U.S. patent application number 09/754747 was filed with the patent office on 2001-09-27 for electrically operated viscous fluid dispensing apparatus and method.
This patent application is currently assigned to Nordson Corporation. Invention is credited to Estelle, Peter W., Saidman, Laurence B., Schmidt, Paul.
Application Number | 20010023876 09/754747 |
Document ID | / |
Family ID | 24125566 |
Filed Date | 2001-09-27 |
United States Patent
Application |
20010023876 |
Kind Code |
A1 |
Estelle, Peter W. ; et
al. |
September 27, 2001 |
Electrically operated viscous fluid dispensing apparatus and
method
Abstract
An electrically operated fluid dispenser for dispensing a
pattern of viscous fluid onto a substrate during a run mode. The
dispenser is turned off and does not dispense the viscous fluid
during a standby mode of operation. The dispenser includes a
dispenser body having an outlet and an armature disposed in the
dispenser body for movement between an opened position allowing a
fluid flow from the outlet and a closed position preventing the
fluid flow from the outlet. A coil is mounted adjacent the armature
and selectively generates an electromagnetic field for moving the
armature between the opened and closed positions. A controller
includes different apparatus and methods for using the coil as a
heater as well as providing other heat transfer devices on the
dispensing valve to maintain a constant temperature either, during
only the run mode or, during both, the run and the standby modes.
The above dispensing valve heating control facilitates a design of
an electrically operated fluid dispenser having a body with a fluid
passage intersecting first and second sides of the body and a
dispensing outlet in fluid communication with the fluid passage.
The dispenser includes a heater and has feed member mounted to the
first side of the body with one end of the fluid passage in the
feed plate fluidly connecting with one end of the fluid passage in
the dispenser body. The dispenser also has an cap mounted to the
second side of the dispenser body to terminate the fluid passage on
the second side of the dispenser body.
Inventors: |
Estelle, Peter W.;
(Norcross, GA) ; Saidman, Laurence B.; (Duluth,
GA) ; Schmidt, Paul; (Sugar Hill, GA) |
Correspondence
Address: |
WOOD, HERRON & EVANS, L.L.P.
2700 Carew Tower
Cincinnati
OH
45202
US
|
Assignee: |
Nordson Corporation
|
Family ID: |
24125566 |
Appl. No.: |
09/754747 |
Filed: |
January 4, 2001 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
09754747 |
Jan 4, 2001 |
|
|
|
09533347 |
Mar 23, 2000 |
|
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|
Current U.S.
Class: |
222/146.5 ;
222/504; 222/54 |
Current CPC
Class: |
B05C 5/0279 20130101;
B05C 5/001 20130101; G05D 23/1919 20130101; B05C 5/0237
20130101 |
Class at
Publication: |
222/146.5 ;
222/54; 222/504 |
International
Class: |
B67D 005/62 |
Claims
1. An electrically operated fluid dispenser for dispensing a
viscous fluid onto a substrate during a run mode and not dispensing
the viscous fluid during a standby mode, the fluid dispenser
comprising: a body having an outlet; an armature disposed in said
body and movable between an opened position allowing a fluid flow
from said outlet and a closed position preventing the fluid flow
from said outlet; a coil mounted adjacent said armature generating
an electromagnetic field capable of moving said armature between
the opened and closed positions; and a control connected to said
coil and comprising a thermal controller for energizing said coil
during the run mode to dispense the viscous fluid onto the
substrate and simultaneously maintain said coil at a desired
temperature during the run mode.
2. A fluid dispenser of claim 1 wherein said thermal controller
provides a stepped waveform signal having an initial peak current
followed by a hold current to energize said coil and dispense the
viscous fluid from the fluid dispenser during the run mode.
3. A fluid dispenser of claim 2 wherein said stepped waveform
signal comprises one of an initial peak current having a variable
duration, an initial peak current having a variable magnitude or a
hold current having a variable magnitude.
4. A fluid dispenser of claim 2 wherein said thermal controller
further comprises: a current sensor providing a feedback signal
representing current in said coil; a comparator providing an error
signal representing a difference between a setpoint correlated to a
desired temperature of said coil and said feedback signal; and a
waveform generator providing a stepped waveform signal to said
coil, said waveform generator modifying said waveform signal to
cause said error signal of said comparator to have a zero value,
thereby maintaining said coil at a desired temperature.
5. A fluid dispenser of claim 4 wherein said thermal controller
provides said stepped waveform signal during an on-time and said
current sensor provides said feedback signal representing current
in said coil during the on-time.
6. A fluid dispenser of claim 4 wherein said thermal controller
provides said stepped waveform signals during on-time periods and
nonzero waveform signals during off-time periods separating the
on-time periods, and said current sensor provides a feedback signal
representing current in said coil during the off-time periods.
7. A fluid dispenser of claim 6 wherein each of the nonzero
waveform signals is one of a pulsed waveform, a continuous nonzero
waveforms or a substantially sinusoidal waveform.
8. A method of operating an electric viscous fluid dispenser to
dispense a viscous fluid onto a substrate during a run mode
comprising: energizing a coil positioned with respect to an
armature within the fluid dispenser with a drive current to actuate
the fluid dispenser to dispense the viscous fluid onto the
substrate in response to said drive current; and simultaneously
varying said drive current to maintain said coil at a substantially
constant temperature during the run mode.
9. A method of operating an electric viscous fluid dispenser of
claim 8 wherein said drive current is comprised of current pulses
during an on-time, each current pulse having an initial peak
current followed by a hold current and the method further comprises
varying one of a magnitude of the hold current of said drive
current, a duration of the peak current of said drive current, or a
magnitude of the peak current of said drive current.
10. A method operating an electric viscous fluid dispenser of claim
8 further comprising varying an RMS value of said drive current to
maintain said coil at a substantially constant temperature during
the run mode.
11. A method operating an electric viscous fluid dispenser of claim
8 further comprising: producing a feedback signal representing
current in said coil; generating an error signal representing a
difference between a setpoint correlated to a desired temperature
of said coil and said feedback signal; and energizing said coil
with a drive current having a stepped waveform to cause said error
signal to have a zero value, thereby maintaining said coil at a
desired temperature.
12. A method operating an electric viscous fluid dispenser of claim
11 further comprising: energizing said coil with a stepped waveform
during on-times of said drive current; and producing a feedback
signal representing current in said coil during the on-times.
13. A method operating an electric viscous fluid dispenser of claim
11 further comprising: energizing said coil with a stepped waveform
during on-times of said drive current and a nonzero waveform during
off-times separating the on-times; and producing a feedback signal
representing current in said coil during the off-times.
14. A method operating an electric viscous fluid dispenser of claim
13 wherein said nonzero waveform during the off-times comprises one
of a nonzero pulse waveform, a substantially constant magnitude
waveform or a substantially sinusoidal waveform.
15. A method operating an electric viscous fluid dispenser of claim
8 further comprising energizing said coil with a second current
while the viscous fluid is not being dispensed in a standby mode to
maintain said coil at a substantially constant temperature.
16. A method operating an electric viscous fluid dispenser of claim
15 further comprising varying RMS values of said drive and second
currents to maintain said coil at a substantially constant
temperature during the run and standby modes.
17. An electrically operated fluid dispenser for dispensing viscous
fluid onto a substrate during a run mode and not dispensing the
viscous fluid during a standby mode, the fluid dispenser
comprising: a body having an outlet; an armature disposed in said
body and movable between an opened position allowing a fluid flow
from said outlet and a closed position preventing the fluid flow
from said outlet; a coil mounted adjacent said armature and
generating an electromagnetic field capable of moving said armature
between the opened and closed positions; and a controller connected
to said coil and providing output signals to cause current flow in
said coil during both the run and standby modes.
18. A fluid dispenser of claim 17 wherein said controller
comprises: power switches for providing a drive current signal to
said coil; and a thermal controller for providing a current
waveform signal to said power switches, said current waveform
signal operating said power switches to maintain said coil at a
constant temperature.
19. A fluid dispenser of claim 18 wherein said thermal controller
comprises a power control providing said current waveform signal in
response to differences between a measured power value at said coil
and a power setpoint.
20. A fluid dispenser of claim 18 wherein said thermal controller
comprises a current control providing a current waveform signal as
a function of differences between a measured current value at said
coil and a current setpoint.
21. A fluid dispenser of claim 18 wherein said thermal controller
comprises a temperature control providing a current waveform signal
as a function of differences between a measured temperature value
at said coil and a temperature setpoint.
22. A fluid dispenser of claim 17 wherein said controller
comprises: power switches for providing a drive current to said
coil; a high frequency power supply; and a switching device
connected between said power switches, said coil and said high
frequency power supply, said switching device connecting said coil
to said power switches during the run mode and connecting said coil
to said high frequency power supply during the standby mode.
23. An electrically operated fluid dispenser for dispensing viscous
fluid onto a substrate during a run mode and not dispensing the
viscous fluid during a standby mode, the fluid dispenser
comprising: a body having an outlet; an armature disposed in said
body and movable between an opened position allowing a fluid flow
from said outlet and a closed position preventing the fluid flow
from said outlet; a coil having first and second windings disposed
adjacent said armature; and a controller providing output signals
to said first and second windings of said coil to cause current
flow in said coil windings during the run and standby modes, said
controller comprising a switching apparatus placing said first and
second windings in an additive relationship during the run mode to
move said armature between the opened and closed positions, and in
an opposing relationship during the standby mode to maintain said
armature immobile in the closed position.
24. A fluid dispenser of claim 23 wherein said controller further
comprises: a power supply; power switches connected to said power
supply and providing a drive current signal to said coil; a thermal
controller providing a current waveform signal to said power
switches, said current waveform signal operating said power
switches to maintain said coil at a constant temperature; and a
switching device selectively placing said first and second windings
in an additive relationship during the run mode, and in an opposing
relationship during the standby mode.
25. A fluid dispenser of claim 24 wherein said switching device
connects said first and second windings in series.
26. A fluid dispenser of claim 24 further comprising: a power
supply; power switches connected between said first and second coil
windings and said power supply; a switch controller connected to
said power switches and selectively connecting said first and
second windings in parallel to said power supply to independently
control current flow through said first and second coil
windings.
27. A fluid dispenser of claim 23 further comprising: a power
supply having a DC output and a common output; a first power switch
connected between said one end of said first coil winding and said
DC output of said power supply; a second power switch connected
between an opposite end of said first coil winding and said common
output of said power supply; third and fourth power switches
connected between one end of said second coil winding and said DC
and common outputs, respectively, of said power supply; fifth and
sixth power switches connected between an opposite end of said
second coil winding and said DC and common outputs, respectively,
of said power supply; and a switch controller connected to said
power switches and selectively connecting said first and second
windings in parallel to said DC and common outputs of said power
supply.
28. A fluid dispenser of claim 27 wherein each of said power
switches has a control input and said switch controller has an
output connected to each of said switch controllers for selectively
opening and closing a respective power switch.
29. A fluid dispenser of claim 27 wherein each of said power
switches has a control input and said switch controller has an
output connected to each of said switch controllers for selectively
opening and closing a respective power switch over a selectable
duty cycle.
30. A fluid dispenser of claim 27 wherein each of said power
switches has a control input and said switch controller has first
outputs connected to said first and second power switches to
selectively open and close said first and second power switches
over a first duty cycle.
31. A fluid dispenser of claim 30 wherein said switch controller
has second outputs connected to said third and sixth power switches
to selectively open and close said third and sixth power switches
over a second duty cycle different from the first duty cycle.
32. A fluid dispenser of claim 31 wherein said switch controller
has third outputs connected to said fourth and fifth power switches
to selectively open and close said fourth and fifth power switches
over a third duty cycle different from the first duty cycle.
33. A fluid dispenser of claim 32 wherein said controller further
comprises a thermal controller providing a current waveform signal
to said power switches.
34. An electrically operated fluid dispenser for dispensing viscous
fluid onto a substrate during a run mode and not dispensing the
viscous fluid during a standby mode, the fluid dispenser
comprising: a body having an outlet; an armature disposed in said
body and movable between an opened position allowing a fluid flow
from said outlet and a closed position preventing the fluid flow
from said outlet; a coil having first and second windings disposed
adjacent said armature; a heating and cooling heat transfer device
mounted in a heat transfer relationship with said coil; and a
controller connected to said heat transfer device to cause said
heat transfer device to selectively add heat to and remove heat
from said coil during the run and standby modes to maintain said
coil at a constant temperature.
