Electrocoat management system

• US 20050010321A1
• Filed: 03/04/2004
• Published: 01/13/2005
• Est. Priority Date: 03/04/2003
• Status: Active Grant

• Current Assignee: Swimc, LLC (The Sherwin-Williams Company)
• Original Assignee: Valspar Sourcing, Inc. (Sherwin-Williams Company)
• Inventors: Contos, Michael A., Bourdeau, Michael J., Sailer, Robert A., Pillar, Lonnie L.
• Granted Patent: US 7,349,755 B2
• Time in Patent Office: Days
• US Class Current: 700/123
• CPC Class Codes: C25D 13/22 Servicing or operating apparatus or multistep processes
• CPC Class Codes: C25D 21/12 Process control or regulation controlling or regulating in general G05
• CPC Class Codes: G05B 23/0235 based on a comparison with predetermined threshold or range, e.g. "classical methods", carried out during normal operation; threshold adaptation or choice; when or how to compare with the threshold

Abstract

A processor-based system for monitoring and optimizing an electrocoating operation comprising at least one data acquisition module configured to receive characteristics of the electrocoating operation and at least one process control module in communication with the at least one data acquisition module and the electrocoating operation. An electrocoating process that includes such a process or based system and methods of using the system are also disclosed.

Claims

1. A processor-based system for monitoring and optimizing an electrocoating operation comprising:

at least one data acquisition module configured to receive characteristics of the electrocoating operation; and

at least one process control module in communication with the at least one data acquisition module and the electrocoating operation.

2. The system of claim 1, wherein the at least one data acquisition module is integral with the at least one process control module.

3. The system of claim 1, further comprising at least one remote access module in communication with at least one of the data acquisition module and the at least one process control module.

4. The system of claim 1, further comprising a master programmable unit in communication with at least one of the at least one data acquisition module and the at least one process control module.

5. The system of claim 1, further comprising a display module.

6. The system of claim 5, wherein the display module is wireless.

7. The system of claim 1, further comprising a data tracking module.

8. The system of claim 1, wherein the data tracking module includes statistical process control software.

9. The system of claim 1, wherein the at least one process control module comprises an output signal.

10. The system of claim 9, wherein the output signal is a system selected from a group consisting of a visual alert, an audible alert, an alarm, a process adjustment, and combinations thereof.

11. The system of claim 9, wherein the output signal is transmittable to a wireless receiver.

12. The system of claim 1, wherein the data acquisition module comprises at least one probe.

13. The system of claim 12, wherein the at least one probe is configured to measure a parameter selected from a group consisting of pressure, temperature, pH, concentration, conductivity, liquid level, microorganism count, microorganism type, and flow rate.

14. The system of claim 1, wherein the process control module is a programmable logic controller.

15. An electrocoating process comprising

an electrocoat application system;

and

a processor-based system in communication with and configured to monitor and control, the electrocoat application system.

16. The process of claim 15, further comprising

a surface preparation system preceding the electrocoat application system;

a post rinse system following the electrocoat application system; and

a curing system following the post rinse system,

wherein the processor-based system is in communication with and configured to monitor and control at least one of the surface preparation, electrocoat application, post rinse, and curing systems.

17. A method for monitoring an electrocoating operation, the method comprising:

a) establishing an acceptable range for at least one characteristic of the operation;

b) retrieving at least one value corresponding to the at least one characteristic;

c) analyzing the at least one value; and

d) assessing whether the at least one value is within the acceptable range.

18. The method according to claim 17, further comprising identifying a corresponding action if the at least one value is not within the acceptable range.

19. The method according to claim 18, wherein identifying a corresponding action is performed by a processor.

20. The method according to claim 18, further comprising modifying a process parameter of the electrocoating operation.

21. The method according to claim 20, wherein modifying a process parameter is performed by an automated tool.

22. The method according to claim 18, wherein the corresponding action is chosen from a group consisting of a process adjustment, an alert signal, an alarm, data storage, or combinations thereof.

23. The method according to claim 17, further comprising repeating steps a) thru d).

24. The method according to claim 17, wherein the at least one characteristic is selected from the group consisting of liquid level, microorganism count, microorganism type, concentration, pH, pressure, temperature, conductivity, and flow rate.

25. The method according to claim 17, further comprising using a remote system to perform at least one of steps a) thru d).

26. The method according to claim 20, further comprising repeating steps b) thru e) until the at least one value is within the acceptable range.