Sensor Kit for Spray Gun

Abstract

A sensor kit for use with a spray gun is provided. The sensor kit acquires relevant data while the spray gun is in use and can provide feedback to the user of the spray gun on specific parameters of the spray operation, allowing the user to adjust the spraying method in real time. Moreover, the feedback can be adjusted for various types of coatings using predetermined data related to the specific coating. Furthermore, data obtained during spraying can be transmitted to a remote server, where data for multiple spray operations using a specific type of coating can be collected. Using the data obtained during spraying, it may be possible to reconstruct what the applied coating looked like and / or what the surface to which the coating was applied looked like.

Description

Technical Field

[0001] The present invention relates to a sensor kit for a spray gun.

Background Art

[0002] Spray painting is a technique that uses a spray gun to spray a coating onto a surface through air. The coating can be paint, ink, varnish, clear coat, or any other type of coating. The spray gun is held by hand by an operator, and the spray gun may require significant skill to apply a thin coating with a uniform layer thickness.

Summary of the Invention

Problems to be Solved by the Invention

[0003] It is preferable to provide a spray gun that does not require much skill to apply a thin coating with a uniform layer thickness.

Means for Solving the Problems

[0004] The first aspect is a sensor kit for a spray gun configured to apply a coating to a surface, the sensor kit comprising a housing having a connection module configured to connect the sensor kit to the spray gun, a sensor module provided within the housing and configured to obtain spray operation parameter values, and a processing unit, the processing unit comprising an input module configured to receive one or more reference parameter values, and a comparison module configured to compare at least a portion of the obtained spray operation parameter values ​​with one or more corresponding reference parameter values ​​and to generate a comparison data signal based on the result of the comparison, wherein the sensor kit further comprises a user feedback module configured to generate a user feedback signal based on at least a portion of the comparison data signal.

[0005] Accordingly, according to the sensor kit in accordance with the first aspect, feedback may be provided to the user of the spray gun. This feedback may allow the user to adjust the way in which they handle the spray gun, for example, to apply a coating that has a more uniform layer thickness and / or better coating quality overall.

[0006] The sensor module may include a proximity sensor configured to obtain distance data indicating the distance between the spray gun and the surface to which the coating is to be applied. The distance between the spray gun and the surface to which the coating is to be applied may be a factor that affects, for example, the quality of the coating on the surface and / or the thickness of the coating layer.

[0007] In one embodiment, the proximity sensor may include an optical transmitter configured to emit an optical signal, and an optical receiver for receiving an optical signal reflected as a reflection of the emitted optical signal, and the proximity sensor further includes a proximity processor configured to determine the spray distance between the proximity sensor and the surface based on the relationship between the emitted optical signal and the reflected optical signal.

[0008] The emitted light signal may have a wavelength spectrum of 800 nm to 1200 nm, and more particularly 900 nm to 1000 nm. In embodiments, the wavelength spectrum may be selected so that the light signal can pass through the mist of the aerosol coating material.

[0009] The spray distance may be based on the time period between the emission of the emitted light signal and the reception of the reflected light signal.

[0010] In several embodiments, the sensor module may include an orientation sensor for obtaining orientation data indicating the orientation of the spray gun. The orientation of the spray gun may be a factor that affects, for example, the quality of the coating on the surface and / or the thickness of the coating layer.

[0011] The orientation sensor may be configured to determine at least one angle of the orientation sensor with respect to a reference plane. The reference plane may be, for example, a horizontal plane, a vertical plane, or a plane corresponding to the surface on which the coating is applied or to be applied.

[0012] In a further embodiment, the sensor module may include a movement sensor for obtaining motion data indicating the movement of the spray gun. The movement of the spray gun may be a factor that affects, for example, the quality of the coating on the surface and / or the thickness of the coating layer.

[0013] The input module may be further configured to receive user identification data. Thus, as one example, the sensor kit may be tailored to the preferences of a particular user.

[0014] The sensor kit may include a battery for storing and supplying electrical energy to the sensor module, and a wireless charging module for charging the battery, wherein both the battery and the wireless charging module are located within the housing. In this embodiment, the housing is substantially sealed so that coatings, gases, fluids, and / or other particles are substantially unable to enter the housing.

[0015] In several embodiments, any of the components provided by the sensor kit may be located inside or outside the housing. If one component is located outside the housing, it may be provided by an additional device, such as a computer device, smartphone, tablet computer, or any other device. For example, the processing unit may be located inside the housing. In another example, the user feedback module is located inside the housing.

[0016] The user feedback module may include at least one of the following: a speaker module for providing an audio signal based on the feedback signal; an optical module for providing a visual signal based on the feedback signal; and a tactile module for providing a tactile signal based on the feedback signal.

