WO2020258815A1 - 点胶控制设备及其出胶控制方法 - Google Patents

点胶控制设备及其出胶控制方法 Download PDF

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Publication number
WO2020258815A1
WO2020258815A1 PCT/CN2019/130259 CN2019130259W WO2020258815A1 WO 2020258815 A1 WO2020258815 A1 WO 2020258815A1 CN 2019130259 W CN2019130259 W CN 2019130259W WO 2020258815 A1 WO2020258815 A1 WO 2020258815A1
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WO
WIPO (PCT)
Prior art keywords
air pressure
glue
exhaust valve
control device
air
Prior art date
Application number
PCT/CN2019/130259
Other languages
English (en)
French (fr)
Inventor
张晋
孙培
曲东升
赵亚军
Original Assignee
常州铭赛机器人科技股份有限公司
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from CN201910555990.8A external-priority patent/CN110170426B/zh
Priority claimed from CN201910557123.8A external-priority patent/CN110102443A/zh
Application filed by 常州铭赛机器人科技股份有限公司 filed Critical 常州铭赛机器人科技股份有限公司
Priority to KR1020207037841A priority Critical patent/KR102450258B1/ko
Priority to JP2020573263A priority patent/JP7100719B2/ja
Priority to SG11202101447VA priority patent/SG11202101447VA/en
Priority to EP19935282.4A priority patent/EP3991855B1/en
Priority to PL19935282.4T priority patent/PL3991855T3/pl
Publication of WO2020258815A1 publication Critical patent/WO2020258815A1/zh

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05C—APPARATUS FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05C5/00—Apparatus in which liquid or other fluent material is projected, poured or allowed to flow on to the surface of the work
    • B05C5/02—Apparatus in which liquid or other fluent material is projected, poured or allowed to flow on to the surface of the work the liquid or other fluent material being discharged through an outlet orifice by pressure, e.g. from an outlet device in contact or almost in contact, with the work
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05C—APPARATUS FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05C11/00—Component parts, details or accessories not specifically provided for in groups B05C1/00 - B05C9/00
    • B05C11/10—Storage, supply or control of liquid or other fluent material; Recovery of excess liquid or other fluent material
    • B05C11/1002—Means for controlling supply, i.e. flow or pressure, of liquid or other fluent material to the applying apparatus, e.g. valves
    • B05C11/1007—Means for controlling supply, i.e. flow or pressure, of liquid or other fluent material to the applying apparatus, e.g. valves responsive to condition of liquid or other fluent material
    • B05C11/1013—Means for controlling supply, i.e. flow or pressure, of liquid or other fluent material to the applying apparatus, e.g. valves responsive to condition of liquid or other fluent material responsive to flow or pressure of liquid or other fluent material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05C—APPARATUS FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05C11/00—Component parts, details or accessories not specifically provided for in groups B05C1/00 - B05C9/00
    • B05C11/10—Storage, supply or control of liquid or other fluent material; Recovery of excess liquid or other fluent material
    • B05C11/1002—Means for controlling supply, i.e. flow or pressure, of liquid or other fluent material to the applying apparatus, e.g. valves
    • B05C11/1026—Valves
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05D—SYSTEMS FOR CONTROLLING OR REGULATING NON-ELECTRIC VARIABLES
    • G05D7/00—Control of flow
    • G05D7/06—Control of flow characterised by the use of electric means
    • G05D7/0617—Control of flow characterised by the use of electric means specially adapted for fluid materials
    • G05D7/0629—Control of flow characterised by the use of electric means specially adapted for fluid materials characterised by the type of regulator means
    • G05D7/0635—Control of flow characterised by the use of electric means specially adapted for fluid materials characterised by the type of regulator means by action on throttling means
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05D—SYSTEMS FOR CONTROLLING OR REGULATING NON-ELECTRIC VARIABLES
    • G05D7/00—Control of flow
    • G05D7/06—Control of flow characterised by the use of electric means
    • G05D7/0617—Control of flow characterised by the use of electric means specially adapted for fluid materials
    • G05D7/0629—Control of flow characterised by the use of electric means specially adapted for fluid materials characterised by the type of regulator means
    • G05D7/0635—Control of flow characterised by the use of electric means specially adapted for fluid materials characterised by the type of regulator means by action on throttling means
    • G05D7/0641—Control of flow characterised by the use of electric means specially adapted for fluid materials characterised by the type of regulator means by action on throttling means using a plurality of throttling means
    • G05D7/0664—Control of flow characterised by the use of electric means specially adapted for fluid materials characterised by the type of regulator means by action on throttling means using a plurality of throttling means the plurality of throttling means being arranged for the control of a plurality of diverging flows from a single flow
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
    • H01L24/00—Arrangements for connecting or disconnecting semiconductor or solid-state bodies; Methods or apparatus related thereto
    • H01L24/74—Apparatus for manufacturing arrangements for connecting or disconnecting semiconductor or solid-state bodies
    • H01L24/741—Apparatus for manufacturing means for bonding, e.g. connectors
    • H01L24/743—Apparatus for manufacturing layer connectors

Definitions

  • the invention relates to the technical field of glue dispensing, in particular to a glue dispensing control device and a glue output control method thereof.
  • Conventional pneumatic dispensing controller its built-in analog barometer, digital barometer or barometric sensor is connected to the pipeline between the outlet of the first pressure reducing device and the inlet of the first exhaust valve for It measures and displays the set air pressure, and cannot monitor the air pressure waveform in the rubber barrel pipeline, and does not have the function of monitoring the air pressure in the rubber barrel.
  • the dispensing parameters are determined when the glue tank is full. As the number of dispensing times increases, the remaining amount of glue in the glue tank gradually decreases, and the amount of glue is also reduced. When the amount of glue is significantly reduced below the glue amount requirement, the operator needs to change the dispensing parameters (generally, the duration of the glue is appropriately increased).
  • the core problems of this dispensing application First, the operator needs to change the dispensing parameters multiple times, and whether the changed parameters are appropriate or not needs to be tested and verified; the second is that if the operator changes the dispensing parameters multiple times, the glue will be discharged. There is obvious fluctuation in the amount of glue, that is, when the amount of glue is significantly reduced, the dispensing parameters are suddenly changed, resulting in a significant increase in the next glue amount.
  • the present invention aims to solve at least one of the technical problems existing in the prior art.
  • the present invention proposes a glue dispensing control device, which can realize the self-adaptive adjustment of glue dispensing parameters, the alarm function of insufficient remaining glue quantity and the self-adaptive feedback control of suction air pressure.
  • the invention also provides a control method of the glue dispensing control equipment.
  • a dispensing control device includes: a body having a first input interface suitable for connecting an air source, a first output interface suitable for connecting an external glue bucket, and a first Two output interfaces; a first pressure reducing device, the first pressure reducing device is provided in the body, and the air inlet end of the first pressure reducing device is connected to the first input interface; a first exhaust valve, The first exhaust valve is provided in the body, and the air inlet of the first exhaust valve is connected to the outlet end of the pressure reducing device; the second exhaust valve is The inlet is connected to the outlet of the first exhaust valve and the first output interface, and the outlet of the second exhaust valve is connected to the second output interface; a first air pressure sensor, the first air pressure sensor Set between the air outlet of the first exhaust valve and the first output interface to collect the real-time air pressure of the pipeline between the first exhaust valve and the first output interface; a control device, The control device is provided in the body, and the control device is electrically connected to and controls the first pressure
  • the body is further provided with a third output interface
  • the dispensing control device further includes a suction air pressure generating device
  • the suction air pressure generating device includes a second pressure reducing device
  • the air inlet of the second pressure reducing device is connected to the first input interface; a vacuum generator, the vacuum generating port of the vacuum generator is connected to the exhaust port of the first exhaust valve, and the vacuum
  • the air inlet of the generator is connected with the air outlet of the second pressure reducing device, and the air outlet of the vacuum generator is connected with the third output interface.
  • the pipeline connecting the vacuum generating port of the vacuum generator and the exhaust port of the first exhaust valve is the suction port of the suction air pressure generating device
  • the dispensing control The device further includes: a second air pressure sensor connected to the suction port of the suction pressure generating device to collect the suction pressure generated by the suction pressure generating device, and the second The air pressure sensor is electrically connected to the control module, and the control module continuously receives its collection signals.
