Automated system for control and diagnostics for dispensing systems

• US 6,704,617 B2
• Filed: 04/11/2002
• Issued: 03/09/2004
• Est. Priority Date: 04/11/2002
• Status: Expired due to Fees

• Current Assignee: C&S Manufacturing Co.
• Original Assignee: Flexible Products Co. (Dow, Inc.)
• Inventors: Cocciadiferro, Edward, Cherfane, Raymond
• Primary Examiner(s): Tran, Khoi H.
• Application Number:
  US10/120,915
• Publication Number:
  US 20030195651A1
• Time in Patent Office: 698 Days
• Field of Search: 700/231, 700/233, 700/239, 700/241, 700/244, 700/265, 222/52, 222/638, 222/639, 137/3, 137/4, 137/88, 137/93, 137/607
• US Class Current: 700/239
• CPC Class Codes: B29B 7/728 Measuring data of the driving system, e.g. torque, speed, power, vibration B29B7/724 takes precedence
• CPC Class Codes: B29B 7/7404 Mixing devices specially adapted for foamable substances B29B7/76 takes precedence
• CPC Class Codes: B29B 7/7409 with supply of gas
• CPC Class Codes: B29B 7/7428 Methodical aspects
• CPC Class Codes: B29B 7/7433 Plants
• CPC Class Codes: B29B 7/7447 including means for feeding the components
• CPC Class Codes: F04C 13/001 Pumps for particular liquids
• CPC Class Codes: G05B 23/0213 Modular or universal configuration of the monitoring system, e.g. monitoring system having modules that may be combined to build monitoring program; monitoring system that can be applied to legacy systems; adaptable monitoring system; using different communication protocols
• CPC Class Codes: Y10T 137/0329 Mixing of plural fluids of diverse characteristics or conditions
• CPC Class Codes: Y10T 137/0335 Controlled by consistency of mixture
• CPC Class Codes: Y10T 137/2499 Mixture condition maintaining or sensing

Abstract

This embodiment relates generally to a foam dispensing system, and more particularly to an automated monitoring and diagnostic system for use with foam dispensing systems that permits remote control of the dispensing of foam. A control console is provided that is interconnected, preferably by way of a high-speed data link, with a foam dispenser, the A and B foam component pumps, a power source and controller, and a gateway. The console preferably includes a plurality of individual control circuits, typically disposed within one or more integrated circuits. The console may instead, or additionally, include software to perform some or all of the data exchange functions. The control circuits and/or software are preferably disposed within modules that are mounted to various components of the system. The modules may include one or more sensors operatively connected to the controller that monitor and record operational parameters. The system can optionally incorporate a wide-area network and multiple local-area networks, wherein each local-area network is dedicated to a single foam-dispensing unit and includes a main console and gateway associated therewith.

Claims

1. A dispensing monitoring apparatus which dispenses a polyurethane foam formed as the reaction product from the mixing together of a plurality of streams of reactive foam components comprising:

a power supply;

a processor;

a memory operatively coupled to the processor;

motor control circuitry operatively coupled to the processor;

at least two supply sources of reactive foam components;

a dispensing unit for dispensing the polyurethane foam, the dispensing unit having a plurality of inputs for receiving respective supply streams of the plurality of reactive foam components, the dispensing unit further including a trigger that is selectively actuable by a user to dispense a preselected amount of the reactive foam components mixed together to form the polyurethane foam;

a plurality of foam component supply pumps for delivering the plurality of reactive foam component supply streams from the supply sources to said dispensing unit;

a pair of supply hoses interconnecting outputs of the plurality of pumps to the plurality of inputs of the dispensing unit;

a datastore for storing at least one of system parameters, shot data, and node location data;

at least one sensor operatively coupled to the processor for gathering shot data and transmitting the shot data to the processor;

a first clock operatively coupled to the trigger for recording a time and date of the dispensing;

a second clock operatively coupled to the trigger for recording a duration of the at least one shot; and

a user interface for receiving from the processor and displaying data generated by at least one of the first clock, the second clock, and the at least one sensor comprising;

a visual display; and

a user-interactive data entry device.

2. The apparatus of claim 1 wherein the user-interactive data entry device is a console keypad.

3. The apparatus of claim 1 wherein the at least one sensor is at least one of a revolutions-per-minute sensor, a pressure sensor and a temperature sensor.

