Patent Publication Number: US-2020301454-A1

Title: Device, system, and method for tracking the configuration or operational history of a nozzle in a fluid jetting system

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application is a continuation of U.S. patent application Ser. No. 14/388,468, filed Sep. 26, 2014, which is a U.S. National Phase of International Patent Application No. PCT/US2013/023536, filed Jan. 29, 2013, which claims priority to U.S. Provisional Application No. 61/636,485, filed Apr. 20, 2012, the entire disclosures of each of which are hereby incorporated by reference as if set forth in their entirety herein. 
    
    
     TECHNICAL FIELD 
     The present invention generally relates to fluid material dispensing systems, and more particularly, to systems and methods for tracking the configuration or operational history of a nozzle used in a fluid jetting system. 
     BACKGROUND 
     Fluid dispensing systems, for dispensing liquid or viscous materials, have become an integral part of the electronics manufacturing process for depositing underfill, encapsulants, solder fluxes, surface mount adhesives, conformal coatings, and other viscous materials onto a substrate, such as a printed circuit board. One type of fluid dispensing system operates by forcing a measured quantity of the fluid to be deposited through an aperture, or nozzle, to generate one or more droplets of the fluid that release from the nozzle without wetting the substrate and are deposited on the substrate. Fluid dispensing systems of this type, which are commonly known as jetting dispensers, typically include a replaceable nozzle that is coupled to a fluid applicator. The applicator includes a fluid chamber and a valve that work cooperatively to provide the forced quantity of fluid to the nozzle. To allow fluid to be dispensed in selected locations on the substrate, the applicator is typically coupled to a fluid dispensing machine by an X-Y positioner, although systems may also use mechanisms that move the substrate relative to the applicator. A system controller is coupled to the X-Y positioner and applicator valve, and provides a means of controlling the deposition of fluids on the substrate by selectively activating the X-Y positioner and the valve. 
     Typically, the valve includes an elongated member, or needle, with a tip configured to selectively engage a valve seat. During a jetting operation, the needle is moved relative to the valve seat by a driving mechanism. Contact between the tip of the needle and the valve seat seals off a discharge passage in the valve seat from the fluid chamber, which is supplied with fluid material under pressure. To dispense droplets of the fluid material, the needle is retracted from contact with the valve seat to allow a finite amount of the fluid material to flow through the newly formed gap and into the discharge passage. The tip of the needle is then moved rapidly toward the valve seat to close the gap, which generates pressure that accelerates the finite amount of fluid material through the discharge passage and causes a droplet of the material to be ejected, or jetted, from an outlet of the discharge passage. 
     The fluid dispensing machine is configured to provide controlled movements of the applicator above the substrate as the fluid material is jetted to land on an intended application area of the substrate. By rapidly jetting the material “on the fly” (i.e., while the jetting device is in motion), the dispensed droplets may be joined to form a continuous line or other pattern. Fluid dispensing machines with applicators may therefore be easily programmed to dispense a desired pattern of droplets of fluid material. This versatility has made jetting fluid dispensing systems suitable for a wide variety of applications in the electronics industry. For example, underfill material can be applied using a jetting dispenser to dispense fluid material proximate to one or more edges of the chip, with the material then flowing under the chip by capillary action. To allow the applicator to be adapted to different fluid dispensing operations, the nozzle is typically detachable from the applicator so that a nozzle can be selected and utilized which has the dispensing characteristics necessary for the desired dispensing operation or fluid type. 
     During a normal production run, the valve seat may be subjected to several million operation cycles. Over time, repeated contact between the valve needle and valve seat will cause valve seat to wear, altering the dimensions of the discharge passage. These changes in the discharge passage dimensions tend to alter the dispensing characteristics of the nozzle. In addition, the fluid may erode the nozzle discharge passage, further altering the shape, size, and uniformity of the droplets deposited by the applicator. These changes in the dispensing characteristics of the nozzle depend not only on the number of operation cycles, but also on the materials used to construct the valve seat, and the types of fluids being dispensed. For example, depositing fluids that have abrasive characteristics will typically cause the nozzle to wear out more quickly than depositing non-abrasive fluids. Likewise, a nozzle with a ceramic valve seat will typically have a different life expectancy than a nozzle with a metal valve seat. Thus, to maintain the desired fluid dispensing characteristics of the dispensing system, the nozzle must occasionally be replaced, with the required replacement time depending on the operational history of the nozzle. 
