Non-contact ultrasonic nozzle cleaner with closed loop automatic clogging detection

Abstract

A system and method for operating and cleaning a coating system is disclosed. A method for applying material to a substrate includes dispensing the material onto the substrate with an applicator configured to receive the material and expel the material from the applicator toward the substrate, the method including measuring a parameter of the material being expelled through the applicator, determining whether the parameter is within a predetermined range, if the parameter is not within the predetermined range, stopping the dispensing of the material onto the substrate and cleaning the applicator so that the parameter is within the predetermined range, and resuming the dispensing of the material after cleaning the applicator.

Description

[Technical field]

[0001] The present invention relates generally to the application of conformal coating materials, and more particularly to mechanisms and methods for cleaning conformal coating applicators to reduce the occurrence of clogging of the conformal coating applicator.

[0002] [Citation to Related Applications] This application is a claim of U.S. Provisional Patent Application No. 63 / 214,386, filed June 24, 2021, the disclosure of which is incorporated by reference in its entirety. [Background technology]

[0003] Conformal coating is typically a process in which a dielectric is applied to electronic components, such as printed circuits, printed circuit boards (PCBs), devices mounted on printed circuit boards, and / or the like, to protect them from moisture, mildew, dust, corrosion, abrasion, vibration, chemicals, tin whiskers, other environmental stresses, and / or the like. Conformal coating materials range from solvent-based materials that harden upon evaporation of the solvent to "100% solids" conformal coating materials. Common conformal coating materials include silicones, acrylics, urethanes, epoxy synthetic resins, various polymers, and / or the like. When applied to a PCB, a uniform thickness insulating resin film is usually formed when the solvent is evaporating or when the solvent-free material is curing.

[0004] Automated selective coating systems are known. Such systems may include conformal coating dispensers that dispense material in various patterns with varying deposition accuracy, resulting in coatings of varying thickness. During operation, some parts of the coating system may hold some percentage of the coating material. The nozzles of the coating dispensers may deposit coating material due to the nature of the coating material itself, due to the specific application process and pattern, and / or otherwise. The deposited coating material may harden, harden, or otherwise interfere with the continued dispensing of coating material from a clogged or affected dispenser nozzle.

[0005] Several mechanisms exist in the art for cleaning and removing deposited or residual coating material from the nozzle. In some approaches, when the dispenser nozzle is not in use, the dispenser nozzle may be stored in a reservoir containing a solvent that interacts with any uncured coating deposited on the nozzle and prevents the uncured coating from curing and / or solidifying and clogging the nozzle. However, in some coating approaches, excess coating material deposited on the nozzle during operation begins to harden and form clogs during the operation process itself. Thus, the solution of storing the nozzle in a reservoir with solvent reduces the formation of clogs when the excess material has not yet cured, but does not help prevent clogs caused by material that hardens during operation. Typically, storing the nozzle in a solvent after the material has already cured is less effective at removing excess material from the nozzle.

[0006] Another technical solution sometimes used is to mechanically clean the nozzle with a suitable tool. In this way, the user can brush or wipe the excess material off the nozzle. The nozzle may be configured to be moved relative to the brush to remove the excess material. However, as a result of this solution, the brush accumulates excess material over time and, if not properly cleaned or replaced, will deposit some of the accumulated material back onto the nozzle in the next cleaning or washing step. In addition, some nozzles may be made of delicate materials that may be damaged by the mechanical scrubbing of the brush bristles. Summary of the Invention [Problem to be solved by the invention]

[0007] Therefore, there is a need for an improved mechanism and / or process for cleaning excess coating material from a conformal coating dispenser. [Means for solving the problem]

[0008] The above needs are met by various aspects of the disclosed coating assembly and associated methods. According to one aspect of the disclosure, a method of applying material to a substrate with a coating system includes dispensing the material onto the substrate with an applicator configured to receive the material and expel the material from the applicator toward the substrate, the method further including measuring a parameter of the material being expelled through the applicator and comparing the measured parameter to a reference value. Based on the comparison, the method includes ceasing the dispensing of the material onto the substrate and cleaning the applicator so that the parameter is within a predetermined range. The method includes resuming the dispensing of the material after cleaning the applicator.

[0009] Optionally, the step of measuring a parameter of the material measures at least one of a flow rate of the material, a temperature of the material, and a pressure of the material.

[0010] Optionally, measuring the parameter may include measuring a first parameter and measuring a second parameter, and the method may include comparing the measured first parameter to the measured second parameter. Determining whether the parameter is within a predetermined range may include comparing the measured second parameter to the first parameter to determine whether it is within the predetermined range.

[0011] Optionally, the applicator may be in the active position when the dispensing step is being performed, and the method may further include moving the applicator to a cleaning position if the parameter is not within the predetermined range.

[0012] Optionally, cleaning the applicator may include contacting the applicator with a cleaning material for a predetermined period of time.

[0013] Optionally, the cleaning material may comprise a solvent.

[0014] Optionally, the method may further include activating an ultrasonic transducer to agitate the cleaning material, thereby creating cavitation bubbles in the cleaning material.

[0015] Optionally, the method may further include the step of receiving electronic feedback from the ultrasonic transducer and adjusting operation of the ultrasonic transducer based on the received electronic feedback.

[0016] Optionally, the electronic feedback may include at least one of current feedback and phase feedback.

[0017] Optionally, adjusting operation of the ultrasonic transducer based on received electronic feedback may include operating the ultrasonic transducer at its resonant frequency.

[0018] Optionally, the method may further include measuring a fluid level of the cleaning material, comparing the measured fluid level to a predetermined value, and, in response to determining that the measured fluid level is below the predetermined value, adding cleaning material to raise the fluid level of the cleaning material above the predetermined value.

[0019] Optionally, the reference value may be a predetermined range defined between a lower threshold and an upper threshold, and the comparing step may include determining whether the measured parameter is within the predetermined range.

[0020] Optionally, the step of stopping dispensing may include the step of instructing the coating system to stop dispensing immediately after completion of the comparison step.

[0021] Optionally, the step of ceasing dispensing may include instructing the coating system to cease dispensing a predetermined amount of time after completion of the comparison step.

[0022] According to another aspect of the invention, a method for predicting a future occurrence of a clog in a coating system including a dispenser applicator configured to dispense a material onto a substrate is disclosed. The method includes measuring a first parameter of the material in the dispenser applicator at a first time point, identifying the presence of a first clog condition, finding an association between the first parameter and the first clog condition, measuring the first parameter of the material at a second time point after the first time point, and predicting a future occurrence of the second clog condition using the measured first parameter at the second time point and the found association.

[0023] Optionally, predicting a future occurrence of the second clog condition may include using a predetermined control value for the first parameter.

[0024] Optionally, the predetermined control value comprises a control predetermined value range.

[0025] Optionally, the method may further include the step of notifying a user of a predicted future occurrence of the second clog condition.

[0026] Optionally, the method may further include activating a cleaning process before a predicted future occurrence of the second clogging condition occurs, the cleaning process including removing accumulated material from the dispenser applicator.

[0027] Optionally, the first parameters may include at least one of coating system operating parameters and coating material parameters, where the coating system operating parameters include at least one of dispense applicator size, material discrimination, and substrate discrimination, and the coating material parameters include at least one of coating material pressure, coating material flow rate, coating material temperature, duration of the coating operation, time since last applicator clean, amount of substrate being coated, and amount of substrate coated since last applicator clean.

[0028] Optionally, the method may include finding a correlation between the time elapsed since the last applicator cleaning and the first clog condition.

[0029] Optionally, the method may further include finding a plurality of associations, where a future occurrence of the second clog condition includes identifying a portion of the plurality of induced associations and extrapolating a predicted association between the first parameter and a future second clog condition using the portion of the plurality of induced associations.

[0030] According to another aspect of the present invention, a method for cleaning a volumetric dispenser applicator that dispenses material onto a substrate includes measuring a parameter associated with the volumetric dispenser applicator with a sensor when the volumetric dispenser applicator is in a volumetric dispense position, in which the volumetric dispenser applicator is configured to dispense material onto a substrate, the method includes moving the volumetric dispenser applicator from the volumetric dispense position to a cleaning position if the measured parameter exceeds a predetermined threshold, in which the volumetric dispenser applicator is not configured to dispense material onto a substrate, and the method includes cleaning the volumetric dispenser applicator in the cleaning position.

[0031] Optionally, the step of measuring the parameter may include measuring the parameter at a first iteration and measuring the parameter at a second iteration, and the method may further include comparing the measured parameter at the first iteration with the measured parameter at the second iteration to determine whether a difference between the measured parameter at the first iteration and the measured parameter at the second iteration exceeds a predetermined threshold.

[0032] Optionally, the step of measuring a parameter may include measuring a first parameter and a second parameter.

[0033] Optionally, the first parameter may include a temperature of the material and the second parameter may include a flow rate of the material.

[0034] Optionally, if the measured temperature of the material during the second iteration does not exceed a predetermined threshold compared to the measured temperature during the first iteration and the flow rate of the material during the second iteration is below a predetermined threshold, the method may include moving the constant-volume dispenser applicator from the constant-volume dispense position to a cleaning position to clean the constant-volume dispenser applicator.

[0035] Optionally, the cleaning step may include contacting the dispensing applicator with a cleaning material.

[0036] Optionally, the cleaning material may include a solvent.

[0037] Optionally, the cleaning step may include activating a cleaning device having an ultrasonic transducer to generate ultrasonic waves within the cleaning material, thereby processing the cleaning material to generate cavitation bubbles.

[0038] Optionally, the method may include the step of receiving electronic feedback from the ultrasonic transducer and adjusting operation of the ultrasonic transducer based on the received electronic feedback.

[0039] Optionally, the electronic feedback may include at least one of current feedback and phase feedback.

[0040] Optionally, adjusting operation of the ultrasonic transducer based on received electronic feedback may include operating the ultrasonic transducer at its resonant frequency.

[0041] Optionally, the method may include the step of measuring the parameter after the washing step.

[0042] Optionally, the method may include the step of moving the dosing applicator to a dosing position and dispensing material via the dosing applicator after the cleaning step and prior to measuring the parameter.

[0043] Optionally, the method may include the step of moving the dosing applicator to a purging position and dispensing material via the dosing applicator after the cleaning step and prior to measuring the parameter.

[0044] According to yet another aspect of the invention, a coating system for dispensing material onto a substrate includes an applicator configured to receive coating material from a coating material source, the applicator having an outlet through which the material flows toward the substrate, the coating system including a dosing assembly configured to cause dispensing of the material from the applicator, an applicator positioning assembly operatively connected to the applicator and configured to move the applicator between a dosing position and a cleaning position, and a cleaning assembly configured to remove residual material from the applicator, when the applicator is in the dosing position the applicator is not in contact with the cleaning assembly and the applicator is configured to dispense material onto the substrate, and when the applicator is in the cleaning position the applicator is in contact with the cleaning assembly and the applicator is not configured to dispense material and is configured to be cleaned by the cleaning assembly.

[0045] Optionally, the coating system may include a heater configured to heat the material within the applicator.

[0046] Optionally, the coating system may further include a controller configured to control operation of the coating system, the controller including a plurality of sensors and a processor.

[0047] Optionally, the plurality of sensors may include at least one of the following sensors: a temperature sensor, a flow sensor, and a pressure sensor.

[0048] Optionally, the processor may be configured to receive signals from a number of sensors and store the received signals in memory.

[0049] Optionally, the processor may be configured to compare received signals from at least two of the plurality of sensors to each other to determine whether a jam condition exists.

[0050] Optionally, the processor may be configured to compare received signals from the plurality of sensors with a predetermined control signal to determine whether a jam condition exists.

[0051] Optionally, the processor may be configured to receive signals from the plurality of sensors during a first iteration and receive signals from the plurality of sensors during a second iteration after the first iteration, and the processor may be configured to compare the received signals during the second iteration with the received signals during the first iteration to determine whether a clog condition exists.

[0052] Optionally, the signal may include a temperature and flow rate of the material, and the processor may be configured to compare the temperature and flow rate at the first iteration with the temperature and flow rate at the second iteration, and if the temperature at the second iteration is within a predetermined threshold compared to the temperature at the first iteration and the flow rate at the second iteration is below a predetermined threshold compared to the flow rate at the first iteration, the processor may be configured to send a signal to the applicator positioning assembly to move the applicator to a cleaning position.

[0053] Optionally, the coating system may further include a controller configured to control operation of the coating system, the controller including the vision system.

[0054] Optionally, a vision system may be positioned on-board or downstream of the applicator.

[0055] Optionally, the vision system may include a camera configured to capture an image of a nozzle through which material is dispensed from the applicator.

[0056] Optionally, the camera may be arranged to capture an image of an opening in the nozzle.