[0017] The second aspect provides a sensor data processing device comprising a sensor kit according to any of the embodiments described above, and a data processing device, the data processing device comprising: an electronic input unit configured to receive a coat identifier that identifies a coating material configured to be sprayed by a spray gun; an electronic query module configured to use the coat identifier in an electronic memory to retrieve a reference parameter value corresponding to the coat identifier; an electronic memory communication module configured to read the retrieved reference parameter value; and an electronic data communication module configured to transmit the read reference parameter value, wherein the input module of the sensor kit is configured to receive the transmitted reference parameter value from the data processing device.

[0018] Each coating can have a variety of properties with respect to viscosity, solvent capacity, therefore drying time of the applied coating, color appearance dependency on layer thickness, other properties, or any combination thereof. Therefore, various coating materials may require various spray job parameter value boundaries within which the spray job parameter must be kept for best results.

[0019] It should be noted that the boundary may be variable and depend on several spraying parameters, for example, if the ambient temperature is at a certain level, it may be difficult to change the temperature. Secondly, at higher temperatures, the coating may be less viscous than at lower temperatures. This means that at higher temperatures, the distance between the spray gun and the substrate to which the coating is applied may be greater or smaller than at lower ambient temperatures if the coating is more viscous. Other spraying parameter reference boundaries may depend on other spraying parameters.

[0020] In several embodiments, the electronic input unit may be further configured to receive a user identifier, the sensor kit may include a sensor kit communication module configured to transmit spray operation parameter values, and the electronic data communication module may be configured to receive the transmitted spray operation parameter values, wherein the sensor data processing device may further include an external communication module configured to transmit the received spray operation parameter values, the sensor kit identifier, and the user identifier to a data processing server.

[0021] The collected data may be linked to a specific user identifier and imposed on the parameters of the final applied coating with respect to the coating thickness, the coating smoothness, other parameters of the coating, or any combination thereof. Furthermore, data from users known to possess exceptionally high spraying skills may be used to update spray operation parameter boundaries, which may then be provided to the sensor kit for training less experienced operators.

[0022] The third aspect provides a spray gun configured for applying a coating to a surface, the spray gun comprising a spray gun housing, an input for receiving a coating material, a nozzle for outputting the coating material, and a sensor kit according to the first aspect, wherein the housing of the sensor kit is connected to the spray gun housing via a connection module.

[0023] The fourth aspect provides a method for generating a feedback signal in a sensor kit for a spray gun, the method comprising: an input module receiving a reference parameter value; a sensor module obtaining a spray operation parameter value while the spray gun is in use; a comparison module comparing at least a portion of the obtained spray operation parameter values ​​with at least a portion of the received reference parameter values; an output module outputting a comparison data signal determined by the comparison module to a feedback module; and the feedback module receiving the comparison data signal and generating a feedback signal based on at least a portion of the comparison data signal.

[0024] In an embodiment, the method according to the fourth aspect may further include, by the input module, receiving user identification data, and by the output module, outputting at least a portion of the obtained spray operation parameter values ​​to a server system and at least a portion of the user identification data to the server system.

[0025] A fifth aspect provides a method for reconstructing coating data in a server system for communicating with a sensor kit for a spray gun, the method comprising receiving at least one of spray operation parameter values ​​from the sensor kit, the spray operation parameter value comprising distance data over a first time period indicating the distance between the spray gun and a surface to be coated, orientation data over the first time period indicating the orientation of the spray gun during the application of the coating, and motion data over the first time period indicating the movement of the spray gun during the application of the coating, the method further comprising reconstructing coating data based on at least a portion of the distance data, the orientation data, and the motion data.

[0026] According to the method according to the fifth aspect, it may be possible to reconstruct how the layer of the applied coating looks on a specific part of the surface to be coated. This can be used as evidence of the specific spraying operation.

Brief Description of Drawings

[0027] [Figure 1] Figure 1 shows a schematic overview of one embodiment of a sensor kit, a spray gun, and a surface. [Figure 2] Figure 2 shows a flowchart of a method for generating a feedback signal in a sensor kit for a spray gun. [Figure 3] A flowchart of a method for reconstructing coating data is shown.

Embodiments for Carrying Out the Invention

[0028] Figure 1 shows a schematic overview of one embodiment of a sensor kit 100 having a sensor kit body 102 as a housing. The sensor kit body 102 includes a spray gun connector 104 as a connection module. A spray gun 200 is connected to the body 102 via the connector 104. The spray gun 200 includes a spray gun housing 201. The spray gun 200 can be, for example, a high volume low pressure (HVLP) spray gun.

