Capacitive Adhesive Level Sensor for Precision Control
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Solution Overview
Problem
Existing methods for monitoring and regulating adhesive levels in storage containers are not precise enough for small changes and often require contact or lengthy warm-up phases, leading to unproductive waiting times and high energy consumption.
Innovation Solution
A capacitive level sensor that determines adhesive levels through a variable electric field, allowing for accurate measurement without contact and reducing preparation times by adjusting its immersion depth or distance from the adhesive, using two concentrically arranged electrodes with a galvanically isolated air gap to generate a uniform capacitive field.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If contact-based sensors are used to determine adhesive levels, then measurement reliability is improved, but preparation time increases due to required warm-up phases
Solution Approach 1:
The patent replaces contact-based mechanical/sensor systems with a capacitive field-based measurement system. The capacitive sensor determines adhesive level through a variable electric field without physical contact, eliminating the need for warm-up phases while maintaining measurement reliability. This substitution of measurement principle directly resolves the contradiction between reliable measurement and preparation time.
2Quantity of substance
If large amounts of adhesive are maintained in storage containers, then sufficient adhesive is available for production, but energy consumption increases for heating and preparation
Solution Approach 1:
The capacitive level sensor provides continuous feedback on the actual adhesive level in the storage container. This feedback enables the control system to monitor adhesive quantity in real-time and trigger refilling operations at optimal moments. By maintaining adhesive levels based on actual consumption rather than keeping large reserves, the system reduces the quantity of adhesive that requires continuous heating, thereby lowering energy consumption while ensuring sufficient adhesive availability for production.
3Measurement precision
If sensors dip into the filling level for calibration, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The patent replaces complex calibrated contact sensors with a simpler capacitive field-based sensor that determines adhesive level without physical immersion. The capacitive sensor measures the dielectric properties of the adhesive through the air gap, eliminating the need for mechanical calibration procedures and complex sensor positioning systems. This substitution maintains measurement precision while significantly reducing device complexity.
4Stability of the object's composition
If adhesive is heated for extended periods to ensure liquidity, then adhesive flow properties are improved, but productivity decreases due to unproductive waiting times
Solution Approach 1:
The capacitive level sensor enables preliminary detection of adhesive levels before critical situations arise. By continuously monitoring the adhesive level and predicting when refilling will be needed, the system can plan refilling operations during optimal moments rather than during production interruptions. This preliminary action allows the system to maintain adhesive liquidity through targeted heating only when needed, rather than continuous extended heating, thereby improving productivity while ensuring adequate adhesive flow properties.
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
Enables quick and precise determination of adhesive levels, reducing preparation times and energy consumption by allowing only the necessary adhesive to be maintained, and facilitating efficient refilling and heating processes.
Implementation Method 1
capacitive level sensor that determines adhesive levels through a variable electric field
Implementation Method 2
two concentrically arranged electrodes with a galvanically isolated air gap to generate a uniform capacitive field
Data Source
Figure 1
Figure 2
AI summary
The method involves using a metering device for application of an adhesive (10) by a roller on the surface of workpiece or a strip-shaped sheet. A sensor (15) projected in a container has end immersed in the adhesive or end projecting into the container by the adhesive. A variable electric field (23) is stored at end of adhesive immersed sensor or the adhesive spaced apart end of sensor corresponding to distance with respect to adhesive, for maintaining predetermined level of adhesive and appropriate filling of container. An independent claim is included for apparatus for controlling/regulating filling level of adhesive used for adhering strip paths or surfaces of workpieces.