  • the second pressure reducing device is an electric proportional valve or an electric pneumatic pressure reducing valve.
  • the first pressure reducing device is a precision pressure reducing valve, an electric proportional valve or an electropneumatic pressure reducing valve; and/or at least one of the first exhaust valve and the second exhaust valve One is a two-position three-way solenoid valve, and the flow rate of the second exhaust valve is greater than the flow rate of the first exhaust valve.
  • the first pressure reducing device includes: a first pressure reducing valve having at least an air inlet and an air outlet, the air inlet constituting the first reducing valve The air inlet of the pressure device is connected to the air inlet of the first exhaust valve.
  • the first pressure reducing device further includes: a special-shaped pipe joint, the special-shaped pipe joint defines a lumen penetrating in its axial direction, and the outer wall of the special-shaped pipe joint is provided with One or more air flow channels communicated with the lumen, and the special-shaped pipe joint is connected between the air outlet of the first pressure reducing valve and the air inlet of the first exhaust valve.
  • the minimum diameter of the air flow channel is not more than 1 mm or the minimum cross-sectional area is not more than 1 mm 2 .
  • the dispensing control device further includes: a gas storage tank connected between the special-shaped pipe joint and the first exhaust valve.
  • the dispensing control device further includes: a speed control valve connected between the special-shaped pipe joint and the first exhaust valve to be suitable for adjusting the first exhaust valve The maximum flow output of a pressure reducing device.
  • the dispensing control device further includes: a reducing pipe connected between the special-shaped pipe joint and the gas storage tank.
  • a glue dispensing control method adopts a dispensing control device according to the embodiment of the first aspect of the present invention.
  • the glue discharge control method includes the following steps:
  • S1 set working air pressure, suction air pressure, and glue discharge duration
  • step S6 Based on the remaining amount of glue, adjust the working air pressure, suction air pressure, and glue discharge duration in step S1, and repeat step S5;
  • step S7 When the remaining amount of glue in step S5 is less than the remaining amount alarm threshold, a warning signal is issued to stop the glue dispensing and return to step S4.
  • detecting each of the first air pressure waveform and the second air pressure waveform includes the following steps:
  • Figure 1 is a schematic diagram of a dispensing control device according to an embodiment of the present invention.
  • Figure 2 is a schematic diagram of a first pressure reducing device of a dispensing control device according to a first embodiment of the present invention
  • Figure 3a is a schematic diagram of a first pressure reducing device of a dispensing control device according to a second embodiment of the present invention
  • Fig. 3b is a schematic diagram of the special-shaped pipe joint in the first pressure reducing device in Fig. 3a;
  • FIG. 4 is a schematic diagram of a first pressure reducing device of a dispensing control device according to a third embodiment of the present invention.
  • FIG. 5 is a schematic diagram of a first pressure reducing device of a dispensing control device according to a fourth embodiment of the present invention.
  • FIG. 6 is a schematic diagram of a first pressure reducing device of a dispensing control device according to a fifth embodiment of the present invention.
  • Fig. 7 is a schematic diagram of a first pressure reducing device of a dispensing control device according to a sixth embodiment of the present invention.
  • FIG. 8 is a schematic diagram of a first pressure reducing device of a dispensing control device according to a seventh embodiment of the present invention.
  • FIG. 9 is a schematic diagram of a first pressure reducing device of a dispensing control device according to an eighth embodiment of the present invention.
  • FIG. 10 is a flowchart of a glue output control method of a glue dispensing control device according to an embodiment of the present invention.
  • FIG. 11 is a flow chart when detecting the first or second pressure waveform in FIG. 10;
  • Fig. 12 is an operation explanatory diagram of the dispensing control device according to the embodiment of the present invention.
  • first and second are only used for descriptive purposes, and cannot be understood as indicating or implying relative importance or implicitly indicating the number of indicated technical features. Thus, the features defined with “first” and “second” may explicitly or implicitly include one or more of these features. Further, in the description of the present invention, unless otherwise specified, “plurality” means two or more.
  • a dispensing control device 1000 includes: a body 100, a first pressure reducing device 200, a first exhaust valve 300, a second exhaust valve 400, a first air pressure sensor 500, and a control device 600.
  • the body 100 has a first input interface 110 suitable for connecting a gas source, a first output interface 1200 suitable for connecting an external rubber bucket 2000, and a second output interface 130.
  • the first pressure reducing device 200 is provided in the body 100, and the air inlet 210 of the first pressure reducing device 200 is connected to the first input interface 110.
  • the first exhaust valve 300 is provided in the body 100, and the air inlet 310 of the first exhaust valve 300 is connected to the air outlet 220 of the pressure reducing device.
  • the principle of glue dispensing is: when the dispensing control device 1000 is not working, the first exhaust valve 300 is in a closed state.
  • the set working air pressure output by the first pressure reducing device 220 flows into the cavity of the glue bucket through the first exhaust valve 22, and the glue is squeezed out from the glue output end at the end of the glue bucket.
  • the first exhaust valve 22 is switched from the conducting state to the closed state.
  • the inlet 410 of the second exhaust valve 400 is connected to the outlet 320 of the first exhaust valve 300 and the first output interface 1200, and the outlet 420 of the second exhaust valve 400 is connected to the second output interface 130.
  • the first air pressure sensor 500 is provided between the air outlet 320 of the first exhaust valve 300 and the first output interface 1200 to collect the real-time air pressure of the pipeline 330 between the first exhaust valve 300 and the first output interface 1200.
  • the control device 600 is provided in the body 100.
  • the control device 600 is electrically connected to and controls the first pressure reducing device 200, the first exhaust valve 300, the second exhaust valve 400, and the first air pressure sensor 500.
  • the control device 600 is configured as a continuous
  • the real-time air pressure collected by the first air pressure sensor 500 is received, and after real-time processing of the real-time air pressure, characteristic parameters of the air pressure increase are extracted. Therefore, in a single dispensing operation, the first air pressure sensor 500 collects the increase, stabilization, and drop of the working air pressure in real time, and the control device 600 processes the collected data to form a complete air pressure waveform curve.
  • the first air pressure sensor 500 is provided on the working air pressure output air path between the air outlet of the first exhaust valve 300 and the working air pressure output port.
  • the working air pressure output port refers to a gas path joint penetrating through the controller panel, and the gas path joint is connected to the air outlet 320 of the first exhaust valve 300 inside the control device 600.
  • the specific working process of the dispensing control device 1000 is as follows: According to the specific volume of the glue bucket 2000 and the length of the connecting pipe, the glue bucket 2000 is connected to the first output interface 120 of the dispensing control device 1000 through the connecting pipe, the dispensing control device 1000 according to the set working parameters (including the duration of the glue, working air pressure and suction air pressure) for dispensing operations. As the remaining amount of glue in the glue barrel decreases, in the entire working air pressure waveform collected by the first air pressure sensor 500, the air pressure increase process will gradually slow down, and there is no obvious difference between the air pressure stability and the decrease process.
  • the key parameters are extracted from the waveform difference in the air pressure increase process collected by the first air pressure sensor 500, and the remaining amount of glue in the glue bucket can be calculated through the built-in prediction algorithm, so as to realize the accurate prediction of the remaining amount of glue in the glue bucket. .
  • the dispensing control device 1000 can continuously adjust the dispensing parameters according to different remaining amounts of glue to achieve extremely high consistency of the dispensing amount.
  • the glue dispensing control device 1000 can also turn on an alarm function of insufficient glue remaining.
  • the dispensing control device 1000 outputs an alarm signal that the remaining amount of glue is insufficient, prompting the operator to refill or replace the glue.
  • the first air pressure sensor 500 can collect the air pressure waveform of a single dispensing in real time and extract the characteristic parameters of the air pressure increase. Predict the remaining amount of glue, and can automatically adjust the working parameters of the glue controller, so as to achieve a very high consistency of glue amount in the entire dispensing process of the glue tank from full to empty.
  • the dispensing control device 1000 enters the calibration mode.
  • the control device 600 and the first air pressure sensor 500, the first row The air valve 300, the first pressure reducing device 80, and the second exhaust valve 400 interact to collect the working air pressure when the full rubber barrel (or empty rubber barrel) is connected, and obtain the first air pressure waveform and the first air pressure waveform and The second air pressure waveform under the full rubber bucket working condition, and extract the air pressure increase rate from the collected waveform, respectively complete the extraction and calibration of the pressure increase characteristic parameters of the two rubber bucket full and empty working conditions.
