or may indicate a need to repeat the calibration operations described above. The controller 32 may continue to perform monitoring operations as long as the application system 10 is applying material to a substrate, and thus the controller 32 may continuously monitor the flow sensors 66a-66c and adjust the operation of the RMS pumps 58a-58c as necessary.

[0033] With continued reference to FIGS. 6-1 and 6-2, a method 100 for calibrating the flow sensors 66a-66c of the remote metering system 50 is described. The method 100 includes a step 102 that initially includes pumping material to the first applicator 70a. In step 102, the controller 32 may instruct the main pump 24 to pump the material from the storage device 20 to the remote metering system 50, and the remote metering stand 54 may direct the flow of material to only the first applicator 70a so that the first flow sensor 66a in fluid communication with the first applicator 70a may be calibrated. During step 102, only the first RMS pump 58a may be operated, and the second RMS pump 58b and the third RMS pump 58c may not be operated. Step 106 may be performed while material is provided to only the first applicator 70a. At step 106, the controller 32 receives a first feedback signal from the primary flow sensor 28, which monitors a characteristic of the flow of material from the primary pump 24. The first feedback signal is indicative of the characteristic monitored by the primary flow sensor 28. Additionally, at step 106, the controller 32 receives a second feedback signal from the first flow sensor 66a, which monitors a characteristic of the flow of material to the first applicator 70a. The second feedback signal is indicative of the characteristic monitored by the first flow sensor 66a.

[0034] After step 106, in step 110, the controller 32 compares the first and second feedback signals received from the primary flow sensor 28 and the first flow sensor 66a, respectively. Ideally, the first and second feedback signals represent the same material flow characteristics. However, during operation, the first and second feedback signals may differ, which may indicate a defect in the first flow sensor 66a or other problems therewith. If the first and second feedback signals differ by any amount or by a predetermined threshold, step 114 may be executed. In step 114, the controller 32 may determine a correction factor for the first flow sensor 66a based on the difference between the first and second feedback signals. The correction factor may correct for deviations in the difference received from the primary flow sensor 28 and the first flow sensor 66a, and may be automatically applied to future feedback signals received by the controller 32 form the first flow sensor 66a. This correction factor allows the controller 32, and likewise the operator of the application system 10, to most accurately monitor the flow characteristics of the material flowing through the first applicator assembly 56a.

[0035] After the correction factor for the first flow sensor 66a has been determined, the controller 32 may then perform a similar analysis for the second flow sensor 66b. To do this, the controller 32 may instruct the remote weigh stand 54 to stop the flow of material to the first applicator 70a in step 118, and instruct the remote weigh stand 54 to direct all material flow from the primary pump 24 to the second applicator 70b in step 122. During step 122, only the second RMS pump 58b may be operated, and the first RMS pump 58a and the third RMS pump 58c may not be operated. While material is provided only to the second applicator 70b, step 126 may be performed. In step 126, the controller 32 receives a third feedback signal from the primary flow sensor 28, which monitors a characteristic of the flow of material from the primary pump 24. The third feedback signal is indicative of the characteristic monitored by the primary flow sensor 28. Additionally, in step 126, the controller 32 receives a fourth feedback signal from a second flow sensor 66b monitoring a characteristic of the flow of material to the second applicator 70b. The fourth feedback signal is indicative of the characteristic monitored by the second flow sensor 66b.

[0036] After step 126, in step 130, the controller 32 compares the third and fourth feedback signals received from the primary flow sensor 28 and the second flow sensor 66b, respectively. Ideally, the third and fourth feedback signals represent the same material flow characteristics. However, during operation, the third and fourth feedback signals may differ, which may indicate a defect in or other problem with the second flow sensor 66b. If the third and fourth feedback signals differ by any amount or by a predetermined threshold, step 134 may be performed. In step 134, the controller 32 may determine a correction factor for the second flow sensor 66b based on the difference between the third and fourth feedback signals. The correction factor may correct for deviations in the feedback received from the primary flow sensor 28 and the second flow sensor 66b, and may be automatically applied to future feedback signals received by the controller 32 from the second flow sensor 66b. This correction factor allows the controller 32, and likewise the operator of the application system 10, to most accurately monitor the flow characteristics of the material flowing through the second applicator assembly 56b.

