Abstract: A gas delivery system is provided comprising an electrical backplane, a system controller operatively coupled to the electrical backplane, and a plurality of mass flow controllers. Each mass flow controller includes respective mass flow control circuitry operatively coupled to the electrical backplane. The system controller and each mass flow control circuitry are physically mounted on the electrical backplane. The gas delivery system further comprises a pump/purge system to help eliminate pressure build up in the system and provide a quick stop to a flow process in the system. Accordingly, a row associated with a flow process may be evaluated so that a mass flow controller may be swapped out as needed.

Abstract: A mass flow controller, including a block body having a flow path and a valve provided at least in part within the flow path. The mass flow controller may further include a valve position sensor, a first temperature sensor, a first pressure sensor located on an upstream side of the flow path from the valve, and a second pressure sensor located on a downstream side of the flow path from the valve. The mass flow controller may further include a processor configured to receive valve position data, first temperature data, first pressure data, and second pressure data. The processor may be further configured to estimate a flow rate of fluid in the flow path at least in part by applying a trained machine learning model to the valve position data, the first temperature data, the first pressure data, and the second pressure data.

Abstract: A gas delivery apparatus is provided, comprising a system controller configured to collect valve position information and sensor information from at least a plurality of the sensors and valves, store the valve position information and sensor information into the monitored gas delivery process data, and execute the discriminative classifier including a first artificial intelligence (AI) model configured to extract features in a first input image of the monitored gas delivery process; a second AI model configured to extract features in a second input image of a golden gas delivery process; and a contrastive loss function configured to calculate a similarity between the first input image and the second input image based on outputs of the first AI model and the second AI model, and output a repeatability confidence value based on a similarity index between the first input image and the second input image.

Abstract: A gas delivery apparatus is provided, comprising a system controller configured to collect valve position information and sensor information from at least a plurality of the sensors and valves, store the valve position information and sensor information into the monitored gas delivery process data, and execute the discriminative classifier including a first artificial intelligence (AI) model configured to extract features in a first input image of the monitored gas delivery process; a second AI model configured to extract features in a second input image of a golden gas delivery process; and a contrastive loss function configured to calculate a similarity between the first input image and the second input image based on outputs of the first AI model and the second AI model, and output a repeatability confidence value based on a similarity index between the first input image and the second input image.

Abstract: A gas delivery system is provided comprising an electrical backplane, a system controller operatively coupled to the electrical backplane, and a plurality of mass flow controllers. Each mass flow controller includes respective mass flow control circuitry operatively coupled to the electrical backplane. The system controller and each mass flow control circuitry are physically mounted on the electrical backplane. The gas delivery system further comprises a pump/purge system to help eliminate pressure build up in the system and provide a quick stop to a flow process in the system. Accordingly, a row associated with a flow process may be evaluated so that a mass flow controller may be swapped out as needed.

Abstract: A mass flow controller, including a block body having a flow path and a valve provided at least in part within the flow path. The mass flow controller may further include a valve position sensor, a first temperature sensor, a first pressure sensor located on an upstream side of the flow path from the valve, and a second pressure sensor located on a downstream side of the flow path from the valve. The mass flow controller may further include a processor configured to receive valve position data, first temperature data, first pressure data, and second pressure data. The processor may be further configured to estimate a flow rate of fluid in the flow path at least in part by applying a trained machine learning model to the valve position data, the first temperature data, the first pressure data, and the second pressure data.

Abstract: Exemplary embodiments of the present disclosure can provide a foam-in-bag device. The device can include a dispenser unit configured for dispensing a fluid foam-precursor into a web of film material for making foam-in-bag packaging material, a fluid supply conduit connected to the dispenser unit for delivering the foam-precursor to the dispenser unit, a valve connected to the dispenser outlet and that is actuatable between: an open condition allowing flow of the foam-precursor so as to permit the dispensing of the foam precursor, and a closed condition preventing flow of the-foam precursor so as to prevent the dispensing of the foam precursor. The device can further include a power-loss protection mechanism configured to direct auxiliary power to actuate the valve to the closed condition upon a loss of incoming power.

Abstract: Exemplary embodiments of the present disclosure can provide a foam-in-bag device. The device can include a dispenser unit configured for dispensing a fluid foam-precursor into a web of film material for making foam-in-bag packaging material, a fluid supply conduit connected to the dispenser unit for delivering the foam-precursor to the dispenser unit, a valve connected to the dispenser outlet and that is actuatable between: an open condition allowing flow of the foam-precursor so as to permit the dispensing of the foam precursor, and a closed condition preventing flow of the-foam precursor so as to prevent the dispensing of the foam precursor. The device can further include a power-loss protection mechanism configured to direct auxiliary power to actuate the valve to the closed condition upon a loss of incoming power.