  • the control device 600 interacts with the first air pressure sensor 500, the first exhaust valve 300, the first pressure reducing device 80, and the second exhaust valve 400 to collect and extract the air pressure waveform of a single dispensing in real time.
  • the characteristic parameters of the increase in air pressure are accurately predicted by the prediction algorithm of the remaining amount of glue in the glue bucket built in the control device 600.
  • the body 100 is further provided with a third output interface 140
  • the dispensing control device 1000 further includes a suction air pressure generating device 700
  • the suction air pressure generating device 700 includes a second Decompression device 710 and vacuum generator 720.
  • the air inlet 711 of the second pressure reducing device 710 is connected to the first input interface 110.
  • the vacuum generating port 723 of the vacuum generator 720 is connected to the exhaust port 330 of the first exhaust valve 300, the air inlet 721 of the vacuum generator 720 is connected to the air outlet 712 of the second pressure reducing device 710, and the vacuum generator 720
  • the air outlet 722 is connected to the third output interface 140.
  • the second pressure reducing device 710 is an electric proportional valve or an electric pneumatic pressure reducing valve.
  • the control device 600 interacts with the first air pressure sensor 500 and the second pressure reducing device 90 to feedback and adjust in real time to realize the adaptive control of the suck back air pressure.
  • the adaptive control of the suction air pressure can ensure that the glue outlet of the needle at the end of the glue barrel is free of glue dripping and air bubbles during the intermittent time of the glue dispensing operation, so as to ensure the accurate glue dispensing consistency during the dispensing operation.
  • the pipeline connecting the vacuum generating port 723 of the vacuum generator 720 and the exhaust port 330 of the first exhaust valve 300 is the suction of the suction pressure generating device 700 ⁇ 730.
  • the dispensing control device 1000 further includes a second air pressure sensor 800.
  • the second air pressure sensor 800 is connected to the suction port 730 of the suction air pressure generating device 700 to collect the suction air pressure generated by the suction air pressure generating device 700.
  • the second air pressure sensor 800 is electrically connected to the control module and is continuously connected by the control module. Receive its acquisition signal.
  • a second air pressure sensor 70 is provided at the suction port of the suction air pressure generating device between the vacuum generator 60 and the exhaust port of the first exhaust valve 300. After the suction air pressure is turned on, the second air pressure sensor 70 collects the suction air pressure in real time, and interacts with the control device 600 to realize adaptive feedback control of the suction air pressure.
  • the first pressure reducing device 200 is a precision pressure reducing valve, an electric proportional valve or an electric pneumatic pressure reducing valve. In some alternative embodiments,
  • At least one of the first exhaust valve 300 and the second exhaust valve 400 is a two-position three-way solenoid valve, and the flow rate of the second exhaust valve 400 is greater than the flow rate of the first exhaust valve 300.
  • the first exhaust valve 300 is formed as a two-position, three-way solenoid valve, and the first exhaust valve 300 is a conventional element, which is convenient to obtain materials.
  • the second exhaust valve 400 is formed as a two-position three-way solenoid valve, and the flow rate of the second exhaust valve 400 is greater than the flow rate of the first exhaust valve 300.
  • the second exhaust valve 400 is also a conventional component, and it is convenient to obtain materials.
  • hose 900 which is convenient to connect and easy to install.
  • the first exhaust valve 300 Since the first exhaust valve 300 will switch from the conducting state to the closed state when the glue dispensing operation is finished, the gas output flow of the first exhaust valve 22 suddenly drops to zero, resulting in the load side gas connected to its gas outlet The flow suddenly drops to zero, causing an overshoot in the output pressure of the first pressure reducing valve 230, and the first pressure reducing device can reduce the time required for its output pressure to drop from the overshoot to the set pressure.
  • the first decompression device 200 is described in detail. According to the dispensing control device of the embodiment of the present invention, by adopting such a first pressure reducing device, the dispensing operation can be performed in a shorter dispensing repetitive cycle, which increases dispensing efficiency and ensures consistent dispensing accuracy.
  • the first pressure reducing device 200 includes a first pressure reducing valve 230.
  • the first pressure reducing valve 230 has at least an air inlet 231 and an air outlet 232, and the air inlet 231
  • the air inlet 210 of the first pressure reducing device 200 is formed, and the air outlet 232 is connected to the air inlet 310 of the first exhaust valve 300.
  • the first pressure reducing valve 230 also has an exhaust port, and the exhaust port of the pressure reducing valve 10 can be left empty or a silencer (not shown in the figure) can be installed.
  • the first pressure reducing device 200 is exemplified as including only the first pressure reducing valve 230.
  • the present invention is not limited to this.
  • the first pressure reducing device 200 may further include a special-shaped pipe joint 240.
  • the special-shaped pipe joint 240 defines a lumen 241 penetrating along its axial direction, and the outer wall surface of the special-shaped pipe joint 240 is provided with one or more airflow channels 242 communicating with the lumen 241.
  • the working principle of the first pressure reducing device 200 is as follows: when the terminal load connected to the gas outlet 220, that is, the glue barrel 2000 does not consume or consumes gas at a constant flow, the first The stable output air pressure of the pressure reducing device 220 is consistent with the set air pressure. When the flow of gas consumed on the load side suddenly decreases (even the flow drops to zero), the output pressure of the first pressure reducing device 200 is higher than the set pressure. From the special-shaped pipe joint 240 connected to the pressure output port of the pressure reducing valve 230, A part of the output air pressure of the pressure reducing valve 230 is flowed out at a fixed flow rate. When the flow at the end of the rubber barrel decreases, the time required for the output pressure of the pressure reducing valve 230 to fall from overshoot to the set pressure is reduced.
  • the special-shaped pipe joint 240 can be a modified air channel based on a standard product on the market, or a self-made part designed and manufactured with a simple structure. Based on the implementation of the transformation of the standard pipe joint, when the standard pipe joint is connected to the air outlet of the first pressure reducing valve 230, a hole is punched on the surface of the cavity where the standard pipe joint directly contacts the output air pressure and penetrates directly or curvedly to The outer surface of the special-shaped pipe joint standard product forms the special-shaped pipe joint 240.
  • the holes on the outer surface must ensure that the special-shaped pipe joint 240 is not covered or obscured after being connected to the first pressure reducing valve 230 and the connected load 21 (the purpose is to ensure the first The output air pressure of the pressure reducing valve 230 continuously and smoothly leaks from the air flow channel).
  • the air pressure output from the air outlet of the first pressure reducing valve 230 continuously flows out a part of the air flow channel at a fixed flow rate.
  • the first pressure reducing valve 230 is always in a flow output state (that is, an obvious feedback adjustment).
  • the benefits are as follows: When the air pressure flow at the load end decreases (even the flow drops to 0), the first pressure reduction The feedback adjustment of the valve 230 cannot be realized quickly, and an obvious air pressure overshoot will occur in an instant, resulting in an output air pressure overshoot.
  • the air flow channel continuously consumes the output air pressure at a fixed flow rate, which directly speeds up the recovery process of the output air pressure overshoot and reduces the output air pressure from the overshoot to the set pressure. The time required.
  • the first pressure reducing device can increase the pressure higher than the set pressure in a shorter time.
  • the output air pressure of the first pressure reducing device is restored to be consistent with the set air pressure, which can greatly reduce the interval between repeated dispensing and obtain a highly consistent dispensing effect.
  • the minimum diameter of the air flow channel 242 is not more than 1 mm or the minimum cross-sectional area is not more than 1 mm 2 .
  • the airflow channel is used to continuously leak high-pressure air at a low flow rate, and the key to low-flow leakage is that the narrowest part of the airflow channel cannot be too large.
  • different airflow channels can be set with the narrowest aperture, and the time required for the output air pressure to drop from the overshoot to the set air pressure can be tested in detail. The optimal air flow channel flow rate and the narrowest aperture of the air channel under specific conditions.
  • the special-shaped pipe joint 240 may be connected between the air outlet of the first pressure reducing valve 230 and the air inlet of the first exhaust valve 300.
  • a first pressure reducing device including the first pressure reducing valve 230 and the special-shaped pipe joint 240 is not only simple in structure, but also capable of reducing the overshoot of the output air pressure and returning the output air pressure higher than the set air pressure to Consistent with the set air pressure, especially to improve the consistency of the working air pressure when the dispensing control device quickly repeats dispensing.