[0037] After the correction factors for the first and second flow sensors 66a, 66b have been determined, the controller 32 may then perform a similar analysis for the third flow sensor 66c. To do this, the controller 32 may instruct the remote weigh stand 54 to stop the flow of material to the second applicator 70b in step 138 and instruct the remote weigh stand 54 to direct all material flow from the primary pump 24 to the third applicator 70c in step 142. During step 142, only the third RMS pump 58c may be operated, and the first RMS pump 58a and the second RMS pump 58b may not be operated. While material is provided only to the third applicator 70c, step 146 may be performed. In step 146, the controller 32 receives a fifth feedback signal from the primary flow sensor 28, which monitors a characteristic of the flow of material from the primary pump 24. The fifth feedback signal is indicative of the characteristic monitored by the primary flow sensor 28. Additionally, in step 146, the controller 32 receives a sixth feedback signal from a third flow sensor 66c monitoring a characteristic of the flow of material to the third applicator 70c. The sixth feedback signal is indicative of the characteristic monitored by the third flow sensor 66c.

[0038] After step 146, in step 150, the controller 32 compares the fifth and sixth feedback signals received from the primary flow sensor 28 and the third flow sensor 66c, respectively. Ideally, the fifth and sixth feedback signals represent the same material flow characteristics. However, during operation, the fifth and sixth feedback signals may differ, which may indicate a defect in or other problem with the third flow sensor 66c. If the fifth and sixth feedback signals differ by any amount or by a predetermined threshold, step 154 ​​may be performed. In step 154, the controller 32 may determine a correction factor for the third flow sensor 66c based on the difference between the fifth and sixth feedback signals. The correction factor may correct for deviations in the feedback received from the primary flow sensor 28 and the third flow sensor 66c, and may be automatically applied to future feedback signals received by the controller 32 from the third flow sensor 66c. This correction factor allows the controller 32, and likewise the operator of the application system 10, to most accurately monitor the flow characteristics of the material flowing through the third applicator assembly 56c.

[0039] After the aforementioned calibration steps have been performed, the application system 10 can begin dispensing material onto a substrate during normal operation. To begin this, in step 158, the controller 32 can instruct the main pump 24 to pump material to the remote metering system 50, and the remote metering stand 54 can divide the flow of material into separate flow portions. In this embodiment, in step 158, the remote metering stand 54 can divide the flow of material into a first portion provided to the first applicator assembly 56a and a second portion provided to the second applicator assembly 56b. In step 158, the remote metering stand 54 can also divide the flow of material into a third portion provided to the third applicator assembly 56c. Although three flow portions are explicitly described, during operation, the number of flow portions can vary with the number of applicator assemblies included in the application system 10, as discussed above. Each of the first, second, and third flow portions may have particular characteristics based on the intended dispensing operation to be performed by the applicator 70a-70c to which the particular flow portion is directed. These characteristics may be altered by the remote weigh stand 54 upon automatic and / or manual direction from the controller 32.

[0040] In step 158, each of the RMS pumps 58a-58c may meter the portion of the material flow provided to its corresponding applicator assembly. Thus, the rate at which material flows through each of the applicators 70a-70c is not limited to the rate at which the material enters the applicator assemblies 56a-56c after being pumped by the main pump 24. In operation, the first RMS pump 58a may pump a first portion of the material flow through the first applicator assembly 56a at a first rate, the second RMS pump 58b may pump a second portion of the material flow through the second applicator assembly 56b at a second rate, and the third RMS pump 58c may pump a third portion of the material flow through the third applicator assembly 56c at a third rate. The first, second, and third rates may be the same or different as desired, depending on the requirements of each individual dispensing operation.

[0041] In step 162, the controller 32 may perform a monitoring operation to ensure that the first, second, and third velocities remain consistent and do not deviate from intended levels throughout the application process. This may include the controller 32 receiving feedback signals from the flow sensors 66a-66c indicative of characteristics of the respective flow portions at discrete times. In particular, in step 166, the controller 32 may receive a feedback signal indicative of a characteristic of a first portion of the material flow from the first flow sensor 66a, a feedback signal indicative of a characteristic of a second portion of the material flow from the second flow sensor 66b, and / or a feedback signal indicative of a characteristic of a third portion of the material flow from the third flow sensor 66c. It should be noted that each or any combination of the flow sensors 66a-66 may be operated during the monitoring operation using correction factors determined by the controller 32 during the calibration operation.