[0057] Optionally, the controller may be configured to generate one or more signals to activate the camera to capture an image of the nozzle, process the image to generate a first value based on the residual material on the nozzle, compare the first value to a predetermined value, and in response to determining that the first value is outside a set tolerance for the predetermined value, activate the applicator positioning assembly to move the applicator to a cleaning position and activate the cleaning assembly to remove at least some of the residual material from the applicator.

[0058] Optionally, the controller may be further configured to generate one or more signals to, following activation of the cleaning assembly to remove at least a portion of the residual material from the applicator, activate the applicator positioning assembly to move the applicator to a dispense position, activate the camera to capture a second image of the nozzle, process the second image to generate a second value based on the residual material on the nozzle, compare the second value to a predetermined value, and activate the dispense assembly to cause a dispense of material from the applicator.

[0059] Optionally, the vision system may include a camera configured to capture an image of the fluid pattern of the material being dispensed.

[0060] Optionally, the controller is configured to generate one or more signals to activate the camera to capture an image of the fluid pattern, process the image to generate actual fluid pattern information for the fluid pattern, compare the actual fluid pattern information to the fluid pattern information for the fluid pattern, determine that the actual fluid pattern is outside of a set tolerance for the fluid pattern based on a comparison of the actual fluid pattern information to the fluid pattern information, and in response to determining that the actual fluid pattern is outside of a set tolerance for the fluid pattern, move the applicator to a cleaning position and activate the cleaning assembly to remove at least a percentage of the residual material from the applicator.

[0061] Optionally, the images of the fluid pattern may include at least one image of the fluid pattern from a first angle and at least one image of the fluid pattern from a second angle different from the first angle.

[0062] Optionally, the camera may be configured to move between a first position for capturing at least one image of the fluid pattern from a first angle and a second position for capturing at least one image of the fluid pattern from a second angle.

[0063] Optionally, the controller may be configured to determine a three-dimensional model of the fluid pattern based on the image, and to ascertain actual fluid pattern information of the fluid pattern based on the three-dimensional model.

[0064] Optionally, the coating system may further include a light source configured to emit light into the fluid pattern of material dispensed from the dispensing nozzle, the light source being positioned facing the fluid pattern to direct the light emitted into the fluid pattern.

[0065] Optionally, the cleaning assembly may include a cleaning device configured to receive the cleaning material and configured to receive the applicator when the applicator is in the cleaning position.

[0066] Optionally, the method may include measuring a fluid level of the cleaning material, comparing the fluid level to a predetermined value, and, in response to determining that the measured fluid level is below the predetermined value, adding cleaning material to raise the fluid level of the cleaning material above the predetermined value.

[0067] Optionally, the coating system may further include a fluid level sensor configured to measure the fluid level of the cleaning material.

[0068] Optionally, the coating system may further include a gravity-fed reservoir configured to add cleaning material to raise a fluid level of the cleaning material above a predetermined value.

[0069] Optionally, the cleaning material may include a solvent.

[0070] Optionally, the cleaning device may include an ultrasonic transducer configured to generate ultrasonic waves through the cleaning material to agitate the cleaning material, such that cavitation bubbles are generated in the cleaning material.

[0071] Optionally, the method may include the step of receiving electronic feedback from the ultrasonic transducer and adjusting operation of the ultrasonic transducer based on the received electronic feedback.

[0072] Optionally, the electronic feedback may include at least one of current feedback and phase feedback.

[0073] Optionally, adjusting operation of the ultrasonic transducer based on received electronic feedback may include operating the ultrasonic transducer at its resonant frequency.

[0074] Optionally, the cleaning assembly may include a lid configured to be removably attached to the cleaning device, such that the cleaning material is enclosed between the cleaning device and the lid and prevented from exiting the cleaning device beyond the lid.

[0075] Optionally, the lid may be provided with an aperture configured to receive the applicator therethrough.

[0076] According to yet another aspect of the present invention, a method for applying material to a substrate with a coating system includes dispensing material onto the substrate using an applicator configured to receive material and expel the material from the applicator toward the substrate, the method further including performing a visual inspection of the applicator using a vision system, stopping the dispensing of material onto the substrate based on the visual inspection of the applicator and cleaning the applicator, and resuming the dispensing of material after cleaning the applicator.

[0077] Optionally, performing a visual inspection may include visually inspecting a fluid pattern of the material being dispensed.

[0078] Optionally, the step of visually inspecting the fluid pattern of the material being dispensed may include capturing an image of the fluid pattern of the material being dispensed with a camera of the vision system.

[0079] Optionally, the method may further include processing the image to generate actual fluid pattern information of the fluid pattern, comparing the actual fluid pattern information to the fluid pattern information for the fluid pattern, determining that the actual fluid pattern is outside a set tolerance for the fluid pattern based on a comparison of the actual fluid pattern information to the fluid pattern information, and in response to determining that the actual fluid pattern is outside a set tolerance for the fluid pattern, moving the applicator from the dispense position to a cleaning position, and removing at least a percentage of the residual material from the applicator.

[0080] Optionally, the images of the fluid pattern may include at least one image of the fluid pattern from a first angle and at least one image of the fluid pattern from a second angle different from the first angle.

[0081] Optionally, the method may further include moving the camera between a first position for capturing at least one image of the fluid pattern from a first angle and a second position for capturing at least one image of the fluid pattern from a second angle.

[0082] Optionally, the method may further include determining a three-dimensional model of the fluid pattern based on the image, and ascertaining actual fluid pattern information of the fluid pattern based on the three-dimensional model.

[0083] Optionally, the method may further include emitting light into the fluid pattern of material dispensed from the dispense nozzle via a light source, the light source being positioned facing the fluid pattern to direct the emitted light into the fluid pattern.

[0084] Optionally, the step of performing a visual inspection may include visually inspecting a nozzle through which the material is expelled from the applicator for contamination.

[0085] Optionally, the step of visually inspecting the nozzle may include capturing an image of the nozzle with a camera of a vision system.

[0086] Optionally, the camera may be arranged to capture an image of an opening in the nozzle.

[0087] Optionally, the method may further include the steps of processing the image to generate a first value based on the residual material on the nozzle, comparing the first value to a predetermined value, and in response to determining that the first value is outside a set tolerance for the predetermined value, moving the applicator to a cleaning position and removing at least a percentage of the residual material from the applicator.

[0088] Optionally, the method may further include the steps of moving the applicator to a dispensing position following removal of at least some of the remaining material from the applicator, capturing a second image of the nozzle, processing the second image to generate a second value based on the remaining material on the nozzle, comparing the second value to a predetermined value, and dispensing the material from the applicator.

[0089] Optionally, the step of performing a visual inspection may include visually inspecting the substrate.

[0090] Optionally, visually inspecting the substrate may include capturing an image of the substrate with a camera of a vision system.

[0091] Optionally, the method may further include processing the image to generate a first value based on the dispensed material on the substrate, comparing the first value to a predetermined value, and in response to determining that the first value is outside a set tolerance for the predetermined value, moving the applicator to a cleaning position and removing at least a percentage of the residual material from the applicator.

[0092] Optionally, the first value represents at least one of a location and an amount of dispensed material onto a substrate.

[0093] Optionally, the method may further include, following removal of at least some of the residual material from the applicator, moving the applicator to a dispense position, capturing a second image of the substrate, processing the second image to generate a second value based on the dispensed material on the nozzle, comparing the second value to a predetermined value, and dispensing material from the applicator.

[0094] Optionally, the applicator is in the active position when the dispensing step is being performed, and the method may further include the step of moving the applicator to a cleaning position during cleaning of the applicator.

[0095] Optionally, cleaning the applicator may include contacting the applicator with a cleaning material for a predetermined duration.

[0096] Optionally, the method may further include measuring a fluid level of the cleaning material, comparing the measured fluid level to a predetermined value, and, in response to determining that the measured fluid level is below the predetermined value, adding cleaning material to raise the fluid level of the cleaning material to above the predetermined value.

[0097] Optionally, the cleaning material may comprise a solvent.

[0098] Optionally, the method may further include activating an ultrasonic transducer to agitate the cleaning material, thereby creating cavitation bubbles within the cleaning material.

[0099] Optionally, the method may further include the step of receiving electronic feedback from the ultrasonic transducer and adjusting operation of the ultrasonic transducer based on the received electronic feedback.

[0100] Optionally, the electronic feedback may include at least one of current feedback and phase feedback.

[0101] Optionally, adjusting operation of the ultrasonic transducer based on received electronic feedback may include operating the ultrasonic transducer at its resonant frequency.

[0102] This application will be better understood when read in conjunction with the accompanying drawings, in which: For the purpose of illustrating the teachings of the invention, exemplary aspects of the invention are shown in the drawings, but the teachings disclosed herein are not limited to the specific methods, apparatus, or systems disclosed. A brief description of the drawings follows: [Brief description of the drawings]

[0103] [Figure 1] 1 is a schematic diagram of a coating assembly system according to one aspect of the present invention. [Diagram 2] 2 is a schematic diagram of a memory of a processor of a coating assembly system according to an aspect of the present invention. [Diagram 3] 1 is a perspective view of a portion of a cleaning assembly system according to one aspect of the present invention. [Figure 4] 4 is another perspective view of a portion of the cleaning assembly system of FIG. 3. [Diagram 5] FIG. 4 is another perspective view of a portion of the cleaning assembly system of FIG. 3, illustrating an applicator disposed within the cleaning assembly system in accordance with one aspect of the present invention. [Figure 6] FIG. 2 is a perspective view of a portion of a cleaning assembly system according to another aspect of the present invention. [Figure 7] FIG. 7 is another perspective view of a portion of the cleaning assembly system of FIG. 6, illustrating an applicator disposed within the cleaning assembly system in accordance with one aspect of the present invention. [Figure 8] FIG. 2 is a side cross-sectional view of a cleaning assembly system according to yet another aspect of the present invention. [Figure 9] 4 is a flow diagram illustrating a clog detection process in accordance with one aspect of the present invention. [Figure 10] 2 is a schematic diagram of a coating assembly according to another aspect of the present invention. [Figure 11] 1 is a schematic diagram of a machine learning unit according to an aspect of the present invention. [Figure 12] 12 is a schematic diagram of a learning module of the machine learning unit of FIG. 11 according to one aspect of the present invention. [Figure 13]4 is a flow diagram illustrating a process for predicting future occurrences of a clog condition in accordance with an aspect of the present invention. [Figure 14] 1 is a flow diagram illustrating a process for calibrating a flow rate of material deposited on one or more substrates through a nozzle of a coating system in accordance with an aspect of the present invention. [Figure 15] 4 is a flow diagram illustrating a process for visually inspecting a dispensing nozzle according to an aspect of the present invention. [Figure 16] 4 is a flow diagram illustrating a process for visually inspecting a fluid pattern according to an aspect of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0104] Aspects of the present invention will now be described in detail with reference to the figures, in which the above-mentioned reference characters refer to the same elements throughout the figures unless otherwise specified.

[0105] Referring to FIG. 1, an exemplary conformal coating system 10 is illustrated including a conformal coating applicator or dispenser, hereafter applicator 20. The applicator 20 is configured to receive one or more conformal coating materials 50 from a material source 54. The applicator 20 has an applicator tip 24 configured to dispense the material 50 received through the applicator tip 24 onto one or more substrates 30. The dispensing of the material 50 may be controlled by one or more dosing assemblies 42 disposed within and / or operably connected to the applicator 20. The dosing assemblies 42 may include actuated valves, valve components, and / or the like, which may include actuators for effecting movement of the valves or valve components, which may be embodied, for example, by a solenoid. The coating system 10 may include a heater 36 configured to heat the coating material 50. The heater 36 may be located adjacent the material source 54, the applicator 20, or anywhere else within the coating system 10. In some aspects, the coating system 10 may include multiple heaters 36.

[0106] The substrate 30 may include a printed circuit, a printed circuit board (PCB), other electronic components, and / or the like configured to receive the conformal coating in a deposited state. In some aspects, one or more substrates 30 may be coated in a batch mode. One or more of the substrates 30 may be moved continuously past the applicator 20, for example, by a conveyor (not shown). In some aspects, the applicator 20 may be moved relative to the substrate 30. The applicator 20 may be operably coupled to an applicator positioning assembly 34. The applicator positioning assembly 34 may be configured to translate the applicator 20 relative to the substrate 30 along one, two, or three directional axes, each of which is orthogonal to any of the other axes. In some aspects, the applicator positioning assembly 34 may be configured to rotate the applicator 20 about one, two, or three directional axes. The applicator positioning assembly 34 may include a drive coupled in a known manner to an independently controllable motor (not shown). The applicator positioning assembly 34 is configured to rapidly move the applicator 20 relative to the substrate 30. Movement of the applicator 20 may align the applicator 20 with the substrate 30 based on a desired orientation. In some aspects, the applicator positioning assembly 34 may be configured to move the applicator 20 between an operating position and a cleaning position. In the operating position, the applicator 20 is configured to dispense the material 50 onto the substrate 30. When the applicator 20 is in the operating position, the applicator 20 may be movable relative to the substrate 30. In the cleaning position, the applicator 20 may be spaced from the substrate 30 such that the applicator is prevented from dispensing the material 50 onto the substrate 30.

