System and method for managing improved hot melt liquid dispensing systems

Abstract

To provide systems and methods for enhanced hot melt liquid dispensing system management.SOLUTION: In an example method for determining an operating instruction for a hot melt liquid dispensing system having an applicator and a heater, the operating instruction is determined based on a filtered applicator parameter value associated with gun cycle counts of the applicator and a filtered heater parameter value associated with duty cycle values of the heater. The filtered applicator parameter value is determined based on historic applicator parameter values that are updated according to a current applicator parameter value. The filtered heater parameter value is determined based on historic heater parameter values that are updated according to a current heater parameter value.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] (Cross-reference of related applications) This application claims priority to U.S. Patent Application No. 62 / 810,380, filed on 26 February 2019, which is incorporated herein by reference in its entirety.

[0002] (Field of Invention) This disclosure relates, in general, to liquid dispensing, and more specifically, to enhanced hot melt liquid dispensing system management. [Background technology]

[0003] Hot melt liquid dispensing systems are useful in a variety of applications. For example, such systems can apply hot melt adhesives during the manufacture of disposable sanitary products. Another example is that hot melt liquid dispensing systems can apply hot melt adhesives to assemble various types of packaging, such as paper-based packaging for food and beverages. One example of a hot melt adhesive used in such applications is moisture-curing hot melt polyurethane adhesive ("hot melt PUR"), which is often used when a stable bond between surfaces must be formed. Other conventional hot melt adhesives can be used to fasten a variety of similar and dissimilar materials together in interlocking relationships, such as wood, plastics, corrugated films, paper, carton stock, metals, rigid polyvinyl chloride (PVC), fabrics, and leather. Hot melt adhesives can be particularly useful in applications where it is desirable for the adhesive to solidify rapidly after melting and dispensing.

[0004] In an exemplary configuration of a hot melt liquid dispensing system, the solid form of the hot melt adhesive is supplied to a melter equipped with a heating tank and / or heating grid to produce molten hot melt adhesive. After heating, the molten adhesive is fed through a heated hose to an applicator, sometimes called a dispensing "gun" or "gun module," which is equipped with a valve and a nozzle. The hot melt adhesive liquid dispensing system may include two or more applicators. The applicators may be equipped with their own heater(s) to further maintain the temperature of the hot melt adhesive before it is dispensed. Furthermore, operating a hot melt adhesive dispensing system with ideal efficiency presents numerous challenges. For example, hot melt adhesives discolor or degrade over time. This is especially likely while the hot melt adhesive is held at the high temperature required for application and / or over longer periods of time. This problem can be exacerbated in systems with relatively low flow rates.

[0005] Degraded hot melt adhesive tends to adhere to the inner surfaces of hoses and other components in the hot melt adhesive dispensing system, thereby hindering the effective flow of the adhesive. Degraded hot melt adhesive can further form carbon deposits in blackened or burnt areas of the adhesive. Degraded hot melt adhesive can cause numerous problems in the dispensing system, including clogging of filters and applicators, and more frequent cleaning of the hoses that deliver the hot melt adhesive to the applicators. Degraded hot melt adhesive generally increases system maintenance and repairs and reduces the operating time.

[0006] This disclosure addresses these and other shortcomings. [Overview of the Initiative] [Means for solving the problem]

[0007] A system and method for controlling a hot melt liquid dispensing system having an applicator configured to dispense a hot melt liquid and a hot melt liquid heater associated with the applicator are disclosed herein. An exemplary method for determining the operation commands of the hot melt liquid dispensing system is provided, which includes a plurality of past applicator parameter values ​​for a first operation parameter of the applicator and a plurality of past heater parameter values ​​for a second operation parameter of the hot melt liquid heater. Each of the plurality of past applicator parameter values ​​is temporally associated with a past time interval of a past time block. Each of the plurality of past heater parameter values ​​is associated with a past time interval of a past time block. The current applicator parameter value for the first operation parameter of the applicator and the current heater parameter value for the second operation parameter of the hot melt liquid heater are received. The current applicator parameter value is temporally associated with the current time interval corresponding to a first past time interval of a past time block, and the current heater parameter value is associated with the current time interval. The filtered applicator parameter value for the first operating parameter of the applicator is determined based on the current applicator parameter value and a past applicator parameter value from among a plurality of past applicator parameter values ​​temporally associated with a first past time interval. The filtered heater parameter value for the second operating parameter associated with the hot melt liquid heater is determined based on the current heater parameter value and a past heater parameter value from among a plurality of past heater parameter values ​​temporally associated with a first past time interval. Based on the filtered applicator parameter value and the filtered heater parameter value, an instruction to operate the hot melt liquid dispensing system is determined according to the operating parameter value of the third operating parameter of the hot melt liquid dispensing system.

[0008] An exemplary method for predicting applicator failure in a hot melt liquid dispensing system is provided, which includes a plurality of applicator parameter values ​​for a first operating parameter of the applicator and a plurality of heater parameter values ​​for a second operating parameter of the hot melt liquid heater. Each of the plurality of applicator parameter values ​​is temporally associated with a time interval in a first time block, and each of the plurality of heater parameter values ​​is associated with an applicator parameter value among the plurality of applicator parameter values. First and second subsets of the plurality of applicator parameter values ​​are determined. Each applicator parameter value in the first subset of applicator parameter values ​​indicates no dispensing activity of the applicator for a time interval that is temporally related to the first time block. Each applicator parameter value in the second subset of applicator parameter values ​​indicates dispensing activity of the applicator for a time interval that is temporally related to the first time block. First and second subsets of the plurality of heater parameter values ​​are determined. Each heater parameter value in the first subset of applicator parameter values ​​is associated with an applicator parameter value in the first subset of applicator parameter values, and each heater parameter value in the second subset of heater parameter values ​​is associated with an applicator parameter value in the second subset of applicator parameter values. The applicator failure prediction time is determined based on the first subset and the second subset of heater parameter values.

[0009] The accompanying drawings, which are incorporated into and constitute part of this specification, illustrate various embodiments and, in conjunction with the description, will be helpful in illustrating the principles of the methods and systems provided. [Brief explanation of the drawing]

[0010] [Figure 1] This figure shows an exemplary dispensing system according to one embodiment of the present disclosure. [Figure 2]An exemplary system and network configuration according to an embodiment of the present disclosure are shown. [Figure 3] An exemplary data flow diagram according to an embodiment of the present disclosure is shown. [Figure 4] An exemplary data flow diagram according to an embodiment of the present disclosure is shown. [Figure 5] An exemplary method flow diagram according to an embodiment of the present disclosure is shown. [Figure 6] An exemplary method flow diagram according to an embodiment of the present disclosure is shown.

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

Embodiments for Carrying Out the Invention

[0012] The systems and methods of the present disclosure relate to enhanced hot melt liquid ejection system management. The enhanced hot melt liquid ejection system management may be implemented within a ejection system for hot melt adhesives. Although mainly referring to hot melt adhesives, the techniques described herein may be applicable to any type of hot melt liquid, including non - adhesives.

[0013] FIG. 1 shows an exemplary hot melt adhesive system 10 in which the technology described herein may be implemented. The hot melt adhesive system 10 includes a dispenser unit 20 that includes an adhesive supply 22 for receiving and melting a solid or semi-solid hot melt adhesive 24a, such as pellets, a manifold 26 connected to the adhesive supply 22, a controller 28, and a user interface 29. The adhesive supply 22 may be, among other things, a tank-type melter or a grid and reservoir-type melter. When melted, the solid or semi-solid hot melt adhesive 24 stored within the adhesive supply 22 is converted to a liquid hot melt adhesive 24. The adhesive supply 22 includes a sidewall 30, a removable cover 31, and a base 32 that includes one or more adhesive supply heaters 34 for melting and heating the hot melt adhesive 24a and the liquid hot melt adhesive 24 within the adhesive supply 22. An adhesive supply outlet 36 proximate to the base 32 is coupled to a passage 38 that connects to an inlet 40 of the manifold 26.

[0014] A positive displacement pump 58, such as a vertically oriented piston pump (as shown) or gear pump, is coupled to the manifold 26 to pump liquid hot melt adhesive 24 from the adhesive supply unit 22 into the manifold 26. A pump motor 59 drives the pump 58. The manifold 26 is mounted to the side wall 30 of the adhesive supply unit 22 using spacers 41 and spaced away from the adhesive supply unit 22 at a distance 42 sufficient to provide thermal isolation of the adhesive supply unit 22 from the manifold 26. The manifold 26 includes a plurality of outlet ports 44 that can be adapted to heated hoses 46 attached to one or more adhesive applicators 48, 50 for supplying liquid adhesive 24 to the applicators 48, 50. The manifold 26 may include a manifold heater 56, separate from the adhesive supply heater 34 and which can be controlled independently by a controller 28. In some embodiments, a single heater can be used to heat the adhesive supply unit 22 and the manifold 26. Figure 1 shows an adhesive supply unit 22 that is physically close to the manifold 26, but other configurations are possible in which the hot melt adhesive source is physically separated from the manifold. In such configurations, two or more pumps can be used to move the hot melt adhesive from the adhesive supply unit 22 to the final application point.

[0015] The manifold 26 can generate multiple flows that are carried to applicators 48, 50 by corresponding heated hoses 46. The hoses 46 are electrically coupled to the controller 28 by a set of cords 62 associated with each hose 46. The applicators 48, 50 include one or more adhesive dispensing modules 54 configured to dispense / apply liquid hot melt adhesive 24 to products such as cartons, packages, or other objects. The adhesive dispensing modules 54 are mounted on an applicator body 51 having an applicator heater 53 and supported on a frame 52. The hot melt adhesive system 10 includes two applicators 48, 50, each having one applicator positioned on either side of the dispensing unit 20, as shown in Figure 1, but other implementations of the hot melt adhesive system 10 may use a different number of applicators, dispensing modules, and other configurations. For example, each applicator 48, 50 may consist of a single adhesive dispensing module 54, or each may consist of a pair of adhesive dispensing modules 54. The adhesive dispensing modules 54 of applicators 48 and 50 may be commonly monitored, controlled, and operated by a common air supply. Alternatively, the adhesive dispensing modules 54 of applicators 48 and 50 may be independently monitored, controlled, and operated by separate air supply units. Applicators 48 and 50 and / or adhesive dispensing modules 54 may be referred to as applicators or dispensers, respectively.