4. The apparatus of claim 1 wherein the at least two pumps are of the gerotor type.

5. The apparatus of claim 1 wherein the system parameters include limits to at least one of a duration of the at least one shot, amounts of the at least two chemical components dispensed during the at least one shot, temperatures of the at least two chemical components dispensed during the at least one shot, and pressures of the at least two chemical components dispensed during the at least one shot.

6. The apparatus of claim 1 wherein the shot data includes at least one of a location of the at least one shot, a success indicator of the at least one shot, amounts of the at least two chemical components dispensed during the at least one shot, temperatures of the at least two chemical components dispensed during the at least one shot, and pressures of the at least two chemical components dispensed during the at least one shot.

7. The apparatus of claim 1 wherein the node location data includes a network address of at least one node and a textual representation of the location of the at least one node.

8. The apparatus of claim 1 wherein the shot data is formatted to compose a real time inventory.

9. A dispensing system including a local area network comprising:

a foam dispensing monitoring apparatus which dispenses a polyurethane foam formed as the reaction product from the mixing together of a plurality of streams of reactive foam components comprising;

a power supply;

a processor;

a memory operatively coupled to the processor;

motor control circuitry operatively coupled to the processor;

at least two supply sources of reactive foam components;

a dispensing unit for dispensing the polyurethane foam, the dispensing unit having a plurality of inputs for receiving respective supply streams of the plurality of reactive foam components, the dispensing unit further including a trigger that is selectively actuable by a user to dispense a preselected amount of the reactive foam components mixed together to form the polyurethane foam;

a plurality of foam component supply pumps for delivering the plurality of reactive foam component supply streams from the supply sources to said dispensing unit;

a pair of supply hoses interconnecting outputs of the plurality of pumps to the plurality of inputs of the dispensing unit;

a datastore for storing at least one of system parameters, shot data, and node location data;

at least one sensor operatively coupled to the processor for gathering the shot data and transmitting the shot data to the processor;

a first clock operatively coupled to the trigger for recording a time and date of the dispensing;

a second clock operatively coupled to the trigger for recording a duration of the at least one shot; and

a user interface for receiving from the processor and displaying data generated by at least one of the first clock, the second clock, and the at least one sensor comprising;

a visual display; and

a user-interactive data entry device; and

a gateway apparatus comprising;

a first data communication link operatively coupling the gateway apparatus to the foam dispensing monitoring apparatus; and

a second data communication link for operatively coupling the gateway apparatus to a master controller apparatus.

10. The foam dispensing local area network of claim 9 further comprising:

an interface apparatus operatively coupled to the foam dispensing monitoring apparatus and operatively coupled to external equipment,

wherein the interface apparatus facilitates bi-directional communication between the foam dispensing monitoring apparatus and the external equipment.

11. The foam dispensing local area network of claim 10 wherein the interface module is operatively coupled to a plurality of external equipment.

12. The foam dispensing local area network of claim 10 wherein the external equipment is at least one of sensors dedicated to the local area network.

13. The foam dispensing local area network of claim 10 wherein the external equipment is a conveyor apparatus.

14. The foam dispensing local area network of claim 9 further comprising:

a data collection apparatus operatively coupled to the foam dispensing monitoring apparatus and operatively coupled to external equipment,

wherein the data collection apparatus facilitates unidirectional communication between the foam dispensing monitoring apparatus and the external equipment.

15. The foam dispensing local area network of claim 14 wherein the data collection apparatus is operatively coupled to a plurality of external equipment.

16. The foam dispensing local area network of claim 14 wherein the external equipment is a bar-code reader.

17. The foam dispensing local area network of claim 16 wherein the bar-code reader is capable of reading at least one of a one-dimensional barcode format and a two-dimensional barcode format.

18. The foam dispensing local area network of claim 9 wherein the shot data is formatted to compose a real time inventory.

