Electrostatic gun driver and method for implementing the same

Abstract

The electrostatic gun driver includes an inverter configured to receive power from a power source, a controller configured to control the inverter, and a filter configured to generate a sinusoidal drive signal and provide the sinusoidal drive signal to the material application system and / or material application device.

Description

[Technical Field]

[0001] REFERENCE TO RELATED APPLICATIONS This application claims the benefit of U.S. Provisional Application No. 63 / 420,968 (filed October 31, 2022), which is incorporated herein by reference in its entirety for all purposes as if fully set forth herein.

[0002] Field of Disclosure The present disclosure relates to an electrostatic gun driver. Additionally, the present disclosure relates to a method for implementing an electrostatic gun driver. [Background technology]

[0003] Background to the disclosure Powder coating materials, such as powder paints, are typically applied to objects by spraying the powder coating material. Typically, a spray gun or material application device is used, and the spray gun may be manually held and operated, or an electronically controlled automatic spray gun may be used. Spray techniques include, for example, electrostatic, non-electrostatic, triboelectric, etc.

[0004] Typically, as shown in FIG. 13, a gun driver circuit uses a DC power supply to provide a drive waveform to the spray gun. In particular, a DC power supply is used in conjunction with a boost converter power stage, such as a flyback converter or DC inverter, to provide a PWM drive waveform for the spray gun. However, typical gun driver circuits have low power efficiency, resulting in waste heat. This in turn requires more expensive cooling equipment. Furthermore, typical gun driver circuits have a larger form factor, which results in higher packaging costs. Furthermore, typical gun driver circuits require the use of many electrical circuit components, which results in a larger design size and a higher cost for the gun driver circuit. Furthermore, typical gun driver circuits employ a square PWM drive waveform, which impacts performance.

[0005] Therefore, there is a need for driver circuits that have improved power efficiency, less waste heat generation, lower cost cooling equipment, smaller form factors, smaller and lower cost packaging, reduced electrical circuit component part count, better performance, etc. Summary of the Invention

[0006] Disclosure Overview In one general aspect, an electrostatic gun driver includes an inverter configured to receive power from a power source, a controller configured to control the inverter, and a filter configured to generate a sinusoidal drive signal and provide the sinusoidal 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, the method further includes generating a sinusoidal drive signal with a filter, and providing the sinusoidal drive signal to a material application system and / or a material application device.

[0008] There have thus been outlined, rather broadly, some aspects of the present disclosure in order that the detailed description thereof may be better understood, and in order that the present contribution to the art may be better appreciated. There are, of course, additional aspects of the present disclosure that will be described below and that will form the subject matter of the claims appended hereto.

[0009] In this regard, before describing at least one aspect of the present disclosure in detail, it is to be understood that the disclosure is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the drawings. The disclosure is capable of aspects in addition to those described and may be practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein, as well as the abstract, are for the purpose of description and should not be regarded as limiting.

[0010] As such, those skilled in the art will appreciate that the conception underlying the present disclosure may readily be utilized as a basis for the designing of other structures, methods, and systems for carrying out the several purposes of the present disclosure. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present disclosure. [Brief explanation of the drawings]

[0011] [Figure 1] FIG. 1 is a schematic diagram of an electrostatic gun driver according to an embodiment of the present disclosure implemented in a material application system. [Figure 2] FIG. 2 is a schematic diagram of an electrostatic gun driver according to an embodiment of the present disclosure implemented in a material application system. [Figure 3] FIG. 3 illustrates an exemplary implementation of an electrostatic gun driver and inverter according to aspects of the present disclosure. [Figure 4] FIG. 4 illustrates an exemplary implementation of an electrostatic gun driver and inverter according to aspects of the present disclosure. [Figure 5] FIG. 5 is a schematic diagram of an electrostatic gun driver according to an embodiment of the present disclosure. [Figure 6] FIG. 6 is a schematic diagram of an electrostatic gun driver according to an embodiment of the present disclosure. [Figure 7] FIG. 7 illustrates an exemplary implementation of a filter according to aspects of the present disclosure. [Figure 8] FIG. 8 illustrates an exemplary implementation of a filter according to aspects of the present disclosure. [Figure 9] FIG. 9 illustrates an exemplary implementation of an inverter according to aspects of the present disclosure. [Figure 10] FIG. 10 shows an exemplary implementation of the inverter according to FIG. [Figure 11] FIG. 11 is a diagram illustrating exemplary waveforms of a sinusoidal drive signal and modulated voltage pulses according to the present disclosure. [Figure 12] FIG. 12 illustrates an exemplary method of implementing an electrostatic gun driver of the present disclosure. [Figure 13] FIG. 13 is a diagram showing a prior art gun driver circuit. DETAILED DESCRIPTION OF THE INVENTION

[0012] Detailed Description In the drawings, like reference numbers refer to like parts throughout.

[0013] FIG. 1 shows a schematic diagram of an electrostatic gun driver according to an embodiment of the present disclosure implemented in a material application system.

[0014] In particular, Figure 1 shows a schematic diagram of an electrostatic gun driver 100 according to an embodiment of the present disclosure. The electrostatic gun driver 100 may include an inverter 102, a controller 106, a filter 108, etc. Furthermore, the embodiment of Figure 1 and its description may be implemented with any other figure and / or embodiment of the present disclosure. Furthermore, the embodiment of any other figure and its description may be implemented with the embodiment of Figure 1.