[0042] Upon receiving these feedback signals modulated by the correction coefficients, the controller 32 may compare the modulated feedback signals to the characteristics represented in step 166. This comparison may be made against the intended characteristics of any of the first, second, and / or third portions of the material flow. If any of the flow characteristics differ from the intended characteristics for a particular flow portion, the controller 32 may adjust the operation of the pump corresponding to that flow portion in step 170. For example, step 170 may involve adjusting the operation of the first RMS pump 58a if the feedback signal from the first flow sensor 66a indicates flow characteristics that do not match or differ by a threshold amount from the intended characteristics for the first portion of the fluid flow. Additionally, step 170 may involve adjusting the operation of the second RMS pump 58b if the feedback signal from the second flow sensor 66b indicates flow characteristics that do not match or differ by a threshold amount from the intended characteristics for the second portion of the fluid flow. Further, step 170 may involve adjusting operation of the third RMS pump 58c if the feedback signal from the third flow sensor 66c indicates flow characteristics that do not match or differ by a threshold amount from the intended characteristics for the third portion of the fluid flow. In addition to or alternatively to step 170, the controller 32 may generate an alert when one of the feedback signals indicates characteristics that are outside of or exceed a set deviation from the intended characteristics for that particular flow portion, step 174. The alert may indicate that a component within the application system 10 has failed and needs to be replaced, or that any number of the flow sensors 66a-66c require recalibration. After either or both of steps 170, 174 have been performed, the controller 32 may continuously monitor the flow sensors 66a-66c, step 178, and adjust operation of the RMS pumps 58a-58c as necessary. This may include continuously or intermittently receiving feedback signals from the flow sensors 28 and 66a-66c and / or adjusting the operation of the RMS pumps 58a-58c.Additionally, during steady state operation, step 182 may be executed in which the controller 32 sums the feedback signals from the flow sensors 66a-66c and compares the summed signal to the feedback signal received from the primary flow sensor 28. As noted above, this may be done continuously and in real-time to verify the integrity of the system, which may be particularly beneficial given the high value of high speed production.

[0043] The above-described systems and methods for calibrating and monitoring flow sensors in a dispensing system with multiple applicators help ensure accuracy and consistency throughout the dispensing process. The types of sensors typically utilized as flow sensors 66a-66c may be small and low cost, thus allowing them to be installed in applicator assemblies 56a-56c up to the point of application. However, such sensors may not have the same level of accuracy as the types of sensors typically utilized as primary flow sensor 28, such as gear-type flow sensors. Thus, by determining the correction factors for flow sensors 66a-66c by the above-described methods, dispensing system 10 may take full advantage of the accuracy of primary flow sensor 28 to ensure that flow accuracy and consistency are maintained up to the point of application. Furthermore, by monitoring the flow portion during the dispensing process after calibration, any discrepancies between intended and actual flow characteristics may be quickly corrected in real time by controller 32.

[0044] Although various inventive aspects, concepts, and features of the present invention may be described and illustrated herein as embodied in combination in exemplary embodiments, these various aspects, concepts, and features may be used in many alternative embodiments, individually or in various combinations and subcombinations. All such combinations and subcombinations are intended to be within the scope of the present invention, unless expressly excluded herein. Furthermore, although various alternative embodiments of the various aspects, concepts, and features of the present invention may be described herein, such as alternative materials, structures, configurations, methods, circuits, devices and components, software, hardware, control logic, form, fit, and function alternatives, such descriptions are not intended to be a complete or comprehensive list of available alternative embodiments, whether currently known or later developed. Those skilled in the art can readily adopt one or more of the aspects, concepts, or features of the present invention into additional embodiments and applications within the scope of the present invention, even if such embodiments are not expressly disclosed herein. Furthermore, exemplary or representative values ​​and ranges may be included to aid in understanding the present disclosure, but such values ​​and ranges should not be construed in a limiting sense, and are intended to be significant values ​​or ranges only when expressly recited. The description of an example method or process is not intended to be limited as requiring the inclusion of every step in all cases, nor is the order in which the steps are presented intended to be essential, unless expressly stated.

[0045] Although the present invention has been described herein using a limited number of embodiments, these specific embodiments are not intended to limit the scope of the invention as otherwise described and claimed herein. The exact arrangement of the various elements and order of the steps of the articles and methods described herein should not be considered limiting. For example, although method steps are described with reference to a sequential series of reference numbers and block progressions in the figures, the method can be performed in a particular order as desired.