[0029] Although the sensor kit body 102 is schematically shown as a rectangle in Figure 1, in different embodiments, the body 102 may have a different shape. For example, the body 102 may be molded around the shape of the spray gun housing 201 to which the body 102 is configured to be connected. The shape of the body 102, and / or the center of gravity of the sensor kit 100, may also be adapted so that the center of gravity of the spray gun 200 remains within a desired range when attached to the spray gun 200. Thus, the handling of the spray gun 200 may be minimally affected by connecting the sensor kit 100.

[0030] The spray gun 200 may be used to apply a layer 202 of paint as a coating onto a vehicle body 204 as a surface. The spray gun 200 includes a nozzle 206 from which a mist of aerosol paint 208 can be discharged, and an input for receiving the paint as a coating material. The spray gun 200 may be a handheld spray gun 200 that includes a trigger that can be operated by the user to control the discharge of the paint 208 from the spray gun 200 at a certain speed.

[0031] The trigger can control the throughput area of ​​the conduit that leads paint or another coating fluid to the nozzle. Alternatively or additionally, the trigger—or another trigger or control knob—can control the position of a control needle in a throughput orifice, e.g., the nozzle 206 or another orifice. In one embodiment, the control needle may be used to precisely control the flow of the coating fluid, and the trigger may be used to switch the nozzle between an "on" and an "off" state. In addition to the precision control mechanism, the flow of the coating fluid may also be controlled by a fluctuating pressure from which the coating fluid is supplied. One or more of the precision control setting, the coating fluid pressure, and the trigger state may be considered optional spray operation parameters.

[0032] The user can move and reorient the spray gun 200 as desired, thereby moving the spray gun 200 further away from the vehicle body 204 or closer to the vehicle body 204 at a certain speed and acceleration. The user can further orient the spray gun 200 as desired, thereby changing the orientation of the nozzle 206 relative to the vehicle body 204 so that the paint can be applied from various approach angles.

[0033] The sensor kit body 102 is equipped with a time-of-flight sensor 106 as a proximity sensor provided by the sensor module. The time-of-flight sensor 106 is configured to obtain distance data as a spray operation parameter value relating to the distance d between the sensor 106 and the vehicle body 204 and / or the paint layer 202. Therefore, when the sensor kit 100 is connected to the spray gun 200, the nozzle 206 also faces the vehicle body 204 and / or the paint layer 202, so the time-of-flight sensor 106 preferably faces in the same direction as the nozzle 206.

[0034] The time-of-flight sensor 106, as a proximity sensor, may include a laser or an LED as an optical transmitter configured to emit a laser beam as an emitted optical signal. The time-of-flight sensor 106 may further include an optical receiver for receiving the 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 106 and the surface 204 based on the relationship between the emitted laser beam and the reflected laser beam.

[0035] The emitted light signal may have a near-infrared wavelength spectrum, for example, 800-1200 nm, more particularly 900-1000 nm, most preferably 940 nm. Electromagnetic radiation of such waves is invisible. Such waves can travel through materials that may appear opaque to the human eye but are transparent to electromagnetic radiation between 900-1000 nm, and especially 940 nm.

[0036] The sensor kit body 102 may be made of an opaque material, and therefore, the light emitted by the time-of-flight sensor 106 may be obstructed by the sensor kit body 102. In the embodiment shown in Figure 1, the sensor kit body 102 optionally includes a partially transparent viewing window 108 through which the light emitted by and reflected by the time-of-flight sensor 106 can pass. Alternatively, at least a portion of the sensor kit body 102 through which the light should pass may be made of a material that is at least partially transparent to the wavelength of light used by the time-of-flight sensor 106, which may be, for example, wavelengths in the infrared spectrum.

[0037] In the embodiment shown in Figure 1, the sensor kit 100 includes a microcontroller 110 as a processing unit. The microcontroller 110 includes a data input unit 112 as an input module configured to receive one or more reference parameter values. The received reference parameter values ​​can be stored in a memory 114. Distance data is transmitted from the time-of-flight sensor 106 to the data input unit 112 of the microcontroller 110 and can optionally be stored in the memory 114.

[0038] In this embodiment of the sensor kit 100, the microcontroller 110 is located inside the sensor kit body 102. Embodiments of the sensor kit 100 are also envisioned in which another microcontroller is located outside the sensor kit body 102 as part of the processing unit. This other microcontroller may be provided, for example, by one or more external computer devices, such as a server, smartphone, tablet, any other computer device, or any combination thereof.

[0039] If at least a portion of the processing unit is located 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 any other protocol may be used for data exchange.