35. A fluid dispenser of claim 34 wherein said controller comprises
a comparator having a first input providing a temperature setpoint
and a second input receiving a second input representing a
temperature of said coil.
36. A fluid dispenser of claim 35 further comprising a temperature
sensor mounted in a heat transfer relationship with said coil and
having an output in electrical communication with said second input
of said comparator.
37. A fluid dispenser of claim 35 wherein said controller provides
stepped waveform signals to said coil during on-time periods and
said controller provides a nonzero waveform signal during each
off-time period separating the on-time periods, and said second
input of said comparator is responsive to a feedback signal
representing current in said coil during the off-times.
38. A fluid dispenser of claim 37 wherein said nonzero waveform
signal is one of a waveform pulse, a continuous nonzero waveform
having a substantially constant magnitude or a substantially
sinusoidal waveform.
39. A method of operating an electric viscous fluid dispenser
having a coil mounted adjacent an armature, the coil having first
and second coil windings for generating an electromagnetic field to
move the armature between opened and closed positions, the method
comprising: supplying a first current to each of first and second
coil windings of the coil in one direction with respect to a coil
polarity of the coil windings to move the armature to the opened
position and dispense viscous fluid onto a substrate during a run
mode; and supplying a second current to the first coil winding in
the one direction with respect to the coil polarity of the first
coil winding and to the second coil winding in an opposite
direction with respect to the coil polarity of the second coil
winding to maintain the armature in the closed position and not
dispense the viscous fluid during a standby mode, thereby
maintaining the coil at a substantially constant temperature during
the run and standby modes.
40. A method of operating an electric viscous fluid dispenser of
claim 39 further comprising: varying the first current to cause the
coil to have a desired temperature during the run mode; and varying
the second current to cause the coil to have approximately the
desired temperature during the standby mode to maintain the coil at
a substantially constant temperature during the run and standby
modes.
41. A method of claim 39 further comprising: connecting the first
and second coil windings in a serial circuit with a power supply so
that the coil polarities are in an additive relationship during the
run mode; and connecting the first and second coil windings in a
serial circuit with the power supply so that the coil polarities
are in an opposing relationship during the standby mode to maintain
the coil at a substantially constant temperature during the run and
standby modes.
42. A method of claim 39 further comprising: connecting during the
run and standby modes the first coil winding in parallel with a
power supply so that current flows in one direction with respect to
the coil polarity of the first coil winding; and selectively
connecting during the run and standby modes the second coil winding
in parallel with the power supply so that current flows in a
selected one or opposite direction with respect to the coil
polarity of the second coil to maintain the coil at a substantially
constant temperature during the run and standby modes.
43. A method of claim 39 further comprising: establishing during
the run and standby modes a current setpoint representing a desired
current in the coil; measuring during the run and standby modes
current in the coil; and generating during the run and standby
modes a current waveform signal as a function of a difference
between a measured current and the current setpoint to maintain the
coil at a substantially constant temperature during the run and
standby modes.
44. A method of claim 39 further comprising: establishing during
the run and standby modes a power setpoint representing a desired
power in the coil; measuring during the run and standby modes power
in the coil; and generating during the run and standby modes a
current waveform signal as a function of a difference between a
measured power and the power setpoint to maintain the coil at a
substantially constant temperature during the run and standby
modes.
45. A method of claim 39 further comprising: establishing during
the run and standby modes a temperature setpoint representing a
desired temperature in the coil; measuring during the run and
standby modes temperature of the coil; and generating during the
run and standby modes a current waveform signal as a function of a
difference between a measured temperature and the temperature
setpoint to maintain the coil at a substantially constant
temperature during the run and standby modes.
46. A method of claim 39 further comprising: generating during the
run and standby modes a current waveform signal as a function of a
difference between a measured variable and a desired value for that
variable; and supplying the currents to the first and second coil
windings during the run and standby modes in response to a current
waveform signal having an initial spike portion followed by a hold
portion.
47. A method of claim 46 further comprising changing one of, a
magnitude of the initial spike portion of the current waveform
signal, a duration of the initial spike portion of the current
waveform signal or a magnitude of the hold portion of the current
waveform signal, in response the difference between a measured
variable and a desired value for that variable.
48. A temperature monitor for monitoring a temperature of an
electrically operated fluid dispenser having a coil mounted
adjacent an armature, the coil selectively generating an
electromagnetic field to move the armature between opened and
closed positions, the temperature monitor comprising: a current
measuring circuit for measuring a current in the coil; a comparator
for comparing a measured current to a desired current, said
measured and desired currents representing measured and desired
temperatures, respectively; and an indicator device providing an
indication representing a relationship between the measured
temperature and the desired temperature.
49. A temperature monitor of claim 48 wherein said current
measuring circuit comprises a current measuring device for
measuring an average value of said current in the coil.
50. A temperature monitor of claim 48 wherein said current
measuring circuit comprises a current measuring device for
measuring an RMS value of said current in the coil.
51. A temperature monitor of claim 48 wherein said current
measuring circuit comprises an integrated circuit chip for
measuring an RMS value of said current in the coil.
52. A temperature monitor of claim 48 wherein said comparator
comprises circuitry for comparing said measured current to a
plurality of reference current values.
53. A temperature monitor of claim 48 said indicator device
comprises an indication representing one of a measured value of the
temperature exceeding the desired value of the temperature, a
measured value of the temperature near but not exceeding the
desired value of the temperature or a measured value of the
temperature less than the desired value of the temperature.
54. A method for monitoring a temperature of an electrically
operated fluid dispenser having a coil mounted adjacent an
armature, the coil generating an electromagnetic field to move the
armature between opened and closed positions, the method
comprising: measuring a current in the coil; comparing a measured
current value to a desired current value, said measured and desired
current values representing measured and desired temperatures,
respectively; and providing an indication representing a
relationship between the measured temperature and the desired
temperature.
55. A method of claim 54 further comprising measuring an RMS value
of the current.
56. A method of claim 54 further providing an indication
representing one of a measured temperature exceeding the desired
temperature, a measured temperature near but not exceeding the
desired temperature or a measured temperature less than the desired
temperature.
57. An electrically operated fluid dispenser comprising: a first
body having a fluid passage intersecting first and second sides of
said first body and an outlet in fluid communication with said
fluid passage; a first armature disposed in said first body and
movable between an opened position allowing a fluid flow from said
outlet and a closed position preventing the fluid flow from said
outlet; a first coil mounted adjacent said first armature and
selectively generates an electromagnetic field capable of moving
said first armature between the opened and closed positions; and a
first heater for maintaining said first coil at a substantially
constant temperature.
58. An electrically operated fluid dispenser of claim 57 further
comprising: a feed member having a fluid passage intersecting first
and second ends of said feed member, said first end of said feed
member being mounted to said first side of said body with one end
of said fluid passage in said feed member fluidly connecting with
one end of said fluid passage in said body; and a cap mounted to
said second side of said body and terminating said fluid passage on
said second side of said body.
59. An electrically operated fluid dispenser of claim 58 further
comprising: a second body having a fluid passage intersecting two
sides of said second body and an outlet in fluid communication with
said fluid passage, said first side of said second body being
mounted against said second side of said first body with one end of
said fluid passage in said second body fluidly connecting with an
opposite end of said fluid passage in said first body, and said cap
being mounted to said second side of said second body; a second
armature disposed in said second body for movement between an
opened position allowing a fluid flow from said outlet and a closed
position preventing the fluid flow from said outlet; a second coil
mounted adjacent said second armature and selectively generates an
electromagnetic field capable of moving said second armature
between the opened and closed positions; and a second heater for
maintaining said second coil at a substantially constant
temperature.
60. An electrically operated fluid dispenser of claim 59 further
comprising a spacer plate having a fluid passage intersecting first
and second sides of said spacer plate, said first side of said
spacer plate being mounted to said second side of said first body
with one end of said fluid passage in said spacer plate fluidly
connecting with an opposite end of said fluid passage in said first
body, and said second side of said spacer plate being mounted to
said first side of said second body with one end of said fluid
passage in said second body fluidly connecting with an opposite end
of said fluid passage in said spacer plate.
61. An electrically operated fluid dispenser of claim 57 wherein
said first heater comprises said first coil being energized by a
current in said coil.
62. An electrically operated fluid dispenser of claim 57 wherein
said first heater comprises a heating and cooling heat transfer
device mounted in a heat transfer relationship to said first
coil.
63. An electrically operated fluid dispenser of claim 59 wherein
said first and second heaters comprise said first and second coils,
respectively, being energized by currents in said respective first
and second coils.
64. An electrically operated fluid dispenser of claim 59 wherein
said first and second heaters comprise first and second heating and
cooling heat transfer devices mounted in a heat transfer
relationship to said first and second coils, respectively.
Description
FIELD OF THE INVENTION
[0001] The present invention generally relates to an apparatus for
dispensing viscous fluids and more specifically, to an electrically
operated apparatus for dispensing viscous liquids, such as hot melt
adhesives.
BACKGROUND OF THE INVENTION
[0002] Pneumatic and electric viscous fluid dispensers have been
developed for dispensing applications requiring precise placement
of a viscous fluid. Pneumatic dispensers have a significant
advantage in that the pneumatic solenoid operating the dispensing
valve can be made very strong, so that the dispensing valve
operation is essentially independent of the viscosity of the fluid
being dispensed. However, pneumatic dispensers have disadvantages
in that they generally have a shorter life than electric fluid
dispensers, and the operation of the pneumatic solenoid is subject
to less precise control than the electric solenoid in an electric
fluid dispenser. Therefore, in some applications, electrically
operated viscous fluid dispensers are preferred over pneumatic
viscous fluid dispensers.
[0003] Generally, electrically operated dispensers include an
electromagnetic coil surrounding an armature that is energized to
produce an electromagnetic field with respect to a magnetic pole.
The electromagnetic field is selectively controlled to open and
close a dispensing valve by moving a valve stem connected to the
armature. More specifically, the forces of magnetic attraction
between the armature and the magnetic pole move the armature and
valve toward the pole, thereby opening the dispensing valve. At the
end of a dispensing cycle, the electromagnet is de-energized, and a
return spring returns the armature and valve stem to their original
positions, thereby closing the dispensing valve.
[0004] In the operation of an electric viscous fluid dispensing
gun, the coupling between the coil and the armature is not
efficient; and therefore, in order to achieve the highest actuation
speed, a current pulse or spike is typically provided to the coil
during an initial turn-on period in order to initiate the motion of
the armature as quickly as possible. However, maintaining such a
level of current to the coil quickly and substantially increases
coil temperature. Further, maintaining such a high level of current
increases the time required for the energy stored in the coil's
inductance to dissipate, thereby increasing the turn-off time and
the time required to close the fluid dispenser. Therefore, after
the initial current spike, the current through the coil is normally
reduced to approximately the minimum value required to hold the
armature in its open position by overcoming the opposing force of
the return spring. Such a stepped current waveform is useful in
reducing the current induced heat load in the coil, thereby
allowing the coil to operate at a lower temperature than if the
stepped waveform were not used. However, as is described below, the
operation of the coil and armature during the fluid dispensing
process creates other heat related issues that impact the quality
of the fluid dispensing process.
[0005] The continued development and use of viscous fluid electric
dispensers has resulted in more demanding performance
specifications as well as a greater understanding of how heat in
the dispenser can potentially effect performance. For example, the
electric coil of an electric dispensing valve normally is not
capable of providing the same forces as a pneumatic solenoid and
therefore, is more subject to changes in resistance to valve stem
motion that may be caused by changes in viscosity of the fluid
being dispensed. Thus, as the viscosity of the fluid being
dispensed changes, the load on the electromagnetic coil changes,
and the time required to open and close the dispensing valve will
likewise change. Such changes in timing of the dispensing valve
opening and closing will change the location of the adhesive being
dispensed on the substrate.
[0006] In addition to the above, newer applications have more
demanding performance specifications and require ever-increasing
gun speeds, that is, a shortening of the time required to open and
close the dispensing valve. The operational speed of the dispensing
valve can be increased by increasing the electrical power applied
to the electric coil operating the valve. The electrical power is
normally increased by increasing the current being supplied to the
coil which also adds heat to the coil, thereby causing the
temperature of the coil to rise. A hotter or higher coil
temperature impacts the consistency of the viscous fluid dispensing
in several ways. First, heat from the coil is conducted through the
armature and the valve stem which is adjacent the valve seat and is
surrounded by the viscous fluid. As the temperature of the armature
fluctuates, for example, goes up, the viscosity of the fluid to be
dispensed likewise fluctuates and, in this example, decreases,
thereby changing the flow of the viscous fluid from the
dispenser.
