Method and apparatus for determining distance in an aerosol environment - Patents.com

Abstract

A distance sensor (100) may be arranged on the spray gun (140) to determine the distance between the spray gun (140) for applying the coating fluid to the surface and the surface. The sensor provides a value related to the distance between the spray gun (140) and the surface, but also the distance between the spray gun (140) and the aerosol particles. From all these values, the distance between the spray gun (140) and the surface is estimated by checking if the value received by the distance acceptance criteria is valid for the distance to the surface. The distance acceptance criteria may be based on previous values. A value that meets the criteria in the set, for example the median or the mean, is used to provide an estimate of the distance to the surface.

Description

[Technical field]

[0001] The present invention relates to a sensor kit for a spray gun and to processing data received from the sensor kit, and more particularly to determining the distance between objects in an environment containing small suspended particles, such as liquid droplets or mist fluids. [Background technology]

[0002] Spray painting is a technique in which a coating is sprayed onto a surface through the air using a spray gun. The coating may be paint, ink, varnish, clear coat, or any other type of coating. The spray gun may be hand-held by an operator, and it may require significant skill to apply a thin coating with a consistent layer thickness. Whether the operator has skill or not, the final thickness of the layer will vary, which may affect the durability of the coating and the reliability of sensors covered by the coating, such as proximity radar systems in automobiles. Summary of the Invention [Means for solving the problem]

[0003] A first aspect provides a method in an electronic data processor for determining a distance between a distance sensor connected to a coating fluid applicator and a surface being spray coated. The method includes receiving data values ​​from the sensor over time indicative of a distance between the sensor and a detected object, obtaining distance tolerance criteria for valid distance values ​​to be satisfied, and applying the distance tolerance criteria to the received values. A set of received data values ​​received in a predetermined time interval is determined, and at least one base value indicative of a distance between the sensor and the surface is determined based on data values ​​that satisfy the distance tolerance criteria. The base value is made outputtable by the electronic data processor.

[0004] For airborne particles, such as droplets of coating fluid, dust particles, etc., or a combination thereof, the distance value provided by the distance sensor may not only provide an indication of the distance to the surface, but also provide a specific value indicative of the distance between the sensor and the particle. Particles yield distance values ​​with a distance of 0 and a distance between the sensor and the surface to be coated. These values ​​are present in the signal from the distance sensor or are values ​​indicative of the actual distance between the sensor and the surface to be coated. Distance acceptance criteria are applied to filter the latter values. Such distance acceptance criteria may be implemented in various ways, as will be evident from the options provided below.

[0005] The distance acceptance criteria applied to the received values ​​can be determined on at least one previously received value. At least some of the distance measurements by the distance sensor are measurements of the distance between the sensor and the surface. Such measurements can provide valid measurements and provide a basis for determining whether subsequent values ​​- directly subsequent or subsequent values ​​- are valid values.

[0006] The applicable received values ​​forming the criteria for the distance tolerance criterion may be included in a set. That way the set is formed before obtaining the distance tolerance criterion and once the values ​​are in the set the distance tolerance criterion is applied. Thereafter non-valid values ​​may be removed from the set. If only one value is used as the previously received value for obtaining the distance tolerance criterion, this may be performed before or after determining the set. These options may be applied in combination with further options described above or below.

[0007] The distance tolerance criterion may be a fixed difference value. Such may be a base value that is fixed or based on multiple previous values, on the one hand a previously obtained value and on the other hand a difference between values.

[0008] The distance tolerance criterion may further be based on the time interval between the received value and the last received value. The nozzle providing the coating fluid may move during the application procedure, preferably in an atomized state. In the case of a spray nozzle, there is a maximum movement speed. This is determined by the weight of the spray device, the maximum speed of the robot carrying the spray device, the human anatomy, or a combination thereof. Based on the difference between the two measurements and the time difference between them, a tentative movement speed of the spray device to which the sensor is connected may be determined. If the time interval is known - with a fixed sampling frequency - the maximum realistic difference between the two values ​​can be determined. If the difference is too large, the measurement is considered not valid.