[0040] The microcontroller 110, as a processing unit, further comprises a comparison module 116 configured to compare at least a portion of the obtained spray operation parameter values ​​with one or more corresponding reference parameter values. Accordingly, the comparison module 116 may be configured to receive at least a portion of the spray operation parameter values ​​and at least a portion of the reference parameter values ​​from, for example, the data input unit 112, and / or to read at least a portion of the spray operation parameter values ​​and at least a portion of the reference parameter values ​​from the memory 114.

[0041] The comparison module 116 is further configured to generate a comparison data signal based on the results of the comparison. The comparison data signal may be received by an output module 118, which is configured and can be used to transmit the comparison data signal to other components of the sensor kit 100. In some embodiments, the output module 118 may be provided by the processing unit, the comparison module, the sensor module, or generally by the sensor kit 100.

[0042] The data input unit 112 may be configured to receive user identification data that can identify a specific user or group of users. For example, the user identification data may include employer data, name, and / or any other data from which a specific user within a group of users can be identified. The user identification data may be stored in the memory 114. If the user identification data is stored in the memory 114, a specific sensor kit 100 may be associated with a specific user.

[0043] A feedback controller 120, acting as a user feedback module, is provided by the sensor kit 100 to provide feedback to a user using the spray gun 200. 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 data output unit 118 and / or read at least a portion of the comparison data signal from the memory 114.

[0044] In the embodiment shown in Figure 1, the feedback controller 120 is located inside the sensor kit body 102. Embodiments are also envisioned in which at least a portion of the feedback controller 120 is located outside the sensor kit body 102. In such embodiments, at least a portion of the generated feedback signal may be transmitted via a wired or wireless connection to an external feedback device, such as a speaker, display, or light.

[0045] In the embodiment shown in Figure 1, the feedback controller 120 includes a display 122 configured to provide a visual signal based on the feedback signal. The display 122 is shown as being installed within the sensor kit body 102. In this embodiment, the display 122 may also be installed in a different location and could be, for example, a smartphone, tablet, head-up display (HUD), smartwatch, smart glasses display, or any other display.

[0046] To obtain orientation data indicating the orientation of the spray gun 200, an embodiment of the sensor kit 100 may include an orientation sensor 130, which may be an absolute or 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.

[0047] The orientation data may include data indicating the roll, yaw, and pitch of the spray gun 200. Since the housing body 102 is preferably firmly connected to the spray gun 200, the roll, yaw, and pitch of the orientation sensor 130 can substantially correspond to, or at least be converted to, the roll, yaw, and pitch of the spray gun 200. Any output parameter or a set of parameters of the orientation sensor 130 can be considered arbitrary spray operation parameters.

[0048] Furthermore, or alternatively, the orientation sensor 130 is configured to determine at least one angle of the orientation sensor with respect to a reference plane. The reference plane may be, for example, a horizontal plane, a vertical plane, or a plane representing the surface 204 to which the coating 202 is to be applied.

[0049] To obtain motion data indicating the movement of the spray gun 200, an embodiment of the sensor kit 100 may include an accelerometer 132 as one example of a motion sensor.

[0050] The motion data may include data indicating the velocity and / or acceleration of the spray gun 200 in one or more directions. Since the housing body 102 is preferably firmly connected to the spray gun 200, the velocity and / or acceleration of the motion sensor 132 can substantially correspond to the velocity and / or acceleration of the spray gun 200, or can be converted to at least the velocity and / or acceleration of the spray gun 200. One or more of the velocity and acceleration can be considered as either scalars or vectors, as arbitrary spray operation parameters.

[0051] As one option, the embodiment of the sensor kit 100 shown in Figure 1 includes a speaker 126 as a speaker for providing an audio signal based on the feedback signal. Depending on the feedback signal, the audio signal may have different volumes and / or frequencies, for example, to indicate a particular type of feedback to the user.

[0052] As a further option, the embodiment of the sensor kit 100 shown in Figure 1 includes a vibration unit 128 as a tactile module for providing vibration as a tactile signal based on the feedback signal. The vibration can be transmitted via a connector 104 to the spray gun body 201, which can be held by the user of the spray gun 200. Thus, the user can feel the vibration while holding the spray gun 200.

[0053] As a further option, an embodiment of the sensor kit 100 is envisioned in which the sensor module is equipped with a temperature sensor for obtaining temperature data indicating the temperature of the surface 204 to be spray-painted. In such an embodiment, the reference parameter values ​​may include the minimum temperature that the surface 204 should have. If the comparison module provides a comparison data signal indicating that the temperature of the surface 204 is lower than the minimum temperature, the user feedback module may indicate to the user that the temperature of the surface 204 is excessively low.

[0054] To power the components of the sensor kit 100 that require electrical energy, the sensor kit 100 may 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 fluid from entering the housing and / or to prevent electrical components from being exposed to paint fumes. This substantially sealed state may make it impossible to use a wired connection to charge the battery 134 and / or to easily replace a depleted battery.

