Modular and scalable powder venturi and high-density platforms for powder system

Abstract

A powder coating system (100) includes a system controller (102) comprising a processor (108), a memory (106), and a graphical user interface (104), and a device controller (110-110N) communicatively coupled to the system controller (102). The device controller (110-110N) is configured to control at least one valve that sends air to a powder pump (118-118N) coupled to a powder spray gun (114-114N) and to control a voltage supplied to the spray gun (114-114N). The device controller (110-110N) is further configured to identify and transmit to the system controller (102) an indication of a type of the powder pump (118-118N) coupled to the device controller (110-110N) upon coupling of the powder pump (118-118N) to the device controller (110-110N).

Description

MODULAR AND SCALABLE POWDER VENTURI AND HIGH-DENSITY PLATFORMS FOR POWDER SYSTEMCROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims priority to and all benefit of U.S. Provisional Patent Application Serial No. 63 / 706,805, filed on October 14, 2024 and entitled MODULAR AND SCALABLE POWDER VENTURI AND HIGH-DENSITY PLATFORMS FOR POWDER SYSTEM, the entire disclosure of which is incorporated by reference herein.BACKGROUND

[0002] Powder coating material such as powder paint is commonly applied to an object by spraying the powder coating material. Typically, a spray gun or material application device is used, and spray guns may be manually held and operated or automatic spray guns may be used that are controlled electronically, for example, according to a stored program or recipe. Manual powder coating equipment (e.g., on a portable cart or dolly) is often preferred for smaller scale applications, due to lower relative cost, size, and portability, while automatic, programmable powder coating equipment (e.g., in an electronic controls equipped booth or workstation) may be preferred for increased efficiency and throughput). may utilized to provide lower cost Spray technologies include for example electrostatic, non-electrostatic and tribo-electric. Exemplary manual and automatic powder coating equipment are described in U.S. Patent No. 9,649,651 and PCT Application Pub. No. 2006 / 033813, the entire disclosures of which are incorporated herein by reference.

[0003] In conventional powder coating systems, manual powder guns require adjustments to material delivery parameters based on different powder and part types. These parameters may be saved in “recipes” and / or may be manually controlled based on operator experience and know how. When recipes are not used, operators (users) may use the wrong parameters and / or make incorrect parameter adjustments, resulting in too much or too little material being delivered to an object or part surface and causing improper coating of the part. Manual powder gun systems also rely on operators to monitor and respond appropriately to faults. Missed or ignored faults may lead to system malfunctions, resulting in downtime, poor quality, and lost profits. Moreover, manual powder gun systems rely on operators to perform their jobs for a given duration. Operators not fully performing their job for their full work shift can also lead to a loss in productivity and profit.

[0004] Additionally, typical manual powder gun systems have multiple parts, including electrostatic spray guns, powder pumps, and valves. These parts are subject to wear and tear, requiring periodic maintenance and / or replacement. Missed or ignored maintenance and / or replacement requirements may result in downtime, poor quality, and lost profit.

[0005] Moreover, conventional powder coating systems may not be easily altered from their defined configurations after purchase, often requiring the purchase of an entire new powder coating system. This may occur when, for example, a customer has purchased a single gun controller but later determines that they need multiple gun controllers. This can also occur when, for example, a customer has purchased a gun controller for a targeted application (e.g., a venturi type gun controller) but later identifies a different targeted application (e.g., a high density type gun).

[0006] Furthermore, conventional manual powder applicators (e.g., powder spray guns) may use predefined powder recipes (e.g., a set of operational instructions) to deliver powder coating material to parts properly. If an incorrect recipe is selected, too much or too little material is delivered to the parts surface, which may lead to poor quality and lost profits. Having multiple operators on different manual guns spraying the same part increases the chance of an incorrect recipe being selected by one of the operators.

[0007] Powder systems may also have a hardware limitation in the number of guns they can practically support before requiring additional systems for expanded gun networks. The expanded networks may be difficult to set up properly and coordinate by a supervisor (administrator) and operators, resulting in downtime and poor coating quality. The foregoing problems and deficiencies have not been adequately addressed by conventional powder coating systems or approaches.SUMMARY

[0008] The following is a brief summary of subject matter that is described in greater detail herein. This summary is not intended to be limiting as to the scope of the claims.

[0009] Described herein are various technologies relating to powder coating systems, and more particularly to a modular and scalable powder coating system. In one embodiment, a modular powder coating system comprises a system controller including a graphical user interface (GUI), a memory and a processor. One or more device controllers are communicatively coupled to and receive instructions from the system controller via a controller area network (CAN) connection (wired or wireless). Each device controllercontrols one powder pump and spray gun via a local interconnect network (LIN, I2C, etc.) and / or digital and / or analog input / output connections and is configured to determine a type of a powder pump module (e.g., venturi or high density; also referred to herein simply as a “powder pump”) upon coupling of the powder pump module to the device controller. The device controller employs device control instructions stored in the device controller for the corresponding identified powder pump module type. The device controller determines the type of powder pump module by detecting a presence or absence of a high density (HD) flow module (also referred to herein as an “HD air flow controller” or simply “air flow controller”) in the powder pump module. Presence of the high density flow module is determined by detecting a voltage associated with the high density flow module. In one embodiment, the system controller receives an indication from the device controller indicative of the type of powder pump connected to the device controller and displays to a user a corresponding interface for the indicated type of powder pump module. A single system controller can be coupled to multiple device controllers controlling the same or different types of powder pump modules. The powder coating system can be employed in a manual spray coating dolly or in a multiple spray gun wall mount or rail mount configuration. Multiple powder coating systems can be coupled / coordinated via direct connection, a central server, or a higher level controller or programmable logic controller.