  • the dispensing control device 1000 may further include a gas storage tank 800 connected between the special-shaped pipe joint 240 and the first exhaust valve 300.
  • the air storage tank 23 can restrain the pressure drop of the output pressure of the first pressure reducing device 200 at the moment when the dispensing control device starts dispensing glue, and restrain the overshoot of the pressure output of the first pressure reducing device 200 when the dispensing control device finishes dispensing glue. . This can further shorten the time required for the first pressure reducing device to reduce its output air pressure from overshoot to the set air pressure.
  • the dispensing control device 1000 may further include a speed control valve 910, and the speed control valve 910 is connected between the special-shaped pipe joint 240 and the first exhaust valve 300.
  • the speed control valve 24 is used to adjust the maximum flow output of the first pressure reducing device, and test and determine the specific air flow speed of the speed control valve 24 according to the specific dispensing parameters of the application. Therefore, according to the specific dispensing parameters of the application, the maximum flow rate output by the first pressure reducing device 220 is adjusted to further shorten the time required for the first pressure reducing device 220 to reduce its output pressure from overshoot to consistent with the set pressure.
  • the speed control valve 910 can alternatively and the above-mentioned gas storage tank 800 be separately arranged between the special-shaped pipe joint 240 and the first exhaust valve 300, as shown in FIG. 6; it can also be arranged in the special-shaped pipe simultaneously with the gas storage tank 800 Between the joint 240 and the first exhaust valve 300, as shown in FIG. 7, this can greatly shorten the time required for the first pressure reducing device to reduce its output pressure from the overshoot to the set pressure.
  • the speed control valve 910 can be integrally formed with the special-shaped pipe joint 240 and sealed and hard-connected with the first pressure reducing valve 230. Through the integration of components, the number and space of components are reduced. Occupied.
  • the dispensing control device 1000 may further include a reducing pipe 920, which is connected between the special-shaped pipe joint 240 and the gas storage tank 800, and can achieve the same as the speed control valve 24 Performance effect.
  • the reducing pipe 920 may be integrally connected with the special-shaped pipe joint 240.
  • the glue output control method of the glue dispensing control device 1000 according to another embodiment of the present invention will be described in detail below with reference to FIGS. 10-12.
  • the glue output control method of the glue dispensing control device 1000 includes the following steps:
  • S1 set working air pressure, suction air pressure, and glue discharge duration
  • step S7 When the remaining amount of glue in step S5 is less than the remaining amount alarm threshold, a warning signal is issued to stop the glue dispensing and return to step S4.
  • the remaining amount of glue in the glue bucket can be predicted in real time, and the working parameters of the dispensing controller can be automatically adjusted to realize the entire working process of the glue bucket from full to empty.
  • the consistency of the dispensing volume is extremely high.
  • the remaining amount of glue in the glue tank can be predicted in real time.
  • the alarm threshold of the remaining amount of glue can be set and calculated and judged with the remaining amount of glue. If the current remaining amount of glue in the glue tank is insufficient, an alarm signal will be issued to remind the user. So as to avoid the dispensing operation with little or no glue.
  • the adaptive feedback control based on the suction air pressure can ensure that the glue outlet of the needle at the end of the glue barrel is free from dripping and air bubbles during the intermittent time of the dispensing operation, ensuring accurate dispensing during the dispensing operation consistency.
  • step S2 detecting each of the first air pressure waveform and the second air pressure waveform includes the following steps:
  • the operation method of using the glue control device according to the embodiment of the present invention to perform glue control is as follows:
  • P1 set the dispensing parameters
  • the dispensing control device 1000 automatically performs the calculation and storage of calibration parameters according to the collected air pressure waveforms of the full and empty plastic buckets.
  • the dispensing control device 1000 enters the calibration mode, and the control device 600 Interact with the first air pressure sensor 500, the first exhaust valve 300, the first pressure reducing device 80, and the second exhaust valve 400 to collect the working air pressure when the full rubber bucket (or empty rubber bucket) is connected and collect the waveforms
  • the air pressure increase rate is extracted in the process, and the air pressure increase characteristic parameters of the two working conditions of the full and empty rubber tank are extracted and calibrated.
  • P7 Determine whether to turn on this function according to the requirements of the remaining amount alarm function; if this function is turned on, set the remaining amount alarm threshold and related parameters through the human-computer interaction menu item of the dispensing control device 1000 after it is turned on;
  • the dispensing control device 1000 enters the standby state for dispensing, waiting for the dispensing trigger signal;
  • the dispensing control device 1000 When the dispensing control device 1000 receives the dispensing trigger signal, it outputs dispensing air pressure from the first output interface 120 according to the current dispensing parameters, and at the same time, the first air pressure sensor 500 performs pressure waveform acquisition.
  • the dispensing control device 1000 is based on Real-time collected pressure waveform and stored calibration parameters to predict the remaining amount of glue in the glue tank;
  • the dispensing control device 1000 corrects and automatically updates the dispensing parameters based on the predicted remaining amount of glue in the tank;
  • the dispensing control device 1000 If the remaining amount alarm function is turned on and the predicted remaining amount of glue in the glue tank is lower than the set glue remaining amount alarm threshold, the dispensing control device 1000 generates a low liquid alarm signal; skip to step P9.
  • the control device 600 interacts with the first air pressure sensor 500, the first exhaust valve 300, the first pressure reducing device 80, and the second exhaust valve 400 to collect the air pressure of a single dispensing in real time.
  • the waveform is extracted and the characteristic parameters of the air pressure increase are extracted, and an accurate prediction of the current remaining amount of glue is realized by the prediction algorithm of the remaining amount of glue in the glue barrel built in the control device 600.
  • the dispensing control device 1000 can continuously adjust the dispensing parameters according to the remaining amount of different glue to achieve extremely high consistency of the amount of glue; it can be turned on The alarm function for insufficient remaining amount of glue.
  • the dispensing control device 1000 outputs an alarm signal that the remaining amount of glue is insufficient to prompt the glue to be filled or replaced.
  • the control device 600 interacts with the first air pressure sensor 500 and the second pressure reducing device 90 to feedback and adjust in real time to realize the adaptive control of the suck back air pressure.
  • the adaptive control of the suction air pressure can ensure that the glue outlet of the needle at the end of the glue barrel is free of glue dripping and air bubbles during the intermittent time of the glue dispensing operation, so as to ensure the accurate glue dispensing consistency during the dispensing operation.
  • the glue dispensing parameters include the duration of glue dispensing, working air pressure and suction air pressure.
  • the glue dispensing parameters are easy to measure and adjust, and are easy to operate.
  • this method can predict the remaining amount of glue in the glue bucket in real time, and automatically adjust the working parameters of the glue controller, so as to achieve a very high amount of glue during the entire dispensing process of the glue bucket from full to empty. Performance; real-time prediction of the remaining amount of glue in the glue barrel, setting the alarm threshold of the remaining amount of glue, prompting that the remaining amount of glue in the current barrel is insufficient, and avoiding dispensing operations with little or no glue; based on suction air pressure Self-adaptive feedback control can ensure that the glue outlet of the needle at the end of the glue barrel is free of glue dripping and air bubbles during the intermittent time of the glue dispensing operation, ensuring accurate glue delivery consistency during the dispensing operation.