[0007] Second, the speed at which the armature can be moved between
the open and closed positions is a function of the rate of change
of current in the coil, which, in turn, is controlled by the
electrical time constant of the coil. The electrical time constant
is a function of the coil resistance which, in turn, is a function
of temperature. The coil utilized in the viscous fluid dispenser
discussed herein can experience an approximately 50% variation in
resistance over its normal range of operating temperature. Such a
change in resistance substantially affects the electrical time
constant of the coil, thereby similarly affecting the speed at
which the coil can open and close the valve.
[0008] The thermal time constant of the coil is a function of the
coil mass and its thermal connections to surrounding materials such
as the gun body and ambient temperature. The thermal time constant
of the coil and its surrounding thermal system affects the time
required for the thermal system to reach a steady state condition.
When the dispensing system is running at a constant speed, and a
steady state condition is achieved, the thermal time constant
normally does not present a source of variation in the operation of
the dispensing coil. However, the steady state condition can change
for several reasons, for example, if the production line speed is
either increased or decreased or, the dispensing gun is not
operating and in the standby mode. Either of those conditions
causes the coil temperature to change, and the thermal time
constant presents a source of variations in the operation of the
viscous fluid dispenser.
[0009] Of further concern is the maximum temperature rating of the
coil wire insulation. Under normal operating conditions, the
temperature rating of the wire insulation exceeds the wire
temperature. However, in a worse case situation, if the temperature
of the wire exceeds the temperature rating of the wire insulation,
the integrity of the coil wire insulation may be compromised,
thereby causing coil windings to short-circuit together. Any coil
windings that short-circuit together will change the resistance of
the coil and potentially adversely effect the consistency of the
fluid dispensing operation of the dispenser.
[0010] Thus, by using a stepped current waveform, known electric
fluid dispensers attempt to reduce the temperature of the coil.
Further, it is known to utilize a heater in a manifold to which the
fluid dispenser is mounted to control the temperature of the fluid
circulating through the manifold and the fluid dispenser, thereby
indirectly controlling the temperature of the dispenser itself.
However, as will be appreciated, there have been no attempts to
control the temperature of the fluid dispenser directly with a self
contained device in order to maintain the electric fluid dispenser
at a constant temperature.
SUMMARY OF INVENTION
[0011] The present invention provides an improved electric
dispenser for viscous fluids that manages the thermal condition of
the dispenser directly to provide a substantially improved, more
consistent dispensing of viscous fluids. The electric dispenser of
the present invention provides more consistent actuation of the
dispensing valve independent of changes in the speed of operation
of the dispenser. The electric fluid dispenser of the present
invention reduces the range of temperature fluctuations resulting
from changes in speed of the production line and changes in the
frequency of operation of the fluid dispenser. Further, the
electric fluid dispenser of the present invention maintains a
generally constant coil temperature independent of the rate of gun
operation. Providing a fluid dispenser that has a self-contained
temperature control that reduces the range of temperature
variations helps to maintain the viscosity of the fluid within the
dispenser constant. By better controlling the temperature within
the electric viscous fluid dispenser, a more consistent, faster and
reliable operating cycle is achieved. Thus, the electric dispenser
of the present invention provides the advantage of dispensing a
viscous fluid more accurately, precisely and with a higher quality
than was heretofore possible.
[0012] In accordance with the principles of the present invention
and the described embodiments, the invention in one embodiment
provides an electrically operated fluid dispenser for dispensing a
viscous fluid onto a substrate during a run mode. The dispenser
includes a body having an outlet and an armature disposed in the
dispenser body for movement between an opened position allowing a
fluid flow from the outlet and a closed position preventing the
fluid flow from the outlet. A coil is mounted adjacent the armature
and selectively generates an electromagnetic field for moving the
armature between the opened and closed positions. A controller is
connected to the coil and provides output signals to energize a
coil positioned with respect to an armature within the fluid
dispenser with a drive current to actuate the fluid dispenser and
to simultaneously maintain the coil at an approximately constant
temperature during the run mode.
[0013] In one aspect of the one embodiment, the controller includes
power switches providing a drive current signal to the coil and a
thermal controller providing a current waveform signal to the power
switches. The current waveform signal operates the power switches
to maintain the coil at a constant temperature in response to a
temperature control loop.
[0014] In another aspect of the one embodiment, a heat transfer
device is mounted in a heat transfer relationship with the
dispenser body; and the controller is connected to the heat
transfer device to cause the heat transfer device to selectively
transfer heat between the heat transfer device and the dispenser
body during the run and standby modes, thereby maintaining the
dispenser body at a constant temperature during the run and standby
modes.
[0015] In a second embodiment of the invention, the dispenser is
turned off and does not dispense the viscous fluid during a standby
mode of operation; and the controller provides further output
signals to energize the coil with a current to maintain the coil at
an approximately constant temperature during the standby mode.
[0016] In another embodiment of the invention, the coil has first
and second windings disposed adjacent the armature, the controller
selectively provides output signals to the first and second
windings of the coil to cause current flow in the coil windings
during the run and standby modes. The controller further includes a
switching apparatus selectively placing the first and second
windings in an additive relationship during the run mode to move
the armature between the opened and closed positions and in an
opposing relationship during the standby mode to maintain the
armature immobile in the closed position.
[0017] In one aspect of this other embodiment, the controller
includes power switches providing a drive current signal to the
coil; and a thermal controller for provides a current waveform
signal to the power switches. The current waveform signal operates
the power switches to maintain the coil at a constant temperature.
The thermal controller generates the current waveform signal in
response to changes in either power, current or temperature
variables with respect to a respective desired value of those
variables.
[0018] In another aspect of this other embodiment, the controller
includes a high frequency power supply and a switching device
connected between the power switches, the coil and the high
frequency power supply. The switching device connects the coil to
the power switches during the run mode and connects the coil to the
high frequency power supply during the standby mode.
[0019] In a further aspect of this other embodiment, the controller
includes power switches for connecting the coil windings in
parallel across a power supply to permit the duty cycle of the
current flow in each of the coil windings to be individually
controlled, thereby uncoupling and independently controlling the
power heating of the coil from the actuation power provided by the
coil windings.
[0020] In a still further embodiment of the invention, a method is
provided for operating an electric viscous fluid dispenser to
maintain a coil positioned with respect to an armature within the
dispensing gun at an approximately constant temperature during the
run mode by heating the coil. In an additional embodiment, the
above method includes maintaining the coil at an approximately
constant temperature while the viscous fluid is not being
distributed during a standby mode by heating the coil during the
standby mode. In different aspects of this invention, the coil is
heated during the run and standby modes by current flowing through
the coil or by a separate heating and cooling heat transfer device.
In a further aspect of the invention, the heating of the coil is
controlled by an RMS value of the current in the coil.
[0021] The above embodiments of a fluid dispenser temperature
controller have the advantages of reducing the range of temperature
variations within the fluid dispenser and normally, maintaining the
temperature of the fluid dispenser approximately constant. Thus,
the fluid dispenser temperature controller does not rely on the
user being able to control the best current waveform parameters,
but instead, is adaptive and self-adjusting to maintain a constant
coil temperature. The active temperature control protects the coil
from overheating in the event that the user adjusts the current
waveform such that an excessive temperature would otherwise be
produced. With a constant coil temperature, the viscosity of the
fluid within the dispensing gun is held more consistent, thereby
improving the consistency of the dispensing process. Further, by
maintaining the constant temperature over the full range of
operating frequency of the dispensing gun, the coil temperature
controller provides a further advantage of providing a higher
quality and more consistent viscous fluid dispensing operation. In
addition, such a temperature control permits the dispensing gun to
be consistently operated at a rate that is very close to, if not
at, the theoretical maximum temperature limit of the gun without
overheating.
[0022] In a further embodiment of the invention, an electrically
operated fluid dispenser has a body with a heater and a fluid
passage intersecting first and second sides of the body and a
dispensing outlet in fluid communication with the fluid passage.
The dispenser includes a feed member having a fluid passage
intersecting ends of the feed plate. One end of the feed member is
mounted to the first side of the body with one end of the fluid
passage in the feed member fluidly connecting with one end of the
fluid passage in the body. The dispenser also has a cap mounted to
the second side of the body to terminate the fluid passage on the
second side of the body.
[0023] In one aspect of this further embodiment, the dispenser
includes a second dispenser with a body having a heater, a fluid
passage intersecting first and second sides of the second body and
a dispensing outlet in fluid communication with the fluid passage.
The first side of the second body is mounted to the second side of
the first body with one end of the fluid passage in the second
dispenser body fluidly connecting with an opposite end of the fluid
passage in the first dispenser body.
[0024] In other aspects of this further embodiment, the dispenser
includes a spacer plate disposed between the first and second
bodies, and the heater is comprised of either a coil mounted with
respect to an armature within the body or, a heating and cooling
heat transfer device.
[0025] This further embodiment of the invention with the use of the
coil heater has the advantage of maintaining the viscous fluid
within the passage at the desired temperature without requiring a
separate fluid distribution manifold plate to which the dispensing
gun is normally mounted. A dispensing gun of this construction has
the further advantage of being substantially more compact than the
traditional manifold plate design. Further, the construction of the
dispensing gun is substantially less expensive; and its simpler
construction provides substantially greater flexibility in mounting
the dispensing gun with associated equipment.
[0026] In yet another embodiment of the invention, a temperature
monitor for monitoring a temperature of an electrically operated
fluid dispenser has a coil mounted adjacent an armature within the
dispenser, the coil selectively generates an electromagnetic field
to move the armature between opened and closed positions. The
temperature monitor includes current measuring apparatus for
measuring a current in the coil and a comparator for comparing a
measured current value to a desired current value. An indicator
provides an indication representing a relationship between the
measured current value and the desired current value.
[0027] In different aspects of this embodiment, the temperature
monitor measures the RMS value of the current in the coil and has
different indicators for providing different indications
representing different values of the measured current relative to a
desired current value.
[0028] The thermal monitor has the advantage of providing the user
with a real time indication of whether the user's adjustments to
the current waveform provide a coil temperature that is less than,
close to or in excess of the maximum coil temperature. In addition,
the thermal monitor has the further advantage of helping the user
select the temperature limits which are appropriate for the
dispensing gun being used and the dispensing application being
effected.
[0029] Various additional advantages, objects and features of the
invention will become more readily apparent to those of ordinary
skill in the art upon consideration of the following detailed
description of the presently preferred embodiments taken in
conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF DRAWINGS
[0030] FIG. 1 is an axial cross-sectional view of an electrically
operated fluid dispenser constructed according to the invention;
and
[0031] FIGS. 2A-2D are schematic diagrams of current waveform
signals used to provide a drive current signal to the coil of the
dispensing valve of FIG. 1.
[0032] FIG. 3 is a schematic block diagram of a gun controller that
includes a thermal controller for controlling the temperature of
the dispensing valve coil in accordance with the principles of the
present invention.
[0033] FIG. 4 is a schematic block diagram of one embodiment of the
thermal controller of FIG. 3.
[0034] FIG. 5 is a flow chart illustrating process steps associated
with the learn mode of the gun controller.
[0035] FIG. 6 is a schematic block diagram of another embodiment of
the thermal controller of FIG. 3 utilizing a current setpoint.
[0036] FIGS. 7A and 7B are schematic block diagrams of further
alternative embodiments of the thermal controller of FIG. 3 that
utilize a temperature control loop.
[0037] FIG. 8 is a schematic block diagram illustrating a second
embodiment of a gun controller for controlling the temperature of
the dispensing valve coil in accordance with the principles of the
present invention.
[0038] FIG. 9 is a schematic block diagram of a further embodiment
of a gun controller for controlling the temperature of the
dispensing valve in accordance with the principles of the present
invention.
[0039] FIG. 10 is a partially disassembled view of a dispensing gun
utilizing the coil heating capabilities of the present
invention.
[0040] FIG. 11 is a schematic diagram of an embodiment utilizing an
integrated circuit chip to detect temperature variations in the
dispensing valve coil.
[0041] FIG. 12 is a schematic diagram of an alternative embodiment
for interconnecting coil windings of a bifilar coil.