[0010] In another embodiment, the system controller provides multiple levels of access and functionality. Different levels of access are granted to different individuals using corresponding access credentials, wherein different profiles (e.g., user profile, administrator profile, etc.) and / or profile interfaces (e.g., user profile interface, administrator profile interface, etc.) corresponding to the different respective access levels are presented on the system controller GUI. Login profile permission and / or access defaults are defined by the profile type (administrator, user, etc.). For example, an administrator profile is provided a level of system access that permits the administrator to interact with an administrator profile interface displayed on the GUI to create, edit, and control multiple user profiles; limit one or more users’ ability to customize or control recipes or spray settings in the system; audit each user’s operation of the system; etc. The system controller stores information related to user operation of, and interaction with, the powder coating system and can store information related to multiple user work shifts on a single system or across multiple systems. The system controller also allows the administrator to search and filter user operation / interaction parameters, and the user operation / interaction information is presented to the administrator via an administrator profile interface. A user profile is granted an access level that permits alogged-in user to interact with a user profile interface displayed on the GUI to customize the user profile interface within administrator-defined constraints; access administrator- authorized recipes; control system settings within administrator-defined parameters, etc.

[0011] In another embodiment, the system controller is configured to track operational parameters of connected system parts (powder spray guns, pumps, valves, etc.). The system controller automatically identifies parts upon connection to the system using part numbers stored in a database or assigned by an administrator, or using serial numbers detected through a system part interface or entered / assigned by an administrator. Tracked operational part parameter information can include usage time, service / maintenance events (event, time, and servicer identity), fault information, part descriptors (e.g., part type, part number, serial number, service / maintenance period, etc.) etc. Tracked operational part parameter information can be filtered and searched by an administrator. The system controller also displays alarm messages upon detection of a part fault level above a predefined threshold, warning messages upon detection of a part fault level below the predefined threshold, and maintenance messages when a part has reached or exceeded its service / maintenance period.

[0012] In another embodiment, the system controller is communicatively coupled to multiple device controllers, each device controller being further coupled to a powder coating spray gun (e.g., manual or automatic, venturi or high density, etc.). The system controller transmits to the device controllers a single powder recipe (recipe information and instructions) entered or selected by a user or administrator. Each device controller controls a powder coating spray gun to employ the same powder recipe (i.e., a single recipe common to multiple spray guns and / or device controllers) to ensure uniform and consistent coating across multiple spray guns. The system controller controls the multiple spray guns independently or synchronously. Multiple powder coating systems can also be coordinated via direct connection, a higher level controller or programmable logic, a central server, etc.

[0013] It will be understood that information described as being stored on, in, or by the system controller may also be stored on, in, or by a database and / or server (remote, distributed, or local) that is accessible by the system controller to retrieve said information for display on the system controller. It will further be appreciated that although the systems and methods described herein are discussed in the context of powder coating systems, one of skill in the art will understand that the described systems and methods are also germane to other coating systems (e.g., liquid, etc.) and other control systems.

[0014] The above summary presents a simplified summary in order to provide a basic understanding of some aspects of the systems and / or methods discussed herein. This summary is not an extensive overview of the systems and / or methods discussed herein. It is not intended to identify key / critical elements or to delineate the scope of such systems and / or methods. Its sole purpose is to present some concepts in a simplified form as a prelude to the more detailed description that is presented later.BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Fig. 1 illustrates a scalable, modular powder coating system, in accordance with one or more features described herein.

[0016] Fig. 2 is an illustration of the device controller, in accordance with one or more features described herein.

[0017] Fig. 3 is an illustration of the system controller, in accordance with one or more features described herein.

[0018] Fig. 4 is an illustration of a powder coating system that employs a venturi spray gun, in accordance with one or more features described herein.

[0019] Fig. 5 is an illustration of a powder coating system that employs a high-density (HD) spray gun, in accordance with one or more features described herein.

[0020] Fig. 6 is an illustration showing internal communication between components of the system controller, in accordance with one or more aspects described herein.

[0021] Fig. 7 is an illustration of the part tracking module of the system controller showing various part tracking access levels and permissions for an administrator and a user, respectively.

[0022] Fig. 8 is an illustration of the user tracking module of the system controller showing various user tracking access levels and permissions for an administrator and a user, respectively.

[0023] Fig. 9 is an illustration of the powder system in which the recipe sharing module of the system controller is employed, in accordance with one or more features described herein.

[0024] Fig. 10 illustrates a multiple powder system arrangement in which a plurality of powder systems are communicatively coupled by a system coupler.

[0025] Fig. 11 is an illustration of an automatic powder spray system, showing a stack of two device controller cabinets, each comprising device controllers for up to 10 spray guns.

[0026] Fig. 12 illustrates an exploded view of a manual powder spray dolly in which the described system controller and device controller can be employed, in accordance with one or more features described herein.

[0027] Fig. 13 is an illustration representing the modularity of the described systems and components, with one or more features described herein.

[0028] Fig. 14 is an illustration of the device controller mounting plate mounted to an interior wall of a venturi pneumatic module.

