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    • 专利摘要:
    ADHESIVE DISTRIBUTION SYSTEM AND METHOD USING INTELLIGENT FUSION HEATING CONTROL An adhesive distribution system is configured to automatically reduce the temperature of the adhesive material to reduce adhesive degradation caused by keeping the adhesive at an application temperature during periods of low transfer rate. To that end, a system controller operates a heating unit to maintain a unit setpoint temperature to heat and melt the adhesive until a defined threshold time has elapsed since the last adhesive supply to the system through a system. filling. Once the time elapsed since the last supply of adhesive exceeds the set threshold time, the heating unit is reduced in temperature to reduce the temperature of the adhesive. This temperature reduction is large enough to minimize gas degradation and emission, but small enough to allow for quick heating times after a new supply of adhesive occurs.
    公开号:BR102013027438B1
    申请号:R102013027438-0
    申请日:2013-10-24
    公开日:2021-01-26
    发明作者:Benjamin J. Bondeson；Peter W. Estelle；Kent Hand
    申请人:Nordson Corporation；
    IPC主号:
    专利说明:

    [0001] This application claims the benefit of US Provisional Patent Application Serial No. 61 / 718,311, filed on October 25, 2012 (pending), the disclosure of which is hereby incorporated by reference in its entirety. FIELD OF THE INVENTION
    [0002] The present invention relates generally to an adhesive distribution system, and, more particularly, to control components and methods used with heating units that melt adhesive in the adhesive distribution system. FUNDAMENTALS
    [0003] A conventional distribution system for supplying heated adhesive (ie, a hot melt adhesive distribution system) generally includes an inlet to receive adhesive materials in solid or liquid form, a heating grid in communication with the inlet for heating and / or melting of the adhesive materials, an outlet in communication with the heating grid to receive the heated adhesive from the heating grid, and a pump in communication with the heating grid and the outlet to direct and control the distribution of the heated adhesive through the exit. One or more hoses can also be connected to the outlet to direct the dispensing of heated adhesive to adhesive dispensing guns or modules located downstream of the pump. In addition, conventional distribution systems generally include a controller (for example, a processor and memory) and input controls electrically connected to the controller to provide a user interface with the distribution system. The controller is in communication with the pump, heating grid, and / or other components of the distribution system, in such a way that the controller controls the distribution of the heated adhesive.
    [0004] Conventional hot melt adhesive delivery systems normally operate at sufficient temperature ranges to melt the received adhesive and heat the adhesive to a high application temperature before dispensing the heated adhesive. In order to ensure that the demand for heated adhesive from the gun (s) and module (s) is met, the adhesive delivery systems are designed with the ability to generate a predetermined maximum flow of the melted adhesive. As throughput requirements increase (for example, up to 9,072 kg (20 pounds) / hour or more), adhesive delivery systems have traditionally increased the size of the heating grid and the size of the feeder and of the reservoir associated with the heating grid, to ensure that the maximum flow of molten adhesive can be provided.
    [0005] However, large feeders and reservoirs result in a large amount of hotmelt adhesive being kept at a high application temperature inside the adhesive dispensing system. Keeping the hotmelt adhesive at a high application temperature can keep the hotmelt adhesive at an elevated temperature for only about 1 to 2 hours during maximum flow, but most conventional adhesive distribution systems do not operate continuously at full flow. To this end, adhesive dispensing systems typically operate over long periods of time when the production line is not in use and demand for molten adhesive is zero, or less than the maximum flow. During these periods of operation, large amounts of hotmelt adhesive can be kept at high application temperature for long periods of time, which can lead to the degradation and / or carbonization of the adhesive, negative effects on the adhesive bonding characteristics, clogging of the adhesive. adhesive distribution system, and / or additional suspensions.
    [0006] In order to avoid or reduce the amount of degradation caused in the adhesive, several conventional adhesive distribution systems have included a standby mode. When activated, the standby mode turns off the heat energy applied by the components of the distribution system, thereby reducing the temperature of the adhesive within the distribution system. Standby mode is activated based on an input received in the controller from the gun or module, and this input requires the supply of one or more additional wires or cables extending from the module or gun back to the controller. This additional wiring can be unsightly and increases the risk of grabbing cable connections to adjacent structures while the gun or module is running. In addition, the dispensing system generally requires a relatively long warm-up period (5-30 minutes) to return the adhesive in the dispensing system back to the elevated application temperature after the dispensing system has been in standby mode for a period of time. These additional delays in heating the system are undesirable for end users. As a result, virtually all end users do not use the standby mode available in conventional adhesive dispensing systems when the standby mode is the only mechanism designed to prevent degradation during long periods of inactivity of the adhesive dispensing system.
    [0007] For reasons such as these, an improved hot melt adhesive delivery system, including a control process to further reduce adhesive degradation would be desirable. SUMMARY OF THE INVENTION
    [0008] According to an embodiment of the invention, an adhesive delivery method is carried out with an adhesive delivery system. The method includes operating a heating unit to maintain the unit setpoint temperature which is sufficient to melt and heat the adhesive to an application temperature. The method also includes determining that the adhesive dispensing system requires an adhesive supply and then triggering a filling system for supplying adhesive to the adhesive dispensing system. Following an adhesive supply, it is determined whether a first defined threshold time has elapsed after the last activation of the filling system. If the first set threshold time has elapsed since this last activation, then the temperature of the heating unit is reduced below the temperature of the unit setpoint, while continuing to operate the heating unit ^ This reduces the temperature at which the adhesive is kept within the adhesive distribution system.
    [0009] In one aspect, the method also includes increasing the temperature of the heating unit back to the setpoint temperature of the unit when the filling system is triggered. A timer can be reset on this filling system drive, and this timer is used to determine whether the first set threshold time has been exceeded since the last adhesive supply. As a result, long periods of relative inactivity or low throughput will automatically cause the adhesive to cool down, which reduces the rate of adhesive degradation and minimizes gas output at an adhesive / air interface within the adhesive distribution system.
    [0010] The adhesive delivery system may also include a reservoir configured to receive heated adhesive from the heating unit, the reservoir includes a heating device. In these circumstances, the method may also include using the heating device to maintain a reservoir setpoint temperature, which maintains the temperature of the adhesive within the reservoir, both before and after the first defined threshold time has elapsed. As a result, the variation in the temperature of the adhesive in the heating unit caused by the reduction of the temperature of the heating unit is limited (such as at about 10 ° C), which allows a reduction in the heating time from this melting state. intelligent. For this purpose, the heating time for the heating unit can be so short that the distribution operations proceed immediately without delay when the heating unit is returned from the state of intelligent melting.
    [0011] Alternatively, the timer can be used to determine whether a second defined threshold time has elapsed after the last start of the filling system. When the second defined threshold time has elapsed, the reservoir temperature can also be. reduced while the heating device continues to operate, and this increases the change in the temperature of the adhesive in the adhesive distribution system to further reduce the degradation of the adhesive. For example, the total adhesive temperature change can be an additional 5 ° C in such an arrangement. The reduction in the temperature of the reservoir can be compensated in time by reducing the temperature of the heating unit to provide a stepwise reduction in the temperature of the adhesive. The temperature reduction in the heating unit can also be periodically switched 'to preventively heat adhesive back before a new adhesive supply is activated in the filling system.
    [0012] In another aspect, the smart fusion mode can also be accompanied by a standby mode in the adhesive dispensing system. For this purpose, the time can also determine whether a defined waiting threshold time has elapsed after the last activation of the filling system. This set threshold time will typically be much longer than the first set threshold time that determines when smart fusion mode is activated. Once the set waiting threshold time has elapsed, the standby mode is activated by turning off the heating unit to interrupt the application of heat energy to the adhesive until the next supply of adhesive to the adhesive dispensing system. Therefore, the advantages of a standby mode can also be combined with the smart fusion mode to allow an improved operation of the adhesive delivery system controlled based on refills or adhesive sources in the adhesive delivery system.