[0042] FIG. 13 is a schematic block diagram of an alternative
embodiment of a gun controller with a thermal controller for
controlling the temperature of the dispensing valve coil in
accordance with the principles of the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0043] Referring first to FIG. 1, an electrically operated viscous
fluid dispenser or dispensing gun 10 comprises one or more
dispensing modules or valves 33 mounted on a fluid distribution
manifold plate 45 in a known manner. The dispensing valve 33
includes a dispenser body 12 and a fluid dispensing nozzle body 14.
The dispenser 10 is adapted for dispensing high viscosity fluids,
such as a hot melt adhesive, but other dispensed fluids can benefit
from the invention as well. Such other fluids include soldering
fluxes, thermal greases, heat transfer compounds and solder pastes.
Furthermore, the dispenser 10 is mounted in a dispensing machine or
system (not shown) in a known manner to dispense fluids in discrete
amounts, preferably as droplets or dots, but alternatively in
continuous beads. As shown in FIG. 1, the dispenser body 12 used in
conjunction with the fluid dispensing nozzle body 14 is
particularly constructed to dispense droplets 18 of the viscous
fluid onto a substrate 19. Relative motion between the substrate 19
and dispenser 10 is provided in a known manner.
[0044] A valve stem 26 is mounted in an interior portion 20 of the
dispenser body 12, and the valve stem includes a shaft 28 through
the interior portion 20. A ball 30 is mounted to a lower end 28a of
the shaft 28 which is shown in FIG. 1 in sealing engagement with a
valve seat 32 positioned in the nozzle body 14. Thus, the valve
stem 26 and ball reciprocate between opened and closed positions
with respect to the valve seat 32, thereby operating as a
dispensing valve 33. With the ball 30 sealingly engaging valve seat
32, high viscosity fluid, such as an epoxy, cannot flow through an
outlet 34 in the valve seat 32. The nozzle body 14 also has a
nozzle tip 36 with an orifice 38 aligned with the outlet 34 and
flush mounted to the valve seat 32 by a threaded retaining nut 40.
The nozzle tip 36 can be readily exchanged with a different nozzle
tip to produce droplets of a different size and, in some cases, a
different shape.
[0045] A fluid inlet passageway 46 intersects the interior portion
20 and is connected to a fluid passage 49 in the manifold 45 which
in turn is fluidly connected to a source 47 of hot melt adhesive
which normally is pressurized. Arrows 50 indicate the flow path of
the fluid entering through the fluid inlet passageway 46 and
through the interior portion 20.
[0046] An armature 60 is disposed within the interior portion 20
and is coaxially aligned with and, preferably, formed integrally
with shaft 28. An electromagnetic coil 70 is disposed about the
armature 60. Although any suitable electromagnetic coil could be
used, it is contemplated that the electromagnetic coil 70 will be
generally toroidal in shape. The coil 70 is contained in a housing
72 and connected to a power source (not shown). When supplied with
electrical current, the coil 70 generates an electromagnetic field
which actuates the valve stem 26 to an open position as will be
described below.
[0047] A bore 80 extends into the armature 60 to house a return
spring 82. The return spring 82 biases the valve stem 26 and, more
specifically, the ball 30, to sealingly engage the valve seat 32 in
a closed position. The return spring 82 is normally a compression
spring which is placed under compression within the bore 80 through
engagement with an electromagnetic pole 84. To achieve an opened
position, the electromagnetic coil 70 must generate a sufficient
electromagnetic field between the armature 60 and the pole 84 so as
to attract the armature 60 and the pole 84 together. Since the pole
84 cannot move, the armature 60 will move against the force of the
spring 82 until it hits the pole 84. The stroke length is the
distance between the armature 60 and the pole 84 as shown in FIG.
1. An adjustment nut 86 provides a means to initially set the
stroke length. More specifically, brazing 88 connects the pole 84
to a tubular member 90. The tubular member 90 has a lower threaded
portion 92 received within an internally threaded lower housing
portion 94. A tool, such as a screwdriver, may be used to turn the
pole 84 and, therefore, the tubular member 90, as an O-ring 96
slides against an interior surface of the lower housing portion 94.
This adjustment varies the distance between the lower end of the
pole 84 and the upper end of the armature 60 or, in other words,
varies the stroke length of the valve stem 26. A lower donut 98 is
disposed about the tubular member 90 and rests against an upper
side of the lower housing portion 94 while an upper donut 100 is
held against the coil housing 72 by the nut 86 and a lock washer
102. Such a dispenser 10 is further described in commonly-assigned,
U.S. Pat. No. 5,875,922, entitled APPARATUS FOR DISPENSING AN
ADHESIVE, issued on Mar. 2, 1999, which is hereby incorporated by
reference herein in its entirety.
[0048] As previously discussed, electric guns are preferred because
of the precision with which they may be controlled during a
manufacturing operation. However, electric guns have a disadvantage
in that temperature variations within the gun directly effect the
guns' performance. Further, known electric fluid dispensers apply a
stepped current waveform to the coil that has an initial spike and
then steps down to a magnitude sufficient to hold the valve stem 28
in its open position by overcoming the opposing force of the return
spring 82. A series of such current waveform signals is
schematically illustrated in FIG. 2A. To turn the gun on, thereby
opening the dispensing valve 33, an initial current magnitude
I.sub.pk is applied for a duration or period of time T.sub.pk in
response to a trigger pulse. Thereafter, the current is reduced to
a lesser hold level I.sub.h for the remaining period of the on-time
T.sub.on. The zero current value is then maintained for an off-time
T.sub.off during the remaining time of the current waveform period
T.sub.P. As will be appreciated, the waveform illustrated in FIGS.
2A-2D is for purposes of discussion and the real waveform consists
of exponential functions that transition the current between
levels. The real time on-time wave shape can look radically
different from the idealized waveform of FIG. 2A-2D, depending on
many factors such as I.sub.pk, I.sub.h, T.sub.pk, T.sub.on,
T.sub.p, L.sub.coil, R.sub.coil, etc. The T.sub.on and T.sub.p are
related to the adhesive pattern required for a particular product.
The inductance and resistance of the coil are a function of the gun
itself, and the I.sub.pk is normally bounded by the limits of
magnetic saturation of the dispensing gun 10.
[0049] The current waveform period T.sub.p is inversely related to
frequency. Thus, as the frequency of the trigger pulses increases,
the period T.sub.p of the current waveform decreases. Thus, over
time, coil heating is a function of the frequency of operation of
the dispensing gun 10, the peak current magnitude I.sub.pk, the
duration of the peak current T.sub.pk, the magnitude of the hold
current I.sub.h and the current waveform on-time T.sub.on. Initial
values of magnitudes of the peak and hold currents are based on the
coil specifications, however, the peak current magnitude I.sub.pk,
the magnitude of the hold current I.sub.h and the duration of the
peak current T.sub.pk are all adjustable by the user. The user
often adjusts the current waveform and the dispensing line rate in
order to tune the dispensing operation to its peak performance.
However, the user has no real time feedback as to the effects of
such adjustments on the coil temperature which, as discussed
earlier, can have adverse effects on the quality of the dispensing
process. Thus, such system tuning is also influenced by other
constantly changing conditions which make such adjustments not
repeatable and somewhat of an art form.
[0050] The present invention actively controls the current waveform
parameters over substantially the full range of operation of the
dispensing gun 10, so that the coil temperature is maintained at a
constant value less than a maximum coil temperature. If coil
temperature is maintained constant for different triggering
frequencies, the adverse effects of changes in coil temperature are
eliminated, thereby providing a more consistent and precise viscous
fluid dispensing operation.
[0051] One embodiment for regulating coil temperature is
illustrated in FIG. 3 in which the coil 70 is a bifilar coil, that
is, a coil having two independent coil windings 110, 112. The coil
windings are connected by a switching device 114 which can be
implemented using switching relay or semiconductor switches such as
MOSFET, IBGT, BJT, etc. In FIG. 3, the switching device 114 is
illustrated as a switching relay comprised of switching contacts
116 and a switching solenoid 118. During a run mode during which
fluid is being dispensed, the switching device 114 connects the
coil windings 110, 112 via the contacts A such that the first coil
winding 110 is in series with the second coil winding 112, and the
current therethrough flows in a common direction with respect to
the coil polarity of the coil windings 110, 112. In a standby mode,
the dispensing gun 10 is inactive; and therefore, in response to a
standby signal, the switching device 114 switches the coil winding
112 to contacts B, thereby connecting the coil windings 110, 112 in
opposition. Thus, during the standby mode, current flows through
coil winding 110 in one direction with respect to its coil
polarity, however, current flows in the opposite direction in
winding 112 with respect to its coil polarity. The flux fields
created by windings 110 and 112 oppose and cancel each other. With
a net flux of zero, the current flow through the coil 70 is unable
to overcome the force of the return spring 82. Consequently, during
the standby mode, the armature is maintained immobile in the
presence of current flow through the coil 70, and the dispensing
valve 33 remains in its closed position. Consequently, a
substantially constant current flows through the coil 70 at all
times independent of the dispensing operation of the dispensing
valve 33, thereby maintaining a substantially constant temperature
within the coil 70.
[0052] Referring to FIG. 3, the coil 70 is connected to a gun
controller 120 including a power supply 122, a coil current
modulator 124, a thermal controller 126 and a current sensor 128.
The current sensor 128 can implement one of many current measuring
methods including using a simple resistor, a Hall effect device, a
current transformer, etc. The gun controller 120 is further
connected to a machine or system control 130 and provides output
signals to warning and fault indicators 132 which may be included
within the gun controller 120 or a part of other devices, for
example, the system control 130. The system control 130 includes
all of the other known dispensing system or machine controls
necessary for the operation of the dispensing system. The system
control 130 also includes input devices such as a keypad,
pushbuttons, etc. and output devices such as a display, indicator
lights, etc. that provide communication links with a user in a
known manner. The thermal controller 126 can be implemented using
analog or digital circuit components; however, the thermal
controller is normally implemented with a programmable
microcomputer control that operates in response to stored program
instructions as well as signal inputs to the controller 126.
[0053] In this embodiment of the invention, in order for the
temperature of the coil 70 to remain constant, the power being
supplied to the coil should also be constant. The power to the coil
can theoretically be no more than the power being supplied to the
coil with the production line running at its maximum rate. In order
to determine that power value, the gun controller 120 executes a
learn mode of operation which is typically initiated by the user
actuating a switch on the system control 130 that provides a learn
signal on an output 130 to the gun controller 120. A schematic
functional block diagram of one embodiment of a portion of the
thermal controller 126 is illustrated in FIG. 4. The thermal
controller 126 includes a power control 137 that is implemented
with a programmable microprocessor control having programmed
instructions to implement the devices shown within the control 137.
The learn mode process executed by the thermal controller of FIG. 4
is illustrated by the flow chart illustrated in FIG. 5. The first
step, at 502, of the learn mode process is to operate the
dispensing gun 10 at its maximum rate. Normally, the system control
130 is used to run the production line at its maximum rate which,
in turn, causes the dispensing gun 10 to also operate at its
maximum rate.
[0054] The dispensing gun 10 is operated in response to a trigger
pulse suppled on output 131 from the system control 130. With each
trigger pulse, a waveform signal, as illustrated in FIG. 2A, is
provided by a waveform generator 148. The waveform signal, for
example, a current waveform, determines the waveform of an output
signal, for example, a drive current, that is provided by the coil
current modulator 124. The values of I.sub.pk and T.sub.pk are
generally chosen as a function of the viscosity of the fluid being
dispensed. Further, the value of the hold current I.sub.h is set to
a nominal value equal to the minimum current required to hold the
valve in the open position, that is, the minimum value of current
to overcome the biasing force of the compressed spring 82 (FIG. 1).
That current waveform passes through the D/A converter 149 and from
the thermal controller 126 on an output 151. The current waveform
then drives power switches 154 in the coil current modulator 124 to
provide the desired current or power from the power supply 122 to
the coil 70. Thus, the dispensing valve 33 is operated at the
maximum frequency that would be expected in the current
application. Alternatively, it may be possible to use the system
control 130 to operate the dispensing valve 33 independently of the
production line. Next, at 503, the rate at which trigger pulses are
being generated at the maximum frequency is stored in the system
control 130. As will be appreciated, this process step is optional
depending on how current is applied to the coil in the standby mode
of operation.
[0055] When operating in the learn mode, the maximum current or
power being consumed by the dispensing gun 10 must be identified to
establish a power target or setpoint for the control of the gun
during the run or dispensing mode of the dispensing gun 10. Thus,
the next step 504 in the learn mode is to measure the current flow
through the coil 70 while the gun is operating at its maximum rate.
