Electrostatic gun driver and method for implementing electrostatic gun driver

Abstract

An electrostatic gun driver (100) includes an inverter (102) configured to receive power from a power source (104). The electrostatic gun driver (100) also includes a controller (106) configured to control the inverter (102). The electrostatic gun driver (100) also includes a filter (108) configured to generate a sine wave drive signal and provide the sine wave drive signal to the material application system (200) and / or the material application device (210).

Description

Cross - Reference to Related Applications

[0001] This application claims the benefit of U.S. Provisional Application No. 63 / 420,968, filed on October 31, 2022, the entire content of which is incorporated herein by reference as if fully set forth herein. Technical Field

[0002] The present disclosure relates to an electrostatic gun driver. In addition, the present disclosure also relates to a method of implementing an electrostatic gun driver. Background Art

[0003] Powder coating materials (such as powder paint) are typically applied to an object by spraying. A spray gun or a material application device is usually used, and the spray gun can be manually held and operated, or an electronically controlled automatic spray gun can be used. For example, spraying techniques include electrostatic, non - electrostatic, triboelectric, etc.

[0004] Generally, as Figure 13 shown, an electrostatic gun driver circuit uses a DC power supply and provides a drive waveform for the spray gun. In particular, the DC power supply is used together with a boost converter power stage (such as a flyback converter, a DC inverter, etc.) to provide a pulse - width modulation (PWM) drive waveform to the spray gun. However, a typical electrostatic gun driver circuit has a low power efficiency. This results in waste heat generation. In addition, this requires a more expensive cooling device. In addition, a typical electrostatic gun driver circuit has a large form factor, which results in higher packaging costs. In addition, a typical electrostatic gun driver circuit requires the use of many electrical circuit components. This results in a larger - sized design and a higher - cost electrostatic gun driver circuit. In addition, a typical electrostatic gun driver circuit implements a square - wave PWM drive waveform that affects performance.

[0005] Therefore, there is a need for a driver circuit with improved power efficiency, less waste heat generation, a lower - cost cooling device, a smaller form factor, a smaller and lower - cost package, a reduced number of electrical circuit components, better performance, etc. Summary of the Invention

[0006] In one general aspect, an electrostatic gun driver includes an inverter configured to receive power from a power supply. The electrostatic gun driver further includes a controller configured to control the inverter. The electrostatic gun driver further includes a filter configured to generate a sine - wave drive signal and provide the sine - wave drive signal to a material application system and / or a material application device.

[0007] In one general aspect, a method includes: configuring an inverter to receive power from a power source. The method further includes configuring a controller to control the inverter. Additionally, the method includes generating a sine wave drive signal with a filter and providing the sine wave drive signal to a material application system and / or a material application device.

[0008] Accordingly, certain aspects of the present disclosure have been outlined rather broadly in order to better understand the detailed description of the present disclosure herein and to better understand the contribution to the art. Of course, other aspects of the present disclosure will be described below, which will form the subject matter of the appended claims.

[0009] In this regard, before explaining at least one aspect of the present disclosure in detail, it should be understood that the application of the present disclosure is not limited to the construction details and the arrangement of components set forth in the following description or shown in the drawings. The present disclosure is capable of having other aspects than those described, and the present disclosure is capable of being practiced and carried out in various ways. Further, it should be understood that the language and terminology used herein, as well as the abstract, are for descriptive purposes only and should not be regarded as limiting.

[0010] Accordingly, those skilled in the art will understand that the concepts on which the present disclosure is based can be readily used as a basis for designing other structures, methods, and systems to achieve several purposes of the present disclosure. Therefore, it is important that the claims be regarded as including such equivalent structures as long as they do not depart from the spirit and scope of the present disclosure. BRIEF DESCRIPTION OF THE DRAWINGS

[0011] Figure 1 A schematic diagram of an electrostatic gun driver implemented in a material application system in accordance with aspects of the present disclosure is shown.

[0012] Figure 2 A schematic diagram of an electrostatic gun driver implemented in a material application system in accordance with aspects of the present disclosure is shown.

[0013] Figure 3 An exemplary embodiment of an electrostatic gun driver and an inverter in accordance with aspects of the present disclosure is shown.

[0014] Figure 4 An exemplary embodiment of an electrostatic gun driver and an inverter in accordance with aspects of the present disclosure is shown.

[0015] Figure 5 A schematic diagram of an electrostatic gun driver in accordance with aspects of the present disclosure is shown.

[0016] Figure 6 A schematic diagram of an electrostatic gun driver in accordance with aspects of the present disclosure is shown.

[0017] Figure 7An exemplary embodiment of a filter according to aspects of the present disclosure is shown.

[0018] Figure 8 An exemplary embodiment of a filter according to aspects of the present disclosure is shown.

[0019] Figure 9 An exemplary embodiment of an inverter according to aspects of the present disclosure is shown.

[0020] Figure 10 An exemplary embodiment of an inverter according to Figure 9 is shown.

[0021] Figure 11 Exemplary waveforms of a sine wave drive signal and a modulation voltage pulse according to aspects of the present disclosure are shown.

[0022] Figure 12 An exemplary method of implementing an electrostatic gun driver of the present disclosure is shown.

[0023] Figure 13 An electrostatic gun driver circuit of the prior art is shown. DETAILED DESCRIPTION

[0024] The present disclosure will now be described with reference to the accompanying drawings, in which like reference numerals refer to like components throughout the drawings.

[0025] Figure 1 A schematic diagram of an electrostatic gun driver implemented in a material application system according to aspects of the present disclosure is shown.

[0026] In particular, Figure 1 a schematic diagram of an electrostatic gun driver 100 according to aspects of the present disclosure is shown. The electrostatic gun driver 100 may include an inverter 102, a controller 106, a filter 108, etc. In addition, Figure 1 aspects thereof and the description thereof may be implemented in any other drawing and / or aspect of the present disclosure. In addition, aspects of any other drawing and the description thereof may be implemented in Figure 1 aspects of.