[0009] Received values ​​that do not meet the distance acceptance criteria may be filtered out from the determined set, thus preventing invalid values ​​from burdening the processing power and memory capacity of the system.

[0010] The method may include determining a further set of received data values ​​received at a further predetermined time interval, the further set of received data values ​​overlapping with the set of received data values. The data may be obtained, for example, as a median or average or similar type of value over a sliding or fixed window.

[0011] The method may further comprise providing at least a portion of the data values ​​which meet the distance tolerance criteria as a base value at an output of the electronic data processor. Of the valid values, a median, average or similar characteristic value may be listed. Alternatively or additionally, all or at least a number of the valid values ​​may be provided at the output.

[0012] The distance criteria may include a requirement that the data value by which the base value is determined be a predetermined amount of the highest value in the determined set. The particle is between the surface and the spray orifice. Thus, the highest value provided by the sensor is, subject to error, a value indicative of the distance between the nozzle and the surface. And values ​​in between are indicative of the distance between the sensor and the particle.

[0013] The distance tolerance criteria may be implemented by filtering. Such filters may be median filters, average filters, LULU filters, other smoothing filters, or combinations thereof. Such distance tolerance criteria may be combined with other criteria.

[0014] The method may further include receiving a distance compliance criterion and comparing the base value to the distance compliance criterion. If the base value complies with the distance compliance criterion, a first signal value is provided at the output of the electronic data processor, and if the base value does not comply with the distance compliance criterion, a second signal value is provided at the output of the electronic data processor. For both automated and manual spray coating processes, the distance between the nozzle and the surface is important. Preferably, this distance is maintained within a certain interval - this may serve as the distance compliance criterion. Based on compliance therewith, feedback may be provided such as a green light if the distance is within the interval and a red light if the distance is outside the interval. Alternatively or additionally, feedback may be provided by sound, tactile feedback, other visual feedback, etc., or a combination thereof.

[0015] The method may further include providing a third signal value at an output of the electronic data processor, the third signal value being indicative of the base value. An operator may prefer to receive data regarding the actual distance between the nozzle and the surface. For automated processing, this is generally preferred.

[0016] A second aspect provides an apparatus for a method of determining a distance between a distance sensor connected to a spray applicator for spraying a coating fluid and a surface being spray coated. The apparatus comprises a distance sensor arranged to determine a distance between the sensor and an object, and an electronic data processor configured to receive data values ​​from the sensor over time indicative of a distance between the sensor and a detected object, determine a set of received data values ​​received at a pre-determined time interval, determine a distance tolerance criterion for satisfying a valid distance value, apply the distance tolerance criterion to values ​​in the determined set, determine at least one base value indicative of a distance between the sensor and the surface based on data values ​​that satisfy the distance tolerance criterion, and enable the base value to be output by the electronic data processor.

[0017] A third aspect is a spray applicator for coating fluid arranged to spray the coating fluid from a spray orifice in a spray direction, the applicator comprising an apparatus according to the second aspect. A distance sensor senses distance in the sense direction, and the apparatus is connected to the applicator such that the spray direction is substantially parallel to the sense direction. The spray applicator is arranged to have the apparatus connected thereto or to have the apparatus connected thereto, allowing enhanced feedback and control of the spray applicator by a human or machine.

[0018] In a spray applicator, the sensing line in the sensing direction from the distance sensor can be offset relative to the spray line in the spray direction from the spray orifice. If the sensing line coincides with or is very close to the spray line, the signal from the distance sensor may provide a value related primarily to the distance to the particle, rather than the distance to the surface being coated. By separating these lines, this problem is mitigated. [Brief description of the drawings]

[0019] Various embodiments and variations thereof will be discussed in further detail in conjunction with the drawings. [Figure 1] 1 shows a schematic diagram of an example sensor kit, spray gun, and surface. [Diagram 2] 1 shows a first flowchart. [Diagram 3] 2 shows a second flowchart. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0020] 1 shows a schematic overview of an embodiment of a sensor kit 100 comprising a sensor kit body 102 as a housing. The sensor kit body 102 comprises a spray gun connector 104 as a connection module. A spray gun 140 is connected to the body 102 via the connector 104. The spray gun 140 comprises a spray gun housing 141. The spray gun 140 may be, for example, a high volume low pressure (HVLP) spray gun.