Abstract: A film supply apparatus supplying film in a foam-in-bag system having a film feeding device for feeding film from a film source to a location for bag formation, a bag forming apparatus, a foam material dispenser positioned for feeding foam material for reception in a bag of the bag forming apparatus, and a web tensioning system with a web tensioning driver in driving communication with the film source and which is in communication with a controller for monitoring the film feed and web tension states and directing adjustments in the web tension system. The web tensioning driver is arranged to move film backwards or in a direction opposite to a direction of film feed induced by the film feeding means and with the film source including a roll of film and the web tensioning system including a drive transmission in communication with the roll of film for rotational driving of the roll of film and also in communication with web tensioning driver.

Abstract: A system and method for providing operational control and/or remote monitoring of a manufacturing device as in a foam dispenser device such as a foam-in-bag dispensing device. In architecture, the remote monitoring system includes a server device containing a remote monitoring system. The remote monitoring system further includes a transceiver to receive an indication of a help condition, connect to the manufacturing device; and receive data from the manufacturing device. The present invention can also be viewed as a method for providing remote monitoring of a manufacturing device. The method operates by (1) receiving an indication of a help condition; (2) connecting to the manufacturing device; and (3) receiving data from the manufacturing device.

Abstract: A foam chemical dispenser apparatus having a chemical supply device and a dispenser device with housing and foam chemical output. A chemical passageway is provided from the source to the output. In a preferred embodiment, the passageway is at least partially defined by a hose and a chemical conduit formed in the dispenser housing. A heating system is included having a first heater element extending within the hose from a first end positioned closer to the chemical supply device to a second feedthrough supported end positioned closer to the dispenser device, and a second heating element is provided in the dispenser device. A temperature sensor system is included with a first temperature sensor positioned for sensing temperature of chemical in the hose and a second temperature sensor positioned for sensing chemical temperature in the dispenser device.

Abstract: A film supply apparatus supplying film in a foam-in-bag system having a film feeding device for feeding film from a film source to a location for bag formation, a bag forming apparatus, a foam material dispenser positioned for feeding foam material for reception in a bag of the bag forming apparatus, and a web tensioning system with a web tensioning driver in driving communication with the film source and which is in communication with a controller for monitoring the film feed and web tension states and directing adjustments in the web tension system. The web tensioning driver is arranged to move film backwards or in a direction opposite to a direction of film feed induced by the film feeding means and with the film source including a roll of film and the web tensioning system including a drive transmission in communication with the roll of film for rotational driving of the roll of film and also in communication with web tensioning driver.

Abstract: A foam chemical dispenser apparatus having a chemical supply device and a dispenser device with housing and foam chemical output. A chemical passageway is provided from the source to the output. In a preferred embodiment, the passageway is at least partially defined by a hose and a chemical conduit formed in the dispenser housing. A heating system is included having a first heater element extending within the hose from a first end positioned closer to the chemical supply device to a second feedthrough supported end positioned closer to the dispenser device, and a second heating element is provided in the dispenser device. A temperature sensor system is included with a first temperature sensor positioned for sensing temperature of chemical in the hose and a second temperature sensor positioned for sensing chemical temperature in the dispenser device.

Abstract: A film supply apparatus supplying film in a foam-in-bag system having a film feeding device for feeding film from a film source to a location for bag formation, a bag forming apparatus, a foam material dispenser positioned for feeding foam material for reception in a bag of the bag forming apparatus, and a web tensioning system with a web tensioning driver in driving communication with the film source and which is in communication with a controller for monitoring the film feed and web tension states and directing adjustments in the web tension system. The web tensioning driver is arranged to move film backwards or in a direction opposite to a direction of film feed induced by the film feeding means and with the film source including a roll of film and the web tensioning system including a drive transmission in communication with the roll of film for rotational driving of the roll of film and also in communication with web tensioning driver.

Abstract: A film supply apparatus supplying film in a foam-in-bag system having a film feeding device for feeding film from a film source to a location for bag formation, a bag forming apparatus, a foam material dispenser positioned for feeding foam material for reception in a bag of the bag forming apparatus, and a web tensioning system with a web tensioning driver in driving communication with the film source and which is in communication with a controller for monitoring the film feed and web tension states and directing adjustments in the web tension system. The web tensioning driver is arranged to move film backwards or in a direction opposite to a direction of film feed induced by the film feeding means and with the film source including a roll of film and the web tensioning system including a drive transmission in communication with the roll of film for rotational driving of the roll of film and also in communication with web tensioning driver.

Abstract: A system and method for providing operational control and/or remote monitoring of a manufacturing device as in a foam dispenser device such as a foam-in-bag dispensing device. In architecture, the remote monitoring system includes a server device containing a remote monitoring system. The remote monitoring system further includes a transceiver to receive an indication of a help condition, connect to the manufacturing device; and receive data from the manufacturing device. The present invention can also be viewed as a method for providing remote monitoring of a manufacturing device. The method operates by (1) receiving an indication of a help condition; (2) connecting to the manufacturing device; and (3) receiving data from the manufacturing device.

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

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