In one aspect of the invention, the current is measured by a
current sensor 128, and a measured current value on an output 129
is provided to the controller 126 by means of an A/D converter 136
of FIG. 4. The digital current value from the A/D converter 136 is
then sampled, averaged and stored. The RMS value of the current or
the voltage at the coil is a measure of the heating power in the
coil. Therefore, normally, the RMS value of the current is
computed, which provides a value that is very representative of the
temperature of the coil. As is appreciated, computing the RMS value
of the current consumes significant resources within the control
137. Therefore, alternatively, the current sensor 128 output can be
input to an integrated circuit chip that senses the current and
provides a DC voltage output having a magnitude value proportional
to the RMS value of the sensed current. Such an integrated circuit
chip is illustrated as chip 180 in FIG. 11, and an output 188 from
the chip 180 is then an input to the A/D converter 136.
[0056] The learn mode at 506 then requires a computation of the
coil power at the maximum gun operating rate. The coil power is
determined within the controller 126 by a current-to-power
converter 138. As will be appreciated, any known relationship
between current, voltage, coil resistance and power may be used to
compute the power, however, the power is normally computed
utilizing the formula P=I.sup.2.sub.coil.times.R.sub- .coil. Thus,
the resistance of the coil is required for the power computation.
The resistance of the coil can be determined in one of several
ways. First, a previously determined and stored coil resistance
value can be read from a store (not shown) within the processor 126
and used in the current-to-power conversion. However, as discussed
earlier, the resistance of the coil is a function of the coil
temperature. Therefore, alternatively, a table correlating coil
temperature to coil resistance values may be stored in the
controller 126, and a temperature sensor 139, shown in phantom in
FIG. 3, mounted in a heat transfer relationship with the coil 70
can be used to detect the temperature of the coil. In this aspect
of the invention, the temperature sensor 139 is read by the
controller 126 and a comparable coil resistance read from the
table.
[0057] Alternatively, the resistance of the coil can be calculated
in real time based on temperature measurements from the sensor 139
in accordance with the equation
R.sub.h=R.sub.c(1+.alpha.(T.sub.h-T.sub.c)), where R.sub.h and
R.sub.c are the respective hot and cold resistances of the coil;
T.sub.h and T.sub.c are the respective hot and cold temperatures of
the coil; and .alpha. is the coefficient of thermal resistance of
copper, that is, 0.00218/.degree. F. A preproduction cold
resistance of the coil R.sub.c is determined at T.sub.c by applying
minimal power to the coil and calculating R.sub.c as the ratio of
an applied voltage to a measured current. The T.sub.c, R.sub.c and
alpha values are stored, and at selected times during the run mode,
the temperature of the coil T.sub.h is measured with the sensor
139, and the above formula is used with the stored values to
calculate the resistance of the coil R.sub.h.
[0058] In a further alternative, the resistance of the coil can be
measured in real time by other methods. For example, referring to
FIG. 2B, during the off-time T.sub.off of the current waveform, the
control circuit provides a sample current pulse to the coil 70; and
the coil current and voltage are measured in a known manner. The
resistance value of the coil can then be computed from the samples
of voltage and current in accordance with Ohm's Law. FIG. 2C
illustrates another method in which during the off-time T.sub.off
of the current waveform, a small, non-zero, substantially constant
magnitude current waveform is applied to the coil 70. In a similar
manner, the coil current and voltage are measured and used to
compute the resistance of the coil 70. The magnitude of the small,
nonzero current of FIGS. 2B and 2C is less than the magnitude of
the hold current, so that the even though the coil is electrically
turned-on, the spring force maintains the coil 70 mechanically
turned-off.
[0059] Coil resistance can be measured using a still further
alternative illustrated in FIG. 2D in which a sine wave is applied
to the coil 70 during the off-time T.sub.off of the current
waveform. The sine wave has a peak-to-peak value that is less than
the magnitude of the hold current, so that the coil 70 is
electrically on but mechanically off. Further, the sine wave
normally has a frequency of approximately 67 Hertz, but as will be
appreciated, other frequencies may be used. The coil 70 is a
combination of an inductance and a resistance. With a pure
inductance the voltage waveform leads the current waveform by
90.degree.. However, the resistance component of the coil 70 will
proportionally reduce the amount by which the voltage waveform
leads the current waveform. That lead time can be determined by
detecting a zero crossing of the voltage waveform on output 123 of
the power switches 154 (FIG. 3) that is applied to the coil 70.
That zero crossing is used to start a timer or counter (not shown)
in the thermal controller 126; and thereafter, the next zero
crossing of the current waveform as detected on the output 129 of
the current sensor 128 is used to stop the counter. That measured
time shift can be used in conjunction with a table correlating time
shift to coil resistance values to determine a current resistance
of the coil 70. The table of time shift versus coil resistance
values is created experimentally. In a preproduction test using the
coil 70, the resistance and temperature of the coil 70 can be
measured with instrumentation in response to operating the coil at
different power levels and hence at different temperatures. The
time shift can be measured and recorded in the manner described
above, and a table of time shift versus coil resistance and
temperature created and stored.
[0060] After the coil power at the maximum dispensing rate is
computed, the learning process, at 508 of FIG. 5, then causes the
control 137 to set the power setpoint or target equal to the
computed coil power value. Thus, the maximum dispensing rate is
going to produce a desired maximum temperature of the coil 70, and
the power or target setpoint is correlated to and representative of
that maximum temperature. Consequently, maintaining the power in
the coil equal to the power setpoint will result in the coil 70
being maintained at a constant temperature equal to the desired
maximum temperature. The learning process further, at 510,
determines whether the power setpoint is greater than a
predetermined and stored maximum value; and if so, at 512, a
warning indicator 132 is activated.
[0061] After the power setpoint has been determined in the learn
mode, the gun controller 120 is ready to begin operation in one of
two operational modes, that is, a run mode or a standby mode. One
of those modes is normally selected by a signal on output line 140
from system control 130 in response to a user input or selection.
In the run mode, the thermal controller 126 causes the switching
device 114 to connect the coil winding 112 to contacts A, thereby
connecting the contact windings 110, 112 in series. In this
connection, the flux generated by the current flowing through the
coil windings 110, 112 is in the same direction and effective to
operate the armature 60 of the dispensing valve 33. When in the
standby mode, the switching device 114 switches the connections of
the coil winding 112 to the B contacts, thereby placing the coil
windings 110, 112 in opposition. The flux generated by current flow
through the coil windings 110, 112 is in opposition and in a
canceling relationship. Thus, with little or no net flux, the
current through the coil windings 110, 112 is incapable of moving
the armature of the viscous fluid dispenser 10.
[0062] Assuming the dispenser 10 is operating in the run mode, a
measured current signal from the current sensor 128 is provided to
the A/D converter 136 of the thermal controller 126. In a manner as
previously described, the value of the current is used with the
coil resistance to determine a power value in the current-to-power
converter 138. That power value is then compared or algebraically
summed in a comparator or summing junction 141 with the power
setpoint determined during the learn mode. The difference between
the currently measured power value from the converter 138 and the
power setpoint is provided as an error signal on output 142 from
the comparator 141. If the measured power is greater than the power
setpoint, a warning indicator 132 may be activated indicating to
the user that the selected current waveform parameters are
producing a coil temperature in excess of the selected maximum coil
temperature. Thus, the user can then modify the current waveform
parameters until the warning indicator is deactivated, thereby
assuring the user that the current waveform is producing a coil
temperature less than the maximum temperature.
[0063] The error signal on output 142 is input to a feedback
controller 144 which is normally implemented using a
proportional-integral-derivativ- e ("PID") in a known manner.
However, as will be appreciated, other control schemes may be used.
An output signal from the feedback controller 144 is provided to a
power-to-current converter 146. The power value is converted to a
current value utilizing known relationships as described with
respect to the operation of the current-to-power converter 138. In
other words, given a power value from the feedback controller 144
and a coil resistance value, a current value is readily
determined.
[0064] That current value is then supplied to a waveform generator
148 which, in turn, is initiated by a trigger pulse on output 131
of the system control 130. The trigger pulse defines the point in
time at which the current waveform is to be supplied to the coil
70, thereby opening the dispensing valve 33. The trigger pulses are
normally produced within the system control 130 by a known pattern
controller or programmable limit switch (not shown). The pattern
controller stores a matrix of values that represent the operation
of various dispensing guns to provide the desired dispensing
operation. The generation of a trigger pulse to initiate the
operation of a dispensing gun 10 is determined by a relative
position of a detectable feature or portion of the substrate 19
with respect to the dispensing gun 10. That relative position can
be determined and tracked by utilizing the pattern controller or
programmable limit switch in a known manner. Thus, in response to
each trigger pulse, the waveform generator 148 provides an output
to control the operation of a D/A converter 149 in such a manner as
to provide the stepped waveform illustrated in FIG. 2.
[0065] In producing the stepped waveforms of FIGS. 2A-2D, the
waveform generator 148 normally chooses values of I.sub.pk and
T.sub.pk as a function of the viscosity of the fluid being
dispensed. In some applications, it may be appropriate to assume
that the viscosity of the fluid remains constant; and therefore,
the values of I.sub.pk and T.sub.pk may be chosen and remain fixed
throughout the dispensing cycle. In other control systems, it is
known to provide signals representing changes in viscosity. A table
of I.sub.pk and T.sub.pk values associated with different viscosity
values may be established and the appropriate I.sub.pk and T.sub.pk
values chosen as a function of a currently determined viscosity
value. The dispensing on-time T.sub.on varies as a function of the
operating speed of the dispensing system within which the
dispensing gun 10 operates. Further, the value of the hold current
I.sub.h is nominally set to a value equal to the minimum current
required to hold the valve in the open position, that is, the
minimum value of current to overcome the biasing force of the
compressed spring 82 (FIG. 1).
[0066] If the dispensing system is operating at its maximum rate,
the current being detected by the current sensor 128 results in a
power value that is substantially equal to the power setpoint; and
hence, there is a zero difference signal on the output 142 from the
summing junction 141. Therefore, in that situation, theoretically
no modification of the current waveform driving the coil 70 is
required. However, as will be appreciated, the dispensing system
may often be operated at a rate that is less than the maximum
operating rate. In those situations, the current measured by the
current sensor 128 will result in a power value from the converter
138 that is less than the power setpoint. If the coil is operated
at that lesser current value, the temperature of the coil will drop
from the temperature it had achieved during operation at maximum
rate. That lesser temperature changes the resistance of the coil 70
and further results in a decrease in the temperature of the coil.
The disadvantages of such temperature variations have previously
been discussed. Therefore, in accordance with the principles of the
present invention, if the RMS current value provided to the summing
junction 141 decreases, it is desirable to subsequently increase
the RMS current value being supplied to the coil 70 so that the
power being consumed by the coil 70 remains substantially constant
and equal to the power setpoint. Thus, the current waveform
functions to provide a drive current to the coil 70 (FIG. 1) that
first, moves the valve stem 28 to open the dispensing valve 33 and
dispense the viscous fluid and second, simultaneously varies
current in the coil 70 to maintain a substantially constant
temperature.
[0067] The analog current value on the output 151 of the D/A
converter 149 is provided to a coil current modulator 124 (FIG. 3).
The modulator 124 includes a comparator or summing junction 150
having inputs responsive to the output 151 of the D/A converter 149
and the output 129 of the current sensor 128. The summing junction
150 provides an output 152 that is an error signal representing the
difference between those two current values. That error signal is
used to provide a pulse width modulation of the power switches 154
in a known manner. The power switches 154 operate to provide a
desired drive current signal to the coil 70 but with a current
waveform having a general shape corresponding to the shape
determined by the waveform generator 148. The coil switches are
normally semiconductor switches such as, for example, MOSFET
switches or bipolar transistors which can be configured in known
H-bridge or other switching circuit.
[0068] If the dispensing system is operating at less than its
maximum rate, heat may be added to the coil 70 in one of several
different ways. First, the waveform generator 148 increases the
value of the hold current I.sub.h in response to an output from the
feedback controller 144. As the hold current increases, the current
sensor 128 will detect an increase in the current value which, in
turn, will increase the value from the power converter 138. That
process is iterated until the power value from the power converter
138 is equal to the power setpoint and the error signal on the
output 142 of the summing junction 141 has an approximately zero
value. Alternatively, the waveform generator 148 can increase the
time width T.sub.pk of the peak current I.sub.pk. As a third
alternative, the waveform generator 148 can also increase the
magnitude of the peak current I.sub.pk in response to an error
signal on the output 142 of the summing junction 141. The extent to
which the peak current can be varied is a function of the current
required to saturate the magnetic circuit. As will be appreciated,
the waveform generator 148 can modify one or more of the above
variables in a desired pattern to control the current being
supplied to the coil 70.