[0027] In addition, Figure 1 a material application system 200 implementing an exemplary material application device 210 is shown. The electrostatic gun driver 100 is configured to generate a sine wave drive signal 190 and provide the sine wave drive signal 190 to the material application system 200 and / or the exemplary material application device 210. The inverter 102 of the electrostatic gun driver 100 may be configured to receive power from a power supply 104.

[0028] Compared with existing technology drivers, the disclosed embodiments of the electrostat gun driver 100 implementing the inverter 102 provide improved power efficiency, less waste heat generation, reduced cost of cooling devices, etc. for the electrostat gun driver 100, the material application system 200, etc. In addition, the disclosed embodiments of the electrostat gun driver 100 implementing the inverter 102 can achieve a smaller form factor, which results in smaller and lower-cost packaging options. In addition, the disclosed embodiments of the electrostat gun driver 100 implementing the inverter 102 can lead to a reduction in the number of electrical circuit component parts, which results in an electrostat gun driver circuit with the same or better (true sine wave) performance, a smaller size design, and lower cost compared to existing technology electrostat gun drivers. In particular, the disclosed embodiments of the electrostat gun driver 100 implementing the inverter 102 can generate a true sine wave.

[0029] In some aspects, the electrostat gun driver 100, the inverter 102, etc. can be implemented separately from the exemplary material application device 210. In other aspects, the electrostat gun driver 100, the inverter 102, etc. can be implemented within the exemplary material application device 210. In this regard, as described above, the disclosed aspects of the electrostat gun driver 100, the inverter 102, etc. are configured to be more compact and can thus be implemented within the exemplary material application device 210.

[0030] In some aspects, the inverter 102 can be implemented as a four-switch inverter that generates modulated voltage pulses 192 from a power source 104 (as Figure 11 shown). In some aspects, the controller 106 can implement a single-pole modulation scheme to control the gating of two diagonal switch pairs of the inverter 102 to generate pulses that are modulated to generate the modulated voltage pulses 192. The filter 108 filters and smooths the modulated voltage pulses 192 into a sine wave drive signal 190 (as Figure 11 shown) to drive the exemplary material application device 210.

[0031] In some aspects, the electrostatic gun driver 100 implementing the inverter 102, the controller 106, and / or the filter 108 can directly generate a sinusoidal drive signal 190 from the power supply 104 to have a peak-to-peak voltage sinusoid, such that the boost converter power stage, the flyback converter, the DC inverter, etc. can be eliminated from the design. This removal of the boost converter power stage, the flyback converter, the DC inverter, etc. improves the overall system efficiency of the electrostatic gun driver 100 and reduces the number of electrical component parts of the electrostatic gun driver 100. Additionally, the disclosed embodiments of the electrostatic gun driver 100 reduce the required circuit support substrate space, such as printed circuit board (PCB) space, which reduces the total cost and / or provides other benefits. Thus, in some aspects, the electrostatic gun driver 100 is configured without a boost converter power stage, a flyback converter, and a DC inverter. In some aspects, the electrostatic gun driver 100 is configured without a boost converter power stage; the electrostatic gun driver 100 is configured without a flyback converter; and / or the electrostatic gun driver 100 is configured without a DC inverter.

[0032] In some aspects, compared with the existing square wave waveform and / or non-sinusoidal waveform in the existing drive design, the electrostatic gun driver 100 implementing the inverter 102, the controller 106, and / or the filter 108 can generate a sinusoidal drive signal 190 as a sinusoidal multiplier drive waveform.

[0033] In some aspects, the electrostatic gun driver 100 and / or the inverter 102 generate a sinusoidal drive signal 190 having a specific frequency. The frequency of the sinusoidal drive signal 190 can be from 1 kHz to 1000 kHz, from 1 kHz to 25 kHz, from 25 kHz to 35 kHz, from 28 kHz to 32 kHz, from 35 kHz to 45 kHz, from 45 kHz to 90 kHz, or from 90 kHz to 100 kHz. In some aspects, the electrostatic gun driver 100 and / or the inverter 102 generate a sinusoidal drive signal 190 having a specific voltage and / or amplitude. The voltage of the sinusoidal drive signal 190 can be from 0 V peak-to-peak to 100 V peak-to-peak, from 0 V peak-to-peak to 30 V peak-to-peak, from 30 V peak-to-peak to 50 V peak-to-peak, from 50 V peak-to-peak to 60 V peak-to-peak, from 60 V peak-to-peak to 80 V peak-to-peak, or from 80 V peak-to-peak to 100 V peak-to-peak.

[0034] In some aspects, power supply 104 can be an industrial standard power supply. In some aspects, power supply 104 can be an industrial standard DC power supply. In some aspects, power supply 104 can be an industrial standard DC power supply that generates a DC voltage of 2 V to 100 V, 2 V to 20 V, 20 V to 30 V, 30 V to 60 V, or 60 V to 100 V.

[0035] Figure 1 An exemplary material application device 210 configured for implementation in conjunction with the electrostatic gun driver 100 is also shown. In this regard, the exemplary material application device 210 can be implemented as a manually operated material application device. However, the disclosed embodiments of the electrostatic gun driver 100 can also be implemented in combination with other types and embodiments of the exemplary material application device 210. For example, as Figure 2 shown, the exemplary material application device 210 can be a robotically operated embodiment. In the examples herein, the exemplary material application device 210 can be, for example, any suitable material application device, spray gun, powder spray gun, etc. However, it should be understood that the exemplary material application device 210 can be implemented in a variety of forms and is not limited to just spray guns and is not limited to that term.