[0021] Although the sensor kit body 102 is shown generally as a rectangle in FIG. 1, in different embodiments the body 102 may have different shapes. For example, the body 102 may be molded around the shape of the spray gun housing 141 to which it is arranged to be connected. Also, the shape of the body 102 and / or the center of gravity of the sensor kit 100 may be adapted such that when attached to the spray gun 140, the center of gravity of the spray gun 140 is kept within a desired range. In that way, handling of the spray gun 140 may be minimally affected by connecting the sensor kit 100.

[0022] The spray gun 140 can be used to apply a layer of paint 142 as a coating to a vehicle body part 144 as a surface. The spray gun 140 includes a nozzle 146 capable of emitting a mist of aerosol paint 148 and an inlet for receiving the paint as a coating material. The spray gun 140 can be a handheld spray gun 140 with a trigger that a user can activate to control the release of the paint 148 from the spray gun 140 at a particular rate.

[0023] The trigger may control the throughput area of ​​a conduit that directs paint or another coating fluid to the nozzle. Alternatively or additionally, the trigger or another trigger or control knob may control the position of a throughput orifice, such as a control needle in the nozzle 146 or another orifice. In one embodiment, the control needle may be used to precisely control the flow of coating fluid, and the trigger may be used to switch the nozzle between an "on" and an "off" state. In addition to the precise control mechanism, the flow of coating fluid may also be controlled to vary the pressure at which the coating fluid is delivered. One or more of the precision control setting, the coating fluid pressure, and the trigger state may be considered as optional spray job parameters.

[0024] The user can move and redirect the spray gun 140 as needed, either away from the body part 144 or toward the body part 144 at a certain speed and acceleration. The user can further redirect the spray gun 140 as desired, thus changing the orientation of the nozzle 146 relative to the body part 144 so that paint can be applied from different approach angles.

[0025] In the sensor kit body 102, a distance sensor module 106 is provided with one or more time-of-flight sensors as a proximity sensor constituted by the distance sensor module 106. The time-of-flight sensors are arranged to obtain distance data as spray job parameter values ​​relating to distances d1, d2 and d3 between the respective sensors and the body part 144 and / or the paint 142. As such, the time-of-flight sensors in the distance sensor module 106 are preferably oriented in the same direction as the nozzle 146, since when the sensor kit 100 is connected to the spray gun 140, the nozzle 146 will also face the body part 144 and / or the layer of paint 142.

[0026] The top right diagram of Figure 1 shows the location of the time-of-flight sensor of the distance sensor module 106 relative to the nozzle 146 and the spray cone of mist of aerosol paint 148. A commonly used spray gun provides a cone-shaped cone 148 of aerosol paint as a coating. The cross section of the cone can be circular or elliptical. Around the periphery of the spray cone 148 there can be small droplets of coating fluid in the form of a mist.

[0027] In the figure, an elliptical cross section is shown from the perspective of the spray gun 140. Additionally, the sensing direction 192 of the field of view sensor of the distance sensor module 106 is shown, as is the spray direction 186, but in this case away from the perspective.

[0028] At the center of the spray cone 148, an origin may be defined, as well as the vertical axis 182 and the horizontal axis 184. A sense direction 192 - a line from the time-of-flight sensor in the distance sensor module 106 that is substantially parallel to the centerline of the spray cone 148, is offset in this embodiment from the horizontal axis 184 as well as the vertical axis 182. In other embodiments, the sense direction may be on one of the horizontal axis 184 and the vertical axis 182. It may likewise be envisioned to provide the sense direction 192 at the origin of the two axes. This would require the time-of-flight sensor in the distance sensor module 106 to be at the heart of the spray gun.