[0069] Thus, in accordance with the above, the gun controller 120
is effective to maintain the power and hence, the temperature, of
the coil 70 substantially constant, independent of the operating
frequency of the dispensing gun 10 during the run mode. Thus, the
current waveform functions to provide an appropriate drive current
to the coil 70 (FIG. 1) that first, moves the valve stem 28 to open
the dispensing valve 33 and dispense the viscous fluid and second,
simultaneously varies current in the coil 70 to maintain a
substantially constant temperature. Therefore, the gun controller
120 of FIG. 3 not only provides the proper current waveform to
actuate the fluid dispensing gun, but it introduces heat into the
coil in a controlled manner to reduce the range of temperature
variations that would otherwise be experienced by the fluid
dispenser.
[0070] At a subsequent time, the user will switch the system from
the run mode into the standby mode. The state of the signal on
output 140 of the system control changes, which causes the thermal
controller to change the state of operation of the switching
solenoid 118, thereby switching the contacts 116 to the B contacts
and placing the coils in opposition. Simultaneously, the coil
current modulator switches the power switches 154 on at a
predetermined magnitude for the duration of the standby mode,
thereby supplying continuous current flow the coil windings 110,
112. The predetermined magnitude of the current is normally
determined by the average value of current supplied to the coil
during the run mode. Therefore, during the standby mode, current is
supplied to the coil 70 in a manner as previously described with
respect to the run mode. The opposing relationship of the coil
windings 110, 112 prevents the armature from being moved, and the
dispensing valve remains closed. However, the power being supplied
to the coil remains equal to the power setpoint, and the
temperature of the coil in the standby mode remains substantially
constant. As will be appreciated, instead of applying a constant
current magnitude during the standby mode, alternatively, the
pattern controller within the system control 130 provides output of
trigger pulses at a frequency that is equal to the maximum
frequency of the trigger pules that was stored during the learn
mode, thereby supplying continuous current flow the coil windings
110, 112.
[0071] An alternative embodiment of the microprocessor control 137
is illustrated in FIG. 6. As will be appreciated, the power control
137 of FIG. 4 requires two current/power conversions in the
converters 138, 146. Those current/power conversions must be
performed in real time and utilize valuable processor time. The
devices within the current control 160 of FIG. 6 utilize only
current, thereby eliminating the requirement for the converters
138, 146. In a manner similar to that previously discussed, during
the learning mode, the current control 160 is implemented with a
microprocessor controller and stores a current setpoint value
I.sub.sp measured by the current sensor 128 when the dispensing
system is operating at its maximum rate. Thus, the maximum
dispensing rate is going to produce a desired maximum temperature
of the coil 70, and maintaining the current in the coil equal to
the current setpoint will result in the coil 70 being maintained at
a constant temperature equal to the desired maximum temperature.
Thereafter, during the run and standby modes, the A/D converter 136
provides a digital signal to the comparator or summing junction 141
which algebraically adds or compares the measured current value
during the run and standby modes with the current setpoint. If the
measured current value is greater than the current setpoint, a
warning indicator or other diagnostic can be activated. The
difference between those current values is provided as an error
signal on the output 142 of the summing junction 141. A feedback
controller 162 utilizes a control loop such as a PID control to
provide a signal to the waveform generator 164. The waveform
generator 164 operates in a manner as previously described to
modify the hold current, spike duration or peak current either
individually or in combination to provide a drive signal to the D/A
converter 149. The D/A converter 149 provides a signal on the
output 151 to the current modulator 124 such that the current
provided to the coil 70 is maintained at the setpoint value. Thus,
the temperature of the coil 70 is maintained constant, and the coil
temperature does not contribute to changes in viscosity of the
fluid being dispensed.
[0072] A still further embodiment of the thermal controller 126 is
illustrated in FIG. 7A which uses a temperature control loop as
opposed to a current control loop. A temperature setpoint T.sub.sp
is generally a function of the coil insulation system and may, for
example, be 425.degree. F. The temperature setpoint can selected by
the user using input devices associated with the system control
130. Alternatively, the temperature setpoint can be automatically
established in the learn mode by reading the valve of the
temperature sensor 139 when the dispensing system is operating at
its maximum rate. The temperature sensor 139 can be implemented
with any known temperature sensing device, for example, a
resistance temperature device, a thermocouple, a thermistor, a
solid state sensor, etc.
[0073] Thereafter, during the run and standby modes, a measured
temperature signal is provided as an input to the summing junction
142. The summing junction 141 algebraically adds or compares the
measured temperature value during the run and standby modes with
the temperature setpoint. If the measured temperature value is
greater than the current setpoint, a warning indicator or other
diagnostic can be activated. The difference between those
temperature values is provided as an error signal on the output 142
of the summing junction 141. The feedback controller 162 and
waveform generator 164 operate in a manner as previously described
to modify the hold current, spike duration or peak current either
individually or in combination to provide a drive control signal to
the D/A converter 149. The D/A converter 149 provides a comparable
analog signal on output 151 to the current modulator 124 such that
the current provided to the coil 70 is regulated to maintain the
temperature of the coil 70 at the temperature setpoint value. Thus,
the constant coil temperature maintains a constant viscosity of the
fluid being dispensed.
[0074] Another embodiment of the thermal controller 126 having a
temperature control loop is illustrated in FIG. 7B. An A/D
converter 133 has an input connected to an output 123 of the power
switches 154; and an A/D converter 135 has an input connected to an
output 129 of the current sensor 128. A temperature calculator 145
is responsive to the voltage and current signals from the
respective A/D converters 133, 135 to provide on its output 161 a
signal representing a current, measured temperature of the coil 70.
This embodiment can be used to determine the temperature setpoint
T.sub.SP using either of the alternative off-time current waveforms
illustrated in FIGS. 2B-2C. In a learn mode, with the dispensing
system operating at its maximum rate, after the temperature
calculator 145 samples the voltage and current signals from the A/D
converters 133, 135, the resistance of the coil can be computed in
accordance with Ohm's Law. The maximum temperature or temperature
setpoint is then read from a table correlating coil resistance to
coil temperature that had been previously determined by
experimentation as previously described.
[0075] The maximum temperature or temperature setpoint can
alternatively be determined using the off-time waveform as
previously described using the sinusoidal waveform of FIG. 2D. It
should be noted that the initiation of the sinusoidal waveform of
FIG. 2D is delayed for a short period of time after the end of the
on-time. That delay provides time for any currents induced by the
collapsing electromagnetic field to dissipate. During the
application of the sinusoidal waveform, the temperature calculator
145 detects a zero crossing of the voltage waveform on output 123
of the power switches 154 (FIG. 1) that is applied to the coil 70.
That zero crossing is used to start a timer or counter (not shown)
in the temperature calculator 145; and thereafter, the temperature
calculator 145 detects the next zero crossing of the current
waveform as detected on the output 129 of the current sensor 128.
That zero crossing of the current waveform is used to stop the
counter; and therefore, the value measured by the counter in the
temperature calculator 145 represents a measured time shift between
the voltage and current signals that are applied to the coil 70.
The temperature calculator 145 uses that measured time shift in
conjunction with a table correlating time shift to temperature that
was created as previously described, and the temperature calculator
145 provides on its output 161 a signal representing the current
temperature of the coil 70.
[0076] When the dispenser is operating in the run mode, the
embodiment of FIG. 7B can utilize any of the current waveforms
illustrated in FIGS. 2B-2D to continuously provide a measured
temperature signal on the output 161 of the temperature calculator
145. That measured temperature signal to provided to the comparator
141 to produce an error signal therefrom and modify the current
waveform as described with respect to FIG. 7A to maintain the
temperature of the coil 70 at the desired temperature setpoint
value.
[0077] Referring to FIG. 8, an alternative embodiment of the
invention for maintaining a constant coil temperature is
illustrated. In this embodiment, a standard coil 71 is utilized and
is connected to the current sensor 128. A switching device 170, for
example, a switching relay, has a switching solenoid 171 connected
to switching contacts 172. As previously described with respect to
FIG. 3, the thermal controller 126 provides a run/standby signal on
an output 127 as it is received from the system control 130. The
run/standby signal is provided to the switching solenoid 171 over
the output 127 of the thermal controller 126. In the run mode, the
switching solenoid 171 moves the switching contacts 172 to the
illustrated A position, thereby connecting the coil 71 to the power
switches 154. In the run mode, the gun controller 120 operates in a
manner substantially identical to that described with respect to
FIGS. 3-6. A drive current signal is provided to the coil 71 that
is derived from a current, power or temperature setpoint, whichever
is used.
[0078] When the thermal controller 126 detects that the operating
mode has been switched to the standby mode, the state of the signal
on the output 127 is changed, thereby causing the switching
solenoid 177 to switch the contacts 172 to the B contacts. In this
position, the coil 71 is connected to a high frequency power supply
173. The output frequency of the high frequency power supply 173 is
chosen to have a frequency value higher than the response time of
the coil, that is, sufficiently high that the coil 71 is incapable
of moving the armature 60. If the high frequency signal swings
equally above and below an average value, the gun acts like a low
pass filter. If the average value is zero, the gun will not be
actuated. Further, the frequency chosen should not permit the coil
71 to dither the armature 60 and dispensing valve 33 to such an
extent that the dithering action generates heat at the end of the
dispensing gun 10 or permits minute quantities of fluid to pass
through the dispensing valve 33. Therefore, such a frequency may be
10 KHz or less or as high as 1 MHz or more; but normally, the
frequency is around 100 KHz.
[0079] In a manner similar to that previously described with
respect to power switches 174, the high frequency power supply 173
is responsive to the output 152 of summing junction 150 in order to
vary the magnitude of the high frequency signal applied on the
output 174 of the power supply 173. The net result is that the
average or RMS current as detected by the current sensor 128 and
thermal controller 126 is maintained equal to the respective
current, power or temperature setpoint during the standby mode of
operation, thereby maintaining the temperature of the coil 71
constant and hence, a more constant viscosity within the dispensing
gun 10.
[0080] Referring to FIG. 9, a further embodiment of the apparatus
for controlling the temperature of the coil 71 is illustrated. The
coil 71 is mounted adjacent an armature 60 within a dispensing body
12. One or more Peltier elements 176 are mounted on the exterior of
the dispensing body 12. A heat sink 177 is mounted over the Peltier
element 176. A Peltier element is a two-terminal bidirectional
device capable of heating or cooling by reversing the direction of
current flow through the Peltier element. Peltier elements are
commercially available from Melcor of Trenton, N.J.
[0081] In one mode of operation, the gun controller 120 receives a
run/standby signal from the system control 130 and a waveform
generator 165 creates a waveform similar to that described with
respect to FIG. 2A. The variables associated with the waveform are
determined in a traditional manner in that the peak current
magnitude I.sub.pk and peak current duration T.sub.pk are
determined as a function of the viscosity of the fluid being
dispensed. Further, the hold current I.sub.h is determined to be
the minimum current required to hold the dispensing valve 33 open.
That waveform is provided to the coil current modulator 124 and a
drive current signal is provided to the coil 71 in accordance with
the output from the waveform generator 165 and the feedback from
the current sensor 128 in a manner similar to that previously
described. In this embodiment, a temperature setpoint T.sub.sp is
provided to a summing junction 179. The temperature setpoint may
either be permanently stored within the gun controller 120 or
provided in any of the ways previously described with respect to
FIG. 7B including utilizing the current waveforms of FIGS. 2B-2D.
The summing junction 179 compares the temperature setpoint with a
temperature feedback signal and provides a signal representing the
difference between the inputs to a Peltier heat/cool control 181.
The temperature feedback signal is provided in any one of several
ways. For example, the temperature feedback signal may be a
temperature sensing device 175, shown in phantom, that is mounted
in a heat transfer relationship with the coil 71. The temperature
sensing device 175 can be any of several known devices may be used,
for example, a temperature resistance device, thermal couple or
other known temperature sensing device. Further, as will be
appreciated, instead of using a separate temperature sensing device
175, the Peltier element 176 can be used to sense the temperature.
