Systems and methods for enhanced coating dispensing control

Abstract

To provide systems and methods for enhanced coating dispensing control.SOLUTION: A dispensing system is configured to apply material to a sequence of substrates. The dispensing system applies a first amount of material to a first substrate according to a first value of an operating parameter. A sensor is used to measure a characteristic of the first amount of material applied onto the first substrate. Based on the characteristic of the first amount of material applied onto the first substrate, a characteristic of an amount of material after being applied onto a subsequent substrate in the sequence of substrates may be estimated to be outside of a range. The value of the operating parameter is adjusted in response thereto, and a second amount of material is applied to a second substrate.SELECTED DRAWING: Figure 5

Description

[Technical Field]

[0001] [CROSS-REFERENCE TO RELATED APPLICATIONS] This application claims priority to U.S. Provisional Patent Application No. 62 / 584,622, filed November 10, 2017, the disclosure of which is incorporated herein by reference.

[0002] FIELD OF THE DISCLOSURE The present disclosure relates generally to the application of liquids, and more particularly to systems and methods for enhanced coating dispensing control. [Background technology]

[0003] Precision, accuracy, and consistency are important aspects in nearly every industrial process. This is especially true in many dispensing applications, such as systems that apply conformal coatings or other fluids to substrates. Conformal coating typically refers to the process of applying a fluid to selected areas of a substrate, such as a printed circuit board (PCB). Various complex components of inconsistent shapes and arrangements are typically affixed to the surface of a PCB or other such substrate. The conformal coating process must navigate irregularities in the substrate and apply fluid to specific thicknesses in specific locations. Due to the complex and delicate nature of PCBs or other target substrates, it is clear that the coating process must be performed within strict tolerances over many iterations. Other types of dispensing systems, such as jetting systems, that apply fluids to various types of substrates are similarly demanding.

[0004] However, many current systems have difficulty maintaining such high levels of precision and accuracy. This disclosure addresses these and other shortcomings. Summary of the Invention

[0005] Disclosed herein are systems and methods for enhanced coating dispensing control. In one exemplary method, a dispensing system is operated by a controller and includes a dispensing device configured to apply material to a series of substrates. Initially, the dispensing system applies a first amount of material to a first substrate in the series according to a first value of an operating parameter of the dispensing system. A sensor is used to measure a characteristic of the first amount of material applied to the first substrate. Based on the characteristic of the first amount of material applied to the first substrate, it is determined whether a characteristic of the amount of material applied to a subsequent substrate in the series is expected to be out of range. The value of the operating parameter is adjusted in response, and a second amount of material is applied to a second substrate in the series. The characteristic of the first amount of material applied to the first substrate differs from the characteristic of the second amount of material applied to the second substrate.

[0006] An exemplary dispensing system includes a dispensing device and a sensor positioned to measure a characteristic of a quantity of material applied by the dispensing device to a substrate in a series of substrates. The system further includes a controller configured to generate one or more signals to perform the following steps: the dispensing device is operated to apply a first quantity of material to a first substrate in the series of substrates according to a first value of an operating parameter of the dispensing system; information regarding the characteristic of the first quantity of material applied to the first substrate is generated using the sensor; an estimate is determined based on the information regarding the characteristic of the first quantity of material, the estimate being a characteristic of the quantity of material after being applied to a subsequent substrate in the series of substrates; the estimate of the characteristic of the quantity of material after being applied to the subsequent substrate is compared to a range to determine that the estimate of the characteristic falls outside the range; the value of the operating parameter is adjusted to a second value in response to determining that the estimate of the characteristic of the quantity of material after being applied to the subsequent substrate falls outside the range; and a second quantity of material is applied from the dispensing device to a second substrate in the series of substrates according to the second value of the operating parameter. The properties of the first amount of material applied onto the first substrate are different from the properties of the second amount of material applied onto the second substrate.

[0007] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments and, together with the description, serve to explain the principles of the methods and systems provided. [Brief explanation of the drawings]

[0008] [Figure 1] FIG. 1 shows a side view of a coating system according to one embodiment of the present disclosure.

[0009] [Figure 2A] 1 illustrates a coating assembly according to one embodiment of the present disclosure. [Figure 2B] FIG. 1 shows a schematic diagram of an alternative coating system according to an embodiment of the present disclosure.

[0010] [Figure 3A] 1 illustrates a portion of an inspection station according to one embodiment of the present disclosure. [Figure 3B] 1 illustrates a portion of an inspection station according to one embodiment of the present disclosure. [Figure 4] FIG. 1 illustrates a data flow diagram according to one embodiment of the present disclosure. [Figure 5] 1 shows a method flowchart according to one embodiment of the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0011] Aspects of the present disclosure will now be described in detail with reference to the drawings, wherein like reference numerals refer to like elements throughout unless otherwise specified.

[0012] The disclosed systems and methods relate to enhanced control in a coating dispensing process implemented in a system having a dispenser that applies fluid to a substrate, an inspection station that measures one or more values ​​of various properties of the applied fluid, and / or a curing oven that cures the coated substrate.

[0013] The dispenser and / or other components of the system operate according to one or more operating parameters that affect various properties of the applied fluid. One exemplary operating parameter can be the fluid pressure of the fluid as it is delivered to the dispenser. As previously described, substrates coated according to these operating parameters can be inspected, such as via a camera, to determine one or more values ​​of the coating property. Based on that value and / or stored values ​​of similar past values, a prediction of future values ​​of that coating property for subsequent substrates can be made. If the predicted value is unacceptable or represents a trend toward an unacceptable value, the operating parameter value can be adjusted for subsequent substrates. For example, the fluid pressure of the fluid can be reduced or increased, as appropriate. Preferably, the system proactively avoids errors or failures caused by various coating property values ​​of the fluid exceeding a set tolerance range.

[0014] The disclosed systems and methods can also be used in verifying the capabilities of a dispensing portion of a system (e.g., a dispenser), including any processes performed by the dispensing portion of the system. For example, the disclosed systems and methods can be used to verify the capabilities of a C pk These can be used in determining a process capability index or process capability ratio, such as:

[0015] The teachings disclosed herein may be applied to a wide variety of material dispensing system types, including those having variations in dispensing operation mode, mechanical configuration, valve type, substrate, and / or material. Accordingly, teachings made with reference to coating, dispensing, applying, spraying, needle (or similar form descriptor), or any other characterization of a device type, valve type, and / or operation, can be equally applied to all other types of devices, valves, and / or operations. This is to be understood, unless otherwise indicated. Similarly, any teachings made with reference to a type or characteristic of a material (e.g., coating, fluid, liquid, viscous material, and / or combinations thereof) can be equally applied to all other materials, unless otherwise clearly indicated, either explicitly or by context. The same is true for any teachings made with reference to a particular type of substrate, such as a printed circuit board (PCB). Thus, teachings made with reference to PCBs apply equally to other types of substrates. Similarly, teachings made solely with reference to substrates can also be applied to substrates of any form, including PCBs. Again, a clear statement or unambiguous context may indicate that the teachings apply only to a particular type of substrate.

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

[0017] 2A , the coating assembly 104 includes a coating dispenser 108 for selectively applying fluid to the substrate 114. It should be noted that the specific coating assembly 104 and dispenser 108 described and illustrated herein are merely exemplary, and the disclosure is not so limited. Rather, the dispenser 108 can be implemented in one of a variety of forms, some of which may operate according to different dispensing mechanisms or principles of operation. For example, the dispenser 108 can be implemented in a form configured to apply fluid as droplets or beads, monofilaments (e.g., straight or looped lines), swirls or spray patterns / areas, or any combination thereof. As another example, the dispenser 108 can be configured with one or more air jets (not shown) to atomize or otherwise impinge on the fluid as it exits the nozzle of the dispenser 108. Conversely, the dispenser 108 can be configured without air jets altogether and dispense fluid without atomization or other effects caused by airflow. FIG. 2B shows an exemplary alternative coating system.

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

[0019] The coating assembly 104 may be configured with one or more flow meters 146, each configured to measure the flow rate, velocity, and / or fluid pressure of the fluid flowing through an associated structure. For example, the flow meters 146 may be integrated with or positioned in association with the fluid source 106, the passageway (unnumbered) from the fluid source 106 to the dispenser 108, and / or the nozzle 134 of the dispenser 108. Data measured by the flow meters 146 may be communicated to the controller 132, which may use this data to determine whether tolerance ranges are likely to be exceeded and to determine which operating parameters should be adjusted and by how much.

[0020] The coating assembly 104 may be configured to provide the dispenser 108 with three degrees of freedom of movement, such as X, Y, and Z coordinates, where the frame of reference is the planar surface of the substrate 114 or the surface on which the substrate 114 rests. In some cases, the dispenser 108 may be configured to tilt the nozzle 134 relative to its longitudinal axis (i.e., the axis of the nozzle 134 that is parallel to the Z axis when the nozzle 134 is at rest). The surface supporting the substrate 114 may be configured to move relative to the dispenser 108 in addition to, or instead of, the dispenser 108 moving relative to the substrate 114.

