Method for calibrating production flow of electric sprayer

Abstract

The invention relates to the technical field of flow calibration, in particular to an electric sprayer production flow calibration method which comprises the following steps: applying standard working voltage to a finished product through a battery pack, and detecting actual flow; the method comprises the following steps: when a deviation is detected, externally connecting a first high voltage or a second high voltage according to the deviation to trigger calibration, detecting the voltage by a built-in MCU through a divider resistance network, correspondingly increasing or reducing a PWM duty ratio when the voltage is continuously greater than or equal to 500ms, and storing parameters in an on-chip EEPROM / Flash nonvolatile memory. After power failure, the MCU calls storage parameters to control the diaphragm pump, flow calibration is achieved, the speed regulation board potentiometer is used for initial flow setting, the double-resistance circuit distinguishes normal voltage from calibration voltage, false triggering is avoided, the method does not need to disassemble a machine, the PWM duty ratio is automatically adjusted through voltage signals, single-time calibration is short in time consumption and high in precision, and the production efficiency and the product consistency are improved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of flow calibration, specifically a flow calibration method for electric sprayer production. BACKGROUND

[0002] In the current production process of electric sprayers, ensuring that the actual spraying flow of each device meets the design requirements is a key quality control link. However, traditional flow calibration methods have many problems and limitations, mainly in the following aspects: Complexity of manual adjustment of potentiometer: Existing method: Traditional electric sprayers usually adjust the output flow of the diaphragm pump by manually adjusting the potentiometer. This adjustment method requires disassembling the device shell, finding and adjusting the built-in potentiometer to achieve the required flow.

[0003] Problem: This method is not only complex, time-consuming and labor-intensive, but also prone to inaccurate adjustment due to human error, and may even damage the device. In addition, frequent disassembly and assembly processes also increase the risk of device damage, affecting product reliability and service life.

[0004] Lack of precision and consistency: Existing method: Since manual adjustment depends on the experience and technical level of the operator, there may be significant flow differences between different batches or the same batch, making it difficult to ensure product consistency and quality stability.

[0005] Problem: This not only increases the workload of subsequent quality detection, but also may cause some products to not meet user requirements, affecting market competitiveness and user experience.

[0006] Insufficient data storage and power protection: Existing method: The traditional adjustment method cannot effectively store the adjusted parameters, and once the device is powered off or restarted, the previous adjustment results may be lost, requiring recalibration.

[0007] Problem: This lack of data persistence mechanism requires re-adjustment every time the device is turned on, increasing unnecessary workload and being prone to operational errors.

[0008] Weak anti-interference ability and prevention of accidental triggering: Existing method: The traditional adjustment method lacks effective voltage detection and anti-misfire mechanisms, and is easily affected by transient voltage fluctuations in actual use, leading to unnecessary calibration actions and affecting device normal operation.

[0009] Problem: Especially in industrial environments, voltage fluctuations are common, and without appropriate protection measures, device performance will be affected, and even malfunctions may occur.

[0010] The debugging process is complicated: Existing method: In order to ensure the flow consistency of each device, it usually needs to be manually adjusted and tested for many times, and the whole debugging process is complicated and inefficient.

[0011] Problem: This not only increases the production cost, but also prolongs the production cycle and reduces the market response speed of the enterprise. SUMMARY

[0012] In view of the shortcomings of the prior art, the present application provides a flow calibration method for electric sprayer production.

[0013] In order to achieve the above purpose, the present application provides the following technical scheme: a flow calibration method for electric sprayer production, comprising the following steps: a) providing a voltage-adjustable stabilized power supply and a battery pack, the battery pack applies a standard working voltage to the finished electric sprayer, and detects the actual spraying flow; b) according to the flow deviation, the voltage-adjustable stabilized power supply triggers calibration at a first high voltage or a second high voltage; c) the finished electric sprayer is provided with an MCU, which detects the first high voltage or the second voltage, and correspondingly increases or decreases the PWM duty cycle, and stores the adjusted parameters; d) the MCU cuts off the voltage-adjustable stabilized power supply, and after power off, the battery pack supplies power, and the MCU calls the stored parameters to control the diaphragm pump output, thereby realizing flow calibration.

[0014] Preferably, the standard working voltage is the rated voltage of the battery pack of the electric sprayer, and the rated voltage range is 18-21V.

[0015] Further preferably, the first high voltage is 25V, corresponding to an increase of ΔP in PWM duty cycle, and the second high voltage is 23V, corresponding to a decrease of ΔP in PWM duty cycle, wherein ΔP is the minimum PWM duty cycle adjustment amount.

