METHODS OF OPERATING THE SAME

CROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims the benefit of U.S. Provisional Patent Application No. 62/103,936, filed January 15, 2015, and U.S. Patent Application Serial No. 14/994,253, filed January 13, 2016, the content of both of which is incorporated herein by reference in its entirety.

FIELD

[0002] The invention relates to manifold assemblies for distributing cooling fluids for light sources, and more particularly, to intelligent manifold assemblies for use with light sources.

BACKGROUND

[0003] Lamp systems including light producing elements (e.g., ultraviolet radiation

LEDs, also known as UV LEDs) are used in connection with many applications such as, for example, UV curing applications (e.g., UV curing of inks, bonding agents such as adhesives, coatings, etc.). Certain light producing devices (e.g., a group of UV LEDs) produce a substantial amount of heat, and are typically cooled using a cooling fluid.

[0004] For example, the cooling fluid may be water provided by a chiller system. It is typically desirable to maintain certain characteristics (e.g., water flow rate) of the cooling fluid. Further, in certain instances, it is desirable to shut off flow of the cooling fluid used to cool the lamp systems.

[0005] Existing cooling fluid distribution systems, and the monitoring, control, and operation of such systems, do not adequately address the complex issues that arise in the industry.

[0006] Thus, it would be desirable to provide improved cooling fluid distribution systems, light sources including such improved cooling fluid distribution systems, and methods of operating such improved cooling fluid distribution systems, to overcome one or more of the deficiencies in the industry.

SUMMARY

[0007] According to an exemplary embodiment of the invention, a manifold assembly for distribution of a cooling fluid is provided . The manifold assembly is configured for use with a light source. The manifold assembly i ncludes a fluid manifold for providing a cooling fluid to a lamp head assembly of the light source, at least one sensor for sensing at least one characteristic of the cooling fluid in the fluid manifold, and a microprocessor for receiving information related to the at least one characteristic from the at least one sensor.

[0008] Accordi ng to another exemplary embodiment of the i nvention, a light source is provided . The light source includes: (a) a lamp head assembly including at least one light producing device; and (b) a manifold assembly for distributing a cooling fl uid, the manifold assembly being configured for use with the light source, the manifold assembly i ncluding (i) a fluid manifold for providing the cooling fluid to the lamp head assembly, (ii) at least one sensor for sensing at least one characteristic of the cooling fluid i n the fluid manifold, and (iii) a microprocessor for receiving information related to the at least one characteristic of the cooling fluid from the at least one sensor.

[0009] According to yet another exemplary embodiment of the invention, a method of operating a manifold assembly for distributi ng a cooling fluid is provided . The manifold assembly is configured for use with a light source. The method includes the steps of: (a) providing a cooling fluid to the manifold assembly for cooli ng a light source; (b) sensing at least one characteristic of the cooli ng fluid at the manifold assembly using at least one sensor; and (c) transmitting data i ncludi ng i nformation related to the at least one characteristic sensed by the at least one sensor to a microprocessor i ncl uded i n the manifold assembly.

BRIEF DESCRIPTION OF THE DRAWINGS

[0010] The i nvention is best understood from the followi ng detailed description when read in connection with the accompanying drawi ngs. It is emphasized that, according to common practice, the various features of the d rawi ngs are not to scale. On the contrary, the dimensions of the various features are arbitrarily expanded or reduced for clarity. Included in the drawings are the following figures:

FIG. 1 is a top view of a manifold assembly in accordance with an exemplary embodiment of the invention;

FIG. 2 is a front perspective view of the manifold assembly of FIG. 1 in accordance with an exemplary embodiment of the invention ;

FIG. 3 is a back perspective view of the manifold assembly of FIG. 1 in accordance with an exemplary embodiment of the invention;

FIG. 4 is a block diagram view of a graphical user interface in accordance with an exemplary embodiment of the invention;

FIG. 5 is a block diagram view of an light source including a manifold assembly, and related elements, in accordance with an exemplary embodiment of the invention ; and

FIG. 6 is a flow diagram illustrating a method of operating a manifold assembly configured for use with a light source in accordance with an exemplary embod iment of the invention.

DETAILED DESCRIPTION

[0011] The invention may have particular applicability to manifold assemblies configured for use with light sources such as UV light sources. Exemplary UV light sources include UV lasers, UV LED light sources, and vertical cavity surface emitting lasers

(VCSEL) . Nonetheless, other light sources, such as visible light sources, are contemplated .