[0036] The exemplary material application device 210 can include a nozzle portion 212, a barrel portion 214, an electrical cable 226, etc. The electrical cable 226 or electrical connection can be provided between the electrostatic gun driver 100, the control system 188, and / or similar devices and the electrical input 230 of the exemplary material application device 210. The material application system 200, the control system 188, and / or the electrostatic gun driver 100 can receive one or more signals from the exemplary material application device 210, such as a trigger actuation signal indicating that the operator has activated the actuation device 232. When the actuation device 232 is activated, an electrical signal or condition (such as a closed contact) is sent to or detected by the control system 188 to cause the coating material to start flowing towards the exemplary material application device 210, and other signals can be generated to activate the electrical power that can be provided by the electrostatic gun driver 100 for the exemplary material application device 210. All electrical signals or conditions between the exemplary material application device 210 and the control system 188 or other system components can be transmitted along electrical lines through the electrical cable 226.

[0037] Figure 2 A schematic diagram of an electrostatic gun driver implemented in a material application system in accordance with aspects of the present disclosure is shown.

[0038] In particular, Figure 2Shows an electrostatic gun driver 100 implemented in a material application system 200. In some aspects, the material application system 200 may include a robotic system 250 configured to operate within the material application system 200 and manipulate and move an exemplary material application device 210. Additionally, Figure 2 Aspects thereof and their descriptions may be implemented in any other figures and / or aspects of the present disclosure. Additionally, aspects of any other figures and their descriptions may be implemented in Figure 2 Aspects thereof.

[0039] In some aspects, the robotic system 250 may include one or more arms and one or more motors for moving the one or more arms, which may provide up to three or more axes of movement. Additionally, the one or more arms may hold the exemplary material application device 210. In some aspects, the one or more arms may include one or more suction cups, manipulators, and / or similar devices for grasping, moving, etc., the exemplary material application device 210. Additionally, the robotic system 250 may include a controller configured to control the operation of the various components of the robotic system 250. Additionally, the robotic system 250 may include a vision system configured to assist in identifying and locating objects within the material application system 200.

[0040] Figure 3 Shows an exemplary embodiment of an electrostatic gun driver and an inverter according to aspects of the present disclosure.

[0041] In particular, Figure 3 Shows an exemplary embodiment of an electrostatic gun driver 100, a filter 108, and an inverter 102 according to aspects of the present disclosure. Additionally, Figure 3 Aspects thereof and their descriptions may be implemented in any other figures and / or aspects of the present disclosure. Additionally, aspects of any other figures and their descriptions may be implemented in Figure 3 Aspects thereof.

[0042] More specifically, Figure 3 Shows that the electrostatic gun driver 100 is configured to generate a sine wave drive signal 190 and provide the sine wave drive signal 190 to the material application system 200 and / or the exemplary material application device 210. The inverter 102 of the electrostatic gun driver 100 may be configured to receive power from a power source 104. The inverter 102 generates a modulated voltage pulse 192, and the filter 108 receives the modulated voltage pulse 192 and generates the sine wave drive signal 190.

[0043] Figure 4 Shows an exemplary embodiment of an electrostatic gun driver and an inverter according to aspects of the present disclosure.

[0044] In particular,Figure 4 An exemplary embodiment of an electrostatic gun driver 100 and an inverter 102 in accordance with aspects of the present disclosure is shown. Additionally, Figure 4 the aspects thereof and the description may be implemented in any other figure and / or aspect of the present disclosure. Additionally, the aspects of any other figure and the description thereof may be implemented in Figure 4 the aspects thereof.

[0045] Additionally, the inverter 102 may include a first switch Qa 112, a fourth switch Qd 114, a third switch Qc 116, and a second switch Qb 118. The electrostatic gun driver 100 in combination with the inverter 102 may be configured to convert direct current (DC) from a power source 104 into alternating current (AC) for an exemplary material application device 210. In particular, the electrostatic gun driver 100 in combination with the inverter 102 may be configured to generate a modulated voltage pulse 192 from the power source 104. In particular, the controller 106 may quickly turn on and off the power from the power source 104 to the first switch Qa 112, the fourth switch Qd 114, the third switch Qc 116, and the second switch Qb 118. In some aspects, one or more of the first switch Qa 112, the fourth switch Qd 114, the third switch Qc 116, and the second switch Qb 118 may be implemented as a transistor, FET, MOSFET, etc. In some aspects, when the first switch Qa112 and the fourth switch Qd 114 are turned on, while the third switch Qc 116 and the second switch Qb 118 are turned off, the inverter 102 may be implemented as a half-bridge inverter circuit having the first switch Qa 112, the fourth switch Qd 114, the third switch Qc 116, and the second switch Qb 118.

[0046] In some aspects, the inverter 102 may be implemented as a four-switch inverter having the first switch Qa 112, the fourth switch Qd 114, the third switch Qc 116, and the second switch Qb 118, and these switches generate pulses that are modulated to generate the modulated voltage pulse 192.

[0047] The filter 108 filters and smooths the modulated voltage pulse 192 generated by the power source 104 into a sine wave drive signal 190. Thereafter, the filter 108 may provide the sine wave drive signal 190 to drive the exemplary material application device 210. In particular, the filter 108 may provide the sine wave drive signal 190 on an electrical cable 226 to drive the exemplary material application device 210.

[0048] Figure 5 A schematic diagram of an electrostatic gun driver in accordance with aspects of the present disclosure is shown.

[0049] In particular, Figure 5Exemplary details of the power supply 104 and the controller 106 are shown. Additionally, Figure 5 Aspects thereof and their descriptions can be implemented in any other figures and / or aspects of the present disclosure. Additionally, aspects of any other figures and their descriptions can be implemented in Figure 5 the aspects of

[0050] In certain aspects, the inverter 102 can include a signal line 182 that connects the controller 106 to the first switch Qa 112, the fourth switch Qd 114, the third switch Qc 116, and the second switch Qb 118. In particular, the controller 106 can be configured to implement a single-pole modulation scheme to control the gating of the first switch Qa 112, the fourth switch Qd 114, the third switch Qc 116, and the second switch Qb 118. More specifically, the controller 106 can be configured to implement a single-pole modulation scheme; and this single-pole modulation scheme can be implemented by the controller 106 as a control signal on the signal line 182. In certain aspects, the signal line 182 can be connected between the controller 106 and the first switch Qa 112, the fourth switch Qd 114, the third switch Qc 116, and the second switch Qb 118. Thus, the controller 106 can control the first switch Qa 112, the fourth switch Qd 114, the third switch Qc 116, and the second switch Qb 118 via the signal line 182. In particular, the controller 106 can control two diagonal switch pairs of the first switch Qa 112, the fourth switch Qd 114, the third switch Qc 116, and the second switch Qb 118 of the inverter 102 to generate pulses, and the pulses are modulated to generate modulated voltage pulses 192. In particular, the diagonal switch pairs can be the first switch Qa 112 and the fourth switch Qd 114; or, the diagonal switch pairs can be the third switch Qc 116 and the second switch Qb 118.