    [0013] In another embodiment, an adhesive delivery system includes a heating unit adapted to heat an adhesive to an application temperature, a level sensor for detecting a level of adhesive remaining for melting and heating by the heating unit, and a operative filling system to supply the adhesive to the heating unit. A controller is configured to trigger the filling system for supplying adhesive to the adhesive dispensing system whenever the level sensor that detects the adhesive level is below a refill threshold. The controller also operates the heating unit to maintain the unit setpoint temperature which is sufficient to melt and heat the adhesive to an application temperature. A timer is operationally coupled to the controller and configured to control a time that has elapsed since the last activation of the filling system. The controller continues to operate the heating unit while reducing the temperature of the heating unit if the elapsed time exceeds a defined first threshold. In this regard, an intelligent fusion process is activated to reduce degradation and carbonization of the adhesive during periods of low transfer rate from the adhesive distribution system.
    [0014] These and other objectives and advantages of the invention will become more readily apparent during the following detailed description taken in conjunction with the drawings presented herein. BRIEF DESCRIPTION OF THE DRAWINGS
    [0015] The accompanying drawings, which are incorporated and constitute a part of this specification, illustrate one embodiment of the invention and, together with the general description of the invention given above and the detailed description of the embodiment given below, serve to explain the principles of the invention. Figure 1 is a schematic block diagram view of an adhesive delivery system according to an embodiment of the invention. Figure 2 is a front cross-sectional view of a melting subset included in the adhesive distribution system of Figure 1. Figure 3 is a flow chart that illustrates a series of operations performed by a controller of the adhesive distribution system of Figure 1, according to a first modality of the method used with the adhesive distribution system. Figure 4 is a time graph showing the operating states of a filling system and a heating unit for the adhesive distribution system of Figure 1 operating the series of operations of Figure 3 during a volume transfer rate period. elevated. Figure 5 is a time graph showing the operational states of the filling system and the heating unit of the adhesive dispensing system of Figure 1 operating the series of operations of Figure 3 during a low volume transfer rate period. Figure 6 is a flow chart illustrating a series of operations performed by a controller of the adhesive distribution system of Figure '1, according to another modality of the method used with the adhesive distribution system. Figure 7 is a time graph showing the operating states of a filling system, a heating unit, and a reservoir of the adhesive distribution system in Figure 1 operating the series of operations in Figure 6, over a period of high volume transfer rate. Figure 8 is a time graph showing the operating states of a filling system, a heating unit, and a reservoir of the adhesive distribution system in Figure 1 operating the series of operations in Figure 6, over a period of low volume transfer rate. Figure 9 is a flow chart that illustrates a series of operations performed by a controller of the adhesive distribution system of Figure 1, according to yet another modality of the method used with the adhesive distribution system. Figure 10 is a time graph showing the operating states of a filling system and a heating unit for the adhesive dispensing system of Figure 1 operating the series of operations in Figure 9. DETAILED DESCRIPTION OF THE ILLUSTRATIVE MODALITIES
    [0016] Referring to Figures 1 and 2, an adhesive delivery system 10 according to an embodiment of the invention is shown. The adhesive dispensing system 10 is configured to optimize the dispensing operation by means of an intelligent melt heating control process to reduce the temperature of the hotmelt adhesive maintained within the dispensing system 10 during periods of low throughput. This temperature reduction is automatically triggered based on the frequency of refilling of a feeder 12 into the distribution system 10, significantly reducing the rate of adhesive degradation during periods of low transfer rate. In addition, unlike a standby process that requires a long heating time to return to dispensing operations, the reduction in adhesive temperature caused by the smart melting heating process is adapted to allow quick or immediate heating for the distribution operations after a temperature reduction. In addition, the standby mode can still be used after a long period of low transfer rate has elapsed, but 'the smart fusion heating process reduces the risk of degradation for much of the time before a standby mode necessary, as described in more detail below. Therefore, degradation caused by keeping hot melt adhesive at a high application temperature for long periods of time is reduced without the need for any additional wiring or actions taken by the end user of the distribution system 10.
    [0017] Before describing the specific operation and functionality related to the intelligent melting heating control process, a brief description of an exemplary adhesive delivery system 10 is provided below. Although this exemplary embodiment of the adhesive dispensing system 10 is described in some detail to explain the structural components that can be used to perform the advantageous intelligent melting heating control process, it will be appreciated that the control process of the present invention can be used with adhesive dispensing systems with different component arrangements without departing from the scope of the invention. With particular reference to Figure 1, an exemplary adhesive delivery system 10 can include a melting subset 14 having said feeder 12, a level sensor 16, a heating unit 18 that receives adhesive from feeder 12, and a reservoir / collector 20 that receives adhesive from the heating unit 18. The melting subset 14 also includes a pump 22 configured to deliver heated adhesive from the reservoir / collector 20 to a dispensing gun 24 or module. Each of these elements of the fusion subset 14 is described in more detail below. The adhesive delivery system 10 also includes a filling system 26 operable to supply solid or semi-solid adhesive material to the feeder 12, to refill the reservoir 12, when the level of adhesive material in the adhesive delivery system 10 becomes low. Therefore, as the heating unit 18 and the pump 22 operate to supply molten adhesive material to the gun 24 to distribute to a substrate, the feeder 12 periodically empties and the filling system 26 periodically supplies adhesive to fill the adhesive distribution system. 10 when this occurs,
    [0018] The adhesive delivery system 10 shown in Figure 1 also includes a controller 28 for the operation of various components of the delivery system 10. As shown by connection lines in Figure 1, controller 28 is operationally connected to the filling system 26 , the level sensor 16, the pump 22, and the heating devices (not shown in figure 1) in the heating unit 18 and the reservoir / collector 20. Controller 28 includes a processor and memory (not shown), and also program code resident in memory and configured to be executed by the processor. As described in more detail below, the program code operates to control the adhesive levels in the feeder 12, trigger refill operations by the filling system 26, and control the heat energy applied to the heating unit 18 and / or the reservoir / collector 20 to reduce the degradation of adhesive material kept within the melting subset 14. For this purpose, the controller 28 includes or is connected to a timer 30 configured to measure the time elapsed since the last filling operation of the filling system 26 As a result, controller 28 can use the intelligent fusion heating control process to reduce the temperature of the adhesive in the fusion subset 14 when the time has elapsed since a filling operation exceeds a time threshold, indicating that the distribution system 10 is operating with low throughput. This reduction in temperature is sufficient to significantly reduce the rate of degradation of the adhesive in the melt subset 14 while also being small enough to allow rapid or immediate heating or recovery to a high application temperature when the transfer rate is increased again. It should be understood that the intelligent fusion heating control process can be used with other types of distribution systems with a different arrangement of components, without departing from the scope of the present invention.
    [0019] The exemplary adhesive delivery system 10 shown schematically in Figure 1 is illustrated in more detail in Figure 2. Many of the components of the adhesive delivery system 10 are also described in Copending Patent Application No. US by Clark et al, entitled " Adhesive dispensing device with optimized reservoir and capacitive level sensor "(Our Ref: .. NOR-1496US), whose disclosure is incorporated by reference in yours. wholeness.