The heating/cooling cycles of the Peltier element 176 can be
interrupted for short periods of time during which the Peltier
element 176 provides an output voltage proportional to temperature.
Alternatively, the temperature feedback signal may be provided by
using any of the current waveforms of FIGS. 2B-2D as previously
described. The Peltier control is a known heating control and may
be implemented using proportional, proportional integral or PID
control to operate the Peltier element 176.
[0082] The temperature setpoint represents an expected temperature
of the coil 71 when the system is operating at a maximum rate. The
Peltier heat/cool control 181 is operative to cause the Peltier
element 176 to selectively heat or cool the dispenser body 12 in
response to the temperature sensing device 175 detecting a
temperature that is respectively less than or greater than the
temperature setpoint. Thus, for example, if the system is operating
at maximum rate in an environment that does not permit proper
cooling of the dispenser body 12, the dispenser body may reach a
temperature in excess of the desired temperature setpoint. In that
situation, the Peltier heat/cool control 181 causes the Peltier
element 176 to cool the dispenser body 12 to the temperature
setpoint. Alternatively, if the gun controller is switched from the
run mode to the standby mode in which no current is being supplied
to the coil 71, the dispenser body cools to a temperature less than
the temperature setpoint. That cooler temperature, as detected by
the temperature sensor 175, causes the Peltier heat/cool control
181 to operate the Peltier element 176 to heat the dispenser body
back to the temperature setpoint.
[0083] The use of the Peltier element 176 has the further advantage
of permitting the coil to be operated in a power range, that is, at
a rate, that exceeds its specified rate. For example, if the coil
71 is specified to operate at a rate that is equivalent to nine
watts of power being applied to the coil and the Peltier element is
capable of cooling three watts of power from the coil, the coil
current modulator 124 may be used to drive the coil at a rate that
is equivalent to twelve watts of power, thereby substantially
increasing the frequency of operation of the dispensing valve 33.
Even though the coil is being supplied with twelve watts of power,
the Peltier element is able to remove three watts of heat, thereby
maintaining the net power heat of the coil 71 at nine watts and
within its specifications.
[0084] While the Peltier heat/cool control 181 is illustrated in
FIG. 9 as being part of a closed temperature control loop utilizing
the temperature sensor 175, as will be appreciated, the temperature
sensor 175 may be eliminated and the Peltier heat/cool control
operated in an open loop mode responsive only to the temperature
setpoint. The temperature control of FIG. 9 has further versatility
in that, as will be appreciated, the temperature setpoint may be
fixed, user selectable to accommodate different sizes of coils, a
constant value over time or even a value that varies as a function
of some other parameter.
[0085] The above embodiments of a coil temperature control for
maintaining the constant coil temperature have many advantages.
First, the gun controller does not rely on the user being able to
select the best current waveform parameters, but instead, is
adaptive and self-adjusting to maintain a constant coil
temperature. With a constant coil temperature, the viscosity of the
fluid within the dispensing gun is held more consistent, thereby
improving the consistency of the dispensing process. Further, by
maintaining the constant temperature over the full range of
operating frequency of the dispensing gun, the quality of the fluid
dispensing operation is further enhanced and more consistent.
Further, such a temperature control permits the dispensing gun to
be consistently operated at a rate that is very close to, if not
at, the theoretical maximum temperature limit of the gun without
overheating. The active temperature control protects the coil from
overheating in the event that the user adjusts the current waveform
such that an excessive temperature would otherwise be produced.
[0086] Further, by activating an overheat indicator when the
measured feedback current or temperature exceeds the setpoint
value, valuable feedback is provided to the user with respect to
the adverse effect of the selected current waveform parameters,
thereby allowing the user to take appropriate action.
[0087] Utilizing the dispensing valve coil to add heat to the
module provides an opportunity for a new and different design of a
dispensing gun. Referring to FIG. 1, the dispensing gun includes
one or more valve dispensing modules 33 mounted onto a manifold 45.
Normally, the manifold 45 includes a heater and temperature
feedback device (not shown) for maintaining the viscous fluid at a
desired temperature. In the past, the circulation of the heated
fluid through the manifold 45 and dispensing valve 33 proved to be
an adequate thermal management strategy. However, as discussed
earlier herein, the heat of the coil of the electric gun introduces
a new and significant thermal management issue. In accordance with
the principles of the present invention, by controlling the heating
of the coil, the temperature of the dispensing module or valve is
controlled. Thus, for the first time, the thermal management of the
dispensing module is self contained within the module and
independent of other elements, for example, the manifold plate 45.
This new module capability provides new opportunities for a
different construction of the dispensing gun.
[0088] Referring to FIG. 10, a dispensing gun 192 is constructed by
serially connecting dispensing valves or modules 193, 203 without
requiring a fluid distribution manifold 45 (FIG. 1) as is required
in known fluid dispenser constructions. The modules 193, 203 are
mounted immediately adjacent each other or are separated by a
spacer plate 194 to provide the desired spacing between the nozzles
195 of the modules 193, 203. In the design of FIG. 1, the desired
spacing of the modules 33 is achieved by mounting the modules 33 at
the desired spacing on the manifold plate 45.
[0089] A second distinction from known fluid dispensers is that the
viscous fluid is fed serially through the dispensing modules 193,
203 from one end of the dispensing gun 192. In contrast, in FIG. 1,
each dispensing module 33 is fed directly from the manifold plate
45 by a dedicated feed passage 49 within the manifold plate 45. The
dispensing gun 192 of FIG. 10 receives the viscous fluid from a
feed member or end plate 196 coupled to one end of the dispensing
gun. The feed member 196 has a fluid inlet 197 intersecting one
side 210 of the member 196, and the fluid inlet is fluidly
connected to a source of pressurized viscous fluid 47 (FIG. 1). The
fluid inlet 197 is fluidly connected to a first fluid passage
portion 199a that intersects an opposite side 211 of the feed
member 196. The opposite end of the dispensing gun 192 is
terminated with a cap or end plate 198, the sole function of which
is to terminate the continuous fluid passage 199 extending from the
inlet 197, through the feed member 196, the dispensing valve 193,
spacer plate 194 and the dispensing valve 203. A second fluid
passage portion 199b within the dispensing module 193 intersects
two sides, for example, opposite sides 212, 213 of the dispensing
module 193. A third fluid passage portion 199c intersects two
sides, for example, opposite sides 214, 215 of the spacer plate
194, and a fourth fluid passage portion 199d intersects two sides,
for example, opposite sides 216, 217 of the dispensing module 203.
As will be appreciated, the above construction permits the use of
only a single dispensing module or any number of dispensing
modules. as is required by the application. The spacer block 194
can be of any width desired, or the dispensing modules 193, 203 can
be mounted together without an intervening spacer block 194. In
addition, the cap 198 may be implemented by a plate or a plug that
is threaded into the passage 199d at the side 217. Similarly, the
feed member 196 can be implemented with a plate, a nipple or other
fitting threaded into the passage 199a at the side 210. Further,
the internal fluid passages 199b and 199d can be L-shaped or
T-shaped, so that the passages 199b, 199d intersect other sides of
the modules 193, 203, thereby providing more flexibility in
designing a dispensing gun for a particular application.
[0090] By incorporating heaters in the dispensing modules 193, 203
either by using the coil as a heater or, by incorporating other
heaters as described with respect to FIG. 7A, the dispensing
modules 193, 203 are capable of providing sufficient heat to
maintain the viscous fluid within the passage 199 at the desired
temperature without requiring a separate manifold. The construction
of the dispensing gun 192 has the further advantage of being
substantially more compact than the traditional design of FIG. 1.
Further, by eliminating the manifold 45 as well as its associated
heater and heat control apparatus, the construction of the
dispensing gun 192 of FIG. 10 is substantially less expensive; and
its simpler construction provides substantially greater flexibility
in mounting the dispensing gun 192 with associated equipment.
[0091] The embodiments described thus far in FIGS. 2-9 are directed
to providing an automatic control of coil temperature to reduce the
adverse effects of varying coil temperature during the fluid
dispensing process. As will be appreciated, in any application,
providing the user with data or indicators relating to an excessive
temperature and a potentially excessive temperature is also
valuable. In many dispensing systems, the user has the ability to
manually adjust the peak current magnitude I.sub.pk, the peak
current duration T.sub.pk and the magnitude of the hold current
I.sub.h. Further, the dispensing process involves many variables
that are application dependent such as the dispensing pattern, the
liquid viscosity, the production rate, the substrate material, etc.
In an effort to optimize the dispensing process, the user often
changes the shape of the current waveform being provided to the
coil. Further, the user has no knowledge of when such adjustments
come close to or exceed the power specification or maximum
temperature limit for the coil. Further, typical users generally do
not have instruments, such as an oscilloscope or current probe,
that would permit them to monitor the current being supplied to the
coil. Thus, a system that provides the user with an indication of
whether a chosen current waveform produces an excessive coil
temperature would be of significant benefit. Thus, when adjusting
the waveform of the current being supplied to the coil, the user
would have a real time feedback of whether such adjustments are
approaching or exceeding the maximum temperature limit of the
coil.
[0092] FIG. 11 is one embodiment of such a thermal monitor and
diagnostic circuit. A measure of heating power in the coil is best
represented by a measurement of the RMS value of the current or
voltage applied to the coil. Such RMS values have a direct
correspondence to coil heating and provide a reasonable indication
of temperature. As previously mentioned, the measurement of an RMS
current value and its conversion to a direct current value can be
effected either computationally or with a specialized integrated
circuit chip. One such integrated circuit chip is Model No. AD736
commercially available from Analog Devices. Other chips such as
Model Nos. AD737 and AD637 as well as similar chips from other
manufacturers may also be used. Referring to FIG. 11, such an
integrated circuit chip 180 is responsive to coil current on an
input 181 and provides an output to red, yellow and green LEDs 182,
183, 184, respectively, that provide a qualitative indication of
coil temperature. The coil current on the input 181 is provided to
the chip 180 via an input circuit 185 that includes a gain adjust
potentiometer 186. The chip 180 is powered by a power supply
circuit 187, and the chip 180 provides a DC signal on an output 188
that is proportional to the RMS value of the coil current supplied
on the input 181. A comparator circuit 189 compares the magnitude
of the DC voltage on the output 188 to reference voltages that are
selectable via potentiometers 190, 191.
[0093] The monitor circuit of FIG. 11 must be set for the
temperature characteristics of each different electric fluid
dispenser. The temperature characteristics can be determined
experimentally by storing a temperature versus power or current
relationship for the fluid dispenser. Such a relationship can be
determined by applying different magnitudes of current to the
dispenser and measuring the resultant temperature. The maximum
temperature for the fluid dispenser is normally determined as a
function of the manufacturer's specifications for the fluid
dispenser. Using the stored current-temperature relationship, a
first current value can be determined based on the maximum
dispenser temperature. That first current valve is applied to the
input 181, and the potentiometer 190 is adjusted until the red
indicator light 182 turns on.
[0094] Similarly, a lesser temperature close to the maximum
temperature, for example, a temperature that is 90% or 95% of the
maximum temperature, is selected. Using the stored
temperature-current relationship, a corresponding current is
determined and applied to the input 181 of the monitor circuit.
Potentiometer 191 is then adjusted until a yellow caution LED 183
is illuminated. Thus, the yellow caution LED 183 indicates when the
current in the coil is representative of a temperature between the
lesser temperature and the maximum temperature. If the coil current
on the input 181 is below the threshold of the comparator circuit
189 necessary to illuminate the yellow LED 183, the green LED 184
is illuminated, thereby apprising the user that the current
waveform being selected by the user is less than the lesser
temperature and will not produce an excessive coil temperature.
While FIG. 11 illustrates one example of a coil temperature
monitor, it should be noted that the embodiments of FIGS. 3-9 all
have the capability of providing a coil temperature monitor feature
whether separately identified as indicators 132 or integrated in
the machine control 130. Further, the as shown in FIGS. 2B-2D,
current sampling during the off-time of the current waveform can
also be used to provide a temperature monitor.