[0021] FIG. 2B illustrates a coating system 10 that may be used with system 100 in addition to (fully or partially) or in place of (fully or partially) the coating assembly 104 shown in FIG. 2A. Coating system 10 may be used to apply a liquid coating material, such as a conformal coating material, to a range of substrates, such as exemplary substrate 12. While the operation of exemplary coating system 10 is described herein, those skilled in the art will appreciate that a wide variety of other coating systems may be used to complete the methods described below. Coating system 10 may be, for example, a model SC-105, SC-205, or SC-400 conformal coating applicator commercially available from Asymtek (Carlsbad, Calif.).

[0022] In an exemplary embodiment, coating system 10 includes a multi-axis electromechanical positioner or robot 14 and a conformal coating applicator 16 coupled to robot 14. For example, applicator 16 may be suspended from robot 14 above substrate 12. In one embodiment, robot 14 is adapted to move applicator 16 in directions defined within an XYZ Cartesian coordinate frame to provide three degrees of freedom. Robot 14 includes drives coupled to independently controllable motors (not shown) in a known manner. Applicator 16 is manipulated by robot 14 relative to substrate 12 to apply a quantity of liquid coating material to selected areas of substrate 12.

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

[0024] Substrates 12, such as printed circuit boards with attached semiconductor dies and other components, are supported in operative relationship with applicator 16 in a known manner, and liquid coating material is applied from applicator 16 onto selected areas of each substrate 12. Depending on the dispensing application, a series of substrates 12 may be coated in a batch mode. Alternatively, substrates 12 may be continuously transported past applicator 16 on an automated conveyor 20. Conveyor 20 may have a conventional design and may further have a width that can be adjusted to accommodate substrates 12 of different sizes. Conveyor 20 may also include a pneumatic lift and lock mechanism (not shown) and receives command signals from a conveyor controller 22.

[0025] Applicator 16 is electrically coupled to applicator controller 24, which provides command signals that control operation of applicator 16. Motion controller 26 is electrically coupled to robot 14 by communication link 21. Solenoid 34 is electrically coupled to motion controller 26 by communication link 23. Conveyor controller 22 and motion controller 26 are also electrically coupled to controller 18 via respective communication links 25 and 27. Motion controller 26 is electrically coupled to conveyor controller 22 via communication link 29. Thus, a programmable control system for coating system 10 includes controller 18, applicator controller 24, motion controller 26, and optional conveyor controller 22 as interconnected components that communicate with each other.

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

[0027] Applicator 16 includes a body 30 suspended from robot 14, a nozzle 31 attached to one end of body 30, and a flow control mechanism (not shown) disposed inside body 30. The flow control mechanism within body 30 may include an air-actuated needle, an air piston, and a valve seat that cooperate to form a dispensing valve (not shown) operable to control the flow of conformal coating material dispensed from applicator 16. A pressurized fluid supply 32 and a solenoid 34 cooperate to provide pressurized fluid in a known manner to regulate the operation of the dispensing valve within body 30. Specifically, solenoid 34 controls the air pressure in a conduit 33 connecting pressurized fluid supply 32 with applicator 16 to move an air piston, thereby moving a needle relative to the valve seat to provide an open position of the dispensing valve through which liquid coating material is dispensed from applicator 16 onto substrate 12. The solenoid 34 can vent air pressure acting on the air piston, allowing the needle to return to a closed position in which it contacts the valve seat and interrupts dispensing.

[0028] The coating system 10 may include a fan width sensor 62, which may be disposed on, for example, the robot 14 or the applicator 16. In some embodiments, the fan width sensor 62 may also be a separate module independent of the robot 14 and the applicator 16. The fan width sensor 62 may be configured to determine various characteristics (e.g., width or shape) of the fan of material dispensed from the applicator 16. As used herein, a fan of material refers to the shape and dimensions of the stream 42 of material from the applicator 16. For example, the applicator 16 may dispense material in a conical spray with a known distance between the applicator 16 and the substrate 12, such that the conical spray produces a circular coating area on the substrate 12 having a specific diameter. As the applicator 16 moves along the substrate 12, the conical spray of material produces a strip of coating on the substrate 12 having a width corresponding to the specific diameter of the conical spray. The fan width sensor 62 may be communicatively coupled to the motion controller 26 and / or the controller 18. For example, data points indicative of the fan of material and determined by the fan width sensor 62 may be communicated to the controller 18 and stored in the memory 44 therein.

[0029] In one aspect, the fan width sensor 62 may include a camera and a light or laser source, and the stream of material 42 may be positioned between the camera and the light or laser source to determine various characteristics of the stream of material 42 (e.g., width or shape). The camera may be configured to capture an image of the fluid pattern of the stream 42 as it is dispensed from the applicator 16. The image captured by the camera may be a still image or an image comprising a video stream. The camera may transmit the image of the fluid pattern to the controller 18, which may use the image to perform other processing steps, such as a fan width control routine. The light or laser source may be configured to emit a light or laser through the fluid pattern of the stream 42. For example, the light or laser source may be located on the other side of the applicator 16, directly in front of and on the same horizontal plane as the camera. The light or laser source may provide illumination of the fluid pattern of the stream 42 to improve the image quality of the image captured by the camera. A fan width sensor 62 configured in this manner may allow the fan width or other characteristics of the stream 42 to be determined, and possibly adjusted in real time, while the substrate is being coated.

[0030] Coating system 10 includes a pressurized liquid supply 38 that operates in a known manner under command of controller 18 to generate a continuous flow or supply of pressurized liquid coating material. For example, pressurized liquid supply 38 may include a diaphragm or piston pump that draws a quantity of liquid coating material from a reservoir and then pumps the stream of liquid coating material from the reservoir through a fluid path to applicator 16. Pressurized liquid supply 38 is electrically connected to controller 18 by communication link 39, which enables controller 18 to regulate operating parameters, such as the temperature and pressure of the liquid coating material, by communicating appropriate control signals to pressurized liquid supply 38 via communication link 39.

[0031] Pressurized liquid supply 38 is optionally configured with one or more conventional heating elements 38a electrically coupled to a conventional temperature controller 60, which is electrically coupled to controller 18. The construction and operation of conventional heating elements, such as heating element 38a, and temperature controllers, such as temperature controller 60, will be understood by those skilled in the art. In alternative embodiments, applicator 16 may include a heating element (not shown), or a heating element (not shown) may be disposed within one of conduits 51, 53, 55. Regardless of the particular location of the heating element within the flow path between pressurized liquid supply 38 and nozzle 31, the liquid coating material may be heated within that flow path before being applied to substrate 12.

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

[0033] The coating system 10 is operated as instructed by a library of operating cycles or sequences stored in memory 44 associated with the controller 18 and / or stored in another computer. Operating sequences are recalled, organized into specific operating programs, and executed on the controller 18 as needed. Operating sequences can be adjusted to accommodate different environmental conditions, different types of substrates 12, or different types of conformal coating materials. During operation, the controller 18 can transfer an entire operating program as electrical signals to the motion controller 26 via the communication link 25 for execution by the motion controller 26. Alternatively, the controller 18 can transfer one or more instructions as electrical signals to the motion controller 26 in batches of instructions and data via the communication link 25 for subsequent execution. An operator can input parameters into the HMI device 19, such as the type of substrate 12, the identifier of the substrate 12, the brand of the substrate 12, the type of liquid coating material, the liquid pressure, the auxiliary air pressure, the speed of the applicator 16, and the distance between the substrate 12 and the applicator 16. The entered parameters are stored in memory 44 of controller 18 for future use in operational sequences. Each substrate 12 is matched by controller 18 with a coating program that determines which specific components and areas of substrate 12 should be coated with the liquid coating material. Typically, the liquid coating material is applied only to selected areas and / or components on substrate 12.

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

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

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

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

[0038] During use, controller 18 retrieves a coating program for substrate 12 when substrate 12 is properly positioned relative to applicator 16. The coating program determines which components and / or areas of substrate 12 should be coated with the liquid coating material. The liquid coating material is typically applied in strips. For example, in some cases, 25 separate components or areas of substrate 12 may be coated with a strip of liquid coating material. Controller 18 retrieves a motion sequence from its memory 44 and then communicates control signals representing the motion sequence to motion controller 26 via communications link 25. Motion controller 26 sends command signals via communications link 21 to robot 14 instructing robot 14 to move applicator 16 to a desired location relative to substrate 12 at a specified speed. The motion controller 26 controls the movement of the robot 14 to move the applicator 16 in a plane (e.g., in the X and Y directions) across the substrate 12, opening and closing dispensing valves in the applicator 16 as needed during the movement to apply the liquid coating material to desired components and areas of the substrate 12.

