Suck Back Coating Valve Remote Control via Displacement Sensor
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Solution Overview
Problem
Existing suck back type intermittent coating devices require visual inspection to set and confirm the coating position and length, limiting the ability to automate the production process and remotely control the coating state, especially for detecting the boundary lines of the coating section.
Innovation Solution
Incorporating a displacement sensor to detect the position and movement of the movable valve body, allowing for remote computer control of the solenoid valve operations and eliminating the need for visual inspection by using a control device that inputs pulse signals from an encoder and outputs electrical commands to the solenoid valve, enabling remote confirmation and correction of the coating state.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If visual observation is used to confirm coating state, then coating position and length can be set, but automation is limited and remote control is not possible
Solution Approach 1:
The patent replaces the mechanical/visual inspection method with an optical sensing system. A light source and sensor are positioned to detect the coating state, and this optical detection system substitutes for the mechanical valve body movement detection that would require visual observation. The sensor detects coating position and boundary lines automatically, enabling remote control without visual inspection.
Solution Approach 2:
The patent introduces an intermediary sensing system between the coating device and the control system. The sensor acts as an intermediary that detects coating state and transmits this information to the control unit, which then controls the solenoid valve remotely. This intermediary layer enables automation and remote control by bridging the gap between physical coating state and electrical control signals.
2Ease of operation
If displacement sensor is added to detect valve body position, then remote control becomes possible, but device complexity increases
Solution Approach 1:
The patent replaces complex mechanical linkage systems with simpler optical sensing and electrical control. Instead of using mechanical sensors or visual inspection, the system uses a light source and optical sensor to detect coating state, which is then converted to electrical signals for remote control. This substitution reduces mechanical complexity while enabling remote operation.
Solution Approach 2:
The patent implements a feedback control system where the sensor continuously monitors coating state and feeds this information back to the control unit. The control unit adjusts the solenoid valve operation based on this feedback, ensuring accurate coating position and length. This feedback mechanism simplifies the overall system by using simple sensors and electrical control rather than complex mechanical positioning systems.
3Productivity
If solenoid valve is controlled by visual observation, then coating state can be confirmed, but production speed is limited by inspection time
Solution Approach 1:
The patent enables continuous coating operation by eliminating interruptions for visual inspection. The optical sensor continuously monitors coating state in real-time, and the control unit continuously adjusts the solenoid valve without stopping the coating process. This continuous operation maintains high productivity while eliminating the time loss associated with periodic visual inspections.
Solution Approach 2:
The patent replaces the time-consuming visual inspection process with rapid optical detection. The light source and sensor system provides instant feedback on coating state, eliminating the need for operators to visually inspect and manually adjust. This substitution dramatically reduces inspection time and allows for continuous high-speed coating operation.
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 remote control of the coating process, automates the production site by clearly detecting the front and rear edge positions of the coating section, and ensures normal operation of the valve mechanism, thus eliminating the need for on-site visual inspection.
Implementation Method 1
a displacement sensor for detecting a displacement of the movable valve body (20) is provided
Implementation Method 2
a solenoid valve (4) for controlling the operation of the valve manipulating mechanism (3)
Implementation Method 3
a control device (10) which is provided to input thereinto from an encoder (9) a pulse signal Sp indicative of the travel state (travel speed, etc.) of a base material W
Data Source
AI summary
A suck back type intermittent coating system including a valve mechanism, a valve manipulating mechanism, and a solenoid valve for controlling the operation of the valve manipulating mechanism; and a control device that inputs therein a pulse signal indicative of the travel state (travel speed, etc.) of a base material traveling along a coating line, and outputs an electrical command to the solenoid valve. A displacement sensor for detecting a displacement of the movable valve body of the valve mechanism is provided so that the operation of the valve manipulating mechanism is remotely controlled by a command signal to the solenoid valve; and with a computer having a feedback function that issues a correction signal to the operation of the solenoid valve confirmation and tally of the operation of a coating gun module is performed even when away from a production line.