[0029] The figure shows that the sensing direction, represented here as a sensing line in the sensing direction from the time-of-flight sensor towards the body part 144, is substantially parallel to and offset from the spool line of the spray direction from the nozzle 146 towards the body part 144. More specifically, the sensing line is offset from at least one of the major and minor axes of the elliptical cross section of the spray cone 148. The offset from the major axis is preferably greater than the offset from the minor axis.

[0030] The time-of-flight sensor as a proximity sensor may include a laser or LED as an optical transmitter arranged to emit a laser beam as an emitted optical signal. The time-of-flight sensor may further include an optical receiver for receiving a reflected optical signal as a reflection of the laser beam. A proximity processor may be used to determine the spray distance between the time-of-flight sensor and the surface 144 based on the relationship between the emitted laser beam and the reflected laser beam.

[0031] The emitted light signal may have a near infrared wavelength spectrum, for example 800-1140 nm, more particularly 900-1000 nm, most preferably 940 nm. Such wave electromagnetic radiation is invisible. Electromagnetic radiation, especially 900-1000 nm and 940 nm, is transparent, although some may appear opaque to the human eye and travel through materials.

[0032] The sensor kit body 102 may be constructed from a non-translucent material, and light such as that emitted by the time-of-flight sensor may be obstructed by the sensor kit body 102. In the embodiment of FIG. 1, the sensor kit body 102 optionally includes an at least partially translucent observation window 108 through which the light emitted by the time-of-flight sensor and reflected back may pass. Alternatively, at least a portion of the sensor kit body 102 through which the light must pass may be made of a material that is at least partially translucent to the wavelengths of light used by the time-of-flight sensor, which may be wavelengths in the infrared spectrum, for example.

[0033] In one embodiment, the time-of-flight sensors are spaced apart such that their lights do not interfere with each other, between 20 and 50 centimeters, the typical spray distance. That way, different values ​​of distances d1, d2, and d3 can be obtained.

[0034] In the embodiment of Fig. 1, the sensor kit 100 comprises a microcontroller 110 as a processing unit. The microcontroller 110 comprises a data input 112 as an input module arranged to receive one or more reference parameter values. The received reference parameter values ​​can be stored on a memory 114. Distance data can be sent by the time-of-flight sensor 106 to the data input 112 of the microcontroller 110 and can also be optionally stored in the memory 114.

[0035] The microcontroller 110 is an embodiment of the sensor kit 100 that is provided inside the sensor kit body 102. The sensor kit 100 also contemplates an embodiment in which a separate microcontroller as part of the processing unit is provided outside the sensor kit body 102. This separate microcontroller may be constituted by one or more external computing devices, such as, for example, a server, a smartphone, a tablet, any other computing device, or any combination thereof.

[0036] If at least a part of the processing unit is provided outside the sensor kit body 102, a wired or wireless connection may be provided between the sensor module and the microcontroller 110 to enable data exchange. If a wireless connection is used, for example, NFC, Bluetooth, Wi-Fi, or other protocols may be used for data exchange.

[0037] The microcontroller 110 as a processing unit further comprises a comparison module 116 arranged to compare at least some of the obtained spray job parameter values ​​with one or more corresponding reference parameter values. Thus, the comparison module 116 may be arranged to receive at least some of the spray job parameter values ​​and at least some of the reference parameter values, for example, from the data input 112 and / or to retrieve at least some of the spray job parameter values ​​and at least some of the reference parameter values ​​from the memory 114.

[0038] The comparison module 116 is further configured to generate a comparison data signal based on the result of the comparison. The comparison data signal may be received by the output module 118, which may be arranged and used to send the comparison data signal to other components of the sensor kit 100. In an embodiment, the output module 118 may be configured by the processing unit, the comparison module, the sensor module, or the sensor kit 100 in general.

[0039] The data input 112 may be configured to receive user identification data indicative of a particular user or group of users. For example, the user identification data may include employee data, name, and / or any other data by which a particular user of a group of users may be identified. The user identification data may be stored on the memory 114. When the user identification data is stored on the memory 114, a particular sensor kit 110 may be linked to a particular user.