[0016] Again preferably, the MCU is provided with a voltage detection module and a timer module, and the calibration trigger condition is that the voltage duration is greater than or equal to 500ms.

[0017] Preferably, the MCU is internally integrated with a non-volatile memory for storing the adjusted PWM duty cycle value.

[0018] Further preferably, the non-volatile memory is an EEPROM or a Flash memory, which ensures that the data is not lost after power off.

[0019] Again preferably, the finished electric sprayer is configured with a speed regulation plate, and the speed regulation plate contains a potentiometer for initially setting the diaphragm pump output flow, and the MCU determines the supply voltage range through two resistors to ensure that the normal working voltage is between 15-21V.

[0020] Preferably, when the second high voltage power supply is detected, the MCU reduces the PWM duty cycle by 2%, and continues to reduce by 2% when the second high voltage power supply is detected again; when the first high voltage power supply is detected, the MCU increases the PWM duty cycle by 2%, and continues to increase by 2% when the first high voltage power supply is detected again.

[0021] Compared with the prior art, the present application provides an electric sprayer production flow calibration method, which has the following beneficial effects: No need to disassemble and adjust: The traditional potentiometer adjustment method needs to be disassembled and adjusted manually, which is time-consuming and laborious and easy to cause damage to the equipment. The technical solution automatically adjusts the PWM duty cycle through external high voltage triggering MCU, and the calibration can be completed without disassembly, greatly improving the production efficiency.

[0022] Precise flow control: During calibration, the first high voltage (25V) and the second high voltage (23V) are used to increase or decrease the PWM duty cycle respectively, and the minimum adjustment amount is ΔP. Multiple power-on and power-off operations can gradually accumulate the adjustment amount, and finally realize accurate flow control, ensuring that the actual spraying flow is consistent with the design requirements.

[0023] Data storage and power-off protection: The MCU is internally integrated with a non-volatile memory (such as EEPROM or Flash memory) for storing the adjusted PWM duty cycle value. Even in the case of power failure, the latest parameters can be maintained to avoid data loss caused by power failure, improving the reliability and stability of the system.

[0024] Prevent false triggering: The MCU is internally integrated with a voltage detection module, and the calibration trigger condition is voltage duration ≥ 500ms, effectively preventing false triggering caused by transient voltage fluctuations. In addition, the supply voltage range is determined through two resistors to ensure that the normal working voltage is between 15-21V, further enhancing the anti-interference ability of the system.

[0025] Simplify the debugging process: The finished product electric sprayer is configured with a speed regulation plate, and the speed regulation plate comprises a potentiometer for initially setting the output flow of the diaphragm pump. During the calibration process, the MCU automatically adjusts the PWM duty cycle according to the detected first high voltage or second high voltage, and stores the adjusted parameters in the non-volatile memory. Each time the MCU calls the stored parameters to control the diaphragm pump output, the debugging process is simplified, and the operation difficulty is reduced.

[0026] Flexible adjustment mechanism: When the second high voltage power supply is detected, the MCU reduces the PWM duty cycle by 2%, and continues to reduce by 2% when the second high voltage power supply is detected again; when the first high voltage power supply is detected, the MCU increases the PWM duty cycle by 2%, and continues to increase by 2% when the first high voltage power supply is detected again. This flexible adjustment mechanism makes the calibration process more precise and controllable, and adapts to the needs of different working conditions.

[0027] Improve product consistency: Through the standardized calibration process, the consistency of the actual spraying flow of each electric sprayer can be significantly improved, the product performance fluctuation caused by individual differences can be reduced, and the product quality and user satisfaction can be improved. BRIEF DESCRIPTION OF DRAWINGS

[0028] Fig. 1 The figure is a schematic diagram of the workflow structure of the present application; Fig. 2 The figure is a schematic diagram of the circuit principle structure of the present application. DETAILED DESCRIPTION

[0029] The technical solutions in the embodiments of the present application will be described clearly and completely below with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are only a part of the embodiments of the present application, not all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative labor are within the scope of protection of the present application.

