Abstract: In one example, a melter has a housing, a heater, a vent, and a filter medium. The housing defines a receiving space that supports adhesive therein. The heater heats the receiving space of the housing to melt the adhesive. The melter defines an adhesive inlet therein that receives adhesive carried by a transport supply gas into the receiving space. The vent extends through a wall of the melter and permits the transport supply gas to escape from the melter. The filter medium is supported in the vent to capture particulates from the transport supply gas escaping the receiving space, and is positioned relative to the receiving space such that heat from the receiving space causes the particulates captured by the filter medium to melt and fall into the receiving space.

Abstract: Systems and methods for controlling adhesive application are disclosed. The systems and methods may include a controller and one or more sensors configured to measure an amount of adhesive applied to a plurality of substrates by a pump, detect a number of the substrates, determine an amount of adhesive applied per substrate, compare the adhesive applied per substrate to a target value, and adjust a pressure of the pump based on the comparison. The sensor(s) may include one or more of a valve sensor coupled to an adhesive supply, a flow rate sensor coupled to a manifold, a flow rate sensor coupled to one or more hoses, and a flow rate sensors coupled to a gun.

Abstract: Systems and methods for controlling adhesive application are disclosed. The systems and methods may include a controller and one or more sensors configured to measure an amount of adhesive applied to a plurality of substrates by a pump, detect a number of the substrates, determine an amount of adhesive applied per substrate, compare the adhesive applied per substrate to a target value, and adjust a pressure of the pump based on the comparison. The sensor(s) may include one or more of a valve sensor coupled to an adhesive supply, a flow rate sensor coupled to a manifold, a flow rate sensor coupled to one or more hoses, and a flow rate sensors coupled to a gun.

Abstract: Systems and methods for direct heater diagnostics for a hot melt liquid dispensing system are disclosed. At least one of a current measurement or a voltage measurement is received from a respective current and/or voltage sensor positioned at an electrical circuit that supplies electric power to a heater associated with the dispensing system. The heater can be for an applicator or heated hose attached to the dispensing system, a melter of the dispensing system, or a pump of the dispensing system. A state of the electrical circuit is determined based on the at least one of the current or voltage measurement.

Abstract: Systems and methods for air pressure control in a hot melt liquid dispensing system are described. An example hot melt liquid dispensing system includes a pump that pumps hot melt liquid to an applicator. The hot melt liquid dispensing system also includes an air flow path that supplies pressurized air to the pump and an electronic pressure sensor associated with the air flow path. The hot melt liquid dispensing system also includes a controller that receives an electronic signal from the electronic pressure sensor indicative of an air pressure in the air flow path and causes adjustment to the air pressure in the air flow path based on the electronic signal from the electronic pressure sensor.

Abstract: Systems and methods for tuning a closed-loop controller for a hot melt liquid dispensing system are disclosed. In an example method, based on a set temperature setpoint, the hot melt liquid dispensing system is maintained at a steady state with respect to a temperature process variable and a heater duty cycle control variable. The heater duty cycle control variable is brought to a sustained oscillation. An amplitude and an ultimate period are determined. An ultimate gain is determining based on the step value and the amplitude. A proportional, integral, or derivative constant is determined based the ultimate period and/or ultimate gain. The closed-loop controller is implemented using the proportional, integral, or derivative constant.

Abstract: An adhesive dispensing device (10) includes a melt module (12) including a housing (78) that defines a receiving space to receive adhesive and a heater (114) to heat the housing to melt the adhesive, and a control module (14) releasably connected to the melt module. The control module includes a controller (36) to automatically recognize a characteristic associated with the melt module and operate the melt module using instructions stored on the controller that correspond to the characteristic of the melt module. A method of operating the adhesive dispensing device is also disclosed.

Abstract: In one example, a melter has a housing, a heater, a vent, and a filter medium. The housing defines a receiving space that supports adhesive therein. The heater heats the receiving space of the housing to melt the adhesive. The melter defines an adhesive inlet therein that receives adhesive carried by a transport supply gas into the receiving space. The vent extends through a wall of the melter and permits the transport supply gas to escape from the melter. The filter medium is supported in the vent to capture particulates from the transport supply gas escaping the receiving space, and is positioned relative to the receiving space such that heat from the receiving space causes the particulates captured by the filter medium to melt and fall into the receiving space.

Abstract: Systems and methods for adaptive preventative maintenance are disclosed. In a method to determine a maintenance interval estimate for equipment, a first maintenance interval estimate associated with the equipment is provided. The first maintenance interval estimate is expressed according to a usage metric associated with the equipment. An indication that the equipment has been replaced may be received. An elapsed usage of the equipment in a time period may be determined. The time period may span from a reference time point associated with the first maintenance interval estimate to a later replacement time point associated with the replacement of the equipment. A second maintenance interval estimate may be determined based on the elapsed usage of the equipment. The second maintenance interval estimate may be expressed according to the usage metric associated with the equipment.

Abstract: A hot melt dispensing system is described. The hot melt dispensing system includes a melter that melts solid material into hot melt, a pump that pumps the hot melt from the melter to at least one applicator, and a pressure control system that controls a pressure of pressurized air for operating the pump. The pressure control system includes a regulator assembly that controls the pressure of the pressurized air, and a drive component that actuates the regulator assembly. The hot melt dispensing system also includes a controller that determines a pressure setting for the pressurized air. The drive component receives the pressure setting from the controller and actuates the regulator assembly to a position associated with the pressure setting.

