Motor control for a fluid sprayer

Abstract

A fluid sprayer includes an electric motor that powers reciprocation of a displacement pump that pumps fluid to a spray gun for spraying. A controller controls operation of the electric motor to cause the pump to output the spray fluid according to a target parameter. A user input provides the target parameter to the controller. The user input is configured such that for a portion of a range of the input the controller controls operation of the electric motor based on a first target parameter and for a different portion of the range of the input the controller controls operation of the electric motor based on a second target parameter different from the first target parameter.

Description

[0001] MOTOR CONTROL FOR A FLUID SPRAYER

[0002] CROSS-REFERENCE TO RELATED APPLICATION(S)

[0003] This application claims priority to U.S. Provisional Application No. 63 / 610,257 filed December 14, 2023 and entitled “MOTOR CONTROL FOR A FLUID SPRAYER,” the disclosure of which is hereby incorporated by reference in its entirety.

[0004] BACKGROUND

[0005] The present disclosure relates generally to fluid pumping systems and parts thereof. More particularly, this disclosure relates to motor control for a fluid pumping system.

[0006] Fluid sprayers include pumps that pressure spray fluid and drive the spray fluid to a nozzle for outputting the spray fluid as an atomized fluid spray. Fluid sprayers include spray guns that can be held and manipulated by the user. The spray guns typically receive paint or other coating fluid under pressure and atomize the spray fluid. The spray fluid is typically put under pressure by a piston or diaphragm, which is referred to as airless spray.

[0007] Airless spray can typically range in pressure from about 500 pounds per square inch (psi) (about 3.45 Megapascal (MPa)) to about 7000 psi (about 48.26 MPa), however lower and higher pressures are possible. Due to the action of the piston or the diaphragm, uneven spray patterns can be developed, particularly on stopping and starting of spray or due to cyclical directional reversing of the piston or diaphragm. For example, internal chambers within the flowpath may contain pockets of spray fluid through which pressure waves can reverberate or otherwise echo and cause uneven spray patterns.

[0008] SUMMARY

[0009] According to an aspect of the disclosure, a fluid sprayer includes an electric motor; a drive connected to the electric motor and configured to convert a rotational output from the electric motor to linear reciprocating motion; a pump connected to the drive to be reciprocated by the drive to pump fluid; a parameter input setting configured to set a target operating parameter; and a controller operably connected to the electric motor to control operation of the electric motor based on the target operating parameter. The target operating parameter is a target output pressure with the parameter input setting in a first input portion of a range of the parameter input setting, and the target operating parameter is a target motor speed with the parameter input setting in a second input portion of the range.

[0010] According to an additional or alternative aspect of the disclosure, a fluid sprayer includes an electric motor; a drive connected to the electric motor and configured to convert a rotational output from the electric motor to linear reciprocating motion; a pump connected to the drive to be reciprocated by the drive to pump fluid; a parameter input setting configured to set a target operating parameter, the parameter input setting adjustable across a range, the range including a first input portion and a second input portion; and a controller operably connected to the electric motor to control operation of the electric motor based on the target operating parameter. The parameter input setting is configured such that a value of an operating parameter increases within the first input portion and the value of the operating parameter drops with the parameter input setting in the second input portion.

[0011] According to another additional or alternative aspect of the disclosure, a fluid sprayer includes an electric motor; a drive connected to the electric motor and configured to convert a rotational output from the electric motor to linear reciprocating motion; a pump connected to the drive to be reciprocated by the drive to pump fluid; a parameter input setting configured to set a target operating parameter, wherein the parameter input setting includes a dial adjustable across a range, the range including a first input portion and a second input portion; and a controller operably connected to the electric motor to control operation of the electric motor based on the target operating parameter. The controller is configured to control operation of the electric motor based on a sensed output pressure with the parameter input setting in the first input portion and the controller is configured to control operation of the electric motor based on a sensed motor speed with the parameter input setting in the second input portion.

[0012] According to yet another additional or alternative aspect of the disclosure, a fluid sprayer includes an electric motor; a drive connected to the electric motor and configured to convert a rotational output from the electric motor to linear reciprocating motion; a pump connected to the drive to be reciprocated by the drive to pump fluid; a parameter input setting operable across a range to set a target operating parameter, the target operating parameter forming a primary operating parameter; and a controller operably connected to the electric motor to control operation of the electric motor based on the primary operating parameter and one or more secondary operating parameters. The primary operating parameter is one of a motor speed and an output pressure within a first input portion of the range and the primary operating parameter is the other one of the motor speed and the output pressure in a second input portion of the range.

[0013] According to yet another additional or alternative aspect of the disclosure, a fluid sprayer includes an electric motor; a drive connected to the electric motor and configured to convert a rotational output from the electric motor to linear reciprocating motion; a pump connected to the drive to be reciprocated by the drive to pump fluid; a parameter input setting operable across a range to set a target operating parameter, the target operating parameter forming a primary operating parameter; and a controller operably connected to the electric motor to control operation of the electric motor based on the primary operating parameter and one or more secondary operating parameters. An operating parameter forms the primary operating parameter in a first input portion of the range and the operating parameter forms a secondary operating parameter in a second input portion of the range; and a value of the operating parameter drops from a top end of the first input portion to within the second input portion.

[0014] According to yet another additional or alternative aspect of the disclosure, a fluid sprayer includes an electric motor; a drive connected to the electric motor and configured to convert a rotational output from the electric motor to linear reciprocating motion; a pump connected to the drive to be reciprocated by the drive to pump fluid; a parameter input setting configured to set a target operating parameter, the parameter input setting comprising a dial which rotates from a first rotational end to a second rotational end; and a controller operably connected to the electric motor to control operation of the electric motor based on the target operating parameter. The dial can be rotated through a first portion of a range in which the target operating parameter is progressively increased as the dial is rotated away from the first rotational end and toward the second rotational end, and the dial can be rotated through a second portion of the range in which the target operating parameter is decreased relative to a part of the first range which is closest to the second range, the second range closer to the second rotational end than to the first rotational end.