[0029] Fig. 15 is an illustration of the device controller mounting plate with the device controller installed wherein the device controller mounting plate is mounted to an interior wall of an HD pneumatic module.

[0030] Fig. 16 illustrates a rear view (i.e., opposite the device controller) of the device controller mounting plate.

[0031] Fig. 17 illustrates an exemplary computing device that can be used in accordance with the systems and methodologies disclosed herein.DETAILED DESCRIPTION

[0032] Various technologies pertaining to powder coating systems are now described with reference to the drawings, where like reference numerals are used to refer to like elements throughout. In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of one or more aspects. It may be evident, however, that such aspect(s) may be practiced without these specific details. In other instances, well-known structures and devices are shown in block diagram form in order to facilitate describing one or more aspects. Further, it is to be understood that functionality that is described as being carried out by certain system components may be performed by multiple components. Similarly, for instance, a component may be configured to perform functionality that is described as being carried out by multiple components.

[0033] Moreover, the term “or” is intended to mean an inclusive “or” rather than an exclusive “or.” That is, unless specified otherwise, or clear from the context, the phrase “X employs A or B” is intended to mean any of the natural inclusive permutations. That is, the phrase “X employs A or B” is satisfied by any of the following instances: X employs A; X employs B; or X employs both A and B. In addition, the articles “a” and “an” as used in thisapplication and the appended claims should generally be construed to mean “one or more” unless specified otherwise or clear from the context to be directed to a singular form.

[0034] Further, as used herein, the terms “component,” “system,” “module,” and “model” are intended to encompass computer-readable data storage that is configured with computer-executable instructions that cause certain functionality to be performed when executed by a processor. The computer-executable instructions may include a routine, a function, or the like. It is also to be understood that a component, system, module, or model may be localized on a single device or distributed across several devices.

[0035] Fig. 1 illustrates a scalable, modular powder coating system 100, in accordance with one or more features described herein. The powder coating system 100 comprises a system controller 102 including a graphical user interface (GUI) 104, a memory 106, and a processor 108. The memory 106 stores computer-executable instructions that, when executed by the processor 108, caused the processor to perform certain acts. One or more device controllers 110 are communicatively coupled to the system controller 102 via a controller area network (CAN) connection 112 (wired or wireless). Each device controller 110 controls one powder pump 118 and spray gun 114 via local interconnect network (LIN) connections 117, 12C connections 117, and / or digital and analog input / output connections and is configured to determine a type of a powder pump module 118 (e.g., venturi or high density) associated with each spray gun 114 upon coupling of the powder pump module 118 to the device controller 110. It will be understood that the device controller 110 controls at least one valve that sends air to the powder pump 118 in order to control the powder pump 118. Additionally, the device controller 110 controls a voltage supplied to the spray gun 114. One or multiple spray guns 114-114N (where N is a positive integer greater than 1) can be employed to coat an object 120 (stationary or moving).

[0036] The device controller 110 employs device control instructions stored in the device controller 110 for the corresponding identified powder pump module type. Determination of the type of powder pump module is performed by detecting a presence or absence of a high density flow module (also referred to herein as an air flow controller; not shown in Fig. 1) in the powder pump module 118. Presence of the high density flow module is determined by detecting a voltage associated with the high density flow module. In one embodiment, the system controller 102 receives an indication from the device controller 110 indicative of the type of powder pump connected to the device controller 110 and displays to a user a corresponding interface for the indicated type of powder pump module. A single system controller 102 can be coupled to multiple device controllers 110-110N employing thesame or different types of powder pump modules. The powder coating system 100 can be employed in a manual spray coating dolly or in a multiple spray gun wall mount or rail mount configuration. Moreover, multiple powder coating systems 100 can be coupled and coordinated via direct connection, a central server, or a higher level controller or programmable logic controller.

[0037] Fig. 2 is an illustration of a device controller 110, in accordance with one or more features described herein. The device controller 110 comprises a printed circuit assembly (PCA) 200 comprising a processor 202, a memory 204, and a card edge connector 206 via which the device controller 110 can be coupled to a circuit board of, for instance, a spray gun dolly or rack assembly. The PCA 200 also comprises a 12-pin connector 208 via which an air flow controller PCA 210 can be coupled to the device controller PCA 200 for communication over the I2C connection 117. In one embodiment, the air flow controller PCA 210 is configured to control an iFlow® HD air flow controller device such as is manufactured by Nordson Corporation.

[0038] The device controller PCA 200 may further comprise venturi valve drive circuitry for controlling a venturi valve that provides powder to a spray gun (Fig. 1), and a CAN communication module 214 via which the device controller 110 communicates with a system controller (Fig. 1). A 24V input power filter 216 is provided, as is a LIN communication module 218 via which the device controller 110 communicates with a spray gun and an I2C communication module 219 via which the device controller 110 communicates with an HD powder pump and the air flow controller PCA 210. Additionally, the controller device comprises digital and / or analog inputs and outputs (I / O) 220 via which the device controller 110 communicates with a venturi powder pump. Vibratory box feeder (VBF) solenoid control circuitry 222 is provided on the PCA 200 for controlling a VBF solenoid. A gun drive component 224 is provided and comprises drive circuitry 226 for controlling a powder spray gun. The drive circuitry 226 comprises manual gun drive circuitry 228 and automatic gun drive circuitry 230. Additionally, the device controller PCA 200 comprises board alarm circuitry 232, board and backbone identification information 234, and one or more light emitting diode (LED) indicators 236.