[0039] Specifically, at any particular location on substrate 12, motion controller 26 also provides a command signal to solenoid 34 to change state, opening the dispense valve and dispensing liquid coating material from nozzle 31. Simultaneously, motion controller 26 provides a command signal to robot 14 to initiate motion of applicator 16 relative to substrate 12. Stream 42 of liquid coating material may optionally be manipulated by an auxiliary fluid, such as air, to influence the shape of stream 42 dispensing from applicator 16. After a predetermined time has elapsed, motion controller 26 then changes the state of the valve command signal, returning solenoid 34 to its original state. This action closes the dispense valve and discontinues dispensing of liquid coating material from nozzle 31 of applicator 16. Motion controller 26 causes the dispense valve of applicator 16 to open and close multiple times (e.g., 25 times) during a range of coating programs, allowing multiple components and regions of substrate 12 to each receive a certain amount of liquid coating material.

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

[0041] The reader is reminded that, for example, any teaching made with respect to a particular device type, mode of operation, or material may be equally applicable to all other types of devices, modes of operation, and materials unless otherwise indicated by clear statement and / or context. Thus, any teaching made to describe each of the systems of Figures 2A and 2B is equally applicable to each other. Similarly, any other teaching elsewhere herein that refers to one of the systems of Figures 2A and 2B may also be applicable to the other.

[0042] 1 and 2A , after the operation of dispensing fluid onto substrate 114 is completed, coated substrate 114 is transported (e.g., via conveyor 122) to inspection station 130. Using one or more sensors, inspection station 130 can measure and / or determine values ​​of properties of the fluid applied to substrate 114 (which may be referred to herein as “coating properties”). For example, inspection station 130 may measure the placement of the fluid relative to substrate 114 and / or relative to other portions of the fluid on substrate 114. In a related example, inspection station 130 may measure the shape and other related properties of the coated material formation. For example, inspection station 130 may measure the dimensions and proportions of the fluid formation disposed between two rows of elements.

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

[0044] In one embodiment, the inspection station 130 may measure the value of a coating property of a fluid applied to a predetermined location on the substrate 114. For example, a location on the substrate 114 may be designated as a “sample area.” The sample area may be located on an area of ​​the substrate 114 that is a void of any functional components and is preferably flat. This may help separate the target coating property of the fluid from other variables that may otherwise be introduced elsewhere on the substrate 114. For example, the vertical surfaces of a component may make it difficult to accurately measure some coating properties, such as fluid thickness, for a fluid applied to an area of ​​the vertical component. Additionally, misplacement or misalignment of a component may cause the associated fluidic component to appear misplaced relative to that component when, in fact, the component placement relative to the substrate 114 as a whole is correct. It is simply misplacement or misplacement of a component that may cause a false positive regarding the placement of the fluidic component. The sample area on the substrate 114 may be visually marked on the substrate 114 to visually identify the target area for application of the sample fluid.

[0045] This application of sample fluid onto a designated sample area and subsequent measurement may not be performed for each coated substrate 114. Instead, it may be performed at predetermined intervals, such as every number of coated substrates 114 (e.g., every 50 substrates), every number of tests (e.g., every 10 tests of a substrate 114), or every elapsed time (e.g., every hour). The application of fluid to the sample area and its measurement may also be responsive to operator input. Note that the sample area may accommodate the application of multiple fluidic constructs, such as multiple dots or beads of fluid.

[0046] The value of the property of the fluid on the substrate 114 may be communicated to and stored in the controller 132 for processing. Additionally, subsequent substrates 114 in the series of substrates 114 are coated by the coating assembly 104 and transported to the inspection station 130. The inspection station 130 may similarly measure the value of the coating property of each successive substrate 114 and communicate the data to the controller 132.

[0047] Additionally, the controller 132 may be comprised of a processor, memory (volatile and / or non-volatile), and various communication interfaces. The memory may store, for example, instructions that, when executed by the processor, cause the processor to perform various operations indicated in the instructions. Examples of such operations are provided herein. The controller 132 may communicate with various components of the system 100, including the coating assembly 104, the dispenser 108, the conveyor 122, the inspection station 130, the curing oven 102, and any subcomponents thereof. The controller 132 may manage the cooperative operation of the various components of the system 100. The operating parameters according to which the various components operate may be set and / or adjusted by the controller 132. Thus, the controller 132 may maintain operating parameter values ​​for many of the components of the system 100. This may facilitate the performance of those portions of the disclosed techniques in which the controller 132 adjusts the value of an operating parameter of a component in response to determining or estimating that an acceptable value for a coating characteristic has been exceeded or is likely to be exceeded.

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

[0049] As previously mentioned, the controller 132 may communicate with the inspection station 130 and may receive and store data transmitted from the inspection station 130, including data indicative of values ​​of coating properties. The controller 132 may repeatedly receive and store data from the inspection station 130, which reflects the respective values ​​of the coating properties for each of the successive sets of coated substrates 114 that have each been inspected. This body of data may represent a "time" sequence of values ​​of the coating properties for the set of successive substrates 114 inspected. Note, however, that the set of successive substrates 114 inspected need not represent all substrates 114 coated within a corresponding period of time. Rather, some substrates 114 may be coated but not inspected during the intervening time between the inspection of two other coated substrates 114. The "time" aspect of the time series may refer to inspected coated substrates 114 (or coated substrates 114 whether inspected or not) in a series of successive inspected coated substrates 114. The "time" aspect of a time series can also be considered in its typical sense, i.e., elapsed chronological time.

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

[0051] Various predictive and statistical modeling, trend estimation, and / or time series forecasting techniques may be applied to the coating characteristic value data received from the inspection station 130. For example, linear regression techniques may be applied to a linear representation of a time series of coating characteristic values ​​taken on a series of inspected coated substrates 114. In other words, the coating characteristic values ​​may form the Y-axis of a line graph, and a series of successive coated substrates 114 may form the X-axis of the line graph. For example, the data points on the X-axis may be the first coated substrate 114, the second coated substrate 114, the third coated substrate 114, etc. For each coating characteristic value, pairs of coated substrates may be represented as data points on the line graph. A trend line for these data points may be determined, such as by a linear regression process. Out-of-tolerance values ​​for the coating characteristic may be cross-referenced with the trend line to determine the corresponding number of coated substrates 114 (or other metric) that are or may be exceeding the tolerance. It should be noted that, in this specification, the "time" that a tolerance is exceeded or likely to be exceeded can refer to time over time or another metric, unless otherwise stated or indicated by context. Examples of metrics other than time over time can include the number of substrates coated or the number of coated substrates inspected. Of course, if the rate (in terms of time) of coating and / or inspection is known, one can be extrapolated (estimated) from the other.

[0052] If the controller 132 determines or estimates that an acceptable value for a coating characteristic has been exceeded or is likely to be exceeded, the controller 132 may adjust one or more operating parameters of a component of the system 100. For example, the operating parameters of the dispenser 108 may be adjusted. Examples of operating parameters of the dispenser 108 that may be adjusted by the controller 132 include: 1) the fluid pressure at which the fluid is provided to the nozzle 134; 2) the air pressure at which one or more air jets apply air to the fluid as it exits the nozzle 134; 3) the timing between coating applications; 4) the position of the dispenser 108 and / or the nozzle 134 (e.g., the vertical distance between the nozzle 134 and the substrate 114); 5) the timing of actuation of the actuator 144 and / or the drive pin 138; 6) the flow rate (i.e., volume per unit time) of the fluid supplied to the nozzle 134; and / or 7) the speed and / or velocity at which the valve 136 is opened and closed. As an operating parameter of the coating assembly 104, the fluid (or its attributes) supplied by the fluid source 106 may be varied, for example, with respect to the viscosity of the fluid. Other operating parameters that may be adjusted include the speed at which the conveyor 122 transports the substrates 114, or the overall speed at which the coating process of the coating assembly 104 is performed and / or the coating and inspection processes are performed together. Further examples of operating parameters that may be adjusted include the intensity of heat applied to the curing oven 102, or the length of time the coated substrates 114 remain in the curing oven 102.

[0053] The adjustment of the operating parameters preferably results in new values ​​that slow or stop the trend of the coating characteristic value toward the tolerance limit. It is also preferred that the new values ​​to which the operating parameters are adjusted reverse the trend toward the tolerance limit and begin to move the coating characteristic value toward the target value. More preferably, the new operating parameter values ​​result in the coating characteristic value being within the tolerance range at the next inspection.