[0016] The pump 58 is located outside the adhesive supply unit 22 and is connected to a pneumatic regulator 70 that receives air from the air supply unit 61. More specifically, the pneumatic regulator 70 is mounted on the discharge unit 20 and connected to the air supply unit 61. In some implementations, the pump 58 may be mounted on the manifold 26 and heated by a manifold heater 56. This arrangement allows a larger tank opening 60 to increase the tank capacity and reduces the time required to heat the pump 58. Furthermore, a flow meter 80 may be mounted on the manifold 26. The flow meter 80 comprises a pair of sensors electrically coupled to the controller 28 by their respective codes 63a, 63b associated with each sensor. At least one product detector 90, such as an optical sensor, is also electrically coupled to the controller 28.

[0017] The dispensing unit 20 includes a controller 28 that houses a power supply and an electronic control unit for the hot melt adhesive system 10. The controller 28 may be configured to monitor, store, and set values ​​for various operating parameters of the hot melt adhesive system 10 and its components. For example, the controller 28 may be configured to capture one or more operating parameter values ​​at set time intervals (e.g., every 5 minutes) and store those captured operating parameter values. Additionally or alternatively, the controller 28 may transmit the collected and / or stored operating parameter values ​​to a remote computer system. Thus, the controller 28 may consist of one or more processors and one or more processors and memory configured to store instructions that, when executed by the one or more processors, cause the controller 28 to perform the various operations described herein. The controller 28 may be configured using a network interface (e.g., wired or wireless) for communicating with a remote computer system, such as transmitting the collected and / or stored operating parameter values ​​to the remote computer system.

[0018] The controller 28 may be configured to monitor, store, and set values ​​for the operating parameters of the applicators 48, 50, and the adhesive dispensing module 54 includes operating parameters associated with dispensing hot melt adhesive. Such parameters may include "gun cycle" counts for the applicators 48, 50 and / or the adhesive dispensing module 54. A gun cycle can refer to a single distinct instance of adhesive dispensing or application, such as the opening and closing cycles of the nozzle valve of the adhesive dispensing module 54. A gun cycle count can refer to a gun cycle of a single adhesive dispensing module 54, a gun cycle of a single applicator 48, 50 (and its adhesive dispensing module 54), or a gun cycle of multiple (or all) constituent applicators 48, 50 of the hot melt adhesive system 10. A gun cycle count can refer to an absolute count of gun cycles, a gun cycle rate, and / or a count of gun cycles within a time interval. The controller 28 can also monitor, store, and set the operating modes of the applicators 48, 50 and the adhesive dispensing module 54, such as "on" mode, "off" mode, and "ready" mode. The applicators 48, 50 or the adhesive dispensing module 54 may be in "on" mode, but may be in "on" mode rather than "ready" mode during an ongoing initialization process or when the associated hot melt adhesive is not yet at a suitable or preferred operating temperature for dispensing. The applicators 48, 50 or the adhesive dispensing module 54 may be in "ready" mode when the associated hot melt adhesive is at a suitable or preferred temperature for dispensing.

[0019] Regarding the heating mechanism of the hot melt adhesive system 10, the controller 28 is electrically coupled to heaters including an adhesive supply heater 34, a manifold heater 56, and an applicator heater 53, as well as an optional hose heater. The controller 28 may also be coupled to various temperature sensors within the hot melt adhesive system 10, which may be associated with or included in the adhesive supply heater 34, the manifold heater 56, the applicator heater 53, and any optional hose heaters. The controller 28 independently monitors and adjusts the adhesive supply heater 34, the manifold heater 56, the applicator heater 53, and any optional hose heaters. It melts the solid or semi-solid hot melt adhesive 24a received in the adhesive supply unit 22 and maintains the temperature of the (molten) hot melt adhesive 24 to ensure the appropriate viscosity of the hot melt adhesive 24 supplied to the applicators 48, 50 and dispensed by the adhesive dispensing module 54. For example, the controller 28 receives temperature information (current temperature value) from the temperature sensor and sends heater control commands to each heater to adjust the temperature (target temperature value). Such heater control commands can raise or lower the temperature of any or all of the heaters in the hot melt adhesive system 10.

[0020] The current or target temperature can be the operating temperature at which the hot melt adhesive is suitable or preferred for application or dispensing. The current or target temperature can also be a lower "setback" temperature. Hot melt adhesive held at the setback temperature may experience less carbonization and other degradation that may occur if held at higher temperatures, such as the operating temperature. Hot melt adhesive held at the setback temperature may not have the viscosity or other attributes preferred for dispensing. Holding the hot melt adhesive at the setback temperature may be effective, for example, when there are short to moderate pauses in operation. In this or a similar example, the hot melt adhesive can be lowered to the setback temperature to reduce degradation and discoloration during the pause, but can return to the operating temperature relatively quickly when the dispensing operation resumes.

[0021] In addition to the above, the controller 28 can therefore monitor, store, and set various operating parameter values ​​associated with the temperature of the hot melt adhesive in the hot melt adhesive system 10. In addition to the current and target temperature values ​​of the adhesive supply heater 34, as well as the current and target temperature values ​​of the manifold heater 56, applicator heater 53, and hose 46, the controller 28 may also monitor, store, and set duty cycle information for any or all of the heaters of interest. For example, the controller 28 may monitor, store, and set duty cycle information for the adhesive supply heater 34. The duty cycle of a heater can refer to the percentage or ratio of time within a time interval during which the heater is activated (i.e., heating the hot melt adhesive in question). Such time intervals for duty cycles may coincide with time intervals during which the controller 28 can collect various other operating parameter values ​​of the hot melt liquid adhesive system 10, including gun cycle data. For example, the heater's duty cycle value could be 20% activation over a 10-minute time interval, thus indicating that the heater was activated for 2 minutes (e.g., cumulatively) over the 10-minute period.

[0022] In one embodiment, the duty cycle may be controlled according to a time interval shorter than the time interval at which the controller 28 collects other operating parameter values ​​of the hot melt adhesive system 10 (a partial time interval of the duty cycle). For example, while the time interval at which other operating parameters of the hot melt adhesive system 10 are collected is 10 minutes, the heater temperature may be evaluated every 30 seconds, and the duty cycle may be adjusted accordingly. In one embodiment, the duty cycle values ​​of multiple shorter duty cycle partial time intervals within a longer time interval can be averaged, and this average may be used as a representative duty cycle value for the longer time interval. In another embodiment, one duty cycle value from multiple shorter duty cycle partial time intervals within a longer time interval may be used as a representative duty cycle value for the longer time interval. For example, the duty cycle value from the last duty cycle partial time interval within a longer time interval may be used as a representative duty cycle value for the longer time interval.

[0023] The heater duty cycle is not typically a configurable operating parameter. Rather, a temperature is typically specified for the heater, and the heater duty cycle is adjusted to maintain this temperature of the hot melt adhesive within the heater. The heater duty cycle may also be based on the operation of the associated applicators 48, 50 and / or adhesive dispensing module 54, such as the count of gun cycles within a time interval. That is, the heater duty cycle is typically a function of at least some of the operation of the associated applicators 48, 50 and / or adhesive dispensing module 54. For example, an increase in the count of gun cycles within a time interval may result in a similar increase in the duty cycle value of the associated heater during that time interval. The increase in the duty cycle value may be necessary to maintain the flow of hot melt adhesive to the associated applicators 48, 50 and / or adhesive dispensing module 54 at the dispensing temperature. As an example, the duty cycle value of applicator heater 53 over a time interval may be a function of the count of gun cycles of applicator 48 (and / or its adhesive dispensing module 54) during that time interval. The time interval of the duty cycle value may be time-offset (e.g., later) from the time interval of the gun cycle count associated with this duty cycle value. This may be due to delays in demand by the applicators 48, 50 or adhesive dispensing module 54 for hot melt adhesive supplied by the associated heater.

[0024] The heater's duty cycle may also be affected by the functional state of the associated applicators 48, 50 and / or adhesive dispensing modules 54, such as whether the applicators 48, 50 and / or adhesive dispensing modules 54 are operating as intended. For example, an air-leaking applicator 48, 50 and / or adhesive dispensing module 54 may be associated with an increased duty cycle of the corresponding applicator heater 53.

[0025] Figure 2 shows an exemplary system and network configuration that can implement the technology described herein. In such a configuration, the dispensing system 220 (e.g., the hot melt adhesive system 10 in Figure 1), the computer system 230, and the client device 240 can communicate with each other via the network 210. Communication with the dispensing system 120 may be achieved via the controller 222 of the dispensing system 220 (e.g., the controller 28 in Figure 1). The network 210 may include one or more wired and / or wireless networks. To give some examples, the network 210 may include the Internet, an intranet, a (wireless) local area network, and / or a cellular network.

[0026] As described with respect to Figure 1, the controller 222 may collect, store, set, and transmit various operating parameter values ​​for components of the dispensing system 220, including various operating parameter values ​​for any applicator (e.g., applicators 48, 50 and adhesive dispensing module 54 in Figure 1) and various operating parameter values ​​for any heater components (e.g., adhesive supply heater 34, manifold heater 56, hose heater and applicator heater 53 in Figure 1). The operating parameters for dispensing components may include gun cycle speed or count time interval or gun cycle count in other indicators. The operating parameters for heater components may include duty cycle values ​​of heater components in time intervals.

[0027] The computer system 230 may comprise one or more computing devices, such as various computer servers and network devices. The computer system 230 may comprise one or more networked computing devices. The computer system 230 may be located separately from the dispensing system 220. For example, the computer system 230 may comprise a cloud computing system. In contrast, the dispensing system 220 may be located in a manufacturing or assembly facility, or in another type of plant or factory. The computer system 230 may be associated with the manufacturer of at least a portion of the dispensing system 220. The owner / operator of the dispensing system 220 may be an ongoing client or customer of the manufacturer.

[0028] The client device 240 may include a computing device such as a desktop computer, laptop computer, tablet computer, or mobile device (e.g., a smartphone). The client device 240 may be configured with one or more input and output components, which may allow the user to view and manipulate data from the computer system 230. For example, the user can use the client device 240 to view and approve a proposed operating schedule for the dispensing system 220 determined by the computer system 230. The client device 240 may be located in the same location as the dispensing system 220, or it may be located remotely from the dispensing system 220. The client device 240 may be associated with an operator who views the dispensing system 220.