[0051] Figure 6 A schematic diagram of an electrostatic gun driver according to an aspect of the present disclosure is shown.

[0052] In particular, Figure 6 Exemplary details of the power supply 104 and the controller 106 are shown. Additionally, Figure 6 Aspects thereof and their descriptions can be implemented in any other figures and / or aspects of the present disclosure. Additionally, aspects of any other figures and their descriptions can be implemented in Figure 6 the aspects of

[0053] As Figure 6As shown, the controller 106 may implement a single - pole modulation scheme. Specifically, the controller 106 may be configured to implement a single - pole modulation scheme by receiving a sine - wave reference 152 and a carrier waveform 154. The sine - wave reference 152 may be compared with the carrier waveform 154. For the left side of the bridge of the inverter 102 (including the first switch Qa 112 and the second switch Qb 118), if the voltage of the sine - wave reference 152 is higher than the voltage of the carrier waveform 154, the first switch Qa 112 may be turned on; otherwise, the first switch Qa 112 may be turned off. The second switch Qb 118 is the inverse of the first switch Qa 112. On the other side of the bridge of the inverter 102, that is, the third switch Qc 116 and the fourth switch Qd 114, operate in the same manner but use the inverse of the voltage of the sine - wave reference 152 as a reference.

[0054] Figure 7 An exemplary embodiment of a filter according to aspects of the present disclosure is shown.

[0055] In particular, Figure 7 An exemplary embodiment of a filter 108 according to aspects of the present disclosure is shown. Additionally, Figure 7 the aspects and their descriptions can be implemented in any other figures and / or aspects of the present disclosure. Additionally, the aspects and their descriptions of any other figures can be implemented in Figure 7 the aspects.

[0056] As Figure 7 shown, the filter 108 may include a shunt power line 174. The shunt power line 174 may receive the modulated voltage pulses 192 generated by the inverter 102. Additionally, the filter 108 may filter and smooth the modulated voltage pulses 192 generated by the inverter 102 into a sine - wave drive signal 190. Thereafter, the filter 108 may provide the sine - wave drive signal 190 to drive an exemplary material application device 210. In particular, the filter 108 may provide the sine - wave drive signal 190 on an electrical cable 226 to drive an exemplary material application device 210. In this regard, the filter 108 may implement any type of electronic filtering technique using any type of electrical components.

[0057] In some aspects, the filter 108 may include an inductor 170 and a capacitor 172. In some aspects, the inductor 170 may be arranged in series on one embodiment of the shunt power line 174. In some aspects, the capacitor 172 may be arranged to be connected between the shunt power lines 174.

[0058] Figure 8 An exemplary embodiment of a filter according to aspects of the present disclosure is shown.

[0059] In particular, Figure 8An exemplary embodiment of a filter 108 in accordance with aspects of the present disclosure is shown. Additionally, Figure 8 the aspects and their descriptions thereof may be implemented in any other figures and / or aspects of the present disclosure. Additionally, the aspects and their descriptions of any other figures may be implemented in Figure 8 the aspects thereof.

[0060] In some aspects, the filter 108 may include a buck converter 160. In some aspects, the buck converter 160 may be implemented as a buck and / or boost converter. In some aspects, the buck converter 160 may reduce and / or increase the voltage of the power supply 104.

[0061] In some aspects, the filter 108 may include a load resistor 162. The load resistor 162 may be connected between parallel power lines 174.

[0062] In some aspects, the filter 108 may include a current sensor 164. The current sensor 164 may be connected in series with one of the parallel power lines 174. In some aspects, the current sensed by the current sensor 164 may be provided to the controller 106, the control system 188, the material application system 200, and so on.

[0063] In some aspects, the filter 108 may include a voltage sensor 166. The voltage sensor 166 may be connected between parallel power lines 174. In some aspects, the voltage sensed by the voltage sensor 166 may be provided to the controller 106, the control system 188, the material application system 200, and so on.

[0064] In some aspects, the filter 108 may include a current sensor 178. The current sensor 178 may be connected in series with one of the parallel power lines 174. In some aspects, the current sensed by the current sensor 164 may be provided to the controller 106, the control system 188, the material application system 200, and so on.

[0065] Figure 9 An exemplary embodiment of an inverter in accordance with aspects of the present disclosure is shown.

[0066] Figure 10 Shown in accordance with Figure 9 is an exemplary embodiment of an inverter.

[0067] In particular, Figure 9 and Figure 10 show an exemplary embodiment of an inverter 102 in accordance with aspects of the present disclosure. Additionally, Figure 9 and Figure 10 the aspects and their descriptions thereof may be implemented in any other figures and / or aspects of the present disclosure. Additionally, the aspects and their descriptions of any other figures may be implemented in Figure 9 andFigure 10 implemented in aspects of

[0068] In some aspects, the inverter 102 can be implemented as a half - bridge inverter circuit having a first switch Qa 112, a fourth switch Qd 114, a third switch Qc 116, and a second switch Qb 118. In some aspects, the first switch Qa 112, the fourth switch Qd 114, the third switch Qc 116, and the second switch Qb 118 can include anti - parallel diodes. As Figure 10 shown, an embodiment of the fourth switch Qd 114 with an anti - parallel diode 198 is shown in detail.

[0069] Figure 11 Exemplary waveforms of a sine - wave drive signal and a modulation voltage pulse according to the present disclosure are shown.

