Liquid Coating Dispensing Control via Volume Feedback
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Solution Overview
Problem
Conventional coating material dispensing systems are inaccurate when applying conformal coatings to circuit boards due to inaccuracies in calculating the flow rate, leading to improper material dispensing and inefficiencies.
Innovation Solution
A system comprising a robot, applicator, regulator, and control system that uses volume signals from a meter to accurately dispense liquid coating material, adjusts the flow based on error signals, and matches specific components and areas of substrates for precise coating, utilizing a library of operational sequences to accommodate different substrates and conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the dispensing valve is opened for a very short time interval to dispense small amounts of coating material, then the coating precision is improved, but the flow rate calculation accuracy deteriorates due to significant inaccuracies in encoder counts and time interval measurements
Solution Approach 1:
The system implements feedback control by continuously monitoring the actual dispensed volume through the flow meter and comparing it to the desired volume. The controller adjusts the dispensing parameters based on the difference between actual and target values, enabling precise coating application even when dispensing small amounts of material over short time intervals.
Solution Approach 2:
The system performs preliminary calibration and setup by establishing a library of operational sequences stored in memory associated with the controller. These pre-programmed sequences contain optimized parameters for different substrate types and coating requirements, allowing the system to accurately control dispensing volume before the actual coating process begins.
2Productivity
If conventional flow rate calculation methods are used with short dispensing intervals, then the system operation speed is maintained, but the coating material dispensing accuracy deteriorates leading to improper material application
Solution Approach 1:
The controller uses feedback from the flow meter to continuously monitor and adjust the dispensing process. By comparing actual dispensed volume against target volume in real-time, the system maintains high accuracy in coating material application while preserving operational speed through automated corrections.
Solution Approach 2:
The system employs a universal controller that integrates multiple functions: it manages the dispensing valve, processes flow meter signals, stores operational sequences in memory, and performs real-time calculations. This multi-functional approach eliminates the need for separate systems, maintaining productivity while achieving precise dispensing control through centralized intelligent management.
3Adaptability or versatility
If the system uses a library of operational sequences stored in memory to match different substrates, then the adaptability is improved, but the device complexity increases
Solution Approach 1:
The system performs preliminary organization of operational parameters by storing optimized sequences in memory before production begins. Each sequence contains pre-calculated settings for different substrate types, allowing the controller to quickly match and select appropriate parameters without complex real-time calculations, thereby reducing operational complexity while maintaining high adaptability.
Solution Approach 2:
The system uses digital copies of operational sequences stored in memory rather than requiring physical reconfiguration for each substrate type. The controller retrieves and executes these stored sequences, enabling versatile substrate handling through software-based parameter sets rather than hardware modifications, thus managing complexity through information processing.
Data Source
AI summary
Systems and methods for applying liquid coating materials to a substrate, such as an electronic component or circuit board. A control system (18, 24, 26) of a coating system (10) controls an applicator (16) and a robot (14) moving the applicator (16) to apply the liquid coating material to the substrate (12) in accordance with the information contained in a coating program. The control system (18, 24, 26) determines a volume of liquid coating material actually dispensed onto the substrate (12) during the coating program, and compares the dispensed volume to a desired dispensed volume of liquid coating material to produce an error signal representing the difference between the calculated and desired volume values. The control system (18, 24, 26) uses the error signal to change the dispensed volume of liquid coating material on a subsequent substrate by a future coating program.