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Abstract

一种点胶控制设备(1000)及其出胶控制方法，点胶控制设备 (1000) 包括：具有第一输入接口(110)、第一输出接口(120)和第二输出接口(130)的机体（100），设在机体（100）内的第一减压装置(200)、第一排气阀(300)、第二排气阀(400)、第一气压传感器(500)和控制装置(600)，第一气压传感器(500)设在所述第一排气阀(300)的出气口 (320) 和第一输出接口(120)之间，以采集第一排气阀(300)与第一输出接口(120)之间的管路的实时气压，控制装置(600)被构造成连续接收第一气压传感器(500)采集的实时气压、且实时处理所述实时气压后提取气压提高的特征参数。

Description

点胶控制设备及其出胶控制方法 技术领域
本发明涉及点胶技术领域，尤其涉及一种点胶控制设备及其出胶控制方法。
背景技术
常规的气动式点胶控制器，其内置的模拟式气压表、数字式气压表或气压传感器连接至第一减压装置出气口和第一排气阀进气口之间的管路，用于测量和显示设定气压，无法监测胶桶管路中的气压波形，不具备胶桶内气压监测功能。
具体的点胶工艺，在胶桶内满胶量时确定好的点胶参数，随着出胶次数的增加，胶桶内胶液剩余量逐渐减少，出胶量也随之减少。当出胶量明显减少至低于胶量要求时，需要操作人员变更点胶参数(一般是适当增大出胶持续时间)。该点胶应用的核心问题：一是需要操作人员多次变更点胶参数，而且变更后的参数是否合适还需要对胶量进行测试验证；二是操作人员多次变更点胶参数会导致出胶量出现明显波动，即出胶量明显减少时突然变更点胶参数，导致下一次出胶量明显增大。
综上，这样的点胶操作不仅需要操作人员多次调整参数，而且点胶一致性难以提升。胶液剩余量逐渐减少直至无胶液剩余时，将突然无胶点出，这导致在自动点胶设备或生产线上的点胶工序异常，并直接影响整个工艺流程。
发明内容
本发明旨在至少解决现有技术中存在的技术问题之一。
本发明提出了一种点胶控制设备，能够实现点胶参数的自适应调整和剩余胶液量不足的报警功能以及回吸气压的自适应反馈控制。
本发明还提供一种点胶控制设备的控制方法。
根据本发明第一方面实施例的一种点胶控制设备，包括：机体，所述机体上具有适于连接气源的第一输入接口、适于连接外部胶桶的第一输出接口、和第二输出接口；第一减压装置，所述第一减压装置设在所述机体内，所述第一减压装置的进气端与所述第一输入接口相连；第一排气阀，所述第一排气阀设在所述机体内，所述第一排气阀的进气口与所述减压装置的出气端相连；第二排气阀，所述第二排气阀的进口与所述第一排气阀的出气口、所述第一输出接口相连，所述第二排气阀的出口与所述第二输出接口连接；第一气压传感器，所述第一气压传感器设在所述第一排气阀的出气口和所述第一输出接口之间，以 采集所述第一排气阀与所述第一输出接口之间的管路的实时气压；控制装置，所述控制装置设在所述机体内，所述控制装置电连接并控制所述第一减压装置、所述第一排气阀、所述第二排气阀、第一气压传感器，所述控制装置被构造成连续接收所述第一气压传感器采集的实时气压、且实时处理所述实时气压后提取气压提高的特征参数。
根据本发明的一些实施例，所述机体还设有第三输出接口，所述点胶控制设备还包括回吸气压产生装置，所述回吸气压产生装置包括：第二减压装置，所述第二减压装置的进气口与所述第一输入接口相连；真空发生器，所述真空发生器的真空产生口与所述第一排气阀的排气口相连，所述真空发生器的进气口与所述第二减压装置的出气口相连，所述真空发生器的出气口与所述第三输出接口相连。
根据本发明的一些实施例，所述真空发生器的真空产生口与第一排气阀的排气口相连的管路为所述回吸气压产生装置的吸气口，所述点胶控制设备还包括：第二气压传感器，所述第二气压传感器与所述回吸气压产生装置的吸气口连接以采集所述回吸气压产生装置产生的回吸气压，所述第二气压传感器与所述控制模块电连接并由所述控制模块连续接收其采集信号。
根据本发明的一些实施例，所述第二减压装置为电气比例阀或电空减压阀。
根据本发明的一些实施例，所述第一减压装置为精密减压阀、电气比例阀或电空减压阀；和/或所述第一排气阀和第二排气阀中的至少一个为两位三通电磁阀，且所述第二排气阀的流量大于所述第一排气阀的流量。
根据本发明的一些实施例，所述第一减压装置包括：第一减压阀，所述第一减压阀至少具有进气口和出气口，所述进气口构成所述第一减压装置的进气端，所述出气口与所述第一排气阀的进气口相连。
根据本发明的一些实施例，所述第一减压装置还包括：异形管接头，所述异形管接头内限定有沿其轴向贯通的管腔，所述异形管接头的外壁面设有与所述管腔连通的一个或多个气流通道，所述异形管接头连接在所述第一减压阀的出气口和所述第一排气阀的进气口之间。
根据本发明的一些实施例，所述气流通道的最小直径不大于1mm或最小横截面积不超过1mm 2。
根据本发明的一些实施例，所述点胶控制设备还包括：储气罐，所述储气罐连通于所述异形管接头与所述第一排气阀之间。
根据本发明的一些实施例，所述点胶控制设备还包括：速度控制阀，所述速度控制阀连通于所述异形管接头与所述第一排气阀之间以适于调节所述第一减压装置输出的最大流 量。
根据本发明的一些实施例，所述点胶控制设备还包括：变径管，所述变径管连通于所述异形管接头与所述储气罐之间。
根据本发明第二方面实施例的一种出胶控制方法，采用根据本发明第一方面实施例的一种点胶控制设备。所述出胶控制方法包括以下步骤：
S1、设定工作气压、回吸气压、出胶持续时间；
S2、预设空胶桶连接至所述第一输出接口时的第一气压波形、和满胶桶连接至所述第一输出接口时的第二气压波形；
S3、预设剩余量报警阈值；
S4、检测所述第一输出接口是否连接有待执行点胶的胶桶，并检测是否收到点胶触发信号；
S5、当收到所述点胶触发信号时，输出所述工作气压P01，并在所述出胶持续时间内实时检测所述第一气压传感器采集的实时气压波形，根据所述实时气压波形、第一气压波形和第二气压波形，预判断胶桶内的胶液剩余量；
S6、基于所述胶液剩余量，对步骤S1中的工作气压、回吸气压、出胶持续时间进行调整，并重复回到步骤S5；
S7、当步骤S5中的胶液剩余量小于所述剩余量报警阈值时，发出预警信号，停止出胶并回到步骤S4。
根据本发明的一些实施例，所述步骤S2中，检测所述第一气压波形和第二气压波形的每一个时，包括以下步骤：
S21、检测所述第一输出接口是否已连接待检测的胶桶，并检测是否接收到执行信号；
S22、接收到所述执行信号后，启动所述第一气压传感器在预设检测时间内采集气压波形；
S23、存储相应的所述气压波形。
本发明的附加方面和优点将在下面的描述中部分给出，部分将从下面的描述中变得明显，或通过本发明的实践了解到。
附图说明
本发明的上述和/或附加的方面和优点从结合下面附图对实施例的描述中将变得明显和容易理解，其中：
图1为根据本发明实施例的点胶控制设备的示意图；
图2是根据本发明第一个实施例的点胶控制设备的第一减压装置的示意图；
图3a是根据本发明第二个实施例的点胶控制设备的第一减压装置的示意图；
图3b是图3a中的第一减压装置中的异形管接头的示意图；
图4是根据本发明第三个实施例的点胶控制设备的第一减压装置的示意图；
图5是根据本发明第四个实施例的点胶控制设备的第一减压装置的示意图；
图6是根据本发明第五个实施例的点胶控制设备的第一减压装置的示意图；
图7是根据本发明第六个实施例的点胶控制设备的第一减压装置的示意图；
图8是根据本发明第七个实施例的点胶控制设备的第一减压装置的示意图；
图9是根据本发明第八个实施例的点胶控制设备的第一减压装置的示意图；
图10为根据本发明实施例的点胶控制设备的出胶控制方法的流程图；
图11为图10中检测第一或第二气压波形时的流程图；
图12为根据本发明实施例的点胶控制设备的操作说明图。
具体实施方式
下面详细描述本发明的实施例，所述实施例的示例在附图中示出，其中自始至终相同或类似的标号表示相同或类似的元件或具有相同或类似功能的元件。下面通过参考附图描述的实施例是示例性的，仅用于解释本发明，而不能理解为对本发明的限制。