Claims

1. 1. A method for calibrating a plurality of fluid sensors in a remote metering system, the method comprising: pumping material from a main pump of a material supply device to a first applicator of the remote metering system; receiving a first feedback signal from a primary flow sensor of the material supply system in communication with the primary pump and a second feedback signal from a first flow sensor in communication with the first applicator, the first and second feedback signals indicative of characteristics of material flow through the primary pump and the first applicator, respectively; comparing the first and second feedback signals; determining a correction factor for the first flow sensor of the remote metering system; stopping the flow of material to the first applicator; pumping the material from the primary pump to a secondary applicator of the remote metering system; receiving a third feedback signal from the primary flow sensor and a fourth feedback signal from a second flow sensor of the remote metering system in communication with the second applicator, the third and fourth feedback signals indicative of a characteristic of the flow of material through the primary pump and the second applicator, respectively; comparing the third and fourth feedback signals; determining a correction factor for the second flow sensor; pumping a first portion of the material flow to the first applicator and a second portion of the material flow to the second applicator; receiving a fifth feedback signal from the first flow sensor and a sixth feedback signal from the second flow sensor; comparing the fifth and sixth feedback signals to intended characteristics of the first and second portions of the material flow, respectively; adjusting operation of a first remote metering stand pump of the remote metering system in fluid communication with the first applicator such that the first remote metering stand pump pumps the first portion at a first rate when the fifth feedback signal indicates characteristics inconsistent with the intended characteristics of the first portion transferred from the first remote metering stand pump through a first supply hose to the first applicator; adjusting operation of the second remote metering stand pump of the remote metering system in fluid communication with the second applicator such that the second remote metering stand pump pumps the second portion at a second speed different from the first speed when the sixth feedback signal indicates characteristics inconsistent with the intended characteristics of the second portion transferred from the second remote metering stand pump through a second supply hose to the second applicator; A method comprising:

2. Stopping the flow of the material to the second applicator; pumping the material from the primary pump to a third applicator; receiving a seventh feedback signal from the primary flow sensor and an eighth feedback signal from a third flow sensor in communication with the third applicator, the seventh and eighth feedback signals indicative of a characteristic of the flow of material through the primary pump and the third applicator, respectively; comparing the seventh and eighth feedback signals; The method of claim 1 , further comprising: determining a correction factor for the third flow sensor.

3. A method as described in claim 1 or 2, further comprising generating an alert when one of the fifth and sixth feedback signals exhibits a characteristic that is outside a predetermined range.

4. A method described in any one of claims 1 to 3, further comprising continuously repeating receiving and comparing the fifth and sixth feedback signals.

5. A method described in any one of claims 1 to 4, wherein the first flow sensor is integral with the first applicator and the second flow sensor is integral with the second applicator.

6. A method according to any one of claims 1 to 5, wherein the remote metering system includes a remote metering stand that receives the material from the main pump via a third hose, the remote metering stand configured such that the first remote metering stand pump and the second remote metering stand pump are mountable to the remote metering stand, and the remote metering stand communicates wirelessly and / or wired with a controller via a signal connection.

7. A method described in any one of claims 1 to 6, wherein the first, second, third, and fourth feedback signals are proportional to the volumetric flow rate or mass flow rate of the material flow.

8. A method according to any one of claims 1 to 7, wherein the main flow sensor is a geared flow meter located remotely from the remote metering system and connected to the remote metering system via a main hose, the first flow sensor is a first anemometer sensor, and the second flow sensor is a second anemometer sensor.

9. Receiving the first feedback signal and the second feedback signal occurs while the primary pump is pumping the material to the remote metering system and while the remote metering system is directing the flow of the material only to a first supply line that transfers the material to the first applicator; stopping the flow of material to the first applicator occurs after receiving the first feedback signal and the second feedback signal; 9. The method of claim 1, wherein receiving the third feedback signal and the fourth feedback signal occurs after the flow of material to the first applicator is stopped while the main pump is pumping the material to the remote metering system, while the flow of material is not being directed by the remote metering system to the first applicator, and while the remote metering system is directing the flow of material only to a second supply line that transports the material to the second applicator.