     Determining the operational history of a jetting dispenser may be difficult, however, because the nozzle may have been moved between different fluid dispensing machines over its lifetime, as well as used to dispense various fluids. Nozzles may therefore be replaced prematurely, or left in service too long, because system operators have lost track of the operational history of the nozzle. Nozzles that have been used to dispense one type of fluid may also be inadvertently attached to a fluid dispensing machine used to deposit a different, incompatible type of fluid. These errors may result in unnecessary expenses from replacing nozzles that have not yet worn out and from substrates that must be discarded or recycled due to improper fluid deposition. 
     Thus, there is a need for improved devices, systems, and methods of tracking the configuration or operational history of nozzles, such as jetting dispenser nozzles, and for determining when nozzles have reached the end of their operational lifetimes. 
     SUMMARY 
     In one embodiment, an apparatus is provided for use with an applicator. The apparatus includes a nozzle configured to be removably coupled to the applicator and to receive amounts of fluid therefrom, and having an outlet through which the amounts of fluid are discharged. The apparatus further includes a communication device coupled to the nozzle that includes a memory and that is configured to transmit a response signal containing data residing in the memory in response to receiving a query signal. 
     In another embodiment, a system is provided for use with a nozzle configured to receive and dispense amounts of fluid through an outlet, and that has a communication device with a memory and that is configured to transmit a response signal containing data residing in the memory in response to receiving a query signal. The system includes an applicator configured to removably receive the nozzle, and an interrogation device configured to transmit the query signal to the communication device of the nozzle. 
     In another embodiment, a method of using a nozzle is provided. The method includes receiving a query signal in a communication device coupled to the nozzle, and in response to receiving the query signal, transmitting a response signal containing data residing in a memory of the communication device. 
     In another embodiment, a nozzle for use with an applicator for fluid or viscous materials is provided. The nozzle includes an inlet through which the fluid or viscous material is received and an outlet through which amounts of the fluid or viscous material are discharged. The nozzle further includes a communication device coupled to the nozzle that includes a memory. The communication device is configured to transmit a response signal containing data residing in the memory in response to receiving a query signal. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate various embodiments of the invention and, together with the general description of the invention given above, and the detailed description of the embodiments given below, serve to explain the embodiments of the invention. 
         FIG. 1  is a diagrammatic illustration of a fluid dispensing machine including an applicator, a nozzle, and a system controller. 
         FIG. 2  is a schematic block diagram illustrating the system controller, applicator, and nozzle of  FIG. 1  with a communication device and an interrogation device. 
         FIG. 3A  is a schematic block diagram of the communication device and the interrogation device of  FIG. 2 . 
         FIG. 3B  is a schematic block diagram of the communication device and the interrogation device of  FIG. 2  for an alternative embodiment of the invention. 