[0015] 1 further illustrates a material application system 200 implementing an exemplary material application device 210. An electrostatic gun driver 100 is configured to generate and provide a sinusoidal drive signal 190 to the material application system 200 and / or the exemplary material application device 210. An inverter 102 of the electrostatic gun driver 100 may be configured to receive power from a power source 104.

[0016] Compared to prior art drivers, the disclosed implementation of the electrostatic gun driver 100 implementing the inverter 102 provides improved power efficiency for the electrostatic gun driver 100, material application system 200, and / or the like, resulting in less waste heat generation, lower-cost cooling equipment, etc. Furthermore, the disclosed implementation of the electrostatic gun driver 100 implementing the inverter 102 can be implemented in a smaller form factor, resulting in lower-cost packaging options. Furthermore, the disclosed implementation of the electrostatic gun driver 100 implementing the inverter 102 reduces the component count of the electrical circuitry, potentially resulting in a more compact design and lower-cost gun drive circuit with the same or better (true sine wave) performance compared to prior art electrostatic gun drivers. In particular, the disclosed implementation of the electrostatic gun driver 100 implementing the inverter 102 can generate a true sine wave.

[0017] In some aspects, the electrostatic gun driver 100, inverter 102, and / or similar devices may be implemented separately from the example material application apparatus 210. In other aspects, the electrostatic gun driver 100, inverter 102, and / or similar devices may be implemented within the example material application apparatus 210. In this regard, the disclosed aspects of the electrostatic gun driver 100, inverter 102, and / or similar devices are configured to be more compact, as described above, and therefore, may be implemented within the example material application apparatus 210.

[0018] In some embodiments, the inverter 102 may be implemented as a four-switch inverter that generates modulated voltage pulses 192 (shown in FIG. 11 ) from the power supply 104. In some embodiments, the controller 106 may implement a unipolar 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 sinusoidal drive signal 190 (as shown in FIG. 11 ) to drive the exemplary material application apparatus 210.

[0019] In some aspects, an electrostatic gun driver 100 implementing the inverter 102, controller 106, and / or filter 108 is configured to generate a sinusoidal drive signal 190 having a peak-to-peak voltage sine wave directly from the power supply 104, thereby allowing a boost converter power stage, a flyback converter, a DC inverter, and / or similar circuitry to be omitted from the design. This omission of the boost converter power stage, the flyback converter, the DC inverter, and / or similar circuitry increases the overall system efficiency of the electrostatic gun driver 100 and reduces the electrical component count of the electrostatic gun driver 100. Furthermore, the disclosed implementations of the electrostatic gun driver 100 reduce required circuit support board space, such as printed circuit board (PCB) space, which reduces overall cost and / or provides other benefits. Accordingly, in some aspects, the electrostatic gun driver 100 is configured to omit a boost converter power stage, a flyback converter, and a DC inverter. In some embodiments, the electrostatic gun driver 100 is configured to omit a boost converter power stage, the electrostatic gun driver 100 is configured to omit a flyback converter, and / or the electrostatic gun driver 100 is configured to omit a DC inverter.

[0020] In some aspects, the electrostatic gun driver 100 implementing the inverter 102, controller 106, and / or filter 108 can generate the sinusoidal drive signal 190 as a sine multiplier drive waveform compared to existing square and / or non-sinusoidal waveforms of existing driver designs.

[0021] In some embodiments, the electrostatic gun driver 100 and / or the inverter 102 generate a sinusoidal drive signal 190 having a frequency. The frequency of the sinusoidal drive signal 190 may be between 1 kHz and 1000 kHz, between 1 kHz and 25 kHz, between 25 kHz and 35 kHz, between 28 kHz and 32 kHz, between 35 kHz and 45 kHz, between 45 kHz and 90 kHz, or between 90 kHz and 100 kHz. In some embodiments, the electrostatic gun driver 100 and / or the inverter 102 generate a sinusoidal drive signal 190 having a voltage and / or amplitude. The voltage of the sinusoidal drive signal 190 may be between 0 V peak-to-peak and 100 V peak-to-peak, between 0 V peak-to-peak and 30 V peak-to-peak, between 30 V peak-to-peak and 50 V peak-to-peak, between 50 V peak-to-peak and 60 V peak-to-peak, between 60 V peak-to-peak and 80 V peak-to-peak, or between 80 V peak-to-peak and 100 V peak-to-peak.

[0022] In some embodiments, power supply 104 can be an industry standard power supply. In some embodiments, power supply 104 can be an industry standard DC power supply. In some embodiments, power supply 104 can be an industry standard DC power supply that generates a DC voltage of 2V to 100V, 2V to 20V, 20V to 30V, 30V to 60V, or 60V to 100V.

[0023] FIG. 1 further illustrates an example material application device 210 configured to be implemented with the electrostatic gun driver 100. In this regard, the example material application device 210 may be implemented as a manually operated material application device. However, the disclosed implementation of the electrostatic gun driver 100 may be implemented with other types and implementations of the example material application device 210. For example, the example material application device 210 may be a robotically operated implementation such as that shown in FIG. 2. In the examples herein, the example material application device 210 may be, for example, any suitable material application device, spray gun, powder spray gun, etc. However, it should be understood that the example material application device 210 may be embodied in many forms other than simply a spray gun and is not limited to that term.