[0055] A coil 136, acting as a wireless charging module for charging the battery 134, may be provided by the sensor kit 100 and may be installed inside the sensor kit housing 102 together with the battery 134. Electrical energy can be supplied to the battery 134 via the coil 136, for example, by using inductive charging. Since this electrical energy transmission is wireless, there is no need to install a connector inside the housing 102, and electrical components do not need to be exposed to ambient air that may contain flammable coating materials in the aerosol.

[0056] One embodiment of method 300 for generating a feedback signal in a sensor kit for a spray gun is schematically shown in Figure 2 and will be described in detail in conjunction with the sensor kit 100 as shown in Figure 1. It will be understood that method 300 may also be applied in conjunction with other embodiments of the sensor kit 100, and that the sensor kit 100 in Figure 1 may be used in conjunction with other embodiments of method 300.

[0057] The method 300 begins with a terminator 301. A second step 302 in the method includes receiving reference parameter values, for example, by the data input unit 112. At least a portion of the reference parameter values ​​may be received from an external source, for example, a server 210. The server 210 may have memory storing a database containing the reference parameter values, or at least have access to that memory. In a further embodiment, at least a portion of the reference parameter values ​​may already be present in the memory 114 of the sensor kit 100.

[0058] The reference parameter values ​​may include a coating type and a corresponding set of preferred spray parameters. The spray parameters may be specific to the coating type. For example, for a particular first coating type, the preferred spray distance between the nozzle 206 and the surface 204 is within a first distance interval. Preferred spray parameters may be provided to the sensor kit as the operator selects a particular coating via the server 210.

[0059] The reference parameter values ​​may, in several examples, include data relating to the minimum and / or maximum speed, orientation, and / or acceleration of the spray gun 200, data relating to the minimum or maximum motion temperature and / or pressure, data relating to the minimum or maximum flow rate of the coating fluid, and / or any other data that may be relevant to the spray operation, or any combination thereof.

[0060] In the third step 303, spray operation parameter values ​​are obtained using at least one sensor provided by the sensor module, for example, the time-of-flight sensor 106. The third step 303 may begin after the sensor kit 100 has been initialized or when an actual spray operation has started. The spray operation parameter values ​​may be obtained at a constant rate of data points per second over a predetermined period of time or until it is determined that the spray operation has been completed or temporarily suspended.

[0061] In a fourth step 304 which may be performed simultaneously with the third step 303, at least a portion of the spray operation parameter values ​​are compared with at least a portion of the received reference parameter values, for example, using a comparison module 116.

[0062] In a fifth step 305, which may be performed simultaneously with either the third step 303 or the fourth step 304, the comparison data signal is output, for example, by the data output unit 118 to the feedback controller 120, which serves as the user feedback module. This enables the feedback controller 120 to function based on the comparison data signal or at least a portion thereof.

[0063] In a sixth step 306, which may be performed simultaneously with any of the third step 303, the fourth step 304, and the fifth step 305, the comparison data signal is received by the feedback controller 120, and a feedback signal is generated based on at least a portion of the comparison data signal.

[0064] The method 300 ends in the terminator 307, for example, when the spraying operation is completed. While the spray gun 200 is in use, any of the second, third, fourth, fifth, and sixth steps may be repeated as needed, simultaneously, in parallel, and / or sequentially, preferably in real time or at least substantially in real time, so that the operator of the spray gun 200 can respond to the feedback.

[0065] As one example, the method 300 is discussed in which the sensor kit 100 is used to provide feedback to a user using the spray gun 200 regarding the distance d between the sensor kit 100 and the surface 204.

[0066] The method 300 is initialized by the user connecting the sensor kit 100 to the spray gun 200. For example, the spray gun 200 may be provided with a magnet configured to operate a magnetic switch provided by the sensor kit 100 in order to switch on the sensor kit 100.

[0067] Next, the user selects the type of coating to be sprayed by the spray gun 200 by selecting this type, for example, through a graphical user interface configured to allow user interaction with the server 210. Alternatively, the server 210 may be embodied as an application on a smartphone, tablet, personal computer device, or any other device that enables the user to select the type of coating. In several embodiments, a barcode scanner may be provided to scan a barcode on the container of the coating material in order to obtain data indicating the type of coating.

[0068] When the user selects the type of coating, the server 210 retrieves the reference parameter value corresponding to the coating type, for example, directly from internal or external memory, or via a connection, such as a LAN, WAN, the Internet, Wi-Fi, Bluetooth, or any other wired or wireless connection. Some of the reference parameter value may be provided locally, while other parts of the reference parameter value may be provided remotely.