[0107] The conformal coating system 10 may further include one or more controllers configured to send and / or receive signals to direct operation of one or more components of the conformal coating system 10. A system controller 100 may be configured to send data and / or signals to and / or receive data and / or signals from one or more components of the conformal coating system 10 to control operation of the conformal coating system 10. The controller 100 may be configured to operate one or more heaters 36 and / or other components of the conformal coating system 10. The controller 100 may include or be operatively connected to one or more sensors configured to detect and measure various parameters of the coating system 10.

[0108] 1 , the controller 100 may include or be connected to a pressure sensor 108 that may be configured to detect and measure the pressure of the material 50 at one or more points along the flow path as the material 50 is moved from the material source 54 towards the applicator 20. The controller 100 may include or be connected to a flow meter 112 that may be configured to detect and measure the flow rate of the material 50 at one or more points along the flow path as the material 50 is moved from the material source 54 towards the applicator 20. The controller 100 may include or be connected to a temperature sensor 116 that may be configured to measure the temperature of the material 50 at one or more points along the flow path as the material 50 is moved from the material source 54 towards the applicator 20. In some aspects, the coating system 10 may include pressure sensors 108, flow gauges 112, and / or temperature sensors 116, and the disclosure is not limited by the specific quantity or respective arrangement of the various sensors and gauges described. It should be understood that the specific arrangement of the above-mentioned components may follow any suitable arrangement, and may depend on the dimensions of the individual components selected, the number of components selected, manufacturing constraints, and / or other considerations common in the industry. The arrangement shown in the schematic diagram of FIG. 1 is exemplary and therefore does not limit the invention in terms of the relative positioning of the components described.

[0109] The controller 100 may include a processor 120 configured to receive signals from the pressure sensor 108, the flow meter 112, and / or the temperature sensor 116. Additionally, the controller 100 may include an analog-to-digital converter, a digital-to-analog converter, at least one filter, and / or the like to generate and condition the signals. The received signals may include measurements of material pressure, material flow rate, and / or material temperature, respectively. The processor 120 may include a programmable logic controller (PLC), a microprocessor-based controller, an enhanced personal computer, or other conventional programmable controller capable of performing the functions described herein, as will be appreciated by those skilled in the art. The processor 120 may perform the necessary operations by distinguishing between one discrete physical state and the next discrete physical state and transitioning from one discrete physical state to the next discrete physical state by operating switching elements that change the states. Switching elements generally include electronic circuits that maintain one of two binary states, such as flip-flops, and electronic circuits that provide an output state based on a logical combination of the states of one or more other switching elements, such as logic gates. These basic switching elements can be combined to create more complex logic circuits, including registers, adders and subtractors, arithmetic logic units, floating point units, and others.

[0110] The processor 120 may be configured to couple to and communicate with a memory 124 configured to receive and store measurements. The memory 124 may include random access memory (RAM) and / or computer readable storage media, such as read only memory (ROM) or non-volatile RAM (NVRAM), for storing basic routines for initiating and / or operating the controller 100 and / or other components of the coating system 10 and transmitting information between various components and devices of the coating system 10. The memory 124 may also store other software components necessary for the operation of the controller 100 and / or other components of the coating system 10, including an operating system, software for executing the process 170, software for executing the machine learning unit 200, software for executing the learning module 208, and / or others. The processor 120 may include, be connected to, or otherwise be in communication with a computer readable storage medium for storing and retrieving information, such as program modules, data structures, or other data. As should be appreciated by those skilled in the art, computer-readable storage media may be any available media that allows for non-transitory storage of data and is accessible to the processor 120. By way of example, and not limitation, computer-readable storage media include volatile and non-volatile storage media, transient computer-readable storage media, non-transitory computer-readable storage media, and removable and non-removable media embodied in any manner or with any technology.Examples of computer readable storage media include, but are not limited to, RAM, ROM, erasable programmable ROM ("EPROM"), electrically erasable programmable ROM ("EEPROM"), flash memory or other solid state memory technology, compact disc ROM ("CD-ROM"), digital versatile disc ("DVD"), high definition digital versatile disc ("HD-DVD"), BLU-RAY, or other optical storage devices, magnetic cassettes, magnetic tapes, magnetic disk storage devices, other magnetic storage devices, or any other medium that can be used to non-temporarily store the desired information.

[0111] 2, the memory 124 may include a repository for measurement data 128 and control data 132. The measurement data 128 may include measurements received from one or more of the pressure sensor 108, the flow meter 112, the temperature sensor 116, and / or other components of the coating system 10. In addition, the measurement data 128 may include collection time, other environmental data, and / or the like. The control data 132 may include predefined information that may be pre-programmed into the processor 120 prior to operation of the coating system 10. In operation, the processor 120 may compare the measurement data 128 to the control data 132, which will be described in more detail below.

[0112] Processor 120 may also be configured to send one or more signals to one or more components of coating system 10. In some aspects, processor 120 may be configured to send one or more signals to or via a component located outside of coating system 10, such as a wired connection, a wireless connection, a network connection, a cloud network connection (not shown), and / or the like.

[0113] Referring again to FIG. 1 , a pressure regulator 104 may be included that is configured to regulate the pressure of the material 50 at one or more points flowing between the material source 54 and the applicator 20. The pressure regulator 104 may include one or more valves and / or one or more pumping mechanisms. The pressure regulator 104 may be actuated to selectively increase or decrease the pressure of the material 50. The processor 120 may send one or more signals to the pressure regulator 104 to cause the pressure regulator 104 to vary the pressure of the material 50 and / or to adjust the flow rate of the material 50 differently. The higher the pressure of the material 50, the higher the flow rate of the material 50 may be within the coating system 10, and conversely, the lower the pressure of the material 50, the lower the flow rate of the material 50 may be within the coating system 10. The processor 120 may be configured to control the pressure regulator 104 to maintain a desired pressure of the material 50. If the pressure of the material 50 measured by the pressure sensor 108 is outside of the predetermined pressure range (e.g., above an upper threshold value of the predetermined range or below a lower threshold value of the predetermined range), the processor 120 can send a signal to the pressure regulator 104 to decrease or increase, respectively, the pressure of the material 50 so that the measured pressure falls within the predetermined pressure range. In some aspects, a single pressure value (e.g., either an upper or lower threshold value) may be referenced rather than a range of values. In some aspects, the predetermined range and / or the predetermined value may be configured to vary depending on other parameters of the coating system 10, such as temperature, flow rate, duration of operation, or other operating characteristics.

[0114] In some aspects, if the flow rate of material 50 in coating system 10 as measured by flow meter 112 is outside of a predetermined flow rate range, processor 120 can cause pressure regulator 104 to increase or decrease the pressure accordingly, thereby increasing or decreasing the flow rate, respectively, so that the measured flow rate falls within the predetermined flow rate range. It should be understood that the predetermined flow rate range can alternatively be a single predetermined flow rate value rather than a range of values, and coating system 10 can be configured to respond to measured flow rates above, below, or equal to the predetermined flow rate value. In some aspects, the predetermined range and / or the predetermined value can be configured to vary depending on other parameters of coating system 10, such as temperature, pressure, duration of operation, or other operating characteristics.

[0115] Flow rate regulation can generally be accomplished by any suitable means to suit the particular application. By way of non-limiting example, an exemplary system and method for calibrating flow rate is described in commonly owned U.S. Patent No. 11,185,879, the disclosure of which is incorporated by reference herein in its entirety for all purposes.

[0116] By way of non-limiting example, Figure 14 illustrates a flow diagram of an exemplary process 1400 for calibrating the flow rate of material deposited on one or more substrates through a nozzle of a coating system. Process 1400 may be performed, at least in part, by controller 18. In general, process 1400 may include a flow control routine (steps 1402-1414) that calculates and sets a first operating pressure of the coating system 1410 based on a received target flow rate for the material through the nozzle and a pressure-flow rate relationship (i.e., the relationship between the operating pressure of the coating system and the flow rate of the material through the nozzle). If the difference between the determined operating flow rate and the received target flow rate is outside a predetermined control range (e.g., ± a predetermined percentage of the target flow rate), process 1400 may adjust the operating pressure of the coating system to a second operating pressure before coating one or more additional substrates.

[0117] In step 1402 of process 1400, the coating system may receive a target flow rate for the material through the nozzle. For example, an operator may enter the target flow rate into an HMI device. The target flow rate may be stored in a memory of a controller for use in process 1400. In accordance with aspects of the invention, the target flow rate received by the coating system may be calculated manually or automatically in response to received operating parameters of the coating system. The received operating parameters may include, for example, a target coating thickness of the material, a target coating width of the material, a solids percentage of the material, and a speed of an applicator of the coating system. The operating parameters may be entered into an HMI device, for example, by an operator, and stored in a memory of the controller for automatic calculation of the target flow rate.

[0118] Calculating the target flow rate may involve manually or automatically solving the following target flow rate equation: TIFF2024529255000002.tif20150

[0119] In the target flow rate equation, "T" is the received target coating thickness of the material, "W" is the received target coating width of the material, "P" is the received solids percentage of the material, "S" is the receiving speed of the applicator, and "FR" is the calculated target flow rate. Additionally, when solving the equation, unit conversions may be performed, if necessary, to normalize any unit discrepancies between the input operating parameters, as would be readily understood by one of ordinary skill in the art. When automatically calculating the target flow rate, the controller may reproduce the operating parameters stored in memory and utilize these operating parameters to solve the target flow rate equation for FR, i.e., the calculated target flow rate for the fluid through the nozzle. Thus, the calculated target flow rate may match the target flow rate received at step 1402 that is utilized in process 1404.

[0120] According to aspects of the invention, it can be determined that a target flow rate calculated using operating parameters entered by an operator is outside a predetermined flow capacity range of the coating system. The predetermined flow capacity range of the coating system can be a range of flow rates that can be reliably achieved by the coating system, which can be a function of the capabilities of the coating system and / or the properties of the coating material, as will be readily understood by those skilled in the art. In response to determining that the calculated target flow rate is outside the predetermined flow capacity range, the rate of the applicator operating parameters can be adjusted to thereby bring the calculated target flow rate within the predetermined flow capacity range. By adjusting the rate of the applicator operating parameters while holding constant the remaining operating parameters that affect the coating properties (i.e., the target coating thickness of the material, the target coating width, and the solids percentage of the material) entered into the target flow equation, the calculated target flow rate can be adjusted to fall within the predetermined flow capacity range without changing the coating properties desired by the operator. The adjustment of the rate of the applicator operating parameters can be the result of an iterative process. For example, the rate of applicator operating parameters may be repeatedly adjusted and re-entered until the target flow rate, as calculated from the target flow rate equation, falls within the predetermined flow capacity range.

[0121] Alternatively, the adjustment of the rate of the applicator operating parameter may be the result of a calculation that uses a set target flow rate to solve a target flow rate equation for the rate of the applicator operating parameter while holding all other operating parameters constant. The set target flow rate may be, for example, an outer boundary of a predetermined flow capacity range, or alternatively, any flow rate within the predetermined flow capacity range. As a non-limiting numerical example, the predetermined flow capacity range of the exemplary coating system may be 0.1 mL / min to 10.0 mL / min. If the target flow rate using the operating parameters entered by the operator is calculated to be 12.0 mL / min (i.e., outside the predetermined flow capacity range), the target flow rate may be set to 10.00 mL / min (i.e., the outer upper limit of the predetermined flow capacity range of the exemplary coating system 10). The rate of the applicator operating parameter may be adjusted by solving a target flow rate equation for the rate of the applicator operating parameter while holding all other operating parameters constant while using a set target flow rate. That is, by rewriting the target flow equation, the following adjusted velocity equation can be solved for the applicator velocity: TIFF2024529255000003.tif20150

[0122] In the adjusted speed equation, "T" is the received target coating thickness of the material, "W" is the received target coating width of the material, "P" is the received percentage solids of the material, "FR'" is the set target flow rate, and "S'" is the adjusted speed of the applicator 16. In addition, when solving this equation, unit conversions may be performed, if necessary, to normalize any unit discrepancies between the input operating parameters, as would be readily understood by one of ordinary skill in the art. The adjusted speed of the applicator 16 may be calculated, for example automatically, so that the controller can reproduce the operating parameters and the set target flow rate stored in memory, which can be used to solve the adjusted speed equation for S', i.e., the adjusted speed of the applicator. Thus, the coating system may be operated at the adjusted speed of the applicator and the set target flow rate. The set target flow rate may correspond to the target flow rate received in step 1402.

