Printhead Control Circuit Integration for Precise Coating Valves
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Solution Overview
Problem
Conventional print heads with electromagnetic valves face challenges when installed on multi-axis robots due to complex movement sequences, high power requirements, cable flexibility issues, electromagnetic compatibility problems, and limited accuracy, leading to application inaccuracies and safety risks.
Innovation Solution
Integrating a control circuit and power electronics directly into the print head to reduce cable length, minimize electromagnetic interference, and enhance control precision, allowing for faster switching times and improved reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the print head is installed on a multi-axis robot, then the applicator can reach complex geometries and improve versatility, but the cable bundle must be routed through robot arms and hand axes which limits cable flexibility and increases complexity
Solution Approach 1:
The control circuit is integrated directly into the applicator unit, merging the control electronics with the actuator. This eliminates the need for long cable bundles running through robot arms, as the control circuit now resides within the applicator itself, significantly reducing cable routing complexity while maintaining full robot versatility
Solution Approach 2:
The control circuit is extracted from the external robot control system and embedded directly into the applicator unit. This extraction removes the problematic long cable connections from the robot arms while keeping the control functionality localized where it is needed, simplifying the overall system architecture
2Adaptability or versatility
If a large number of electrical coils are installed in the print head to control multiple nozzles, then the print head can apply complex patterns and improve functionality, but the cable cross-section increases and the cable bundle becomes larger and less flexible
Solution Approach 1:
The control circuit for multiple coils is merged into a single integrated unit within the applicator. This consolidation allows multiple coil control functions to be managed from one localized control circuit, eliminating the need for separate external control connections for each coil and maintaining cable flexibility
Solution Approach 2:
The integrated control circuit performs multiple functions - controlling numerous individual coils, managing power distribution, and executing complex printing patterns - all within a single multi-functional unit. This universal control approach enables sophisticated pattern control without proportionally increasing cable requirements
3Adaptability or versatility
If long cables are used to connect the control circuit to the electromagnetic valves, then the print head can be positioned flexibly, but power losses increase and electromagnetic interference worsens
Solution Approach 1:
The control circuit and power electronics are merged with the electromagnetic valves in an integrated applicator unit. This merging eliminates long cable connections, ensuring that power and control signals are delivered directly at the point of use, thereby eliminating power losses and electromagnetic interference from long cables while maintaining full positioning flexibility
Solution Approach 2:
The integrated control circuit acts as an intermediary embedded within the applicator structure, providing direct electrical connections to the electromagnetic valves without requiring external cable intermediaries. This eliminates the problematic long cable paths while maintaining the ability to position the applicator flexibly on the robot
4Device complexity
If the control circuit is installed outside the print head, then the print head structure remains simple, but the cable length increases causing power losses and temporal influences
Solution Approach 1:
The control circuit is merged into the print head structure, creating an integrated unit where control electronics and actuation mechanisms coexist. This integration eliminates long external cables, preventing power losses and temporal influences, while the modular design keeps the overall structure manageable and maintainable
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 reduces cable susceptibility to interruptions, minimizes power losses, and enhances application accuracy, safety, and reliability by shortening lines and reducing electromagnetic emissions, enabling precise control of the coating process.
Implementation Method 1
A magnetic piston (valve needle) is guided in a coil and raised by supplying electricity to the coil
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to an applicator (1), in particular a printhead (1), for applying a coating material, especially a paint, to a component, in particular to a motor vehicle body component or an add-on part for a motor vehicle body component, with several nozzles for applying the coating material in the form of a coating material jet, and several coating material valves (2) for controlling the coating material dispensing through the individual nozzles, as well as with several electrically controllable actuators for controlling the coating material valves (2). The invention provides that a control circuit (5, 6) for electrically controlling the actuators is integrated into the applicator (1).