[0070] In particular, Figure 11 Exemplary waveforms of a sine - wave drive signal 190 and a modulation voltage pulse 192 generated by various components of the electrostatic gun driver 100 are shown. In this regard, the sine - wave drive signal 190 generated by the electrostatic gun driver 100 can be a true sine wave.

[0071] Figure 12 An exemplary method of implementing an electrostatic gun driver according to the present disclosure is shown.

[0072] In particular, Figure 12 An exemplary method of implementing the electrostatic gun driver 300 according to the present disclosure is shown. In particular, it should be noted that the method of implementing the electrostatic gun driver 300 is merely exemplary and can be modified according to various aspects disclosed herein. It should be noted that the method of implementing the electrostatic gun driver 300 can be performed in a different order consistent with the above - mentioned aspects. In addition, the method of implementing the electrostatic gun driver 300 can be modified to have more or fewer method steps consistent with various aspects disclosed herein. In particular, the method of implementing the electrostatic gun driver 300 can be the method of implementing the electrostatic gun driver 100 according to the present disclosure.

[0073] The method of implementing the electrostatic gun driver 300 according to the present disclosure can include receiving power from a power source 302. In this regard, receiving power from the power source 302 can include any one or more of the materials, structures, arrangements, methods, etc. described herein. In addition, according to the present disclosure, one or more pre - or post - method steps can also be implemented regarding receiving power from the power source 302. In particular, receiving power from the power source 302 can include receiving power from the power source 104.

[0074] A method of implementing the electrostatic gun driver 300 of the present disclosure may include generating a modulated voltage pulse with the inverter 304. In this regard, generating a modulated voltage pulse with the inverter 304 may include any one or more of the materials, structures, arrangements, methods, etc. described herein. Additionally, according to the present disclosure, one or more pre - or post - sequence methods may also be implemented regarding generating a modulated voltage pulse with the inverter 304. In particular, generating a modulated voltage pulse with the inverter 304 may include generating a modulated voltage pulse 192 with the inverter 102.

[0075] A method of implementing the electrostatic gun driver 300 of the present disclosure may include generating a sine - wave drive signal with the filter 306. In this regard, generating a sine - wave drive signal with the filter 306 may include any one or more of the materials, structures, arrangements, methods, etc. described herein. Additionally, according to the present disclosure, one or more pre - or post - sequence methods may also be implemented regarding generating a sine - wave drive signal with the filter 306. In particular, generating a sine - wave drive signal with the filter 306 may include generating a sine - wave drive signal 190 with the filter 108.

[0076] A method of implementing the electrostatic gun driver 300 of the present disclosure may include providing the sine - wave drive signal to the material application device 308. In this regard, providing the sine - wave drive signal to the material application device 308 may include any one or more of the materials, structures, arrangements, methods, etc. described herein. Additionally, according to the present disclosure, one or more pre - or post - sequence methods may also be implemented regarding providing the sine - wave drive signal to the material application device 308. In particular, providing the sine - wave drive signal to the material application device 308 may include providing the sine - wave drive signal 190 to the exemplary material application device 210.

[0077] Return reference Figure 1 , in some aspects, the exemplary material application device 210 may include a handle portion 216. The handle portion 216 may be implemented in the form of, for example, a handle 218 that is manually grasped or held during the operation of the exemplary material application device 210. For the exemplary material application device 210, the handle 218 may include a portion that contacts and is grounded to the operator's hand. For the purposes of this description, the term "handle" is generally used to refer to any structure or component that is manually grasped or held by an operator to support and control the exemplary material application device 210 during the operation of the exemplary material application device 210, where a handgrip, grip, or other structure is an exemplary embodiment of such a handle.

[0078] As Figure 1As further shown, the coating material supply source can serve as the source of the coating material for the exemplary material application device 210. A feed or supply hose 222 can be used to connect the exemplary material application device 210 to the coating material supply source. A hose connector 224 can be provided to securely attach the supply hose 222 to the exemplary material application device 210. The control system 188 and / or the electrostatic gun driver 100 can be configured to control the input power and operation in the gun electrical requirements, as well as control the operation of the coating material supply source, the cleaning supply source, and other system-related features such as the spray booth, the part conveyor, etc. (not shown). The coating material supply source generally includes one or more pumps controlled by the control system 188 so that the control system 188 starts the pump in response to the operator actuating the actuating device 232. This causes the coating material to flow through the handle 218, the barrel portion 214, and out of the nozzle portion 212 to form the desired spray pattern S, for example, generally in the form of a cloud-like pattern of powder coating material.

[0079] The cleaning supply source under the control of the control system 188 can provide pressurized cleaning air or other gas to the exemplary material application device 210 through a cleaning hose 236. The cleaning hose 236 can be connected to a suitable hose connector input provided on the handle portion 216, and in this example, to the base 240 of the handle 218. Thus, the cleaning air inlet of the handle portion 216 can be separated from the coating material input at the hose connector 224 such that the cleaning air initially enters the coating material flow path by first passing through the cleaning air flow path within the handle portion 216 ( Figure 1 not shown).

[0080] Accordingly, the present disclosure presents a desired driver circuit having improved power efficiency, less waste heat generation, lower cost of cooling devices, smaller form factor, smaller and lower cost packaging, reduced number of electrical circuit component parts, better performance, etc.

[0081] The following are several non-limiting examples of aspects of the present disclosure.

[0082] One example includes: The electrostatic gun driver includes an inverter configured to receive electrical energy from a power source. The electrostatic gun driver further includes a controller configured to control the inverter. The electrostatic gun driver further includes a filter configured to generate a sine wave drive signal and provide the sine wave drive signal to the material application system and / or the material application device.