在本发明的描述中，需要理解的是，术语“中心”、“上”、“下”、“前”、“后”、“左”、“右”、“竖直”、“水平”、“顶”、“底”“内”、“外”等指示的方位或位置关系为基于附图所示的方位或位置关系，仅是为了便于描述本发明和简化描述，而不是指示或暗示所指的装置或元件必须具有特定的方位、以特定的方位构造和操作，因此不能理解为对本发明的限制。
需要说明的是，术语“第一”、“第二”仅用于描述目的，而不能理解为指示或暗示相对重要性或者隐含指明所指示的技术特征的数量。由此，限定有“第一”、“第二”的特征可以明示或者隐含地包括一个或者更多个该特征。进一步地，在本发明的描述中，除非另有说明，“多个”的含义是两个或两个以上。
根据本发明实施例的一种点胶控制设备1000，包括：机体100、第一减压装置200、第一排气阀300、第二排气阀400、第一气压传感器500和控制装置600。
如图1所示，机体100上具有适于连接气源的第一输入接口110、适于连接外部胶桶2000的第一输出接口1200、和第二输出接口130。第一减压装置200设在机体100内，第一减压装置200的进气端210与第一输入接口110相连。第一排气阀300设在机体100内， 第一排气阀300的进气口310与减压装置的出气端220相连。出胶原理为：当点胶控制设备1000不进行工作时，第一排气阀300处于闭合状态。需要执行点胶工作时，第一减压装置220输出的设定工作气压通过第一排气阀22流入胶桶空腔内，将胶液从胶桶末端的胶液输出端挤出。而当执行出胶作业结束时，第一排气阀22由导通状态切换为闭合状态。
第二排气阀400的进口410与第一排气阀300的出气口320、第一输出接口1200相连，第二排气阀400的出口420与第二输出接口130连接。第一气压传感器500设在第一排气阀300的出气口320和第一输出接口1200之间，以采集第一排气阀300与第一输出接口1200之间的管路330的实时气压。
控制装置600设在机体100内，控制装置600电连接并控制第一减压装置200、第一排气阀300、第二排气阀400、第一气压传感器500，控制装置600被构造成连续接收第一气压传感器500采集的实时气压、且实时处理实时气压后提取气压提高的特征参数。从而，在单次点胶作业中，第一气压传感器500将工作气压的提高、稳定和下降实时采集，并由控制装置600对采集数据处理，形成完整的气压波形曲线。
可选地，第一气压传感器500设在第一排气阀300出气口和工作气压输出口之间的工作气压输出气路上。其中，工作气压输出口指的是贯穿于控制器面板的气路接头，该气路接头在控制装置600内部与第一排气阀300的出气口320连接。
点胶控制设备1000的具体工作过程如下：根据具体选用的胶桶2000的容积和连接管长度，将胶桶2000通过连接管连接至点胶控制设备1000的第一输出接口120，点胶控制设备1000按设定的工作参数(包括出胶持续时间、工作气压和回吸气压)进行点胶作业。随着胶桶内胶液剩余量的减少，第一气压传感器500采集的整个工作气压波形中，气压提高过程将逐渐变缓，气压的稳定和下降过程无明显差异。从而，从第一气压传感器500采集的气压提高过程中的波形差异中提取关键参数，经过内置的预测算法可计算得到胶桶内的胶液剩余量，实现胶桶内胶液剩余量的精准预测。
基于胶液剩余量的精准预测，在点胶作业时，点胶控制设备1000可根据不同的胶液剩余量连续地调整点胶参数，实现点出胶液量的极高一致性。可选地，点胶控制设备1000还可以开启胶液剩余量不足的报警功能。当胶液剩余量低于设定的报警阈值时，点胶控制设备1000输出胶液剩余量不足的报警信号，提示操作人员胶液加注或更换。
根据本发明实施例的点胶控制设备1000，通过设置第一气压传感器500，在点胶作业时，第一气压传感器500可以实时采集单次出胶的气压波形并提取气压提高的特征参数，实现当前胶液剩余量的预测，并可以自动调整点胶控制器的工作参数，实现胶桶胶液从满到空整个点出过程中点出胶液量极高的一致性。
需要说明的是，基于第一气压传感器500的胶桶内胶液剩余量预测功能，需要在进行点胶作业前进行胶桶满和空两个工况下的气压提高特征参数的提取和标定。在点胶作业前，需要分别将满胶桶和空胶桶通过连接管连接至第一输出接口120，点胶控制设备1000进入标定模式，由控制装置600与第一气压传感器500、第一排气阀300、第一减压装置80、第二排气阀400交互，进行连接满胶桶(或空胶桶)时的工作气压采集，分别得到空胶桶工况下的第一气压波形和满胶桶工况下的第二气压波形，并从采集的波形中提取出气压提高速率，分别完成胶桶满和空两个工况的气压提高特征参数提取和标定。
在点胶作业时，由控制装置600与第一气压传感器500、第一排气阀300、第一减压装置80、第二排气阀400交互，实时采集单次出胶的气压波形并提取气压提高的特征参数，由控制装置600内置的胶桶内胶液剩余量预测算法实现当前胶液剩余量的精准预测。
根据本发明的一些实施例，如图1所示，机体100还设有第三输出接口140，点胶控制设备1000还包括回吸气压产生装置700，回吸气压产生装置700包括第二减压装置710和真空发生器720。第二减压装置710的进气口711与第一输入接口110相连。真空发生器720的真空产生口723与第一排气阀300的排气口330相连，真空发生器720的进气口721与第二减压装置710的出气口712相连，真空发生器720的出气口722与第三输出接口140相连。可选地，第二减压装置710为电气比例阀或电空减压阀。
在工作过程中，点胶控制设备1000开启回吸功能后，由控制装置600与第一气压传感器500、第二减压装置90交互，实时反馈调节，实现回吸气压的自适应控制。回吸气压的自适应控制可在点胶作业的间歇时间内，保证胶桶末端针头的出胶口没有胶液的滴漏和气泡混入，保证点胶作业时精准的出胶一致性。
如图1所示，根据本发明的一些实施例，真空发生器720的真空产生口723与第一排气阀300的排气口330相连的管路为回吸气压产生装置700的吸气口730。点胶控制设备1000还包括第二气压传感器800。第二气压传感器800与回吸气压产生装置700的吸气口730连接以采集回吸气压产生装置700产生的回吸气压，第二气压传感器800与控制模块电连接并由控制模块连续接收其采集信号。也就是说，在真空发生器60和第一排气阀300排气口之间的回吸气压产生装置的吸气口设置第二气压传感器70，开启回吸气压后，第二气压传感器70实时采集回吸气压，并与控制装置600交互实现回吸气压的自适应反馈控制。
根据本发明的一些可选的实施例，第一减压装置200为精密减压阀、电气比例阀或电空减压阀。在一些可选的实施例中，
第一排气阀300和第二排气阀400中的至少一个为两位三通电磁阀，且第二排气阀400的流量大于第一排气阀300的流量。第一排气阀300形成为两位三通电磁阀，第一排气阀 300为常规元件，取材方便。
在本发明的一个实施例中，第二排气阀400形成为两位三通电磁阀，且第二排气阀400的流量大于第一排气阀300的流量。第二排气阀400也为常规元件，取材方便。
需要说明的是，多个元件的接头之间分别通过软管900连接，软管900连接方便，便于安装。
由于当执行出胶作业结束时，第一排气阀300将由导通状态切换为闭合状态，此时第一排气阀22的气体输出流量突然降为零，导致其出气端连接的负载端气体流量突然降为零，导致第一减压阀230输出气压出现过冲，第一减压装置能够减小其输出气压从过冲降至与设定气压一致所需时间。在本发明的以下实施例中，对第一减压装置200进行了详细说明。根据本发明实施例的点胶控制设备，通过采用了这样的第一减压装置，能够以较短的点胶重复周期执行点胶作业，增加点胶效率并保证了一致的点胶精度。
[根据细则91更正 13.02.2020]　
根据本发明的一些具体实施例，如图2所示，第一减压装置200包括第一减压阀230，第一减压阀230至少具有进气口231和出气口232，进气口231构成第一减压装置200的进气端210，出气口232与第一排气阀300的进气口310相连。第一减压阀230还具有排气口，减压阀10的排气口可以留空或安装消音器(图未示出)。