    [0020] With reference to Figure 2, a cyclonic separation unit 40 can be mounted on top of the feeder 12 and is separated from the reservoir / collector 20 by the heating unit 18 and the feeder 12. Thus, a flow generally based on the gravity of the adhesive is caused from the cyclonic separation unit 40 to the heating unit 18 for melting and then from the heating unit 18 into the reservoir / collector 20. The reservoir / collector 20 includes a reservoir 42 coupled with the unit heating element 18 and a collector 44 coupled to the reservoir 42 on the opposite side of the heating unit 18. For this purpose, the collector 44 defines a bottom surface of the reservoir 42. Although these elements are shown as distinct elements in Figure 2, it must it is understood that the reservoir / collector 20 can alternatively be formed as a unitary integral component. In addition, reservoir 42 can be defined by a larger melting tank, and collector 44 can be positioned at a distance from reservoir 42 instead of being located adjacent to reservoir 42 in other embodiments. The manifold 44 of the exemplary embodiment includes several ducts extending to the pump 22 (not shown in figure 2) and one or more outlets leading to the dispensing gun (s) 24. In short, the melting subset 14 operates to receive solid adhesive from the filling system 26, melt and heat the adhesive, and deliver the molten adhesive to the dispensing gun 24.
    [0021] With continued reference to Figure 2, the cyclonic separation unit 40 receives granules of adhesive driven by a flow of pressurized air through an inlet hose (not shown) leading to the filling system 26. The cyclonic separation unit 40 includes a generally cylindrical tube 52, which receives airflow and adhesive granules and slows down this flow before depositing the adhesive granules to feeder 12. Feeder 12 defines a compartment that can be positioned adjacent to cyclonic separation unit 40, the housing including an open bottom 70 communicating with the heating unit 18. Although the term "feeder" is used throughout the description of this exemplary embodiment of the adhesive delivery system 10, it will be understood that alternative structures for feeding solid adhesive can be provided from the filling system 26 to the heating unit 18. In this respect, the feeder 12 can be defined by or replaced with a receiving space or chamber, of any shape and size configured for. feeding the adhesive to the heating unit 18, in other embodiments consistent with the scope of the invention.
    [0022] The level sensor 16 is provided in the feeder 12 to monitor the level of adhesive in the adhesive dispensing system 10. For example, the level sensor 16 may include a capacitive level sensor in the form of a plate element 7 6 mounted along one of the peripheral side walls 78 of the feeder 12 .. The plate element 76 includes a driven electrode 80 and a portion of the side wall 78 or another side wall 78 of the feeder 12 acts as a second electrode (ground) of the pressure sensor level 16. For example, plate element 76 may also include a ground electrode in some embodiments. The level 16 sensor determines the amount or level of adhesive material in the adhesive distribution system 10 by detecting with the plate element 7 6 where variations in the capacitance level between the driven electrode 80 and ground (for example, an open space or air in the feeder 12 provides a different capacitance than the adhesive material in the feeder 12). The level sensor 16 is connected to the controller 28, and provides the information corresponding to the level of adhesive within the adhesive distribution system 10 to the controller 28. More specifically, the exemplary level sensor 16 shown in Figure 2 can operate to provide indications corresponding to the level of adhesive passing multiple threshold levels in the feeder 12 (for example, a first threshold level, where it will be necessary to fill quickly and a second threshold level also referred to as a refill threshold, in which refill is immediately required). filling system 26). Alternatively, the level sensor 16 can be replaced by multiple smaller level sensors (not shown) connected to controller 28 that each detects if adhesive is located at a particular level, thus providing similar indications as the higher level sensor 16 shown in Figure 2. The level 16 sensor, therefore, allows a refinement of the intelligent fusion heating control process described below by providing information to controller 28 regarding the supply of the adhesive to the adhesive dispensing system 10 is about to occur and when delivery is needed.
    [0023] The heating unit 18 of the exemplary embodiment includes a peripheral wall 88 and a plurality of dividers '90 extending through the space between the feeder 12 and the reservoir 42. In this regard, the heating unit 18 of the exemplary embodiment is in the form of a heating grid. The heating unit 18, therefore, defines a plurality of openings 92 through the heating unit 18 and between the partitions 90 for adhesive flow. It should be understood that the plurality of openings 92 can be defined by a different structure than grid-like partitions in other modes of the heating unit 18, including, but not limited to, fin-like structures extending from the peripheral wall 88, without moving away the scope of the invention. In this context, the "heating unit" 18 may even include a non-grid structure for heating the adhesive in other embodiments of the invention, the only necessary condition being that the heating unit 18 offers one or more openings 92 for the flow of adhesive through the adhesive dispensing system 10. With respect to the exemplary embodiments described below, the heating unit 18 can be referred to as a heating grid normally operating at a grid setpoint temperature (or a temperature unit setpoint), but this use of the term grid is not intended to prevent these alternative structures for the heating unit 18 within the scope of the current invention.
    [0024] The peripheral wall 88 is configured to receive a heating element 96, such as a resistance heater, a tubular heater, a heating cartridge, or other equivalent heating element, which can be inserted or fused in the heating unit 18. 0 heating element 96 receives signals from controller 28, and applies heat energy to heating unit 18, which is conducted through peripheral wall 88 and partitions 90 (or the alternative structure for heating unit 18, as described above) to transfer the heat energy to the adhesive material flowing through the openings 92, as well as to the feeder 12 and reservoir 42 through conduction. The heating unit 18 may also include one or more sensors configured to provide operational data for the controller 28, such as the temperature of the heating unit 18 (referred to as a grid setpoint temperature in several examples below). For example, the exemplary mode of the heating unit 18 includes a temperature sensor 98 to detect the temperature of the heating unit 18. The temperature sensor 98 is positioned to detect the temperature in the peripheral wall 88, and can indirectly detect the temperature of the heating unit. adhesive too, although it should be understood that the adhesive temperature tends to lag behind the temperature changes of the heating unit 18 by a small margin. This detected temperature can be used to control the output of heat energy by the heating element 96 of the heating unit 18, such as during the operation of the intelligent fusion heating control process. It is to be understood that a plurality of additional sensors can be located inside the heating unit 18 and various elements of the melting sub-assembly 14 for communicating with the controller 28 to control the exact operation of the adhesive dispensing system 10.
    [0025] Reservoir 42 includes a peripheral wall 100 extending between an open top end 102 communicating with the heating unit 18 and an open bottom end 104 communicating with and connected by the collector 44. At least one of the reservoir 42 and the collector 44 includes a heating device 106 in the form of a resistance heater, a tubular heater, a heating cartridge, or similar type of heating element inserted or melted in position in reservoir 42 or collector 44 for applying heat energy to these locations downstream of the heating unit 18 for the adhesive. The heating device 106 receives signals from the controller 28, and applies heat energy to the adhesive in the reservoir / collector 20. The reservoir 42 can also include one or more sensors configured to provide operational data for the controller 28, such as the reservoir temperature 42 (referred to as a reservoir setpoint temperature in several cases below). For example, the exemplary embodiment of reservoir 42 includes a temperature sensor 108 to detect the temperature of the peripheral wall 100 of reservoir 42. Similar to the temperature sensor 98 described above, temperature sensor 108 in the reservoir can alternatively extend as a probe for the adhesive in reservoir 42 in other embodiments. This detected temperature can be used to control the output of heat energy by the heating device 106 in the reservoir / collector 20, such as during the operation of the intelligent fusion heating control process.