[0015] According to yet another additional or alternative aspect of the disclosure, a fluid sprayer includes an electric motor; a drive connected to the electric motor and configured to convert a rotational output from the electric motor to linear reciprocating motion; a pump connected to the drive to be reciprocated by the drive to pump fluid; a parameter input setting configured to set a target operating parameter, the parameter input setting comprising a dial which rotates from a first rotational end to a second rotational end; and a controller operably connected to the electric motor to control operation of the electric motor based on the target operating parameter. The dial can be rotated through a first portion of a range in which the target operating parameter is progressively increased as the dial is rotated away from the first rotational end and toward the second rotational end, and wherein further rotation of the dial toward the second rotational end decreases the target operating parameter. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] FIG. 1 is a simplified block diagram of a pumping system.

[0017] FIG. 2 is an isometric view of a pumping assembly.

[0018] FIG. 3 is a simplified diagram of a parameter input setting and range.

[0019] DETAILED DESCRIPTION

[0020] The present disclosure relates to motor control for a fluid pumping system, such as a fluid spraying system. An electric motor outputs rotational motion to cause pumping by a pump. A controller is operatively connected to the electric motor to control operation of the electric motor. A user input is operatively connected to the controller to provide a target operating parameter (e.g., pressure, flow rate, motor speed, etc.) to the controller, and the controller is configured to control operation of the electric motor based on the target operating parameter. The user input is configured such that for a portion of a range of the user input the controller controls operation of the electric motor based on a first target operating parameter and such that for another portion of the range of the user input the controller controls operation of the electric motor based on a second target operating parameter.

[0021] According to aspects of the disclosure, the user input can be configured as a dial that provides the target operating parameter to the controller. The user input can provide a target fluid parameter (e.g., pressure or flow rate) to the controller over a first portion of a range of the dial. The user input can provide a target motor parameter (e.g., motor speed) to the controller over a second portion of the range of the dial.

[0022] According to some aspects of the disclosure, the target operating parameter can be considered to form a primary operating parameter while other operating parameters can be considered to form secondary operating parameters. The controller can be configured to control operation of the electric motor based on the secondary operating parameters while controlling operation of the electric motor to achieve the primary operating parameter. For example, if the primary operating parameter is motor speed, the controller can limit operation of the motor based on the output pressure, which pressure is a secondary operating parameter. In another example, if the primary operating parameter is fluid pressure, the controller can vary the motor speed to achieve the desired output pressure.

[0023] Components can be considered to radially overlap when those components are disposed at common axial locations along an axis and such that a line extending radially from the axis will extend through each of the radially overlapping components. Components can be considered to axially overlap when those components are disposed at common radial and circumferential locations relative to an axis such that an axial line parallel to the axis extends through each of the axially overlapping components. Components can be considered to circumferentially overlap when aligned about the axis at a common radial distance from the axis such that a circle centered on the axis passes through each of the circumferentially overlapping components.

[0024] FIG. 1 is a simplified block diagram of fluid pumping system 10. Fluid pumping system 10 includes pumping assembly 12, reservoir 14, supply line 16, and spray gun 18. Pumping assembly 12 includes assembly body 20, stand 22, pump 24, motor 26, drive 28, and controller 30. Stand 22 includes supports 32. Pump 24 includes pump body 34 and piston 36. Controller 30 includes control circuitry 38, memory 40, and user interface 42. Spray gun 18 includes gun handle 44, trigger 46, and nozzle 48.

[0025] Fluid pumping system 10 is configured to displace a fluid under pressure to a location downstream of pump. In the example shown, fluid pumping system 10 can also be considered to form a fluid spraying system as the downstream location is spray gun 18 that is configured to output sprays of the pumped fluid for application on a target substrate. It is understood, however, that not all examples are so limited and fluid pumping system 10 can be utilized to pump fluid to locations other than a spray gun 18.

[0026] Pumping assembly 12 is configured to draw a fluid (e.g., paint, varnish, water, oil, stains, finishes, aggregate, coatings, and solvents, amongst other options) from reservoir 14 and drive the fluid to spray gun 18 under pressure for spraying by spray gun 18. Fluid pumping system 10 can be an airless spray system in that fluid pumping system 10 does not rely on pressurized air to shape or atomize the fluid spray. Instead, pump 24 generates sufficient pressure to cause nozzle 48 to atomize the fluid into the fluid spray.

[0027] Stand 22 supports other components of pumping assembly 12 relative to a support surface, such as a floor or the ground. Stand 22 is formed by one or more supports 32 that extend vertically relative to assembly body 20 and contact the support surface. Supports 32 can be formed by legs, rails, etc. Supports 32 are shown as extending from assembly body 20 proximate a front end of assembly body 20 (the side including pump 24) and a rear end of assembly body 20 opposite the front end. It is understood, however, that some examples of stand 22 include supports 32 extending from proximate the rear end of assembly body 20 only. For example, supports 32 can include a vertically-extending portion extending from assembly body 20 and a horizontal portion contacting the support surface. In some examples, stand 22 can include one or more wheels that contact the ground surface to facilitate moving of pumping assembly 12, such as around a job site. Assembly body 20 is supported by stand 22 vertically above the support surface. Assembly body 20 supports and can enclose one or more components of pumping assembly 12. Pump 24 is supported by assembly body 20. Pump 24 can be removably connected to assembly body 20 such that pump 24 can be removed from assembly body 20 for servicing, storage, replacement, etc. Pump body 34 is connected to assembly body 20, such as by a clamp, support (e.g., ring or flange), interfaced threading, among other mounting options. Piston 36 is at least partially disposed within pump body 34 and is configured to reciprocate along an axis (axis PA in FIG. 1) to pump the fluid from reservoir 14 to the downstream location. It is understood that pump 24 can be of any form suitable for pumping the fluid to spray gun 18 under pressure for spraying. In some examples, pump 24 is a double displacement pump such that pump 24 outputs fluid during both an up or suction stroke of piston 36 and a down or pressure stroke of piston 36.