Abstract: A melter melts particulate hot melt adhesive into a liquefied form. The melter includes a heated receiving device having an interior with an inlet that receives the particulate hot melt adhesive and an outlet. The heated receiving device melts the particulate hot melt adhesive and directs the liquified hot melt adhesive to the outlet. A prepackaged container holds a supply of the particulate hot melt adhesive and includes an outlet. A particulate hot melt adhesive feed device allows the particulate hot melt adhesive to be directed from the outlet of the prepackaged container to the inlet of the heated receiving device.

Abstract: A hot melt dispensing system is described. The hot melt dispensing system includes a melter that melts solid material into hot melt, a pump that pumps the hot melt from the melter to at least one applicator, and a pressure control system that controls a pressure of pressurized air for operating the pump. The pressure control system includes a regulator assembly that controls the pressure of the pressurized air, and a drive component that actuates the regulator assembly. The hot melt dispensing system also includes a controller that determines a pressure setting for the pressurized air. The drive component receives the pressure setting from the controller and actuates the regulator assembly to a position associated with the pressure setting.

Abstract: A melter for heating and melting particulate hot melt adhesive into a liquefied form is disclosed. The melter includes a heated receiving device having an interior with an inlet configured to receive the particulate hot melt adhesive and an outlet. A flexible hopper holds a supply of the particulate hot melt adhesive and a particulate hot melt adhesive feed device allows the particulate hot melt adhesive to be directed from the flexible hopper to the inlet of the heated receiving device.

Abstract: An adhesive dispensing system is disclosed. The system includes a heater unit configured to heat an adhesive to an application temperature, a fill system configured to supply the adhesive to said heater unit, and a controller. The controller is configured to actuate the fill system to supply the adhesive to the heater unit, operate the heater unit to maintain a unit set point temperature sufficient to heat the adhesive to the application temperature, and operate the heater unit to reduce its temperature from the unit set point temperature following a first set threshold time from actuation of the fill system to supply the adhesive to the heater unit.

Abstract: An adhesive dispensing device includes a heater unit for melting adhesive, a fill system communicating with a receiving space for feeding the heater unit, and a reservoir for receiving melted adhesive from the heater unit. The dispensing device also includes a capacitive level sensor located along a sidewall of the receiving space such that the level of adhesive in the receiving space can be detected by sensing the difference in dielectric capacitance where the adhesive is located compared to where air acts as the dielectric. The size of the driven electrode produces a broader sensing window capable of generating multiple control signals corresponding to different fill levels of adhesive. The receiving space and reservoir are minimized in size so that adhesive is not held at elevated temperatures long enough to char or degrade.

Abstract: Systems and methods for controlling adhesive application are disclosed. The systems and methods may include a controller and one or more sensors configured to measure an amount of adhesive applied to a plurality of substrates by a pump, detect a number of the substrates, determine an amount of adhesive applied per substrate, compare the adhesive applied per substrate to a target value, and adjust a pressure of the pump based on the comparison. The sensor(s) may include one or more of a valve sensor coupled to an adhesive supply, a flow rate sensor coupled to a manifold, a flow rate sensor coupled to one or more hoses, and a flow rate sensors coupled to a gun.

Abstract: An adhesive dispensing system is disclosed. The system includes a heater unit configured to heat an adhesive to an application temperature, a fill system configured to supply the adhesive to said heater unit, and a controller. The controller is configured to actuate the fill system to supply the adhesive to the heater unit, operate the heater unit to maintain a unit set point temperature sufficient to heat the adhesive to the application temperature, and operate the heater unit to reduce its temperature from the unit set point temperature following a first set threshold time from actuation of the fill system to supply the adhesive to the heater unit.

Abstract: An adhesive dispensing system includes a pump and at least one sensor positioned to sense movements of a component of the pump and produce signals based on the sensed movements. The dispensing system also includes a controller communicating with the at least one sensor to collect information regarding operational cycles of the pump based on the signals. As a result, one or more diagnostic processes are enabled at the controller during operation of the adhesive dispensing system. These diagnostic processes may include a leak rate test for the dispensing system, an overspeed detection test for the pump, and expected life cycle monitoring of the pump or other components.

Abstract: An adhesive dispensing system is configured to automatically reduce the temperature of adhesive material to reduce degradation of the adhesive caused by holding the adhesive at an application temperature during periods of low throughput. To this end, a controller of the system operates a heater unit to maintain a unit set point temperature to heat and melt adhesive until a set threshold time has elapsed since the most recent supply of adhesive to the system by a fill system. Once the time elapsed since the most recent supply of adhesive exceeds the set threshold time, the heater unit is reduced in temperature to reduce the temperature of adhesive. This reduction is temperature is large enough to minimize degradation and outgassing but small enough to enable rapid warm-up times after a new supply of adhesive occurs.

Abstract: A melter for heating and melting particulate hot melt adhesive into a liquefied form is disclosed. The melter includes a heated receiving device having an interior with an inlet configured to receive the particulate hot melt adhesive and an outlet. A flexible hopper holds a supply of the particulate hot melt adhesive and a particulate hot melt adhesive feed device allows the particulate hot melt adhesive to be directed from the flexible hopper to the inlet of the heated receiving device.