Dispensing and coating technologies are widely used in industries such as semiconductors, electronics , automotive, medical, optoelectronics, and other manufacturing sectors. The coating and dispensing technology is primarily used for accurately applying adhesives or other liquid coating materials onto workpiece surfaces.
With technological advancements, precision manufacturing fields like microelectronics, packaging, and electronic component production have increasingly higher requirements for dispensing processes, such as smaller dispensing volumes, higher accuracy, and faster production efficiency.
Traditional dispensing equipment often has limitations in glue volume control, coating accuracy, and real-time measurement and adjustment, making it unable to meet the demands of advanced manufacturing for high efficiency and high quality.

Flow Rate Measurement Challenges in Dispensing, Gluing, Spraying, and Other Coating Equipment

1. Unstable Dispensing Volume Control: Traditional dispensing equipment may experience significant fluctuations in dispensing volume during high-frequency operations, leading to inconsistent dispensing results, increased product defect rates, and reduced device reliability.

2. Lack of Real-Time Glue Flow Measurement Methods: Traditional dispensing equipment often lacks real-time flow rate measurement and feedback systems, making it impossible to promptly detect and correct issues during the dispensing process, which affects final product quality.

3. Lack of Intelligent Management: Traditional dispensing equipment typically does not have flow data recording and analysis functions, lacking effective management tools to optimize production processes and improve efficiency.

Common Issues Encountered by Traditional Flow Sensors/Flow Meters in Measuring Glue Flow

1. Vortex, gear, and other flow meters have poor compatibility with glue types and cannot effectively handle glues of different viscosities and/or densities.

2. Electromagnetic, turbine, gear, vortex, and other flow meters require cutting the tubing for installation, introducing downtime and contamination risks that affect production line efficiency.

3. Mechanical flow meters, such as rotor or turbine flow meters, lack accuracy in micro-flow rate measurements, making it difficult to meet the process requirements of advanced manufacturing fields like micro-dispensing and coating.

4. High-accuracy  flow meters, such as Coriolis flow sensors, are expensive, with high long-term maintenance costs that dispensing and coating equipment may not afford.

5. Electromagnetic flow meters can only measure conductive liquids, while glues are often non-conductive.

Solution
TGU Series Ultrasonic Flow Sensor – Designed for Ultra-Low Coating Flow Measurement

1. Accurate Micro-Flow Rate Measurement: Min measurable flow as low as 1 mL/min, with flow measurement accuracy up to ±1% and repeatability as low as 0.002 mL.

2. Fast Response and Real-Time Data Output: Can provide feedback on flow rate within milliseconds, supporting multiple output methods; integrates with control systems for dynamic adjustment of coating parameters.

3. Compatible with Various Types of Coating Pumps: Supports piezoelectric pumps, diaphragm pumps, screw pumps, gear pumps, air pumps, etc.

4. Adaptable to Multiple Glue Media: Can measure various glues with viscosities less than 1000 cP ), such as conformal coatings and epoxy resins.

5. No Clogging: Internal components do not obstruct the liquid path, ensuring smooth flow channels.

6. Corrosion-Resistant Materials: Flow path made of PEEK material, adaptable to various media.

7. Bubble Detection: Real-time bubble detection, bubble alarm.

8. Bi-Directional Flow Measurement: Supports forward and reverse flow detection, with strong adaptability to different operating conditions.

9. Standardized Connectors for Easy Installation: Integrates into existing liquid supply system via international standardized tubing connectors, convenient installation.

CPD Series Ultrasonic Flow Sensor – Clamp-On Installation, Non-Invasive Flow Measurement

1. No tube cutting, No installation downtime 

2. Suitable for Small Tubing Diameter Flow Measurement (starting from 6.4 mm OD), adaptable to various rigid plastic tubing materials.

3. Equipped with an OLED Display for viewing real-time flow, cumulative volume, etc.

4. Flow Measurement Accuracy up to ±2%, with multiple flow output signal methods for easy closed-loop control.

5. Non-invasive Measurement, no need for regular cleaning, reducing maintenance and usage costs.

6. Capable of Measuring Liquids with Viscosities from 0-5000 cP.

Application Scenarios

1. Real-Time Flow Rate Measurement

Dispensing and coating equipment start spraying based on the selected mode and preset parameters. The TGU or CPD series ultrasonic flow sensor / flow meters monitors the glue flow rate in real-time and feeds it back to the controller. The control system controls the dispensing pump/valve based on the preset flow rate, ensuring that the dispensing nozzle operates at the preset flow rate for consistent dispensing volumes each time, guaranteeing dispensing efficiency and quality.

2. Flow Anomalies and Bubble Alarms

When the TGU or CPD series ultrasonic flow sensor / flow meter detects abnormal fluctuations in glue flow, such as decreases or increases, it can provide real-time alarms and feedback to the control system for quick response and handling of flow anomalies. It supports bubble detection and alarms, reducing defect rates in dispensing and coating.

3. Various Adaptation Scenarios

1) Coating and Developing Equipment in Semiconductor Manufacturing Processes

2) Bonding equipment and spin coating in semiconductor advanced packaging.

3) Dispensing machines and conformal coating machines in PCB manufacturing.

4) Micro-dispensing equipment in electronic product manufacturing.

5) Spraying equipment in automotive manufacturing.

6) Gluing equipment in new energy battery manufacturing.Various precision dispensing and coating scenarios in industrial electrical and other fields.

Customer Value

1. Significant Improvement in Glue Volume Control Accuracy

The TGU micro flow sensor and CPD series clamp on ultrasonic flow sensors support real-time glue flow data collection, precisely converting flow data into bases for coating parameter adjustments, enabling analysis of spraying flow status and dynamic parameter optimization, reducing glue volume fluctuations, enhancing coating repeatability, and improving quality consistency and process stability.

2. Real-Time Alarms for Flow and Bubble Anomalies

Reduce coating defect rates and improve production efficiency.

3. Suitable for Multiple Glue Media

Adaptable to various dispensing and coating processes and scenarios, with easy installation and quick integration, reducing maintenance and usage costs for dispensing and coating equipment.

More about TGU series Ultrasonic Flow Sensor / Flow Meter, please visit XY-TEK website at https://xy-tek.com/Products/show?id=6

Please contact XY-TEK team at global@xy-tek.cn

XY-TEK engineers would be delighted to arrange the flow sensor/flow meter demonstration or provide further information to help make the flow meter selection choice.

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