[0012] As used herein, the terms "processor" and "microprocessor" are used interchangeably, and shall be broadly construed to refer to any device including a processing unit (e.g., a central processi ng u nit) or other hardware that executes computer program instructions. Examples of "processors" and "microprocessors" include

microcontrollers, digital signal processors (DSPs), prog rammable logic controllers (PLCs), computers, etc. As is understood by those skilled in the art, "processors" and "microprocessors" may i nclude elements such as ra ndom access memory (RAM), read only memory (ROM), and peri pherals.

[0013] Certain embodiments of the invention relate to an intelligent manifold assembly for use with (and/or inclusion in) a light source, such as an ultraviolet (UV) light source or a visible light source. The intelligent manifold assembly may be configured to report certai n characteristics related to a cooling fluid in the ma nifold assembly (or other elements of a light sou rce) such as, for example : inlet flow rate of the cooling fluid, outlet flow rate of the cooling fluid, pH of the cooling fluid, pressure of the cooling fluid, inlet temperature of the cooling fluid, outlet temperature of the cooling fluid, and ambient temperature of the system. Various benefits may be provided by monitoring such characteristics. For example, the system may be used to ensure a uniform flow of cooling fluid (e.g., cooli ng water) throughout the system. Further, the manifold assembly may also shut off the cooling fluid (e.g., by operation or one or more valves) when : (i) the lamp head of the light source (including the light producing elements) is not in operation; (ii ) if the cooling fluid hoses/tubes are accidentally cut or are leaki ng; (iii) if the manifold assembly does not maintain a desired level of cooling fluid pressure; etc. As will be explained herein, in one or more embodiments, the manifold assembly may include sensors, cooling fluid hoses/tubes, plumbing fixtures, electrical/communication cables, valves (e.g., solenoid valvies) and a printed circuit board.

[0014] As will be appreciated by those skilled in the art, lamp systems (and the associated cooli ng fluid systems) often have certain limitations a nd challenges. For example, specific values for cooling fluid pressure, cooling fluid pH, cooli ng fluid flow rate, cooling fluid temperature, etc. are desirably maintained to ensure the preferred

performance of the system.

[0015] Another challenge is controlling the cooling fluid pressu re during start up of the system, which tends to result in a cooling fl uid pressure spike when the system is turned on. The lamp head assembly often includes elements that may be sensitive to a relatively signficiant start up pressure spike. In accordance with the i nvention, the cooling fluid pressure may be ramped according to a predefined pressure profile duri ng the i nitial start up. Thus, accurate closed loop control of cooling fluid pressure is desirable.

[0016] Yet another challenge relates to extended testing on cooling fluid sources (e.g., lifetesting on a chiller, which may occur overnight). Such testi ng may result in a pressure leak somewhere in the system. If such a leak occurs, and the chiller runs in a dry state, this may result in damage (and possibly permanent failure) of elements of the light source system and/or the cooling system.

[0017] Yet another challenge relates to a situation where a cooling fluid line is cut, resulting in a loss of pressure, which may result in an interlock shutting off the lamp system (including a shutdown of energy, such as DC power, provided by a power supply to energize the light producing elements of the lamp head). While the elements of the lamp head system may be protected in such a situation, cooling fluid (e.g., water from a chiller) may continuously run through the leaking cooling fluid distribution system, creating a potential safety hazard.

[0018] Yet another challenge relates to distribution of the cooling fluid when the lamp is shut off. Even if there is not be a substantial safety risk, or a risk of equipment damage, if the cooling fluid continues to operate when it is not needed this results in the wasteful cooling of a lamp system (and the associated waste of energy, and related resources).

[0019] To address certain of the aforementioned issues and challenges, according to certain exemplary embodiments of the invention, a profile (e.g., a time based profile that tracks operation of the system) is developed based on the anticipated performance of the system. The profile corresponds to operation of the lamp system, with thresholds (or acceptable ranges) for each of a plurality of cooling fluid characteristics being monitored (and potentially controlled) in connection with the profile, using sensors included in the manifold assembly. Exemplary characteristics include cooling fluid pressure, cooling fluid temperature, cooling fluid pH, and cooling fluid flow rate.