[0039] Fig. 3 is an illustration of the system controller 102, in accordance with one or more features described herein. The system controller 102 comprises the GUI 104, the memory 106, and the processor 108, as described with regard to Fig. 1. The memory 106 comprises a user interface (UI) module 300 that comprises computer executable instructions, routines, subroutines, applications, etc., for presenting the GUI 104 to a user and / oradministrator and enabling the user and / or administrator to interact with the GUI 104. For example, the UI module 300 presents a user profile (via a user profile interface) to a logged- in user. Similarly, the UI module 300 presents an administrator profile (via an administrator profile interface) to a logged-in administrator. The memory 106 also comprises a communication module 302 that facilitates communicating via a plurality of communication protocols. To this end, the communication module 302 comprises a CAN communication module 304 for communicating over a controller area network, a LIN communication module 306 for communicating over a local interconnect network, an Ethernet communication module 308 for communicating via an Ethernet connection, and a Bluetooth communication module 310 for communicating using a Bluetooth protocol.

[0040] The memory 106 further comprises an open platform communications unified architecture (OPCUA) module 312 for communication between the communication module 302 and the user interface module 300 and a standard query language (SQL) database 314 that is accessible by the UI module 300, the communication module 302, and the OPCUA module 312, as described in greater detail with regard to Fig. 6.

[0041] As shown, a part tracking module 316 may be provided and may comprise computer-executable instructions for tracking system parts (e.g., identity, type, location, maintenance schedules, faults, etc.) as described in greater detail with regard to Fig. 7. The exemplary part tracking module 316 comprises a general lookup database 318 in which an administrator can create and edit information such as part type, part descriptors (e.g., part numbers, serial numbers, etc.) and a part identification database 320 in which an administrator can create and edit information related to part type, part number, serial number service and maintenance period, etc. Additionally, a part tracking database 322 may be provided in which part information (e.g., hours of use, faults, service and maintenance messages, service and maintenance history, service and maintenance actions, etc.) is stored. Information stored in the general lookup database 318, the part identification database 320, and the parts tracking database 322 may be viewable by a user (e.g., non-administrator). It will be understood by one of skill and the art that one or more of the general lookup database 318, the part identification database 320, and the park tracking database 322 can be part of, or comprised by, the SQL database 314.

[0042] The exemplary memory 106 also comprises a user tracking module 324 that tracks user interaction with the powder coating system, as described in greater detail with regard to Fig. 8. The exemplary user tracking module 324 comprises one or more editable user profiles 326, powder recipe use information 328, and search filters 330 for searching auser information database 332. The user information database 332 can comprise, for example, powder recipes used by the user, operation settings, alarms or faults, usage time, etc. It will be understood by one of skill in the art that the user information database 332 can be a standalone database or can be part of, or comprised by, the SQL database 314.

[0043] A recipe sharing module 334 may be provided and may facilitate sending a single powder recipe 336 to multiple device controllers 110, as described in greater detail with regard to Fig. 9. In this manner, multiple spray guns can employ a common recipe to coat one or more objects from different sides, positions, or angles. Advantages of this feature include reduced coating time and improved coating uniformity across spray guns in a multigun platform.

[0044] Fig. 4 is an illustration of an exemplary powder coating system 400 that employs a venturi spray gun 402, in accordance with one or more features described herein. The system 400 comprises the system controller 102, which communicates with the device controller 110 via a CAN connection 112. The device controller 110 communicates with a venturi spray gun 402 via digital and / or analog inputs and outputs 404.

[0045] With regard to communication between the various components of the exemplary system 400, the system controller 102 provides to the device controller 110, via the CAN 112, information related to system operation. The information provided by the system controller 102 to the device controller 110 can include without limitation: selected powder recipes entered via the user interface of the system controller 102; system configuration information received by the user interface of the system controller 102; etc. Additionally, upon a failed data integrity test or reboot of the system controller 102, the system controller 102 can provide to the device controller 110 last (i.e., most recent) programmed recipe information, last program configuration information, etc.

[0046] The device controller 110 also provides system operation information to the system controller 102 via the CAN connection 112. Information provided by the device controller 110 to the system controller 102 can include without limitation: powder spraying status; alarms and warnings; the serial number of the device controller 110 and / or the venturi spray gun 402; etc. The device controller 110 also provides to the system controller 102 information related to the venturi spray gun 402, including but not limited to: powder spraying status; alarms and warnings; device controller and / or venturi spray gun serial numbers; etc.

[0047] The venturi spray gun 402 also provides information to the device controller 110 via the digital and / or analog inputs and outputs 404, including but not limited to: triggeractivation and / or release information; purge actuation and / or completion information, etc. Information provided by the venturi gun 402 to the device controller 110 can be relayed to the system controller 102.

[0048] Fig. 5 is an illustration of an exemplary powder coating system 500 that employs a high-density (HD) spray gun 502, in accordance with one or more features described herein. The system 400 comprises the system controller 102, which communicates with the device controller 110 via a CAN connection 112. The device controller 110 communicates with an HD spray gun 502 via a LIN connection 116. An air flow controller PCA 210 is coupled to the device controller 110 (e.g., via the 12-pin connector 208 of Fig. 2) to create an inter-integrated circuit (I2C) connection 504 that provides I2C and digital and / or analog I / O connectivity (e.g., for transmitting voltage signals or the like) and which may be similar or identical to the I2C connection 117 of the preceding figures.