         FIG. 4  is a flowchart illustrating an operation of the fluid dispensing machine in  FIG. 1   
     
    
    
     DETAILED DESCRIPTION 
     Embodiments of the invention are directed to a nozzle that includes a communication device configured to receive and transmit data relating to the nozzle, such as operational history data or configuration data, as well as systems and methods of communicating with the communication device. To this end, the communication device includes a memory that allows the nozzle to maintain a record of the operational history of the nozzle and as well as store data relating to the nozzle configuration. The communication device communicates with other fluid dispensing system components, such as a fluid dispensing machine or inventory management system, which may exchange data relating to the operational history of the nozzle with the communication device. The operational history data may include one or more parameters relating to a previous operation of the nozzle, and may be stored in the memory to maintain an accessible and accurate record of the operational history of the nozzle. The operational history parameters may include, but are not limited to: a cumulative number of operation cycles the nozzle has experienced (i.e., a number of times that the valve has opened and closed), an identity of a fluid dispensing machine or applicator to which the nozzle has been coupled, or a type of fluid or viscous material that has been dispensed by the nozzle. The memory may also store data that includes parameters relating to the configuration of the nozzle. These nozzle configuration parameters may include a size of an opening in a valve seat of the nozzle, a type of material of which a valve seat of the nozzle is comprised, or a nozzle identifier, e.g., a nozzle serial or model number. In an embodiment of the invention, the communication device may be a radio frequency identification (RFID) tag that communicates wirelessly with the other fluid dispensing system components via one or more RFID tag readers. 
     Referring now to the figures,  FIG. 1  illustrates an exemplary fluid dispensing machine  10  of a type that is commercially available from the Asymptotic Technologies, Inc, doing business as Nordson Asymtek, of Carlsbad, Calif. The fluid dispensing machine  10  includes a rectangular frame  12  made of interconnected horizontal and vertical steel beams. The rectangular frame  12  provides support for the main components of the fluid dispensing machine  10 , which include an X-Y positioner  14 , a system controller  16 , a working surface  18 , a control panel  20 , a system display  22  and an interrogation device  24 . An applicator  26  may be operatively coupled to the X-Y positioner  14 , and includes a fluid source  28 , such as a syringe, that supplies the fluid to be dispensed by the machine  10 . The applicator  26  may be coupled to the X-Y positioner  14  by a Z-axis drive (not shown) to move the applicator  26  vertically up and down, so that the applicator  26  can be selectively positioned in three axes relative to the working surface  18  by the system controller  16 . The working surface  18  may also be part of a conveyer system (not shown) that delivers substrates, such as PC boards, to the fluid dispensing machine  10 . The working surface  18  may also include one or more service stations, such as a priming station  30 , a calibration station  32 , and a communication station  34 . 
     Referring now to  FIG. 2 , the system controller  16  includes a processor  36 , a memory  38 , and an input/output (I/O) interface  40 . The processor  36  may include one or more devices selected from microprocessors, micro-controllers, digital signal processors, microcomputers, central processing units, field programmable gate arrays, programmable logic devices, state machines, logic circuits, analog circuits, digital circuits, or any other devices that manipulate signals (analog or digital) based on operational instructions that are stored in the memory  38 . Memory  38  may be a single memory device or a plurality of memory devices including but not limited to read-only memory (ROM), random access memory (RAM), volatile memory, non-volatile memory, static random access memory (SRAM), dynamic random access memory (DRAM), flash memory, cache memory, or any other device capable of storing digital information. Memory  38  may also include a mass storage device (not shown) such as a hard drive, optical drive, tape drive, non-volatile solid state device or any other device capable of storing digital information. 
     Processor  36  may operate under the control of an operating system  42  that resides in memory  38 . The operating system  42  may manage the system controller resources so that computer program code embodied as one or more computer software applications, such as a controller application  44 , residing in memory  38  may have instructions executed by the processor  36 . In an alternative embodiment, the processor  36  may execute the applications directly, in which case the operating system  42  may be omitted. The I/O interface  40  operatively couples the processor  36  to the interrogation device  24 , a valve driver circuit  46 , and the X, Y and Z drives  48 . The I/O interface  40  may also employ one or more suitable communication protocols for communicating with other external devices or networks, such as a TCP/IP protocol over a IEEE 802.3 (Ethernet) or 802.11 (Wi-Fi) connection, or one or more RS-232 and SMEMA CIM communications busses that are compatible with most types of automated equipment utilized in substrate production assembly lines. 