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

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

[0056] The system 100 may include one or more vents. A first vent 116 may be connected to the curing oven 102 to allow the movement of gases, such as evaporated solvent, from the interior of the curing oven 102 to an environment external to the curing oven 102. A second vent 117 may be connected to the coating assembly 104. The second vent 117 may allow the flow of gases from within the coating assembly 104 to an environment external to the coating assembly 104. One or more of the first and second vents 116, 117 may be configured with a regulator 118 (schematically illustrated in connection with the first vent 116), which may be adjusted to vary the rate at which evaporated solvent or other gases may flow from within the volume 110 of the curing oven 102 and / or from within the coating assembly 104 to the environment external to the curing oven 102 and / or coating assembly 104, respectively. The regulator 118 may include a baffle, gate, valve, or other suitable device that can be adjusted to allow or block the passage of evaporated solvent or other gases. One or more of the first and second vents 116, 117 may be configured with a fan 120, the operation of which may, in some cases, create a negative pressure within the volume 110 of the curing oven 102 and / or within the interior of the coating assembly 104. Other types of curing systems, such as a UV curing system, a batch oven curing system, or an air temperature curing system, may additionally or alternatively be implemented in the system 100.

[0057] In an alternative embodiment, inspection station 130 may be configured to receive substrate 114 for inspection after the coating on the substrate 114 has cured. For example, as shown in FIG. 1 , the arrangement of coating assembly 104, inspection station 130, and curing oven 102 may be modified so that curing oven 102 is positioned between coating assembly 104 and inspection station 130. As a result, coating assembly 104 may apply fluid to substrate 114, and the coated substrate 114 may be passed to curing oven 102 where the fluid on substrate 114 is cured. The coated and cured substrate 114 may then be passed to inspection station 130. Inspection station 130 may measure various coating properties of the cured fluid in the same or similar manner as when inspecting uncured fluid immediately after the fluid is applied to substrate 114. The coating properties of the cured fluid may include the same or similar coating properties as those described above for the uncured fluid.

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

[0059] To position the dispenser 108 and / or testing component during each operation, the movable arm(s) may move on the X-, Y-, and Z-axes of the substrate 114 while the substrate 114 is held stationary. Alternatively, one or more axes of movement can be implemented by the movable arm, with the substrate 114 moving on one or more of the other axes of movement. For example, the movable arm may move on the X- and Z-axes (i.e., one direction parallel to the planar surface of the substrate 114 and one direction perpendicular to the planar surface of the substrate 114), while the substrate 114 may move on the remaining Y-axis. Additionally or alternatively, the testing component may be fixed to a static support.

[0060] 1 and 2A, Figure 3A illustrates an example configuration of inspection system 300, and Figure 3B illustrates a camera subsystem 316 associated with inspection system 300. Inspection station 130 and other related components of system 100 may be configured in the same or similar manner as shown in Figures 3A and 3B.

[0061] The inspection system 300 may include an illumination subsystem 304 having an ultraviolet (UV) light source 308 that directs UV light onto a fluid 302 applied to the substrate 114 (identified as "PCB to be inspected" in FIG. 3A). The fluid 302 may include a tracer that fluoresces in the presence of UV light. The illumination subsystem 304 may also include an optional white light source 312 that directs white light onto the fluid 302 on the substrate 114. The inspection system 300 further includes a camera subsystem 316 (shown in detail in FIG. 3B) that includes a camera 340. The camera 340 has a lens 344 positioned above the substrate 114 to capture one or more images of the illuminated substrate 114 as light is emitted onto the substrate 114. Specifically, the camera 340 may be angled or positioned perpendicular to the facing surface 114a of the substrate 114. As shown in FIG. 3B , when positioned perpendicular to the facing surface 114 a, the inspection system 300 may include an angled mirror 348. Although depicted as being positioned above the substrate 114 in FIG. 3A and perpendicular to the substrate 114 in FIG. 3B , the camera 340 may be angled, for example at a 45° angle, relative to the facing surface 114 a of the substrate 114 so that the lens 344 captures one or more edge images of the illuminated outer edge 114 b of the substrate 114. Images from the camera 340 are sent to an image processing computer 334, which may be integrated with or operate in cooperation with the controller 132 to determine whether the substrate 114 is properly coated. Alternatively, the image processing computer 334 may be separate from but in electronic communication with the controller 132. The image processing computer or other applicable components of the system 100 can apply various image processing techniques, such as, for example, object recognition, pattern recognition, or feature (line, corner, interest point, etc.) evaluation, to determine values ​​of various coating properties.

[0062] The inspection system 300 may also include a substrate holder subsystem 338 configured to support the substrate 114 while it is inspected. The substrate holder subsystem 338 may be configured to hold the substrate 114 around one or more of its edges during inspection. In another embodiment, the substrate holder subsystem 338 may include support pins (not shown) that hold the substrate 114 during inspection. To adjust the position of the camera subsystem 316, the camera subsystem 316 may be connected to an XY-axis motor 320. The XY-axis motor 320 is configured to move the camera subsystem 316 relative to the substrate 114 upon receiving commands from a motion controller 332 and / or an image processing computer 334. Like the image processing computer 334, the motion controller 332 may be integrated with the controller 132 or may be separate from but operate in cooperation with the controller 132. Although one type of inspection device is described, the inspection system 300 may include various other types of inspection devices as desired, such as a laser sensor for measuring a coating thickness on a substrate.

[0063] 4 shows a data flow diagram 400 that at least partially illustrates a process for enhanced coating dispensing control according to one embodiment of the present disclosure. While reference is made to coating materials, coating operations, coating systems, and other coating conditions, the disclosure is not so limited. The various components of diagram 400 and their descriptions apply equally to all types of devices (e.g., needle-type dispensers), operations (e.g., jetting operations), and materials (e.g., viscous materials).

[0064] By way of introduction, a coating system (e.g., system 100 of FIG. 1 ) generally performs a coating operation according to respective values ​​of a number of different operating parameters of the coating system. A current coating operation 406 is performed according to current operating parameter values ​​404 for applying fluid to a substrate (e.g., substrate 114). An operating parameter is a parameter of the coating that affects the value of an associated coating characteristic. The current value of the operating parameter is preferably, but not necessarily, within an acceptable tolerance range 402. The fluid on the substrate is then inspected to determine a coating characteristic value 408 related to the characteristic of the fluid. A set of coating characteristic values ​​410 is updated based on the current coating characteristic value 408. The set of coating characteristic values ​​410 is analyzed to determine and / or estimate one or more future predicted coating characteristic values ​​412 for the fluid on subsequent coated substrates. Based on the predicted coating characteristic value(s) 412, the operating parameter values ​​404 are adjusted as necessary to preferably prevent the coating characteristic values ​​of the subsequent substrate from falling outside the tolerance range 402, thereby avoiding failure or defects of the subsequent substrate.

[0065] The tolerance range 402 may refer to a range of values ​​deemed acceptable by, for example, a substrate manufacturer or their customer. The values ​​of the tolerance range 402 may correspond to a particular coating characteristic of a fluid to be applied to the substrate. Various coating characteristics are described below with reference to coating characteristic values ​​408. The tolerance range 402 may include an upper limit and a lower limit. In some cases, the tolerance range 402 may actually or practically include only one of the upper limit or the lower limit.

[0066] In some embodiments, tolerance range 402 may include multiple sets of tolerance ranges, one within the other. Two ranges may indicate, for example, a low level alarm and a high level alarm. The multiple ranges may be used when comparing predicted coating characteristic value(s) 412 to tolerance range 402 and / or when determining adjustments to operational parameter values ​​404. In one example, if predicted coating characteristic value(s) 412 are outside the outermost tolerance range, the adjustment of operational parameter values ​​404 may be larger, while if the predicted coating characteristic value is outside the inner tolerance range but within the outer tolerance range, the adjustment of operational parameter values ​​404 may be smaller.

[0067] The operating parameter values ​​404 may represent values ​​of operating parameters associated with the coating system, components of the coating system, or any other variable related to the operation of the coating system, but which are not strictly part of the coating system itself. The operating parameters may be any parameters that can substantially affect the coating operation and / or the fluid applied to the substrate, e.g., coating characteristic values ​​408.

[0068] The operating parameters may include operating parameters of a coating dispenser (e.g., dispenser 108 in FIG. 1 ), such as the fluid pressure or flow rate of fluid supplied from a fluid source and / or to a nozzle of the coating dispenser. Another operating parameter of a coating dispenser may include the rate at which the coating dispenser applies various formations (e.g., dots) of fluid to a substrate, or the speed at which the dispenser is moved relative to the substrate while performing a coating operation. The operating parameters of a coating dispenser may also include any parameters related to the fluid dispensing itself, such as the velocity of the fluid as it exits the nozzle, or the size, shape, or directionality of the fluid in flight between the nozzle and the substrate. The operating parameters of a coating dispenser may relate to the positioning of the coating dispenser, such as the distance between the nozzle and the substrate.

[0069] Further examples related to coating dispensers include operating parameters related to the fluid source, such as the flow rate or fluid pressure at which the fluid is delivered. Another exemplary operating parameter may relate to the actuator and / or drive pin / valve seat configuration, such as actuation frequency or speed, or the force of impact of the drive pin on the valve seat. Another exemplary operating parameter may relate to the air flow (e.g., from an air jet) to which the fluid is exposed as it is dispensed from the nozzle, including air pressure or air directionality.