[0020] Certain of the sensors included in the manifold assembly may desirably be provided in line with the cooling fluid supply (e.g., water from the chiller), with the sensors being connected (e.g., via cabling) to a printed circuit board of the manifold assembly. Such a printed circuit board may include signal conditioning circuitry for receiving, converting, and otherwise manipulating signals from the sensors. Output from the signal conditioning circuit may be used locally (at the manifold assembly) and/or may be sent via a communication link to a remote location such as a central processing unit of the power source (e.g., a power supply) that provides energy to illuminate light producing elements of the lamp head. [0021] According to certain exemplary embodiments of the invention, and based on the desired (e.g ., optimal) performance of the system, an acceptable (or unacceptable) threshold value may be established for each sensor characteristic, or an acceptable (or unacceptable) range may be established for each sensor characteristic. Real time data is collected by the plurality of sensors, where the data may be stored in memory local to the manifold assembly and/or may be sent to the processor (e.g . , a microcontroller) on a printed circuit board local to the manifold assembly. As provided above, the data from the sensors (which may be reconditioned, reformatted, aggregated, mathematically manipulated, etc. ) may then be transmitted via cable to a remote processor (e.g ., the central processing unit of the power supply) that compares the data to the predetermi ned criteria for the specific characteristic bei ng sensed. If the sensor data is outside of an acceptable predefined value (as determined using a threshold, a range, etc. ), software may be used to (i) initiate a warning through a user interface (e.g . , a graphical user interface, etc. ), (ii) engage an interlock to shut down water flow (e.g ., through valve operation), etc. The determination of whether the sensor data is acceptable (and/or the initiation of a warning or engagement of an interlock) may be accomplished by a local processor (at the manifold assembly) as opposed to the remote processor.

[0022] FIGS. 1-3 provide various views of a manifold assembly 100, illustrating various exemplary components, in accordance with one or more embodiments of the invention. A mounting bracket 102 is provided to support various components of manifold assembly 100. Manifold assembly 100 provides a cooling fluid (e.g., cooling water from a chiller such as a closed-loop chiller system, a simple heat exchanger chiller system, etc. ) to a lamp head (not shown in FIGS. 1-3) . The cooling fluid provided by the chiller is received at coolant supply line 106 of manifold assembly 100. The cooling fluid proceeds to inlet manifold 118, and from inlet manifold 118 the cooling fluid proceeds to provide cooling to portions of the lamp head (not shown in FIGS. 103) through connections 120a, 120b. As will be appreciated by those skilled in the art, the distribution of the cooling fluid in the lamp head may follow any desired path, and may include micro channels in a heat exchanger element provided adjacent the light producing elements to cool the system .

[0023] From the lamp head the cooling fluid returns to outlet manifold 124 through connections 126a, 126b, and then proceeds to coolant return l ine 108. From coolant return line 108 the cooling fluid returns to a cooling fluid supply (e.g . , a chiller) . A plurality of sensors (which may be in line with the cooling fluid supply) included in manifold assembly 100 monitor characteristics of the cooling fluid (and/or of other parts of the light source), and provide signals related to the monitored characteristics to a manifold board 104 (e.g., a printed circuit board) included in manifold assembly 100.

[0024] Manifold assembly 100 also includes a valve 110 (e.g., a solenoid valve), a pressure regulator 112, a pressure gauge 114, and a cooling fluid filter 116. The exemplary plurality of sensors shown in FIGS. 1-3 include cooling fluid

pressure/temperature sensors 122, cooling fluid pH sensor 128, and cooling fluid flow sensors 130a, 130b. Of course, additional sensors are contemplated.

[0025] Referring specifically to FIG. 3, exemplary circuit elements are shown on manifold circuit board 104 including a microprocessor 130, a static memory device 132 (e.g ., an electrically erasable programmable read-only memory, that is, an EEPROM), a conditioning circuit(s) 134, and a communication port 136. Signals from the plurality of sensors (including information related to the monitored characteristics) are received by microprocessor 130 after conditioning by conditioning circuit(s) 134.

[0026] A user interface may be desirable, such that a user of a light source

(including the manifold assembly) may visually monitor the status of certain

characteristics (e.g., including certain of the monitored characteristics of the cooling fluid). FIG. 4 illustrates an exemplary graphical user interface (GUI) for a system including water as a cooling fluid. Manifold interface 400 illustrates the monitored water pressure, water pH, the inlet water flow rate, the outlet water flow rate, the water valve position, the lamp status, the inlet water temperature, the outlet water temperature, the ambient

temperature, and the status of communication with manifold board 104. While FIG. 4 primarily illustrates status information (e.g., information related to the sensed cooling fluid characteristics), it is understood that such an interface may provide other functionality such as, for example, user input functionality (e.g., user control of cooling fluid

characteristic setpoints, user control of cooling fluid valves, emergency stop functions, etc.).