[0024] The example material application apparatus 210 may include a nozzle portion 212, a barrel portion 214, an electrical cable 226, etc. The electrical cable 226 or electrical connection may be provided between the electrostatic gun driver 100, the control system 188, etc. and an electrical input 230 of the example material application apparatus 210. The material application system 200, the control system 188, and / or the electrostatic gun driver 100 may receive one or more signals from the example material application apparatus 210, such as a trigger actuation signal indicating that an operator has actuated an actuator 232. When the actuator 232 is actuated, an electrical signal or condition (e.g., a closed contact) may be sent or detected by the control system 188 to initiate the flow of coating material to the example material application apparatus 210, and other signals may be generated to activate power that may be provided by the electrostatic gun driver 100 for the example material application apparatus 210. All electrical signals or conditions between the example material application apparatus 210 and the control system 188 or other system components may be transmitted along electrical wires through the electrical cable 226.

[0025] FIG. 2 is a schematic diagram of an electrostatic gun driver according to an embodiment of the present disclosure implemented in a material application system.

[0026] In particular, Figure 2 illustrates the electrostatic gun driver 100 implemented in a material application system 200. In some embodiments, the material application system 200 may include a robotic system 250 configured to operate within the material application system 200 and manipulate and move the example material application device 210. Additionally, the embodiment of Figure 2 and its description may be implemented in any other figure and / or embodiment of the present disclosure. Additionally, the embodiment of any other figure and its description may be implemented in the embodiment of Figure 2.

[0027] In some embodiments, robotic system 250 can include one or more arms, one or more motors for moving the one or more arms, which can provide up to three or more axes of motion. Further, one or more arms can hold exemplary material application device 210. In some embodiments, one or more arms can include one or more suction cups, manipulators, etc. for grasping, moving, and / or the like, exemplary material application device 210. Additionally, robotic system 250 can include a controller configured to control the operation of various components of robotic system 250. Furthermore, robotic system 250 can include a vision system configured to aid in identifying and locating objects within material application system 200.

[0028] FIG. 3 illustrates an exemplary implementation of an electrostatic gun driver and inverter according to aspects of the present disclosure.

[0029] In particular, Figure 3 illustrates an example implementation of an electrostatic gun driver 100, a filter 108, and an inverter 102 according to aspects of the present disclosure. Furthermore, the aspects of Figure 3 and its description may be implemented in any other figure and / or aspect of the present disclosure. Furthermore, the aspects of any other figure and its description may be implemented in the aspect of Figure 3.

[0030] 3 illustrates an electrostatic gun driver 100 configured to generate and provide a sinusoidal drive signal 190 to a material application system 200 and / or an example material application device 210. An inverter 102 of the electrostatic gun driver 100 may be configured to receive power from a power supply 104. The inverter 102 generates modulated voltage pulses 192, and a filter 108 receives the modulated voltage pulses 192 and generates the sinusoidal drive signal 190.

[0031] FIG. 4 illustrates an exemplary implementation of an electrostatic gun driver and inverter according to aspects of the present disclosure.

[0032] In particular, Figure 4 illustrates an example implementation of an electrostatic gun driver 100 and an inverter 102 according to aspects of the present disclosure. Furthermore, the aspects of Figure 4 and its description may be implemented in any other figure and / or aspect of the present disclosure. Furthermore, the aspects of any other figure and its description may be implemented in the aspect of Figure 4.

[0033] Further, 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, together with the inverter 102, may be configured to convert direct current (DC) from the power supply 104 to alternating current (AC) for the example material application apparatus 210. In particular, the electrostatic gun driver 100 in cooperation with the inverter 102 may be configured to generate modulated voltage pulses 192 from the power supply 104. In particular, the controller 106 may rapidly switch on and off power from the power supply 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 Qa112, the fourth switch Qd114, the third switch Qc116, and the second switch Qb118 may be implemented as a transistor, a FET, a MOSFET, etc. In aspects, the inverter 102 may be implemented as a half-bridge inverter circuit having the first switch Qa112, the fourth switch Qd114, the third switch Qc116, and the second switch Qb118 when the first switch Qa112 and the fourth switch Qd114 are on and the third switch Qc116 and the second switch Qb118 are off.

[0034] In an embodiment, the inverter 102 may be implemented as a four-switch inverter having a first switch Qa 112, a fourth switch Qd 114, a third switch Qc 116, and a second switch Qb 118 that generate pulses that are modulated to generate modulated voltage pulses 192 from the power supply 104.

[0035] The filter 108 filters and smooths the modulated voltage pulses 192 generated by the power supply 104 into a sinusoidal drive signal 190. The filter 108 can then provide the sinusoidal drive signal 190 to drive the exemplary material application device 210. In particular, the filter 108 can provide the sinusoidal drive signal 190 on an electrical cable 226 to drive the exemplary material application device 210.

[0036] FIG. 5 shows a schematic diagram of an electrostatic gun driver according to an embodiment of the present disclosure.