19. A dispensing system including a wide area network comprising:

at least one foam dispensing monitoring apparatus which dispenses a polyurethane foam formed as the reaction product from the mixing together of a plurality of streams of reactive foam components comprising;

a power supply;

a processor;

a memory operatively coupled to the processor;

motor control circuitry operatively coupled to the processor;

at least two supply sources of reactive foam components;

a dispensing unit for dispensing the polyurethane foam, the dispensing unit having a plurality of inputs for receiving respective supply streams of the plurality of reactive foam components, the dispensing unit further including a trigger that is selectively actuable by a user to dispense a preselected amount of the reactive foam components mixed together to form the polyurethane foam;

a plurality of foam component supply pumps for delivering the plurality of reactive foam component supply streams from the supply sources to said dispensing unit;

a pair of supply hoses interconnecting outputs of the plurality of pumps to the plurality of inputs of the dispensing unit;

a datastore for storing at least one of system parameters, shot data, and node location data;

at least one sensor operatively coupled to the processor for gathering the shot data and transmitting the shot data to the processor;

a first clock operatively coupled to the trigger for recording a time and date of the dispensing;

a second clock operatively coupled to the trigger for recording a duration of the at least one shot; and

a user interface for receiving from the processor and displaying data generated by at least one of the first clock, the second clock, and the at least one sensor comprising;

a visual display; and

a user-interactive data entry device;

a master controller apparatus comprising;

a master processor;

a master memory operatively coupled to the master processor; and

a master datastore for storing and identifying locations of nodes on the wide area network; and

the at least one gateway apparatus comprising;

a first data communication link operatively coupling the at least one gateway apparatus to the at least one foam dispensing monitoring apparatus; and

a second data communication link operatively coupling the at least one gateway apparatus to the master controller apparatus.

20. The foam dispensing wide area network of claim 19 further comprising:

a remote communication apparatus operatively coupled to the master controller apparatus for facilitating communication to a remote gateway apparatus.

21. The foam dispensing wide area network of claim 20 herein the remote communication apparatus facilitates at least one of remote monitoring of and remote control over operations of the foam dispensing wide area network.

22. The foam dispensing wide area network of claim 19 further comprising:

a personal computer operatively coupled to the master controller apparatus and operatively coupled to external equipment.

23. The foam dispensing wide area network of claim 19 wherein the shot data is formatted to compose a real time inventory.

24. A dispensing system including a wide area network comprising:

a foam dispensing monitoring apparatus which dispenses a polyurethane foam formed as the reaction product from the mixing together of a plurality of streams of reactive foam components comprising;

a power supply;

a processor;

a memory operatively coupled to the processor;

motor control circuitry operatively coupled to the processor;

at least two supply sources of reactive foam components;

a dispensing unit for dispensing the polyurethane foam, the dispensing unit having a plurality of inputs for receiving respective supply streams of the plurality of reactive foam components, the dispensing unit further including a trigger that is selectively actuable by a user to dispense a preselected amount of the reactive foam components mixed together to form the polyurethane foam;

a plurality of foam component supply pumps for delivering the plurality of reactive foam component supply streams from the supply sources to said dispensing unit;

a pair of supply hoses interconnecting outputs of the plurality of pumps to the plurality of inputs of the dispensing unit;

a datastore for storing at least one of system parameters, shot data, and node location data;

at least one sensor operatively coupled to the processor for gathering the shot data and transmitting the shot data to the processor;

a first clock operatively coupled to the trigger for recording a time and date of the dispensing;

a second clock operatively coupled to the trigger for recording a duration of the at least one shot; and

a user interface for receiving from the processor and displaying data generated by at least one of the first clock, the second clock, and the at least one sensor comprising;

a visual display; and

a user-interactive data entry device;

a master controller apparatus comprising;

a processor;

a memory operatively coupled to the processor; and

a datastore for storing and identifying locations of nodes on the wide area network;

a gateway apparatus comprising;

a first data communication link operatively coupling the gateway apparatus to the foam dispensing monitoring apparatus; and

a second data communication link operatively coupling the gateway apparatus to the master controller apparatus;

an interface apparatus operatively coupled to the foam dispensing monitoring apparatus and operatively coupled to interfaced external equipment,

wherein the interface apparatus facilitates bi-directional communication between the foam dispensing monitoring apparatus and the interfaced external equipment;

a data collection apparatus operatively coupled to the foam dispensing monitoring apparatus and operatively coupled to data collection external equipment,

wherein the data collection apparatus facilitates unidirectional communication between the foam dispensing monitoring apparatus and the data collection external equipment;

a remote communication apparatus operatively coupled to the master controller apparatus for facilitating communication to a remote gateway apparatus; and

a personal computer operatively coupled to the master controller apparatus and operatively coupled to computer-driven external equipment.