[0070] Another exemplary operating parameter may relate to the overall speed at which a series of substrates are moved through and coated by the coating dispenser. More generally, an operating parameter may refer to the speed or velocity at which a series of substrates are processed by the entire coating system. This may include the speed of one or more conveyors or other devices for moving substrates through the coating system. The aforementioned operating parameter relating to the speed of operation may be increased, for example, if the coating characteristic value 408 remains stable over multiple iterations. Another example of an operating parameter relates to the properties of the fluid itself, such as its viscosity and / or temperature.

[0071] The coating operation 406 may be performed according to the operational parameter values ​​404. Specifically, a coating dispenser applies a volume of fluid to at least some area of ​​the substrate. The areas of the substrate to which the fluid may be applied include any electrical or other components positioned on the substrate, areas of the substrate that do not have components (e.g., between two components), or any combination of the two, including overlapping areas and boundaries between component and non-component sub-areas.

[0072] Additionally, as already mentioned above, fluid can be applied to a "sample area" of a substrate that lacks any components or functional aspects (other than those primarily implemented to further facilitate use of the sample area). The sample area can be used as a surface for applying one or more volumes of fluid (e.g., in various configurations such as droplets or lines). The fluid applied to the sample area can primarily function as a test object for measuring one or more properties of the fluid in isolation from other variables that may affect the measurement of the properties. For example, the three-dimensional and complex nature of many components can interfere with measuring the thickness of the fluid. Other imperfections introduced by previous processes on the substrate can also interfere with certain measurements. For example, components mounted on the substrate may be misaligned, causing an applied fluid that should have been correctly aligned to appear incorrectly positioned on the substrate. The sample area can be indicated by a dot or other marker. The dot or other marker can be used as a frame of reference in determining the true coating property value of the fluid, particularly with regard to positioning coverage. Additionally, the sample area can be flat, for example, so that the thickness of the fluid can be measured more accurately.

[0073] In some embodiments, the substrate subjected to coating operation 406 may also undergo curing operation 407 before the fluid on the substrate is inspected and coating characteristic values ​​408 are determined and / or measured. In this case, a curing oven (e.g., curing oven 102 in FIG. 1 ) may be positioned between the inspection station or other similar component and the dispenser. Thus, references such as "coated substrate" may be understood to include substrates that have been both coated and cured, unless otherwise clearly indicated by statement or context.

[0074] After the coating operation 406 (and optionally the curing operation 407) is completed, a value of a coating property (i.e., coating property value 408) for at least a portion of the fluid applied to the substrate is determined. The coating property value 408 may be determined by a camera or other sensor (e.g., camera assembly 316 of FIGS. 3A and 3B). The sensor may be part of an inspection station (e.g., inspection station 130 of FIG. 1) separate from the coating assembly, and thus the coated substrate may require transport to the inspection station. Alternatively, the inspection station may be at least partially integrated into the coating assembly or other component of the coating system (e.g., a curing oven).

[0075] A coating characteristic may refer to a fluid covering one portion of a substrate, while another coating characteristic may refer to a fluid covering a second, different portion of the substrate, even if the coating characteristics are the same "type." In one example, the coating characteristics of two portions may refer to the coating thickness on each portion of the coated substrate.

[0076] As an example, a coating characteristic may refer to the location of a fluid, or a portion thereof (i.e., coating coverage), relative to the substrate as a whole, or in relation to one or more designated features or other landmarks on the substrate. The portion of the substrate may include the aforementioned "sample area" and / or its target point. As previously mentioned, the fluid may be applied to the substrate as discrete features, such as dots or beads, lines (straight or looped), or area coats (i.e., "swirl" patterns). Thus, the location of the fluid may refer to a particular fluid feature on the substrate.

[0077] A coating property can refer to the location of a coating and / or coating composition relative to a specified area of ​​a substrate to which the coating is intended to be applied. For example, the value of such a coating property can indicate the percentage of that area that has coverage and / or lacks coverage. Additionally or alternatively, the value of such a coating property can indicate the percentage of the coating composition that is outside of its intended coverage area and / or the percentage that is inside of its intended coverage area. The percentage value can also be expressed by other quantitative metrics instead of percentage.

[0078] Additionally or alternatively, the location of the fluid may refer to a portion of the fluid configuration. For example, a precisely applied area coat configuration may cover the area between two rows of components without penetrating into any of the components. Furthermore, the area coat configuration may include a precisely applied first section that covers a portion of a designated area without being applied to any of the components. This area coat configuration may also include an imprecisely applied second section that is offset from the intended location and does not completely cover the intended area between the rows of components. In addition, the second section also covers a portion of a component. Thus, the location of the fluid may refer to a defective portion of the area coating configuration rather than the location of the area coating configuration as a whole.

[0079] Additionally or alternatively, the location of a fluid construct may be represented by a single location, such as the center point of the fluid construct. Thus, the overall location of a fluid construct is the same as the location of the corresponding single location. Additionally or alternatively, the location of a fluid construct may be relative to another fluid construct or part of a fluid. For example, a pair of fluid dots may be intended to be positioned at a specific distance between them. Thus, the location of the first dot may be a frame of reference for indicating the location of the second dot.

[0080] As another example, a coating characteristic may refer to one or more dimensions or shapes of a fluidic structure (or portion of a fluid). A dimension of a fluidic structure may include a width, length, diameter, or other distance between two points on the fluidic structure. A shape of a fluidic structure may include a circle, a dot, an oval, a straight or elliptical shape, or an elongated shape. A shape of a fluidic structure may refer to the relative proportions and angles of the width(s), length(s), or other dimensional features of the fluidic structure, as well as the contour or other features that define the perimeter of the fluidic structure. A shape may be classified according to one or more predetermined shapes or characteristics, such as a circle, an oval, or an elongated shape.

[0081] As yet another example, a coating characteristic may indicate that a fluidic component or other portion of a fluid is intended for "sample" use, which may be determined by the location of the fluidic component or other portion of a fluid within a designated sample region of the substrate.

[0082] Other examples of coating properties may include the overall thickness of the fluid on the substrate, the thickness of a fluidic component, or the thickness of a portion of the fluid on the substrate. Here, thickness may be defined as the distance between a point on the substrate and a point corresponding to the vertical of the top of the fluid. Vertical refers to a direction perpendicular to the plane of the substrate. In some examples, the thickness at a point or a subset of points within a fluidic component may represent the thickness of the fluidic component. In other examples, the thickness of a fluidic component may be a minimum or maximum thickness value across various measurement points of the fluidic component. Other coating properties include material volume, flow rate of material on the substrate, UV reflectance, and refractive index.

[0083] Other examples of coating properties may include applied attributes of the fluid itself, such as electrical insulation, resistance to mechanical stress, vibration damping, moisture permeability, and temperature insulation.

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

[0085] The determined or measured coating characteristic value 408 may be added to a set of coating characteristic values ​​410. The set of coating characteristic values ​​410 may include coating characteristic values ​​that have been previously measured and / or determined and / or associated with previously coated and / or inspected coated substrates of the current coated substrate associated with the current coating characteristic value 408. Note that not every coated substrate in a series of consecutive coated substrates need be inspected. Rather, only a subset, such as every fifth coated substrate in the series of consecutive coated substrates, may be inspected.

[0086] In one example, the coating characteristic values ​​in the set of coating characteristic values ​​410 may be ordered and / or configured to facilitate determining the predicted coating characteristic value(s) 412. Each coating characteristic value may be associated with a corresponding coated substrate in the series of consecutive substrates. Thus, the coating characteristic values ​​in the set of coating characteristic values ​​410 may be ordered according to the order of the consecutive coated substrates. Additionally or alternatively, the coating characteristic values ​​408 and other coating characteristic values ​​may be associated with time or may incorporate timestamps by which the values ​​in the set of coating characteristic values ​​410 may be ordered. The set of coating characteristic values ​​410 may be organized as a time series of coating characteristic values. The time series may be represented as a dual-axis line graph, with one axis representing time (or a similar metric) and the other representing the coating characteristic values. As previously mentioned, the “time” aspect of the time series may refer to either chronological time or the order of inspected coated substrates (or simply coated substrates, whether inspected or not) in the series of consecutive coated substrates 114.

[0087] In another example, the set of coating property values ​​410 may not indicate time, associated coating substrates, or any other indication of relative ordering between the coating property values. In this (or other) cases, the coating property values ​​in the set of coating property values ​​410 may be unordered and / or may not be orderable.

[0088] The set of coating property values ​​410 may form at least one basis in determining and / or estimating predicted coating property value(s) 412. The predicted coating property value(s) 412 may include one or more (predicted) coating property values ​​of a fluid to be applied to a substrate at a future time. The term "future" or the like may refer to a chronological time or an order in a series of successive coated substrates.