[0095] The thermal monitor circuit of FIG. 11 has the advantage of
providing the user with a real time indication of whether the
user's adjustments to the current waveform provide a coil
temperature that is less than, close to or in excess of the maximum
coil temperature. Further, the speed of a production line is often
increased incrementally as various adjustments are made and the
increased speed does not adversely impact quality. As the line
speed increases, the average coil current increases; and the
monitor circuit of FIG. 11 continuously senses the coil current and
warns the user via the LEDs 182, 183 that the coil current is close
to or exceeds a value that produces an excessive temperature. In
addition, the thermal monitor uses an RMS value of coil current or
voltage and therefore, provides an excellent indicator of
temperature. In addition, the thermal monitor allows the user to
select the temperature limits which are appropriate for the
dispensing gun being used and the dispensing application being
effected. As will be appreciated, other gradations of temperature
may be provided, for example, by a bar graph; and other forms of
sensory perceptible indicators, for example, audio indicators, may
also be used.
[0096] While the present invention has been illustrated by a
description of various preferred embodiments and while these
embodiments have been described in considerable detail in order to
describe the best mode of practicing the invention, it is not the
intention of Applicant to restrict or in any way limit the scope of
the appended claims to such detail. Additional advantages and
modifications within the spirit and scope of the invention will
readily appear to those skilled in the art. For example, the
run/standby signal is described as being user selectable and
provided from the system control 130 to the thermal controller 126.
As will be appreciated, the system control 130 can alternatively be
used to directly drive the switching solenoid 171 and other
components with the run/standby signal instead of the thermal
controller 126. Further, other methods of providing a run/standby
signal can be readily derived. As will be appreciated, other
signals, such as setpoint values, may originate in, or be stored
in, the gun controller 120 or the machine control 130 as is
appropriate. Further, the gun controller may also include user
input and output devices as is appropriate and is generally a
matter of design choice.
[0097] In the described embodiments with respect to FIGS. 3-9, the
respective power, current and temperature setpoints were set to be
representative of the temperature of the coil with the system
operating at a maximum dispensing rate. Further, warning indicators
are activated in response to the measured power, current or
temperature exceeding the respective power, current or temperature
setpoint. As will be appreciated, the setpoint used in the control
loop in the thermal controller 126 may be any temperature. Further,
the thermal controller 126 may compare the measured power, current
or temperature to several reference values of power, current or
temperature to provide other warning indicators. For example, the
measured power, current or temperature values may be compared to a
respective power, current or temperature setpoint representing a
coil temperature at a chosen operating frequency or rate to control
the waveform generator as described. In addition, the measured
power, current or temperature values may be compared to a
respective power, current or temperature reference value
representing a maximum coil temperature, and a warning indicator
activated when the maximum coil temperature is exceeded.
[0098] The learn signal is described as being a user selected input
to the system control 130, however, as will be appreciated, the
learning processes may be implemented using other methods. For
example, the gun controller can, while the system is operating,
keep track of the highest trigger frequency and corresponding
measured power, current or temperature. Subsequently, the
corresponding power, current or temperature is defined as the
setpoint value. Alternatively, the learn signal can be avoided
altogether by running the coil at the maximum power, current or
temperature that the gun can tolerate. In other words, the power,
current or temperature setpoint is assumed to be the maximum for
the equipment rather than being application or installation
specific.
[0099] The switching device 114 of FIG. 3 provides a fixed
switching of the coil winding 112 with respect to the coil winding
110. Further, the power switches 154 are effective to provide
essentially the same drive current to the coil 70 in both the run
and the standby modes. Thus, the relationship between the heating
power and the actuation force resulting from the current flow
through the coil 70 in the run mode is equal to the sum of the
currents flowing through the coil windings 110, 112. However, the
heating power provided by the current flow through the coil 70 in
both the run and standby modes is equal to the sum of the square of
the currents flowing through the coil windings 110, 112. In the
switching arrangement illustrated in FIG. 3, the coil windings 110,
112 are serially connected by the switching device 114; and
therefore, for any given drive current provided by the power
switches 154, the actuation force and the heating power will have a
fixed relationship. If the coil windings 110, 112 were not serially
connected, but were connected in parallel with respect to the power
supply 122, then the current flow through the coil winding 110
could be independently controlled and different from the current
flow in the coil winding 112.
[0100] Such a switching arrangement is illustrated in FIG. 12 as an
alternative embodiment of the coil current modulator 124. Power
switches PS1-PS4 connect each end of the coil windings 110, 112 to
one side of the power supply +V.sub.DC. Further, power switches
PS5-PS8 connect each end of the coil windings 110, 112 to the power
supply common. Each of the power switches PS1-PS8 has a control
input 202 connected to respective outputs 1-8 of a switch
controller 204. The switch controller is a logic processor that
responds to a run/standby signal from output 140 of the system
control 130 (FIG. 1) to connect the coil windings 110,112 in either
an additive relationship or in opposition. For example, in the run
mode, the switch controller 204 provides outputs to close power
switches PS1, PS6, PS3 and PS8, thereby causing current to flow in
the coil windings 110, 112 in an additive relationship. When the
standby mode is active, the switch controller 204 will provide
outputs to open power switches PS3 and PS8 and close power switches
PS4 and PS7, thereby reversing the current flow with respect to the
coil winding 112 and placing the coil windings 110, 112 in
opposition.
[0101] The switch controller 204 includes the further capability of
varying the duty cycle of the operation of the power switches
PS1-PS8 by utilizing, for example, a pulse width modulation
process. Therefore, for example, if the power switches PS1 and PS6
are closed 100% of the time, a current flow of 3 amps passes
through coil winding 110. However, if, utilizing the pulse width
modulation capability of the switch controller 204, the duty cycle
of the power switches PS1 and PS6 is reduced to 50%, the current
flow through the coil winding 110 is reduced to 1.5 amps. Using
that capability, the following are several examples of how the
heating power provided by the coil windings 110, 112 can be varied
substantially while maintaining a constant actuation force for
opening the dispensing valve.
[0102] In the first example, assume that during the run mode, the
switch controller 204 operates the power switches at a 33% duty
cycle. Continuing with the numerical examples of the prior
paragraph, a 33% duty cycle results in 1 amp flowing through coil
windings 110, 112 in response to power switches PS1, PS6, PS3 and
PS8 being closed. The actuation force is determined by the sum of
the current flows through the coil windings 110, 112 and is
therefore, 2 amps. Further, the power heating capability is equal
to the sum of the square of the current flowing through the coil
windings 110, 112 and is also 2 amps. The same result is achieved
in the standby mode when power switches PS3 and PS8 are opened and
power switches PS4 and PS7 are closed.
[0103] In a second example, assume that in the run mode, power
switches PS1 and PS6 are operated at a 67% duty cycle to provide 2
amps of current flow through coil winding 110, whereas power
switches PS3 and PS8 are operated at a zero duty cycle, thereby
providing no current flow through coil winding 112. Once again, the
actuation force resulting from the sum of the current flows is 2
amps. However, the heating power, which is a result of the sum of
the square of the current flows, is equal to 4 amps. In the standby
mode, power switches PS1, PS6, PS4 and PS7 are operated at a 47%
duty cycle providing a current flow of approximately 1.4 amps
through the coil windings 110, 112. Since the coil windings are
connected in opposition, the sum of the current flows is zero and
the actuation force is likewise zero. However, the sum of the
squares of the current flows is approximately 4 amps which is the
same as the heating power provided during the run mode.
[0104] In a third example, during the run mode, power switches PS1
and PS6 are operated at a 100% duty cycle providing a 3 amp current
flow through coil winding 110. In addition, power switches PS4 and
PS7 are operated at a 33% duty cycle providing a current flow of 1
amp through coil winding 112. The coil windings 110, 112 are
connected in opposition; and therefore, the 1 amp flow through coil
winding 112 subtracts from the 3 amp flow through coil winding 110
to provide a net sum of a 2 amp actuating force. However, the power
heating capability, being the sum of the squares of the currents,
is approximately 10 amps. In the standby mode, the power switches
PS1, PS6, PS4 and PS7 are operated at a 75% duty cycle to provide
opposing current flows in coil windings 110, 112 of 2.25 amps. The
equal opposing current flows sum to a zero current flow and a zero
actuation force, however, the sum of the squares of the current
flows is approximately 10 amps.
[0105] The power switches PS1-PS8 are implemented using
commercially available semiconductor switches several types of
which have been previously identified herein. The modulation of the
operation of the power switches PS1-PS8 to vary their duty cycle
occurs at a frequency that is substantially greater, for example,
100 times greater, than the maximum expected frequency of the
current waveforms provided on the output 152 of the summing
junction 150. As will be appreciated, other configurations of power
switches can be implemented, for example, the power switches PS2
and PS5 can be eliminated from the circuit. The power switching
circuit of FIG. 12 provides a substantial range of temperature
control as well as significant design flexibility and precision in
the control of temperature of the gun coil. Further, the ability to
manipulate the temperature of the gun coil during the run and
standby modes is also substantially more flexible. By uncoupling
the heating capability of the coil from the actuation force
required to operate the coil, a substantially wider range of heat
control is possible.
[0106] In the embodiments described with respect to FIG. 3-9 and
12, temperature control is obtained by maintaining a constant
temperature during both the run and standby modes of operation,
that is, both, while the dispensing gun is dispensing fluid, and
while the dispensing gun is inactive and not dispensing fluid.
Maintaining a constant coil temperature during all modes of
operation theoretically provides the best results and the least
impact on the quality of the dispensing operation, but it comes at
a substantial price in terms of additional components and
complexity to the dispensing control system. For example, in the
described embodiments, such components may include a bifilar coil
and associated switching circuits or, alternatively, a high
frequency power supply and associated switching circuits, etc.
[0107] An alternative embodiment is illustrated in FIG. 13 in which
a temperature control is provided by maintaining a constant
temperature during only the run mode of operation. The embodiment
of FIG. 13 is identical to the embodiment of FIG. 3 except that
there is no bifilar coil and coil switching circuits, and thus, the
operation of the apparatus of FIG. 13 is identical to the operation
of the apparatus of FIG. 3 except with respect to the standby mode
of operation. The embodiment of FIG. 13 does not heat the coil 70
during the standby mode of operation. The embodiment can be
operated in a learn mode to determine a maximum current or power
being consumed by the dispensing gun to establish a power, current
or temperature setpoint. In the run mode of operation, a current
feedback is provided to the thermal controller 126, and a waveform
generator 148 as previously described provides a stepped current
waveform to the coil current modulator 124. The coil current
modulator 124 provides a drive current to the coil 70 to maintain a
current or power in the coil substantially equal to the respective
current or power setpoint. Thus, the coil 70 is first operative to
actuate the dispensing valve 33 (FIG. 1) to dispense the fluid and
is used simultaneously as a heater in the run mode to maintain the
temperature of the coil generally constant. As previously
described, the values of the peak current I.sub.pk, hold current
I.sub.h, time width T.sub.pk and other current waveform variables,
may be adjusted to change the RMS value of the current being
supplied to the coil 70. As will also be appreciated, all of the
different embodiments of the thermal controller 126 illustrated and
described with respect to FIGS. 4, 6, 7 and 9 including the use of
current sampling during the off-time of the current waveform as
shown and described with respect to FIGS. 2B-2D are equally
applicable to the embodiment of FIG. 13. Hence, the thermal
controller 126 of FIG. 13 can be implemented with a power control
loop as described with respect to FIG. 4, with a current control
loop as described with respect to FIG. 6, or with a temperature
control loop as illustrated in FIG. 7A and 7B. Alternatively, a
Peltier device 181 (FIG. 9) can be used only in the run mode to
maintain the coil at a constant temperature.
[0108] Thus, the embodiment of FIG. 13 maintains the coil 70 at a
desired temperature during the run mode of operation; and during
the run mode, all of the advantages of having a constant
temperature dispensing gun are realized by using the embodiment of
FIG. 13. With the embodiment of FIG. 13, the temperature of the
coil 70 and the dispensing gun 10 most probably decreases during
the standby mode. And, when the run mode is again activated, the
temperature of the coil 70 and the dispensing gun 10 increases
until it reaches the desired value. Thus, the embodiment of FIG. 13
allows for some temperature variations and the disadvantages
associated therewith. However, the embodiment of FIG. 13 in
providing for temperature control during only the run mode provides
many of the previously described advantages over known devices.
[0109] Further, the embodiments illustrated with respect to FIGS.
3-7 and 13 are described as being implemented using digital
processors and/or controllers; however, as will be appreciated, one
skilled in the art may choose to implement portions or the entirety
of those embodiments with analog devices.
[0110] Therefore, the invention in its broadest aspects is not
limited to the specific detail shown and described. Consequently,
departures may be made from the details described herein without
departing from the spirit and scope of the claims which follow.
* * * * *