[0123] In step 1404, a first operating pressure for the coating system can be calculated. The coating system can calculate the first operating pressure based on a target flow rate for the material through the nozzle and a relationship between pressure and flow rate. Additionally, the operating pressure of the coating system can be set to the first operating pressure. For example, under command of the controller, the operation of a pump of the pressurized liquid source can be adjusted to increase or decrease the operating pressure of the material delivered to the applicator to set the coating system to the first operating pressure.

[0124] The pressure-flow relationship may be a function of the nozzle configuration and the properties of the material passing through the nozzle. The pressure-flow relationship may be used, for example, to determine an operating pressure (e.g., a first operating pressure) for the coating system that is predicted to achieve a particular operating flow rate (e.g., a target operating flow rate) of material emitted from the nozzle, thereby achieving a coating characteristic (e.g., a target coating thickness) desired by an operator. In embodiments, the pressure-flow relationship may be entered into an HMI device by an operator and stored in the memory of the controller for use in process 1400.

[0125] Alternatively, the relationship between pressure and flow rate may be calculated. For example, while the coating system is operating at a first calibration pressure, material may be discharged from the nozzle, for example into a container, and a first flow rate of the material discharged from the nozzle may be determined. As the material is being discharged from the nozzle, the discharge amount of the material and the discharge time of the material may be measured, which may be used to determine the first flow rate. For example, as the material flows from the pressurized liquid source and exits the applicator, the flow meter may transmit a count or an electrical pulse for each fixed amount of material passing through the flow meter to the controller. As another example, the discharge amount of the material may be measured according to the weight difference of the remaining material in the pressurized liquid source. According to yet another example, the amount of material collected in the container may be measured. The amount of material may be measured by volume and / or by weight. The controller may measure, for example, the total time for discharging the material. The first flow rate of the material may be determined from a measured amount of material discharged over a measured time for discharging the material, as will be readily understood by those skilled in the art.

[0126] The operating pressure of the coating system can be adjusted to a second calibration pressure that is different (i.e., higher or lower) than the first calibration pressure. The coating system can emit material from the nozzle while the coating system is operating at the second calibration pressure, and a second flow rate of the material emitted from the nozzle can be determined. That is, as the material is being emitted from the nozzle, the amount of material emitted and the length of time the material is emitted can be measured (e.g., according to any of the techniques described above), which can be used to calculate the second flow rate.

[0127] The pressure-flow relationship can be calculated based on the first calibration pressure, the first flow rate, the second calibration pressure, and the second flow rate. In addition to the first and second calibration pressures and the corresponding first and second flow rates, the pressure-flow relationship can be calculated, for example, based on the third, fourth, ... nth calibration pressures and the corresponding third, fourth, ... nth flow rates, which can be calculated in a manner similar to the first and second flow rates described above. The pressure-flow relationship can be calculated based on the calibration pressures and the corresponding flow rates, for example, as a simple regression analysis, as will be readily understood by those skilled in the art. The simple regression analysis model can be used as a predictive function, whereby the pressure / flow rate can be calculated based on the known flow rate / pressure. Thus, the simple regression analysis model can calculate a first operating pressure of the coating system based on the target flow rate received at step 1402, and the operating pressure of the coating system can be set to the first operating pressure.

[0128] In step 1406, the substrate, or a portion thereof, may be coated with a material, i.e., at least a portion of the substrate may be sprayed with material flowing through a nozzle while the coating system is operated at a first operating pressure.

[0129] In step 1408, an operational flow rate of the material may be determined. For example, the operational flow rate of the material flowing through the coating system may be determined in situ during coating of the substrate. That is, as the substrate is being coated with the material, the amount of material may be measured over a measured length of time. For example, as material flows from the pressurized liquid source and exits the applicator, a flow meter may transmit a count or an electrical pulse to the controller for each fixed amount of material passing through the flow meter over a measured period of time. As another example, the amount of material applied to the substrate may be measured according to the weight difference of the material remaining in the pressurized liquid source. The amount of material may be measured volumetrically and / or weightwise.

[0130] Alternatively, after spraying the material on the substrate, while the coating system is operating at the first operating pressure, further material can be discharged from the nozzle, for example, into a container, and an operating flow rate of the material discharged from the nozzle can be determined. For example, as the material flows from the pressurized liquid source, exits the applicator, and flows into the container, the flow meter can transmit a count or an electrical pulse to the controller for each fixed amount of material passing through the flow meter over a measured period of time. As another example, the amount of material applied to the substrate can be measured according to the weight difference of the remaining material in the pressurized liquid source. According to yet another embodiment, the amount of material collected in the container can be measured. The amount of material can be measured in terms of volume and / or weight. The controller can measure, for example, the total time the material is discharged. The operating flow rate of the material can be determined from the measured amount of material over a measured time that the material is sprayed / discharged, as will be readily understood by those skilled in the art.

[0131] In step 1410, the operating flow rate of the material determined in step 1408 can be compared to the received target flow rate to determine whether the determined operating flow rate is outside of a predetermined control range. The predetermined control range can be, for example, within ±5% of the target flow rate. In another embodiment, the predetermined range can be within ±1% of the target flow rate. If the difference between the determined operating flow rate and the target flow rate is outside of the predetermined control range, the process 1400 can proceed to step 1412. However, if the difference between the determined operating flow rate and the target flow rate is within the predetermined range, the process can proceed directly to step 1414.

[0132] In step 1412, the operating pressure of the coating system can be adjusted to a second operating pressure. For example, under command of the controller, operation of a pump of the pressurized liquid source can be adjusted to increase or decrease the operating pressure of the material delivered to the applicator to set the coating system to the second operating pressure. In one embodiment, the operating pressure of the coating system can be increased or decreased in proportion to the determined difference between the determined operating flow rate and the target flow rate from the first operating pressure to the second operating pressure. As a non-limiting numerical example, if the determined operating flow rate is 2% higher than the target flow rate, the second operating pressure can be 2% lower than the first operating pressure.

[0133] In another embodiment, a pressure-flow relationship between the operating pressure of the coating system and the pressure of the material flow rate through the nozzle can be calculated or recalculated to determine a second operating pressure required to achieve the target flow rate. That is, alternatively or in addition to determining that the difference between the determined operating flow rate and the target flow rate is outside of a predetermined control range, it can be determined whether at least one of the material properties (e.g., viscosity) and nozzle geometry (e.g., expansion due to increased temperature) have changed during operation of the coating system. As a result, the pressure-flow relationship between the operating pressure of the coating system 10 and the material flow rate through the nozzle utilized in step 1404 may no longer be representative of the material / coating system, and the pressure-flow relationship may be recalculated or recalibrated according to any of the techniques described above.

[0134] Upon completion of the flow control routine, additional substrates may be coated with the material in step 1414. At least some of the steps of process 1400 may be iterative processes. For example, when additional substrates are coated in step 1414, this may be considered as restarting process 1400 in step 1406, whereby the flow control routine of steps 1406-1414 may continue to iteratively adjust the pressure of the coating system, if applicable, as described above for steps 1410 and 1412, as the coating system is coating additional substrates, etc.

[0135] The processor 120 may be configured to automatically adjust the pressure and / or flow rate, as described above. Alternatively, the processor 120 may be configured to determine that the pressure and / or flow rate are outside their respective predetermined ranges and alert a user of the coating system 10 via a human machine interface. The user may then command or otherwise control the processor 120 via the human machine interface to send a signal to the pressure regulator 104 to increase or decrease the pressure of the material 50 in the coating system 10. The user may send one or more commands to the processor 120 via a human machine interface, such as a user input / output assembly 140 operatively coupled to the coating system 10. The processor 120 may transmit one or more signals (e.g., indicative of that the pressure and / or flow rate are outside their respective predetermined ranges) to the input / output assembly 140. In some aspects, the input / output assembly 140 may include a display (e.g., an LCD screen, a projector, or other output device) configured to visually represent signals from the processor 120. The input / output assembly 140 may include an audio device (e.g., a speaker) to audibly produce signals from the processor 120. The input / output assembly 140 may include one or more user-actuable input devices, such as buttons, levers, sliders, a touch screen, a microphone, a keyboard, a mouse, a touch pad, an electronic stylus, and / or the like, through which a user may input or send commands to the processor 120. The input / output assembly 140 may be physically connected to the coating system 10 or, alternatively, may be wirelessly connected via one or more known wireless transmission protocols, such as Wi-Fi, Bluetooth, NFC, infrared, radio, or other suitable wireless communication methods. The coating system 10 may include multiple input / output assemblies 140.

[0136] During operation, coating system 10 may be configured to detect various clog conditions in applicator 20. Specifically, processor 120 may be configured to detect the occurrence of an occurring clog, the formation of a clog, and / or conditions predisposing to the formation of a clog within applicator 20. For purposes of this disclosure, a clog may be referred to as the accumulation, solidification, and / or hardening of a residual portion of material 50 on applicator 20, e.g., on applicator tip 24.

[0137] The viscosity of the material 50 may be affected by the temperature of the material 50. A change in temperature may cause viscosity and / or other changes, which may cause a change in flow rate. A lower temperature of the material 50 may cause an increase in viscosity. The processor 120 may be configured to determine whether a plugging condition is met using measured temperature values ​​received from the temperature sensor 116, pressure values ​​received from the pressure sensor 108, and / or flow rate values ​​received from the flow meter 112 in the coating system 10. The coating system 10 may include a desired predetermined temperature range within which the material 50 is desired to be maintained. The predetermined temperature range may include a lower threshold temperature value and all temperature values ​​between the upper and lower threshold temperature values. In some aspects, the predetermined temperature may include a single temperature value rather than a range of values. The predetermined range and / or the predetermined value may be configured to change depending on other parameters of the coating system 10, such as pressure, flow rate, operation duration, or operation characteristics.

[0138] The processor 120 may receive continuous or intermittent results from one or more of the pressure sensor 108, the flow meter 112, and the temperature sensor 116. As will be appreciated, the particular frequency of measurements received may depend on the operating parameters of the coating system 10, the type of material 50 utilized, the type of substrate 30 utilized, manufacturing constraints, operator preferences, and / or the like, and the present disclosure is not limited to any particular frequency or pattern for collecting data from each sensor.

[0139] Results received from one or more of the sensors listed above may be stored in the memory 124 of the processor 120, for example in the measured data section 128. The storage of data may be iterative, such that each successive data value is stored sequentially after the preceding data value. The processor 120 may store a number of measured data values ​​from one or more of the above-mentioned sensors in a data set based on the time at which a particular data value was received and / or otherwise obtained. For example, a measured pressure, flow rate, and / or temperature value received at a first time point P1 may be stored in a first data set D1, and a subsequent measured pressure, flow rate, and / or temperature value received at a second time point P2 may be stored in the memory 124 in a second data set D2. In this manner, values ​​in the first data set D1 may be compared with values ​​in the second data set D2. The processor 120 may store a number of pressure values ​​P1, P2, ..., P n , several flow values ​​F1, F2, ... , F n , and / or multiple temperature values ​​T1, T2, ... , T n The processor 120 may be configured to record the received values ​​in a number of data sets D1, D2, ..., D n where values ​​P1, F1 and / or Tn1 correspond to data set D1, values ​​P2, F2 and / or T2 correspond to data set D2, and values ​​P n ,F n ,T n is the dataset D n It supports.

[0140] The processor 120 may be configured to compare received values ​​with other received values ​​and / or with pre-programmed control values. The processor 120 may compare values ​​of one data set, e.g., a second data set D2 including values ​​P2, F2, and T2, with values ​​of another data set, e.g., a first data set D1 including values ​​P1, F1, and T1. In some aspects, the memory 124 may include a control data section 132 configured to receive and store control values. The control values ​​may be programmed by a user prior to operating the coating system 10. Alternatively, the control values ​​may be programmed at a factory prior to operating the coating system 10. The control values ​​may include values ​​for pressure, flow rate, and / or temperature. For example, the control data section 132 may include a control pressure value P C , control flow rate value F C , and / or the control temperature value T C Control data set D containing C The processor 120 stores the data sets D1, D2, ..., D n Any one of the control data sets D in the control data section 132 C Preferably, the method is configured to compare the

[0141] The processor 120 selects D1, D2, ..., D n Let any data set in be data sets D1, D2, ... , D n and / or a control data set D CThe comparison result may be indicative of sufficient material flow, indicative of the formation of a clog, and / or otherwise. In comparing measured and / or controlled values ​​associated with values, e.g., pressure, flow rate, and / or temperature, it may be calculated whether one of the values ​​is within an acceptable deviation from the other value to which the one is compared. For comparison purposes, acceptable ranges of values ​​(and / or individual values) may be preprogrammed into the processor 120 by a user or by a program of the coating system 10. Each range is defined by a lower threshold below the comparison value and an upper threshold above the comparison value. The lower and upper thresholds may be determined based on the operating parameters of the coating system 10, the type of material 50 used, the environment of the coating system 10, manufacturing constraints, and / or other parameters (e.g., pressure, flow rate, and / or temperature values) that define the desired value. The lower and upper thresholds may be defined by an acceptable deviation value that is subtracted from or added to the comparison value, respectively. Although a given value is described as a range of values ​​throughout this application, it should be understood that a given value may alternatively include a single value or multiple values ​​rather than a numerically represented range of values.