[0029] During operation, the dispensing system 220 may determine past (i.e., previous) and current parameter values ​​of one or more operating parameters associated with the temperature of the hot melt adhesive of the dispensing system 220. For example, the dispensing system 220 may determine one or more past and current parameter values ​​indicating the duty cycle of the heater associated with the applicator of the dispensing system 220. The dispensing system 220 may further determine past and current parameter values ​​of one or more operating parameters associated with the applicator of the dispensing system 220. For example, the dispensing system 220 may determine past and current parameter values ​​indicating the gun cycle count of the applicator of the dispensing system. The dispensing system 220 may transmit the above-mentioned past and current parameter values ​​to the computer system 230 via the controller 222.

[0030] The computer system 230 may receive past and current parameter values ​​from the dispensing system 220. In some examples, the computer system 230 may already have stored past parameter values ​​previously received from the dispensing system 220. The computer system 230 can process the past and current parameter values ​​to determine the schedule for the dispensing system 220. For example, the parameter values ​​may be filtered, such as by determining a moving average of each operating parameter. The schedule may be determined based on the temporal trend of the parameter values. This trend may reflect the time or time range during which the dispensing system 220 is not actively operating to dispense hot melt adhesive, for example, when facility workers are on break or when the facility is closed in other cases. The schedule may indicate one or more instructions for operating the dispensing system 220. The schedule may indicate the time and conditions under which one or more heaters of the dispensing system 220 are operating. For example, the schedule may indicate one or more times during which a heater switches from off mode to on mode or from on mode to off mode. The schedule may indicate the target temperature of the heater, as well as the time at which the heater begins heating (or allows cooling) the hot melt adhesive to reach its target temperature. The target temperature may be the discharge temperature or the setback temperature.

[0031] The computer system 230 may send the (proposed) schedule to a client device 240 that may be associated with a user responsible for supervising the dispensing system 220. The user may review the schedule on the client device 240 and approve or reject it. If approved, the schedule may be provided to the dispensing system 220. If the schedule is rejected, the computer system 230 may notify the user of this and determine an alternative proposed schedule. The alternative schedule may be sent to the client device 240 for approval, etc.

[0032] Figure 3 shows an exemplary data flow diagram 300 according to one embodiment of the present disclosure. In the data flow diagram 300, one or more filtered operating parameters 340 are determined based on one or more current operating parameters 310, one or more past operating parameters 320, and one or more state parameters 330. The filtered operating parameters 340 may be determined by filtering the past operating parameters 320 based on the current operating parameters 310. For example, the past operating parameters 320 may include multiple moving averages of each past operating parameter 320. The multiple moving averages may be updated based on the corresponding current operating parameters 310 to determine the filtered operating parameters 340. The multiple moving averages of the filtered operating parameters 340 may be determined for each time interval with respect to the corresponding time intervals of the current operating parameters 310 and the past operating parameters 320. One or more instructions 350 may be determined based on the filtered operating parameters 340.

[0033] The current operating parameter 310 may include one or more operating parameters on which the dispensing system (e.g., the hot melt adhesive system 10 in Figure 1 or the dispensing system 220 in Figure 2) operates. More specifically, the current operating parameter 310 may include one or more parameter values ​​from the current operating parameter 310. Similarly, the past operating parameter 320 may include one or more operating parameters on which the dispensing system operates. Even more specifically, the past operating parameter 320 may include one or more parameter values ​​from the past operating parameter 320. The parameter values ​​may correspond to a predetermined time interval. Two or more parameter values ​​may be associated with the same time interval, such as both the heater duty cycle parameter value and the applicator gun cycle count parameter value. The duration of the time interval may be in the range of 1 to 10 minutes (including 1 minute and 10 minutes). An exemplary time interval duration may be 5 minutes. Another exemplary time interval duration may be 10 minutes.

[0034] The parameter values ​​of past operating parameters 320 may be related to past (i.e., previous) time intervals. That is, the past parameter values ​​of past operating parameters 320 may correspond to time intervals prior to the current time interval. Furthermore, each past parameter value of past operating parameters 320 may correspond to past time intervals of multiple time intervals prior to the current time interval. The parameter values ​​of current operating parameters 310 may be related to the current time interval. The current parameter values ​​of current operating parameters 310 may correspond to the current time interval. The current time interval may follow a past time interval associated with past operating parameters 320. The term “current” as used herein and where used elsewhere in this disclosure should be interpreted not literally, but in a broad, general sense. For example, the “current” time interval may be several minutes, several hours, or several days prior to the time when the filtered operating parameters 340 are determined. In some embodiments, the current parameter value may refer to the most recent or most recent measurement of the operating parameter used to determine the filtered operating parameters 340. For example, the current parameter value may be in contrast to past parameter values ​​in that past parameter values ​​may represent a moving average of the parameter based on the parameter's previous values, but the corresponding current parameter value may include parameter values ​​that follow (e.g., subsequently measured or determined) the parameter values ​​that constitute the moving average.

[0035] In some embodiments, the current parameter value can refer to multiple parameter values ​​for a given time block. For example, a given time block may be a portion of a day, a day, several days, or a week. Similarly, past parameter values ​​can refer to multiple parameter values ​​for a given time block preceding the current time block (e.g., a portion of a day, a day, several days, or a week). A time block may include multiple time intervals (e.g., multiple 5-minute intervals), and each time interval in the block corresponds to one or more parameter values. For example, the current parameter value may be the current parameter value for each time interval during recent weeks, and past parameter values ​​may be past parameter values ​​for the corresponding time intervals in previous weeks or weeks, or they may be represented (e.g., as moving averages). A time block may be subdivided, such as a week subdivided into several days. A particular current parameter value within the current time block may correspond to a past parameter value (or its moving average) for the same relative time interval within the time block. For example, the current parameter value on Tuesday, the relative time interval of 11:30-11:35 within the current time block (current week), is the same Tuesday, 11:30-11:35, but may correspond to past parameter values ​​(or their moving average) within past time blocks (previous weeks(s)). The relationship between the current parameter value within the current time block and past parameter values ​​within past blocks will be further examined with reference to Figure 4.

[0036] As described above, the past parameter values ​​of a past operating parameter 320 may be a moving average based on previous past parameter values ​​of a particular past operating parameter 320. The moving average of past parameter values ​​may be a specific time interval over a time block, such as two or more consecutive Wednesday 15:30-15:35 time intervals. Thus, the moving average of past parameter values ​​over a Wednesday 15:30-15:35 time interval may be based on the parameter values ​​of previous Wednesday 15:30-15:35 time intervals. The moving average may include a simple moving average, a cumulative moving average, or a weighted moving average. The moving average may also include an exponentially smoothed moving average, also known as an exponentially weighted moving average.

[0037] The current operating parameter 310 may include a heater parameter 312 associated with the current temperature of the hot melt adhesive in the dispensing system. In particular, the current operating parameter 310 may include the current parameter value of the heater parameter 312. The past operating parameter 320 may similarly include a heater parameter 322 associated with one or more past temperatures of the hot melt adhesive in the dispensing system. In particular, the past operating parameter 320 may include one or more past heater parameter 322 values. The past heater parameter 322 value may be a moving average of past heater parameters 322 based on previous heater parameter values ​​of a particular past heater parameter 322.

[0038] The heater parameters 312 and 322 may also be operating parameters for the heater of the dispensing system. Such a heater may comprise a melter (e.g., an adhesive supply unit 22 with an adhesive supply heater 34 in Figure 1), a heating hose (e.g., a heating hose 46), an applicator heater (e.g., an applicator heater 53), or a manifold heater (e.g., a manifold heater 56). In one embodiment, the heater comprises an applicator heater of the applicator. The heater parameters 312 and 322 may also include the duty cycle of the associated heater. The duty cycle parameter value may represent a percentage or ratio of time within a time interval in which the heater is activated. The duty cycle may be controlled at a time interval shorter than the time interval in which the other operating parameters 310 and 320 are collected (a partial time interval of the duty cycle). For example, the heater duty cycle may be updated at a partial time interval of 30 seconds, while the time interval in which the other operating parameters 310 and 320 are collected may be 5 or 10 minutes. The heater temperature may be checked according to shorter duty cycle sub-time intervals, and the heater duty cycle may be adjusted accordingly to maintain the target temperature. The duty cycle parameter value may represent the average duty cycle value within a time interval, such as the average duty cycle value over the duty cycle values ​​of the aforementioned shorter duty cycle sub-time intervals. The average duty cycle may be a weighted average, and this weighted average may be biased towards the end of the time interval (for example, biased towards the duty cycle values ​​of shorter duty cycle sub-time intervals at the end of a longer time interval).

[0039] The duty cycle parameter value may be related to the operation of the associated applicator, such as the gun cycle count within a time interval of the associated applicator. The associated applicator may be an applicator that is heated by a heater or that receives heated hot melt adhesive. For example, an applicator heater (applicator heater 53 in Figure 1) may be associated with an applicator (e.g., applicators 48, 50 in Figure 1), and therefore the duty cycle of the applicator heater may be related to the gun cycle count of the applicator. The parameter value of the duty cycle parameter may be additionally or alternatively associated with one or more adhesive dispensing modules of the applicator, including a single adhesive dispensing module of the applicator or all dispensing modules of the applicator.

[0040] The current operating parameter 310 may include an applicator parameter 314 associated with the current dispensing or application of hot melt adhesive by the dispensing system. In particular, the current operating parameter 310 may include the current parameter value of the applicator parameter 314. The past operating parameter 320 may similarly include an applicator parameter 324 associated with the past dispensing or application of hot melt adhesive by the dispensing system. In particular, the past operating parameter 320 may include one or more past parameter values ​​of the applicator parameter 324. The past applicator parameter 324 value may be a moving average of the past applicator parameter 324 based on previous applicator parameter values ​​of a particular past applicator parameter 324.

[0041] Applicator parameters 314, 324 may also be operating parameters of an applicator (e.g., applicators 48, 50 in Figure 1) and / or one or more adhesive dispensing modules (e.g., adhesive dispensing module 54), which will generally be referred to as the applicator unless otherwise specified. Applicator parameters 314, 324 may include a count (e.g., quantity) of gun cycles performed by the applicator during a time interval. Thus, each gun cycle parameter value may be temporally associated with a specific time interval. A gun cycle can refer to a single distinct instance of hot melt adhesive dispensing or application, such as an opening and closing cycle of the nozzle valve of the applicator. A gun cycle count may refer to a gun cycle of a single applicator (e.g., a single adhesive dispensing module) or to a collective gun cycle of two or more applicators (e.g., all gun cycles performed by multiple adhesive dispensing modules of an applicator).