[0028] Motor 26 is operatively connected to pump 24 to cause pumping by pump 24. Motor 26 is disposed at least partially within assembly body 20. Motor 26 can be disposed fully within assembly body 20. Motor 26 is an electric motor in the example shown. For example, motor 26 can be a brushed or brushless direct current (DC) motor, an alternating current (AC) induction motor, among other options. Motor 26 is operably connected to piston 36 to drive reciprocation of piston 36 along pump axis PA to cause pumping by pump 24. Pump axis PA can be a vertical axis, among other options.

[0029] In the example shown, motor 26 and drive 28 cause reciprocation of piston 36. Motor 26 is connected to drive 28 and is configured to provide a rotational output to drive 28. Drive 28 is at least partially disposed within assembly body 20 and is configured to convert the rotational output from motor 26 into a linear reciprocating input to piston 36. Drive 28 can be of any form suitable for converting the rotational output to a linear reciprocating input, such as a cam, scotch yoke, eccentric crank, ball screw, among other options.

[0030] Controller 30 is operatively connected to motor 26 to control operation of motor 26 and thus control pumping by pump 24. Controller 30 can include one or more processors for carrying out the functions described herein. Controller 30 can be at least partially disposed within assembly body 20 or may be separate from assembly body 20. Controller 30 is operatively connected to other components of fluid pumping system 10 to control operation of the other components of fluid pumping system 10. Controller 30 is configured to store software, implement functionality, and / or process instructions. Controller 30 is configured to perform any of the functions discussed herein, including receiving an output from any sensor referenced herein, detecting any condition or event referenced herein, and controlling operation of any components referenced herein. Controller 30 can be of any suitable configuration for controlling operation of components of fluid pumping system 10 (e.g., motor 26), receiving signals from components of fluid pumping system 10 (e.g., a pressure transducer, a flow sensor, among other options), gathering data, processing data, etc. Controller 30 can include hardware, firmware, and / or stored software, and controller 30 can be entirely or partially mounted on one or more circuit boards. Controller 30 can be of any type suitable for operating in accordance with the techniques described herein.

[0031] Control circuitry 38, in one example, is configured to implement functionality and / or process instructions. For example, control circuitry 38 can be capable of processing instructions stored in memory 40. Examples of control circuitry 38 can include one or more of a processor, a microprocessor, a controller, a digital signal processor (DSP), an application specific integrated circuit (ASIC), a field-programmable gate array (FPGA), or other equivalent discrete or integrated logic circuitry. Control circuitry 38 can be entirely or partially mounted on one or more circuit boards.

[0032] Memory 40 can be configured to store information before, during, and / or after operation. Memory 40, in some examples, is described as computer-readable storage media. In some examples, a computer-readable storage medium can include a non- transitory medium. The term “non-transitory” can indicate that the storage medium is not embodied in a carrier wave or a propagated signal. In certain examples, a non-transitory storage medium can store data that can, over time, change (e.g., in RAM or cache). In some examples, memory 40 is a temporary memory, meaning that a primary purpose of memory 40 is not long-term storage. Memory 40, in some examples, is described as volatile memory, meaning that memory 40 does not maintain stored contents when power to controller 30 is turned off. Examples of volatile memories can include random access memories (RAM), dynamic random access memories (DRAM), static random access memories (SRAM), and other forms of volatile memories. In some examples, memory 40 is used to store program instructions for execution by control circuitry 38. Memory 40, in one example, is used by software or applications to temporarily store information during program execution. Memory 40 can be configured to store larger amounts of information than volatile memory. Memory 40 can further be configured for long-term storage of information. In some examples, memory 40 includes non-volatile storage elements. Examples of such non-volatile storage elements can include magnetic hard discs, optical discs, flash memories, or forms of electrically programmable memories (EPROM) or electrically erasable and programmable (EEPROM) memories.

[0033] User interface 42 is configured to receive inputs from a user to provide to controller 30 and / or provide outputs to the user. User interface 42 can be any graphical and / or mechanical interface that enables user interaction with controller 30. For example, user interface 42 can implement a graphical user interface displayed at a display device of user interface 42 for presenting information to and / or receiving input from a user. User interface 42 can include graphical navigation and control elements, such as graphical buttons or other graphical control elements presented at the display device. User interface 42, in some examples, includes physical navigation and control elements, such as physically actuated buttons or other physical navigation and control elements. For example, user interface 42 can be or include a dial, slider, one or more buttons, etc. In general, user interface 42 can include any input and / or output devices and control elements that can enable user interaction with controller 30. In some examples, user interface 42 is configured to receive an output setting from a user. The output setting sets a target output parameter for the fluid output by fluid pumping assembly, such as a target pressure or a target flow rate, among other options. User interface 42 can be disposed on or form a portion of an exterior of assembly body 20.

[0034] Transducer 50 is configured to provide information regarding one or more parameters of the fluid output by pumping assembly 12. For example, transducer 50 can be configured as a pressure sensor configured to provide pressure information to controller 30, transducer 50 can be a flow sensor configured to provide flow rate information to controller 30, transducer 50 can include both pressure and flow sensing elements to provide both pressure and flow rate information to controller 30, among other options. Transducer 50 can also be referred to as a sensor.