[0142] If the measured value is within the acceptable range, the processor 120 may indicate a first signal, e.g., indicating that no problem exists, continue operation, and / or alert the user regarding the comparison result. If the measured value is outside the acceptable range, the processor 120 may indicate a second signal different from the first signal, e.g., indicating an operational anomaly, a change in an operating parameter of the coating system 10, and / or alert the user regarding the comparison result. For example, the control temperature value T C If the control temperature value T is 21°C and the allowable deviation value is 2°C, the lower threshold value is 19°C, the upper threshold value is 23°C, and the allowable range is from 9°C to 23°C. Cis used as a comparison value for a first temperature value T1 of 20° C., the first temperature value T1 of 20° C. may be within the acceptable range and the processor 120 may issue a first signal. If the first temperature value T1 is 18° C., the first temperature value T1 is outside the acceptable range and the processor 120 may issue a second signal. In some aspects, the processor 120 may determine how far the measurement is outside the acceptable range. In aspects that indicate a single predetermined value or multiple predetermined values ​​rather than a range of values, the above steps may include determining whether the measurement exceeds, is less than, or is equal to one or more predetermined values. As will be appreciated, the above examples are for illustrative purposes only and the disclosure is not limited to the specific values ​​set forth above.

[0143] The processor 120 can compare the data sets with their respective temperatures and flow rates to determine whether a clog exists, whether conditions are favorable for the formation of a clog, and / or the like. This comparison process may be performed continuously or repeatedly at predetermined intervals during operation of the coating system 10. Comparisons may be made between values ​​in the measurement data 128 and the control data 132, and / or between subsequent data sets of the measurement data 128. For example, a comparison may be performed between a first data set D1 and a second data set D2 measured after the first data set D1. During such a comparison, if the processor 120 determines that the second measured temperature value T2 of the second data set D2 is within an acceptable range relative to the first measured temperature value T2 of the first data set D1, but the second flow rate value F2 is below a lower threshold of the acceptable range defined for the first flow rate value F1, such a result may indicate the formation of a clog. That is, the processor 120 may be configured to determine whether the temperature of the material 50 remained the same (within an acceptable range) while the flow rate of the material 50 was being reduced. At this stage, the processor 120 may send a first signal associated with the identification of a clog or a condition likely to form a clog. Alternatively, if the processor 120 determines that the second measured temperature value T2 is below a lower threshold value relative to the first measured temperature value T1 and that the second flow rate value F2 is also below a lower threshold value of the tolerance range defined for the first flow rate value F1, such a result may indicate a reduction in the pressure of the material 50 in the coating system 10. This can be supported by a comparison of the first measured pressure value P1 and the second measured pressure value P2. In such a case, the processor 120 may send a second signal different from the first signal and indicating that the pressure has been reduced.

[0144] In some aspects, the second signal can include a signal sent to the pressure regulator 104 to increase the pressure of the material 50. As can be appreciated, in response to the comparison of the temperature and flow rate values ​​of the material 50 within the coating system 10, the processor 120 can send a signal to the pressure regulator 104 to decrease the pressure of the material 50.

[0145] The first signal may include sending an alert to a user via one or more of the input / output assembly 140 and / or another communication device. The first signal may also include a signal to change an operating parameter of the coating system 10, such as moving material 50 through the coating system 10, adjusting pressure via pressure regulator 104, adjusting dispensing from the applicator 20 via the dosing assembly 42, controlling the introduction or movement of the substrate 30 relative to the applicator 20 and / or causing the applicator positioning assembly to move the applicator 20.

[0146] In some aspects, the first signal may include instructions to the applicator positioning assembly 34 to move the applicator 20 from the operating position to the cleaning position. The first signal may further include instructions to the applicator positioning assembly 34 to perform a cleaning operation, as described further below.

[0147] The processor 120 may continue to compare values ​​as described above. If the applicator 20 requires cleaning and is moved to the cleaning position, the processor 120 may perform another comparison process and send another first or second signal. If the applicator 20 is in the cleaning position and the processor 120 is able to send a second signal indicative of no clog, the second signal may further include a signal to the applicator positioning assembly 34 to move the applicator 20 from the cleaning position to the operating position.

[0148] Movement of the applicator 20 between the operating and cleaning positions may be accomplished manually by a user via one or more of the input / output assemblies 140.

[0149] In the cleaning position, the applicator 20 may be disposed within the cleaning device. With reference to FIGS. 3-8, the cleaning device 60 may include a reservoir 64 configured to receive a portion of the applicator 20. The reservoir 64 may be configured to receive and hold the cleaning material 80 as shown in FIG. 3. In some aspects, the cleaning device 60 may be a cup, bowl, or another suitable container or vessel configured to receive the cleaning material 80 and the applicator 20. The cleaning material 80 may include a solvent. As will be appreciated, the solvent may be selected to have a chemical composition suitable for dissolving a portion of the deposit of the material 50 on the applicator 20. In some aspects, the tip 64 of the applicator 20 may be configured to be removably disposed within the reservoir 64 such that at least a portion of the applicator tip 64 may be immersed within the cleaning material 80. When the applicator 20 is placed in the cleaning device 60 and placed in contact with the cleaning material 80 , the cleaning material 80 can remove material 50 that has built up on the applicator 20 , for example, on the applicator tip 24 .

[0150] The cleaning device 60 may include an actuator 72 configured to agitate the cleaning material 80. Agitation of the cleaning material 80 may generate or otherwise cause cavitation bubbles to contact the applicator 20 and the deposited material 50 thereon. Contact of the cavitation bubbles with the applicator 20 and / or the applicator tip 24 may cause the deposited material 50 on the applicator 20 to partially dislodge, remove, and / or break apart. In some aspects, the actuator 72 may include an ultrasonic transducer configured to generate ultrasonic waves. The ultrasonic waves may propagate through the cleaning material 80 to generate the cavitation bubbles as described above. Operation of the actuator 72 may be controlled by an actuator controller 76, which may be operatively coupled to the actuator 72. The actuator controller 76 may include an ultrasonic generator. The actuator controller 76 may be operatively coupled to a processor 120 or another suitable processor connected to or external to the coating system 10. In some aspects, the processor 120 may be configured to send signals to the actuator controller 76 to turn on the actuator 72, turn off the actuator 72, operate the actuator 72 in a predetermined on-off pattern, and / or modify one or more operating parameters of the actuator 72 (e.g., altering intensity, duration, or another suitable parameter of the ultrasonic transducer). In some aspects, electronic feedback (e.g., current feedback and / or phase feedback) may be received from the actuator 72 (e.g., from the ultrasonic transducer). In response to the electronic feedback, operation of the actuator 72 and / or the ultrasonic transducer (e.g., one or more of the operating parameters of the actuator 72) may be adjusted. Such adjustments in operation are generally based on the received electronic feedback and may generally be aimed at operating the actuator 72 (e.g., its ultrasonic transducer) at its resonant frequency.This can be accomplished, for example, using phase tracking between the voltage and current signals and adjusting the drive frequency and power to drive the system at resonance.

[0151] One advantage of such an arrangement is that the resulting cavitation bubbles physically contact the deposited material on the applicator 20 and / or applicator tip 24, thus separating the deposited material from the applicator 20 (specifically from the applicator tip 24). Additionally, the generation of bubbles throughout the cleaning material 80 causes the cleaning material 80 within the cleaning device 60 to move relative to the portion of the applicator 20 inserted therein and / or the applicator tip 24. Such movement allows for better penetration of the cleaning material 80 into and around the deposited material 50 on the applicator 20, as well as into the space between the deposited material 50 and the applicator 20 for better shedding of the deposited material 50. The generated bubbles thus effectively perform a "scrubbing" operation to physically remove the deposited material 50 from the applicator 20. However, the contact of the air bubbles is generally not abrasive and therefore does not damage the applicator 20 (unlike, for example, using a bristled brush to scrub material). Additionally, the movement of the cleaning material 80 caused by the generation of air bubbles by the actuator 72 can better allow the cleaning material 80 to enter small crevices and openings in the applicator 20 itself during the cleaning process, for example, agitation of the cleaning material 80 by the actuator 72 can better drive the cleaning material 80 into the applicator 20. For example, the cleaning material 80 can enter the applicator tip 24 through the opening 26 in the applicator tip 24, and the coating material 50 can be dispensed through the opening 26 during operation of the coating system 10 (see FIG. 8).

[0152] The use of ultrasonic waves propagating through the cleaning material 80 as described herein may, in some aspects, cause evaporation of the cleaning material 80. Thus, due to a production shift, the fluid level of the cleaning material 80 may be reduced below a desired level. A reduction or decrease in the fluid level of the cleaning material 80 may cause a change in the optimal frequency of cleaning with ultrasonic waves and / or the fluid level may be below a level at which the portion of the applicator 20 to be cleaned (e.g., the nozzle) is in contact with the cleaning material 80. In technical efforts to address the above-mentioned evaporation of the cleaning material 80, the fluid level of the cleaning material 80 may be measured. The fluid level of the cleaning material 80 may be measured periodically (e.g., during a production shift) or continuously, and may be measured by any suitable means to tailor it to the desired application. By way of non-limiting example, at the "active" refill system level, a fluid level sensor may be employed, configured to measure the fluid level of the cleaning material 80. By way of further non-limiting example, a "passive" replenishment system may employ a gravity-fed (or gravity-fed) reservoir that is configured to add cleaning material 80. Generally speaking, cleaning material 80 may be added or replenished such that the fluid level is at or above a desired level (i.e., a predetermined value). The desired level or predetermined value may generally correspond to a minimum fluid level that does not adversely alter the optimal frequency for ultrasonic cleaning and / or at which the portion of the applicator 20 to be cleaned (e.g., nozzle) is in contact with cleaning material 80. To determine whether cleaning material 80 should be added or replenished, the fluid level of cleaning material 80 may be monitored or measured as described above. The measured fluid level of cleaning material 80 may then be compared to the desired level or predetermined value. If it is determined that the fluid level of cleaning material 80 is below the desired level or predetermined value, additional cleaning material 80 may be added or replenished to raise the fluid level of cleaning material 80 to or above the desired level or predetermined value.

[0153] In some aspects, when the processor 120 transmits the first signal in response to the comparison process described above, the first signal may include a command to the actuator controller 76 to turn off the actuator 72 when the applicator 20 moves to the cleaning position. The processor 120 may transmit a command to the actuator controller 76 to stop the actuation of the actuator 72. The command to stop the actuator 72 may be part of the second signal described above. The processor 120 may be configured to transmit a command to stop the actuation of the actuator 72 at a predetermined time. For example, in some aspects, the command to stop the actuation of the actuator 72 may be transmitted substantially immediately after the processor 120 determines that one or more measurements are outside of an acceptable range. In other aspects, the command to stop the actuation of the actuator 72 may be transmitted a predetermined duration after the processor 120 determines that one or more measurements are outside of an acceptable range. This allows the clog to clear itself and / or allows the user to initiate another procedure.

[0154] The duration of actuation of the actuator 72 may be predetermined and preprogrammed into the actuator controller 76 and / or the processor 120. If the comparison of values ​​results in the applicator 20 being moved to the cleaning position as described above, the processor 120 may be configured to perform a next comparison of values ​​after a set duration of actuation of the actuator 72, or alternatively, after a set number of actuations of the actuator 72. For example, if the first comparison results in the processor 120 sending a first signal which causes the applicator positioning assembly 34 to move the applicator 20 to the cleaning position, the processor 120 may cause the actuator controller 76 to turn off the actuator 72 for a predetermined duration. After the actuator 72 has been actuated for the predetermined duration (or for a number of predetermined durations), the processor 120 may send a command to the actuator controller 76 to turn off the actuator 72. The processor 120 may then perform a second comparison to determine whether the above-mentioned clog condition is still met or whether the clog condition has been remedied by the cleaning process of the cleaning device 60 and the actuator 72. If the second comparison results in a value within the predetermined range, the processor 120 may send a second signal, which may include returning the applicator 20 to the operating position. If the second comparison results in a value outside the predetermined range, the processor 120 may again send the first signal, which may include sending an instruction to the controller 76 to turn off the actuator 72 again to perform another cleaning process of the applicator 20 and / or the applicator tip 24. The above steps may be repeated until the processor 120 sends a second signal indicating no clogs. In some aspects, the above steps may be repeated a predetermined maximum number of times. If the processor 120 still does not send the second signal after the maximum number of times, the processor 120 may send an instruction to one or more of the input / output assemblies 140 to provide a user with a plan.At this point, the processor 120 may terminate operation of the coating system 10 until a user initiates operation from one or more of the input / output assemblies 140, for example after manually cleaning and / or replacing the applicator 20 and / or applicator tip 24.