[0049] With regard to communication between the various components of the system 500, the system controller 102 provides to the device controller 110, via the CAN 112, information related to system operation. The information provided by the system controller 102 to the device controller 110 can include, without limitation: selected powder recipes entered via the user interface of the system controller 102; system configuration information received by the user interface of the system controller 102; etc. Additionally, upon a failed data integrity test or unplanned reboot of the system controller 102, the system controller 102 can provide to the device controller 110 last (i.e., most recent) programmed recipe information, last program configuration information, etc.

[0050] The device controller 110 may also provide system operation information to the system controller 102 via the CAN connection 112. Information provided by the device controller 110 to the system controller 102 can include without limitation: powder spraying status; alarms and warnings; the serial number of the device controller 110, the HD spray gun 502, and / or the air flow controller PCA 210; etc. The device controller 110 also probably fades to the system controller 102 information related to the air flow controller PCA 210 and the HD spray gun 502, including but not limited to: flow constants employed by the air flow controller 210; atomize / pattem air constants employed by the air flow controller PCA 210; a powder recipe selected for the HD spray gun 502; a selected air / powder flow rate used for the HD spray gun 502; etc.

[0051] The I2C connection 504 may provide a communication link between the device controller 110 and the air flow controller PCA 210 by which the device controller 110 may program into the air flow controller PCA 210 memory (not shown) informationregarding: flow constants to be employed by the air flow controller PCA210; atomize / pattem air constants to be employed by the air flow controller PCA210; serial number information; etc.

[0052] The LIN connection 116 may provide a communication link between the device controller 110 and the HD spray gun 502. The device controller 110 provides to the HD spray gun 502 information including but not limited to: indications of powder recipe changes; indications of air / powder flow rate changes; fault indications; etc. The HD spray gun 502 may provide to the device controller 110 information including but not limited to: indications that the gun trigger has been actuated or released; indications that a purge function has been actuated or completed; indications that a recipe has changed; indications that the air / powder flow rate has changed; etc.

[0053] Fig. 6 is an illustration showing internal communication between components of the system controller 102, in accordance with one or more aspects described herein. The system controller 102 comprises the user interface application 300, which is responsible for displaying information to an operator such as activities, events, alarms and warnings, etc., related to the powder coating system. The user interface application 300 is also configured to allow an operator to select and edit user profiles, powder recipes, powder recipe parameters, system configurations, and the like. To this end the user interface application 300 is configured to present to a user a web browser 602 via a user interface front end 604, and further comprises the user interface back end 606 that interacts with the user interface client 608 configured to communicate with an open platform communications unified architecture (OPCUA) server 610, which may be similar or identical to the OPCUA module 312 of Fig. 3 or accessed thereby. The user interface back end 606 and the OPCUA server 610 are also configured to communicate with the database 612 (e.g., a standard query language (SQL) or SQLite database or the like), which may be similar or identical to the SQL database 314 of Fig. 3.

[0054] Also illustrated in the system controller 102 is a communications application 614 (which may the similar or identical to the communications application 302 of Fig. 3), which may be communicatively coupled to the database 612 and to a controller area network 112, as well as to a communication application client 616 that communicates with the OPCUA server 610. Additionally, the OPCUA server 610 may be communicatively coupled to a plurality networks, for example, via respective Ethernet connections, including but not limited to a local area network (LAN) 620, a wide area network (WAN) 622, a WiFi network 624, etc.

[0055] With regard to the communication between the various components illustrated in Fig. 6, the OPCUA server 610 may provide access to its data to the user interface client 608 and the communications application 614. The communications application 614 may be responsible for communicating data between the system controller 102 and the device controller (not shown in Fig. 6) via the CAN 112. The database 612 may store information that is accessible by the OPCUA server 610, including but not limited to: system tags; device tags; gun tags; system settings; device settings; gun settings; etc. The database 612 may also store information that is accessible by the user interface back end 606, including but not limited to: powder recipes; activities; users; maintenance events and schedules; device settings; gun settings; etc. Additionally, the database 612 stores information that is accessible by the communications application 614, including but not limited to: powder recipes; activities; device settings; gun settings; etc.

[0056] Regarding the various networks to which the system controller can be connected, the CAN can be employed to communicate data between the system controller communications application 614 and the device controller (not shown in Fig. 6). The LAN 620 can be employed for connecting multiple independent powder coating systems. The WAN 622 can be employed to send information to customers and / or to connect multiple independent powder coating systems. The WiFi network 624 can also be employed to send information to customers and / or to connect multiple, independent powder coating systems.

[0057] Fig. 7 is an illustration of an exemplary part tracking module 316 (Fig. 3) of the system controller 102 (Fig.3) showing various part tracking access levels and permissions for an administrator 700 and a user 702, respectively. In one embodiment, the system controller 102 employs software to control login profiles. Login profile permission defaults are defined by the profile type (e.g., administrator or user). Administrator profiles have permissions that allow the administrator, via an administrator profile interface presented on the GUI 104 (Figs. 1 and 3), to create lower level (user) profiles and to individually set the lower level profile permissions and accessibility. The software automatically stores user operation data and provides functionality for subsequent filtered retrieval. For instance, the system controller 102 tracks and stores user interaction information (e.g., user time, alarms, recipes used, operation settings, etc.), supports searching and filtering of user interaction information (e.g., by user ID, date, time, type of alarm, etc.), and supports multiple user shifts. An administrator 700 can create, edit, and control multiple user profiles and can limit customization and control by users 702 on an individual or group basis (e.g., limit users’ ability to select and edit recipes and / or modify spray settings). The administrator 700 is alsoable to track, audit, etc., each user's operation (e.g., user time, alarms, recipes used, operational settings, etc.). The user 702, via the GUI 104 of the system controller 102 (Fig. 1), can customize the interface within constraints defined by the administrator 700, access recipes authorized by the administrator 700, and control settings within parameters defined by the administrator 700.

