Adhesive Dispensing Pressure Control for Consistent Shot Volume
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Solution Overview
Problem
Constant pressure adhesive and sealant dispensing systems require frequent manual adjustments due to variations in material pressure and viscosity, leading to inconsistent volume dispensing and production downtime, with wide limits set to minimize interventions but resulting in significant variation from the target volume.
Innovation Solution
The system automatically adjusts the proportional valve control setting by monitoring the volume of material dispensed during shots and calculating a new setting based on an error equation to maintain a target range, reducing the need for manual interventions and ensuring consistent dispensing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual adjustments are made frequently to maintain target volume, then dispensing precision is improved, but productivity deteriorates due to production downtime
Solution Approach 1:
The system automatically monitors dispensing volume and adjusts the proportional valve control setting without human intervention. The controller continuously receives flow meter signals, calculates actual volume, compares it to target volume, and autonomously modifies valve settings to maintain precision while eliminating manual adjustment downtime.
Solution Approach 2:
The system implements a closed-loop feedback mechanism where the flow meter continuously measures actual material volume dispensed, the controller compares this measurement against the target volume, and automatically adjusts the proportional valve control setting based on the deviation. This real-time feedback ensures consistent dispensing precision without requiring production stoppages for manual intervention.
2Productivity
If wide limits are set to minimize manual interventions, then productivity is improved, but manufacturing precision deteriorates due to significant variation from target volume
Solution Approach 1:
The system maintains tight control limits (±5% of target volume) by implementing continuous automated feedback control. The controller receives real-time flow meter data, compares actual volume against target, and automatically adjusts valve settings within these narrow tolerances, achieving both high precision and continuous production without manual intervention.
Solution Approach 2:
The system replaces manual mechanical adjustment of the proportional valve with an automated electronic control system. The controller electronically modifies the valve control setting based on real-time feedback, eliminating the need for wide tolerance bands that would be required if manual adjustments were infrequent, thereby achieving both precision and productivity.
3Manufacturing precision
If automated control is implemented with tight target range, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The controller performs multiple functions: it receives flow meter signals, calculates actual dispensed volume, compares against target volume, determines valve adjustment needs, and outputs control signals to the proportional valve. By consolidating these functions into a single multi-functional controller, the system achieves tight precision control without proportionally increasing overall system complexity.
Solution Approach 2:
The automated control system monitors and self-adjusts the proportional valve control setting based on real-time dispensing data. This self-service capability eliminates the need for complex manual intervention protocols and reduces the operational complexity despite the sophisticated control algorithms implemented in the controller.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach significantly reduces manual interventions, maintains consistent volume dispensing, and minimizes downtime by automatically adjusting the valve setting to stay within a tight target range (+/−5% of the target volume), improving overall production efficiency.
Implementation Method 1
a proportional valve of the dispensing system that applies an orifice size control pressure corresponding to the proportional valve control setting to an orifice size control inlet of a controlled pressure regulator
Implementation Method 2
monitoring with the controller a volume of the material dispensed during each shot
Data Source
AI summary
A method of a method of controlling a volume of material dispensed by a constant pressure adhesive and sealant dispensing system controlled by a controller during shots includes automatically adjusting a proportional valve control setting for an orifice size of a controlled pressure regulator. An orifice size control pressure corresponding to the proportional valve control setting is applied to an orifice size control inlet of the controlled pressure regulator. A volume of the material dispensed during each shot is monitored and when the volume of material dispensed during each shot of a predetermined number of successive shots is outside a target range, the proportional valve control setting is automatically adjusted by the controller.