[0042] Additional or alternative applicator parameters 314, 324 may include the duration of each gun cycle within a time interval, such as the average duration of gun cycles within a time interval. For example, shorter gun cycle durations may be associated with applicators configured to dispense small amounts (e.g., "dots") of hot melt adhesive at a high frequency during the time interval. Conversely, longer gun cycle durations may be associated with applicators configured to dispense larger amounts (e.g., lines) of hot melt adhesive at a lower frequency during the time interval. Additional or alternative applicator parameters 314, 324 may also include the amount (e.g., volume) of hot melt adhesive dispensed by each gun cycle, for example, the average amount of hot melt adhesive dispensed by gun cycles within a time interval.

[0043] Applicator parameter values ​​314 and 324 may be associated with heater parameter values ​​312 and 322. In some cases, heater parameter values ​​312 and 322 for a given time interval can be considered to correspond to applicator parameter values ​​314 and 324 for the same time interval. In other examples, heater parameter values ​​312 and 322 may be temporally offset from the associated applicator parameter values ​​314 and 324, such as one or more time intervals after the applicator parameter values ​​314 and 324. The offset may be determined to compensate for the delay in when a change in an applicator parameter value 314 or 324 (e.g., gun cycle count) causes or corresponds to a change in a heater parameter value 312 or 322 (e.g., duty cycle value).

[0044] The state parameter 330 can generally indicate the state of the applicator (and / or the entire dispensing system), such as the current state. The state parameter 330 may further indicate previous instances in which the applicator's state was changed, and / or the state of the dispensing system at a particular time (a state "snapshot"). The state parameter 330 may include the on / off state of the applicator (and / or the entire dispensing system). For an applicator in the off state, the state parameter 330 may include the time the applicator was turned off and the time the applicator was last turned on before it is currently turned off. For an applicator in the on state, the state parameter 330 may include the time the applicator was turned on and the time the applicator was last turned off before it is currently turned on. The off state may include a "sleep" state. Other further state parameters 330 of the dispensing system may include a "ready" state of the applicator (and / or the entire dispensing system). The state parameter 330 may include the time the applicator entered the current ready state and / or the time the applicator last entered the ready state. The ready state can refer to the applicator state in which the hot melt adhesive is at a suitable or preferred temperature for dispensing. The not-quite-ready state can refer to the applicator state in which the hot melt adhesive is at a temperature unsuitable or unfavorable for dispensing, such as the setback temperature.

[0045] The filtered operating parameters 340 may include heater parameters 342 and applicator parameters 344. Heater parameter 342 may be the same as heater parameter 312 of the current operating parameters 310 and heater parameter 322 of the past operating parameters 320. Thus, heater parameter 342 can refer to the duty cycle of the heater associated with the applicator. The duty cycle value may be related to a time interval. Furthermore, applicator parameter 344 can refer to the gun cycle of the applicator. The gun cycle count may be related to a time interval.

[0046] The filtered operating parameters 340 may be based on the current operating parameters 310, past operating parameters 320, and / or state parameters 330. In one embodiment, the filtered operating parameters 340 may be an updated version or instance of past operating parameters 320, which are updated based on the current operating parameters 310. Thus, determining the filtered operating parameters 340 may include filtering past operating parameters 320 based on the current operating parameters 310. Determining the filtered operating parameters 340 may also include determining or updating the moving average of past operating parameters 320 using the current operating parameters 310, which serve as additional (e.g., recent) data points to update the moving average. Thus, the filtered operating parameters 340 may include multiple moving averages for each parameter value.

[0047] As described above, the past operating parameter 320 may include the moving average of the heater parameter values ​​of the heater parameter 322. Therefore, determining the filtered heater parameter 342 may include updating the moving average of the past heater parameter 322 values ​​using the current heater parameter 312 value. The current heater parameter 312 value can be considered the most recent heater parameter value for the purpose of updating the moving average. Determining the filtered heater parameter 342 value of the filtered operating parameter 340 can be done according to the following equation (1). (Formula 1) d=f * c+(1-f) * d old

[0048] In equation (1), d represents the updated moving average of the heater parameter values ​​(i.e., the filtered heater parameter 342 values), f represents the filter coefficient, c represents the current heater parameter 312 value, and d oldThis represents 322 past heater parameter values. The filter coefficient f may be a number between 0 and 1, and may indicate the degree to which more recent heater parameter values ​​are weighted over more distant heater parameter values.

[0049] As mentioned above, the past operating parameter 320 may include the moving average of the past applicator parameter values ​​324. Therefore, determining the filtered applicator parameter 344 may include updating the moving average of the past applicator parameter 324 values ​​using the current applicator parameter 314 value. The current applicator parameter 314 value can be considered the most recent applicator parameter value for determining the updated moving average. Determining the filtered applicator parameter 344 value also includes d representing the updated moving average of the applicator parameter values ​​(i.e., the filtered applicator parameter 344 value), f representing the filter coefficient, c representing the current applicator parameter 314 value, and d old This can also be done using equation (1), except that it represents the past applicator parameter 324 value. The filter coefficient f used to determine the filtered applicator parameter 344 value may be different from or the same as the one used to determine the filtered heater parameter 342 value.

[0050] In one embodiment, the current operating parameters 310, past operating parameters 320, state parameters 330, and filtered operating parameters 340 may each be organized, in whole or in part, as one or more matrices. Such matrices can represent time blocks containing multiple time intervals. A time block may be further divided into sub-sub

[0051] Determining the filtered operating parameter 340 values ​​may include performing element-level and parameter-level updates on the moving average shown in the matrix of past operating parameter 320 values, based on the parameter values ​​shown in the corresponding (according to time intervals) elements of the matrix of current operating parameter 310 values.

[0052] Referring to Figure 4, the current operating parameter 310 values ​​are organized as the current operating parameter matrix 410, the past operating parameter 320 values ​​are organized as the past operating parameter matrix 420, and the filtered operating parameter 340 values ​​are organized as the filtered operating parameter matrix 440. The state parameter 330 values ​​may be represented in various ways in any of the aforementioned matrices. Matrices 410, 420, and 440 each represent a one-week time block. The matrix 410 of the current operating parameters 310 may represent a specific week, such as the current week or the most recent week. Since matrices 420 and 440 do not represent specifically measured parameter values ​​but generally show a moving average of parameter values, they may abstractly represent a one-week time block.

[0053] Matrices 410, 420, and 440 are each organized into a plurality of respective columns 418, 428, 448, each representing a day of the week. Matrices 410, 420, and 440 are also each organized into a plurality of respective rows 416, 426, 446, each representing a time interval of a day (according to the 24-hour clock format). The duration of the time interval for each row is 5 minutes. Thus, the first row is the time interval from 00:00 to 00:05, the second row is the time interval from 00:05 to 00:10, and so on. Each element of matrices 410, 420, and 440 represents one or more parameter values corresponding to the day of the week and the time interval during that day of the week. The parameter values of the elements are represented in FIG. 4 according to the format [曜日][時間間隔] and in FIG. 4, the [parameter] field indicates "w" for the heater parameter, "x" for the applicator parameter, "y" for the on / off state parameter, and "z" for the ready state parameter. Thus, w Sun1 |x Sun1 |y Sun1 |z Sun1 represents the heater parameter value, applicator parameter value, on / off state parameter value, and ready state parameter value for the time interval from 00:00 to 00:05 (column 1) on Sunday. The matrix 440 of the filtered operation parameters 340 further uses a prime symbol (') to represent an updated moving average of the parameter values.

[0054] The matrix 440 of the filtered operation parameter 340 values may be determined by updating the past moving average of matrix 420 in element units and parameter units based on the current parameter values shown in matrix 410. The past moving average of the parameter represented by a specific element of matrix 420 may be updated based on the current parameter value represented by the corresponding element of matrix 410. The updated moving average (for that day of the week and that time interval within that day of the week) may be shown in the corresponding element of matrix 440. The updated moving average can be determined using Equation (1).

[0055] As an example, for the time interval from 23:55 to 24:00 (w Sun288The historical moving average of the heater parameter values ​​for Sundays (represented in matrix 420) is calculated over the time interval (w) of the current (e.g., the most recent) Sunday from 23:55 to 24:00. Sun288 It is updated with the current heater parameter values ​​(also represented in matrix 410). The updated moving average of the heater parameter values ​​for the time interval from 23:55 to 24:00 on Sunday is w Sun288 This is represented in matrix 440 by '. The updated moving average of these heater parameter values ​​may also be determined according to equation (1), where c is w of matrix 410. Sun288 The current heater parameter value is represented by d old w in matrix 420 Sun288 This is a moving average of the heater parameter values ​​represented by w in matrix 440, where d is w Sun288 This is an updated moving average of the heater parameter values ​​represented by '.

[0056] x in matrix 440 Sun288 The updated moving average of the applicator parameter values ​​for the time interval from 23:55 to 24:00 on Sunday, represented by ', is similarly the historical moving average of the applicator parameter values ​​(in matrix 420 of the corresponding elements x Sun288 (represented by) the current applicator parameter value for the current (for example, the most recent) Sunday time interval from 23:55 to 24:00 (same as x in matrix 410 of the corresponding elements) Sun288 The updated on / off and ready state parameter values ​​(y) on Sunday are determined by updating them. The updated moving average of the applicator parameter values ​​for the time interval from 23:55 to 24:00 on Sunday can also be determined using equation (1). Sun288 'and z Sun288 The values ​​(represented in matrix 440 by ') are updated at the time interval of 23:55 to 24:00, and the current on / off state and ready state parameter values ​​(y Sun288 and z Sun288The matrix 410 is updated to reflect the corresponding elements. A similar process can be used to determine each element of the filtered operation parameter matrix 440, as well as the heater, applicator, and / or state parameter values.

[0057] The current operation parameter matrix 410 may be determined as the parameter values ​​of its elements are determined. For example, the elements of matrix 410 may be updated in real time or near real time. Alternatively, matrix 410 and its elements may be determined all at once. Similarly, the filtered operation parameter matrix 440 may be determined as the elements of matrix 440 are determined. For example, the elements of matrix 440 may be determined when the corresponding elements of the current operation parameter matrix 410 are determined. Alternatively, matrix 440 and its elements may be determined all at once, for example, after all the elements of the current operation parameter matrix 410 have been determined.

