Optical Spray Width Measurement for Conformal Coating
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Solution Overview
Problem
Existing methods for measuring and controlling the spray pattern width of conformal coating on substrates require moving the dispenser, which is time-consuming and wasteful, necessitating a need for an apparatus and method to automatically control the liquid spray pattern without moving the dispenser.
Innovation Solution
A dispensing control system with a frame component and sensor portions that emit a beam of light to measure the spray pattern width without moving the dispenser, allowing for real-time comparison and adjustment to achieve the desired pattern width, utilizing a regulator and stroke adjuster to adjust fluid flow rate and orifice size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the dispenser is moved to measure the spray pattern width, then the measurement can be obtained, but the application time increases and material is wasted
Solution Approach 1:
The patent replaces the mechanical measurement method (moving the dispenser) with an optical measurement system (light sensor). The sensor emits light through the spray pattern and detects the transmitted light to calculate spray width, eliminating the need for physical dispenser movement while maintaining measurement accuracy.
Solution Approach 2:
The patent introduces a light sensor as an intermediary measurement device between the dispenser and the measurement target. This intermediary enables non-contact measurement by using light transmission through the spray pattern, avoiding direct mechanical interaction and movement of the dispenser.
2Measurement precision
If the dispenser is moved to measure the spray pattern width, then the measurement can be obtained, but additional programming and material waste occur
Solution Approach 1:
The patent replaces the mechanical measurement method (moving the dispenser) with an optical measurement system (light sensor). The sensor emits light through the spray pattern and detects the transmitted light to calculate spray width, eliminating the need for physical dispenser movement while maintaining measurement accuracy.
3Productivity
If a light sensor is used to measure the spray pattern without moving the dispenser, then application time is reduced, but the system complexity increases
Solution Approach 1:
The patent introduces a light sensor as an intermediary measurement device between the dispenser and the measurement target. This intermediary enables non-contact measurement by using light transmission through the spray pattern, avoiding direct mechanical interaction and movement of the dispenser.
Solution Approach 2:
The system uses feedback by comparing the actual spray pattern width (measured by the light sensor) with the desired spray pattern width. Based on this comparison, the system automatically adjusts dispenser parameters to minimize the difference, creating a closed-loop control system that improves productivity through automation.
4Manufacturing precision
If the spray pattern is adjusted to match the desired pattern, then coating quality improves, but additional adjustment mechanisms are required
Solution Approach 1:
The system uses feedback by comparing the actual spray pattern width (measured by the light sensor) with the desired spray pattern width. Based on this comparison, the system automatically adjusts dispenser parameters to minimize the difference, creating a closed-loop control system that improves manufacturing precision through automated feedback control.
Solution Approach 2:
The system adjusts spray pattern parameters (such as fluid flow rate, pressure, or nozzle positioning) based on the measured deviation from the desired pattern. By dynamically changing these parameters in response to real-time measurements, the system achieves precise spray pattern control without requiring complex mechanical adjustment mechanisms.
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 and efficient measurement and adjustment of the spray pattern width without moving the dispenser, reducing application time and material waste while ensuring the actual pattern matches the desired pattern within a tolerance range.
Implementation Method 1
the first sensor portion transmits a beam of light towards the second sensor portion to measure the liquid spray stream exiting the dispenser
Data Source
AI summary
A dispensing control system, including a frame component having a first side surface and a second side surface, a first sensor portion positioned proximate the first side surface, and a second sensor portion positioned proximate the second side surface, the second sensor portion being separated from the first sensor portion a distance to allow a liquid spray stream exiting a dispenser of a conformal coating machine to pass therebetween, wherein the first sensor portion transmits a beam of light towards the second sensor portion to measure the liquid spray stream exiting the dispenser, the beam of light encompassing both edges of the liquid spray stream while the dispenser is stationary, is provided. Furthermore, an associated method is also provided.