[0037] In particular, Figure 5 shows exemplary details of power supply 104 and controller 106. Furthermore, the embodiment of Figure 5 and its description may be implemented in any other figure and / or embodiment of the present disclosure. Furthermore, the embodiment of any other figure and its description may be implemented in the embodiment of Figure 5.

[0038] In some aspects, the inverter 102 may include a signal line 182 connecting 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 may be configured to implement a unipolar 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 may be configured to implement a unipolar modulation scheme, which may be implemented by the controller 106 as a control signal on the signal line 182. In some aspects, the signal line 182 may connect 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. Therefore, 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 another signal line 182. Specifically, the controller 106 can control two diagonal switch pairs, 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 that are modulated to generate modulated voltage pulses 192. In particular, the diagonal switch pair can be the first switch Qa 112 and the fourth switch Qd 114, or the diagonal switch pair can be the third switch Qc 116 and the second switch Qb 118.

[0039] FIG. 6 is a schematic diagram of an electrostatic gun driver according to an embodiment of the present disclosure.

[0040] In particular, Figure 6 shows exemplary details of power supply 104 and controller 106. Furthermore, the embodiment of Figure 6 and its description may be implemented in any other figure and / or embodiment of the present disclosure. Furthermore, the embodiment of any other figure and its description may be implemented in the embodiment of Figure 6.

[0041] As shown in FIG. 6 , the controller 106 can implement a unipolar modulation scheme. In particular, the controller 106 can be configured to implement the unipolar modulation scheme by receiving a sinusoidal reference 152 and a carrier waveform 154. The sinusoidal reference 152 can be compared to 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 sinusoidal reference 152 is higher than the voltage of the carrier waveform 154, the first switch Qa 112 can be switched on; otherwise, the first switch Qa 112 is switched off. The second switch Qb 118 is the inverse of the first switch Qa 112. The other side of the bridge of the inverter 102, the third switch Qc 116 and the fourth switch Qd 114, operate in a similar manner but use the inverse voltage of the sinusoidal reference 152 as a reference.

[0042] FIG. 7 illustrates an exemplary implementation of a filter according to aspects of the present disclosure.

[0043] In particular, Figure 7 illustrates an exemplary embodiment of filter 108 according to an aspect of the present disclosure. Furthermore, the aspect of Figure 7 and its description may be implemented in any other figure and / or aspect of the present disclosure. Furthermore, the aspect of any other figure and its description may be implemented in the aspect of Figure 7.

[0044] 7 , the filter 108 may include a parallel power line 174. The parallel power line 174 may receive the modulated voltage pulses 192 generated by the inverter 102. Further, the filter 108 may filter and smooth the modulated voltage pulses 192 generated by the inverter 102 into a sinusoidal drive signal 190. The filter 108 may then provide the sinusoidal drive signal 190 to drive the example material application device 210. In particular, the filter 108 may provide the sinusoidal drive signal 190 over an electrical cable 226 to drive the example material application device 210. In this regard, the filter 108 may employ any type of electronic filtering technology implementing any type of electrical components.

[0045] 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 an implementation of the parallel power lines 174. In some aspects, the capacitor 172 may be arranged to connect between the parallel power lines 174.

[0046] FIG. 8 illustrates an exemplary implementation of a filter according to aspects of the present disclosure.

[0047] In particular, Figure 8 illustrates an example implementation of filter 108 according to an aspect of the present disclosure. Furthermore, the aspect of Figure 8 and its description may be implemented in any other figure and / or aspect of the present disclosure. Furthermore, the aspect of any other figure and its description may be implemented in the aspect of Figure 8.

[0048] In some aspects, the filter 108 may include a buck converter 160. In some aspects, the buck converter 160 may be implemented as a step-down and / or a step-up converter. In some aspects, the buck converter 160 may step down and / or step up the voltage of the power supply 104.

[0049] In some aspects, the filter 108 may include a load resistor 162. The load resistor 162 may be connected between the parallel power lines 174.

[0050] In some embodiments, 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 embodiments, the current sensed by the current sensor 164 may be provided to the controller 106, the control system 188, the material application system 200, or the like.

[0051] In some embodiments, the filter 108 may include a voltage sensor 166. The voltage sensor 166 may be connected between the parallel power lines 174. In some embodiments, the voltage sensed by the voltage sensor 166 may be provided to the controller 106, the control system 188, the material application system 200, or the like.

[0052] In some embodiments, 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 embodiments, the current sensed by the current sensor 164 may be provided to the controller 106, the control system 188, the material application system 200, or the like.

[0053] FIG. 9 illustrates an exemplary implementation of an inverter according to aspects of the present disclosure.

[0054] FIG. 10 shows an exemplary implementation of the inverter according to FIG.

[0055] In particular, Figures 9 and 10 illustrate example implementations of inverter 102 according to aspects of the present disclosure. Furthermore, the aspects of Figures 9 and 10 and their descriptions may be implemented in any other figure and / or aspect of the present disclosure. Furthermore, the aspects of any other figure and their descriptions may be implemented in the aspects of Figures 9 and 10.

[0056] In some aspects, the inverter 102 may 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 may include anti-parallel diodes. As shown in FIG. 10 , the fourth switch Qd 114 is shown in detail along with an implementation of an anti-parallel diode 198.