[0058] Focusing on Figure 3, the filtered operating parameters 340 may be used to determine one or more instructions 350. Instructions 350 may relate to one or more operating parameters of the dispensing system. For example, instruction 350 may relate to an applicator heater or another heater in the dispensing system. Such instruction 350 can cause the applicator heater to raise its target temperature, lower its target temperature, and / or set its target temperature. Instruction 350 may set the heater to a setback temperature. Instruction 350 can cause the heater to be turned off, turned on, put into sleep mode, or "wake" from sleep mode. Instructions can cause the dispensing system to be turned off, turned on, put into sleep mode, or "wake" from sleep mode. Instruction 350 may indicate the time for which the aforementioned actions are performed or become effective.

[0059] Instruction 350 may indicate a set of instructions to be executed over a period of time. The set of instructions may include a schedule in which the dispensing system and its components operate. The schedule may indicate the days and times when various instructions become effective. For example, the schedule may indicate a first on-time for the heater on a weekday and a different second on-time for the heater on a weekend. These on-times may be optimized so that the hot melt adhesive reaches the ready temperature when the dispensing system later begins production, but not substantially earlier. As another example, the schedule may indicate the time and setback temperature for the dispensing system to enter setback mode, and the time and setback temperature for the dispensing system to enter normal mode and raise the temperature of the hot melt adhesive in the applicator to the dispensing temperature.

[0060] Instruction 350 may be implemented in electronic or digital form. For example, instruction 350 may include digital data that can be determined by a remote computer system (e.g., computer system 230 in Figure 2) and transmitted to a controller of the dispensing system via a network (e.g., network 210 in Figure 2). The controller can receive and process instruction 350 and execute it. Instruction 350 may also include electrical control signals from the controller to one or more components of the dispensing system, such as an applicator heater. The controller can execute the instruction without intervention from a local user.

[0061] Figure 5 shows a flowchart of Method 500 for determining one or more instructions to operate a hot melt liquid dispensing system (e.g., the hot melt adhesive system 10 in Figure 1). In exemplary embodiments, Method 500 may include compiling records of historical applicator parameter values ​​(e.g., gun cycle count) for the applicator (each time-associated with an applicator time interval) and records of relevant historical heater parameter values ​​(e.g., duty cycle value) for the heater (likewise each time-associated with a time interval). Historical applicator parameter values ​​time-associated with each time interval may be filtered based on the current applicator parameter value corresponding to that time interval (e.g., updated as a moving average). Similarly, historical heater parameter values ​​time-associated with each time interval may be filtered based on the current applicator parameter value corresponding to that time interval (e.g., updated as a moving average). Based on the filtered applicator and heater parameter values, instructions to operate the hot melt liquid dispensing system and / or its components may be determined. For example, a command may cause a hot melt liquid heater to raise or lower the temperature of the hot melt liquid supplied to the applicator at a specific time. This specific time may correspond to a period during which the active operation of the hot melt liquid dispensing system is temporarily interrupted.

[0062] In step 502, a plurality of past applicator parameter values ​​for a first operating parameter of the hot melt liquid dispensing system applicator (e.g., applicators 48, 50 and / or adhesive dispensing module(s) 54 in Figure 1) may be provided. The past applicator parameter values ​​may be the same as or similar to the past applicator parameter 324 values ​​in Figure 3. The past applicator parameter values ​​may include a count of gun cycles of the applicator within a time interval. Each of the plurality of past applicator parameter values ​​may be temporally associated with a past time interval of a past time block. For example, the plurality of past applicator parameter values ​​may be realized as a matrix of past parameter values ​​(e.g., matrix 420 in Figure 4), where each element of the matrix represents a past applicator parameter value and the time interval temporally associated with that past applicator parameter value. The matrix may represent a past time block of one week and may be further divided into days of the week corresponding to the columns of the matrix. The time interval may include, for example, a duration of 5 minutes.

[0063] In step 504, a plurality of past heater parameter values ​​for a second operating parameter of the hot melt liquid heater of the hot melt liquid dispensing system (e.g., applicator heater 53 in Figure 2) may be provided. The past heater parameter values ​​may be the same as or similar to the past heater parameter 322 values ​​in Figure 3. The past heater parameter values ​​may include the duty cycle of the hot melt liquid heater. Each of the plurality of past heater parameter values ​​may be temporally associated with a past applicator parameter value. For example, a past heater parameter value may be temporally associated with the same past time interval as the associated past applicator parameter value. As another example, a past heater parameter value may be temporally associated with a past time interval offset from the time interval of the associated past applicator parameter value. The plurality of past heater parameter values ​​may be represented together with the plurality of past applicator parameter values ​​in a matrix of past parameter values. For example, a past heater parameter value and its associated past applicator parameter value may be represented in the same element of the matrix.

[0064] Past applicator parameter values ​​associated with a specific past time interval (e.g., day of the week time interval) may include a moving average of previous past applicator parameter values ​​(of the applicator's first operating parameter) that are each associated with the corresponding past time interval of a previous past block (e.g., a previous day and / or week). Similarly, past heater parameter values ​​associated with a specific past time interval may include a moving average of previous past heater parameter values ​​(of the hot melt liquid heater's second operating parameter) that are associated with the corresponding past time interval of a previous past time block.

[0065] In step 506, the current applicator parameter value of the applicator's first operating parameter may be received. The current applicator parameter value may be the same as or similar to the current applicator parameter 314 value in Figure 3. The current applicator parameter value may be temporally associated with the current time interval. The current applicator parameter value may include the count of the applicator's Gun cycles in the current time interval. The current applicator parameter value may be temporally associated with the current time interval corresponding to a first past time interval in a past time block. For example, the current applicator parameter value may be temporally associated with the current time interval from 00:05 to 00:10 on Saturday, where the current time interval may correspond to a past time interval represented in the past operating parameter matrix 420 in Figure 4 within the element at the intersection of the "Sunday" column and the "00:10" row. By extension, the current applicator parameter value may be associated with a past applicator parameter value that is temporally associated with the corresponding first past time interval described above. The current applicator parameter value may be one of several current applicator parameter values, each of which is temporally associated with the current time interval, as shown in the current operation parameter matrix 410 in Figure 4.

[0066] In step 508, the current heater parameter value of the second operating parameter of the hot melt liquid heater may be received. The current heater parameter value may be the same as or similar to the current heater parameter 312 value in Figure 3. The current heater parameter value may include the duty cycle value of the hot melt liquid heater. The current heater parameter value may be associated with the current applicator parameter value. For example, the current heater parameter value may be temporally associated with the current time interval referred to with respect to the current applicator value. In one embodiment, both the current heater parameter value and the current applicator parameter value may correspond to the same time interval. In another embodiment, the current heater parameter value may correspond to a time interval that is temporally offset from the time interval corresponding to the current applicator parameter value.

[0067] By being associated with the current applicator parameter value, the current heater parameter value may be associated with past applicator parameter values. For example, both the current applicator parameter value and the current heater parameter value may be temporally associated with the same current time interval, and past applicator parameter values ​​and past heater parameter values ​​may be temporally associated with past time intervals corresponding to their current time intervals. The current heater parameter value may be one of several current heater parameter values, each temporally associated with the current time interval, as shown in the current operating parameter matrix 410 in Figure 4.

[0068] In step 510, the filtered applicator parameter value of the applicator's first operating parameter (e.g., the filtered applicator parameter value 344 in Figure 3) may be determined based on the current applicator parameter value and a past applicator parameter value among a plurality of past applicator parameter values. The past applicator parameter value used as a criterion for determining the filtered applicator parameter value may be temporally associated with a first past time interval of a past time block corresponding to the current time interval (referenced with respect to step 506). That is, both the current applicator parameter value and the past applicator parameter value may be temporally associated with the corresponding time interval. In one embodiment, the past applicator parameter value may include a moving average of the applicator's first operating parameter. Thus, determining the filtered applicator parameter value may include updating the moving average indicated by the past applicator parameter value, and the current applicator parameter value acts as a later or more recent data point for the applicator's first operating parameter.

[0069] In step 512, the filtered heater parameter value of the second operating parameter of the hot melt liquid heater (e.g., the filtered heater parameter value 342 in Figure 3) may be determined based on the current heater parameter value and a past heater parameter value among a plurality of past heater parameter values. The past heater parameter value used to determine the filtered heater parameter value may be associated with the first past time interval described above with respect to the filtered applicator parameter value. For example, the past heater parameter value used as a criterion for determining the filtered heater parameter value may be associated with a past applicator parameter value used to determine the filtered applicator parameter value. Specifically, the past heater parameter value used to determine the filtered heater parameter value may be associated with a past applicator parameter value that is temporally associated with a first past time interval of a past time block. For example, the past heater parameter value used to determine the filtered heater parameter value may be temporally associated with a past time interval corresponding to the current time interval.

[0070] The filtered applicator parameter values ​​and filtered heater parameter values ​​may be represented in the filtered operating parameter matrix 440 in Figure 4. The filtered applicator parameter values ​​and filtered heater parameter values ​​may be temporally associated with the same time interval. For example, the filtered applicator parameter values ​​are represented in matrix 440 as X Sat1 It may also be represented as ', and the filtered heater parameter values ​​are in matrix 440 W Sat1 They can also be represented as ', and both are temporally related to the time interval of Saturday from 00:00 to 00:05. The filtered applicator parameter values ​​are X Sat1The current applicator parameter values ​​for the time interval from 00:00 to 00:05 on the current Saturday, represented by the current operating parameter matrix 410, and X Sat1 The filtered heater parameter values ​​may also be determined based on past applicator parameter values ​​for past Saturday time intervals from 00:00 to 00:05 in the past operating parameter matrix 420, which is also represented by W. Sat1 The current heater parameter values ​​for the time interval of 00:00~00:05 on the current Saturday, represented by the current operating parameter matrix 410, and W Sat1 The heater parameter values ​​may also be determined based on past heater parameter values ​​for the 00:00-00:05 time interval on past Saturdays in the past operating parameter matrix 420, which is also represented by the past operating parameter matrix 420. The corresponding process may be carried out to determine further elements of the filtered operating parameter matrix 440 (i.e., further filtered applicator parameter values ​​and / or further filtered heater parameter values).