     A user interface  50  may be operatively coupled to the processor  36  of system controller  16  in a known manner to allow a system operator to interact with the system controller  16 . To this end, the user interface  50  may include the system display  22 , as well as other output devices, such as alphanumeric displays, a touch screen, a speaker, and other audio and visual indicators. The user interface  50  may also include the control panel  20 , as well as other input devices and controls such as an alphanumeric keyboard, a pointing device, keypads, pushbuttons, control knobs, microphones, etc., capable of accepting commands or input from the operator and transmitting the entered input to the processor  36 . 
     The system controller  16  is configured to move the applicator  26  in a controlled manner via selective activation of the X-Y-Z axes drives  48 , thereby rapidly moving the applicator  26  over the working surface  18 . To this end, the X-Y-Z axes drives  48  may include the electro-mechanical components of the X-Y positioner  14  and a Z-axis drive mechanism to provide X, Y and Z axes of motion, respectively. 
     The applicator  26  may be implemented using different designs, and persons having ordinary skill in the art will understand that embodiments of the invention are not limited to the particular applicator configuration described herein. U.S. Pat. No. 8,074,467, the disclosure of which is hereby incorporated by reference in its entirety, shows an example of an applicator that could be used with this invention. The exemplary applicator  26  illustrated in  FIG. 2  includes a nozzle  52  removeably coupled to an applicator body  54 . The nozzle  52  includes a fluid inlet  55 , a valve seat  56  having an opening defining a fluid discharge passage  58 , and a communication device  60 . The applicator body  54  includes a fluid chamber  62  fluidically coupled to the fluid source  28 , and a valve member  64  in the form of a pin or needle that moves reciprocally in a channel  66  in response to urging by a valve driver or actuation mechanism  68 . The actuation mechanism  68  may comprise an electro-mechanical device, such as a piezoelectric drive module or a solenoid. The actuation mechanism  68  may also be an electro-pneumatic device, such as a pneumatic piston coupled to one or more pneumatic solenoids or other suitable device that provides a controlled source of a pressurized fluid. In any case, persons having ordinary skill in the art will understand that any suitable device may be used for the actuation mechanism  68 , and that embodiments of the invention are not limited to a particular type of device. The nozzle  52  may be one of the modular nozzles shown and described in U.S. patent application Ser. No. 13/219,064, filed Aug. 26, 2011 and titled “Modular Jetting Devices, the disclosure of which is hereby incorporated by reference herein in its entirety. 
     A fluid dispensing operation or operation cycle may be initiated by the system controller  16  providing an output pulse signal to the valve driver circuit  46 , which is configured to provide a signal suitable for activating the actuation mechanism  68 . By way of example, in the case of a pneumatic actuation mechanism, motion may be imparted to the valve member  64  by a piston (not shown) located in an air cylinder (not shown) and coupled to the valve member  64 . To operate the valve, the valve driver circuit  46  may port a pulse of pressurized air into the air cylinder in response to the output pulse from the controller  16 . This air pulse may produce a rapid lifting of the piston, which in turn provides upward motion to the valve member  64 . This upward motion of the valve member  64  may allow fluid from the fluid chamber  62  to flow into a space between the discharge passage  58  and the valve member  64 . When the output pulse signal ceases, the pressurized air is released from the air cylinder. In response, a return spring (not shown) may rapidly push the valve member  64  back into contact with the valve seat  56 . The rapid motion of the valve member  64  into contact with the valve seat  56  may cause the fluid in the discharge passage  58  or between the valve member  64  and discharge passage  58  to be rapidly extruded or jetted through the discharge passage  58 . Rapid successive cycling (i.e. opening and closing) of the valve member  64  as the applicator  26  is moved about by the X-Y positioner  14  under control of the system controller  16 , selectively deposits droplets of fluid at selected locations of a substrate placed on the working surface  18 . 
