Multi-Component Material Dispensing With Closed-Loop Ratio Control
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Solution Overview
Problem
Current methods lack precise control over the dispensing of multi-component liquid materials, particularly in manufacturing processes like PCB production, where accurate ratios and amounts of mixed materials are crucial but challenging to automate.
Innovation Solution
A system comprising progressive cavity pumps, sensors, and a controller that adjusts the flow rates of individual materials to achieve precise mixing and dispensing ratios, ensuring accurate dispensing of mixed materials onto a substrate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multi-component materials are dispensed using conventional methods, then dispensing operation can be performed, but precise control over dispensing amounts and ratios cannot be achieved
Solution Approach 1:
The system divides the multi-component material dispensing into separate dispensing operations for each component material. Individual pumps and control mechanisms are used for each material component, allowing precise control of each material's flow rate and amount before mixing, thereby achieving precise dispensing control without requiring a completely complex integrated system.
Solution Approach 2:
The system incorporates sensors that detect the flow rates of individual material components and provide feedback to the controller. The controller automatically adjusts the dispensing parameters based on this feedback to maintain precise control over the mixing ratios and dispensing amounts, resolving the contradiction between precision and complexity through intelligent control.
2Extent of automation
If automatic control of multi-component dispensing is implemented, then dispensing automation is achieved, but control over mixing ratios becomes difficult
Solution Approach 1:
Flow sensors monitor the dispensing rate of each material component in real-time and provide feedback to the controller. The controller automatically adjusts pump speeds and flow rates to maintain the desired mixing ratio, enabling both high automation and precise ratio control simultaneously.
Solution Approach 2:
The system dynamically changes operational parameters such as pump speed, flow rate, and pressure based on real-time conditions to maintain precise mixing ratios. The controller modifies these parameters automatically, achieving both automation and precision in mixing ratio control.
3Manufacturing precision
If individual material flow rates are monitored and adjusted, then mixing ratio precision is improved, but measurement and control complexity increases
Solution Approach 1:
The controller serves multiple functions: it monitors flow rates from sensors, calculates the required mixing ratios, adjusts pump speeds, and coordinates the dispensing process. This multi-functionality consolidates the measurement and control operations into a single intelligent device, improving mixing ratio precision without proportionally increasing overall system complexity.
Solution Approach 2:
The system uses sensors to automatically detect and measure flow rates, and the controller automatically adjusts dispensing parameters based on this data. The system self-regulates the mixing process without requiring external intervention or complex manual measurement procedures, achieving precision while keeping the control system manageable.
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 precise control over the dispensing of mixed materials, improving the accuracy and efficiency of multi-component applications by automatically adjusting flow rates based on real-time measurements, thereby enhancing manufacturing processes.
Implementation Method 1
a first pump configured to pump the first material from the first supply through the outlet of the first pump at a first material flow rate
Implementation Method 2
a sensor that is configured to determine an amount of the first material dispensed and an amount of a second material dispensed
Implementation Method 3
mixing the first material and the second material within a chamber of a mixer to form the mixed material
Data Source
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AI summary
Systems and methods for applying a mixed material to a substrate are disclosed herein. The method includes receiving dispensing operating parameters and dispensing first and second materials at first and second material flow rates and determining amounts of the first and second materials dispensed. The method also includes automatically adjusting the dispensing of the first and second materials to adjusted first and second material flow rates based upon the determined amounts of the first and second materials dispensed. The method includes pumping the first and second materials at the adjusted first and second material flow rates, mixing the first material and the second material within a chamber of a mixer to form the mixed material, and dispensing the mixed material from a dispensing nozzle onto the substrate.