[0035] Motor sensor 51 is configured to provide information regarding one or more operating parameters of the motor 26 to controller 30. For example, motor sensor 51 can be a speed sensor configured to generate information regarding the rotational speed of a rotor of the motor 26. For example, motor sensor 51 can be one or more hall effect sensors, an encoder, etc.

[0036] Spray gun 18 is configured to emit the spray fluid as an atomized fluid spray through nozzle 48. Trigger 46 is operatively connected to a valve (not shown) within spray gun 18 to open and close the flowpath through nozzle 48. The user can grasp gun handle 44 with a single hand and manipulate the orientation of spray gun 18 to aim spray gun 18. The user can actuate trigger 46 with the hand grasping gun handle 44 to control spraying by spray gun 18.

[0037] During operation, controller 30 provides commands to motor 26 to cause operation of motor 26. For example, controller 30 can command motor 26 to operate to cause pump 24 to displace fluid from reservoir 14 and through supply line 16 based on an input from transducer 50 indicating that pumping is required. For example, transducer 50 can provide pressure information indicating a drop in fluid pressure, indicative of spray gun 18 being actuated to output the fluid.

[0038] Motor 26 generates a rotational output that is provided to drive 28. Drive 28 is driven by motor 26 and outputs linear reciprocating motion to piston 36. Piston 36 reciprocates on pump axis PA to draw fluid from reservoir 14 and drive the fluid downstream through supply line 16. To cause spraying, the user actuates trigger 46 to open the valve in spray gun 18 and the fluid is emitted through nozzle 48 as an atomized fluid spray.

[0039] FIG. 2 is an isometric view of pumping assembly 12. Assembly body 20, stand 22, pump 24, suction assembly 52, control assembly 54, and power supply 56. Assembly body 20 includes pump support 58, housing 60, and assembly handle 62. Stand 22 includes supports 32. Pump body 34 and pump mount 64 of pump 24 are shown. Suction assembly 52 includes pump connector 66, inlet tube 68, and hose 70.

[0040] Pumping assembly 12 is configured to draw fluid from a reservoir (e.g., reservoir 14 (FIG. 1)) and drive the fluid to a downstream location (e.g., spray gun 18 (FIG. 1)) under pressure. Assembly body 20 encloses various other components of pumping assembly 12 and can support various components of pumping assembly 12. Housing 60 forms at least a portion of the exterior of pumping assembly 12. Motor 26 and drive 28 are each at least partially disposed within housing 60.

[0041] Assembly handle 62 projects from a top side of housing 60. Assembly handle 62 can, in some examples, be connected to housing 60. Assembly handle 62 can, in some examples, be connected to a frame disposed at least partially within housing 60. Assembly handle 62 provides a location for a user to interface with pumping assembly 12 to move pumping assembly 12 between locations, such as around a job site. The user can grasp assembly handle 62 to pick up and carry pumping assembly 12.

[0042] Pump support 58 is configured to interface with pump 24 to support pump 24 on assembly body 20. For example, pump support 58 can be fully or partially formed by a portion of a frame of the assembly body 20, the frame at least partially disposed within housing 60. In the example shown, a portion of assembly body 20 extends into a gap formed by pump mount 64 of the pump 24 to support the pump 24. The portion of the assembly body 20 that extends into the gap can be considered to form the pump support 58. In some examples, the pump support 58 can be considered to form or can include a flange that extends into the gap to support the pump 24.

[0043] Pump mount 64 is configured to interface with pump support 58 to mount pump 24 to assembly body 20. For example, pump mount 64 can be formed by a pair of rings that define a gap therebetween with the gap configured to receive a portion of the pump support 58 to mount pump 24 on assembly body 20.

[0044] Pump 24 is mounted to assembly body 20 and to drive 28. The piston 36 of pump 24 is connected to drive 28 to be reciprocated by the drive 28. Pump body 34 of pump 24 is connected to assembly body 20 to be supported by assembly body 20. Pump 24 can be considered to be mounted at a static interface and a dynamic interface, the static interface between pump mount 64 and assembly body 20 and the dynamic interface between piston 36 and drive 28.

[0045] Control assembly 54 is supported by assembly body 20. Control assembly 54 is disposed outside of housing 60. Control assembly 54 is fluidly connected to pump 24 to receive the fluid output by pump 24. Control assembly 54 can house a filter among other options. An output hose (not shown) extends between an outlet of pump 24 and an inlet of control assembly 54. Control assembly 54 is configured to control output of the fluid from pumping assembly 12. For example, control assembly 54 can be placed in a priming state in which fluid provided to control assembly 54 is output back to reservoir 14 during priming of pump 24. Control assembly 54 can be placed in an output state in which the fluid is output through outlet fitting 72 to the supply line (e.g., supply line 16) to be provided to the downstream location, such as for spraying.

[0046] Suction assembly 52 is fluidly connected to pump 24. An end of suction assembly 52 opposite the end connected to pump 24 is configured to extend into the reservoir 14 such that the fluid is drawn into the suction assembly 52 from reservoir 14 and provided to pump 24. Pump connector 66 is connected to pump body 34 to connect suction assembly 52 to pump 24. For example, pump connector 66 can be a threaded connector configured to threadedly connect suction assembly 52 with pump body 34. Inlet tube 68 extends between pump 24 and hose 70. Hose 70 extends from inlet tube 68 and is configured to provide fluid flow to inlet tube 68. Hose 70 can be formed as a flexible hose. Inlet tube 68 can be rigid. It is understood that in some examples the suction assembly 52 can extend vertically downward from pump 24 and into a reservoir 14 disposed directly vertically below the pump 24. In such an example the suction assembly 52 can include a rigid body and may not include inlet tube 68 and a flexible hose 70.