[0083] The above examples may also include any one or more combinations of the following examples: The electrostatic gun driver in the above examples, wherein the inverter is configured to generate a true sine wave. The electrostatic gun driver in the above examples, wherein the inverter is implemented as a four-switch inverter that generates modulated voltage pulses from a power supply. The electrostatic gun driver in the above examples, wherein the controller is configured to implement a single-pole modulation scheme to control the gating of two diagonal switch pairs of the inverter to generate pulses, and the pulses are modulated to generate modulated voltage pulses. The electrostatic gun driver in the above examples, wherein the filter is configured to filter and smooth the modulated voltage pulses into a sine wave drive signal to drive the material application device. The electrostatic gun driver in the above examples, wherein the electrostatic gun driver is configured without a boost converter power stage. The electrostatic gun driver in the above examples, wherein the electrostatic gun driver is configured without a flyback converter. The electrostatic gun driver in the above examples, wherein the electrostatic gun driver is configured without a DC inverter. The electrostatic gun driver in the above examples, wherein the electrostatic gun driver and / or the inverter generate a sine wave drive signal with a frequency of 1 kHz to 1000 kHz. The electrostatic gun driver in the above examples, wherein the electrostatic gun driver and / or the inverter generate a sine wave drive signal with a voltage and / or amplitude of 0 V peak-to-peak to 1000 V peak-to-peak. The electrostatic gun driver in the above examples, wherein the inverter generates modulated voltage pulses, and the filter receives the modulated voltage pulses and generates a sine wave drive signal. The electrostatic gun driver in the above examples, wherein the inverter includes a first switch, a fourth switch, a third switch, and a second switch. The electrostatic gun driver in the above examples, wherein the controller is configured to turn on and off the power from the power supply to the first switch, the fourth switch, the third switch, and the second switch. The electrostatic gun driver in the above examples, wherein one or more of the first switch, the fourth switch, the third switch, and the second switch are implemented as transistors, FETs, and / or MOSFETs. The electrostatic gun driver in the above examples, wherein the controller is configured to implement a single-pole modulation scheme to control the gating of the first switch, the fourth switch, the third switch, and the second switch. The electrostatic gun driver in the above examples, wherein the controller is configured to control two diagonal switch pairs of the first switch, the fourth switch, the third switch, and the second switch of the inverter to generate pulses, and the pulses are modulated to generate modulated voltage pulses. The electrostatic gun driver in the above examples, wherein the controller is configured to implement a single-pole modulation scheme by receiving a sine wave reference and a carrier waveform. The electrostatic gun driver in the above examples, wherein the controller is configured to compare the sine wave reference with the carrier waveform to control the first switch, the second switch, the third switch, and the fourth switch. The electrostatic gun driver in the above examples, wherein the filter includes an inductor and a capacitor.The electrostatic gun driver in the above example, wherein the inductor is arranged in series on one embodiment of the parallel power lines. The electrostatic gun driver in the above example, wherein the capacitor is arranged to be connected between the parallel power lines. The electrostatic gun driver in the above example, wherein the inverter is configured to provide improved power efficiency compared to prior art electrostatic gun drivers. The electrostatic gun driver in the above example, wherein the inverter is configured to provide less waste heat generation compared to prior art electrostatic gun drivers. The electrostatic gun driver in the above example, wherein the inverter is configured to provide a smaller form factor compared to prior art electrostatic gun drivers. The electrostatic gun driver in the above example, wherein the material application device is implemented as a manually operated material application device. The electrostatic gun driver in the above example, wherein the material application device is robot-operated. The electrostatic gun driver in the above example, wherein the material application system includes a robotic system configured to operate within the material application system and manipulate and move the material application device. The material application system in the above example. The material application system in the above example, wherein the material application device is implemented as a manually operated material application device. The material application system in the above example, wherein the material application device is robot-operated. The material application system in the above example, wherein the material application system includes a robotic system configured to operate within the material application system and manipulate and move the material application device.

[0084] One example includes: The method includes configuring an inverter to receive power from a power source. The method further includes configuring a controller to control the inverter. The method further includes generating a sine wave drive signal with a filter and providing the sine wave drive signal to the material application system and / or the material application device.

[0085] The above examples may also include any one or more combinations of the following examples: The method in the above examples, wherein the inverter is configured to generate a true sine wave. The method in the above examples, wherein the inverter is implemented as a four-switch inverter that generates a modulated voltage pulse from a power source. The method in the above examples, wherein the controller is configured to implement a single-pole modulation scheme to control the gating of two diagonal switch pairs of the inverter to generate pulses, and the pulses are modulated to generate a modulated voltage pulse. The method in the above examples, wherein the filter is configured to filter and smooth the modulated voltage pulse into a sine wave drive signal to drive the material application device. The method in the above examples, wherein the electrostatic gun driver is configured without a boost converter power stage. The method in the above examples, wherein the electrostatic gun driver is configured without a flyback converter. The method in the above examples, wherein the electrostatic gun driver is configured without a DC inverter. The method in the above examples, wherein the electrostatic gun driver and / or the inverter generates a sine wave drive signal with a frequency of 1 kHz to 1000 kHz. The method in the above examples, wherein the electrostatic gun driver and / or the inverter generates a sine wave drive signal with a voltage and / or amplitude of 0 V peak-to-peak to 1000 V peak-to-peak. The method in the above examples, wherein the inverter generates a modulated voltage pulse, and the filter receives the modulated voltage pulse and generates a sine wave drive signal. The method in the above examples, wherein the inverter includes a first switch, a fourth switch, a third switch, and a second switch. The method in the above examples, wherein the controller is configured to turn on and off the power from the power source to the first switch, the fourth switch, the third switch, and the second switch. The method in the above examples, wherein one or more of the first switch, the fourth switch, the third switch, and the second switch are implemented as transistors, FETs, and / or MOSFETs. The method in the above examples, wherein the controller is configured to implement a single-pole modulation scheme to control the gating of the first switch, the fourth switch, the third switch, and the second switch. The method in the above examples, wherein the controller is configured to control two diagonal switch pairs of the first switch, the fourth switch, the third switch, and the second switch of the inverter to generate pulses, and the pulses are modulated to generate a modulated voltage pulse. The method in the above examples, wherein the controller is configured to implement a single-pole modulation scheme by receiving a sine wave reference and a carrier waveform. The method in the above examples, wherein the controller is configured to compare the sine wave reference with the carrier waveform to control the first switch, the second switch, the third switch, and the fourth switch. The method in the above examples, wherein the filter includes an inductor and a capacitor. The method in the above examples, wherein the inductor is arranged in series on one embodiment of the parallel power lines. The method in the above examples, wherein the capacitor is arranged to be connected between the parallel power lines.The method in the above example, wherein the inverter is configured to provide improved power efficiency compared to prior art electrostatic gun drivers. The method in the above example, wherein the inverter is configured to provide less waste heat generation compared to prior art electrostatic gun drivers. The method in the above example, wherein the inverter is configured to provide a smaller form factor compared to prior art electrostatic gun drivers. The method in the above example, wherein the material application device is implemented as a manually operated material application device. The method in the above example, wherein the material application device is robot-operated. The method in the above example, wherein the material application system includes a robotic system configured to operate within the material application system and manipulate and move the material application device. The method in the above example. The method in the above example, wherein the material application device is implemented as a manually operated material application device. The method in the above example, wherein the material application device is robot-operated. The method in the above example, wherein the material application system includes a robotic system configured to operate within the material application system and manipulate and move the material application device.