[0155] To determine whether the above-mentioned flushing was effective in removing or reducing the clog, the coating system 10 can pass material through the applicator and measure the variables (e.g., temperature, flow rate, pressure, and others). This determination can be made when the applicator 20 is in an operating position, a cleaning position, or another position. In some aspects, the applicator 20 can be in a purge position when the above-mentioned determination is made, the purge position being different from the operating position and the cleaning position. When the applicator 20 is in the purge position, a purge material can be flowed through the applicator so that the coating system 10 can measure the temperature, pressure, flow rate, viscosity, and / or other variables associated with the flow. The purge material can include the material 50, the cleaning material 80, and / or another suitable flowable material. If the coating system 10 has not sufficiently removed or reduced the clog after cleaning, the above-mentioned cleaning steps can be repeated. In view of moving the applicator 20 away from the cleaning position and towards the operating or purging position, the applicator 20 may be returned to the cleaning position.

[0156] In some aspects, the type or format of cleaning material 80 utilized in the cleaning device 60 described above may include a solvent that evaporates quickly. Such evaporation may result in undesirable fumes in or around the coating system 10, which may be harmful to users in the vicinity of the coating system 10. Because the solvent evaporates quickly, the cleaning device 60 may require frequent replenishment with additional solvent. As shown in FIGS. 6-8 , the cleaning device 60 may include a lid 68 configured to be removably attached to the cleaning device 60, the lid 68 configured to enclose at least a portion of the reservoir 60. The lid 68 may be made of any suitable material, such as silicone. As will be appreciated, the materials of the cleaning device 60 and the lid 68 should be compatible with the type of cleaning material 80 and the coating material 50 utilized to limit degradation, rusting, and / or other chemical or structural damage to the cleaning device 60 and / or the lid 68 by the cleaning material 80 and / or the coating material 50.

[0157] A hole 70 may be provided through the lid 68. The hole 70 should be sized sufficiently to allow the applicator 20 and / or applicator tip 24 to pass through the hole 70 when the applicator 20 is moved to the cleaning position. In some particular embodiments, the hole 70 should be sized sufficiently to allow the applicator tip 24 to pass through. The hole 70 should also be sized small enough, i.e., the gap that exists in the hole 70 between the applicator 20 and the lid 68 when the applicator 20 is placed in the hole 70 should be small enough to restrict a significant amount of evaporated solvent in the reservoir 64 from exiting the reservoir 64 through the hole 70. In some aspects, the lid 68 may be made of a resilient material configured to deform, and the hole 70 may be slightly smaller than the applicator 20 (e.g., the applicator tip 24) such that when the applicator 20 is inserted into the hole 70, the applicator 20 deforms the lid 68. In this regard, the lid 68 may be configured to contact most or all of the applicator 20 and / or applicator tip 24 positioned within the hole 70, thus restricting evaporated solvent from exiting the reservoir 64 through the hole 70 when the applicator 20 is inserted within the hole 70.

[0158] An example cleaning process 170 is shown in FIG. 9. The process 170 shown in FIG. 9 and described above may include any one or more of the other features, components, arrangements, and / or the like as described herein. It should be noted that aspects of the process 170 may be performed in a different order consistent with the aspects described herein. In addition, it should be noted that some portions of the process 170 may be performed in a different order consistent with the aspects described herein. Moreover, the process 170 may be modified to be more or less processes consistent with various aspects disclosed herein. In one aspect, the process 170 may be controlled by the processor 120. In one aspect, the process 170 may be embodied by software executed by the processor 120. In an initial step 172, the processor 120 may determine whether cleaning is required. The processor 120 may determine whether a clog exists, whether a clog is forming, and / or whether conditions are ripe for a clog to form, as described in detail above. If the processor 120 determines that cleaning is required, the processor 120 may send a first signal to one or more components of the coating system 10, and if the processor 120 determines that cleaning is not required, the processor 120 may send a second signal.

[0159] If cleaning is not required, the process 170 may proceed to step 182, where operation of the coating system 10 continues per any pre-set parameters as described herein.

[0160] If processor 120 determines that cleaning is required, processor 170 may proceed to step 174, where applicator 20 may be moved from the active position to the cleaning position, which may be accomplished by actuating applicator positioning assembly 34, as described above, to cause movement of applicator 20 as described above.

[0161] When the applicator 20 is in the cleaning position, the applicator 20 may be cleaned at step 176. Cleaning may include any of the cleaning methods and mechanisms described above. Cleaning step 176 includes placing the applicator 20 (e.g., applicator tip 24) in the cleaning device 60 such that the cleaning material 80 contacts at least a portion of the applicator 20 (e.g., applicator tip 24). Cleaning step 176 also includes sending a signal to the actuator controller 76 to activate the actuator 72, which may include an ultrasonic generator that generates ultrasonic waves through the cleaning material 80, thus agitating the cleaning material 80 and creating cavitation bubbles in the cleaning material. Step 176 may continue for a predetermined duration and / or a predetermined repetition, as described above.

[0162] After completing the cleaning process, the process 170 may proceed to step 178, where the processor 120 may perform another test to determine if further cleaning is required. The processor 120 may make this determination primarily in the same or similar manner as in step 172, for example, by comparing different values ​​to each other to determine if a clog exists, if a clog has begun to form, and / or if conditions are ripe for a clog to occur. During step 178, material is flowed through the applicator 20 to allow for the measurement of a flow-related variable, such as flow rate. The material may include the coating material 50, the cleaning material 80, and / or another suitable material. In some aspects, during step 178, the applicator 20 may be moved from a cleaning position to an operating position where material is flowed through the applicator 20 to determine if a clog exists. Alternatively, the applicator 20 may be moved from a cleaning position to a purging position, as described above.

[0163] If the cleaning in step 176 was successful, the processor 20 may determine that no further cleaning is required, and the processor 170 may proceed to step 180, where the applicator 20 is moved from the cleaning position to the operating position. Once the applicator 20 is in the operating position, the coating system 10 may begin or resume a cleaning operation in step 182 per predetermined operating parameters. If, during step 178, the applicator 20 is moved to the operating position to determine whether further cleaning is required, the applicator 20 may remain in the operating position in step 180.

[0164] If processor 120 determines in step 178 that further cleaning is required, the process may repeat step 176 to again clean applicator 20. If applicator 20 is moved away from the cleaning position in step 178 (e.g., to an operating position or a purging position), applicator 20 may again be moved to the cleaning position in step 174. Steps 178 and 176 (and step 174, if necessary) may loop a predetermined number of times until either processor 120 determines in step 178 that further cleaning is no longer required or the number of repeated iterations reaches a predetermined threshold.

[0165] In some aspects, process 170 may include step 184 in which, after a predetermined number of iterations of steps 176 and 178, processor 120 determines that applicator 20 still requires further cleaning and a signal is sent to a user via human machine interface and / or input / output assembly 140. The signal may be a warning signal that may inform the user of an error condition that is indicative of a clog that cannot be cleared from applicator 20 or a fault in processor 120. The warning may be a visual, audible, tactile, and / or other indication that may be perceived by the user. Step 184 may also halt operation of processor 170 and / or operation of coating system 10 until the user resumes operation.

[0166] In some exemplary aspects, the coating system 10 may be configured to learn when a clog may become apparent over time. This learning may be based on a comparison of measured and / or controlled values, as described above, of the coating material 50 being used, the substrate 30 being coated, parameters of the applicator 20, and / or other operating parameters of the coating system 10. Such learning may help the coating system 10 predict when a clog will occur and preemptively clean the applicator 20 before such a clog condition is met. This may help reduce the required cleaning time and / or associated downtime of the coating system 10 while cleaning is occurring. This may also reduce the number of iterations required to adequately clean the applicator 20 and / or applicator tip 24. If such a configuration is not provided and the resulting clogs are difficult to remove, abrasive cleaning procedures must be used, which can cause damage to the applicator 20 and / or applicator tip 24, although pre-cleaning can reduce such damage.

[0167] 10-12, the processor 120 of the coating system 10 may include a machine learning unit 200. The coating system 10 shown in FIGS. 10-12 may include any one or more of the other features described herein. The machine learning unit 200 may include a variable observation module 204, a learning model 208, an action module 212, and / or others. The variable observation module 204 may be configured to receive various measurements and detections of the coating system 10 as described above. The variable observation module 204 may receive measured pressure values ​​P1, P2, ..., P of the coating system 10, which may be stored in the memory 124 of the processor 120. n , measured flow values ​​F1, F2, ... , F n , measured temperature values ​​T1, T2, ... , T n , and / or other measured parameters. The variable observation module 204 may also receive values ​​related to the duration of a coating run of the coating system 10, information related to the coating material 50, such as the type of material 50, information related to the substrates 30, the number of substrates 30 being coated, and / or any other operating parameters. The variable observation module 204 may further receive an indication of when a clog has formed, a clog is forming, or conditions are ripe for a clog to form, as determined by the processor 120.

[0168] Machine learning and / or artificial intelligence may utilize any number of approaches, including one or more of cybernetics / brain simulation, symbolic simulation, cognitive simulation, logical intelligence, anti-logical intelligence, knowledge intelligence, sub-symbolic intelligence, embodied intelligence, computational intelligence, and intelligence / soft computing, machine learning / statistics, and others.

[0169] The learning module 208 may be configured to utilize the variables received by the variable observation module 204 to find associations between the variables and to develop predictive equations to predict when a clog may occur based on some or all of the above variables. The learning module 208 may include a variable association module 220 as shown in FIG. 12, which may be configured to generate associations of two or more of the above variables and / or three or more of the above variables. Various associations may be generated. For example, an association may be generated between the duration of the coating operation, the parameters of the coating material 50, the detection of a clog by the processor 120, and / or others. Another exemplary association may be generated between the duration of the coating operation, the parameters of the coating material 50, the measured flow rate, the measured temperature, the measured pressure, and the detection of a clog. It will be appreciated that the above examples are not limiting of the present invention and any other suitable associations may be generated based on the measured values ​​and / or preprogrammed parameters of the coating system 10.

[0170] The learning module 208 may further include a prediction module 224 configured to utilize one or more associations of variables to predict when a clog may or may not occur, or when various conditions are ripe to cause a clog. For example, utilizing an association between the duration of a coating operation and detection of a clog condition, the prediction module 224 may estimate how long the coating system 10 may operate before a clog may be detected. In general, the prediction module 224 may utilize any of the various variables described above to determine the eventual detection of a clog while the coating system 10 is operating according to these variables and combinations of variables. The prediction module 224 may then predict future instances of a clog condition based on the variable associations generated by the variable association module 220. The prediction module 224 may utilize multiple variable association modules 220, where the variable associations may include associations between different variables, associations between repetitions of the same variable, or both.

[0171] In some aspects, the prediction module 224 can receive instantaneous operating parameters of the operation of the coating system 10. Such instantaneous operating parameters can be compared to various associations generated in the variable association module 220. If an exact match exists in the variable association module 220, the prediction module 224 can predict a future occurrence of a clog condition based on the associations in the variable association module 220. If an exact match does not exist in the variable association module 220, the prediction module 224 can utilize multiple associations that are closest to the received instantaneous operating parameters. The prediction module 224 can then mathematically extrapolate when a future clog condition is likely to occur based on the received operating parameters and the multiple associations from the variable association module 220.

[0172] The machine learning unit 200 may further include an action module 212 that may be configured to communicate with the processor 120. After a prediction of a future clog is obtained by the prediction module 224 of the learning module 208, the action module 212 may communicate instructions to the processor 120 regarding the impending clog condition. The action module 212 may monitor operating parameters of the coating system 10, and when the parameters reach the prediction obtained by the prediction module 224, the action module 212 may initiate a cleaning process, such as the process 170 described above. In some aspects, the action module 212 may initiate the cleaning process if one or more operating parameters received by the variable observation module 204 are within a predetermined variation from the prediction obtained by the prediction module 224. For example, if the prediction module 224 indicates that a clog condition is expected to occur n minutes into the coating operation, the action module 212 may communicate instructions to the processor 120 to initiate the cleaning process at n-5 minutes. This allows the applicator 20 to be pre-cleaned before a clog condition is met. As will be appreciated, while the above-described embodiments utilize run time, the particular predetermined variation may be any sufficient variation and may apply to any of the particular variables (e.g., flow rate, pressure, temperature, run time, and / or others) and / or utilize other operating parameters (e.g., coating material 50, cleaning material 80, substrates 30, number of substrates, run time, coating operation speed, dimensions of applicator 20, pattern of coating material 50 dispensed from applicator 20, type or configuration of applicator tip 24, and / or other operating parameters).