[0069] The server 210 transmits the reference parameter value to the sensor kit 100, and the data input unit 112 of the sensor kit 100 receives the reference parameter value and stores it in the memory 114. In this example, the reference parameter value includes a desired distance range specific to the selected coating type. The sensor kit 100 can help the user keep the spray gun 200 within this desired distance range by providing feedback. One of the reference parameter values ​​and the desired distance range as an example may be supplied by the coating manufacturer.

[0070] The desired distance range may correspond to the distance between the nozzle 206 of the spray gun and the surface 204, or the distance between any other component of the spray gun and the surface 204, or the distance d between the time-of-flight sensor 106 and the surface 204. In any case, the connection between the sensor kit body 102 and the spray gun 200 is preferably substantially solid, and the dimensions of the components of the sensor kit 100 are known, so any of these distances can be an indicator for the distance between the nozzle 206 and the surface 204.

[0071] Alternatively, if the housing of the sensor kit is not substantially firmly connected to the spray gun, a dynamic model of the substantially non-firm connection may be used to map the data obtained by the sensor kit to data associated with the spray gun.

[0072] During use of the spray gun 200, the time-of-flight sensor 106 obtains distance data indicating the distance d between the time-of-flight sensor 106 and the surface 204 facing the time-of-flight sensor 106. This distance data is then used by the comparison module 116, which compares the obtained data with the desired distance range.

[0073] The results of this comparison may include a value indicating whether a particular data point in the distance data is within or outside the range. If a particular data point is outside the range, the results of this comparison may, alternatively or further, include a value indicating whether the particular data point is excessively large, excessively small, and / or to what extent it is outside the range.

[0074] The output module may be configured to output the comparison data signal to the feedback controller 120, which in turn may be configured to provide feedback of the comparison data signal to the user using the spray gun 200. The feedback is preferably provided in substantially real time so that the user can appropriately modify how they use the spray gun 200 in accordance with the provided feedback.

[0075] After receiving the comparison data signal, the feedback controller 120 generates a feedback signal based on at least a portion of the comparison data signal.

[0076] In one particular embodiment, the feedback controller 120 includes an LED module 126 equipped with an optical module for providing a visual signal to the user based on the generated feedback signal. The LED module 126 may comprise one or more LEDs that can be configured to provide monochromatic light or can be controlled to provide light of various colors, such as red, green, blue, or combinations thereof.

[0077] If the obtained distance is within the desired distance range, the feedback controller 120 may control the LED module 126 to display green light as one example of colored light. If the obtained distance is outside the desired distance range, the feedback controller 120 may control the LED module 126 to display red light as one example of colored light.

[0078] In several embodiments, the feedback controller 120 includes a display 122 as part of the optical module, configured to provide a visual signal based on the feedback signal. The display 122 may be configured to show a value corresponding to the actual distance data obtained by the time-of-flight sensor 106, and thus may be configured to show a numerical value corresponding to the measured distance in millimeters or inches, for example. The obtained distance data may be supplied to the display 122 directly or via the feedback controller 120.

[0079] The feedback controller 120 may be configured to generate a feedback signal to control the vibration engine 124 to provide the user with haptic feedback indicating that the desired distance was not achieved over the predetermined period of time, if the feedback controller 120 receives a comparison data signal corresponding to distance data that is outside the desired range over a predetermined period of time.

[0080] Figure 3 shows a method 400 for reconstructing coating data, which may be performed on a server system 210 for communicating with a sensor kit 100 for a spray gun 200, or on a different computer device, such as a smartphone or tablet computer. The method begins with a terminator 401. In a second step 402, spray operation parameter values ​​are received from the sensor kit 100, for example, from the data input unit 118.

[0081] The received spray operation parameter value may include distance data over a first time period indicating the distance between the spray gun 200 and the surface 204 to which the coating 202 is applied. The first time period may be, for example, the duration of the spray operation on a particular component, such as a vehicle body. The spray operation parameter value may further include orientation data over the first time period indicating the orientation of the spray gun during the application of the coating, and motion data over the first time period indicating the movement of the spray gun during the application of the coating.

[0082] Optionally, the spray operation parameter value may include data indicating additional spray operation parameters, such as the paint flow rate, ambient temperature, ambient pressure, any other relevant spray operation parameters, or any combination thereof.

[0083] The coating data may be reconstructed in the third step 403 using the orientation data, motion data, and optionally more spray operation parameter values ​​over the same time period, which may, for example, indicate how the spray gun has been handled. The reconstruction may also be performed on the coated surface 204 and / or the applied coating 202 layers by having the distance data over the same time period.