[0071] In step 514, a command (e.g., command(s) 350 in Figure 3) may be determined based on the filtered applicator parameter values ​​and the filtered heater parameter values. The determined command may include a command to operate the hot melt liquid dispensing system or its components according to the operating parameter value of a third operating parameter of the hot melt liquid adhesive system. For example, this command may be for operating the hot melt liquid heater. Furthermore, the third operating parameter may include the operating parameter of the hot melt liquid heater. The operating parameter value of the third operating parameter may include a target temperature for the hot melt liquid heater, such as a predetermined dispensing temperature or a predetermined setback temperature. The determined command may include a command for the hot melt liquid heater to interrupt the application of heat to the hot melt liquid, a command for the hot melt liquid heater to start the application of heat to the hot melt liquid, or a command for the hot melt liquid heater to enter at least one of on mode, off mode, or ready mode. The determined command may include a command for the hot melt liquid dispensing system to enter an operating mode which includes at least one of on mode, off mode, or ready mode.

[0072] At least a portion of Method 500 may be carried out by a computer system located away from the hot melt liquid dispensing system, such as the computer system 230 in Figure 2. For example, the remote computer system may provide a plurality of past applicator parameter values ​​and / or a plurality of past heater parameter values. The remote computer system can store such parameter values ​​and provide them from a storage device. As another example, the remote computer system may receive current applicator parameter values ​​and / or current heater parameter values ​​from the controller of the hot melt liquid dispensing system, for example. Using the plurality of past applicator parameter values ​​and past heater parameter values ​​provided from the storage device and the current applicator parameter values ​​and current heater parameter values ​​received from the hot melt liquid dispensing system, the remote computer system may determine filtered applicator parameter values ​​and filtered heater parameter values. Furthermore, the remote computer system may determine instructions for operating the hot melt liquid dispensing system. The remote computer system may send the instructions to the controller of the hot melt liquid dispensing system to execute the instructions. The instructions may include control signals generated by the controller.

[0073] This specification further discloses techniques for predicting failure times of applicators (e.g., applicators 48, 50 and / or adhesive dispensing module 54 in Figure 1) of a hot melt liquid dispensing system (e.g., hot melt adhesive system 10 in Figure 1). Such failures may be related to air leakage in or by the applicator, which has been observed to be particularly related to an increase in the duty cycle of the associated heater (e.g., applicator heater 53 in Figure 1). "Failure" is not limited to complete failure of operation but may also include applicator conditions in which performance is unacceptably degraded. For example, applicator performance below or outside a threshold range may be considered an applicator failure. Applicator performance can be measured according to the operating parameters of other components, including the duty cycle of the heater.

[0074] The failure prediction time for the applicator may be determined based on data at least partially described in relation to Figure 3. For example, the failure prediction time may be determined based on current operating parameter 310 values, including current heater parameter 312 values ​​(e.g., current duty cycle) and current applicator parameter 314 values ​​(e.g., current gun cycle count). The failure prediction time may be further determined based on past operating parameter 320 values, including past heater parameter 322 values ​​(e.g., past duty cycle) and past applicator parameter 324 values ​​(e.g., past gun cycle count). The failure prediction time may also be further determined based on state parameters 330, such as the current or past on, off, or ready state of the applicator, heater, or hot melt liquid dispensing system.

[0075] In one embodiment, the heater duty cycle value may be determined for time intervals in which the applicator did not perform gun cycles. Alternatively, the heater duty cycle value may be determined for time intervals in which the applicator performed multiple gun cycles. The duty cycle value for time intervals without gun cycles and the duty cycle value for time intervals with multiple gun cycles can be compared to determine the failure prediction time. The average gun cycle count for those time intervals with multiple gun cycles can also be determined and used to determine the failure prediction time. The duty cycle value for time intervals without gun cycles, the duty cycle value for time intervals with multiple gun cycles, and the gun cycle count for time intervals with multiple gun cycles may each be averaged over time intervals of one day or other time blocks. The relationship between the three averages can be used to determine the failure prediction time.

[0076] Similar analyses of Gun cycle counts and duty cycle values ​​may be performed for the time interval on the second day. Duty cycle values ​​for the second day time interval without Gun cycles, duty cycle values ​​for the second day time interval with multiple Gun cycles, and Gun cycle counts for the second day time interval with multiple Gun cycles may also be averaged. The relationships between the three averages on the second day may be compared to similar relationships between the three averages on the first day. This comparison may be a further criterion for determining the failure prediction time. In addition, similar duty cycle / Gun cycle relationships for additional days can be determined and analyzed in relation to the duty cycle / Gun cycle relationships for the first day and the duty cycle / Gun cycle relationships for the second day. For example, the duty cycle / Gun cycle relationships for each day can be plotted on a graph to identify trends indicating failure prediction time. Trends may be identified by fitting a curve (e.g., a mathematical function) to the data points plotted on the graph.

[0077] Figure 6 shows a flowchart of a method 600 for predicting the failure time of an applicator (e.g., applicators 48, 50 and / or adhesive dispensing module 54 in Figure 1) of a hot melt liquid dispensing system (e.g., hot melt adhesive system 10 in Figure 1) having a heater associated with the applicator (e.g., applicator heater 53 in Figure 1). In step 602, a plurality of applicator parameter values ​​may be provided for a first operating parameter of the applicator (e.g., applicator parameters 314, 324 in Figure 3). Each applicator parameter value of the plurality of applicator parameter values ​​may be temporally associated with a time interval of a first time block. The first operating parameter of the applicator may be a count of gun cycles performed by the applicator within a time interval (e.g., the applicator speed and / or response time within the time interval). Thus, the applicator parameter value may include a gun cycle count for a temporally related time interval. The applicator parameter value may represent a count of zero, one, or more gun cycles.

[0078] The first time block may include the first day or a portion thereof. The time intervals of the first day or other time blocks do not need to be included in every possible time interval within the first day or other time blocks. For example, the time intervals of the first time block may be limited to the time intervals in which at least one of the applicator, heater, or hot melt liquid dispensing system is turned on. Additionally or alternatively, the time intervals of the first time block may be limited to the time intervals in which at least one of the applicator, heater, or hot melt liquid dispensing system is in a ready state. The time intervals may have durations ranging from 1 minute to 10 minutes. For example, the time intervals may have durations of 5 minutes or 10 minutes.

[0079] In step 604, a plurality of heater parameter values ​​for the heater's second operating parameter (e.g., heater parameters 312, 322 in Figure 3) may be provided. Step 604 may be optional in some embodiments, and method 600 may instead proceed to step 606. Each heater parameter value of the plurality of applicator parameter values ​​may be associated with an applicator parameter value among the plurality of applicator parameter values. Each heater parameter value may be further temporally associated with a time interval in the first time block. The heater's second operating parameter may include the heater's duty cycle in the time interval. Both the heater parameter value and the associated applicator parameter value may be temporally associated with the same time interval in the first time block. Alternatively, the heater parameter value may be temporally associated with a time interval offset from the time interval of the temporally associated applicator parameter value, for example, to compensate for a delay effect on the heater's duty cycle caused by a change in the applicator's gun cycle.

[0080] In step 606, a first subset of applicator parameter values ​​from among a plurality of applicator parameter values ​​may be determined. The first subset of applicator parameter values ​​(and the second subset discussed below) may be determined according to whether a given applicator parameter value from among the plurality of applicator parameter values ​​indicates the dispensing activity of the applicator during each time interval, in particular the gun cycle count of the applicator during each time interval, more specifically, whether a given applicator parameter value from among the plurality of applicator parameter values ​​indicates the absence of gun cycles during a time-related interval (e.g., zero gun cycle count) or the presence of one or more gun cycles during a time-related interval (e.g., non-zero or multiple gun cycle count). The first subset of applicator parameter values ​​may include applicator parameter values ​​from among the plurality of applicator parameter values ​​that indicate the absence of dispensing activity during a time-related interval, i.e., a zero gun cycle count.

[0081] In step 608, a second subset of applicator parameter values ​​may be determined from among a plurality of applicator parameter values. The second subset of applicator parameter values ​​may include applicator parameter values ​​that indicate the dispensing activity of the applicator during a time-related time interval. The second subset of applicator parameter values ​​may include applicator parameter values ​​that exceed the applicator parameter value or are within the threshold applicator parameter value range. For example, the second subset of applicator parameter values ​​may include applicator parameter values ​​that indicate a gun cycle count that exceeds the threshold gun cycle count or is within the threshold range of the gun cycle count. The threshold gun cycle count may be zero, and therefore the second subset of applicator parameter values ​​may include all applicator parameter values ​​that indicate a non-zero gun cycle count. Alternatively, the threshold gun cycle count may be greater than zero, and therefore, neither the first subset nor the second subset of applicator parameter values ​​may include some applicator parameter values.

[0082] In step 610, a first subset of heater parameter values ​​may be determined from among a plurality of heater parameter values, and each heater parameter value in the first subset of heater parameter values ​​(e.g., the duty cycle value of the heater for a given time interval) is associated with an applicator parameter value in the first subset of applicator parameter values. Thus, each heater parameter value in the first subset of heater parameter values ​​can be associated with an applicator parameter value that does not indicate dispensing activity by the applicator (e.g., zero gun cycle count) during a time interval temporally associated with the applicator parameter value. For example, each heater parameter value in the first subset of heater parameter values ​​may be temporally associated with a time interval during which no dispensing activity occurred by the applicator. Step 610 may be optional in some embodiments, and method 600 may instead proceed to steps 614a and / or 614b.

[0083] In step 612, a second subset of heater parameter values ​​may be determined from among a plurality of heater parameter values, and each heater parameter value in the second subset of heater parameter values ​​(e.g., the duty cycle value of the heater for a given time interval) is associated with a second subset of applicator parameter values ​​from among the applicator parameter values. Thus, each heater parameter value in the second subset of heater parameter values ​​can be associated with an applicator parameter value in the second subset of applicator parameter values ​​that indicates discharge activity (e.g., non-zero or multiple gun cycle counts) during a time interval temporally associated with the applicator parameter value. For example, each heater parameter value in the second subset of heater parameter values ​​may be temporally associated with a time interval during which discharge activity by the applicator occurred. Step 612 may be optional in some embodiments, and method 600 may instead proceed to steps 614a and / or 614b.