[0173] FIG. 13 illustrates an example process 250 by which the coating system 10 can pre-clean the applicator 20 before a clogging condition exists. The process 250 illustrated in FIG. 13 and described below may include one or more other features, components, configurations, and / or others described herein. It should be noted that aspects of the process 250 can be performed in a different order consistent with aspects described herein. In addition, it should be noted that some parts of the process 250 can be performed in a different order consistent with aspects described herein. Furthermore, the process 250 can be modified to be more or less in accordance with various aspects disclosed herein. In one aspect, the process 250 can be controlled by the processor 120. In one aspect, the process 250 can be embodied by software executed by the processor 120. In step 252, the machine learning unit 200 can receive various operating parameters in the variable observation module 204, such as the operating parameters described above. The operating parameters may include preset parameters of the coating system 10 (e.g., applicator 20 dimensions, coating material 50 parameters, substrate 30 parameters, substrate 30 volume, coating speed, coating pattern, and / or others). The operating parameters may further include measurements of values ​​during operation of the coating system 10 (e.g., coating material 50 pressure, flow rate, and / or temperature, operation duration, time since last cleaning, substrate 30 coating volume, substrate 30 coating volume since last cleaning, and / or others). The operating parameters may further include clog detection, clog formation, and / or conditions ripe for clog formation (collectively, "clog conditions").

[0174] In step 254, the variable association module 220 of the learning module 208 generates associations between the various operating parameters received in step 252. The associations may be between one or more of the predefined parameters and one or more of the measurements and the detected clog condition. As will be appreciated, the clog condition may depend on any one of the predefined parameters and / or measurements or a combination of multiple predefined parameters and / or measurements.

[0175] In step 256, the prediction module 224 may utilize one or more of the associations generated in step 254 to predict a future clog condition. The prediction may be based on predefined and / or measured values ​​received by the variable observation module 204 and / or values ​​stored in the memory 124 (e.g., measured data 128 and / or control data 132). The prediction step 256 may match the received values ​​to the values ​​of the associations generated and / or use the associations to extrapolate a predicted future occurrence of the clog condition. The future prediction may be based on one or more measurable conditions, such as operating time, flow rate, temperature, pressure, material viscosity, and / or others. For example, the prediction module 224 may predict that after n minutes of the clog condition, the measured flow rate of the coating material 50 is F n When the measured temperature of the coating material 50 is T n When the measured pressure of the coating material 50 is P n If , it can be predicted that a clogging condition will occur when n substrates 30 have been coated with coating material 50, and / or otherwise. As will be appreciated, the prediction may be expressed as one or more variables that can be monitored.

[0176] In step 258, action module 212 is configured to receive the prediction obtained in step 256. Action module 212 may communicate with processor 120 to initiate a pre-clean of applicator 20 based on the prediction obtained and the measured operating parameters of coating system 10. For example, the pre-clean may embody process 170, as described above. When one or more operating parameters of coating system 10 reach an indicative predictor variable, action module 212 may communicate to processor 120 that a cleaning process needs to be performed. Processor 120 may initiate such a cleaning process in conjunction with process 170, as described above.

[0177] It will be understood that other processes may be performed in process 250, and that the steps described herein may be performed in a different order relative to one another. One or more steps may be repeated sequentially or elsewhere in process 250.

[0178] In addition to or in lieu of the above aspects of cleaning the applicator based on a comparison of a measured parameter (e.g., flow rate, temperature, pressure) of the substance dispensed by the applicator to a reference value, other parameters or methods may be employed to detect or determine that the applicator should be cleaned. For example, in some aspects, contamination of the applicator (e.g., applicator nozzle) may cause dispensing and / or coating quality problems, such as undesirable coverage or placement accuracy, and measuring material properties (e.g., flow rate, temperature) may not detect such contamination until a clog condition occurs. In some aspects, it may be desirable to detect such contamination prior to the existence of such a clog condition.

[0179] In some aspects, a vision system may be employed. A vision system may be able to more easily and quickly detect the need to clean the applicator even before a clog condition exists. The vision system may be any suitable vision system as desired to suit a particular application. By way of non-limiting example, the vision system may be an on-board vision system (e.g., positioned on-board the applicator) or a downstream vision system (e.g., positioned downstream of the applicator in a coating process). A vision system may be used to perform a visual inspection of the applicator. Based on a visual inspection of the applicator as described herein, dispensing of material from the applicator (e.g., onto one or more substrates) may be stopped, and the applicator may be cleaned as described herein. After cleaning of the applicator, dispensing of material may be resumed.

[0180] Generally, the vision system can include one or more cameras that can be configured to capture one or more images for use in determining whether the applicator should be cleaned. For example, the vision system camera can be configured to capture one or more images of a nozzle dispensing material, a fluid pattern of material being dispensed, and / or a substrate onto which material is dispensed.

[0181] According to one aspect, a nozzle dispensing material from the applicator can be visually inspected. For example, a camera can capture one or more images of the nozzle (e.g., during and / or after dispensing of the material). In some aspects, the camera can capture one or more images of a particular portion of the nozzle (e.g., an opening in the nozzle). The captured images can then be processed to generate a first value based on the residual material on the nozzle. The first value can then be compared to a predetermined value. Based on such comparison, it can be determined whether the first value is outside of a set tolerance for the predetermined value. If the first value is outside of a set tolerance for the predetermined value, the applicator can be moved from a dispensing or operating position to a cleaning position, as described herein. In the cleaning position, at least a portion of the residual material can be removed from the applicator. Following removal of at least a portion of the residual material from the applicator, the applicator can be moved to a dispensing or operating position. In some aspects, an additional image of the nozzle can be captured. The additional captured images can then be processed to generate a second value based on the remaining material on the nozzle. The second value can then be compared to a predetermined value. Based on such comparison, it can be determined whether the second value is outside of a set tolerance for the predetermined value. If the second value is outside of a set tolerance for the predetermined value, the applicator can be further cleaned. Conversely, if the second value is within a set tolerance for the predetermined value, dispensing of material from the applicator can be resumed.

[0182] Visual inspection and / or measurement of contamination on and / or within the applicator (e.g., on and / or within the nozzle of the applicator) can be accomplished by any suitable means to suit a particular application. By way of non-limiting example, representative systems and methods are described in commonly owned U.S. Patent No. 10,906,058, the disclosure of which is incorporated by reference herein in its entirety for all purposes.

[0183] By way of non-limiting example, Figure 15 is a flow diagram illustrating a method 1500 for testing a dosing nozzle. Each of the steps of method 1500 can be performed based on one or more signals generated by a controller.

[0184] In step 1502, an applicator can dispense material onto a substrate (e.g., via a nozzle). A controller can perform step 1502 to estimate the amount of material accumulated on an exterior surface of the dispense nozzle over a predetermined period of time (e.g., about 1-2 dispense times), a predetermined number of cycles, and / or any number of metrics. After the metrics have elapsed, the controller can proceed to step 1504 for testing.

[0185] In step 1504, the controller may operate a camera to capture an image of the dosing nozzle, e.g., a valve, through an opening in the dosing nozzle. The controller may operate a positioning device to align the dosing nozzle with the angled mirror. The image may be captured by the camera in grayscale, which may be processed to determine the amount of material deposited on the dosing nozzle. Alternatively, the image may be captured by the camera in color, which may then be converted to grayscale to facilitate processing.

[0186] In step 1506, the controller may process the images. The controller may capture a predetermined subset of the images depicting the dosing nozzle and process the subset to generate a value based on pixel intensities of the images. In some aspects, the controller may process the captured images by comparing one or more pixels of the captured image to one or more corresponding pixels of an image of a clean dosing nozzle to determine a change in pixel intensity. The pixel intensity change may indicate an amount of material coated on the dosing nozzle since some portions of the dosing nozzle coated with material are darker than corresponding clean portions of the dosing nozzle. The comparison provides an array of pixel intensity changes. The controller may then normalize the array to generate a value as a scalar quantity representing the change in pixel intensity of the captured image and the amount of material deposited on the dosing nozzle.

[0187] An image of a dosing nozzle that is clean (e.g., no material buildup) can be processed by the controller to produce, for example, a high value (e.g., 80-90 on a 0-100 scale) indicating that the nozzle is equivalent to an image of a clean dosing nozzle, and therefore the dosing nozzle can continue to dispense without cleaning. An image of a dosing nozzle after several dosing cycles (e.g., where there is minimal material buildup on the surface of the dosing nozzle, but not enough to reduce dosing efficiency) can be processed by the controller to produce a relatively high value (e.g., 60-70 on a 0-100 scale). On the other hand, an amount of a dosing nozzle that exhibits a significant amount of material buildup on the surface (e.g., where material buildup may block the dosing nozzle opening and reduce dosing quality to an unacceptable level) can be processed based on such processing, and the controller can detect the material buildup at the time the image was processed and produce, for example, a relatively low value (e.g., 9-18 on a 0-100 scale).

[0188] In step 1508, the controller may determine whether this value is within a range relative to a predefined value that indicates that the dispense nozzle is sufficiently clean. For example, the predefined value may be a predefined percentage of clean nozzles (e.g., 50%), and step 1508 may determine whether this value is within the range that indicates that the nozzle is sufficiently clean. If it is determined that this value is not within the range that indicates that the nozzle is sufficiently clean ("NO"), the controller may proceed to step 1510. If it is determined that this value is within the aforementioned range ("YES"), the controller may proceed to step 1512.

[0189] In step 1510, the controller may move the applicator (e.g., the dispense nozzle of the applicator) from a dispense or operating position as described herein to a cleaning position to remove at least some of the residual material from the dispense nozzle, as described further herein. After cleaning the dispense nozzle in step 1512, the controller may return to step 1504, where the camera captures additional images of the dispense nozzle. Additional cleaning may be required to make the dispense nozzle clean enough for dispensing in step 1502.

[0190] In step 1512, the controller may move the applicator (e.g., a dispensing nozzle of the applicator) to a dispensing or active position. The controller may then proceed to step 1602, where the dispensing nozzle dispenses material onto the substrate.

[0191] According to another aspect, a fluid pattern of material being dispensed from the applicator can be visually inspected. For example, a camera can capture one or more images of the fluid pattern as the material is being dispensed. The captured images can then be processed to generate actual fluid pattern information for the fluid pattern. The actual fluid pattern information can then be compared to the fluid pattern information for the fluid pattern. Based on such comparison, it can be determined whether the actual flow rate pattern is outside of a set tolerance for the fluid pattern. If the actual fluid pattern is outside of a set tolerance for the fluid pattern, the applicator can be moved from a dispensing or operating position to a cleaning position as described herein. In the cleaning position, at least some of the remaining material can be removed from the applicator.

[0192] Visual inspection and / or measurement of the fluid pattern of material being dispensed from the applicator can be accomplished by any suitable means to suit a particular application. By way of non-limiting example, representative systems and methods are described in commonly owned U.S. Patent No. 10,758,926, the disclosure of which is incorporated by reference herein in its entirety for all purposes.

[0193] By way of non-limiting example, FIG. 16 is a flow diagram illustrating a process 1600 for inspecting a fluid pattern. The process 1600 may be implemented by a controller. The process 1600 begins at step 1602, where the controller may forward instructions to an applicator and / or dispense nozzle to dispense material or fluid according to one or more system parameters to produce a fluid pattern. The one or more system parameters may include any parameter associated with the operation of a fluid dispense system, such as fluid pressure, velocity, and / or deposition of fluid provided to the dispense nozzle, horizontal and / or vertical position of the dispense nozzle, rotational orientation of the dispense nozzle, and pulse timing and / or pulse duration of fluid dispensed from the dispense nozzle. The one or more system parameters may further include a direction (e.g., horizontal) and / or velocity (e.g., horizontal velocity) of motion of the dispense nozzle relative to the substrate, or an inverse relationship thereof. The dispense nozzle may then dispense fluid according to the one or more system parameters. The stream or spray dispensed by the dispensing nozzle may exhibit an actual fluid pattern that may or may not match the intended fluid pattern. In some aspects, the controller may transmit instructions as a result of operator input.

[0194] In step 1604, an image of the fluid stream or spray indicative of the fluid pattern is received from the camera by the controller. In some aspects, the camera may continuously capture and transmit images of the actual fluid pattern at predetermined time intervals. For example, the controller may receive a video stream of the actual fluid pattern. In other aspects, the controller may transmit instructions to the camera to capture images of the fluid stream or spray at specific times.