[0030] Please refer to Figs. 1-2 The present application is a production flow calibration method for an electric sprayer, comprising the following steps: a) providing a voltage-adjustable stabilized power supply and a battery pack, the battery pack applies a standard working voltage to the finished product electric sprayer to detect the actual spraying flow; b) according to the flow deviation, the voltage-adjustable stabilized power supply triggers calibration at a rated first high voltage or second high voltage; c) the finished product electric sprayer is provided with an MCU, which detects the first high voltage or the second voltage, and increases or decreases the PWM duty cycle accordingly, and stores the adjusted parameters; d), MCU cut off adjustable voltage stabilized power supply, power off, battery pack power supply, MCU call storage parameters control diaphragm pump output, realize flow calibration.

[0031] Voltage trigger calibration principle Through the external adjustable voltage stabilized power supply output non-working voltage range high voltage signal (25V or 23V), trigger the calibration program of the built-in MCU of the electric sprayer. MCU identifies abnormal voltage through voltage detection module (composed of voltage divider circuit composed of resistor R14, R15): 25V (first high voltage): higher than the highest voltage of battery pack (21V), determine "flow increase" instruction, MCU will increase the PWM duty cycle ΔP (such as 2%); 23V (second high voltage): between the upper limit of normal working voltage (21V) and the first high voltage, determine "flow reduction" instruction, MCU will reduce the PWM duty cycle ΔP.

[0032] PWM duty cycle adjustment logic MCU generates PWM signal to control the speed of diaphragm pump through the timer module, and then adjusts the flow. During calibration, each time high voltage is detected for ≥500ms, single adjustment is performed: Flow is small: 25V triggers PWM duty cycle increment (such as from 50% to 52%), diaphragm pump speed increases, flow increases; Flow is large: 23V triggers PWM duty cycle decrement (such as from 50% to 48%), diaphragm pump speed decreases, flow decreases.

[0033] Parameter storage and power failure retention The adjusted PWM duty cycle value is stored in the internal non-volatile memory (EEPROM or Flash) of MCU, and the data is not lost after power failure. When powered on again, MCU directly calls the calibration parameters without the need for re-adjustment.

[0034] Preferred technical solution working principle Dual-resistor voltage detection circuit The resistor on the speed regulation board (such as Fig. 2 As shown, R14, R15) forms a voltage divider network, which monitors the supply voltage in real time: Normal working voltage (15-21V): after voltage division, the voltage input to the AD pin of MCU is ≤3.3V, triggering normal working mode; Calibration voltage (23V / 25V): after voltage division, the voltage is >3.3V, triggering calibration mode, avoiding conflict with normal working condition.

[0035] Cumulative adjustment mechanism The same high voltage triggered multiple times can realize cumulative adjustment (such as n x ΔP): Single 25V trigger: PWM duty cycle +2%; Three 25V triggers: PWM duty cycle +6%, suitable for scenarios with large flow deviation.

[0036] Initial flow setting potentiometer In the early stage of production, the potentiometer (such as Fig. 2 As shown in the figure, R17 sets the base PWM duty cycle, forming the initial flow calibration benchmark. During the calibration process, the potentiometer parameter serves as the base value and is superimposed on the increment / decrement triggered by the high voltage, achieving a combination of "coarse and fine adjustment".

[0037] Detailed workflow summary Preparation stage: Provide an adjustable voltage regulated power supply and battery pack to ensure that the rated voltage range of the battery pack is 18-21V.

[0038] Connect the battery pack to the finished electric sprayer, start the device and detect the actual spray flow rate.

[0039] Flow deviation detection: If the actual spray flow rate detected does not meet the design requirements, the deviation value shall be recorded.

[0040] High voltage trigger calibration: Connect a voltage-regulated power supply with adjustable voltage and set the output voltage to the first high voltage (25V) or the second high voltage (23V). The specific selection depends on the direction of flow deviation.

[0041] The voltage of the regulated power supply must be maintained for ≥500ms to trigger the calibration procedure.

[0042] PWM duty cycle adjustment: After detecting the first high voltage or the second high voltage, the MCU adjusts the PWM duty cycle according to a preset program.

[0043] For the first high voltage (25V), the PWM duty cycle increases by 2%; for the second high voltage (23V), the PWM duty cycle decreases by 2%.

[0044] Storage adjustment parameters: The MCU stores the adjusted PWM duty cycle value in a non-volatile memory (such as EEPROM or Flash memory) to ensure that the data is not lost after power failure.

[0045] To restore battery power: Cut off the adjustable voltage regulated power supply and restore power supply to the battery pack only.

[0046] The MCU calls the stored parameters to control the diaphragm pump output and realize flow calibration.

[0047] Multiple adjustments (if necessary): If a single adjustment cannot achieve the desired flow, multiple power-on and power-off operations can be used to gradually accumulate the adjustment amount, and ultimately achieve accurate calibration.