在图1所示的点胶控制设备1000中，第一减压装置200被示例为仅包括第一减压阀230。但本发明并不限于此。
[根据细则91更正 13.02.2020]　
如图3a所示，在本发明的另一些具体实施例中，第一减压装置200还可以包括异形管接头240。如图3b所示，异形管接头240内限定有沿其轴向贯通的管腔241，异形管接头240的外壁面设有与管腔241连通的一个或多个气流通道242。此时，根据本发明实施例的点胶控制设备中，第一减压装置200的工作原理如下：当其出气端220连接的终端负载即胶桶2000不消耗或恒定流量消耗气体时，第一减压装置220的稳定输出气压与设定气压一致。负载端消耗气体的流量突然减少(甚至流量降至0)时，导致第一减压装置200的输出气压高于设定气压，从与减压阀230的气压输出口连接的异形管接头240，按固定流量将减压阀230的输出气压流出一部分，当胶桶端流量减小时，减少减压阀230的输出气压从过冲降至与设定气压一致所需的时间。
异形管接头240可以是基于市面的标准品进行气流通道的改造，也可以是设计加工的自制件，结构简单。基于管接头标准品的改造实现，管接头标准品密封连接至第一减压阀230的出气口时，在管接头标准品直接接触输出气压的腔体表面打孔，并直接或弯曲地贯穿至异形管接头标准品外表面以形成异形管接头240，外表面的孔需保证异形管接头240密封连接至第一减压阀230和连接负载21后，不被遮盖或遮挡(目的是保证第一减压阀230的 输出气压从该气流通道持续顺畅泄露)。从第一减压阀230出气口输出的气压，从气流通道持续地按固定流量流出一部分。
不论负载端是否需要气流量，第一减压阀230一直处于有流量输出状态(即明显的反馈调节)得益如下：负载端的气压流量减小(甚至流量降为0)时，第一减压阀230的反馈调节不能迅速实现，会在瞬间出现明显的气压超调，导致输出气压过冲。与减压阀标准品的应用相比，气流通道持续地按固定流量消耗输出气压，这直接加快了输出气压超调的恢复过程，减小了输出气压从过冲降至与设定气压一致所需的时间。
因此，根据本发明实施例的点胶控制设备，与现有技术相比，由于异形管接头240上设有气流通道，该第一减压装置用更短的时间即可使高于设定气压的第一减压装置的输出气压恢复至与设定气压一致，从而可极大地减少重复点胶间隔时间，并获得高度一致的点胶效果。
可选地，气流通道242的最小直径不大于1mm或最小横截面积不超过1mm 2。气流通道是用于持续地低流量泄漏高压空气，而低流量泄漏的关键在于所述气流通道的最窄处不能太大。也就是说，根据具体的胶桶端的条件，可以设置不同的气流通道最窄孔径，并详尽测试输出气压从过冲降至与设定气压一致所需的时间，从测试过程中得出适用于具体的条件下最优的气流通道流量及气流通道最窄孔径。
[根据细则91更正 13.02.2020]　
如图3a和图4所示，异形管接头240可以连接在第一减压阀230的出气口和第一排气阀300的进气口之间。这样包括第一减压阀230和的异形管接头240的第一减压装置不仅结构简单，而且能够减弱输出气压的过冲并在更短的时间内使高于设定气压的输出气压恢复至与设定气压一致，尤其能够提升点胶控制设备快速重复点胶时工作气压的一致性。
根据本发明的一些实施例中，如图5所示，点胶控制设备1000还可以包括储气罐800，储气罐800连通于异形管接头240与第一排气阀300之间。储气罐23可以在点胶控制设备开始出胶的瞬间抑制第一减压装置200输出气压的下降，并在点胶控制设备结束出胶的瞬间抑制第一减压装置200输出气压的过冲。由此，可进一步缩短第一减压装置将其输出气压从过冲降至与设定气压一致所需的时间。
在另一些实施例中，点胶控制设备1000还可以包括速度控制阀910，速度控制阀910连通于异形管接头240与第一排气阀300之间。速度控制阀24用于调节第一减压装置输出的最大流量，根据应用的具体点胶参数，测试并确定速度控制阀24的具体气流速度。由此，针对应用的具体点胶参数，调节第一减压装置220输出的最大流量，进一步缩短第一减压装置220将其输出气压从过冲降至与设定气压一致所需的时间。该速度控制阀910可以与上述储气罐800择一地单独设置在异形管接头240与第一排气阀300之间，如图6所示； 也可以与储气罐800同时设置在异形管接头240与第一排气阀300之间，如图7所示，这样能够更大程度上的缩短第一减压装置将其输出气压从过冲降至与设定气压一致所需的时间。
在一些可选地的示例中，如图8所示，速度控制阀910可以与异形管接头240一体连接成型且与第一减压阀230密封硬连接，通过元件集成，减少元件的数量及空间占用。
根据本发明的一些另外的实施例，点胶控制设备1000还可以包括变径管920，变径管920连通于异形管接头240与储气罐800之间，可以达到与速度控制阀24同样的性能效果。如图9所示，可选地，变径管920可以与异形管接头240一体连接成型。
下面将参考图10-图12详细描述根据本发明另一方面实施例的点胶控制设备1000的出胶控制方法。
在一个实施例中，点胶控制设备1000的出胶控制方法包括以下步骤：
S1、设定工作气压、回吸气压、出胶持续时间；
S2、预设空胶桶连接至第一输出接口1200时的第一气压波形、和满胶桶连接至第一输出接口1200时的第二气压波形；
S3、预设剩余量报警阈值；
S4、检测第一输出接口1200是否连接有待执行点胶的胶桶，并检测是否收到点胶触发信号；
S5、当收到点胶触发信号时，输出工作气压，并在出胶持续时间内实时检测第一气压传感器500采集的实时气压波形，根据实时气压波形、第一气压波形和第二气压波形，预判断胶桶内的胶液剩余量；
S6、基于胶液剩余量，对S1中的工作气压、回吸气压、出胶持续时间进行调整，并重复回到步骤S5；
S7、当步骤S5中的胶液剩余量小于剩余量报警阈值时，发出预警信号，停止出胶并回到步骤S4。
由此，根据本发明实施例的出胶控制方法，能实时预测胶桶内胶液剩余量，并自动调整点胶控制器的工作参数，实现胶桶胶液从满到空整个工作过程中，点出胶液量极高的一致性。另外可以实时预测胶桶内胶液剩余量，通过设定胶液剩余量报警阈值并与胶液剩余量进行计算判断，如当前胶桶内胶液剩余量不足时会发出报警信号以提示用户，从而避免少胶甚至无胶状态的点胶作业。此外，基于回吸气压的自适应反馈控制，可在点胶作业的间歇时间内，保证胶桶末端针头的出胶口没有胶液的滴漏和气泡混入，保证点胶作业时精准的出胶一致性。
在一些实施例中，步骤S2中，检测第一气压波形和第二气压波形的每一个时，包括以下步骤：
S21、检测第一输出接口1200是否已连接待检测的胶桶，并检测是否接收到执行信号；
S22、接收到执行信号后，启动第一传感器在预设检测时间内采集气压波形；
S23、存储相应的气压波形。
从操作人员的角度来说，采用根据本发明实施例的出胶控制设备进行出胶控制的操作方法如下：
P1、设定点胶参数；
P2、将满胶桶或空胶桶中的一个通过连接管连接至点胶控制设备1000的第一输出接口120；
P3、按点胶控制设备1000的人机交互菜单项提示，操作点胶控制设备1000执行满胶桶或空胶桶中的一个时的气压波形采集；
P4、将空胶桶或满胶桶通中的另一个过连接管连接至点胶控制设备1000的第一输出接口120；
P5、按点胶控制设备1000的人机交互菜单项提示，操作点胶控制设备1000执行空胶桶或满胶桶中的另一个时的气压波形采集；
P6、点胶控制设备1000根据满胶桶和空胶桶已采集的气压波形，自动执行标定参数的计算和存储。
也就是说，如图12所示，在点胶作业前，需要分别将满胶桶和空胶桶通过连接管连接至第一输出接口120，点胶控制设备1000进入标定模式，由控制装置600与第一气压传感器500、第一排气阀300、第一减压装置80、第二排气阀400交互，进行连接满胶桶(或空胶桶)时的工作气压采集并从采集的波形中提取出气压提高速率，分别完成胶桶满和空两个工况的气压提高特征参数提取和标定。
进一步地，还包括以下操作步骤：
P7、根据剩余量报警功能需求，确定是否开启该功能；如果开启该功能，开启后通过点胶控制设备1000的人机交互菜单项设置剩余量报警阈值及相关参数；