    [0026] In operation, the heating unit 18 is brought up to temperature by the heating element 96 and the reservoir / collector 20 is brought up to the temperature of the heating device 106, such that the adhesive is heated up to the high application temperature desired. Controller 28 receives a signal from temperature sensors 98, 108, when the high application temperature has been reached, which indicates that the melt subset 14 is ready to supply melted adhesive. The pump 22 operates to then remove the molten adhesive material from the reservoir 42, as required by the downstream guns 24. As the pump 22 removes the adhesive material, gravity makes up at least a portion of the remaining adhesive material move down to reservoir 42 from feeder 12 and heating unit 18. Decrease in the level of adhesive granules within feeder 12 is detected by level sensor 16, and a signal is sent to controller 28 indicating that more adhesive granules must be delivered to the melting subset 14. Controller 28 then sends a signal that triggers supply of adhesive granules from filling system 26 through cyclonic separation unit 40 and into feeder 12 to fill the feeder 12. This process continues as long as the adhesive dispensing system 10 is in active operation.
    [0027] With reference to Figure 3, the controller 28 is also configured to perform the series of operations that define the intelligent fusion heating control process, a modality of which is shown in the form of a flowchart, in this Figure. Regardless of the particular structure used to form the adhesive dispensing system 10, controller 28 receives feedback from a level 16 sensor and one or more temperature sensors 98, 108 and sends trigger signals to one or more temperature elements. heating 96, 106, in order to carry out the intelligent fusion heating control process. For this purpose, the controller 28 receives an indication that the adhesive dispensing system 10 requires a refill (block 200). For example, and as described above, controller 28 can receive a signal from level sensor 16 at feeder 12, which indicates that the level of adhesive material has dropped below a defined threshold. To prevent the feeder 12 from running completely out of adhesive and then uncovering the heating unit 18, the controller 28 sends a signal to drive the filling system 26 to supply the adhesive dispensing system 10 with adhesive (block 202 ). Whenever this reload occurs, controller 28 also sets a variable t = 0 and causes timer 30 to start measuring the elapsed time t from the reload operation (block 204). The controller 28, therefore, monitors the time differences between each actuation of the filling system 26. As will be easily understood, faster refill operations are indicative that the adhesive dispensing system 10 is performing a high volume transfer rate, which which means that dispenser guns 24 are emitting adhesive at a relatively high rate.
    [0028] Controller 28 determines whether the elapsed time t is greater than or equal to a first threshold time set to operate the smart fusion mode (block 206). The first defined threshold time can be automatically predefined in controller 28 before being delivered to the end user for a specific period of time that indicates a difference between the low transfer rate of the distribution system 10 and the high transfer rate of the distribution system 10 In exemplary mode, the first defined threshold time can be placed anywhere within a range of about 5 minutes to about 60 minutes. More specifically, the first defined threshold time can be configured to be about 10 minutes. If the elapsed time does not exceed the first defined threshold time, the controller 28 operates the heating unit 18 (and, more specifically, the heating element 96 of the heating unit 18) to maintain the temperature of the heating unit 18 at a grid setpoint temperature used during the regular operation of melting subset 14 (block 208). In other words, unless the time elapsed since the last refill of the adhesive exceeds the first set threshold time, the heating unit 18 maintains a temperature at the grid setpoint temperature that is sufficient to melt and heat the adhesive until the high application temperature. Controller 28 then determines whether the adhesive delivery system 10 requires a refill (block 210). If the adhesive dispensing system 10 does not require refilling, controller 28 returns to block 206 to check again whether the first defined threshold time has exceeded. If the adhesive dispensing system 10 does not require refilling, then the controller 28 returns to block 200 - and the process starts again to time the difference between the filling system drives 26.
    [0029] If, on the other hand, it is determined that the time that has elapsed since the last refill of the adhesive dispensing system 10 exceeds the first defined threshold time, controller 28 operates in smart fusion mode to continue operating the heating unit 18 while reducing the temperature of the heating unit 18 below the grid setpoint temperature used during normal operation (block 212). For example, controller 28 can turn the desired temperature down anywhere in the range of about 6 ° C to about 220 ° C. In a particular example, controller 28 operates heating unit 18 to be at a temperature of 20 ° C below the grid setpoint temperature. As a result of the thermal energy, continuing to be applied to the reservoir / collector 20 through the heating device 106, the adhesive on the heating unit 18 and the feeder 12 will be kept at a slightly colder temperature, such as, for example, 10 ° C below the high application temperature during smart fusion mode.
    [0030] The test results demonstrated that the rate of degradation of some hotmelt adhesives can be reduced by more than 50% for each 10 ° C drop in temperature, so this small change in temperature has a substantial effect on delaying the degradation of the adhesive. in the melt subset 14. In addition, the temperature change in the adhesive remains small enough to allow rapid recovery from the high application temperature in the adhesive dispensing system 10 when necessary after a new refill of the adhesive dispensing system 10. This quick recovery ideally does not affect or delay any dispensing operation, because even in the smart fusion mode, there will still be some adhesive in the reservoir / collector 20 which is kept at a high application temperature and ready for dispensing. In addition, the temperature of the hotmelt adhesive is advantageously reduced where an interface is formed between the adhesive and the air inside the feeder 12. In addition to the reduced degradation rate, the temperature reduction at the air / adhesive interface is believed to provide less gas emissions of the adhesive inside the feeder 12, thereby improving the performance of the adhesive distribution system 10.
    [0031] Continuing from block 212 of the smart fusion heating control process, controller 28 then checks whether the adhesive delivery system 10 requires a refill (block 214). If the adhesive dispensing system 10 does not require refilling, controller 28 returns to block 212 and continues in smart fusion mode. If the adhesive distribution system Í0 does not require refilling, then controller 28 returns to block 200, after resetting the temperature of the heating unit 18 back to the grid setpoint temperature (block 216) and, therefore, the process starts again to time the difference between the filler system performances 26. By using the smart fusion mode as indicated, the adhesive can still be delivered at the high application temperature during periods of high transfer rate, but the adhesive is cooled slightly to reduce or prevent degradation during long periods between refills, such as during periods of low throughput. In this regard, some of the benefits of a standby mode (less degradation / carbonization) are obtained in the background processing of the controller 28 without the need for a complete shutdown and a long warm-up or recovery time. In addition, no positive action should be taken by the end user of the distribution system 10 to operate in smart fusion mode, as it automatically triggers in the background to improve the functioning of the distribution system 10.
    [0032] The beneficial operation of the adhesive dispensing system 10 over the series of operations shown in Figure 3 is shown in the form of a graph in Figures 4 and 5. For this purpose, Figure 4 illustrates a schematic representation of on / off signals for the filling system 26 and temperature setpoint levels for the heating unit 18 during a period of high transfer rate, and Figure 5 illustrates the same signals during a period of low transfer rate. More specifically, in Figure 4, the transfer rate of adhesive provided by the melt subset 14 is high enough to require a refill of the feeder 12 about every 6 or 7 minutes. Assuming that the first threshold time set to operate the smart fusion mode is about 10 minutes, the smart fusion mode will not be used during this period of high throughput. Therefore, the heating unit 18 maintains at the grid setpoint temperature over the time period of about 60 minutes shown in order to maintain and melt and heat the adhesive to the desired high application temperature. Of course, the "Grid Setpoint" signal for heating unit 18, refers only to the amount of heating element 96 required to maintain heating unit 18 at the grid setpoint temperature. As discussed above, the use of the term "grid setpoint" is used for purposes of explanation only and is not limiting the structure of the heating unit 18. In real distribution systems 10, the heating element 96 is switched on and off many times during this "grid setpoint" signal and only about 50-80% of the total time can be active in order to keep the heating unit 18 at the grid setpoint temperature. However, this state of the heating unit 18 is shown as a constant state for the sake of simplicity.