     Referring now to  FIGS. 3A and 3B , the interrogation device  24  and communication device  60  each include an I/O interface  70 ,  72 . The device I/O interfaces  70 ,  72  may be comprised of connection interfaces that are electrically, magnetically, or electromagnetically coupled when the applicator  26  is positioned in the communication station  34 . To this end, the communication station  34  and nozzle  52  may be configured so that the interrogation device  24  and communication device  60  are in close proximity, such as within 20 mm, when the applicator  26  is located in the communication station  34 . The I/O interfaces  70 ,  72  shown in  FIG. 3A  may thereby be conductively coupled (e.g., in physical contact), capacitively coupled, or inductively coupled by positioning the applicator  26  in the communication station  34 . In an alternative embodiment of the invention illustrated in  FIG. 3B , the I/O interfaces  70 ,  72  may be comprised of transceivers  74 ,  76  coupled to antennas  78 ,  80 , respectively, which may be in the form of a coil or conductive patch. In this alternative embodiment, the devices  24 ,  60  may exchange data via radio frequency signals. Devices of this type are commonly referred to as RFID tags (in the case of the communication device  60 ) or RFID tag readers (in the case of the interrogation device  24 ). In an alternative embodiment of the invention in which the devices  24 ,  60  use radio frequency signals having sufficient strength, the devices  24 ,  60  may exchange data while the applicator  26  is not located in the communication station  34 . The interrogation device  24  may include a controller circuit  82  configured to process signals from the controller  16  into a form suitable for transmission via the I/O interface  70 , and to likewise process signals received from the I/O interface  70  into a form suitable for transmission to the system controller  16 . 
     The communication device  60  may include a power supply  84 , a memory  86 , and a memory controller  88 . The power supply  84  may be a circuit coupled to the I/O interface  72 , and is configured to provide power to the circuits in the communication device  60 , including the transceiver  76  (if present), the memory  86 , and the memory controller  88 . In an embodiment of the invention, the power supply  84  obtains power from a query signal  90  that is transmitted to the communication device  60  from the interrogation device  24 . The power supply  84  may rely exclusively on the power obtained from the query signal  90  to power the communication device  60 , or the power supply  84  may include an internal source of power, such as a battery or capacitor (not shown). This internal power source, if present, may be used to augment power obtained from the query signal  90 , or may be used to power the communication device  60  independently of any external sources of power. 
     The query signal  90  may contain data that is decoded or processed by the transceiver  76  or memory controller  88  and stored in memory  86 . The data stored in the memory  86  may include data relating to a previous operation of the nozzle  52 , and may be updated in response to receiving the query signal  90 . To this end, the data updated in the memory  86  may include data relating to a cumulative number of operation cycles to which the nozzle  52  has been subjected, an identity of a fluid dispensing machine  10  or applicator  26  to which the nozzle has been removably coupled, or a type of fluid that has been dispensed by the nozzle  52 . The data may be stored in memory using any suitable protocol, such as a first in-first out (FIFO) memory location selection method. The data may also be written to predetermined regions of the memory  86  based on the content or type of data being stored. For example, data having a header indicating that the data is user specific or user defined data may be written to a region in the memory  86  reserved for a user definable field. Similarly, data relating to a particular event or parameter, e.g., a previous or cumulative number of operation cycles to which the nozzle  52  has been subjected, may be written to a specific location in memory  86  reserved for that data. 
     Similarly, the data in the query signal  90  may include operational history parameters relating to dispensing operations performed by the nozzle  52 . For example, the query signal data may relate to a number of operation cycles to which the nozzle  52  has been subjected during one or more fluid dispensing operations. The one or more dispensing operations may include all the operation cycles since the nozzle  52  was first coupled to the fluid dispensing machine  10 , since a previous query signal  90  was sent to the communication device  60 , or that were performed in a particular dispensing operation. The data may also relate to a cumulative number of operation cycles representing a sum of: (1) a previous number of times the nozzle  52  or the valve seat  56  has experience an operation cycle, which may have been obtained from memory  86  by the system controller  16  at a time the nozzle  52  was coupled to the dispensing machine  10  or in response to entering a production mode; and (2) an additional number of operation cycles representing the number of operation cycles experienced by the nozzle  52  or valve seat  56  since the previous number of operation cycles was obtained from memory  86 . Data representing the cumulative number of operation cycles to which the nozzle  52  has been subjected over the lifetime of the nozzle  52  may thereby be maintained in the memory  86  as the nozzle  52  is moved between multiple fluid dispensing machines  10 . The data contained in the query signal  90  may also include data relating to one or more types of fluid that have been dispensed by the nozzle  52 , a serial number or other identifier of the fluid dispensing machine  10  or applicator  26 , or any other data relating to the operational history of the nozzle  52 . 