[0057] FIG. 11 is a diagram illustrating exemplary waveforms of a sinusoidal drive signal and modulated voltage pulses according to the present disclosure.

[0058] 11 illustrates example waveforms of the sinusoidal drive signal 190 and modulated voltage pulses 192 generated by various components of the electrostatic gun driver 100. In this regard, the sinusoidal drive signal 190 generated by the electrostatic gun driver 100 may be a true sine wave.

[0059] FIG. 12 illustrates an exemplary method of implementing an electrostatic gun driver of the present disclosure.

[0060] In particular, FIG. 12 illustrates an exemplary method for implementing the electrostatic gun driver 300 of the present disclosure. In particular, it should be noted that the method for implementing the electrostatic gun driver 300 is merely exemplary and may be modified in accordance with various aspects disclosed herein. It should be noted that the method for implementing the electrostatic gun driver 300 may be performed in a different order consistent with the aspects described above. Furthermore, the method for implementing the electrostatic gun driver 300 may be modified to have more or fewer method steps consistent with various aspects disclosed herein. In particular, the method for implementing the electrostatic gun driver 300 may be a method for implementing the electrostatic gun driver 100 according to the present disclosure.

[0061] A method of implementing an electrostatic gun driver 300 of the present disclosure may include receiving power from a power source 302. In this regard, receiving power from the power source 302 may include any one or more materials, structures, configurations, methods, etc., as described herein. Additionally, one or more follow-on or subsequent methods may also be implemented with respect to receiving power from the power source 302 consistent with the present disclosure. In particular, receiving power from the power source 302 may include receiving power from the power source 104.

[0062] A method of implementing the electrostatic gun driver 300 of the present disclosure may include generating a modulated voltage pulse using an inverter 304. In this regard, generating a modulated voltage pulse by the inverter 304 may include any one or more materials, structures, configurations, methods, etc., as described herein. Furthermore, one or more follow-on or subsequent methods may also be implemented regarding generating a modulated voltage pulse using the inverter 304 consistent with the present disclosure. In particular, generating a modulated voltage pulse using the inverter 304 may include generating a modulated voltage pulse 192 using the inverter 102.

[0063] A method of implementing the electrostatic gun driver 300 of the present disclosure may include generating a sinusoidal drive signal using the filter 306. In this regard, generating a sinusoidal drive signal using the filter 306 may include any one or more materials, structures, arrangements, methods, and / or the like, as described herein. Furthermore, one or more subsequent or subsequent methods may also be implemented with respect to generating a sinusoidal drive signal using the filter 306 consistent with the present disclosure. In particular, generating a sinusoidal drive signal using the filter 306 may include generating the sinusoidal drive signal 190 using the filter 108.

[0064] A method of implementing the electrostatic gun driver 300 of the present disclosure may include providing a sinusoidal drive signal to the material application device 308. In this regard, providing the sinusoidal drive signal to the material application device 308 may include any one or more materials, structures, arrangements, methods, and / or the like, as described herein. Additionally, one or more subsequent methods or methods may also be implemented regarding providing a sinusoidal drive signal to the material application device 308 consistent with the present disclosure. In particular, providing the sinusoidal drive signal to the material application device 308 may include providing the sinusoidal drive signal 190 to the exemplary material application device 210.

[0065] 1 , in aspects, the exemplary material application device 210 may include a handgrip portion 216. The handgrip portion 216 may be realized, for example, in the form of a handle 218 that is manually held or grasped during operation of the exemplary material application device 210. In the exemplary material application device 210, the handle 218 may include a portion that contacts an operator's hand and is grounded. For purposes of this description, the term handgrip is used generally to refer to any structure, assembly, or member that is manually held or grasped by an operator during operation of the exemplary material application device 210 to support and control the exemplary material application device 210, and handles, grips, or other structures are exemplary embodiments of such handgrip.

[0066] As further shown in FIG. 1 , a coating material supply can be used as a source of coating material to the exemplary material application apparatus 210. A feed or supply hose 222 can be used to connect the exemplary material application apparatus 210 to the coating material supply. A hose connector 224 can be provided to securely attach the supply hose 222 to the exemplary material application apparatus 210. The control system 188 and / or the electrostatic gun driver 100 can be configured to control the operation of the input power and electrical requirements of the spray gun, as well as the operation of the coating material supply, purge supply, and other system-related features (not shown), such as a spray booth, part conveyor, etc. The coating material supply typically includes one or more pumps under the control of the control system 188, which then activates the pumps in response to an operator actuating an actuator 232. This causes the coating material to flow through the handle 218, the barrel portion 214, and exit through the nozzle portion 212 to form a desired spray pattern S, typically in the form of a cloud pattern for powder coating materials, for example.

[0067] A purge supply under the control of control system 188 can be used to supply pressurized purge air or other gas to the example material application apparatus 210 through a purge hose 236. The purge hose 236 can be connectable to a suitable hose connector input located at the handgrip portion 216, in this example, at the base 240 of the handle 218. Thus, the purge air inlet to the handgrip portion 216 can be separate from the coating material input at the hose connector 224, such that the purge air first enters the coating material flow path (not shown in FIG. 1 ) by first passing through a purge air flow path within the handgrip portion 216.