[0089] The predicted coating characteristic value(s) 412 may be considered “predicted” if they are determined and / or estimated with a predetermined confidence level, such as 90%, 95%, or 99% confidence. Thus, the predicted coating characteristic value(s) 412 need not be with absolute certainty. Other indicators of confidence or similar concepts may additionally or alternatively be used. Thus, the confidence level or other similar metric may serve as a threshold requirement for the predicted coating characteristic value to be considered valid. Additionally or alternatively, the confidence level or other metric may be used in other parts of the process. For example, the confidence level or other metric may be one factor by which new operational parameter values ​​404 may be determined for subsequent iterations of the process. In this example, a high confidence level may warrant larger adjustments to the operational parameter values ​​404, while a lower confidence level may result in more conservative or smaller adjustments to the operational parameter values ​​404.

[0090] The predicted coating property value(s) 412 may be associated with a future substrate that will be coated and / or inspected immediately after the currently coated substrate in a series of successive coated substrates. Additionally or alternatively, the predicted coating property value(s) 412 may be associated with a future substrate that does not immediately follow the currently coated substrate in a series of successive coated substrates. Rather, there may be intervening substrates to be coated and / or inspected between the currently coated substrate and the future coated substrate associated with the predicted coating property value(s) 412.

[0091] The predicted coating characteristic value(s) 412 may be similar to the coating characteristic values ​​of the set of coating characteristic values ​​410 and the coating characteristic value 408. That is, each of the foregoing values ​​refers to the same coating characteristic. For example, the coating characteristic value 408, the set of coating characteristic values ​​410, and the predicted coating characteristic value 412 may all refer to a coating thickness.

[0092] The predicted coating property value(s) 412 may be determined via one or more forecasting techniques applied to the set of coating property values ​​410, or a portion thereof. For example, it will be recalled that the set of coating property values ​​410 may form a time series with respect to the order of coated substrates, chronological timing, or other timing criteria. The time series may be represented as various data points on a line graph. Linear regression and / or curve / straight line matching techniques may be used to determine a trend line or other functional representation. This trend line and / or function may be used to determine the predicted coating property value(s) 412. Other techniques for time series forecasting may also be used.

[0093] In some embodiments, various techniques may be applied to the collection of coating property values ​​410 to smooth the time series representation and / or apply variable weights to recent data points in the time series. For example, moving average techniques such as a simple moving average, a cumulative rolling average, a weighted moving average, and / or an exponentially smoothed moving average may be used. Another exemplary technique is an autoregressive-moving average (ARMA).

[0094] In an alternative embodiment, a specific coating characteristic value may be identified and predictive techniques may be used to predict the number of substrates (or other timing metric) that can be coated before the identified coating characteristic value is exceeded. For example, the identified coating characteristic value may be a value in the tolerance range 402. The operating parameter values ​​404 may be adjusted according to this prediction instead of the predicted coating characteristic value 412.

[0095] The predicted coating characteristic value(s) 412 may include two or more predicted coating characteristic values. The multiple predicted coating characteristic values ​​412 may all be values ​​of the same coating characteristic, but each may refer to a predicted coating characteristic value associated with a distinct coated substrate. For example, the multiple predicted coating characteristic values ​​412 may refer to coating characteristic values ​​of immediately succeeding substrates (e.g., the first, second, third, etc. substrate following the currently coated substrate). In another example, the multiple predicted coating characteristic values ​​may refer to coating substrates following each other at predetermined intervals. For example, a first predicted coating characteristic value may predict a coating thickness on a coating substrate that is the fifth coated substrate from the currently coated substrate. A second predicted coating characteristic value may predict a coating thickness on a coating substrate that is the tenth coated substrate following the currently coated substrate. The predicted coating characteristic value(s) 412 may include a predetermined or operator-entered number of predicted coating characteristic values, which may reflect how far ahead the operator desires the system to look when adjusting its operating parameters. The operator may additionally or alternatively indicate the spacing between coated substrates to which the predicted coating property value(s) 412 are directed.

[0096] The operational parameter values ​​404 may be adjusted (e.g., redetermined) to new values ​​based on the predicted coating characteristic value(s) 412. For example, the predicted coating characteristic value(s) 412 may be compared to one or more of the outermost values ​​of the tolerance range 402. Adjustments to the operational parameter values ​​404 may be based on this comparison and / or other factors. In general, if the predicted coating characteristic value(s) 412 are outside the tolerance range 402, the operational parameter values ​​404 may be adjusted to values ​​that are predicted to move the coating characteristic value of subsequent coated substrates (e.g., in further iterations of the process) back within the tolerance range 402, or at least toward within the tolerance range 402. If the predicted coating characteristic value(s) 412 are within the tolerance range 402 but closer to the outer limits of the tolerance range 402 than before, the operational parameter values ​​404 may be adjusted to move the coating characteristic value away from the outer limits of the tolerance range 402. In some cases, the operational parameter values ​​404 may not need to be adjusted. For example, the operational parameter values ​​404 may not need to be adjusted if the predicted coating characteristic value(s) 412 and the current coating characteristic value are the same or within an acceptable variation, such as a 10% variation. Another example of when the operational parameter values ​​404 would not be adjusted may be when the predicted coating characteristic value 412 and the current coating characteristic value 408 differ, but the predicted coating characteristic value 412 does not fall outside the tolerance range 402. As suggested by the above example, the decision to adjust the operational parameter values ​​404 may be based on the current coating characteristic value 408.

[0097] Adjustments are not necessarily limited to a single operating parameter. Rather, in some instances, multiple operating parameter values ​​404 may be adjusted to achieve the same or similar effect and / or under the same or similar criteria as if only a single operating parameter were adjusted.

[0098] It is generally contemplated that process iterations are performed with respect to a single coating characteristic. For example, the process may target coating thickness at one specific location on the coated substrate. In yet other examples, the process may separately track values ​​for multiple coating characteristics (e.g., coating thickness and coating location) over several iterations. Predictions can be determined for values ​​of both coating characteristics, and operating parameters can be adjusted independently based on the predicted value of each coating characteristic.

[0099] Rather than adjusting multiple parameter values ​​independently when multiple coating characteristic values ​​are tracked, the value of one operational parameter may be adjusted based on predicted values ​​of two or more coating characteristics. Adjustments to a single operational parameter value 404 may be made according to one or more criteria. For example, a single operational parameter value 404 may be adjusted to benefit both coating characteristics equally, such as by moving both coating characteristic values ​​“away” from the outer limits of their respective tolerance ranges by proportionally equal amounts. In another example, a single operational parameter may be adjusted to benefit each coating characteristic according to their proportional distance “toward” the outer limits of their respective tolerance ranges. In another example, an operational parameter may be adjusted to affect the single coating characteristic that is most “toward” the outer limit of its tolerance range, which may reflect the coating characteristic that is most likely to move outside its tolerance range 402 first. In yet another example, an operational parameter value 404 may be adjusted to best benefit (e.g., move “away” from) two coating characteristics in the set. In another example, the operational parameter value 404 may be adjusted based on only one of the coating characteristics, with a concomitant beneficial or adverse effect on another coating parameter. In an alternative to this example, the adjustment of the operational parameter may relate to only that one coating characteristic until that other coating characteristic is predicted to fall outside the tolerance range 402. In this case, the operational parameter may be adjusted to fully or partially affect the other coating characteristic.

[0100] After the operating parameter values ​​404 have been adjusted (or not adjusted) based on the predicted coating characteristic values ​​412, this iteration of the process may be considered complete. Another iteration may be performed with respect to a later coated substrate in the series of consecutive coated substrates. The subsequent coated substrate for the next iteration of the process may be the coated substrate immediately following the previous iteration. Alternatively, the new coated substrate for the new iteration of the process may be a later substrate with some interval (either chronologically or by number of coated substrates) between it and the previously inspected coated substrate.

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

[0102] The reader is reminded that references to dispensers, coating operations, fluids, and other terms used in describing the present method 500 should be understood broadly and may encompass any equipment type, dispensing operation, and / or material type, unless expressly dictated to the contrary by statement or context.

[0103] The coating operation may be performed according to operating parameter values ​​(e.g., operating parameter values ​​404 in FIG. 4 ) that affect the value of one or more properties (e.g., coating property values ​​408 in FIG. 4 ) of the fluid as it is applied to the substrate. The operating parameters may include, for example, the fluid pressure of the fluid as it is delivered to the nozzle and / or as it is delivered from the fluid source to the dispenser. As another example, the operating parameters may include nozzle operating parameters, such as how quickly a valve is opened or closed.

[0104] Coating characteristics may include, for example, the thickness of the fluid applied to the substrate, the portion of the substrate, and / or the configuration of the fluid (e.g., a dot, line, or spray area). Coating characteristics may also refer to the coverage aspect of the fluid. This may include the coated location on the substrate and / or the size of the coated area, such as the dimensions and / or shape of the fluid configuration. For example, the coating configuration may reach a target area where the coating configuration should be applied, but not exceed it. Other examples of coating characteristics are described in more detail herein.