     In response to receiving the query signal  90 , the communication device  60  may transmit a response signal  92 . The response signal  92  may contain data read from the memory  86 , which may include data read from both read-only and writable regions of the memory  86 . Data transmitted in the response signal  92  may include nozzle configuration data such as, but not limited to: a size of an opening in the valve seat  56 , a type of material comprising the valve seat  56 , or an identifier of the nozzle  52 , such as a serial or model number. The data in the response signal  92  may also include data regarding the operational history of the nozzle  52 , such as but not limited to: a cumulative number of operation cycles to which the valve seat  56  has been subjected, an identifier of a fluid dispensing machine  10  or applicator  26  to which the nozzle  52  has been coupled, or a type of fluid that has been dispensed by the nozzle  52 . 
     Referring to  FIG. 4 , flow chart  100  illustrates execution of an exemplary production mode program by the system controller  16  that causes the fluid dispensing machine  10  to deposit fluids on a substrate in a desired manner or pattern. In block  102 , the fluid dispensing machine  10  enters a production mode. The production mode may be entered in response to the system operator initiating execution a fluid dispensing program, such as controller application  44 , residing in the system controller memory  38 . The production mode may be entered subsequently or in response to coupling a nozzle  52  to the applicator  26 , or may be entered using a nozzle  52  already coupled to the applicator  26 . In response to entering the production mode, the system controller  16  may proceed to block  104 . In block  104 , the system controller  16  may position the applicator  26  in the communication station  34  via selective activation of the X-Y-Z drives. In response to the applicator  26  being positioned in the communication station  34 , the system controller  16  may proceed to block  106 . 
     In block  106 , the system controller  16  may transmit the query signal  90  via the interrogation device  24 . As previously discussed with respect to  FIGS. 3A and 3B , the query signal  90  may provide power that activates the communication device  60 , and may contain data relating to the fluid to be dispensed by the fluid dispensing machine  10 , an identifier of the fluid dispensing machine  10  or applicator  26 , instructions on what data to include in the response signal  92 , or any other suitable data regarding the operation of the fluid dispensing machine  10  or nozzle  52 . In an alternative embodiment of the invention, the system controller  16  may transmit the query signal  90  in response to entering the production mode without first positioning the applicator  26  in the communication station  34 . This alternative embodiment may be used if, for example, the interrogation device  24  is an RFID tag reader that transmits a query signal  90  having sufficient power to activate the communication device  60  without the communication device  60  being in close proximity to the interrogation device  24 . 
     In block  108 , and in response to receiving the query signal  90 , the communication device  60  may decode the data in the query signal  90 , optionally store the data in memory  86 , and transmit a response signal  92 . The response signal  92  may contain data residing in memory  86 , such as the size of the opening in the valve seat  56 , the type of material comprising the valve seat  56 , an identifier of the nozzle  52  such as a serial or model number, one or more types of fluids that have been dispensed by the nozzle  52 , the previous or cumulative number of operation cycles to which the nozzle  52  or valve seat  56  has been subjected, a user defined parameter, or any other data regarding the configuration or operational history of the nozzle  52 . 
     In block  110 , the interrogation device  24  receives and decodes the data in the response signal  92 . This data may be provided to the system controller  16  and used to adjust the operation of the fluid dispensing machine  10 . For example, the number of operation cycles to which the nozzle  52  has been subjected may be stored in a nozzle operation cycle register residing in the system controller memory  38 . This register may be used by the system controller  16  in determining when the nozzle  52  has reached the end of the nozzle&#39;s service life. 