[0084] The first and / or second subsets of applicator parameter values, and / or the first and / or second subsets of heater parameters, may be further restricted to include only parameter values ​​that are temporally associated with time intervals in which at least one of the heater, applicator, or hot melt liquid dispensing system (if applicable) is in a ready state. The first and / or second subsets of applicator parameter values, and / or the first and / or second subsets of heater parameter values, may be additionally or alternatively restricted to include only parameter values ​​that are temporally associated with time intervals in which the hot melt liquid supplied to the applicator is at a suitable or preferred temperature for dispensing. For example, the first subset of applicator parameter values ​​and the first subset of heater parameter values ​​may be restricted to exclude parameter values ​​that are temporally associated with time intervals in which the hot melt liquid dispensing system is turned off, even if no dispensing activity occurs during those time intervals.

[0085] Method 600 may include either or both of steps 614a and 614b. In steps 614a and / or 614b, the applicator failure prediction time can be determined. The failure prediction times shown in steps 614a and 614b may refer to the same failure prediction time. In step 614a, the applicator failure prediction time can be determined based on a first subset and a second subset of applicator parameter values. In step 614b, the applicator failure prediction time can be determined based on a first subset and a second subset of heater parameter values. If Method 600 includes both steps 614a and 614b, the applicator failure prediction time can be determined based on a first subset of applicator parameter values, a second subset of applicator parameter values, a first subset of heater parameter values, and a second subset of heater parameter values. Alternatively (though not shown), the applicator failure prediction time may be determined based on a first subset of heater parameter values ​​and a second subset of heater parameter values. That is, method 600 in this example may include step 614b, but may not include step 614a.

[0086] For example, the applicator failure prediction time may be determined based on one or more heater parameter values ​​(e.g., duty cycle values) that are time-associated with each time interval in which no discharging activity occurred by the applicator (zero gun cycle counts), and one or more heater parameter values ​​(e.g., duty cycle values) that are time-associated with each time interval in which discharging activity occurred by the applicator (non-zero or multiple gun cycle counts). Determining the failure prediction time may include comparing one or more heater parameter values ​​from a first subset of heater parameter values ​​with one or more heater parameter values ​​from a second subset of heater parameter values.

[0087] The failure prediction time may further be based on the average of duty cycle values ​​temporally associated with time intervals in which no gun cycles occur, and the average of duty cycle values ​​temporally associated with time intervals in which one or more gun cycles occur. The first time block may include one day, thereby averaging the two duty cycle averages day by day. The two duty cycle averages may be compared with each other when determining the failure prediction time. Thus, determining the failure prediction time may further include comparing the average of a first subset of heater parameter values ​​with the average of a second subset of heater parameter values.

[0088] The applicator failure prediction time may be based further on non-zero Gun cycle counts, such as the average of non-zero Gun cycle counts that occurred during two or more time intervals in a first time block. For example, the failure prediction time may be based on the average duty cycle values ​​temporally associated with time intervals in which no Gun cycles occurred, the average duty cycle values ​​temporally associated with time intervals in which one or more Gun cycles occurred, and the average Gun cycle counts temporally associated with time intervals in which one or more Gun cycles occurred. Thus, the applicator failure prediction time may be based on the average duty cycle value of a first subset of heater parameter values, the average duty cycle value of a second subset of heater parameter values, and the average Gun cycle count of a second subset of applicator parameter values.

[0089] The applicator failure prediction time may be based on a relationship between the average duty cycle value of a first subset of heater parameter values, the average duty cycle value of a second subset of heater parameter values, and the average gun cycle count of a second subset of applicator parameter values ​​(i.e., a first parameter relationship associated with a first time block). The first parameter relationship may reflect the difference between the average duty cycle value of the second subset of heater parameter values ​​and the average duty cycle value of the first subset of heater parameter values. The first parameter relationship may further include a relationship between the average gun cycle count of the second subset of applicator parameter values ​​(e.g., a non-zero or multiple gun cycle count) and the above difference between the average duty cycle value of the second subset of heater parameter values ​​and the average duty cycle value of the first subset of heater parameter values. For example, the first parameter relationship may be reflected in the following equation (2).

number

[0090] In equation (2), R may be a value representing the first parameter relation (or other similar relation associated with another time block). R may represent a slope or other relation suitable for plotting on a graph including a y-axis showing the increase in duty cycle value of an applicator in a “failed” state and an x-axis showing the increase in duty cycle value of an applicator that is not in a failed state. g A0 may represent the average duty cycle value of a second subset of heater parameter values ​​(temporally associated with the non-zero gun cycle count time interval), and A0 may represent the average duty cycle value of a first subset of heater parameter values ​​(temporarily associated with the zero (0) gun cycle count time interval). g may represent the average gun cycle count of a second subset of applicator parameter values ​​(e.g., a non-zero or multiple gun cycle count).

[0091] The applicator failure prediction time may further be determined based on additional applicator and heater parameter values ​​that are temporally associated with time intervals of one or more additional time blocks, such as one or more additional days. For example, method 600 may further include providing a second plurality of applicator parameter values ​​for a first operating parameter of the applicator (e.g., gun cycle count) and providing a second plurality of heater parameter values ​​for a second operating parameter of the heater (e.g., duty cycle value). The second plurality of applicator parameter values ​​may be similar to the first plurality of applicator parameter values, except that each applicator parameter value of the second plurality of applicator parameter values ​​may be temporally associated with a time interval of a second time block. For example, the first time block may be the first day, and the second time block may be the second day. The first and second time blocks do not have to overlap.

[0092] Similarly, the second set of heater parameter values ​​may be similar in some ways to the first set of heater parameter values, except that each heater parameter value in the second set of heater parameter values ​​may be associated with an applicator parameter value among the second set of applicator parameter values. Each heater parameter value in the second set of heater parameter values ​​may be temporally associated with a time interval of a further second time block, such as the same time interval as the time interval of the applicator parameter value associated with the heater parameter value.

[0093] Method 600 may further include determining third and fourth subsets of applicator parameter values ​​from a second set of applicator parameter values. In some embodiments, similar to the first subset of applicator parameter values ​​(associated with the first time block), each applicator parameter value in the third subset of applicator parameter values ​​may indicate that no discharging activity by the applicator occurred during the temporally relevant time interval of the second time block. Thus, each applicator parameter value in the third subset of applicator parameter values ​​may indicate a gun cycle count of zero. In some embodiments, similar to the second subset of applicator parameter values ​​(associated with the first time block), each applicator parameter value in the fourth subset of applicator parameter values ​​may indicate that discharging activity by the applicator occurred during the temporally relevant time interval of the second time block. Thus, each applicator parameter value in the fourth subset of applicator parameter values ​​may indicate a non-zero or multiple gun cycle count.

[0094] Method 600 may further include determining third and fourth subsets of heater parameter values ​​from a second set of heater parameter values. In some embodiments, similar to the first subset of heater parameter values ​​(associated with a first time block), each heater parameter value in the third subset of heater parameter values ​​may be associated with an applicator parameter value from the third subset of applicator parameter values. Thus, each heater parameter value in the third subset of heater parameter values ​​may be associated with a zero gun cycle count, such as a time interval in which no discharge activity occurs. In some embodiments, similar to the second subset of heater parameter values ​​(associated with a first time block), each heater parameter value in the fourth subset of heater parameter values ​​may be associated with an applicator parameter value from the fourth subset of applicator parameter values. Thus, each heater parameter value in the fourth subset of heater parameter values ​​can be associated with a non-zero or multiple gun cycle count, such as a time interval in which discharge activity occurs by the applicator.

[0095] In method 600, the applicator failure prediction time may further be based on a third subset and a fourth subset of heater parameter values. For example, the applicator failure prediction time may be based on the heater duty cycle value (e.g., zero gun cycle count) temporally associated with the time interval of a second time block in which no dispensing activity by the applicator occurred, and the heater duty cycle value (e.g., non-zero or multiple gun cycle count) temporally associated with the time interval of a second time block in which dispensing activity by the applicator occurred.

[0096] The failure prediction time may further be based on the average duty cycle value of a third subset of heater parameter values, the average duty cycle value of a fourth subset of heater parameter values, and the average gun cycle count of a fourth subset of applicator parameter values. In particular, the failure prediction time for the applicator may be based on the relationship between the average duty cycle value of the third subset of heater parameter values, the average duty cycle value of the fourth subset of heater parameter values, and the average gun cycle count of a fourth subset of applicator parameter values ​​(i.e., a second parameter relationship associated with a second time block). Similar to the first parameter relationship associated with a first time block, the second parameter relationship may reflect the difference between the average duty cycle value of the fourth subset of heater parameter values ​​and the average duty cycle value of the third subset of heater parameter values. Furthermore, similar to the first parameter relationship, the second parameter relationship may further include the relationship between the average gun cycle count (e.g., non-zero or multiple gun cycle counts) of a fourth subset of applicator parameter values ​​and the above-mentioned difference between the average duty cycle value of the fourth subset of heater parameter values ​​and the average duty cycle value of the third subset of heater parameter values. Furthermore, similar to the first parameter relationship, the second parameter relationship can be expressed in equation (2).

[0097] Determining the failure prediction time for an applicator may include comparing a first parameter relationship associated with a first time block (e.g., the first day) with a second parameter relationship associated with a second time block (e.g., the second day). Comparing the first and second parameter relationships may include determining a trend (e.g., a statistical trend) between the first and second parameter relationships. The trend may be related to a gun cycle count and the heater duty cycle value associated with this gun cycle count. Determining the failure prediction time for an applicator may further include fitting a curve (e.g., a mathematical function) to the trend, such as when the first and second parameter relationships are plotted on a graph.

[0098] Determining the failure prediction time of an applicator may be based on one or more other parameter relationships in addition to the first and second parameter relationships. Each of the one or more other parameter relationships may be associated with a different time block (e.g., a day) than the first and second time blocks. Each of the one or more other parameter relationships may be based on each of several applicator and heater parameter values ​​that are temporally associated with each of the other time blocks. Each of the one or more other parameter relationships may, in some embodiments, be determined in a manner similar to how the first and second parameter relationships may be determined.

[0099] Therefore, determining the failure prediction time of the applicator may further include performing comparisons between the first, second, and one or more other parameter relationships. The comparisons may include determining trends (e.g., statistical trends) between the first, second, and one or more other parameter relationships. The comparisons may further include determining a curve that fits the trends, such as when the first, second, and one or more other parameter relationships are plotted on a graph.