[0105] In step 506, the values ​​of the aforementioned coating properties on the coated substrate may be measured, for example, by an inspection station (e.g., inspection station 130 of FIG. 1). The inspection station or other component may use one or more sensors, such as a camera, to measure the coating property values. The inspection station may measure the coating property values ​​immediately after the substrate is being coated, as shown in FIG. 1. In other embodiments, the inspection station may be positioned within the coating system and may measure the coating property values ​​after the fluid on the substrate has cured. For example, a curing oven (e.g., curing oven 102 of FIG. 1) may be positioned between the dispenser and the inspection station.

[0106] In step 508, a predicted coating characteristic value (e.g., predicted coating characteristic value(s) 412 in FIG. 4 ) may be determined / estimated. The predicted value may refer to a predicted coating characteristic value of a fluid to be subsequently applied to a substrate following the current substrate in a series of consecutive substrates. The subsequent substrate may immediately follow the current substrate or may have multiple intervening substrates between it and the current substrate. For example, the subsequent substrate may be the tenth substrate to be coated and / or inspected after the current substrate. In one embodiment, multiple predicted coating characteristic values ​​may be determined / estimated for multiple subsequent substrates.

[0107] The predicted coating characteristic value may be determined based on the current coating characteristic value. Additionally or alternatively, the predicted coating characteristic value may be based on a collection of historical coating characteristic values ​​(e.g., collection 410 of FIG. 4 ), such as previously inspected coated substrates of a series of substrates, where the current coating characteristic value may be added to the collection. The collection of coating characteristic values ​​may be organized as a time series. One or more of a variety of forecasting and / or prediction techniques may be applied to the time series to determine the predicted coating characteristic value.

[0108] The determined coating characteristic value may have an associated confidence level or other metric that indicates the statistical certainty of the prediction. The confidence level or other metric may serve as a threshold for the prediction to be considered valid. Additionally or alternatively, the confidence level or other similar metric may be a factor by which operational parameters may be adjusted in step 514.

[0109] In step 510, the predicted coating characteristic value from step 508 may be compared to a tolerance range of values ​​(e.g., tolerance range 402 in FIG. 4). If in step 512 the predicted coating characteristic value is outside the tolerance range of values, the method may proceed to step 514. The comparison may be performed at a specified percentage tolerance value and / or value(s) in the tolerance range of values, such as 10% of the predicted coating characteristic value. References to "about" the predicted coating characteristic value and / or tolerance range value(s) shall be understood to mean values ​​that are plus or minus 10% of that value. Other similar uses of "about" shall be considered as well.

[0110] In embodiments in which multiple predicted coating property values ​​are determined for multiple subsequent substrates, a comparison may be made for each of the multiple predicted coating property values, and steps 512 et seq. may be performed in turn for each of the multiple predicted coating property values.

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

[0112] If step 516 indicates that the current substrate is the final substrate or that the method 500 is finished, then the method 500 may end at step 518 .

[0113] Also, in step 516, if the current substrate is not the last substrate in the series of consecutive substrates and there is no other indication to end method 500, method 500 may return to step 504 without adjusting the values ​​of the operational parameters. Returning to step 504 may result in a new iteration of method 500 (specifically steps 504-516) in which a new coating operation is performed on a subsequent substrate in the series of consecutive substrates. The subsequent substrate need not immediately follow the substrate of the previous iteration, but may be spaced apart from the substrate of the previous iteration. The values ​​of the operational parameters in this next iteration of method 500 may be the same as the values ​​of the operational parameters used in the previous iteration.

[0114] If the predicted value of the coating characteristic value in step 512 is outside the tolerance range of values ​​(i.e., represents an unacceptable predicted value), the value of the operational parameter may be adjusted in step 514. For example, the value of the operational parameter may be adjusted so that the coating characteristic value in subsequent iteration(s) of method 500 is (or is predicted to be) within the tolerance range of values ​​or at least close to the tolerance range of values. In some embodiments, the values ​​of multiple operational parameters may be adjusted to affect the coating characteristic value in subsequent iteration(s) of method 500.

[0115] After the value of the operational parameter is adjusted, the method 500 may return to step 504, and in this next iteration, the coating operation may be performed using this adjusted value of the operational parameter at step 504. The method 500 in this next iteration may proceed to step 504, and so on.

[0116] Those skilled in the art will appreciate that the systems and methods disclosed herein may be implemented via a computing device that may include, but is not limited to, one or more processors, a system memory, and a system bus that couples various system components, including coupling the processors to the system memory. In the case of multiple processors, the system may utilize parallel computing.

[0117] For purposes of illustration, application programs and other executable program components, such as operating systems, are illustrated herein as separate blocks, with the understanding that such programs and components sometimes reside in different storage components of a computing device and are executed by the computer's data processor(s). An implementation of the service software may be stored on or transmitted via some form of computer-readable media. All disclosed methods may be performed by computer-readable instructions embodied on computer-readable media. Computer-readable media may be any available medium that can be accessed by a computer. By way of example, and not limitation, computer-readable media may include "computer storage media" and "communications media." "Computer storage media" includes volatile and non-volatile, removable and non-removable media implemented in any method or technology for storage of information, such as computer-readable instructions, data structures, program modules, or other data. Examples of computer storage media include, but are not limited to, RAM, ROM, EEPROM, flash memory or other memory technology, CD-ROM, digital versatile disk (DVD) or other optical storage, magnetic cassettes, magnetic tape, magnetic disk storage or other magnetic storage devices, or any other medium usable to store the desired information and accessible by a computer. The application program, etc. and / or the storage media may be implemented at least partially on a remote system.

[0118] As used in this specification and the appended claims, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise. Numerical ranges may be expressed as from "about" one particular value and / or to "about" another particular value. When a range is expressed in this manner, other embodiments include ranges from the one particular value and / or to the other particular value. Similarly, when a value is expressed as an approximation, by use of "about," it should be understood that the one particular value also applies in other embodiments. Moreover, it should be understood that each endpoint of such a range is valid both in relation to the other endpoint, and independently of the other endpoint.

[0119] The recitation of ranges of values ​​herein is merely intended to serve as a shorthand method of referring individually to each separate value within that range, unless otherwise stated herein, and each separate value is incorporated herein as if it were individually recited herein.

[0120] Throughout this description and claims, the term "comprise" and variations thereof, such as "comprising" and "comprises," mean "including but not limited to" and are not intended to exclude, for example, other components, integers, or steps. The term "exemplary" means "an example of" and is not intended to convey that it is a preferred or ideal embodiment. "Such as" is not used in a limiting sense but is used for descriptive purposes.

[0121] Components are disclosed that can be used to implement the disclosed methods and systems. These and other components are disclosed herein, and although combinations, subsets, interactions, groups, etc. of these components are disclosed, it is understood that each is contemplated and described herein for all methods and systems, even if specific reference to each of the various individual and collective combinations and permutations of those combinations is not explicitly disclosed. This principle applies to all aspects of this application and is not limited to the steps of the disclosed methods. Thus, where there are various additional steps that can be performed, it is understood that each of these additional steps can be performed with any specific embodiment or combination of the disclosed methods.

[0122] Unless expressly stated otherwise, no method described herein is intended to be understood as requiring its steps to be performed in any particular order. Thus, if a method claim does not actually specify the order in which its steps must be followed, or if the claims or description do not specifically state that the steps are limited to a particular order, no order is intended to be implied in any way. This applies to any possible implicit basis for interpretation, including matters of logic regarding the arrangement of steps or operational flow, plain meaning derived from grammar or punctuation, and the number or type of embodiments described herein.

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

Claims

1. 1. A method for controlling a dispensing system, the dispensing system having a dispensing device operated by a controller and configured to apply a liquid or viscous material to a series of substrates moved through the dispensing system; The method comprises: operating the dispensing device according to a first value of an operating parameter of the dispensing system to apply a first amount of material to a first substrate in the series of substrates; measuring a value of a property of the first quantity of material applied to the first substrate using a sensor to obtain a measurement of the property of the first quantity of material applied to the first substrate; determining, based on the measured value of the property of the first quantity of material applied to the first substrate, whether a predicted value associated with a property of a quantity of material to be applied to a subsequent substrate in the series of substrates is predicted to be outside a tolerance range; adjusting the first value of the operating parameter to a second value in response to the determination that the predicted value associated with the characteristic of the amount of material to be applied on the subsequent substrate is predicted to be outside the tolerance range and in response to a determination that the predicted value has a predetermined threshold level of confidence; applying a second amount of material from the dispensing device to the subsequent substrate in the series of substrates in accordance with the second value of the operating parameter; Including, the predetermined confidence threshold level defines a requirement that must be met for the predicted value of the property of the material quantity to be considered valid; the characteristics of the first amount of material applied on the first substrate are different from the characteristics of the second amount of material applied on the subsequent substrate; adjusting the first value of the operating parameter to the second value based on one or more characteristics of the amount of material applied to one or more respective substrates prior to the first substrate in the series of substrates; A method characterized by:

2. The characteristics of the first amount of material applied to the first substrate include at least one of: a location of a coating material formation on the first substrate; a size of a coating material formation on the first substrate; a shape of a coating material formation on the first substrate; and a thickness of a coating material formation on the first substrate.