[0068] Therefore, there is a need for disclosure that describes driver circuits having improved power efficiency, less waste heat generation, lower cost cooling equipment, smaller form factors, smaller and lower cost packaging, reduced electrical circuit component part count, better performance, and / or the like.

[0069] Below are some non-limiting examples of aspects of the present disclosure.

[0070] One embodiment includes: an electrostatic gun driver including an inverter configured to receive power from a power source; the electrostatic gun driver also includes a controller that controls the inverter; and the electrostatic gun driver further includes a filter configured to generate a sinusoidal drive signal and provide the sinusoidal drive signal to the material application system and / or material application device.

[0071] The above embodiments may further include any one or a combination of two or more of the following embodiments: The electrostatic gun driver of the above embodiments, wherein the inverter generates a true sine wave; The electrostatic gun driver of the above embodiments, wherein the inverter is implemented as a four-switch inverter that generates modulated voltage pulses from a power supply; The electrostatic gun driver of the above embodiments, wherein the controller is configured to implement a unipolar modulation scheme to control gating of two diagonal switch pairs of the inverter to generate pulses that are modulated to generate the modulated voltage pulses; The electrostatic gun driver of the above embodiments, wherein the filter is configured to filter and smooth the modulated voltage pulses into a sinusoidal drive signal to drive a material application device; The electrostatic gun driver of the above embodiments, wherein the electrostatic gun driver is configured without a boost converter power stage; The electrostatic gun driver of the above embodiments, wherein the electrostatic gun driver is configured without a flyback converter; The electrostatic gun driver of the above embodiments, wherein the electrostatic gun driver is configured without a DC inverter; The electrostatic gun driver of the above embodiments, wherein the electrostatic gun driver and / or the inverter generates a sinusoidal drive signal having a frequency between 1 kHz and 1000 kHz. The electrostatic gun driver of any of the above embodiments, wherein the electrostatic gun driver and / or inverter generates a sinusoidal drive signal having a voltage and / or amplitude ranging from 0 V peak-to-peak to 1000 V peak-to-peak. The electrostatic gun driver of any of the above embodiments, wherein the inverter generates modulated voltage pulses and the filter receives the modulated voltage pulses to generate the sinusoidal drive signal. The electrostatic gun driver of any of the above embodiments, wherein the inverter may include a first switch, a fourth switch, a third switch, and a second switch. The electrostatic gun driver of any of the above embodiments, wherein a controller switches on / off power from the power source to the first switch, the fourth switch, the third switch, and the second switch. The electrostatic gun driver of any of the above embodiments, wherein one or more of the first switch, the fourth switch, the third switch, and the second switch are implemented as a transistor, a FET, and / or a MOSFET.The electrostatic gun driver of the preceding embodiment, wherein the controller is configured to implement a unipolar modulation scheme to control the gating of the first switch, the fourth switch, the third switch, and the second switch. The electrostatic gun driver of the preceding embodiment, wherein the controller controls two diagonal switch pairs of the first switch, the fourth switch, the third switch, and the second switch of the inverter to generate pulses, which are modulated to generate modulated voltage pulses. The electrostatic gun driver of the preceding embodiment, wherein the controller is configured to implement a unipolar modulation scheme by receiving a sinusoidal reference and a carrier waveform. The electrostatic gun driver of the preceding embodiment, wherein the controller compares the sinusoidal reference with the carrier waveform to control the first switch, the second switch, the third switch, and the fourth switch. The electrostatic gun driver of the preceding embodiment, wherein the filter may include an inductor and a capacitor. The electrostatic gun driver of the preceding embodiment, wherein the inductor is arranged in series in one implementation of parallel power lines. The electrostatic gun driver of the preceding embodiment, wherein the capacitor is arranged to connect between the parallel power lines. The electrostatic gun driver of the above embodiment, wherein the inverter is configured to provide improved power efficiency compared to prior art electrostatic gun drivers. The electrostatic gun driver of the above embodiment, wherein the inverter is configured to provide less waste heat generation compared to prior art electrostatic gun drivers. The electrostatic gun driver of the above embodiment, wherein the inverter is configured to provide a smaller form factor compared to prior art electrostatic gun drivers. The electrostatic gun driver of the above embodiment, wherein the material application device is implemented as a manually operated material application device. The electrostatic gun driver of the above embodiment, wherein the material application device is robotically operated. The electrostatic gun driver of the above embodiment, wherein the material application system may include a robot system operating within the material application system and configured to manipulate and move the material application device. The material application system of the above embodiment. The material application system of the above embodiment, wherein the material application device is implemented as a manually operated material application device. The material application system of the above embodiment, wherein the material application device is robotically operated.The material application system of any of the above embodiments, wherein the material application system may include a robotic system configured to operate within the material application system and manipulate and move the material application device.

[0072] One embodiment includes a method including configuring an inverter to receive power from a power source, the method further including configuring a controller to control the inverter, the method further including generating a sinusoidal drive signal with a filter and providing the sinusoidal drive signal to a material application system and / or a material application device.