[0058] The part tracking module 316 may comprise the general lookup database 318, the part identification database 320, and the part tracking database, 322, as described with regard to Fig. 3. Upon logging in to the system controller 102, the administrator 700 may be granted access and permission to create and / or edit information in each of the databases. Similarly, upon logging into the system controller 102, the user 702 is granted access and permission to view the information in each of the databases. Additionally, the system controller 102 may automatically identify parts 704 upon connection to the system using part numbers stored in a database and / or assigned by an administrator, or using serial numbers detected through a system part interface or entered or assigned by an administrator.

[0059] Monitored parameters of a tracked part 706 can include usage time, service / maintenance events (event, time, action performed, servicer identity, etc.), fault information, part descriptors (e.g., part type, part number, serial number, service / maintenance period, etc.) etc. Part numbers or other identifiers can be stored in one or more of the described database and / or assigned by the administrator 700. Serial numbers can be detected through an interface or assigned by the administrator 700. Tracked operational part parameters associated with the part can be filtered and searched by an administrator. The system also displays alarm messages upon detection of a part fault level above a predefined threshold, warning messages upon detection of a part fault level below the predefined threshold, and maintenance messages when a part has reached or exceeded its service / maintenance period. Additionally, the system provides a warning message when the part is nearing the end of its service / maintenance period. The service / maintenance period assigned to a given part can be retrieved from a database or input by an administrator (supervisor).

[0060] To this end, the general lookup database 318 may comprise part type information (e.g., spray guns, pumps, valves, etc.) and part descriptors (e.g., part numbers, part identifiers, serial numbers, service and / or maintenance periods, etc.). The part identification database 320 may comprise part descriptors as well, including but not limited to part type, part number, part identifier, serial number, service and / or maintenance period information, etc. The part tracking database 322 may comprise tracked part parameterinformation including but not limited to hours of use, faults, service and / or maintenance messages, service and / or maintenance history including service performed, time performed and by whom, etc.

[0061] Fig. 8 is an illustration of an exemplary user tracking module 324 (Fig. 3) of the system controller 102 showing various user tracking access levels and permissions for an administrator 700 and a user 702, respectively. The user tracking module 324 comprises the user profiles 326, the recipe use information 328, the search filters 330, and the user information database 332, as described with regard to Fig. 3. The user tracking module 324 may also comprise an interface 800 via which the administrator 700 can edit permissions for users, and via which a user 702 can edit information for which the administrator has authorized editing. The interface 800 may be the GUI 104 described herein or a component thereof.

[0062] The user 702 may be granted access to the user’s profile 326 as well as to recipe use information 328 that the administrator 700 has authorized the user 702 to access. Additionally, the user 702 may be granted permission to edit the interface 800 and to edit recipe use information 328 that the administrator 700 has authorized the user 702 to edit. The administrator 700 can create, edit, delete, etc., user profiles 326 and can edit user permissions via the interface 800. The administrator 700 can also create, edit, delete, etc., recipe use information 328 including powder recipe information, etc., as well as edit permissions for the user to edit and or access recipe use information 328. Additionally, the administrator via the interface 800 can perform user interaction information 802 retrieval by searching the user information database 332 using one or more search filters 330. User interaction information 802 may be stored in user operation storage 804 (e.g., memory, a computer-readable medium, etc.) and provided to the user information database 332. User interaction information can include but is not limited to user time logged into the system and / or operating a spray gun, alarms or faults that occur during the user’s operation of the spray gun, recipes used by the user, operation settings, etc. The administrator can employ search filters including user ID, date, time, type of access, etc. A gun control module 806 (e.g., software and / or hardware) may also be provided via which the user 702 can control the spray gun 114.

[0063] Fig. 9 is an illustration of an exemplary embodiment of the powder system 100 (Fig. 1) in which the recipe sharing module 334 (Fig. 3) of the system controller 102 is employed, in accordance with one or more features described herein. The recipe sharing module 334 may facilitate providing a single powder recipe to multiple spray guns 114-114N. The multiple spray guns 114-114N can be employed to coat opposite sides of an object 900such as a flat panel or the like, different portions of a part, or different parts. In other embodiments the multiple spray guns 114- 114N are employed to coat an object more rapidly than can be performed using a single spray gun and more uniformly that can be performed using multiple spray guns employing separate recipes.

[0064] The described recipe sharing feature allows a powder system 100 or system controller 102 to send the same powder recipe to multiple spray guns. The powder system 100 or system controller 102 can control multiple spray guns independently or concurrently. Sending the same recipe to multiple spray guns ensures that users (operators) spray the same part using the same spray settings. In one embodiment, the powder system 100 employs internal software and hardware to concurrently control the multiple guns.