2. The method of claim 1 .

3. the property of the first amount of material is measured in a designated non-functional sample area of ​​the first substrate where no functional components are present; The characteristics of the first amount of material applied to the first substrate include at least one of: a location of a coating material formation on the first substrate; a size of a coating material formation on the first substrate; a shape of a coating material formation on the first substrate; and a thickness of a coating material formation on the first substrate.

2. The method of claim 1 .

4. the designated non-functional sample area of ​​the first substrate includes a target location; the target location is visually marked on the first substrate to visually identify a target area for application; The characteristics of the first material quantity include a location of the first material quantity on the first substrate relative to the target location.

4. The method of claim 3.

5. the subsequent substrates are two or more substrates in the series of substrates subsequent to the first substrate; The characteristics of the first amount of material applied to the first substrate include at least one of: a location of a coating material formation on the first substrate; a size of a coating material formation on the first substrate; a shape of a coating material formation on the first substrate; and a thickness of a coating material formation on the first substrate.

2. The method of claim 1 .

6. The characteristics of the first amount of material applied to the first substrate include at least two of: a location of a coating material formation on the first substrate; a size of a coating material formation on the first substrate; a shape of a coating material formation on the first substrate; and a thickness of a coating material formation on the first substrate.

2. The method of claim 1 .

7. The operating parameter is associated with at least one of: a fluid pressure of material being supplied to a nozzle of the dispensing device; a flow rate of material being supplied to the nozzle; a rate at which material is dispensed from the nozzle; a rate at which the series of substrates is coated; or an air pressure of an atomizing air jet of the dispensing device.

7. The method of claim 6.

8. The operating parameter is associated with at least one of: a fluid pressure of material being supplied to a nozzle of the dispensing device; a flow rate of material being supplied to the nozzle; a rate at which material is dispensed from the nozzle; a rate at which the series of substrates is coated; or an air pressure of an atomizing air jet of the dispensing device.

2. The method of claim 1 .

9. the one or more characteristics of the amount of material applied onto one or more substrates prior to the first substrate are represented as time series data; The step of adjusting the value of the operating parameter to the second value further comprises adjusting the value of the operating parameter to the second value based on the time series data.

9. The method of claim 8.

10. Applying a smoothing function to the time series data. Further provided with The smoothing function includes at least one of a simple moving average function, a cumulative rolling average function, a weighted moving average function, an exponentially smoothed moving average function, and an autoregressive moving average function.

10. The method of claim 9.

11. the dispensing device applies the first amount of material according to a first value of a second operating parameter of the dispensing system; The method comprises: adjusting the value of the second operating parameter to a second value in response to the determination that the characteristic of the quantity of material to be applied on the subsequent substrate is estimated to be outside the tolerance range. Further provided with the second amount of material is applied to the subsequent substrate further according to the second value of the second operating parameter; The second operating parameter is associated with at least one of a fluid pressure of material supplied to a nozzle of the dispensing device, a flow rate of material supplied to the nozzle, a rate at which material is dispensed from the nozzle, a rate at which the series of substrates is coated, or an air pressure of an atomizing air jet of the dispensing device.

2. The method of claim 1 .

12. The subsequent substrate is a second substrate; The method comprises: operating the dispensing device according to a third value of the operating parameter of the dispensing system to apply a third amount of material to a third substrate subsequent to the second substrate in the series of substrates; measuring a property of the third amount of material applied to the third substrate using the sensor; determining, based on the characteristics of the third quantity of material applied to the third substrate, that a characteristic of a quantity of material to be applied to a substrate subsequent to the third substrate in the series of substrates is estimated to be within the tolerance range; applying the third amount of material from the dispensing device to a fourth substrate following the third substrate in the series of substrates in accordance with the third value of the operating parameter; Further provided with The third value is different from the first value and the second value.

2. The method of claim 1 .

13. the third substrate is at least two substrates in the series subsequent to the subsequent substrate; The third value of the operating parameter is associated with at least one of a fluid pressure of material supplied to a nozzle of the dispensing device, a flow rate of material supplied to the nozzle, a rate at which material is dispensed from the nozzle, a rate at which the series of substrates is coated, or an air pressure of an atomizing air jet of the dispensing device.

13. The method of claim 12.

14. The subsequent substrate is a second substrate; The method comprises: operating the dispensing device according to a third value of the operating parameter of the dispensing system to apply a third amount of material to a third substrate subsequent to the second substrate in the series of substrates; measuring a property of the third amount of material applied to the third substrate using the sensor; determining, based on the characteristics of the third quantity of material applied to the third substrate, that a characteristic of a quantity of material to be applied to a substrate subsequent to the third substrate in the series of substrates is predicted to be within the tolerance range and outside a second range; adjusting the value of the operating parameter to a fourth value in response to the determination that the characteristic of the quantity of material to be applied onto the subsequent substrate of the third substrate is estimated to be within the tolerance range and outside the second range; applying a fourth amount of material from the dispensing device to a fourth substrate following the third substrate in the series of substrates in accordance with the fourth value of the operating parameter; Further provided with the third value is different from the first value and the second value; The characteristics of the third amount of material applied to the third substrate are different from the characteristics of the fourth amount of material applied to the fourth substrate.

2. The method of claim 1 .

15. The first amount of material on the first substrate is cured when the property of the first amount of material is measured.

2. The method of claim 1 .

16. The subsequent substrate is a second substrate; Determining that the predicted value associated with the characteristic of the quantity of material to be applied to the subsequent substrate in the series of substrates is predicted to be outside the tolerance range further includes determining that the characteristic of the quantity of material to be applied to a third substrate subsequent to the second substrate in the series of substrates is predicted to be outside the tolerance range.

2. The method of claim 1 .

17. 1. A dispensing system for applying a liquid or viscous material to a substrate, the substrate being moved through the dispensing system; The dispensing system comprises: a dispensing device; a sensor positioned to measure a characteristic of the amount of material applied by the dispensing device to a substrate in a series of substrates moved through the dispensing system; A controller; Equipped with The controller generates one or more signals to: operating the dispensing device according to a first value of an operating parameter of the dispensing system to apply a first amount of material to a first substrate in the series of substrates; measuring a value of a property of the first quantity of material applied to the first substrate using the sensor to obtain a measurement of the property of the first quantity of material applied to the first substrate; determining, based on the measured value of the property of the first quantity of material applied to the first substrate, whether a predicted value associated with a property of a quantity of material to be applied to a subsequent substrate in the series of substrates is predicted to be outside a tolerance range; adjusting the first value of the operating parameter to a second value in response to the determination that the predicted value associated with the characteristic of the amount of material to be applied on the subsequent substrate is predicted to be outside the tolerance range and in response to a determination that the predicted value has a predetermined threshold level of confidence; applying a second amount of material from the dispensing device to the subsequent substrate in the series of substrates in accordance with the second value of the operating parameter; and the predetermined confidence threshold level defines a requirement that must be met for the predicted value of the property of the material quantity to be considered valid; the characteristics of the first amount of material applied on the first substrate are different from the characteristics of the second amount of material applied on the subsequent substrate; adjusting the first value of the operating parameter to the second value based on one or more characteristics of the amount of material applied to one or more respective substrates prior to the first substrate in the series of substrates; A dispensing system characterized by:

18. a dispensing assembly including the dispensing device; an inspection station including the sensor and configured to receive a substrate from the series of substrates after an amount of material has been applied to the substrate; 20. The dispensing system of claim 17, further comprising:

19. The dispensing system is configured to apply the amount of material in the form of at least one of a bead, a line, and a spray pattern.

20. The dispensing device of claim 18.

20. The inspection station is separate from the dispensing assembly.

20. The dispensing system of claim 18.

21. a curing oven configured to cure the amount of material applied to a substrate in the series of substrates; 20. The dispensing system of claim 18, further comprising:

22. The curing oven is located between the dispensing device and the inspection station, and the first amount of material on the first substrate is cured.

22. The dispensing system of claim 21.

23. The sensor includes a camera configured to capture images of the amount of material applied to a substrate in the series of substrates.

18. The dispensing system of claim 17.

24. The dispensing device and the sensor are integrated into a common assembly.

18. The dispensing system of claim 17.

25. the common assembly includes a movable arm; At least one of the dispensing device and the sensor is affixed to the movable arm.

25. The dispensing system of claim 24.

26. A movable arm; a sensor assembly secured to the movable arm; Further provided with the sensor assembly includes the sensor and an ultraviolet light source; The sensor includes a camera configured to capture images of the amount of material applied to a substrate in the series of substrates.

18. The dispensing system of claim 17.

Images