10. A coating system for applying a material to a substrate, the coating system comprising: a material supply system including a main pump and a main flow sensor monitoring the output of said main pump; a remote metering system for receiving the material flowing from the material supply device and applying the material to a substrate, the remote metering system comprising: a first applicator assembly including a first applicator and a first flow sensor for monitoring an output of the first applicator; a second applicator assembly including a second applicator and a second flow sensor for monitoring an output of the second applicator; and a controller in signal communication with the remote metering system and the material supply device, the controller comprising: 1) performing a first calibration operation, wherein the controller is configured to: a) instruct the primary pump to pump the material to the first applicator; b) receive a first feedback signal from the primary flow sensor and a second feedback signal from the first flow sensor; c) compare the first and second feedback signals; and d) determine a correction factor for the first flow sensor; 2) stopping the flow of material to the first applicator; and 3) performing a second calibration operation, wherein the controller is configured to: a) instruct the primary pump to pump the material to the second applicator; b) receive a third feedback signal from the primary flow sensor and a fourth feedback signal from the second flow sensor; c) compare the third and fourth feedback signals; and d) determine a correction factor for the second flow sensor; 4) performing a monitoring operation, wherein the controller is configured to: a) direct the primary pump to pump a first portion of the material flow to the first applicator and a second portion of the material flow to the second applicator; b) receive a fifth feedback signal from the first flow sensor and a sixth feedback signal from the second flow sensor; and c) compare the fifth and sixth feedback signals to intended characteristics of the first and second portions of the material flow, respectively. a controller configured to: the first applicator assembly includes a first remote metering stand pump in fluid communication with the first applicator via a first supply hose, the controller being further configured to adjust operation of the first remote metering stand pump such that the first remote metering stand pump pumps the first portion at a first rate when the fifth feedback signal indicates material flow characteristics that do not match the intended characteristics of the first portion of the material flow; the second applicator assembly includes a second remote metering stand pump in fluid communication with the second applicator via a second supply hose, and the controller is further configured to adjust operation of the second remote metering stand pump such that the second remote metering stand pump pumps the second portion at a second speed different from the first speed when the sixth feedback signal indicates material flow characteristics that do not match the intended characteristics of the second portion of the material flow.

11. The remote metering system is located remotely from the material supply device and connected to the material supply device via a main hose; The remote metering system comprises: The application system of claim 10 , further comprising a third applicator assembly including a third applicator and a third flow sensor for monitoring an output of the third applicator.

12. The controller 5) stopping the flow of material to the second applicator; and 6) performing a third calibration operation, the controller being configured to: a) direct the primary pump to pump the material to the third applicator; b) receive a seventh feedback signal from the primary flow sensor and an eighth feedback signal from the third flow sensor; c) compare the seventh and eighth feedback signals; and d) determine a correction factor for the third flow sensor. The coating system of claim 11 , further configured to:

13. An application system as described in any one of claims 10 to 12, wherein the remote metering system includes a remote metering stand that receives the material from the main pump via a third hose, the remote metering stand configured such that the first remote metering stand pump and the second remote metering stand pump are mountable to the remote metering stand, and the remote metering stand communicates wirelessly and / or wired with the controller via a signal connection.

14. The application system of claim 13, wherein the remote weighing stand includes a diverter configured to selectively change the division of the material flow between multiple outputs of the remote weighing stand.

15. An application system as described in any one of claims 10 to 14, wherein the controller is configured to sum the fifth and sixth feedback signals to generate a summed feedback signal and compare the summed feedback signal with a seventh feedback signal received from the main flow sensor.

16. An application system as described in any one of claims 10 to 15, wherein the first, second, third and fourth feedback signals are proportional to the volumetric flow rate or mass flow rate of the material.

17. The controller 1) while the flow of material is not being directed by the remote metering system to the second applicator, the controller performs the first calibration operation: a) instructing the main pump to pump the material to the remote metering system and to direct the flow of material only to a first supply line fluidly connecting the remote metering system to the first applicator; 2) stopping the flow of material to the first applicator after the first calibration operation has been performed; and 3) after the flow of material to the first applicator is stopped, while the flow of material is not being directed to the first applicator by the remote metering system, the controller performs the second calibration operation: a) instructing the primary pump to pump the material to the remote metering system and to direct the flow of material only through a second supply line fluidly connecting the remote metering system to the second applicator; the first flow sensor is a first anemometer sensor and the second flow sensor is a second anemometer sensor; 17. The application system of claim 10, wherein the first anemometer sensor is integral with the first applicator, the first applicator assembly including the first anemometer sensor and the first supply hose configured to provide flow to the first applicator, and the second anemometer sensor is integral with the second applicator, and the second applicator assembly including the second anemometer sensor and the second supply hose configured to provide flow to the second applicator.

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