    [0033] Returning to Figure 5, during a period of low production, the adhesive dispensing system 10 may only require refilling every 25-30 minutes. In such a case, and when the first set threshold time is again about 10 minutes, the heating unit 18 remains in the "grid setpoint" state where the grid setpoint temperature whenever these refills occur and for about 10 minutes after that. However, as the adhesive dispensing system 10 goes more than 10 minutes between refills, the smart fusion mode is activated by lowering the heating unit 18 to a "Low temperature" state whenever the time elapsed from a recharge exceeds the set threshold time of 10 minutes (for example, in time = 15 minutes and time = 40 minutes in Figure 5.). As a result, the adhesive that moves through the melting subset 14 at a slower rate is not kept at the high application temperature for long periods of time, thereby reducing the overall rate of degradation and carbonization that can occur. As noted above, the adhesive can be changed in temperature only about 10 ° C during these periods of inactivity by the heating unit 18, as a consequence of the heat being transmitted and conducted from the heating device 106 in the reservoir / collector 20 to the feeder 12, but such a change in temperature is sufficient to significantly reduce degradation by half or more. Therefore, the intelligent fusion mode automatically activated and executed by the intelligent fusion heating control process reduces the degradation of the adhesive during a low transfer rate period, without any necessary action on the part of the end user and without any need for an expensive sensor and intensive maintenance located below the heating unit 18 in the melting subset 14. The heating or recovery period is also minimized to prevent disturbances in the operation of the adhesive dispensing system 10.
    [0034] It should be understood that the intelligent fusion heating control process can be modified in other ways. For example, the specific defined threshold time and the specific amount that the heating unit 18 is face down by the controller 28 during smart fusion mode can be modified without departing from the scope of the invention. If it is desired to switch off the smart fusion mode, then each of these values (defined threshold time, and unit temperature change) can be set to zero. In addition, more heating elements can be provided at different locations in the adhesive dispensing system 10, such as feeder 12. In embodiments with multiple heating elements, the intelligent melting heating control process can be modified by scaling the reducing the temperature of multiple heating elements over time. In this regard, if independent heating elements are provided in various components of the adhesive dispensing system 10 (such as feeder 12, heating unit 18, and reservoir 42), controller 28 can lower the setpoint by just the heating unit 18 after a first defined threshold time, and then the controller 28 can lower the set point of the heating unit 18 as well as the reservoir 42 after a second defined threshold time. As a result, the reduction of the adhesive temperature can be scaled to limit the amount of heating time required to return from the intelligent melting heating control process in circumstances where the intelligent melting state is actuated for only short periods of time. time.
    [0035] With reference to Figure 6, controller 28 can operate a slightly modified series of operations by defining an intelligent fusion mode according to the example discussed above. For this purpose, a stepwise reduction in the temperature of the adhesive in the adhesive distribution system 10 is activated by multiple heating elements being located in the adhesive distribution system 10. The modified series of operations includes each of the steps 200 to 214 described above. with reference to the first embodiment described in Figure 3, and these steps are not described again in detail below. Therefore, the operating method for controller 28 illustrated in Figure 6 includes determining whether a time that has elapsed since the last refill of the adhesive dispensing system 10 exceeds a defined first threshold, and the heating unit 18 is reduced in temperature below a grid setpoint temperature if the elapsed time exceeds the first threshold set.
    [0036] Continuing with the additional steps in Figure 6, the series of operations continues in a different way than previously described after determining that the adhesive dispensing system 10 does not require refilling in block 214. As described above, this determination is made after the smart fusion mode has been entered in block 212 by reducing the heating unit temperature below a grid setpoint temperature. In this mode, the method then continues to determine whether the elapsed time t exceeds a second defined threshold time (block 220). If the elapsed time t does not exceed the second defined threshold time, then the controller 28 returns to the block 214 to determine whether the adhesive delivery system 10 needs to be refilled. If the second defined threshold time has elapsed, then controller 28 continues to operate heating device 106 while reducing the temperature in reservoir 42 by lowering heating device 106 in reservoir 42 below a reservoir setpoint temperature (block 222). For example, heating device 106 can be lowered by 5 ° C when the second defined threshold time has elapsed, and it still cools the adhesive within the adhesive delivery system 10. Thus, the adhesive is cooled gradually over long periods. time periods to improve the reduction of adhesive degradation, while continuing to limit the heating or recovery time as much as possible in smart fusion mode.
    [0037] After the temperature in the reservoir 42 has been reduced, the controller 28 determines whether the adhesive delivery system 10 requires a new adhesive supply (block 224). If an adhesive refill is not required, controller 28 goes back to block 224 to continue monitoring whether the adhesive dispensing system 10 requires an adhesive refill. During this cycling of the controller 28, the smart fusion mode remains active with both the heating unit 18 and the reservoir 42 lowered from their respective set points to improve the cooling of the adhesive. Once controller 28 determines in block 224 that a refill of adhesive is required, then controller 28 returns to block 216 to set heating unit 18 back to the grid setpoint temperature (and reservoir 42 of back to the reservoir set point temperature, if necessary) and then to block 200 to start the process of filling the adhesive dispensing system 10 again. This sequence of operation shown in Figure 6 reinforces the advantages of the smart fusion mode for the reasons described above.
    [0038] The beneficial operation of the adhesive dispensing system 10 over the series of operations shown in Figure 6 is shown in the form of a graph in Figures 7 and 8. For this purpose, Figure 7 illustrates a schematic representation of on / off signals for the filling system 26 and the temperature setpoint level for the heating unit 18 and reservoir 42 during a period of high transfer rate, and Figure 8 illustrates the same signals during a period of low transfer rate. More specifically, in Figure 7, the adhesive transfer rate provided by the adhesive dispensing system 10 is high enough to require an adhesive refill using the filling system 26, approximately every 6 or 7 minutes. Assuming that the first threshold time set to operate the smart fusion mode is about 10 minutes, the smart fusion mode will not be used during this period of high throughput. Therefore, the heating unit 18 remains at the grid setpoint temperature and the reservoir 42 remains at the reservoir setpoint temperature over the time period of about 60 minutes shown in order to maintain melting and heating adhesive at the desired high application temperature. Of course, the "Grid Setpoint" signal for heating unit 18 refers only to the amount of heating element 96 required to maintain heating unit 18 at a grid setpoint temperature. In the actual distribution systems 10, the heating element 96 is switched on and off many times during this "grid setpoint" signal and can be active only about 50-80% of the total time in order to maintain the cooling unit. 18 heating at the grid setpoint temperature. However, this state of the heating unit 18 is shown as a constant state for the sake of simplicity. The same reasoning applies to the constant sign shown for the sake of simplicity in the reservoir graph.
    [0039] Returning to Figure 8, during a period of low transfer rate, the adhesive delivery system 10 may only require refilling every 25-30 minutes. In such a case, and where the first set threshold time is about 10 minutes and the second set threshold time is about 20 minutes, the heating unit 18 remains in the "Grid setpoint" state at the temperature of grid setpoint whenever these refills occur and for about 10 minutes after that. However, as the adhesive dispensing system 10 goes more than 10 minutes between refills, the smart fusion mode is activated, lowering the heating unit 18 to a "Low temperature" state whenever the time elapsed from a recharge exceeds the set threshold time of 10 minutes (for example, time = 15 minutes and time = 40 minutes in Figure 8). As a result, the adhesive that moves through the melting subset 14 at a slower rate is not kept at the high application temperature for long periods of time, thereby reducing the overall rate of degradation and carbonization that can occur. As noted above, the adhesive can be changed in temperature only about 10 ° C during these periods of inactivity by the heating unit 18, as a consequence of the heat being transmitted and conducted from the heating device 106 in the reservoir / collector 20, but such a change in temperature is sufficient to significantly reduce degradation by half or more.