[0040] To provide feedback to a user using the spray gun 140 with the sensor kit 100, the sensor kit 100 configures a feedback controller 120 as a user feedback module. The feedback controller 120 is configured to generate a user feedback signal based on at least a portion of the comparison data signal. The feedback controller 120 may be further configured to receive at least a portion of the comparison data signal from the output module 118 and / or retrieve at least a portion of the comparison data signal from the memory 114.

[0041] 1, the feedback controller 120 is provided inside the sensor kit body 102. Embodiments are also envisioned in which at least a portion of the feedback controller 120 is provided outside the sensor kit body 102. In such embodiments, at least a portion of the generated feedback signal may be sent to an external feedback device, such as a speaker, display, or light, via a wired or wireless connection.

[0042] 1, the feedback controller 120 is connected to a display 122 as an actuator and is arranged to provide a visual signal based on the feedback signal. The display 122 is depicted as being disposed within the sensor kit body 102. In embodiments, the display 122 may also be disposed in a different location, and the display 122 may be, for example, a display of a smartphone, a tablet, a head-up display (HUD), a smartwatch, smart glasses, or any other display.

[0043] The feedback controller 120 may also be connected to an LED module 124 that includes at least one, and preferably more, LEDs-light emitting diodes, particularly as an actuator and light source for providing feedback. Preferably, the LED module 124 includes a red light source and a green light source. The red light may be activated if the comparison module 116 determines that one or more spray job parameter values ​​are out of bounds relative to one or more reference parameter values ​​or reference intervals. The green light may be activated if one or more spray job parameter values ​​are within bounds relative to one or more reference parameter values ​​or reference intervals.

[0044] To obtain orientation data indicative of the orientation of the spray gun 140, an embodiment of the sensor kit 100 may include an orientation sensor 130, which may be an absolute orientation sensor or a relative orientation sensor 130. The orientation sensor 130 may include a magnetometer, an accelerometer, a compass, a gyroscope, any other sensor, or any combination thereof. The orientation sensor 130 is positioned to measure the angle of the sensor kit, preferably relative to a horizontal plane. Preferably, the orientation sensor is positioned to provide three signals indicative of a first rotation φ across a first axis perpendicular to the spray direction of the nozzle 146, a second rotation θ across a second axis perpendicular to the spray direction and perpendicular to the first axis, and a third rotation ψ across a third axis parallel to the spray direction.

[0045] The orientation data may include data indicative of the roll, yaw, and pitch of the spray gun 140. Because the housing body 102 is preferably rigidly connected to the spray gun 140, the roll, yaw, and pitch of the orientation sensor 130 may substantially correspond to, or at least be translated to, the roll, yaw, and pitch of the spray gun 140. Any output parameter or parameter of the orientation sensor 130 may be considered any spray job parameter.

[0046] Additionally or alternatively, the orientation sensor 130 is configured to determine at least one angle of the orientation sensor relative to a reference plane, which may be, for example, a horizontal plane, a vertical plane, or a plane representing the surface 144 to which the coating 142 is applied.

[0047] To obtain movement data indicative of the movement of the spray gun 140, an embodiment of the sensor kit 100 may include an accelerometer 132 as an example of a movement sensor. The accelerometer 132 is preferably configured to provide three signals indicative of acceleration in three directions. In a preferred embodiment, a first acceleration is measured in a first direction x, a second direction y, and a third direction z. In a more preferred embodiment, each direction is parallel to an axis of rotation as described above. For example, the first direction is parallel to the first axis, the second direction is parallel to the second axis, and the third direction is parallel to the third axis, although other options may be envisaged.

[0048] The movement data may include data indicative of the velocity and / or acceleration in one or more directions of the spray gun 140. Because the housing body 102 is preferably rigidly connected to the spray gun 140, the velocity and / or acceleration of the movement sensor 132 may substantially correspond to, or at least be converted to, the velocity and / or acceleration of the spray gun 140. One or more of the velocity and acceleration, either as a scalar or vector, may be considered as any spray job parameter.