     In block  112 , the system controller  16  determines if the nozzle  52  is compatible with the dispensing operations required by the production mode based on the data received in the response signal  92 . This compatibility determination may be based on a number of compatibility checks, such as, but not limited to: (1) checking the compatibility between the fluids previously dispensed by the nozzle  52  and the fluid to be dispensed while in the current production mode; and (2) checking the compatibility between the configuration of the nozzle  52  and the requirements of the current production mode. If the system controller  16  determines that the nozzle  52  is not compatible with the requirements of the current production mode (“NO” branch of decision block  112 ), the system controller  16  may reject the nozzle  52  by proceeding to block  114 . In block  114 , the system controller  16  stops the dispensing operation and alerts the system operator. This alert may be, for example, in the form of an error message presented on the system display  22  that informs the system operator of the nature of the problem. In an alternative embodiment of the invention, the system controller  16  may also determine if the nozzle  52  will last long enough to complete the production mode as part of the compatibility determination. This determination may be based on the previous number of operation cycles to which the nozzle  52  has been subjected and the expected number of operation cycles required by the production mode. If the nozzle  52  is not expected to last for the duration of the production mode, the system controller  16  may stop the dispensing operation and alert the operator by proceeding to block  114  as described above. 
     If the system controller  16  determines that the nozzle  52  is compatible with the requirements of the current production mode (“YES” branch of decision block  112 ), the system controller  16  may proceed to block  116 . In block  116 , the system controller  16  compares the cumulative number of times the nozzle  52  has been subjected to an operation cycle to a maximum number of operation cycles allowed by the production mode, i.e., a lifetime number of cycles. The lifetime number of cycles may depend on the type of valve seat  56  in the nozzle  52  (e.g., the valve seat material), the types of fluids that have been dispensed by the nozzle  52  (e.g., abrasive fluids or non-abrasive fluids), as well as the tolerance of the current production mode to variations in dot size produced by the nozzle  52 . For example, a nozzle  52  used to dispense abrasive fluids might be considered worn out after 20 million operation cycles, while a nozzle  52  used to dispense non-abrasive fluids might not be considered worn out until after 100 million operation cycles. In response to a determination that the cumulative number of times the nozzle  52  has been subjected to an operation cycle exceeds the lifetime number of cycles allowed by the production mode and nozzle history (“YES” branch of decision block  116 ), the system controller  16  may proceed to block  114 , thereby stopping the dispensing operation and issuing an alert as previously described. 
     In response to a determination that the cumulative number of times the nozzle  52  has been subjected to an operation cycle does not exceed the lifetime number of cycles allowed by the production mode (“NO” branch of decision block  116 ), the system controller  16  may proceed to block  118 . In block  118 , the system controller  16  may cause the fluid dispensing machine  10  to perform a fluid dispensing operation. The fluid dispensing operation may be executed by the system controller  16  issuing one or more signals or commands to the applicator  26  and X-Y-Z axis-drives  48 . In response to these signals or commands, the valve member  64  may be cycled and the applicator  26  moved relative to the substrate so that fluid is dispensed on the substrate in a desired area. 
     In response to completion of the dispensing operation, the system controller  16  may proceed to block  120 . In block  120 , the system controller  16  increments the nozzle operation cycle register, which may reside in the system controller memory  38 , by adding the cycles performed in the dispensing operation to the preexisting number of cycles. The system controller  16  may thereby track the cumulative number of operation cycles to which the nozzle  52  has been subjected. 