[0086] It should be understood that although the terms first, second, etc. may be used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another. For example, without departing from the scope of the present disclosure, a first element may be referred to as a second element, and similarly, a second element may be referred to as a first element. As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed items.

[0087] Relative terms, such as "below" or "above" or "upper" or "lower" or "horizontal" or "vertical", may be used to describe the relationship between one element, layer or region and another element, layer or region, as shown in the drawings. It should be understood that these terms, as well as the terms discussed above, are intended to cover different orientations of the device other than the orientation shown in the drawings.

[0088] The terms used herein are for the purpose of describing particular aspects only and are not intended to limit the present disclosure. 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", "comprising", "includes" and / or "including", when used herein, specify the presence of the stated features, integers, steps, operations, elements and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components and / or combinations thereof.

[0089] Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs. It will be further understood that terms used herein should be interpreted as having a meaning that is consistent with their meaning in the context of this specification and the relevant art and will not be interpreted in an idealized or overly formal manner unless expressly so defined herein.

[0090] Many features and advantages of the present disclosure are apparent from the detailed description, and thus, the appended claims are intended to cover all such features and advantages of the present disclosure that fall within the true spirit and scope of the present disclosure. In addition, since many modifications and variations will readily occur to those of ordinary skill in the art, it is not desired to limit the present disclosure to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents that fall within the scope of the present disclosure may be employed.

Claims

1. An electrostatic gun driver, comprising: an inverter configured to receive electrical energy from a power source; a controller configured to control the inverter; and a filter configured to generate a sine wave drive signal and supply the sine wave drive signal to a material application system and / or a material application device.

2. The electrostatic gun driver according to claim 1, wherein the inverter is configured to generate a true sine wave.

3. The electrostatic gun driver according to claim 1, wherein the inverter is implemented as a four-switch inverter that generates modulated voltage pulses from the power source.

4. The electrostatic gun driver according to claim 1, wherein the controller is configured to implement a single-pole modulation scheme to control the gating of two diagonal switch pairs of the inverter to generate pulses that are modulated to generate modulated voltage pulses.

5. The electrostatic gun driver according to claim 4, wherein the filter is configured to filter and smooth the modulated voltage pulses into the sine wave drive signal to drive the material application device.

6. The electrostatic gun driver according to claim 1, wherein the electrostatic gun driver is configured without a boost converter power stage.

7. The electrostatic gun driver according to claim 1, wherein the electrostatic gun driver is configured without a flyback converter.

8. The electrostatic gun driver according to claim 1, wherein the electrostatic gun driver is configured without a DC inverter.

9. The electrostatic gun driver according to claim 1, wherein the electrostatic gun driver and / or the inverter generates the sine wave drive signal having a frequency of 1 kHz to 1000 kHz.

10. The electrostatic gun driver according to claim 1, wherein the electrostatic gun driver and / or the inverter generates the sine wave drive signal having a voltage and / or amplitude of 0 V peak-to-peak to 1000 V peak-to-peak.

11. The electrostatic gun driver according to claim 1, wherein the inverter generates modulated voltage pulses and the filter receives the modulated voltage pulses and generates the sine wave drive signal.

12. The electrostatic gun driver according to claim 1, wherein the inverter includes a first switch, a fourth switch, a third switch, and a second switch.

13. The electrostatic gun driver according to claim 12, wherein the controller is configured to turn on and off the power from the power source to the first switch, the fourth switch, the third switch, and the second switch.

14. The electrostatic gun driver according to claim 12, wherein one or more of the first switch, the fourth switch, the third switch, and the second switch are implemented as transistors, FETs, and / or MOSFETs.

15. The electrostatic gun driver according to claim 12, wherein the controller is configured to implement a single-pole modulation scheme to control the gating of the first switch, the fourth switch, the third switch, and the second switch.

16. The electrostatic gun driver according to claim 12, wherein the controller is configured to control two diagonal switch pairs of the first switch, the fourth switch, the third switch, and the second switch of the inverter to generate pulses, and the pulses are modulated to generate modulated voltage pulses.

17. The electrostatic gun driver according to claim 12, wherein the controller is configured to implement a single - pole modulation scheme by receiving a sine - wave reference and a carrier waveform.

18. The electrostatic gun driver according to claim 17, wherein the controller is configured to compare the sine - wave reference with the carrier waveform to control the first switch, the second switch, the third switch, and the fourth switch.

19. The electrostatic gun driver according to claim 1, wherein the filter includes an inductor and a capacitor.

20. The electrostatic gun driver according to claim 19, wherein the inductor is arranged in series on one embodiment of the parallel power lines.

21. The electrostatic gun driver according to claim 19, wherein the capacitor is arranged to be connected between the parallel power lines.