[0049] Optionally, the embodiment of the sensor kit 100 as shown in Fig. 1 is configured with a speaker 126 as an actuator, connected to the feedback controller 120, in particular for providing an audio signal based on the feedback signal. Depending on the feedback signal, for example, the audio signal can have different volumes and / or frequencies to indicate a particular type of feedback to the user.

[0050] As a further option, the embodiment of the sensor kit 100 as shown in Fig. 1 comprises a vibration unit 128 as an actuator, a tactile module for providing vibrations, in particular as a tactile signal, based on a feedback signal connected to the feedback controller 120. The vibrations can be transmitted via the connection 104 to the spray gun body 141, which can be held by a user of the spray gun 140. Thus, the user can feel the vibrations when holding the spray gun 140.

[0051] As a further option, an embodiment of the sensor kit 100 is envisioned in which the sensor module includes a temperature sensor for obtaining temperature data indicative of the temperature of the surface 144 to be spray coated. In such an embodiment, the reference parameter value may include a minimum temperature that the surface 144 should have. If the comparison module provides a comparison data signal indicating that the temperature of the surface 144 is below the minimum temperature, the user feedback module can indicate to the user that the temperature of the surface 144 is too low.

[0052] To power components of the sensor kit 100 that require electrical energy, the sensor kit 100 can include a battery 134 in which electrical energy can be stored. In certain embodiments, the sensor kit housing 102 is substantially sealed, for example, to prevent fluids from entering the housing and / or to prevent electrical components from being exposed to painting fumes. Being substantially sealed may not allow for the use of a wired connection to charge the battery 134 and / or for easily replacing a depleted battery.

[0053] A coil 136 as a wireless charging module for charging the battery 134 may be configured by the sensor kit 100 or may be disposed inside the sensor kit housing 102 together with the battery 134. Electrical energy may be provided to the battery 134 via the coil 136, for example by using inductive charging. This transfer of electrical energy is wireless, so there is no need to place connectors inside the housing 102 and no need to expose electrical components to ambient air that may contain flammable coating materials in the aerosol.

[0054] An embodiment of a method for processing data received from a time-of-flight sensor or other distance sensor that may be used is illustrated generally by a first flowchart 200 as shown in Figure 2 and will be elaborated in conjunction with Figure 1. It will be understood that the method may also be applied in conjunction with other embodiments of the sensor kit 100, and that the sensor kit 100 of Figure 1 may be used in conjunction with other embodiments of the method illustrated by the first flowchart 200. The various parts of the flowchart 200 are briefly summarized below: 202 Start 204 Calculate the sensor value 206 Get the previous value 208 Determine the criteria 210 Do the values ​​obtained comply with the acceptance criteria? Include 212 values ​​in the median set 214 Determine the median of a set of medians 216 Discard the oldest value in a collection 218 Contains the median of the mean set 220 Determining the mean in an average set 222 Average is the base value 224 Discard the oldest value in the average set

[0055] The procedure starts at terminator 202 and proceeds by obtaining a sensor value from the sensor in step 204. The sensor value may be the actual distance value directly, but may also be another value indicative of the actual distance. In step 206, one or more pre-obtained values ​​are obtained from an electronic memory configured by the device in which it is stored, the value being preferably a reasonably obtained value, its median, its average, another process value based thereon, or a combination thereof.

[0056] In step 208, a validity criterion is determined. The validity criterion may be retrieved from memory as a pre-determined value or operation. As an operation, the criterion may be a filter, such as a smoothing filter or a median filter. As a value, it may be an absolute or relative value, relative to the obtained value, a previously obtained value, or a value based on one or more previously obtained values, a percentage.

[0057] The value may also be based on the sampling rate of the time-of-flight sensor or other distance sensor. As such, the criterion may be that the spray gun 140 can only move at a certain maximum speed. If, based on previously obtained distance values ​​and the time period between samples, the spray gun 140 appears to be moving too fast, the criterion is that the obtained value is not valid, and may be caused by measuring droplets of coating fluid rather than the surface of the body part 144. The validity criteria are preferably stored in an electronic memory configured by the device.