[0065] Fig. 10 illustrates an exemplary multiple powder system arrangement 1000 in which a plurality of powder systems 100A-100N are communicatively coupled by a system coupler 1002. The system coupler 1002 may be for example a higher level controller, a programmable logic controller (PLC), a central server, or a direct connection between the powder systems 100A-100N. It will be understood by one of skill in the art that although each powder system 100 is illustrated with a single spray gun 114 in Fig. 10, each powder system 100 may employ multiple spray guns 114. For example, a higher level programmable logic controller (PLC) can push powder recipes to one, some, or all device controllers and associated powder pumps and spray guns and initiate a color change purge synchronously or asynchronously as the part or parts move through a paint booth. To further this example, the higher level controller can control lower level controllers such as a conveyor controller carrying and routing parts, a part washer\drier that washes and dries parts before entry into a spray booth and then into an oven after spraying to cure the powder. During the transition of these separate processes, the higher level PLC can send down part tracking (encoder) information, recipes, color change purge commands, to one, some or all of the device controllers and associated powder pump and spray gun assemblies preparing to coat the next part type. The higher level controller thus orchestrates the entire process.

[0066] Fig. 11 is an illustration of an automatic powder spray system 1100, showing a stack of two device controller cabinets 1102, each comprising device controllers (not shown) for a predetermined number of spray guns (not shown). A system controller 102 is coupled to the device controller cabinets 1102 and is communicatively coupled with the device controllers in the cabinets 1102. Each device controller cabinet has capacity to accommodate multiple device controllers for controlling multiple respective devices. Thus, a single system controller 102 can be used to control multiple spray guns.

[0067] Fig. 12 illustrates an exploded view of a manual powder spray dolly 1200 in which the described system controller 102 and device controller (not visible in Fig. 12) can be employed, in accordance with one or more features described herein. The dolly 1200 comprises the system controller 102, which can be removably installed in a system controller module 1202 that mates with an upper dolly portion 1204 and is secured by a system controller bracket 1206. A pneumatic module 1208 houses a device controller 110 (not visible in Fig. 12) and is coupled to the upper dolly portion 1204 and to a dolly base 1210. An air flow controller 1212 is also shown which can be coupled to the pneumatic module when employing an HD spray gun and pump arrangement. Also illustrated are a powder box support platform 1214, a VBF motor 1216, a storage tray 1218, and a feed tube support armature 1220.

[0068] Fig. 13 is an illustration representing the modularity of exemplary embodiments of the described systems and components, with one or more features described herein. The described device controller 110 can be inserted into an automatic system device controller housing 1300 configured to accommodate multiple device controllers 110. In another embodiment, the described device controller 110 can be mounted to a device controller mounting plate 1302 which is then communicatively coupled to the manual powder spray dolly 1200, which also includes the system controller 102.

[0069] Fig. 14 is an illustration of an exemplary device controller mounting plate 1302 mounted to an interior wall 1400 of the pneumatic module 1208 (Fig. 12) in a venturi pneumatic module system. A device controller 110 may be coupled to the mounting plate 1302, for example, for controlling a venturi spray gun powder pump assembly 1402.

[0070] Fig. 15 is an illustration of an exemplary device controller mounting plate 1302 with the device controller 110 installed wherein the device controller mounting plate 1302 may be mounted to an interior wall 1500 of the pneumatic module 1208 (Fig. 12) in an HD pneumatic module system. An HD spray gun powder pump assembly 1502 may also be mounted to the interior wall 1500 of the pneumatic module. The air flow controller PCA 210 may also be installed in the pneumatic module and coupled to the device controller 110 to control the HD spray gun powder pump assembly 1502.

[0071] Fig. 16 illustrates a rear view 1600 (i.e., opposite the device controller 110) of the exemplary device controller mounting plate 1302. In the illustrated arrangement, coupled to the device controller 110 through the mounting plate 1302 are a power supply 1602, a relay PCA 1604, and a line filter 1606. The relay PCA 1604 may allow a single module SKU to accommodate both a 115 VAC and a 230 VAC vibrator motor.

[0072] Referring now to Fig. 17, a high-level illustration of an exemplary computing device 1700 that can be used in accordance with the systems and methodologies disclosed herein is illustrated. For instance, the computing device 1700 may be or include the system controller 102, or vice versa. The computing device 1700 includes at least one processor 1702 that executes instructions that are stored in a memory 1704. The instructions may be, for instance, instructions for implementing functionality described as being carried out by one or more modules, components, or systems discussed above or instructions for implementing one or more of the methods described above. The processor 1702 may be a GPU, a plurality of GPUs, a CPU, a plurality of CPUs, a multi-core processor, a combination of the foregoing, etc. The processor 1702 may access the memory 1704 by way of a system bus 1706.

[0073] The computing device 1700 additionally includes a data store 1708 that is accessible by the processor 1702 by way of the system bus 1706. The data store 1708 may include executable instructions, etc. The computing device 1700 also includes an input interface 1710 that allows external devices to communicate with the computing device 1700. For instance, the input interface 1710 may be used to receive instructions from an external computing device, etc. The computing device 1700 also includes an output interface 1712 that interfaces the computing device 1700 with one or more external devices. For example, the computing device 1700 may transmit control signals to, and receive information from, the device controller 110.

[0074] Additionally, while illustrated as a single system, it is to be understood that the computing device 1700 may be a distributed system. Thus, for instance, several devices may be in communication by way of a network connection and may collectively perform tasks described as being performed by the computing device 1700.