[0027] FIG. 5 is a block diagram of a light source system 500 (e.g., a UV LED system, for example, for providing UV energy for curing, etc.), where similar elements in FIG. 5 have similar functions to the same elements described in connection with FIGS. 1-3, regardless of the reference numeral differences. System 500 includes a light source 520, a chiller 502, a display 514, and a power source 516. Light source 520 includes a lamp head assembly 508 (e.g., including a plurality of light producing elements such as UV LEDs), a manifold assembly 504, and a housing 518 including the lamp head assembly and the manifold assembly. Manifold assembly 504 includes a fluid manifold 510 (e.g., including an inlet manifold such as manifold 118 in FIGS. 1-3, and an outlet manifold such as manifold 124 in FIGS. 1-3) and a manifold board 512. Fluid manifold 510 receives cooling fluid from chiller 502 via inlet piping 506a. Cooling fluid returns to chiller 502 via outlet piping 506b. Although FIG. 5 only illustrates the elements in a block diagram form, it is understood that the cooling fluid passes through fluid manifold 510 in a desired manner to cool elements of lamp head assembly 508 (e.g., to withdraw heat produced by light producing elements such as UV LEDs). FIG. 5 illustrates various exemplary sensors for sensing characteristics of fluid manifold 510, including characteristics of cooling fluid provided by chiller 502 and passing through fluid manifold 510. The illustrated sensors include a pressure sensor 510a, a pH sensor 510b, an inlet flow sensor 510c, an outlet flow sensor 510d, a water valve control 510e (e.g., which may be a valve position indication, valve control, etc.), an inlet temperature sensor 510f, an outlet temperature sensor 510g, and an ambient temperature sensor 510h. Of course, additional or different sensors are contemplated within the scope of the invention.

[0028] Signals from the various sensors are received at one or more conditioning circuits 512d on manifold board 512. Signals from conditioning circuit(s) 512d are received by processor 512b (e.g., a microprocessor). Processor 512b is in communication with EEPROM 512c (or another static memory device), where EEPROM 512c includes information related to at least one of (i) read only data related to one or more of the manifold assembly sensors, and (ii) data written by the microprocessor related to operation of the at least one sensor. That is, as used herein, the terms static memory device (including EEPROM) is intended to refer to a system that may include read only data, and memory for writing additional data. Read only data stored in EEPROM 512c may include, for example, sensor data for one or more of the sensors (e.g., sensor calibration data, sensor manufacturer data such as bar codes and model numbers, sensor service data, sensor warranty data, sensor inventory data, etc.) or similar information related to other parts of the manifold assembly. Data written by the microprocessor to EEPROM 512c may include, for example, information related to the hours of operation of each sensor, data related to characteristics of the cooling fluid sensed by each sensor, etc. A specific example of data that may be written by the microprocessor to EEPROM 512c may include information related to cooling fluid characteristics that exceed predetermined criteria (e.g., alarm conditions, etc.).

[0029] Processor 512b transmits and receives information via communication link

512a (e.g., a wired communication link, a wireless communication link, etc.). For example, information is provided through communication link 512a to display 514 (which may be an interface similar to interface 400 shown in FIG. 4). Information may be provided to processor 512b by a user of display 514 (e.g., a user may provide control instructions for an element of light source 520 via display 514) via communication link 512a. Information may also be transmitted to power source 516 (e.g., to a central processing unit of power source 516) from processor 512b via communication link 512a. Likewise, information may be transmitted to processor 512b from power source 516 via communication link 512a.

[0030] As shown in FIG. 5, power source 516 (e.g., a DC power supply) provides energy to lamp head assembly 508. As is understood by those skilled in the art, light producing elements (e.g., UV LEDs) are energized using energy provided by power source 516.

[0031] Although display 514 and power source 516 are illustrated as separate from one another, it should be understood that display 514 may be: local to power source 516; local to (and even included as part of) light source 520; or at a location distinct from both of light source 520 and power source 516.

[0032] FIG. 6 is a flow diagram in accordance with certain exemplary embodiments of the invention. As is understood by those skilled in the art, certain steps included in the flow diagram may be omitted; certain additional steps may be added; and the order of the steps may be altered from the order illustrated.