[0048] MCU and memory connection relationship and PWM pulse width storage mechanism Hardware connection MCU model: usually use STM32F103C8T6, ESP32-WROOM-32 or ATmega328P series single-chip microcomputer, which integrates non-volatile memory (such as EEPROM or Flash) inside, and the above-mentioned single-chip microcomputer usually has a power detection module (ADC) and a timer built-in.

[0049] Connection method: the memory is an on-chip resource of the MCU, which is accessed directly through the internal bus without the need for external interface chips.

[0050] Non-volatile memory type EEPROM: used to store small data that needs to be frequently read and written (such as PWM duty cycle), with an erase-write life of ≥100,000 times, and a typical storage address range of 0x0000-0x01FF (for example, using STM8).

[0051] Flash memory: used to store program code, calibration parameters can be stored in a specified data partition (such as the user data area), and the entire chip needs to be operated for erasing and writing, which is suitable for storing parameters that are not frequently changed.

[0052] Data read-write mechanism Write timing: after each high-voltage trigger calibration, the MCU executes the PWM adjustment logic and immediately writes the new duty cycle value to the EEPROM specified address (such as 0x0050).

[0053] Read logic: when the MCU is powered on and initialized, it reads the calibration parameters from the EEPROM, and the final PWM duty cycle is generated by superimposing the initial value of the potentiometer.

[0054] Power-off retention: EEPROM stores data based on electrical signals, and does not require continuous power supply. The charge can be maintained for ≥10 years after power-off.

[0055] Although embodiments of the present application have been described, it will be understood by those of ordinary skill in the art that various changes, modifications, replacements and variations can be made to these embodiments without departing from the principles and spirits of the present application, and the scope of the present application is defined by the appended claims and their equivalents.

Claims

1. A method for calibrating the production flow rate of an electric sprayer, characterized in that: The following steps are involved: a) Provide a voltage-regulated power supply with adjustable voltage and a battery pack. The battery pack applies a standard operating voltage to the finished electric sprayer to detect the actual spray flow rate. b) According to the flow deviation, the rated first high voltage or the second high voltage of the adjustable voltage regulated power supply triggers calibration; c) The finished electric sprayer has a built-in MCU. After detecting the first high voltage or the second voltage, the MCU increases or decreases the PWM duty cycle accordingly and stores the adjusted parameters; d) The MCU is used to cut off the voltage-regulated power supply with adjustable voltage. After the power is cut off, the battery pack supplies power, and the MCU calls the stored parameters to control the output of the diaphragm pump to achieve flow calibration.

2. The method for calibrating the production flow rate of an electric sprayer according to claim 1, characterized in that: The standard operating voltage is the rated voltage of the battery pack of the electric sprayer, and the rated voltage range is 18-21V.

3. The method for calibrating the production flow rate of an electric sprayer according to claim 2, characterized in that: The first high voltage is 25V, corresponding to an increase of ΔP in the PWM duty cycle, and the second high voltage is 23V, corresponding to a decrease of ΔP in the PWM duty cycle, where ΔP is the minimum PWM duty cycle adjustment amount.

4. The method for calibrating the production flow rate of an electric sprayer according to claim 3, characterized in that: The MCU has a built-in voltage detection module and a timer module, and the calibration trigger condition is that the voltage duration is ≥500ms.

5. The method for calibrating the production flow rate of an electric sprayer according to claim 4, characterized in that: The MCU is internally integrated with a non-volatile memory for storing the adjusted PWM duty cycle value.

6. The method for calibrating the production flow rate of an electric sprayer according to claim 5, characterized in that: The non-volatile memory is an EEPROM or Flash memory to ensure that data is not lost after power failure.

7. The method for calibrating the production flow rate of an electric sprayer according to claim 6, characterized in that: The finished electric sprayer is equipped with a speed control board, which includes a potentiometer for initially setting the output flow of the diaphragm pump. The MCU determines the power supply voltage range through two resistors to ensure that the normal operating voltage is between 15-21V.

8. The method for calibrating the production flow rate of an electric sprayer according to claim 6, characterized in that: When the second high voltage power supply is detected, the MCU reduces the PWM duty cycle by 2%, and continues to reduce it by 2% when the second high voltage power supply is detected again; when the first high voltage power supply is detected, the MCU increases the PWM duty cycle by 2%, and continues to increase it by 2% when the first high voltage power supply is detected again.

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