[0047] Stand 22 supports other components of pumping assembly 12 on the support surface. Supports 32 extend vertically downward below the bottom end of pump 24 and interface with the support surface. In the example shown, the supports 32 are formed as a plurality of legs. In the example shown, stand 22 includes four legs, though it is understood that other numbers of legs are possible.

[0048] Power supply 56 is configured to provide electrical power to electrically powered components of pumping assembly 12, such as motor 26 and controller 30. In the example shown, power supply 56 is formed as a power cord that is configured to plug into a wall socket. It is understood, however, that is various other examples the power supply 56 can be formed by one or more batteries. For example, the one or more batteries can be removable and rechargeable.

[0049] FIG. 3 is a simplified diagram showing parameter setting input 74 for pumping assembly 12. Parameter setting input 74, range 76, and detent 78 are shown.

[0050] Parameter setting input 74 can be considered to form a portion of user interface 42. Parameter setting input 74 is configured to provide a target operating parameter (e.g., target output pressure, target flow rate, target motor speed, etc.) to controller 30. The controller 30 is configured to control operation of the electric motor 26 based on the target operating parameter. The controller 30 is configured to control operation of the electric motor 26 such that a value of an actual operating parameter (e.g., sensed pressure, sensed flow rate, sensed motor speed, etc.) meets a value of the target operating parameter. For example, the target operating parameter can be a target output pressure and the controller 30 can control operation of the electric motor 26 to cause the actual pressure (e.g., a pressure sensed by transducer 50) to meet the target output pressure.

[0051] The parameter setting input 74 is operable to adjust the target operating parameter over a range 76. For example, the parameter setting input 74 can be configured as a dial that is rotatable to adjust the signal provided to the controller 30. The parameter setting input 74 can be rotatable across the range 76. The parameter setting input 74 can include an indicator 80, such as a projection that extends radially relative to a rotational axis of the parameter setting input 74, to provide visual feedback to the user of the location of the parameter setting input 74 within the range 76. A user can manipulate the parameter setting input 74 to provide commands to the controller 30 for controlling operation of pumping assembly 12. For example, the parameter setting input 74 can be connected to a potentiometer, hall-effect sensor such as an angular hall-effect sensor, among other options, to generate the signal provided to controller 30.

[0052] The target operating parameter can be considered to form a primary operating parameter. The controller 30 controls operation of the motor 26 to cause a value of an actual operating parameter to meet the value set for the primary operating parameter by parameter setting input 74. Operating parameters other than the primary operating parameter can be considered to form secondary operating parameters. It is understood that the controller 30 can be configured to control operation of the motor 26 based on one or more secondary operating parameters while driving to the primary operating parameter.

[0053] For example, if the target operating parameter is an output pressure, then the output pressure can be considered to form a primary operating parameter to which the controller 30 controls the motor 26. Other operating parameters, such as motor speed, can be considered to form secondary operating parameters. The controller 30 can vary the secondary operating parameters to drive the actual primary operating parameter to meet the target primary operating parameter. For example, the controller 30 can vary the speed of the motor 26 to adjust the actual output pressure sensed by transducer 50.

[0054] In another example, if the target operating parameter is motor speed, then the actual speed of the motor 26 (e.g., revolutions per minute (RPM) of a rotor of the motor 26) can be considered to form the primary operating parameter to which the controller 30 controls the motor 26. Other operating parameters, such as the output pressure, can be considered to form secondary operating parameters. In such an example, the controller 30 can control operation of the motor 26 to drive the motor 26 to the target motor speed while also controlling based on the secondary operating parameter. For example, the controller 30 can be configured such that the controller 30 stops driving the motor 26 if the actual pressure reaches a pressure threshold, such as to prevent overpressurization. The controller 30 can be configured to resume driving the motor 26 based on the target motor speed if the actual pressure drops below the pressure threshold. In some examples, the controller 30 is configured to stop driving the motor 26 if the actual pressure reaches an upper pressure threshold and to resume driving the motor 26 if the actual pressure drops to a lower pressure threshold less than the upper pressure threshold.

[0055] The controller 30 can control operation of the motor 26 based on information provided by a sensor (e.g., transducer 50 and / or motor sensor 51) to caused a desired output from pumping assembly 12. For example, if the target output parameter is output pressure, then the controller 30 can compare the actual pressure as sensed by transducer 50 to the target output pressure and can control a speed of motor 26, as indicated by motor sensor 51, to adjust the actual pressure. If the target output parameter is motor speed, then the controller 30 can compare the actual motor speed as sensed by motor sensor 51 to the target motor speed and can adjust the speed of the motor 26 to cause the actual motor speed to meet the target motor speed.

[0056] The range 76 of the parameter setting input 74 extends between a first range end 82a and a second range end 82b. It is understood that, in some examples, range 76 can extend below range end 82a, such as for placing controller 30 in additional or alternative operating modes. A first input portion 84a extends between range end 82a and transition point 86. A second input portion 84b extends between transition point 86 and range end 82b.

[0057] The parameter setting input 74 can be configured such that the target operating parameter provided to controller 30 is a first target operating parameter with the parameter setting input 74 in the first input portion 84a of the range 76 and the target operating parameter provided to controller 30 is a second target operating parameter with the parameter setting input 74 in the second input portion 84b of the range 76. The first target operating parameter can differ from the second target operating parameter. For example, one of the first and second target operating parameters can be a fluid parameter (e.g., output pressure) and the other one of the first and second target operating parameters can be a motor parameter (e.g., motor speed). It is understood that a value of the target operating parameter can vary within the input portion 84a, 84b. For example, if output pressure is the target operating parameter for the first input portion 84a, the value of the target pressure can vary as the pressure setting input 74 traverses across the range 76 (e.g., a lower pressure value closer to range end 82a and a higher pressure value closer to transition point 86).