    [0040] In this mode, the intelligent fusion mode is scaled so that after twenty minutes after filling (for example, in time = 25 minutes and t = 50 minutes in Figure 8), reservoir 42 is lowered from a "Setpoint reservoir "to a" reduced temperature ", until the next filling is triggered. Thus, during the five minute period of time it takes to recharge at t = 30 minutes and the 10 minute time period which leads to recharge at t = 60 minutes shown in the graph, the temperature of the adhesive is further reduced to improve the reduction of degradation and carbonization that can occur over longer periods of time. However, the warm-up or recovery period remains substantially minimized to avoid significant disruptions to the operations of the adhesive dispensing system 10. Even more degradation of the adhesive is avoided in the present embodiment, with only a minimal addition to the warm-up or recovery time. . Again, the minimized heating time may not affect dispensing operations because the temperature of part of the adhesive in the reservoir / collector can still be maintained at a temperature high enough for dispensing immediately at the end of the smart fusion mode. As a result, the stepwise reduction of the temperature of the adhesive using this mode of intelligent fusion mode is another method for improving the use of adhesive delivery systems 10.
    [0041] In another alternative, controller 28 can operate the intelligent fusion heating control process in an adaptive manner that anticipates and adjusts operation of heating elements 96, 106 based on previous operating cycles of the adhesive dispensing system 10. For this purpose , controller 28 can monitor the average or typical period of time between refills of the adhesive dispensing system 10 over a plurality of emptying and refilling cycles. For example, controller 28 would determine in the high throughput scenario shown in Figures 4 and 7, that adhesive delivery system 10 is being reloaded every six minutes, while controller 28 would determine in the low throughput scenario. transfer shown in Figures 5 and 8, that the adhesive delivery system 10 is being refilled every 27 minutes. Based on this average or typical time between recent recharge triggers, controller 28 can be programmed to anticipate the next recharge actuation before the low level signal is received from the level 16 sensor, and then trigger the heating element 96 to start heating the adhesive to the grid setpoint temperature before the refill is triggered. Although this anticipatory reheat cannot always be activated before the refill signal is generated, reheat must start earlier for most distribution / refill cycles and any possible downtime for heating is minimized.
    [0042] More generally, controller 28, in this mode, would store a first threshold time X, which corresponds to the time that must elapse after a recharge before the smart fusion mode is activated, and a defined preemptive reheat threshold time Y , which corresponds to a time that must elapse after the activation of the intelligent fusion mode before the heating element 96 is returned to the setpoint temperature of the grid before the next recharge. If the example in Figures 5 and 8, with about 27 minutes between the recharge triggers, the first time threshold can be 10 minutes, for example, and the preemptive reheat threshold time defined can be 15 minutes, for example. example. These values of X and Y, in this example, would allow the adhesive to cool for 15 every 27 minutes between recharge cycles, in addition to minimizing or eliminating the heating time by starting the heating process about two minutes before the expected recharge. Naturally, variables X and Y can be modified as operating cycles change over time, thus adapting the normal operating cycles of the adhesive dispensing system 10 at the present time. The specific Y and X values could be modified according to the preferences of the end user as well. The controller 28 in the present embodiment effectively learns patterns over time and adapts to the operation of the adhesive dispensing system 10 to allow the intelligent melting heating control process while incurring no disruption to the distribution capacity of the system 10.
    [0043] Alternatively, preemptive heating of the adhesive in the feeder 12 can be achieved without using the defined preemptive reheat threshold time Y in other embodiments. More specifically, the level sensor 16 (or plurality of level sensors) can be designed to detect the level of adhesive by passing several thresholds in the feeder 12. For example, the level sensor 16 shown in Figure 2 may be large enough to provide a first indication when the adhesive level falls below a first level threshold a short time before refilling is required, and a second indication when the adhesive level falls below a second level threshold (also referred to as a threshold refill) indicating an almost empty feeder 12. In such an arrangement, the controller 28 can activate the heating process whenever the heating element 96 is lowered in the smart fusion mode and the level of adhesive is detected to fall below the first level threshold. Then, when the adhesive level falls below the second threshold level, the heating process has already started or ended by the time that the refill is activated in the filling system 26. Similar to the previous modality, this control process eliminates or reduces any heating time required when terminating an intelligent fusion mode on a feeder 12 refill. It will also be understood that if the second indication is not received within a time threshold of the first indication (and the corresponding rotation and heating of the heating element 96 ), Controller 28 can engage smart fusion mode again by lowering the temperature in heating element 96.
    [0044] In yet another embodiment of the intelligent fusion heating control process, the controller 28 can be configured to turn the intelligent fusion mode on and off according to a predetermined schedule. For example, controller 28 can be programmed to: (1) initiate low temperature smart fusion mode on heating unit 18 after a first amount of time, (2) adjust heating element 96 back to the temperature of grid set point after a second period of time, and (3) repeat steps 1 and 2 until a refill is triggered, which resets the timer for the control process. In embodiments of the adhesive delivery system 10 with low throughput, for example, this modified control process would avoid longer heating times while maintaining substantially all the advantages of the intelligent fusion mode. Instead of allowing adhesive to cool significantly over a 50 minute time period (when the threshold time for activating smart fusion mode is 10 minutes, for example), smart fusion mode can be turned on and off at every 20 minutes during that longer period of time. After 20 minutes of operation in the smart fusion mode, the heating element 96 is activated to heat up again to the grid setpoint temperature, and once the temperature is reached, the smart fusion mode can start again. Thus, during long periods of time between refills, the adhesive will not be cooled in such a way that a long heating time is required for the next refill. Cycling on and off smart fusion mode at longer intervals maintains the benefits of smart fusion mode while minimizing any potential warm-up time inconveniences. In addition, the intelligent fusion mode of the present mode or of the modes described above can be combined with a standby mode that shuts off the heating unit 18 after long periods of low throughput or inactivity. A series of samples of operations mixing the smart fusion mode with the standby mode is provided in Figure 9 below. It should be understood that other modifications are possible without departing from the main scope and the advantages of the intelligent melting heating control process and the adhesive delivery system 10 of the present invention.
    [0045] Referring to Figure 9, another embodiment of a method used in the adhesive dispensing system 10 is shown as a series of operations. This series of operations is in many respects similar to the others described previously in Figures 3 and 6, but differs in several aspects described below. The series of operations allows both the smart fusion mode and a standby mode to be used without the need for signals to be delivered back from the distributor gun 24 to the controller 28.
    [0046] The set of operations in Figure 9 begins with controller 28 receiving an indication that the adhesive dispensing system 10 requires a refill (block 300). This indication can be requested by the level sensor 16 in the feeder 12, as described above. Once this refill indication is received, the controller 28 acts the filling system 26 to supply the adhesive distribution system 10 with additional adhesive (block 302). Controller 28 then sets two time variables T (indicating the total time) and t (indicating the current cycle time) to zero and starts timer 30 (block 304). Controller 28 determines whether the current cycle time t is greater than the first defined threshold time (block 306). If the current cycle time t has not yet exceeded the first defined threshold time, controller 28 determines whether the adhesive dispensing system 10 requires an adhesive refill (block 308). If such an adhesive refill is required, controller 28 returns to block 300 to begin the process of filling adhesive dispensing system 10 again. If the adhesive dispensing system 10 does not require an adhesive supply, then controller 28 determines whether the total time T exceeds a defined waiting threshold time (block 310). If the total time T does not exceed the defined wait threshold time, then the standby mode is activated as described in more detail below. If the total time T does not exceed the defined waiting threshold time, then controller 28 returns to block 306 and repeats this set of three queries (blocks 306, 308, 310) until the current cycle time t exceeds the first threshold of defined time, the adhesive dispensing system 10 requires a refill, or the total time T exceeds the defined waiting threshold time.