[0073] The above embodiments may further include any one or a combination of two or more of the following embodiments: the method of the above embodiments, wherein the inverter is configured to generate a true sine wave; the method of the above embodiments, wherein the inverter is implemented as a four-switch inverter that generates modulated voltage pulses from a power supply; the method of the above embodiments, wherein the controller is configured to implement a unipolar modulation scheme that controls the gating of two diagonal switch pairs of the inverter to generate pulses that are modulated to generate the modulated voltage pulses; the method of the above embodiments, wherein the filter is configured to filter and smooth the modulated voltage pulses into a sinusoidal drive signal to drive the material application device; the method of the above embodiments, wherein the electrostatic gun driver is configured without a boost converter power stage; the method of the above embodiments, wherein the electrostatic gun driver is configured without a flyback converter; the method of the above embodiments, wherein the electrostatic gun driver is configured without a DC inverter; the method of the above embodiments, wherein the electrostatic gun driver and / or the inverter generates a sinusoidal drive signal at a frequency between 1 kHz and 1000 kHz. The method of the above embodiment, wherein the electrostatic gun driver and / or inverter generates a sinusoidal drive signal having a voltage and / or amplitude between 0 V peak-to-peak and 1000 V peak-to-peak. The method of the above embodiment, wherein the inverter generates modulated voltage pulses and the filter receives the modulated voltage pulses to generate the sinusoidal drive signal. The method of the above embodiment, wherein the inverter may include a first switch, a fourth switch, a third switch, and a second switch. The method of the above embodiment, wherein the controller is configured to switch on and off power from the power source to the first switch, the fourth switch, the third switch, and the second switch. The method of the above embodiment, 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 of the above embodiment, wherein the controller is configured to implement a unipolar modulation scheme to control the gating of the first switch, the fourth switch, the third switch, and the second switch.The method of the above embodiment, wherein the controller is configured to control two diagonal switch pairs, the first switch, the fourth switch, the third switch, and the second switch, of the inverter to generate pulses that are modulated to generate modulated voltage pulses. The method of the above embodiment, wherein the controller is configured to implement a unipolar modulation scheme by receiving a sinusoidal reference and a carrier waveform. The method of the above embodiment, wherein the controller is configured to compare the sinusoidal reference to the carrier waveform to control the first switch, the second switch, the third switch, and the fourth switch. The method of the above embodiment, wherein the filter may include an inductor and a capacitor. The method of the above embodiment, wherein the inductors are arranged in series in one implementation of parallel power lines. The method of the above embodiment, wherein the capacitor is arranged to connect between the parallel power lines. The method of the above embodiment, wherein the inverter is configured to provide improved power efficiency compared to prior art electrostatic gun drivers. The method of the above embodiment, wherein the inverter is configured to provide less waste heat generation compared to prior art electrostatic gun drivers. The method of the above embodiment, wherein the inverter is configured to provide a smaller form factor compared to prior art electrostatic gun drivers. The method of any of the above embodiments, wherein the material application device is implemented as a manually operated material application device. The method of any of the above embodiments, wherein the material application device is robotically operated. The method of any of the above embodiments, wherein the material application system may include a robotic system operating within the material application system and configured to manipulate and move the material application device. The method of any of the above embodiments, wherein the material application device is implemented as a manually operated material application device. The method of any of the above embodiments, wherein the material application device is robotically operated. The method of any of the above embodiments, wherein the material application system may include a robotic system operating within the material application system and configured to manipulate and move the material application device.

[0074] Terms such as first, second, etc. may be used herein to describe various elements, but it should be understood that these elements should not be limited by these terms. These terms are used only to distinguish one element from another. For example, a first element can be referred to as a second element, and similarly, a second element can be referred to as a first element, without departing from the scope of the present disclosure. As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed items.

[0075] Relative terms such as "bottom" or "top" or "upper" or "below" or "horizontal" or "vertical" may be used herein to describe the relationship of one element, layer, or region to another element, layer, or region as shown in the figures. It will be understood that these terms, and the terms discussed above, are intended to encompass different orientations of the device in addition to the orientation depicted in the figures.

[0076] The terminology used herein is for the purpose of describing particular aspects only and is not intended to be limiting of the disclosure. As used herein, the singular forms "a," "an," and "the" are intended to include the plural forms unless the context clearly dictates otherwise. It is further understood that the terms "comprises," "comprising," "includes," and / or "including," when used herein, specify the presence of stated features, integers, steps, operations, elements, and / or components, but do not exclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof.

[0077] 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 consistent with their meaning in the context of the present specification and related art, and should not be interpreted in an idealized or overly formal sense unless so expressly defined herein.

[0078] The many features and advantages of the present disclosure will be apparent from the detailed description, and thus, it is intended by the appended claims to cover all such features and advantages of the present disclosure that fall within the true spirit and scope of the present disclosure. Further, because numerous modifications and variations will readily occur to those skilled in the art, it is not desired to limit the disclosure to the exact construction and operation shown and described; therefore, all suitable modifications and equivalents may be employed that fall within the scope of the present disclosure.

Claims

1. an inverter configured to receive power from a power source; a controller configured to control the inverter; and a filter configured to generate a sinusoidal drive signal and provide the sinusoidal drive signal to a material application system and / or a material application device.

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

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

4. 10. The electrostatic gun driver of claim 1, wherein the controller implements a unipolar modulation scheme configured to control 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 of claim 4 , wherein the filter is configured to filter and smooth the modulated voltage pulses into the sinusoidal drive signal to drive the material application device.