[0058] The controller 30 is operable in a first control mode with the parameter setting input 74 in the first input portion 84a. The controller 30 is operable in a second control mode with the parameter setting input 74 in the second input portion 84b. The controller 30 controls operation of the motor 26 based on a first target operating parameter when in the first control mode and controls operation of the motor 26 based on a second operating parameter different from the first operating parameter when in the second control mode.

[0059] In some examples, the controller 30 is configured to control operation of the motor 26 based on one of pressure control, in which output pressure is the target operating parameter, and speed control, in which motor speed is the target operating parameter, while operating in the first control mode. The controller 30 is configured to switch to the other one of pressure control and speed control when operating in the second control mode.

[0060] In some examples, the first target operating parameter associated with first input portion 84a is a target fluid parameter. For example, the first target operating parameter can be a target output pressure. In such an example, the controller 30 controls operation of the motor 26 to cause the actual fluid pressure output by the pump 24 to meet the target output pressure. For example, the controller 30 can increase a speed of the motor 26 to increase pressure downstream of the pump 24. In some examples, the second target operating parameter associated with the second input portion 84b is a target motor parameter. For example, the second target operating parameter can be a target motor speed. In such an example, the controller 30 controls operation of the motor 26 to cause the actual speed of a rotor of the motor 26 to meet the target motor speed.

[0061] In some examples, the first target operating parameter associated with first input portion 84a is a target output pressure and the second target operating parameter associated with second input portion 84b is a target motor speed. The controller 30 can be configured such that the target pressure changes depending on the location of the parameter setting input 74 within the first input portion 84a. For example, the target output pressure can increase as parameter setting input 74 moves from range end 82a towards transition point 86. For example, a maximum target pressure (e.g., 2,000 psi, 3,500 psi, or more) can be associated with the portion of first input portion 84a at or immediately before transition point 86. A minimum target pressure (e.g., 0 psi, 50 psi, or another value) can be associated with the portion of first input portion 84 at range end 82a. In some examples, the controller 30 can be configured such that the target motor speed changes depending on the location of the parameter setting input 74 within second input portion 84b. In other examples, the controller 30 can be configured such that the target motor speed remains static regardless of the location of the parameter setting input 74 within second input portion 84b.

[0062] First input portion 84a can be considered to form a lower portion of range 76 and second input portion 84b can be considered to form a top portion of range 76. A control pressure can be considered to be the sensed fluid pressure at which controller 30 stops driving of motor 26 or continues driving of the motor to maintain the sensed pressure steady. For example, if the target operating parameter is an output pressure, then during spray operations during which spray fluid is emitted the controller 30 can continue driving the motor 26 to maintain the pressure at the control pressure to maintain the actual output pressure steady. For example, the control pressure can be the primary operating parameter in examples in which the output pressure is the target operating parameter. The control pressure can be a secondary operating parameter in examples in which the target operating parameter is an operating parameter other than output pressure. As discussed above, in some examples the target operating parameter is output pressure for first input portion 84a and the target operating parameter is motor speed for second input portion 84b. Parameter setting input 74 can be configured such that the control pressure rises between range end 82a and transition point 86 and such that the control pressure drops with parameter setting input 74 in the second input portion 84b that is disposed above the first input portion 84a. For example, the control pressure at the upper end of the first input portion 84a (e.g., at or adjacent to transition point 86) can be a first pressure value and the control pressure within second input portion 84b can be a second pressure value less than the first pressure value. In some examples, the second pressure value can be less than half of the first pressure value. In some examples, the second pressure value can be up to about 60% of the first pressure value. In some examples, the pressure value of the control pressure is variable within the first input portion 84a while the pressure value of the control pressure is steady and unchanging within the second input portion 84b. In some examples, a smallest target output pressure in the first input portion 84a is less than the control pressure in the second input portion 84b.

[0063] Detent 78 is associated with parameter setting input 74. Detent 78 is disposed at a location that parameter setting input 74 crosses over when transitioning between the first input portion 84a and the second input portion 84b. Detent 78 can be a ball detent, such as a ball biased by a spring. The parameter setting input 74 can include a projection, rib, slot, or other structure that passes over the detent 78 as the parameter setting input 74 transitions between the first input portion 84a and the second input portion 84b. Detent 78 can thereby be displaced by parameter setting input 74 passing over detent 78 and can spring back to position after parameter setting input 74 has passed over detent 78. The detent 78 is configured to provide feedback to the user that the parameter setting input 74 has transitioned between the first input portion 84a and the second input portion 84b. Such feedback can indicate that the controller 30 has transitioned between the first control mode and the second control mode. The feedback can be haptic feedback or auditory feedback among other options. For example, the parameter setting input 74 passing over detent 78 can cause vibration in the parameter setting input 74 that the user is manipulating, informing the user that the parameter setting input 74 has transitioned from one of the first input portion 84a and the second input portion 84b to the other one of the first input portion 84a and the second input portion 84b.

[0064] Parameter setting input 74 is configured to provide a target operating parameter to controller 30 that controller 30 utilizes to control operation of motor 26 and cause output of fluid by pump 24. In some examples, the target operating parameter is variable across a portion of range 76 and is static in another portion of range 76. For example, the target operating parameter can be variable across first input portion 84a and static in second input portion 84b.

[0065] In some examples, an operating parameter, whether primary or secondary, rises within the first input portion 84a and then drops when in the second input portion 84b. For example, the control pressure can rise within first input portion 84a until reaching transition point 86 and then the control pressure can drop when parameter setting input 74 enters into the second input portion 84b.

[0066] The parameter setting input 74 provides a gradual increase in the output from pumping assembly 12 through a majority of the range 76 of the parameter setting input 74. It is understood that the parameter setting input 74 provides a gradual increase in the output from pumping assembly 12 through a majority of a rotation of the parameter setting input 74 between range ends 82a, 82b. The parameter setting input 74 then provides a decremented output in the final portion of the range 76. For example, the control pressure can increase within the first input portion 84a and then decrease once parameter setting input 74 enters into the second input portion 84b.

