Intelligent UV Curing Lamp On-Lamp Microprocessor Control
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Solution Overview
Problem
Current UV curing lamp systems lack automated monitoring and inventory control capabilities, requiring manual adjustments and limited remote monitoring due to constraints in cable connectivity and sensor placement, which affects UV output power equalization and real-time air pressure monitoring.
Innovation Solution
An intelligent UV curing lamp system with an on-lamp microprocessor that communicates with internal sensors and intelligent markers via a serial bus, allowing for automated monitoring of performance parameters, part lifetime, and inventory control, and connects with an external power supply using a digital serial communication bus for centralized data processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If manual adjustments are used for UV output power equalization, then system complexity is reduced, but UV output power uniformity deteriorates
Solution Approach 1:
The system divides the monitoring function into multiple independent smart sensors distributed at different locations within the lamp assembly. Each sensor independently monitors local parameters (temperature, pressure, UV intensity) and communicates with the central controller via I2C bus, enabling localized measurements without complex centralized sensing architecture.
Solution Approach 2:
The system implements closed-loop feedback control where smart sensors continuously monitor UV output power and environmental parameters, transmit data to the microcontroller, which then adjusts operating conditions to maintain uniform UV output across all lamp segments, achieving precise power equalization through automated feedback.
2Ease of operation
If cable connectivity constraints are imposed, then ease of operation is improved, but measurement precision deteriorates
Solution Approach 1:
The system replaces mechanical cable connections with wireless communication technology. Smart sensors and the microcontroller communicate monitoring data wirelessly to external systems, eliminating cable connectivity constraints while maintaining high measurement precision for air pressure, temperature, and UV intensity parameters.
3Device complexity
If sensor placement is limited, then device complexity is reduced, but productivity deteriorates
Solution Approach 1:
The smart sensor module is designed as a universal, multi-functional unit capable of measuring multiple parameters (temperature, pressure, UV intensity) simultaneously. This standardized sensor design can be placed at multiple locations without increasing overall system complexity, as each sensor performs the same set of functions locally and communicates through the same I2C protocol.
Solution Approach 2:
The system implements a nested hierarchical architecture where smart sensors are embedded within the lamp assembly structure, the microcontroller is integrated into the sensor module, and all components communicate through nested communication protocols (I2C at sensor-microcontroller level, wireless at controller-external level). This nesting allows multiple sensors to be placed without proportionally increasing system complexity.
4Productivity
If automated monitoring is implemented, then productivity is improved, but device complexity increases
Solution Approach 1:
The smart sensors are designed as self-contained units with integrated processing capability, memory, and communication interfaces. Each sensor autonomously performs measurements, processes data locally, and transmits results without requiring complex external processing hardware, enabling automated monitoring while keeping individual component complexity low.
Solution Approach 2:
The system merges multiple functions (sensing, signal conditioning, data processing, wireless communication) into integrated smart sensor modules. This consolidation reduces the number of separate components and interconnections required, achieving automated monitoring capability without proportionally increasing overall device complexity.
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 automated monitoring and adjustment of UV output power, real-time air pressure management, and enhanced inventory control, improving system efficiency and user-friendliness by reducing the need for manual interventions and extending monitoring capabilities beyond the lamp's proximity.
Implementation Method 1
An intelligent UV curing lamp system with an on-lamp microprocessor that communicates with internal sensors and intelligent markers via a serial bus
Implementation Method 2
Radiant energy is used in a variety of manufacturing processes to treat surfaces, films, and coatings applied to a wide range of materials. Specific processes include, but are not limited to, curing (i.e., fixing, polymerization)
Implementation Method 3
Processes employing radiant energy to polymerize or effect a desired chemical change are rapid and often less expensive compared to a thermal treatment
Implementation Method 4
Ultraviolet light rays 38 radiate from the light source 20 in all directions, striking the inner surfaces of the primary reflector 16, the secondary reflector 25, and the end reflectors 24, 26. Most of the ultraviolet light rays 38 are reflected toward the central axis of the work piece tube 30
Data Source
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AI summary
An "intelligent" UV curing assembly is disclosed. The "intelligent" assembly permits automated monitoring of performance parameters, part lifetime, and inventory control of internal parts. The "intelligent" assembly includes an on lamp microprocessor. The on lamp microprocessor may be configured to recognize the internal parts, record accumulated working time of each part, and sample and process data from the plurality of "intelligent" sensors.