[0058] In step 210, the derived value is evaluated against the criteria obtained or determined in step 208. If the derived value is determined to be invalid based on the evaluation, the derived value is discarded in step 232 and the process returns to step 204.

[0059] If the resulting value is deemed valid, the procedure proceeds to step 212, where the value deemed valid is included in the median set. In step 214, the median of the values ​​in the median set is determined and this value is returned. The oldest value in the median set is then discarded in step 216 to create a sliding window. In an embodiment having a non-sliding window, no values ​​are discarded, and the full set is discarded until the set is full, and after determining the median - or average or other value - the processed values ​​are returned.

[0060] In step 218, the median value is included in the average set. In step 220, the values ​​in the average set are averaged, and in step 222 the resulting value is provided as a base value indicative of the distance between the sensor and the surface of the body part 144, and thus the distance between the nozzle 146 and the body part 144. Calculating the average based on the median value is optional, and the order may be reversed. Subsequently, if a sliding window approach is used and the process branches to step 204, the oldest value in the set is discarded in step 224.

[0061] The base value is used for further data processing, particularly by the sensor kit 100 and the comparison module 116. In the comparison module, the base value for the distance between the sensor module 106 and the surface 144 is used as a spray job parameter value that is compared to a reference parameter value for distance, for example as described above in connection with FIG.

[0062] Another example of a method for processing data received from a time-of-flight sensor or other distance sensor that may be used is illustrated generally by a first flowchart 300 as shown in Figure 3 and detailed in relation to Figure 1. It will be appreciated that the method may also be applied in conjunction with other embodiments of the sensor kit 100, and that the sensor kit 100 of Figure 1 may be used in conjunction with other embodiments of the method depicted by the second flowchart 300. Various portions of the second flowchart 300 are briefly summarized below: 302 Procedure Start 304 Get distance value 306 Include the retrieved value in a set 308 Full set? 310 Get the standard 312 Determine the maximum value 314 Select the highest value 316 Determine the Median 318 Value Output 320 Group Destruction

[0063] The procedure begins with a terminator 302 and proceeds to step 304 where a distance value is obtained, as described above. In step 306, the distance value is included in a set stored in an electronic memory configured by the device. If it is determined in step 308 that the set is not yet full, another distance value is obtained in step 304 and included in the set in step 306. If the set is determined to be full, the procedure proceeds from step 308 to step 310. In 310, a criterion is obtained from an electronic memory configured by the device to determine whether the value included in the set is a valid value for the distance between the distance sensor and the body part.

[0064] The distance criterion may be obtained as described above in relation to Figure 2 and the second flow chart. Alternatively or additionally, the criterion may be defined as a valid value being within 10% of the highest values ​​in the set, or a value within 10% of the highest value in the set being a valid value. Instead of 10%, values ​​such as 1%, 2%, 3%, 4%, 5%, 7%, 8%, 15%, or other relative margins may be used.

[0065] In step 312, the values ​​determined to meet the criteria are selected and other values ​​in the set may be discarded or retained. In step 314, the median of the values ​​determined to be valid is determined. Alternatively or additionally, an average is obtained. In another alternative, the criteria evaluation is skipped and the median of all values ​​in the set is applied as the criteria for selecting the median value as valid. As such, the median of the set, the average of the values ​​in the set, or the result of another filtering, preferably using a smoothing filter such as a median filter or a LULU filter, may be used at the output.

[0066] The base value is used for further data processing, particularly by the sensor kit 100 and the comparison module 116. In the comparison module, the base value for the distance between the sensor module 106 and the surface 144 is used as a spray job parameter value that is compared to a reference parameter value for distance, for example as described above in connection with FIG.

[0067] In step 318, the set is discarded if a fixed window processing algorithm is used. Additionally or alternatively, a moving window may be used for processing, as discussed in connection with the first flowchart 200 of FIG. 2, and the procedure then branches to step 304.