[0067] In some examples, the parameter setting input 74 can be considered to provide an asymmetrically ramped output. An operating parameter can increase through the first input portion 84a and then decrease in the final portion of the range 74. For example, the maximum pressure to which the controller 30 controls operation of pump 24 can increase throughout the first input portion 84a and then drop once parameter setting input 74 moves into the second input portion 84b.

[0068] In some examples, the parameter setting input 74 can be considered to form a tailend decrement modulator. The parameter setting input 74 can be configured such that the controller 30 gradually increases an output from motor 26 through the lower end of the range 76 (e.g., through first input portion 84a) and then the output from motor 26 is decreased in the tail end of the range 76 (e.g., in second input portion 84b).

[0069] In some examples, the first control mode can be considered to form a spray control mode and the second control mode can be considered to form a flush control mode. During operation, the user sets a target output pressure for spraying of a fluid by positioning the parameter setting input 74 at a location within the first input portion 84a associated with the desired spray pressure, thereby setting a target output pressure. The controller 30 controls operation of the motor 26 such that pump 24 outputs the spray fluid at the target output pressure. For example, the controller 30 can increase a speed of the motor 26 to increase the fluid pressure. The controller 30 can stop operation of the motor 26 when the actual fluid pressure reaches the target fluid pressure or continue to drive the motor 26 at a speed suitable for maintaining pressure.

[0070] After spray operations are completed, the pump 24 and other fluid handling components of pumping system 10 are flushed, such as with solvent, to prevent clogging and sticking of components. The user can actuate the parameter setting input 74 to within second input portion 84b to place the controller 30 in the flush control mode. Detent 78 can provide feedback to the user indicating that the control mode has changed from the spray control mode to the flush control mode. While operating in the flush control mode, the controller 30 controls operation of the motor 26 based on a target motor speed. The controller 30 causes the motor 26 to run at the target operating speed to cause the pump 24 to pump the flush fluid through the fluid handling components. As discussed above, the controller 30 can cause the motor 26 to stop running while operating in the fluid control mode based on a sensed fluid pressure exceeding a first pressure threshold. Such a configuration prevents overpressurization and prevents the user from performing spray operations while in the flush control mode, which can be disadvantageous.

[0071] Parameter setting input 74 provides significant advantages. Over a portion of the range 76 the controller 30 controls operation of the motor 26 based on pressure control while over another portion of the range 76 the controller 30 controls operation of the motor 26 based on speed control. The different control schemes allow for responsive motor control depending on the desired operation by the user. As discussed above, a spray control mode can be associated with pressure control so the user can vary the desired fluid pressure depending on the fluid being sprayed and desired spray qualities while a flush control mode can cause the motor 26 to run at a set speed to drive flushing fluid through pumping system 10 during which spray operations are not performed.

[0072] In the example shown, second input portion 84b is disposed at a top end of range 76 beyond the top end of first input portion 84a. A control pressure within the second input portion 84b is less than a control pressure at a top end of the first input portion 84a. As such, the control pressure rises within the first input portion 84a from range end 82a to transition point 86 and then the control pressure drops with parameter setting input 74 between transition point 86 and range end 82b. The lower control pressure in second input portion 84b is sufficient for pumping of flushing fluid, which is typically less viscous than spray fluid, and prevents overpressurization when controlling operation of motor 26 based on motor speed.

[0073] Placing second input portion 84b at the top end of range 76 provides an intuitive position for the second control mode relative to spray operations. The user initially performs spray operations in which the spray fluid is applied to a target substrate. The first input portion 84a is associated with the spray control mode and forms a first portion of the range 76. The user performs flushing operations after spray operations are completed. The second input portion 84b is associated with the flush control mode and forms a second portion of the range 76 that the user actuates to after spraying of the spray fluid.

[0074] Detent 78 provides feedback to the user that the user has switched between operating modes. The exterior of a pumping assembly 12 can become coated with spray fluid such that visual indicators of various operating modes may become obscured. The detent 78 provides feedback as to the user switching between control modes. As such, the user can easily and quickly determine which control mode the controller 30 is operating in based on the feedback provided by detent.

[0075] The parameter setting input 74 providing for gradually increasing output from motor 26 though a first portion of the range 76 and then a decreased output in the tail portion of the range 76 provides for controlled and safe operation of pumping assembly 12 while also avoiding unintended output at the tail end of the range 74.

[0076] While the invention(s) has been described with reference to an exemplary embodiment(s), it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention(s) without departing from the essential scope thereof. Therefore, it is intended that the invention(s) not be limited to the particular embodiment(s) disclosed, but that the invention(s) may include all embodiments falling within the scope of the appended claims. Any single feature, or any combination of features from one embodiment show herein, may be utilized in a different embodiment independent from the other features shown in the embodiment herein. Accordingly, the scope of the invention(s) and any claims thereto are not limited to the particular to the embodiments and / or combinations of the features shown herein, but rather can include any combination of one, two, or more features shown herein.

Claims

CLAIMS:

1. A fluid sprayer comprising: an electric motor; a drive connected to the electric motor and configured to convert a rotational output from the electric motor to linear reciprocating motion; a pump connected to the drive to be reciprocated by the drive to pump fluid; a parameter input setting configured to set a target operating parameter; and a controller operably connected to the electric motor to control operation of the electric motor based on the target operating parameter; wherein the target operating parameter is a target output pressure with the parameter input setting in a first input portion of a range of the parameter input setting, and the target operating parameter is a target motor speed with the parameter input setting in a second input portion of the range.

