Coating Process Parameter Control Using Real-Time CFD Feedback
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Solution Overview
Problem
Current coating processes in battery and fuel cell manufacturing lack efficient and automated monitoring systems that can handle the complexity and interdependence of process parameters, leading to potential human errors, suboptimal product quality, and increased scrap rates due to delayed detection of deviations.
Innovation Solution
A computer-implemented method using analytical models and three-dimensional computational fluid dynamics (CFD) models to determine optimized operating parameters, incorporating real-time process data and material properties, allowing for continuous process monitoring and immediate adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual monitoring and interventions are used to control coating process parameters, then the system can operate with simple control mechanisms, but the detection of deviations is delayed and human errors increase
Solution Approach 1:
The patent implements a closed-loop feedback system where process parameters are continuously monitored in real-time, deviations from target values are automatically detected, and corrective actions are triggered. This eliminates the time delay inherent in manual monitoring and prevents human errors by automating the detection and response mechanism.
Solution Approach 2:
The patent replaces manual mechanical monitoring with an automated electronic control system that uses sensors, processors, and actuators. This substitution enables continuous real-time monitoring without human intervention, significantly reducing detection time and improving reliability through consistent automated operation.
2Manufacturing precision
If comprehensive analysis of interdependent process parameters is performed, then the coating quality is optimized, but the complexity of monitoring and control increases
Solution Approach 1:
The patent employs a universal control platform that can monitor and analyze multiple interdependent process parameters simultaneously. This multi-functional system integrates temperature, pressure, flow rate, and other parameter monitoring into a single cohesive platform, managing complexity through standardized interfaces and centralized processing while maintaining comprehensive analysis capabilities.
Solution Approach 2:
The patent introduces an intermediary processing layer that receives data from multiple sensors, performs automated analysis of interdependencies, and generates control decisions. This intermediary layer simplifies the overall system architecture by centralizing the complex analysis function and providing a clear interface between sensing and actuation components.
3Ease of manufacture
If fixed threshold control systems are used, then the control mechanism is simple to implement, but the full range of process optimization cannot be achieved
Solution Approach 1:
The patent transitions from static fixed threshold control to dynamic adaptive control where target values and control parameters can adjust in real-time based on process conditions. The system maintains simplicity through automated adaptation, allowing the control strategy to evolve with changing process requirements without increasing operational complexity.
Solution Approach 2:
The patent enables continuous adjustment of control parameters beyond fixed thresholds by implementing a system that can modify target values, weighting factors, and control gains dynamically. This allows the system to adapt to a full range of process optimization scenarios while maintaining ease of implementation through automated parameter management.
4Reliability
If real-time data monitoring is implemented, then the detection of inadequate coating is immediate, but the system requires advanced automated monitoring capabilities
Solution Approach 1:
The patent implements real-time feedback monitoring where process parameters are continuously measured and immediately compared against target values. Deviations trigger automatic alerts and corrective actions, ensuring immediate detection of inadequate coating conditions. This closed-loop feedback mechanism provides the advanced automation capability needed for real-time quality assurance.
Solution Approach 2:
The patent replaces manual inspection methods with automated sensor-based monitoring systems that continuously measure coating parameters in real-time. This substitution enables immediate detection of quality issues without human intervention, providing both the real-time detection capability and the automated monitoring infrastructure required for modern quality assurance.
Data Source
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AI summary
The invention relates to a computer-implemented method, a computer-implemented device, a system, and a computer program product for determining optimized operating parameters for a coating process, comprising detecting at least one process parameter associated with the coating process, determining a target parameter range associated with a coating produced by the coating process, wherein the determination is based on an analytical model and/or a three-dimensional computational fluid dynamics (CFD) model, and determining an operating parameter for the coating process at least partially based on the detected parameter and the target parameter range.