    [0047] Now, let's assume that controller 28 determines in block 306 that the current cycle time t exceeds the first defined threshold time. In such a circumstance, the controller 28 activates the smart fusion mode by continuing to operate the heating unit 18 while reducing the temperature of the heating unit below the grid setpoint temperature (block 312). Controller 28 then resets the current cycle time t to zero and continues operation of timer 30 (block 314). Note that the total time T continues to run from the beginning of the series of operations for the purposes set out in more detail below. Controller 28 then performs three queries similar to those described above for blocks 306, 308 and 310. For this purpose, controller 28 determines whether the adhesive delivery system 10 requires an adhesive refill (block 316). If such an adhesive refill is required, controller 28 returns to block 300 to begin the process by filling the adhesive dispensing system 10 again. If the adhesive dispensing system 10 does not require an adhesive supply, then controller 28 determines whether the current cycle time t is greater than the defined reheat threshold time (block 318). If the current cycle time t has not yet exceeded the defined reheat threshold time, then controller 28 determines whether the total time T exceeds a defined wait threshold time (block 320). If the total time T does not exceed the defined wait threshold time, then the standby mode is activated as described in more detail below. If the total time T does not exceed the defined waiting threshold time, controller 28 returns to block 316 and repeats this set of three queries (blocks 316, 318, 320) until the current cycle time t exceeds the threshold time of defined reheat, the adhesive dispensing system 10 requires a refill, or the total time T exceeds the defined wait threshold time.
    [0048] Now, let's assume that controller 28 determines in block 318 that the current cycle time t exceeds the defined reheat threshold time. In such a circumstance, the controller 28 temporarily disables the smart fusion mode by continuing to operate the heating unit 18 while increasing the temperature of the heating unit back to the grid setpoint temperature (block 322). Controller 28 then resets the current cycle time t to zero and continues operation of timer 30 (block 324). Note that the total time T continues to run from the beginning of the series of operations for the purposes set out in more detail below. Controller 28 then returns to block 306 and repeats the three queries described above for blocks 306, 308 and 310. Therefore, controller 28 operates to repeatedly activate and deactivate an intelligent fusion mode over a long period of time between the refill drives so that the adhesive in the adhesive dispensing system 10 is cooled, but not to a point where the heating time would be excessive when dispensing operations at a high rate start again.
    [0049] If controller 28 has already determined that the total time T exceeds the waiting threshold time defined in blocks 310 or 320, controller 28 activates a standby mode, turning off the heating unit 18 (block 326). If necessary, other heating elements in reservoir 42 or elsewhere can also be switched off during standby. The standby mode significantly lowers the temperature of the adhesive after a long period of time between refill cycles so that heating energy is not wasted when the adhesive delivery system 10 is in long periods of non-use. Therefore, the set wait threshold time is typically much longer than the first set threshold time and the reheat threshold time set so that the standby mode is only activated when it is clear that the adhesive dispensing system 10 is in a long period of inactivity. Of course, the standby mode can also be programmed to be programmed from an operator input on a manual control button, as well as in other modes. While in standby mode, controller 28 repeatedly determines whether the adhesive dispensing system requires a refill (block 328). Once such a refill is necessary, then the controller 28 returns to block 300 to start the process again after switching on the heating unit 18 and any other heating equipment switched off again (block 330). A longer warm-up time is likely to be required when exiting standby, but this is acceptable because the standby mode is not activated unless the dispensing activities have actually stopped on the adhesive dispensing system 10. As a result of the combination from smart fusion mode and standby mode, energy efficiency and time are maximized in all operating states of the adhesive dispensing system 10.
    [0050] The beneficial operation of the adhesive dispensing system 10 over the series of operations shown in Figure 9, is shown in the form of a graph in Figure 10. For this purpose, Figure 10 illustrates a schematic representation of on / off signals for the filling system 26 and the temperature setpoint levels for the heating unit 18 during a period of very low throughput. For the purposes of this example, assume that the first set threshold time is set to 10 minutes, the set reheat threshold time is also set to 10 minutes, and the set wait threshold time is set to 45 minutes (which it is unrealistically low in most circumstances, but allows illustration of the standby mode in this graph). The adhesive dispensing system 10 is operated in such a way that the refill operations by the filling system 26 occur at time t = 5 minutes, 20 minutes and 90 minutes. As can be seen in the difference between the first two actuations of the filling system 26, the time difference is 15 minutes, which is longer than the first defined threshold time. As a result, the smart fusion mode is activated from time t = 15 minutes to time t = 20 minutes, thereby reducing the temperature of the adhesive and limiting any degradation of the adhesive over this period of time. Likewise, the time difference between the second and third drives of the filling system 26 is also long enough to make the smart fusion mode activated.
    [0051] In addition, this last time difference is 70 minutes, which allows the first set threshold time of 10 minutes and the set reheat threshold time of 10 minutes to occur repeatedly. This leads to the smart fusion mode being activated and deactivated every 10 minutes starting at time t = 30 minutes. Since the total time since the last recharge is greater than the set waiting threshold time (at time t = 65 minutes), the standby mode is activated and the heating unit 18 is completely switched off, as shown. This wait state remains until the next recharge occurs, thus stopping the repeated heating unit 18 cycle between the grid setpoint temperature and the reduced temperature below the setpoint. Therefore, the degradation of the adhesive in the adhesive delivery system 10 is reduced, and the adhesive delivery system 10 is effectively shut down during long periods of (presumed) inactivity. The energy savings and improvements in adhesive life over a conventional system that keeps the adhesive at the same high set point for all 90 minutes during this example are significant and advantageous.
    [0052] Although the present invention has been illustrated by a description of various modalities, and the modalities have at the same time been described in considerable detail, there is no intention to restrict, or in any way limit the scope of the appended claims to such details. Additional advantages and modifications are readily apparent to those skilled in the art. Therefore, the invention in: its broadest aspects is not limited to the specific details shown and described. The various features described here can be used in any combination necessary or desired for a particular application. Consequently, departures can be made from the details described here without departing from the spirit and scope of the claims that follow.
    权利要求:
    Claims (20)
    [0001]
    Method for dispensing adhesive with an adhesive dispensing system, the method comprising: operating a heating unit (18) to maintain the unit setpoint temperature which is sufficient to melt and heat the adhesive to an application temperature; determining that the adhesive delivery system (10) requires an adhesive supply; driving a filling system (26) for supplying adhesive to the adhesive dispensing system (10); characterized by the fact that: determine whether a first defined threshold time has elapsed after the last activation of the filling system (26); and continue to operate the heating unit (18) while reducing the temperature of the heating unit (18) below the unit setpoint temperature at which the first set threshold time elapsed.
    [0002]
    Method, according to claim 1, characterized by the fact that it also comprises: increase the temperature of the heating unit (18) back to the setpoint temperature of the unit when the filling system (26) is activated.
    [0003]
    Method according to claim 1, characterized in that the adhesive distribution system (10) includes a reservoir (42) configured to receive heated adhesive from the heating unit (18) and a heating device (106 ) associated with the reservoir, and the method further comprises: operating the heating device (106) to maintain a reservoir setpoint temperature that maintains the adhesive at the application temperature before reducing the temperature of the heating unit (18); and continue to operate the heating device (106) to maintain the reservoir set point temperature after reducing the temperature of the heating unit (18), thereby causing a change in the temperature of the adhesive in the adhesive dispensing system to be limited from such that a heating time for the adhesive to return to the application temperature is minimized.
    [0004]
    Method according to claim 3, characterized by the fact that reducing the temperature of the heating unit (18) and continuing to operate the heating device (106) results in a change in the temperature of the heating unit of about 10oC.
