Remote adhesive monitoring system

A method for remotely monitoring an adhesive applied to workpieces moving at a predetermined speed in a process direction on a production line having a reservoir, a pump, and an applicator, the method comprising:

• weighing the adhesive applied to the workpieces;
• providing an applicator sensor for sensing the adhesive applied to the workpieces;
• providing a workpiece sensor for sensing the workpieces moving;
• providing a monitor control and an associated data processing program;
• calculating an ON time for applying the adhesive per each workpiece at said predetermined speed with the monitor control using input from the applicator sensor and the workpiece sensor;
• providing a pump cycle sensor for sensing pump cycles;
• calculating workpieces per pump cycle with the monitor control using input from the workpiece sensor and the pump cycle sensor;
• calculating an ON time to TOTAL time ratio, defined as ON ratio, per each workpiece with the monitor control;
• calculating an amount of adhesive used for said ON ratio with the monitor control;
• varying the line speed over a range of different speed values;
• measuring workpieces per unit of time at each speed value over the range of different speed values with the workpiece sensor;
• calculating workpieces per pump cycle;
• calculating an ON time for applying the adhesive per each workpiece at each speed value over the range of different speed values;
• calculating an ON ratio per each workpiece at each speed value over the range of different speed values;
• calculating weight of adhesive applied per pump cycle at each ON ratio corresponding to each respective speed value;
• plotting weight of adhesive applied per pump cycle at each ON ratio, thereby calibrating the system for each ON ratio;
• and
• monitoring the weight of adhesive applied at a selected ON ratio, with the monitor control.