Adhesive Dispensing Valve Pulse Control for Consistent Dot Size
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Solution Overview
Problem
Existing methods for applying adhesive portions to substrates, such as cigarette pack manufacturing, face issues with inconsistent adhesive quantities due to electromagnetic interference and self-heating effects, which lead to variations in adhesive dot sizes and quantities, and require costly temperature sensors for viscosity control.
Innovation Solution
The method dynamically shortens the actual opening duration of valve openings based on valve operating parameters like frequency, voltage, and current, allowing for compensation of interference effects and viscosity changes without the need for temperature sensors, by adjusting control voltage pulses and duty cycles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If temperature sensors are used to detect adhesive viscosity and adjust valve opening times, then adhesive portion consistency can be maintained, but device complexity and cost increase
Solution Approach 1:
The patent replaces the mechanical/thermal sensing system (temperature sensors) with an electromagnetic sensing system. The coil of the electromagnet serves dual purposes: actuating the valve and sensing adhesive properties through electromagnetic interference measurements, eliminating the need for separate temperature sensors and reducing device complexity.
Solution Approach 2:
The electromagnet coil is designed to perform multiple functions: it acts as both the actuator that opens/closes the valve and as the sensor that detects adhesive viscosity changes through electromagnetic interference. This multi-functionality reduces the number of components needed in the system.
2Manufacturing precision
If temperature sensors are installed and wired into the valve for viscosity control, then adhesive portion consistency can be maintained, but installation cost and complexity increase
Solution Approach 1:
The electromagnet coil is designed to perform multiple functions: it acts as both the actuator that opens/closes the valve and as the sensor that detects adhesive viscosity changes through electromagnetic interference. This multi-functionality reduces the number of components needed in the system.
Solution Approach 2:
The patent replaces the mechanical/thermal sensing system (temperature sensors) with an electromagnetic sensing system. The coil of the electromagnet serves dual purposes: actuating the valve and sensing adhesive properties through electromagnetic interference measurements, eliminating the need for separate temperature sensors and reducing device complexity.
3Manufacturing precision
If valve opening times are adjusted based on temperature predictions, then adhesive portion quantities can be aligned, but measurement precision and response speed are limited
Solution Approach 1:
The patent replaces indirect thermal measurement with direct electromagnetic measurement. The coil detects changes in electromagnetic interference caused by adhesive viscosity changes, providing more precise and faster measurements compared to temperature sensor-based methods.
Solution Approach 2:
The system continuously monitors electromagnetic interference signals from the coil and uses this feedback to dynamically adjust valve opening times. This real-time feedback mechanism allows for more precise control of adhesive portion quantities compared to prediction-based methods.
4Ease of operation
If standard control voltage pulses are used for valve actuation, then valve operation is simple, but electromagnetic interference effects cause actual opening duration to vary
Solution Approach 1:
The system monitors electromagnetic interference signals during valve operation and uses this feedback to dynamically adjust control voltage pulse parameters. This ensures that despite variations in electromagnetic interference effects, the actual opening duration remains consistent and precise.
Solution Approach 2:
The control system dynamically adjusts the control voltage pulse parameters (duration, amplitude) based on real-time electromagnetic interference measurements. This dynamic adjustment compensates for variations in electromagnetic interference effects while maintaining simple valve actuation mechanics.
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 ensures consistent adhesive portion quantities by counteracting electromagnetic interference and viscosity changes, improving the precision and reliability of adhesive application while reducing costs and complexity.
Implementation Method 1
a coil of an electromagnet is subjected to a control voltage pulse for each of the successive dispensings of adhesive portions from the valve, which causes the valve to open
Implementation Method 2
magnetization effects in the electromagnet as well as self-heating of the valve coil lead to an increase in the amount of adhesive portions during operation
Implementation Method 3
self-heating of the valve coil and the associated reduction in adhesive viscosity can lead to an increase in the amount of adhesive portions during operation
Data Source
Figure 1~2
Figure 3
AI summary
The invention relates to a method for applying individual portions of adhesive to a substrate, in which the portions of adhesive are applied to the substrate successively using a valve (13), wherein a coil (18) of an electromagnet is supplied with a control voltage pulse (20) for each successive dispensing of adhesive portions from the valve (13), which causes the valve (13) to open for a specific opening duration, during which adhesive can flow from the valve (13) to dispense the respective portion of adhesive, in particular by moving a closing element (17) of the valve (13) from a closed position to an open position.The invention is characterized in that the actual opening duration of at least one of the valve openings, which follows a temporally preceding valve opening, is preferably dynamically shortened in order to compensate for disturbance effects, in particular electromagnetic disturbances, which extend the actual opening duration of the subsequent valve opening, according to one or more valve operating parameters, in comparison to an actual opening duration of the subsequent valve opening without such compensation, by applying a control voltage pulse (20) to the coil (18) which causes the shortened actual opening duration.