     In block  122 , the system controller  16  determines if the production mode has completed. For example, the production mode may be completed when the fluid dispensing machine  10  has finished processing of one or more substrates or a batch of substrates. In response to the production mode not being completed (“NO” branch of decision block  122 ), the system controller  16  may return to block  116  where the controller  16  compares the number of operation cycles indicated by the value stored in the nozzle operation cycle register to the lifetime number of cycles allowed by the production mode. The system controller  16  may thereby monitor the number of operation cycles on the nozzle  52  during operation of the fluid dispensing machine  10  so that the dispensing operation may be stopped in response to the nozzle  52  reaching the end of the nozzles&#39; service life. In response to completion of the production mode (“YES” branch of decision block  122 ), the system controller  16  proceeds to block  124  and exits the production mode before proceeding to block  126 . 
     In block  126 , and in response to exiting the production mode, the system controller  16  may position the applicator  26  at the communication station  34 . In response to the applicator  26  being positioned at the communication station  34 , the system controller  16  transmits a query signal  90  containing data relating to dispensing operations conducted during the just completed production mode. This data may include an updated cumulative total number of cycles that the valve has performed, as well as information on one or more fluids dispensed by the nozzle  52  while the fluid dispensing machine  10  was in the production mode. In response to receiving the query signal  90 , the communication device  60  may update data stored in the memory  86  of communication device  60  so that the data is available for later use. In an alternative embodiment of the invention, the system controller  16  may transmit the query signal  90  in response to exiting the production mode without first positioning the applicator  26  in the communication station  34 . As discussed previously, this alternative embodiment may be use if, for example, the interrogation device  24  is an RFID tag reader that transmits a query signal having sufficient power to activate the communication device  60  without the communication device  60  being in close proximity to the interrogation device  24 . 
     An operational history of the nozzle  52  may thereby be maintained in the memory  86  of the communication device  60 . This data may used to adjust or control operation of fluid dispensing machines  10  to which the nozzle  52  has been coupled, such as described with respect to  FIG. 4 . The operational history data may also be downloaded to a consumable parts system or process improvement database maintained by the system operator. Using the data stored in the communication device  60 , these systems may associate processed substrates with specific dispensing operations or program modes performed by specific fluid dispensing machines  10 , applicators  26 , or nozzles  52 . Embodiments of the invention may thereby facilitate correlating production yield issues to a particular fluid dispensing machine  10 , applicator  26 , nozzle  52 , or process. In addition, more accurate models for predicting nozzle lifetime based on number of operation cycles or types of fluids dispensed may be developed by correlating operational nozzle histories to actual nozzle performance. More accurate tracking of remaining nozzle lifetimes may also allow better inventory management by providing system operators with more accurate forecasts of the demand for replacement nozzles. 
     References herein to terms such as “vertical”, “horizontal”, “upper”, “lower”, “raise”, “lower”, etc. are made by way of example, and not by way of limitation, to establish a frame of reference. It is understood by persons of ordinary skill in the art that various other frames of reference may be equivalently employed for purposes of describing the embodiments of the invention. 
     It will be understood that when an element is described as being “attached”, “connected”, or “coupled” to or with another element, it can be directly connected or coupled to the other element or, instead, one or more intervening elements may be present. In contrast, when an element is described as being “directly attached”, “directly connected”, or “directly coupled” to another element, there are no intervening elements present. When an element is described as being “indirectly attached”, “indirectly connected”, or “indirectly coupled” to another element, there is at least one intervening element present. 
     The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms “a”, “an”, and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, or groups thereof. Furthermore, to the extent that the terms “includes”, “having”, “has”, “with”, “composed of”, or variants thereof are used in either the detailed description or the claims, such terms are intended to be inclusive in a manner similar to the open-ended term “comprising.” 
     While the present invention has been illustrated by a description of various embodiments and while these embodiments have been described in considerable detail, it is not the intention of the applicants to restrict or in any way limit the scope of the appended claims to such detail. Additional advantages and modifications will readily appear to those skilled in the art. The invention in its broader aspects is therefore not limited to the specific details, representative apparatus and method, and illustrative example shown and described. Accordingly, departures may be made from such details without departing from the spirit or scope of applicants&#39; general inventive concept.