[0084] For example, the coating data may include data indicating the thickness of the coating layer 202 at various locations. Thus, the coating data can provide the user with feedback regarding the consistency of the thickness of the applied coating layer. The coating data can also later provide the basis for the results of the spraying operation to prove, for example, that the maximum thickness of the coating layer is not exceeded at a specific location on the surface 204, for example, on a sensor on a vehicle body, on which the function of the applied coating layer may depend.

[0085] In another example, the coating data may include data indicating the shape of the surface 204 to which the coating is applied. This data may be reconstructed using at least some of the distance data, orientation data, and motion data.

[0086] A sensor data processing device is envisioned, comprising a sensor kit 100 as described in the embodiments of this specification and a computer as a data processing device. The computer may include an electronic input unit configured to receive a coat identifier that identifies a coating material configured to be sprayed by a spray gun.

[0087] For example, the electronic input unit may be embodied as a keyboard, mouse, touchscreen, barcode scanner, or any other input device for providing data input to the computer. The user may provide the code identifier to the computer via the data input unit.

[0088] The coating identifier may include, for example, a trademark, the manufacturer's name, the type of coating, any other data indicating the type of coating, or any combination thereof.

[0089] As an example of a data processing device, the computer further comprises a processing unit as an electronic query module configured to retrieve a reference parameter value corresponding to a code identifier in electronic memory using the code identifier. An electronic communication module may also be provided by the computer and configured to read the retrieved reference parameter value, for example, from local memory or from a remote location, for example, via a WAN or LAN connection.

[0090] The computer further includes an electronic data communication module configured to transmit the read reference parameter value to, for example, the input module of the sensor kit. Thus, the input module of the sensor kit may be configured to receive the transmitted reference parameter value from the data processing device.

[0091] In summary, a sensor kit is provided for use with a spray gun. The sensor kit can acquire relevant data while the spray gun is in use and provide feedback to the user of the spray gun regarding specific parameters of the spray operation so that the user can adjust their spraying method in real time. Furthermore, the feedback can be adjusted to various types of coatings using predetermined data related to a particular coating. Moreover, the data obtained during the spray may be transmitted to a remote server, where data from multiple spray operations using a particular type of coating may be collected. Using the data obtained during the spray, it may be possible to reconstruct how the applied coating looked and / or how the surface to which the coating was applied looked.

[0092] In the above description, when an element, such as a layer, region, or substrate, is considered to be "on top of" or "on" another element, it will be understood that the element may be directly on the other element, or there may be an intervening element. It will also be understood that the values ​​given in the above description are given as examples, and that other values ​​may be possible and / or pursued.

[0093] These various aspects can be implemented in hardware, software, or a combination thereof. The data to be processed can be digital, analog, or a combination thereof. In cases where analog data is provided or received and digital data is required for processing, analog-to-digital conversion may be used, after which the digital data is processed.

[0094] Furthermore, the present invention may also be embodied with fewer components than those provided in the examples described herein, where one component performs multiple functions. Similarly, the present invention may be embodied using more components than those shown in the figures, where the functions performed by one component in the provided examples are distributed across multiple components.

[0095] It should be noted that the figures are schematic representations of examples of the present invention, given merely as non-limiting examples. For the purposes of clarity and concise description, features are described herein as part of the same or separate examples; however, it will be understood that the scope of the present invention may encompass examples having all or some combinations of the described features. The term “comprising” does not exclude the presence of other features or processes other than those listed in a single claim. Furthermore, the terms “a” and “an” are not to be interpreted as limiting to “only one,” but rather are used to mean “at least one,” and do not exclude plurality.

[0096] Those skilled in the art will readily understand that the various parameters and their values ​​disclosed in the description may be modified, and that the various examples disclosed and / or claimed may be combined without departing from the scope of the invention.

[0097] The reference numerals in the claims are not intended to limit the scope of the invention, but are inserted solely to improve the readability of the claims.

Claims

1. 1. A sensor kit for a spray gun configured to apply a coating to a surface, comprising: a housing including a connection module configured to connect the sensor kit to the spray gun; a sensor module disposed within the housing, the sensor module configured to obtain a spray operation parameter value; Processing equipment It is equipped with The processing device comprises: an input module configured to receive one or more reference parameter values; a comparison module configured to compare at least some of the obtained spray operation parameter values ​​with corresponding one or more reference parameter values ​​and to generate a comparison data signal based on the results of the comparison; It is equipped with wherein the sensor kit further comprises a user feedback module configured to generate a user feedback signal based at least in part on the comparison data signal. The sensor kit.

2. The sensor kit of claim 1 , wherein the sensor module comprises a proximity sensor configured to obtain distance data indicative of a distance between the spray gun and the surface to which the coating is to be applied.