[0195] In yet another aspect, the camera may capture one or more images or video streams of the actual fluid pattern from multiple angles. For example, a first camera may capture one or more images or video streams of the actual fluid pattern from a first angle, and a second camera may capture one or more images or video streams of the actual fluid pattern from a second, different angle. The first angle may be perpendicular to the second angle. In another embodiment, the camera 112 may be configured to move between one or more positions relative to the actual fluid pattern (e.g., rotate partially or completely around the actual fluid pattern), thereby capturing one or more images or video streams of the actual fluid pattern from multiple angles. The one or more images or video streams showing the actual fluid pattern from the multiple angles may then be provided to and received by the controller.

[0196] In step 1606, the controller may determine actual fluid pattern information for the actual fluid pattern. The controller may determine the actual fluid pattern information based on the imagery received from the camera. The actual fluid pattern information may include at least one of the dimensions of the actual fluid pattern (e.g., width), the shape of the actual fluid pattern, the horizontal or vertical offset of the actual fluid pattern, the density of the actual fluid pattern, the quality of the actual fluid pattern, the size of the droplets of the actual fluid pattern, the rotational orientation of the actual fluid pattern, or other characteristics of the actual fluid pattern. The offset of the actual fluid pattern may refer to the offset of the position of the actual fluid pattern from the desired alignment. For example, the actual fluid pattern may be centered 2 mm away from the desired location. The controller may determine the actual fluid pattern information based on various image processing algorithms, such as high pass filtering, to determine the edges of the actual fluid pattern.

[0197] In some aspects, the controller may determine a three-dimensional model of the actual fluid pattern based on the images or video stream of the actual fluid pattern received from the camera. The three-dimensional model may be created, for example, by recognizing boundaries and / or features in each of the images of the actual fluid pattern using known techniques and triangulating the recognized boundaries and / or features (and / or using other tomographic methods) to create a representation of the actual fluid pattern within the model. Because the three-dimensional model provides a representation of the actual fluid pattern, the actual fluid pattern information described above may be determined based on the three-dimensional model.

[0198] In step 1608, the controller may compare the actual fluid pattern information to fluid pattern information for an intended fluid pattern corresponding to one or more system parameters. That is, the observed actual fluid pattern information may be compared to fluid pattern information expected using one or more system parameters. The fluid pattern information may be the same type of information as described above for the actual fluid pattern information, except for the information related to the intended fluid pattern. For example, if the actual fluid pattern information represents a width of the actual fluid pattern, the width of the actual fluid pattern may be compared to a desired width of the intended fluid pattern represented by the fluid pattern information. In some aspects, the controller may calculate a significance of the actual fluid pattern information and a difference in the fluid pattern information. In other aspects, the controller may calculate a ratio of the actual fluid pattern information to the fluid pattern information.

[0199] In step 1610, the controller may determine that the actual fluid pattern is outside of a tolerance set for the fluid pattern based on a comparison of the actual fluid pattern information to the fluid pattern information. The tolerance set for the fluid pattern may include at least one of a desired width of the fluid pattern, a desired shape of the fluid pattern, an acceptable offset of the fluid pattern, a desired density of the fluid pattern, a desired quality of the fluid pattern, a desired size of droplets of the fluid pattern, a desired rotational orientation of the fluid pattern, or other design or process limits for the fluid pattern. For example, the controller may determine that the width of the actual fluid pattern at a particular height exceeds the tolerance of the fluid pattern. In another example, the controller may determine that the sphericity of droplets in the actual fluid pattern is below the tolerance of the fluid pattern. The actual fluid pattern information being outside of the tolerance of the fluid pattern may indicate that the applicator (e.g., a dispensing nozzle of the applicator) needs to be cleaned. Based on the actual fluid pattern information and the fluid pattern information, the controller may determine instructions to clean the applicator (e.g., a dispensing nozzle of the applicator) as described herein.

[0200] In step 1612, the controller may transmit a command to the spray system and / or the dosing nozzle that the dosing nozzle needs to be cleaned to improve dosing performance, as described herein.

[0201] In some aspects, the controller can forward an alert to an operator of the fluid dispensing system. The alert can indicate that the actual fluid pattern is outside of a set tolerance for the fluid pattern. The alert can indicate that the applicator (e.g., the applicator's dispensing nozzle) should be cleaned, as described herein.

[0202] According to another aspect, the substrate onto which the material is dispensed can be visually inspected. For example, a camera can capture one or more images of the substrate during and / or after dispensing of the material onto the substrate. The captured images can then be processed to generate a first value (e.g., representative of the location and / or amount of the dispensed material on the substrate) based on the dispensed material on the substrate. The first value can then be compared to a predetermined value. Based on such comparison, it can be determined whether the first value is outside of a set tolerance for the predetermined value. If the first value is outside of a set tolerance for the predetermined value, the applicator can be moved from a dispensing or operating position to a cleaning position as described herein. In the cleaning position, at least a percentage of the residual material can be removed from the applicator. Following removal of at least a percentage of the residual material from the applicator, the applicator can be moved to a dispensing or operating position. In some aspects, an additional image of the nozzle can be captured. The captured images can then be processed to generate a second value based on the dispensed material on the substrate. The second value can then be compared to a predetermined value. Based on the comparison, it can be determined whether the second value is outside of an established tolerance for the predetermined value. If the second value is outside of an established tolerance for the predetermined value, the applicator can be further cleaned. Conversely, if the second value is within an established tolerance for the predetermined value, dispensing of material from the applicator can be resumed.

[0203] Visual inspection of the substrate may be accomplished by any suitable means to suit a particular application, including, but not limited to, by use of an automated optical inspection (AOI) system and / or software available from Nordson Corporation, Westlake, Ohio.

[0204] While the systems and methods have been described in connection with various embodiments in the various figures, those skilled in the art will recognize that changes may be made therein without departing from the broad inventive concepts of the embodiments, and it is therefore intended that the disclosure not be limited to the particular embodiments disclosed, but that it will include modifications within the spirit and scope of the invention as defined by the appended claims.

[0205] Where lists are provided, unless otherwise specified, it is understood that each individual element of the list and every combination of the list is a separate embodiment. For example, a list of embodiments stated as "A, B, or C" should be understood to include the embodiments "A," "B," "C," "A or B," "A or C," "B or C," and "A, B, or C."

[0206] As will be understood, although terms such as first, second, etc. may be used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another element. For example, a first element may be referred to as a second element, and similarly, a second element may be referred to as a first element, without departing from the scope of the present invention. As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed items.

[0207] As will be understood, when an element, e.g., a layer, a region, or a substrate, is described as being located or extending "on" another element, the element may be located or extending directly on the other element, or intervening elements may also be present. In contrast, when an element is described as being located "directly on" or extending "directly on" another element, there are no intervening elements. As will be understood similarly, when an element, e.g., a layer, a region, or a substrate, is described as being located or extending "above" another element, the element may be located or extending directly on the other element, or intervening elements may also be present. In contrast, when an element is described as being located "directly on" or extending "directly on" another element, there are no intervening elements. It is also to be understood that when an element is described as being "connected" or "coupled" to another element, the element may be directly connected or coupled to the other element, or there may be intervening elements. In contrast, when an element is described as being "directly connected" or "directly coupled" to another element, there are no intervening elements present.

[0208] Relative terms, such as "bottom," "top," "upper," "lower," "horizontal," and "vertical," may be used herein to describe the relationship of one element, layer, or region to another element, layer, or region, as shown. It will be understood that these terms and those discussed above are intended to encompass various orientations of the device in addition to the orientation depicted.

[0209] The terminology used in this specification is for the purpose of describing particular aspects only and is not intended to limit the present invention. The singular forms "a", "an" and "the" used in the original specification include the plural forms unless the context clearly dictates otherwise. It is further understood that when the terms "comprises", "comprising", "includes", and / or "including" are used in the original specification, they specify the presence of stated features, stated integers, stated steps, stated operations, stated elements, and / or stated components, but do not exclude the presence or addition of one or more other features, one or more other integers, one or more other steps, one or more other operations, one or more other elements, one or more other components, and / or groups thereof.

[0210] Unless otherwise specified, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by those skilled in the art to which the present invention belongs. It is further understood that the terms used herein should be understood to have meanings consistent with their meanings in the context of the present specification and in the relevant art, and should not be interpreted in an idealized or overly formal sense unless expressly specified above.

Claims

1. A method of applying a material to a substrate in a coating system, the method comprising: quantitatively dispensing the material onto the substrate using an applicator, the applicator being configured to receive the material and discharge the material from the applicator towards the substrate; measuring, with a sensor, parameters of the material being discharged through the applicator; comparing the measured parameters to a predetermined range; based on the comparison, stopping the quantitative dispensing of the material onto the substrate and cleaning the applicator so that the parameters are within the predetermined range; after cleaning the applicator, resuming the quantitative dispensing of the material, a method.

2. The step of measuring the parameters of the material measures at least one of a flow rate of the material, a temperature of the material, and a pressure of the material, the method according to claim 1.

3. The step of measuring the parameters includes a step of measuring a first parameter and a step of measuring a second parameter, the method further comprising comparing the measured first parameter to the measured second parameter, the step of comparing the measured parameters to the predetermined range includes determining whether the measured second parameter is within the predetermined range compared to the first parameter, the method according to claim 1.

4. The applicator is in an operating position while dispensing the material onto the substrate, the method further comprising moving the applicator to a cleaning position if the parameters are not within the predetermined range, the method according to claim 1.

5. The step of cleaning the applicator includes contacting the applicator with a cleaning material for a predetermined period of time, the method according to claim 1.

6. The cleaning material consists of a solvent, the method according to claim 5.

7. The method according to claim 5 further comprising operating an ultrasonic transducer to agitate the cleaning material, thereby generating cavitation bubbles in the cleaning material.

8. The method according to claim 7, further comprising receiving electronic feedback from the ultrasonic transducer and adjusting the operation of the ultrasonic transducer based on the received electronic feedback.

9. The method according to claim 8, wherein the electronic feedback includes at least one of current feedback and phase feedback.

10. The method according to claim 8, wherein the step of adjusting the operation of the ultrasonic transducer based on the received electronic feedback includes operating the ultrasonic transducer at its resonant frequency.

11. Measuring the fluid level of the cleaning material; Comparing the measured fluid level with a predetermined value; The method according to claim 5, further comprising adding cleaning material and raising the fluid level of the cleaning material to be equal to or higher than the predetermined value in response to a determination that the measured fluid level is less than the predetermined value.

12. The predetermined range is a predetermined value range defined between a lower threshold value and an upper threshold value, and the step of comparing the measured parameter with the predetermined range includes determining whether the measured parameter is within the predetermined range. The method according to claim 1.

13. The step of stopping the metered dispensing includes stopping the metered dispensing immediately after instructing the coating system to compare the measured parameter with the predetermined range. The method according to claim 1.

14. The step of stopping the metered dispensing includes stopping the metered dispensing after a predetermined time has elapsed after instructing the coating system to compare the measured parameter with the predetermined range. The method according to claim 1.

15. A method for predicting future occurrences of jams in a coating system including a metered dispenser, the metered dispenser being configured to meteredly dispense a material onto a substrate, the method comprising: Measuring, by at least one sensor, a first parameter of the material in the metered dispenser at a first time point; Identifying, by a controller, the presence of a first jamming condition; Finding, by the controller, a correlation between the first parameter and the first jamming condition; Measuring, by the sensor, the first parameter of the material at a second time point after the first time point. Using the measured first parameter and the identified relevance at the second point in time, predicting, by the controller, a future occurrence of a second clogging condition; a method comprising this step.

16. The method according to claim 15, wherein the step of predicting the future occurrence of the second clogging condition includes using a predetermined control value for the first parameter.

17. The method according to claim 16, wherein the predetermined control value includes a control predetermined value range.

18. The method according to claim 15, further comprising the step of notifying the user of the predicted future occurrence of the second clogging condition.

19. The method according to claim 15, further comprising the step of activating a cleaning process before the predicted future occurrence of the second clogging condition occurs, the cleaning process including removing the deposited material from the metering applicator.

20. The first parameter includes at least one of an operating parameter of the coating system and a coating material parameter, the operating parameter of the coating system includes at least one of the size of the metering applicator, the identification of the material, and the identification of the substrate, and the coating material parameter includes at least one of the pressure of the coating material, the flow rate of the coating material, the temperature of the coating material, the duration of the coating operation, the elapsed time since the previous applicator cleaning, the amount of the substrate being coated, and the amount of coating of the substrate since the previous applicator cleaning; the method according to claim 15.

21. The method according to claim 20, further comprising the step of finding the relevance between the elapsed time since the previous applicator cleaning and the first clogging condition.

22. The method according to claim 21, further comprising the step of finding a plurality of relevances, and the future occurrence of the second clogging condition includes identifying a part of the plurality of generated linkages and using the part of the plurality of generated linkages to extrapolate the predictive relevance between the first parameter and the future second clogging condition.

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