    [0005]
    Method, according to claim 3, characterized by the fact that it also comprises: determine whether a second defined threshold time has elapsed after the last activation of the filling system (26); and continue to operate the heating device (106) while reducing the temperature of the heating device below the temperature of the reservoir setpoint when the second defined threshold time has elapsed, thereby further reducing the temperature of the adhesive in the distribution system. adhesive (10) and providing a stepwise reduction in temperature of the adhesive following an actuation of the filling system (26).
    [0006]
    Method, according to claim 5, characterized by the fact that when the filling system (26) is activated, the method further comprises: increase the temperature of the heating unit (18) back to the setpoint temperature of the unit, and increase the temperature of the heating device (106) back to the reservoir setpoint temperature.
    [0007]
    Method, according to claim 1, characterized by the fact that it also comprises: determine whether a defined reheat threshold time has elapsed after the last heating unit temperature reduction (18) below the unit setpoint temperature, and increase the temperature of the heating unit (18) back to the unit setpoint temperature when the set reheat threshold time has elapsed.
    [0008]
    Method, according to claim 7, characterized by the fact that it further comprises: monitor an average cycle time between filling system refill drives (26); and adjust the first defined threshold time and the defined reheat threshold time based on the average cycle time.
    [0009]
    Method, according to claim 7, characterized by the fact that it further comprises: determine whether the first set threshold time has elapsed again following the temperature rise of the heating unit (18) back to the unit setpoint temperature, reduce the temperature of the heating unit (18) below the unit setpoint temperature when the first set threshold time has elapsed again, and repeat the increase and decrease of the temperature of the heating unit (18) after intervals defined by the defined reheat threshold time and the first defined threshold time until the filling system (26) is activated again, thus, periodically, alternating the unit heating temperature (18) between the unit setpoint temperature and a reduced temperature below the unit setpoint temperature.
    [0010]
    Method, according to claim 9, characterized by the fact that it also comprises: determine whether a defined waiting threshold time has elapsed after the last activation of the filling system (26); and activate a standby mode by turning off the heating unit (18) to interrupt the application of heat energy to the adhesive during the standby mode, in which the activation of the standby mode ends the periodic cycle of the heating unit (18) between the unit setpoint temperature and the reduced temperature.
    [0011]
    Method, according to claim 1, characterized by the fact that it also comprises: determining whether a defined waiting threshold time elapses after the last activation of the filling system (26); and activate a standby mode by turning off the heating unit (18) to interrupt the application of heat energy to the adhesive during standby mode.
    [0012]
    Method, according to claim 1, characterized by the fact that it also comprises: determine that the level of adhesive material in the adhesive distribution system (10) has dropped below a threshold indicating that a refill will be required soon, and increase the temperature of the heating unit (18) back to the setpoint temperature of the unit when the level of adhesive in the adhesive distribution system (10) has dropped below the threshold, thereby heating the adhesive before starting the heating system. filling (26).
    [0013]
    Method, according to claim 1, characterized by the fact that it also comprises: use the adhesive distribution system (10) to perform the steps of operation, determination, activation, determination, and continuity, in which the adhesive distribution system comprises: the heating unit (18), a level sensor (16) for detecting an adhesive level in the adhesive dispensing system, the filling system (26), a controller (28) configured to drive the filling system (26) to deliver the adhesive when the level sensor (16) detects that the adhesive level is below a refill threshold, the controller (28) also configured to operate the heating unit (18), and a timer (30) operatively coupled to the controller (28) and configured to control a time that has elapsed since the last activation of the filling system (26), such that the controller (28) reduces the temperature of the heating unit (18) if the elapsed time tracked by the timer (30) exceeds the first defined threshold time.
    [0014]
    Adhesive distribution system comprising: a heating unit (18) adapted to heat and melt an adhesive to an application temperature, a level sensor (16) for detecting an adhesive level of remnant for melting and heating by said heating unit (18), a filling system (26) for supplying the adhesive for said heating unit (18), a controller (28) configured to drive said filling system (26) to deliver the adhesive when said level sensor (16) detects that the adhesive level is below a refill threshold, the controller (28) also configured to operating said heating unit (18) to maintain a unit setpoint temperature that is sufficient to melt and heat the adhesive to the application temperature, and characterized by the fact that the adhesive distribution system (10) also comprises: a timer (30) operatively coupled to said controller (28) and configured to control a time elapsed since the last activation of said filling system (26), such that said controller (28) continues to operate said unit of heating (18) while reducing the temperature of said heating unit (18) if the elapsed time tracked by said timer (30) exceeds a first defined threshold time.
    [0015]
    Distribution system, according to claim 14, characterized by the fact that said controller (28) is configured to reset said timer (30) after each activation of said filling system (26), which also results in the operation of said heating unit (18) to increase the temperature of said heating unit (18) back to the unit setpoint temperature until the elapsed time exceeds the first again set threshold time.
    [0016]
    Distribution system, according to claim 14, characterized by the fact that it also comprises: a reservoir (42) positioned to receive molten adhesive from said heating unit (18), and a heating device (106) configured to apply heat energy to the molten adhesive within said reservoir (42), wherein said controller (28) is configured to operate said heating device (102) to maintain a temperature of reservoir set point that keeps the adhesive at the application temperature inside said reservoir (42).
    [0017]
    Distribution system according to claim 16, characterized in that said controller (28) operates said heating device (106) to continue to maintain the reservoir set point temperature after reducing the temperature of said heating unit heating (18), thus minimizing a heating time for the adhesive to return to the application temperature following an actuation of said filling system (26) to supply adhesive to said heating unit (18).
    [0018]
    Distribution system according to claim 16, characterized by the fact that said controller (28) is configured to determine whether a second defined threshold time has elapsed after the last activation of said filling system (26), and is also configured to continue to operate said heating device (106) while reducing the temperature of said heating device (106) when the second defined threshold time elapses thereby providing a stepwise reduction in the temperature of the adhesive.
    [0019]
    Distribution system according to claim 14, characterized by the fact that said level sensor (16) is configured to provide a first indication for said controller (28) when the adhesive level falls below a threshold indicating that a supply from said filling system (26) it will be necessary soon and to provide a second indication for said controller (28) when the level of adhesive falls below a level requiring immediate supply from said filling system (26), and said controller (28) increases the temperature of said heating unit (18) back to the setpoint temperature of the unit when the first indication is received from said level sensor (16) to preventively heat the adhesive of back before the second indication is received.
    [0020]
    Distribution system according to claim 14, characterized by the fact that said controller (28) is configured to determine whether a defined waiting threshold time elapses after the last activation of said filling system (26), and is configured to activate a standby mode by turning off said heating unit (18) to stop applying heat energy to the adhesive during the standby mode.
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    法律状态:
    2014-11-25| B03A| Publication of an application: publication of a patent application or of a certificate of addition of invention|
    2018-11-21| B06F| Objections, documents and/or translations needed after an examination request according art. 34 industrial property law|
    2020-04-07| B06U| Preliminary requirement: requests with searches performed by other patent offices: suspension of the patent application procedure|
    2020-10-20| B09A| Decision: intention to grant|
    2021-01-26| B16A| Patent or certificate of addition of invention granted|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 24/10/2013, OBSERVADAS AS CONDICOES LEGAIS. |
    优先权:
    申请号 | 申请日 | 专利标题
    US201261718311P| true| 2012-10-25|2012-10-25|
    US61/718,311|2012-10-25|
    US13/799,737|2013-03-13|
    US13/799,737|US9200741B2|2012-10-25|2013-03-13|Adhesive dispensing system and method using smart melt heater control|
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