22. The electrostatic gun driver according to claim 1, wherein the inverter is configured to provide improved power efficiency compared to prior - art electrostatic gun drivers.

23. The electrostatic gun driver according to claim 1, wherein the inverter is configured to provide less waste heat generation compared to prior - art electrostatic gun drivers.

24. The electrostatic gun driver according to claim 1, wherein the inverter is configured to provide a smaller form factor compared to prior - art electrostatic gun drivers.

25. The electrostatic gun driver according to claim 1, wherein the material application device is implemented as a manually - operated material application device.

26. The electrostatic gun driver according to claim 1, wherein the material application device is robot - operated.

27. The electrostatic gun driver according to claim 1, wherein the material application system includes a robot system configured to operate within the material application system and manipulate and move the material application device.

28. A material application system implementing the electrostatic gun driver and the material application device according to claim 1.

29. The material application system according to claim 28, wherein the material application device is implemented as a manually - operated material application device.

30. The material application system according to claim 28, wherein the material application device is robot - operated.

31. The material application system according to claim 28, wherein the material application system includes a robot system configured to operate within the material application system and manipulate and move the material application device.

32. A method of implementing an electrostatic gun driver, comprising: configuring an inverter to receive power from a power source; configuring a controller to control the inverter; and Generate a sine wave drive signal with a filter and supply the sine wave drive signal to a material application system and / or a material application device.

33. The method of implementing an electrostatic gun driver according to claim 32, wherein the inverter is configured to generate a true sine wave.

34. The method of implementing an electrostatic gun driver according to claim 32, wherein the inverter is implemented as a four-switch inverter that generates modulated voltage pulses from the power supply.

35. The method of implementing an electrostatic gun driver according to claim 32, wherein the controller is configured to implement a single-pole modulation scheme to control the gating of two diagonal switch pairs of the inverter to generate pulses, and the pulses are modulated to generate modulated voltage pulses.

36. The method of implementing an electrostatic gun driver according to claim 35, wherein the filter is configured to filter and smooth the modulated voltage pulses into the sine wave drive signal to drive the material application device.

37. The method of implementing an electrostatic gun driver according to claim 32, wherein the electrostatic gun driver is configured without a boost converter power stage.

38. The method of implementing an electrostatic gun driver according to claim 32, wherein the electrostatic gun driver is configured without a flyback converter.

39. The method of implementing an electrostatic gun driver according to claim 32, wherein the electrostatic gun driver is configured without a DC inverter.

40. The method of implementing an electrostatic gun driver according to claim 32, wherein the electrostatic gun driver and / or the inverter generate the sine wave drive signal with a frequency of 1 kHz to 1000 kHz.

41. The method of implementing an electrostatic gun driver according to claim 32, wherein the electrostatic gun driver and / or the inverter generate the sine wave drive signal with a voltage and / or amplitude of 0 V peak-to-peak to 1000 V peak-to-peak.

42. The method of implementing an electrostatic gun driver according to claim 32, wherein the inverter generates modulated voltage pulses, and the filter receives the modulated voltage pulses and generates the sine wave drive signal.

43. The method of implementing an electrostatic gun driver according to claim 32, wherein the inverter includes a first switch, a fourth switch, a third switch, and a second switch.

44. The method of implementing an electrostatic gun driver according to claim 43, wherein the controller is configured to turn on and off the power from the power supply to the first switch, the fourth switch, the third switch, and the second switch.

45. The method of implementing an electrostatic gun driver according to claim 43, wherein one or more of the first switch, the fourth switch, the third switch, and the second switch are implemented as transistors, FETs, and / or MOSFETs.

46. The method of implementing an electrostatic gun driver according to claim 43, wherein the controller is configured to implement a single-pole modulation scheme to control the gating of the first switch, the fourth switch, the third switch, and the second switch.

47. A method of implementing an electrostatic gun driver according to claim 43, wherein the controller is configured to control two diagonal switch pairs of the first switch, the fourth switch, the third switch, and the second switch of the inverter to generate pulses, and the pulses are modulated to generate modulated voltage pulses.

48. A method of implementing an electrostatic gun driver according to claim 43, wherein the controller is configured to implement a single-pole modulation scheme by receiving a sine wave reference and a carrier waveform.

49. A method of implementing an electrostatic gun driver according to claim 48, wherein the controller is configured to compare the sine wave reference with the carrier waveform to control the first switch, the second switch, the third switch, and the fourth switch.

50. A method of implementing an electrostatic gun driver according to claim 32, wherein the filter includes an inductor and a capacitor.

51. A method of implementing an electrostatic gun driver according to claim 50, wherein the inductor is arranged in series on one embodiment of the parallel power lines.

52. A method of implementing an electrostatic gun driver according to claim 50, wherein the capacitor is arranged to be connected between the parallel power lines.

53. A method of implementing an electrostatic gun driver according to claim 32, wherein the inverter is configured to provide improved power efficiency compared to prior art electrostatic gun drivers.

54. A method of implementing an electrostatic gun driver according to claim 32, wherein the inverter is configured to provide less waste heat generation compared to prior art electrostatic gun drivers.

55. A method of implementing an electrostatic gun driver according to claim 32, wherein the inverter is configured to provide a smaller form factor compared to prior art electrostatic gun drivers.

56. A method of implementing an electrostatic gun driver according to claim 32, wherein the material application device is implemented as a manually operated material application device.

57. A method of implementing an electrostatic gun driver according to claim 32, wherein the material application device is robot-operated.

58. A method of implementing an electrostatic gun driver according to claim 32, wherein the material application system includes a robot system configured to operate within the material application system and manipulate and move the material application device.

59. A method of implementing a material application system, the material application system implementing the method of implementing an electrostatic gun driver according to claim 32.

60. A method of implementing a material application system according to claim 59, wherein the material application device is implemented as a manually operated material application device.

61. A method of implementing a material application system according to claim 59, wherein the material application device is robot-operated.

62. A method of implementing a material application system according to claim 59, wherein the material application system includes a robot system configured to operate within the material application system and manipulate and move the material application device.

Images