3. 3. The sensor kit of claim 2, wherein the proximity sensor comprises an optical transmitter configured to emit an emitted optical signal and an optical receiver for receiving a reflected optical signal as a reflection of the emitted optical signal, and the proximity sensor further comprises a proximity processor configured to determine a spray distance between the proximity sensor and the surface based on a relationship between the emitted optical signal and the reflected optical signal.

4. 4. The sensor kit of claim 3, wherein the emitted optical signal has a wavelength spectrum of 800 nm to 1200 nm, more particularly 900 nm to 1000 nm.

5. 5. The sensor kit of claim 3 or 4, wherein the spray distance is based on a time period between the emission of the emitted optical signal and the reception of the reflected optical signal.

6. 6. The sensor kit of any one of claims 1 to 5, wherein the sensor module comprises an orientation sensor for obtaining orientation data indicative of an orientation of the spray gun.

7. 7. The sensor kit of claim 6, wherein the orientation sensor is configured to determine at least one angle of the orientation sensor relative to a reference plane.

8. The sensor kit of any one of claims 1 to 7, wherein the sensor module comprises a movement sensor for obtaining movement data indicative of movement of the spray gun.

9. The sensor kit of any one of claims 1 to 8, wherein the input module is further configured to receive user identification data.

10. The sensor kit of any one of claims 1 to 9, further comprising a battery for storing and providing electrical energy to the sensor module, and a wireless charging module for charging the battery, wherein the battery and the wireless charging module are both provided within the housing.

11. The sensor kit of any one of claims 1 to 10, wherein the processing device is provided within the housing.

12. The sensor kit of any one of claims 1 to 11, wherein the user feedback module is provided within the housing.

13. The user feedback module a speaker module for providing an audio signal based on the feedback signal; an optical module for providing a visual signal based on the feedback signal; and The sensor kit of any one of claims 1 to 12, comprising at least one tactile module for providing a tactile signal based on the feedback signal.

14. A sensor data processing device, The sensor kit according to any one of claims 1 to 13, Data processing devices and It is equipped with the data processing device an electronic input configured to receive a coat identifier identifying a coating material configured to be sprayed by the spray gun; an electronic query module configured to use the court identifier to retrieve, in an electronic memory, a reference parameter value corresponding to the court identifier; an electronic memory communication module configured to read the retrieved reference parameter values; an electronic data communication module configured to transmit the retrieved reference parameter values; It is equipped with wherein the input module of the sensor kit is configured to receive the transmitted reference parameter values ​​from the data processing device, and the comparison module is configured to use the received reference parameter values ​​to generate comparison data. The sensor data processing device.

15. the electronic input is further configured to receive a user identifier; the sensor kit comprising a sensor kit communication module configured to transmit spray operation parameter values; and the electronic data communication module is configured to receive the transmitted spray operation parameter values; wherein the sensor data processing device further comprises an external communication module configured to transmit the received spray operation parameter values, a sensor kit identifier, and the user identifier to a data processing server. The sensor data processing device according to claim 14 .

16. 1. A spray gun configured to apply a coating to a surface, comprising: a spray gun housing; an input for receiving a coating material; a nozzle for outputting the coating material; The sensor kit according to any one of claims 1 to 13. It is equipped with wherein the housing of the sensor kit is connected to the spray gun housing via the connection module. The spray gun.

17. 17. A method for generating a feedback signal in a sensor kit for a spray gun, in particular a spray gun according to claim 16, comprising: receiving, by an input module, reference parameter values; and, while the spray gun is in use, obtaining spraying operation parameter values ​​through a sensor module; comparing, by a comparison module, at least some of the obtained spray operation parameter values ​​with at least some of the received reference parameter values; outputting a comparison data signal determined by the comparison module to a feedback module; and receiving, by the feedback module, the comparison data signal and generating a feedback signal based at least in part on the comparison data signal; The method comprising:

18. receiving, by the input module, user identification data; and outputting, by the output module, at least a portion of the obtained spray operation parameter values ​​to a server system and at least a portion of the user identification data to the server system.

20. The method of claim 17, further comprising:

19. 14. A method for reconstructing coating data in a server system for communicating with a sensor kit for a spray gun, in particular a sensor kit according to any one of claims 1 to 13, comprising: receiving spray operation parameter values ​​from the sensor kit; The spray operation parameter values ​​are: distance data over a first time period indicative of a distance between the spray gun and a surface to which a coating is being applied; and orientation data over the first time period indicative of an orientation of the spray gun during the application of the coating; and movement data over the first time period indicative of movement of the spray gun during the application of the coating; Including, the method further comprising reconstructing coating data based at least in part on the distance data, the orientation data, and the motion data. The method.

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