[0033] Referring specifically to the flow diagram in FIG. 6, a method of operating a manifold assembly for providing a cooling fluid is provided. The manifold assembly is configured for use with a light source. At Step 600, a cooling fluid (e.g., water from a chiller) is provided to a manifold assembly (such as manifold assembly 100 shown in FIGS. 1-3, manifold assembly 504 shown in FIG. 5, etc.) for cooling a light source (e.g., a UV LED light source for performing curing operations). At Step 602, at least one characteristic of the cooling fluid at the manifold assembly is sensed using at least one sensor (e.g., a pressure sensor for sensing a pressure of the cooling fluid, an inlet flow sensor for sensing a flow value of the cooling fluid into the fluid manifold, an outlet flow sensor for sensing a flow value of the cooling fluid out of the fluid manifold, a temperature sensor for measuring a temperature of the cooling fluid in the manifold assembly, and a pH sensor for measuring a pH of the cooling fluid in the manifold assembly). At Step 604, data including information related to the at least one characteristic sensed by the at least one sensor is transmitted to a microprocessor (e.g., microprocessor 130 in FIG. 3, processor 512b shown in FIG. 5, etc. ) included in the manifold assembly. At Step 606, the data transmitted in step 604 is compared to predetermined criteria - where the predetermined criteria may include an acceptable (or unacceptable) threshold level, an acceptable (or unacceptable) range, etc. For example, the data transmitted may be formatted (e.g., mathematically manipulated) for comparison to the predetermined criteria. At Step 608, a flow of the cooling fluid is controlled based on the results of step 606. For example, if it is determined that there is a leak in the cooling fluid system of the manifold assembly (e.g., as determined by a pressure value, provided by a cooling fluid pressure sensor in the manifold assembly, being outside of an acceptable predetermined range), the lamp head may be shut down (e.g., by a central processing unit of the power source, such as power source 516 in FIG. 4), and flow of the cooling fluid may be stopped (e.g., by closure of one or more valves in the manifold assembly such as valve 110 shown in FIGS. 1-3). The comparison in Step 606 may be accomplished by the microprocessor at the manifold assembly (e.g ., microprocessor 130 in FIG. 3), or by another microprocessor (e.g., a central processing unit at the power source).

[0034] Thus, as described herein, embodiments of the disclosure may provide a proactive approach to the chiller by building an intelligent manifold system. The intelligent manifold system can proactively monitor key indicators to ensure the health of the system, promote safety, and permit users to schedule maintenance for their systems. Performance of the cooling fluid source (e.g., the chiller) may also be monitored.

[0035] Certain embodiments of the invention may provide one or more of the following advantages. A modular manifold assembly, and a modular light source including the manifold assembly, is provided, which has application in a variety of applications, and with a variety of cooling fluid sources. The invention provides a proactive approach to manifold assembly maintenance because (i) of the monitoring of the various fluid characteristics of the manifold assembly, and/or (ii) because of the information available in the static memory device (e.g., an EEPROM) at the fluid manifold (e.g., maintenance instructions related to the manifold assembly, for example, a filter change being needed). The invention provides real time data monitoring, and may be used to ensure substantially uniform flow distribution. The invention may include embodiments where both an inlet and an outlet cooling fluid temperature is sensed, for example, to determine if the chiller is malfunctioning or is underrated. As described above, if the cooling fluid lines are damaged (e.g., cut), a valve(s) may be used to shut off the cooling fluid to and from the lamp head assembly. Likewise, if the lamp head assembly is off, the valve(s) may be used to close the supply of cooling fluid, thereby saving energy.

[0036] Although the invention is primarily described in connection with a processor at a printed circuit board of the manifold assembly, it is understood that the processor may be located at another location of the light source such as, for example, a circuit board including the lamp head driver circuitry. Further, multiple circuit boards may be provided to include the various circuit elements of the manifold assembly.

[0037] Although the invention has largely been described in connection with solid state light sources, it is not limited thereto. That is, the teachings of the invention may be applied to a wide range of light source systems including any system utilizing active cooling, and that preferably is enables by continuous monitoring of characteristics of the light source system and/or a cooling system of the light source system.

[0038] Although the invention is illustrated and described herein with reference to specific embodiments, the invention is not intended to be limited to the details shown. Rather, various modifications may be made in the details within the scope and range of equivalents of the claims and without departing from the invention.