Integrated Printhead Control Circuit for Fast Valve Switching
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Solution Overview
Problem
State-of-the-art drop-on-demand printheads require complex motion sequences and high current requirements for controlling multiple electromagnetic valves, leading to inflexible and susceptible cable bundles, which limit the achievable resolution and cycle time in coating applications.
Innovation Solution
Integration of power electronics and printhead logic directly into the printhead, reducing cable lengths and susceptibility to electromagnetic interference, allowing for shorter switching times and higher cycle rates, and enabling the use of pulse width modulation for efficient actuator control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the number of electromagnetic valves in the printhead is increased to improve coating precision, then the manufacturing precision is improved, but the cable bundle becomes thicker and more inflexible, worsening the ease of operation
Solution Approach 1:
The patent integrates the power electronics directly into the printhead assembly, merging previously separate components (power electronics, control logic, and printhead) into a single integrated unit. This eliminates the need for extensive external cable bundles while maintaining the capability to control multiple electromagnetic valves for high-precision coating applications
2Reliability
If the cable length between power electronics and printhead is reduced to improve reliability, then the reliability is improved, but the power electronics must be integrated into the printhead, worsening the device complexity
Solution Approach 1:
The power electronics are integrated directly into the printhead assembly, eliminating long external cables and their associated susceptibility to electromagnetic interference. The integration combines multiple functions (power conversion, control logic, and fluid ejection) into a single modular unit, reducing reliability issues while managing complexity through functional integration
Solution Approach 2:
The integrated printhead assembly performs multiple functions within a single device: it houses the electromagnetic valves for fluid ejection, contains the power electronics for voltage generation and control, and includes control logic for synchronization with the robot controller. This multi-functionality reduces the need for separate components and extensive wiring
3Productivity
If the switching time of electromagnetic valves is reduced to improve productivity, then the productivity is improved, but the current requirements increase, worsening the use of energy
Solution Approach 1:
The power electronics integrated into the printhead are capable of delivering high peak currents for very short durations to achieve rapid valve switching and high productivity. The system manages energy consumption by providing brief high-current pulses only when needed for actuation, rather than continuous high current, thus achieving fast switching while controlling overall energy use
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 integration results in reduced cable thickness, improved reliability, and increased precision in coating applications by minimizing line losses and external influences, enabling faster and more precise control of coating agent jets.
Implementation Method 1
electromagnetic valves 2...electromagnetic actuators...A first coil connection 9 of the coil L is connected directly to a supply voltage DC...A second coil connection 10 is connected to ground via a controllable switching element S
Data Source
AI summary
The disclosure concerns an applicator, in particular a printhead, for applying a coating agent, in particular a paint, to a component, in particular to a motor vehicle body component or an attachment for a motor vehicle body component, having a plurality of nozzles for applying the coating agent in the form of a coating agent jet, and a plurality of coating agent valves for controlling the release of the coating agent through the individual nozzles, and having a plurality of electrically controllable actuators for controlling the coating agent valves. The disclosure provides that a control circuit for electrically controlling the actuators is integrated in the applicator.