P8、将装有胶液的胶桶通过连接管连接至点胶控制设备1000的第一输出接口120；
P9、点胶控制设备1000进入准备点胶的待机状态，等待点胶触发信号；
P10、点胶控制设备1000收到点胶触发信号时，按当前的点胶参数从第一输出接口120输出点胶气压，同时由第一气压传感器500执行气压波形采集，点胶控制设备1000基于实时采集的气压波形和已存储的标定参数，进行胶桶内胶液剩余量的预测；
P11、点胶控制设备1000基于已预测的胶桶内胶液剩余量，进行点胶参数的修正和自动更新；
P12、若剩余量报警功能已开启，预测的胶桶内胶液剩余量低于设定的胶液剩余量报警阈值，点胶控制设备1000生成低液报警信号；跳转至步骤P9。
具体地，在点胶作业时，由控制装置600与第一气压传感器500、第一排气阀300、第一减压装置80、第二排气阀400交互，实时采集单次出胶的气压波形并提取气压提高的特征参数，由控制装置600内置的胶桶内胶液剩余量预测算法实现当前胶液剩余量的精准预测。
基于胶液剩余量的精准预测，在点胶作业时，点胶控制设备1000可根据不同的胶液剩余量连续地调整点胶参数，实现点出胶液量的极高一致性；可开启胶液剩余量不足的报警功能，胶液剩余量低于设定的报警阈值时，点胶控制设备1000输出胶液剩余量不足的报警信号，提示胶液加注或更换。
需要说明的是，点胶控制设备1000开启回吸功能后，由控制装置600与第一气压传感器500、第二减压装置90交互，实时反馈调节，实现回吸气压的自适应控制。回吸气压的自适应控制可在点胶作业的间歇时间内，保证胶桶末端针头的出胶口没有胶液的滴漏和气泡混入，保证点胶作业时精准的出胶一致性。
优选地，点胶参数包括出胶持续时间、工作气压和回吸气压，该点胶参数便于测量和调整，操作方便。
总而言之，该方法能实时预测胶桶内胶液剩余量，并自动调整点胶控制器的工作参数，实现胶桶胶液从满到空整个点出过程中，点出胶液量极高的一致性；实时预测胶桶内胶液剩余量，设定胶液剩余量报警阈值，提示当前胶桶内胶液剩余量不足，避免少胶甚至无胶状态的点胶作业；基于回吸气压的自适应反馈控制，可在点胶作业的间歇时间内，保证胶桶末端针头的出胶口没有胶液的滴漏和气泡混入，保证点胶作业时精准的出胶一致性。
在本说明书的描述中，参考术语“一个实施例”、“一些实施例”、“示意性实施例”、“示例”、“具体示例”、或“一些示例”等的描述意指结合该实施例或示例描述的具体特征、结构、材料或者特点包含于本发明的至少一个实施例或示例中。在本说明书中，对上述术语的示意性表述不一定指的是相同的实施例或示例。而且，描述的具体特征、结构、材料或者特点可以在任何的一个或多个实施例或示例中以合适的方式结合。
尽管已经示出和描述了本发明的实施例，本领域的普通技术人员可以理解：在不脱离本发明的原理和宗旨的情况下可以对这些实施例进行多种变化、修改、替换和变型，本发明的范围由权利要求及其等同物限定。

Claims (13)

  1. 一种点胶控制设备，其特征在于，包括：
    机体，所述机体上具有适于连接气源的第一输入接口、适于连接外部胶桶的第一输出接口、和第二输出接口；
    第一减压装置，所述第一减压装置设在所述机体内，所述第一减压装置的进气端与所述第一输入接口相连；
    第一排气阀，所述第一排气阀设在所述机体内，所述第一排气阀的进气口与所述减压装置的出气端相连；
    第二排气阀，所述第二排气阀的进口与所述第一排气阀的出气口、所述第一输出接口相连，所述第二排气阀的出口与所述第二输出接口连接；
    第一气压传感器，所述第一气压传感器设在所述第一排气阀的出气口和所述第一输出接口之间，以采集所述第一排气阀与所述第一输出接口之间的管路的实时气压；
    控制装置，所述控制装置设在所述机体内，所述控制装置电连接并控制所述第一减压装置、所述第一排气阀、所述第二排气阀、第一气压传感器，所述控制装置被构造成连续接收所述第一气压传感器采集的实时气压、且实时处理所述实时气压后提取气压提高的特征参数。
  2. 根据权利要求1所述的点胶控制设备，其特征在于，所述机体还设有第三输出接口，所述点胶控制设备还包括回吸气压产生装置，所述回吸气压产生装置包括：
    第二减压装置，所述第二减压装置的进气口与所述第一输入接口相连；
    真空发生器，所述真空发生器的真空产生口与所述第一排气阀的排气口相连，所述真空发生器的进气口与所述第二减压装置的出气口相连，所述真空发生器的出气口与所述第三输出接口相连。
  3. 根据权利要求2所述的点胶控制设备，其特征在于，所述真空发生器的真空产生口与第一排气阀的排气口相连的管路为所述回吸气压产生装置的吸气口，所述点胶控制设备还包括：
    第二气压传感器，所述第二气压传感器与所述回吸气压产生装置的吸气口连接以采集所述回吸气压产生装置产生的回吸气压，所述第二气压传感器与所述控制模块电连接并由所述控制模块连续接收其采集信号。
  4. 根据权利要求2所述的点胶控制设备，其特征在于，所述第二减压装置为电气比例阀或电空减压阀。
  5. 根据权利要求1-4中任一项所述的点胶控制设备，其特征在于，所述第一减压装置为精密减压阀、电气比例阀或电空减压阀；和/或
    所述第一排气阀和第二排气阀中的至少一个为两位三通电磁阀，且所述第二排气阀的流量大于所述第一排气阀的流量。
  6. 根据权利要求1-5中任一项所述的点胶控制设备，其特征在于，所述第一减压装置包括：
    第一减压阀，所述第一减压阀至少具有进气口和出气口，所述进气口构成所述第一减压装置的进气端，所述出气口与所述第一排气阀的进气口相连。
  7. 根据权利要求6所述的点胶控制设备，其特征在于，所述第一减压装置还包括：
    异形管接头，所述异形管接头内限定有沿其轴向贯通的管腔，所述异形管接头的外壁面设有与所述管腔连通的一个或多个气流通道，所述异形管接头连接在所述第一减压阀的出气口和所述第一排气阀的进气口之间。
  8. 根据权利要求7所述的点胶控制设备，其特征在于，所述气流通道的最小直径不大于1mm或最小横截面积不超过1mm 2。
  9. 根据权利要求7所述的点胶控制设备，其特征在于，还包括：
    储气罐，所述储气罐连通于所述异形管接头与所述第一排气阀之间。
  10. 根据权利要求7-9中任一项所述的点胶控制设备，其特征在于，还包括：
    速度控制阀，所述速度控制阀连通于所述异形管接头与所述第一排气阀之间以适于调节所述第一减压装置输出的最大流量。
  11. 根据权利要求9所述的点胶控制设备，其特征在于，还包括：
    变径管，所述变径管连通于所述异形管接头与所述储气罐之间。
  12. 一种根据权利要求1-10中任一项所述的点胶控制设备的出胶控制方法，其特征在于，包括以下步骤：
    S1、设定工作气压、回吸气压、出胶持续时间；
    S2、预设空胶桶连接至所述第一输出接口时的第一气压波形、和满胶桶连接至所述第一输出接口时的第二气压波形；
    S3、预设剩余量报警阈值；
    S4、检测所述第一输出接口是否连接有待执行点胶的胶桶，并检测是否收到点胶触发信号；
    S5、当收到所述点胶触发信号时，输出所述工作气压，并在所述出胶持续时间内实时检测所述第一气压传感器采集的实时气压波形，根据所述实时气压波形、第一气压波形和 第二气压波形，预判断胶桶内的胶液剩余量；
    S6、基于所述胶液剩余量，对步骤S1中的工作气压、回吸气压、出胶持续时间进行调整，并重复回到步骤S5；
    S7、当步骤S5中的胶液剩余量小于所述剩余量报警阈值时，发出预警信号，停止出胶并回到步骤S4。
  13. 根据权利要求11所述的出胶控制方法，其特征在于，所述步骤S2中，检测所述第一气压波形和第二气压波形的每一个时，包括以下步骤：
    S21、检测所述第一输出接口是否已连接待检测的胶桶，并检测是否接收到执行信号；
    S22、接收到所述执行信号后，启动所述第一气压传感器在预设检测时间内采集气压波形；
    S23、存储相应的所述气压波形。
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