2. The fluid sprayer of claim 1, wherein the parameter input setting is a dial.

3. The fluid sprayer of claim 1, wherein the parameter input setting is rotatable across the range.

4. The fluid sprayer of any one of claims 1-3, wherein the second input portion is disposed further along the range than the first input portion.

5. The fluid sprayer of any one of claims 1-4, wherein the first input portion extends between a first range end and a transition point and the second input portion extends between the transition point and a second range end.

6. The fluid sprayer of claim 5, further comprising: a detent disposed at the transition point, the parameter input setting passing over the detent when transitioning between the first input portion and the second input portion.

7. The fluid sprayer of any one of claims 1-6, further comprising: a pressure transducer disposed downstream of the pump, the pressure transducer configured to provide an actual pressure to the controller.

8. The fluid sprayer of any one of claims 1-7, wherein the target output pressure is variable within the first input portion.

9. The fluid sprayer of any one of claims 1-8, wherein the target motor speed is steady within the second input portion.

10. The fluid sprayer of any one of claims 1-9, wherein a largest target output pressure in the first input portion is greater than a control pressure in the second input portion.

11. The fluid sprayer of claim 10, wherein a smallest target output pressure in the first input portion is less than the control pressure in the second input portion.

12. The fluid sprayer of any one of claims 1-11, wherein the controller is configured to vary a speed of the motor when the target operating parameter is the target output pressure.

13. The fluid sprayer of any one of claims 1-12, wherein when the target operating parameter is the target motor speed the controller is configured to stop operation of the electric motor based on an actual fluid pressure reaching a first pressure threshold and the controller is configured to resume operation of the electric motor based on the actual fluid pressure reaching a second pressure threshold, the second pressure threshold less than the first pressure threshold.

14. A fluid sprayer comprising: an electric motor; a drive connected to the electric motor and configured to convert a rotational output from the electric motor to linear reciprocating motion; a pump connected to the drive to be reciprocated by the drive to pump fluid; a parameter input setting configured to set a target operating parameter, the parameter input setting adjustable across a range, the range including a first input portion and a second input portion; and a controller operably connected to the electric motor to control operation of the electric motor based on the target operating parameter; wherein the parameter input setting is configured such that a value of an operating parameter increases within the first input portion and the value of the operating parameter drops with the parameter input setting in the second input portion.

15. A fluid sprayer comprising: an electric motor; a drive connected to the electric motor and configured to convert a rotational output from the electric motor to linear reciprocating motion; a pump connected to the drive to be reciprocated by the drive to pump fluid;a parameter input setting configured to set a target operating parameter, wherein the parameter input setting includes a dial adjustable across a range, the range including a first input portion and a second input portion; and a controller operably connected to the electric motor to control operation of the electric motor based on the target operating parameter; wherein the controller is configured to control operation of the electric motor based on a sensed output pressure with the parameter input setting in the first input portion and the controller is configured to control operation of the electric motor based on a sensed motor speed with the parameter input setting in the second input portion.

16. A fluid sprayer comprising: an electric motor; a drive connected to the electric motor and configured to convert a rotational output from the electric motor to linear reciprocating motion; a pump connected to the drive to be reciprocated by the drive to pump fluid; a parameter input setting operable across a range to set a target operating parameter, the target operating parameter forming a primary operating parameter; and a controller operably connected to the electric motor to control operation of the electric motor based on the primary operating parameter and one or more secondary operating parameters; wherein the primary operating parameter is one of a motor speed and an output pressure within a first input portion of the range and the primary operating parameter is the other one of the motor speed and the output pressure in a second input portion of the range.

17. The fluid sprayer of claim 16, wherein the other one of the motor speed and the output pressure is at least one of the one or more secondary operating parameters in the first input portion and the one of the motor speed and the output pressure is at least one of the one or more secondary operating parameters in the second input portion.

18. A fluid sprayer comprising: an electric motor; a drive connected to the electric motor and configured to convert a rotational output from the electric motor to linear reciprocating motion;a pump connected to the drive to be reciprocated by the drive to pump fluid; a parameter input setting operable across a range to set a target operating parameter, the target operating parameter forming a primary operating parameter; and a controller operably connected to the electric motor to control operation of the electric motor based on the primary operating parameter and one or more secondary operating parameters; wherein an operating parameter forms the primary operating parameter in a first input portion of the range and the operating parameter forms a secondary operating parameter in a second input portion of the range; and wherein a value of the operating parameter drops from a top end of the first input portion to within the second input portion.

19. A fluid sprayer comprising: an electric motor; a drive connected to the electric motor and configured to convert a rotational output from the electric motor to linear reciprocating motion; a pump connected to the drive to be reciprocated by the drive to pump fluid; a parameter input setting configured to set a target operating parameter, the parameter input setting comprising a dial which rotates from a first rotational end to a second rotational end; a controller operably connected to the electric motor to control operation of the electric motor based on the target operating parameter; wherein the dial can be rotated through a first portion of a range in which the target operating parameter is progressively increased as the dial is rotated away from the first rotational end and toward the second rotational end, and the dial can be rotated through a second portion of the range in which the target operating parameter is decreased relative to a part of the first range which is closest to the second range, the second range closer to the second rotational end than to the first rotational end.

20. A fluid sprayer comprising: an electric motor;a drive connected to the electric motor and configured to convert a rotational output from the electric motor to linear reciprocating motion; a pump connected to the drive to be reciprocated by the drive to pump fluid; a parameter input setting configured to set a target operating parameter, the parameter input setting comprising a dial which rotates from a first rotational end to a second rotational end; a controller operably connected to the electric motor to control operation of the electric motor based on the target operating parameter; wherein the dial can be rotated through a first portion of a range in which the target operating parameter is progressively increased as the dial is rotated away from the first rotational end and toward the second rotational end, and wherein further rotation of the dial toward the second rotational end decreases the target operating parameter.

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