[0068] Various aspects and options relate to distance sensors providing data and processing of that data. A distance sensor can be placed on the spray gun to determine the distance between the spray guns for applying the coating fluid to the surface. The sensor provides a value related to the distance between the spray gun and the surface, but also a value related to the distance between the spray gun and the aerosol particles. From all these values, the distance between the spray gun and the surface is estimated by checking if the received value is valid for the distance to the surface by a distance acceptance criterion. The distance acceptance criterion may be based on previous values. The values ​​that meet the criterion in the set are used to provide an estimate of the distance to the surface, for example by providing a median or an average.

Claims

1. 1. A method for determining, in an electronic data processor, a distance between a distance sensor connected to a coating fluid applicator and a surface during spray coating of the surface, the method comprising: obtaining data values ​​from the sensor over time indicative of a distance between the sensor and a detected object; Obtaining distance tolerance criteria for valid distance values ​​to be met; applying distance acceptance criteria to the received values; determining a set of values ​​of the data received over a predetermined time interval; determining at least one base value indicative of a distance between the sensor and the surface based on determining values ​​of the data that meet a distance acceptance criterion; making said base value available for output by an electronic data processing device.

2. The method of claim 1 , wherein the distance tolerance criteria applied to a received value is determined based on at least one previously received value.

3. The method of claim 1 or 2, wherein the distance acceptance criterion is a fixed difference value.

4. The method of claim 1 or 2, wherein the distance acceptance criterion is further based on a time interval between the received value and a previously received value.

5. The method of claim 1 or 2, wherein received values ​​that do not meet the distance acceptance criterion are not included in the determined set.

6. The method of claim 1 or 2, wherein the base value is at least one of a median or an average of the values ​​of the data in the set.

7. 4. The method of claim 3 when dependent on claim 2, wherein the distance criteria includes a requirement that the value of the data for determining the base value be a predetermined amount of the highest value in the determined set.

8. The method of claim 7 , wherein the predetermined amount is based on a total amount of data values ​​in the set.

9. receiving a distance compliance criterion, the method further comprising: comparing said base value to said distance compliance criterion; providing a first signal value at an output of an electronic data processor if said base value complies with said distance compliance criterion; providing a second signal value at an output of the electronic data processor if the base value does not comply with the distance compliance criterion. The method according to claim 1 or 2.

10. 1. An apparatus for a method for determining a distance between a distance sensor connected to a spray applicator for spraying a coating fluid and a surface being spray coated, the apparatus comprising: a distance sensor arranged to determine a distance between the sensor and an object; and an electronic data processor disposed in the receiving data values ​​from the distance sensor over time indicative of a distance between the distance sensor and a detected object; determining a set of values ​​of received data received over a predetermined time interval; Obtaining distance tolerance criteria for valid distance values ​​to be met; applying said distance acceptance criteria to said determined set of values; determining at least one base value indicative of a distance between the distance sensor and a surface based on values ​​of the data that satisfy the distance acceptance criteria; Apparatus for making said base value available for output by an electronic data processing apparatus.

11. a first actuator and a second actuator connected to an output of the electronic data processor, the electronic data processor further comprising: comparing said base value with a distance compliance criterion; providing a first signal value at an output of an electronic data processor for actuating a first actuator if the base value complies with the distance compliance criterion; providing a second signal value to an output of the electronic data processor for actuating a second actuator if the base value does not comply with a distance compliance criterion; 11. The apparatus of claim 10.

12. A spray applicator for a coating fluid configured to spray the coating fluid from a spray orifice in a spray direction, the spray applicator comprising: The distance sensor senses a distance in a sensing direction. The device is connected to the applicator such that the spray direction is parallel to the sensing direction.

13. 13. The spray applicator of claim 12, wherein a line of sensing from the distance sensor in the sensing direction is offset relative to a line of spray from the spray orifice in the spray direction.

14. 14. The spray applicator of claim 13, wherein the spray orifice is arranged to emit the coating fluid in a spray cone having an elliptical cross section, the sensing line being offset from a major axis of the elliptical cross section.

15. 15. A spray applicator as claimed in claim 13 or 14, wherein the spray orifice is arranged to emit the coating fluid in a spray cone having an elliptical cross section, the sensing line being offset from a minor axis of the elliptical cross section.

Images