[0100] Those skilled in the art will understand that the systems and methods disclosed herein are implemented via computing device components that may, but are not limited to, one or more processors, system memory, and a system bus for connecting various system components, such as coupling a processor to system memory. In the case of multiple processors, the system may utilize parallel computing.

[0101] For illustrative purposes, 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 may sometimes reside in different storage components of a computing device and be executed by the computer's data processor(s). Implementations of service software may be stored in or transmitted through some form of computer-readable medium. All disclosed methods may be executed by computer-readable instructions embodied on the computer-readable medium. The computer-readable medium may be any available medium accessible by a computer. Not as an exercise but as an example, computer-readable medium may include “computer storage medium” and “communication medium.” “Computer storage medium” includes volatile and non-volatile, removable and non-removable media implemented by any method or technique for storing information, such as computer-readable instructions, data structures, program modules, or other data. The computer storage media described herein include, but are not limited to, RAM, ROM, EEPROM, flash memory or other memory technologies, CD-ROM, digital versatile disk (DVD) or other optical storage, magnetic cassette, magnetic tape, magnetic disk storage or other magnetic storage devices, or any other media that can be used to store desired information and are accessible by a computer. Application programs and / or storage media may be implemented at least partially on a remote system.

[0102] When used herein and in the appended claims, the singular forms “a,” “an,” and “the” encompass multiple references unless otherwise explicitly indicated in the context. Hereinafter, numerical ranges may be expressed as starting from a particular value preceded by “approximately” and / or ending with another particular value preceded by “approximately.” When one range is expressed in this manner, other embodiments include the range starting from and / or ending with that particular value. Similarly, when a value is indicated by an approximate value preceded by “approximately,” that particular value should be understood to be valid in other embodiments as well. Furthermore, each endpoint of a range should be understood to be valid in relation to and independently of the other endpoints.

[0103] The descriptions of value ranges in this specification are merely intended as a simplified method of referring individually to each distinct value within the range unless otherwise specified herein, and each distinct value is incorporated herein as it is individually listed herein.

[0104] Throughout this specification and the claims, the term “comprise” and its variations, such as “comprising” and “comprises,” are intended to mean “inclusive of, but not limited to,” and not to exclude, for example, other components, integers, or processes. 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 restrictive sense and is used for illustrative purposes only.

[0105] Components that may be used to carry out the disclosed methods and systems are disclosed herein. While these and other components are disclosed herein, and combinations, subsets, interactions, groups, etc., of these components are disclosed, even if each of the various individual and collective combinations and rearrangements thereof are not explicitly mentioned, it should be understood that each is considered and described herein for all methods and systems. This principle applies to all aspects of this application, but is not limited to the steps of the disclosed methods. Therefore, where various additional steps may be carried out, it should be understood that each of these additional steps may be carried out in conjunction with any particular embodiment of the disclosed method or any combination thereof.

[0106] Unless otherwise explicitly stated, no method described herein is intended to be understood as requiring its steps to be performed in a particular order. Therefore, if a claim for a method does not actually specify the order in which its steps should be followed, or if it is not specifically stated in the claims or description that the steps are restricted to a particular order, it is not intended in any way that any order is implied. This applies to implicit grounds that may include interpretation, including issues of logic regarding the arrangement of steps or operational flows, plain meanings arising from grammatical systems or punctuation, and the number or types of embodiments described herein.

[0107] It will be apparent to those skilled in the art that various modifications and changes can be made without departing from the scope or spirit of this specification. Other embodiments will also be apparent to those skilled in the art, given the specification and the practices disclosed therein. It is intended that the specification and examples are to be considered merely illustrative, and that the true scope and spirit are indicated by the following "Claims."

Claims

1. A method for predicting failure of an applicator in a hot melt liquid dispensing system, wherein the applicator is configured to dispense hot melt liquid, the hot melt liquid dispensing system further includes a hot melt liquid heater associated with the applicator, and the method is To provide a plurality of applicator parameter values ​​for a first operating parameter of the applicator, wherein each of the plurality of applicator parameter values ​​is temporally associated with the time interval of a first time block. To provide a plurality of heater parameter values ​​for the second operating parameter of the hot melt liquid heater, wherein each of the plurality of heater parameter values ​​is associated with an applicator parameter value among the plurality of applicator parameter values. Determining a first subset of the applicator parameter values ​​from the plurality of applicator parameter values, wherein each applicator parameter value in the first subset of applicator parameter values ​​indicates that there is no dispensing activity of the applicator for a time interval that is temporally relevant to the first time block. Determining a second subset of the applicator parameter values ​​from the plurality of applicator parameter values, wherein each applicator parameter value in the second subset of applicator parameter values ​​represents the dispensing activity of the applicator during a time interval that is temporally related to the first time block. Determining a first subset of heater parameter values ​​from the plurality of heater parameter values, wherein each heater parameter value in the first subset of heater parameter values ​​is associated with an applicator parameter value in the first subset of applicator parameter values. Determining a second subset of heater parameter values ​​from the plurality of heater parameter values, wherein each heater parameter value in the second subset of heater parameter values ​​is associated with an applicator parameter value in the second subset of applicator parameter values. A method for determining the failure prediction time of an applicator based on a first parameter relationship between the average duty cycle value of a first subset of heater parameter values, the average duty cycle value of a second subset of heater parameter values, and the average gun cycle count of a second subset of applicator parameters, wherein the first parameter relationship reflects the difference between the average duty cycle value of the second subset of heater parameter values ​​and the average duty cycle value of the first subset of heater parameter values, the first parameter relationship represents the slope of a plot on a graph including an axis showing the increase in duty cycle value of an applicator in a failed state and an axis showing the increase in duty cycle value of an applicator that is not in a failed state, and the failure prediction time of the applicator is determined using a function obtained from the plot.

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

3. The method according to claim 2, wherein determining the first subset of applicator parameter values ​​includes determining that each applicator parameter value in the first subset of applicator parameter values ​​represents a gun cycle count of zero during a time interval that is temporally relevant.

4. The method according to claim 3, wherein determining the second subset of applicator parameter values ​​includes determining that each applicator parameter value in the second subset of applicator parameter values ​​indicates a gun cycle count in a temporally relevant time interval that exceeds a threshold gun cycle count.

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

6. To provide a second plurality of applicator parameter values ​​for the first operating parameter of the applicator, wherein each of the second plurality of applicator parameter values ​​is temporally associated with the time interval of a second time block. To provide a second plurality of heater parameter values ​​for the second operating parameter of the hot melt liquid heater, wherein each of the plurality of heater parameter values ​​is associated with an applicator parameter value among the second plurality of applicator parameter values. Determining a third subset of the applicator parameter values ​​from the second plurality of applicator parameter values, wherein each applicator parameter value in the third subset of applicator parameter values ​​indicates that there is no dispensing activity of the applicator for a time interval that is temporally relevant to the second time block. Determining a fourth subset of the applicator parameter values ​​from the second plurality of applicator parameter values, wherein each applicator parameter value in the fourth subset of applicator parameter values ​​represents the dispensing activity of the applicator during a temporally related time interval in the second time block. Determining a third subset of heater parameter values ​​from the second plurality of heater parameter values, wherein each heater parameter value in the third subset of heater parameter values ​​is associated with an applicator parameter value in the third subset of applicator parameter values. The method further includes determining a fourth subset of heater parameter values ​​from the second plurality of heater parameter values, wherein each heater parameter value in the fourth subset of heater parameter values ​​is associated with an applicator parameter value from the fourth subset of applicator parameter values. The method according to claim 1, wherein the failure prediction time of the applicator is further based on the third subset and the fourth subset of heater parameter values.

7. The method according to claim 6, wherein the first time block includes a first day, and the second time block includes a second day following the first day.

8. The method according to claim 6, wherein the time interval of the first time block has a duration in the range of 1 minute to 10 minutes.

9. The method according to claim 6, wherein the failure prediction time of the applicator is further based on the average duty cycle value of the third subset of heater parameter values, the average duty cycle value of the fourth subset of heater parameter values, and the average gun cycle count of the fourth subset of applicator parameter values.

10. Determining the failure prediction time of the applicator is This includes comparing the first parameter relationship associated with the first time block with the second parameter relationship associated with the second time block, The method according to claim 9, wherein the second parameter relationship is between the average duty cycle value of the third subset of heater parameter values, the average duty cycle value of the fourth subset of heater parameter values, and the average gun cycle count of the fourth subset of applicator parameter values.

11. The method according to claim 10, wherein the second parameter relationship reflects the difference between the average duty cycle value of the fourth subset of heater parameter values ​​and the average duty cycle value of the third subset of heater parameter values.

12. The first parameter relationship further includes the relationship between the average gun cycle count of the second subset of applicator parameter values ​​and the difference between the average duty cycle value of the second subset of heater parameter values ​​and the average duty cycle value of the first subset of heater parameter values, The method according to claim 11, wherein the second parameter relationship further includes a relationship between the average gun cycle count of the fourth subset of applicator parameter values ​​and the difference between the average duty cycle value of the fourth subset of heater parameter values ​​and the average duty cycle value of the third subset of heater parameter values.

13. The method according to claim 12, wherein determining the failure prediction time of the applicator includes comparing the first parameter relationship, the second parameter relationship, and one or more other parameter relationships that are temporally associated with the first time block and time blocks other than the second time block.

14. The method according to claim 13, wherein determining the failure prediction time of the applicator includes determining the statistical trend between the first parameter relationship, the second parameter relationship, and one or more other parameter relationships.

15. The method according to claim 14, wherein determining the statistical trend includes determining a mathematical function that fits the statistical trend.

16. The method according to claim 1, wherein the time interval of the first time block includes a time interval in which at least one of the applicator, the hot melt liquid heater, or the hot melt liquid dispensing system is in a ready state.

17. The method according to claim 1, wherein one of the plurality of heater parameter values ​​is temporally associated with the same time interval as the time interval temporally associated with the applicator parameter value associated with the heater parameter value.

18. The method according to claim 1, wherein one of the plurality of heater parameter values ​​is temporally associated with a time interval offset from the time interval temporally associated with the applicator parameter value associated with the heater parameter value.

19. The method according to claim 1, wherein the failure prediction time of the applicator is related to an air leak associated with the applicator.

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