Method of monitoring parameters of coating material dispensing systems and processes by analysis of swirl pattern dynamics
First Claim
1. A method of monitoring the performance of a controlled fiberization device for dispensing a continuous fiber of liquid coating material distributed through a space between the dispensing device and a substrate in a continuous helical pattern which changes position with time by a rotating motion in the space, said method comprising the steps of:
- sensing the rotating motion of the pattern of the material in the space between the dispensing device and the substrate; and
generating in response to the sensed motion a signal representative of characteristics of the motion of the pattern in the space.
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Abstract
A method of monitoring and/or controlling the motion of a moving coating material dispensing pattern or fiber is provided with a monitor that senses a medium such as sound, light or other form of energy near the space between the dispensing device nozzle and a substrate, and a monitoring signal is generated. Information relating to the pattern motion is extracted, and an output signal is generated representative of characteristics of the motion of the pattern in the space. One or more transducers are used to extract the information, which is analyzed, preferably by comparison of a frequency spectrum of the signal with a spectrum of standard signal, to detect deviations in the system operation from desired criteria. Optionally, the output signal is used to control parameters of the system. In another embodiment, plural spaced transducers detect the phase or orientation of the moving pattern and remove background noise, by inverting, summing, multiplying, and otherwise combining the signals. The invention is useful for detecting malfunctions of the system components, for real-time closed loop control of the process, and for quality control inspection of dispensing device components during manufacture.
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Citations
31 Claims
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1. A method of monitoring the performance of a controlled fiberization device for dispensing a continuous fiber of liquid coating material distributed through a space between the dispensing device and a substrate in a continuous helical pattern which changes position with time by a rotating motion in the space, said method comprising the steps of:
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sensing the rotating motion of the pattern of the material in the space between the dispensing device and the substrate; and generating in response to the sensed motion a signal representative of characteristics of the motion of the pattern in the space. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10)
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11. A method of controlling the dispensing of a continuous fiber of liquid coating material distributed in a space between a dispensing device and a substrate to form a pattern in the space, said method comprising the steps of;
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ejecting liquid coating material from a dispensing device toward a substrate in a continuous fiber extending through a space located between the dispensing device and the substrate while causing the fiber to change position in the space with time; sensing motion of the pattern due to the time changing position of the fiber of the material in the space between the dispensing device and the substrate; generating in response to the information a signal representative of characteristics of the motion of the pattern in the space; and controlling the ejection in response to said signal. - View Dependent Claims (12, 13, 14, 15, 16, 17, 18, 19, 20)
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21. A method of dispensing liquid coating material onto a substrate that moves past the dispensing device at a speed which may vary, said method comprising the steps of:
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ejecting coating material at a controlled rate from a dispensing device toward a substrate through a space located between the dispensing device and the substrate, the ejected material being distributed in the space so as to form a pattern in the space which moves such that the distribution of material in the space changes position therein as a function of time; sensing the time changing position of the pattern of the material in the space between the dispensing device and the substrate and generating a feedback signal responsive to the sensed change of position of the pattern; generating a speed signal in response to the speed of the substrate past the dispensing device; and
,varying the rate at which the coating material is ejected from the dispensing device in response to the speed signal and feedback signal so as to vary the rate at which the material is ejected in relation to the speed of the substrate past the dispensing device. - View Dependent Claims (22, 23)
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24. A method of monitoring the performance of a dispensing device for dispensing a coating material in a flowable state through a space between the dispensing device and a substrate in a distribution that forms a continuous rotating pattern in the space that changes position in the space with time so as to modulate energy propagating in the space with information of the time varying change in the position of the distribution of material in the space, said method comprising the steps of:
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sensing the information of the time varying change of the position of the rotating pattern of the material from the propagating energy in the space between the dispensing device and the substrate; and generating in response to the information a signal representative of characteristics of the changing position of the rotating pattern in the space. - View Dependent Claims (25, 26)
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27. A method of monitoring the performance of a dispensing device for dispensing a coating material in a flowable state through a space between the dispensing device and a substrate in a distribution that forms a continuous rotating pattern in the space that changes position in the space with time so as to modulate energy propagating in the space with information of the time varying change in the position of the distribution of material in the space, said method comprising the steps of:
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sensing the information of the time varying change of the position of the rotating pattern of the material from the propagating energy in the space between the dispensing device and the substrate; generating in response to the information a signal representative of characteristics of the changing position of the rotating pattern in the space; dispensing coating material onto the substrate, where the substrate moves past the dispensing device at a speed which may vary, wherein; the ejecting of coating material is at a controlled rate from the dispensing device toward a substrate through a space located between the dispensing device and the substrate so as to cause the material to form a moving rotating pattern as it moves along a path that changes position as a function of time; and the method further comprises the steps of sensing the rotating motion of the pattern of the material in the space between the dispensing device and the substrate and generating a feedback signal responsive to the sensed change of position of the pattern, generating a speed signal in response to the speed of the substrate past the dispensing device, and, varying the rate at which the coating material is ejected from the dispensing device in response to the speed signal and feedback signal so as to vary the rate at which the material is ejected in relation to the speed of the substrate past the dispensing device.
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28. A method of monitoring the performance of a dispensing device for dispensing a coating material in a flowable state through a space between the dispensing device and a substrate in a distribution that forms a continuous rotating pattern in the space that changes position in the space with time so as to modulate energy propagating in the space with information of the time varying change in the position of the distribution of material in the space, said method comprising the steps of:
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sensing the information of the time varying change of the position of the rotating pattern of the material from the propagating energy in the space between the dispensing device and the substrate; generating in response to the information a signal representative of characteristics of the changing position of the rotating pattern in the space; the coating material being dispensed under pressure from the dispensing device, and the controlling step comprising the steps of; comparing the signal representative of the characteristics of the rotating motion of the pattern with stored reference characteristics; and the controlling step includes the step of varying the pressure of the material ejected from the dispensing device in response to said comparing step.
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29. A method of monitoring the performance of a dispensing device for dispensing a coating material in a flowable state through a space between the dispensing device and a substrate in a distribution that forms a continuous rotating pattern in the space that changes position in the space with time so as to modulate energy propagating in the space with information of the time varying change in the position of the distribution of material in the space, said method comprising the steps of:
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sensing the information of the time varying change of the position of the rotating pattern of the material from the propagating energy in the space between the dispensing device and the substrate; generating in response to the information a signal representative of characteristics of the changing position of the rotating pattern in the space; the dispensed coating material being subjected to streams of air emitted under pressure from jets; and the controlling step including the step of comparing a signal representative of the characteristics of the motion of the rotating pattern with stored criteria and, in response the comparing step, varying the pressure of the air emitted from the jets.
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30. A method of monitoring the performance of a dispensing device for dispensing a coating material in a flowable state through a space between the dispensing device and a substrate in a distribution that forms a continuous rotating pattern in the space that changes position in the space with time so as to modulate energy propagating in the space with information of the time varying change in the position of the distribution of material in the space, said method comprising the steps of:
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sensing the information of the time varying change of the position of the rotating pattern of the material from the propagating energy in the space between the dispensing device and the substrate; generating in response to the information a signal representative of characteristics of the changing position of the rotating pattern in the space; and the information being sensed from a plurality of different angular positions around the pattern. - View Dependent Claims (31)
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Specification