6. 10. The electrostatic gun driver of claim 1, wherein the driver does not include a boost converter power stage.

7. 10. The electrostatic gun driver of claim 1, which does not include a flyback converter.

8. 10. The electrostatic gun driver of claim 1, which does not include a DC inverter.

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

10. 2. The electrostatic gun driver of claim 1, wherein the electrostatic gun driver and / or the inverter generate the sinusoidal drive signal having a voltage and / or amplitude between 0 V peak-to-peak and 1000 V peak-to-peak.

11. 2. The electrostatic gun driver of claim 1, wherein the inverter generates modulated voltage pulses, and the filter receives the modulated voltage pulses and generates the sinusoidal drive signal.

12. The electrostatic gun driver of claim 1 , wherein the inverter comprises a first switch, a fourth switch, a third switch, and a second switch.

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

14. 13. The electrostatic gun driver of claim 12, wherein one or more of the first switch, the fourth switch, the third switch, and the second switch are implemented as a transistor, a FET, and / or a MOSFET.

15. 13. The electrostatic gun driver of claim 12, wherein the controller implements a unipolar modulation scheme configured to control gating of the first switch, the fourth switch, the third switch, and the second switch.

16. 13. The electrostatic gun driver of 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 that are modulated to generate modulated voltage pulses.

17. 13. The electrostatic gun driver of claim 12, wherein the controller is configured to implement a unipolar modulation scheme by receiving sinusoidal reference and carrier waveforms.

18. 18. The electrostatic gun driver of claim 17, wherein the controller is configured to compare the sinusoidal reference to the carrier waveform to control the first switch, the second switch, the third switch, and the fourth switch.

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

20. 20. The electrostatic gun driver of claim 19, wherein the inductors are arranged in series in one implementation of parallel power lines.

21. 20. The electrostatic gun driver of claim 19, wherein the capacitor is arranged to connect between parallel power lines.

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

23. 10. The electrostatic gun driver of claim 1, wherein the inverter is configured to provide less waste heat production compared to prior art electrostatic gun drivers.

24. 10. The electrostatic gun driver of claim 1, wherein the inverter is configured to provide a small form factor compared to prior art electrostatic gun drivers.

25. The electrostatic gun driver of claim 1 , wherein the material application device is embodied as a manually operated material application device.

26. The electrostatic gun driver of claim 1 , wherein the material application device is robotically operated.

27. The electrostatic gun driver of claim 1 , wherein the material application system comprises a robotic system configured to operate within the material application system and manipulate and move the material application device.

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

29. 30. The material application system of claim 28, wherein the material application device is implemented as a manually operated material application device.

30. 30. The material application system of claim 28, wherein the material application device is robotically operated.

31. 30. The material application system of claim 28, 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.

32. configuring an inverter to receive power from a power source; configuring a controller to control the inverter; and generating a sinusoidal drive signal with a filter to provide the sinusoidal drive signal to a material application system and / or a material application device.

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

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

35. 33. The method of implementing an electrostatic gun driver of claim 32, wherein the controller implements a unipolar modulation scheme configured to control gating of two diagonal switch pairs of the inverter to generate pulses that are modulated to generate modulated voltage pulses.

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

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

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

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

40. 33. The method of implementing an electrostatic gun driver of claim 32, wherein the electrostatic gun driver and / or the inverter generates the sinusoidal drive signal having a frequency between 1 kHz and 1000 kHz.

41. 33. The method of implementing an electrostatic gun driver of claim 32, wherein the electrostatic gun driver and / or the inverter generates the sinusoidal drive signal having a voltage and / or amplitude between 0 V peak to peak and 1000 V peak to peak.

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

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

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

45. 44. The method of implementing an electrostatic gun driver of 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. 44. The method for implementing an electrostatic gun driver of claim 43, wherein the controller implements a unipolar modulation scheme configured to control gating of the first switch, the fourth switch, the third switch, and the second switch.

47. 44. The method of implementing an electrostatic gun driver of 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 that are modulated to generate modulated voltage pulses.

48. 44. The method for implementing an electrostatic gun driver of claim 43, wherein the controller is configured to implement a unipolar modulation scheme by receiving sinusoidal reference and carrier waveforms.

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

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

51. 51. A method of implementing an electrostatic gun driver as recited in claim 50, wherein the inductors are placed in series in one implementation of parallel power lines.

52. 51. The method of implementing an electrostatic gun driver of claim 50, wherein the capacitor is configured to connect between parallel power lines.

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

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

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

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

57. 33. The method of implementing an electrostatic gun driver of claim 32, wherein the material application device is robotically operated.

58. 33. The method of implementing an electrostatic gun driver of claim 32, wherein the material application system comprises a robotic system configured to operate within the material application system and manipulate and move the material application device.

59. 33. A method of implementing a material application system that implements the method of implementing an electrostatic gun driver of claim 32.

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

61. 60. The method for implementing a material application system of claim 59, wherein the material application device is robotically operated.

62. 60. The method of implementing a material application system of claim 59, wherein the material application system comprises a robotic system configured to operate within the material application system and manipulate and move the material application device.

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