[0075] Various functions described herein can be implemented in hardware, software, or any combination thereof. If implemented in software, the functions can be stored on or transmitted over as one or more instructions or code on a computer-readable medium. Computer-readable media includes computer-readable storage media. A computer-readable storage medium can be any available storage medium that can be accessed by a computer. By way of example, and not limitation, such computer-readable storage media can comprise RAM, ROM, EEPROM, CD-ROM or other optical disk storage, magnetic disk storage or other magnetic storage devices, or any other medium that can be used to store desired program code in the form of instructions or data structures and that can be accessed by a computer. Disk and disc, as used herein, include compact disc (CD), laser disc, optical disc, digital versatile disc (DVD), floppy disk, and Blu-ray disc (BD), where disks usuallyreproduce data magnetically and discs usually reproduce data optically with lasers. Further, a propagated signal is not included within the scope of computer-readable storage media. Computer-readable media also includes communication media including any medium that facilitates transfer of a computer program from one place to another. A connection, for instance, can be a communication medium. For example, if the software is transmitted from a website, server, or other remote source using a coaxial cable, fiber optic cable, twisted pair, digital subscriber line (DSL), or wireless technologies such as infrared, radio, and microwave, then the coaxial cable, fiber optic cable, twisted pair, DSL, or wireless technologies such as infrared, radio and microwave are included in the definition of communication medium. Combinations of the above should also be included within the scope of computer-readable media.

[0076] Alternatively, or in addition, the functionally described herein can be performed, at least in part, by one or more hardware logic components. For example, and without limitation, illustrative types of hardware logic components that can be used include FPGAs, ASICs, Application-specific Standard Products (ASSPs), SOCs, Complex Programmable Logic Devices (CPLDs), etc.

[0077] What has been described above includes examples of one or more embodiments. It is, of course, not possible to describe every conceivable modification and alteration of the above devices or methodologies for purposes of describing the aforementioned aspects, but one of ordinary skill in the art can recognize that many further modifications and permutations of various aspects are possible. Accordingly, the described aspects are intended to embrace all such alterations, modifications, and variations that fall within the spirit and scope of the appended claims. Furthermore, to the extent that the term “includes” is used in either the detailed description or the claims, such term is intended to be inclusive in a manner similar to the term “comprising” as “comprising” is interpreted when employed as a transitional word in a claim.

Claims

CLAIMSWhat is claimed is:

1. A powder coating system, comprising: a system controller comprising a processor, a memory, and a graphical user interface (GUI); and a device controller communicatively coupled to the system controller, wherein the device controller is configured to control at least one valve that sends air to a powder pump coupled to a powder spray gun and to control a voltage supplied to the spray gun; wherein the device controller is further configured to identify and transmit to the system controller an indication of a type of the powder pump coupled to the device controller upon coupling of the powder pump to the device controller.

2. The powder coating system of claim 1, further comprising a plurality of device controllers communicatively coupled to the system controller, each device controller configured to identify a type of the powder pump to which it is connected.

3. The powder coating system of claim 1, wherein the device controller identifies the type of powder pump based on a detected presence or absence of an air flow controller printed circuit assembly (PCA) coupled to the device controller.

4. The powder coating system of claim 3, wherein the device controller detects a presence of the air flow controller PCA by detecting a voltage associated with the air flow controller PCA.

5. The powder coating system of claim 4, wherein the device controller identifies the powder pump as a high density (HD) type powder pump upon detection of the voltage associated with the air flow controller and as a venturi-type powder pump when the voltage associated with the air flow controller is not detected.

6. The powder coating system of claim 3, wherein the device controller communicates with the air flow controller via an inter-integrated circuit (I2C) connection.

7. The powder coating system of claim 1, wherein the GUI displayed to the user is dependent on the type of powder pump identified to the system controller by the device controller.

8. The powder coating system of claim 1, wherein the system controller communicates with the device controller via a controller area network (CAN).

9. The powder coating system of claim 1, wherein the device controller communicates with the powder spray gun via a local interconnect network (LIN).

10. A system controller for a powder coating system, comprising: a graphical user interface (GUI); a processor; and memory storing instructions that, when executed by the processor, cause the processor to perform acts comprising: upon detecting a login to a user profile stored in the memory, displaying on the GUI the user profile, providing a first level of access to the powder coating system and, while the user is logged in, monitoring user interaction with the powder coating system; storing user interaction information in the memory; upon detecting a login to an administrator profile stored in the memory, displaying on the GUI the administrator profile and providing a second level of access to the powder coating system; receiving a request via the administrator profile to access the user interaction information; and displaying the requested user interaction information via the administrator profile on the GUI.

11. The system controller of claim 10, wherein the acts further comprise granting access via the administrator profile to at least one of: create, edit, and control multiple user profiles; limit one or more users’ ability to customize or control powder recipes or spray settings in the powder coating system; and audit users’ operation of the system.

12. The system controller of claim 10, wherein the acts further comprise granting access via the administrator profile to search and filter user interaction information.

13. The system controller of claim 10, wherein the acts further comprise granting access via the user profile to least one of: customize the GUI within administrator-defined constraints; access administrator-authorized recipes; and control system settings within administrator-defined parameters.

14. The system controller of claim 10, wherein the system controller is one of a plurality of system controllers, and wherein the user profile and the administrator profile can be accessed via any of the plurality of system controllers.

15. A system controller for a powder coating system, comprising: a graphical user interface (GUI); a processor; and memory storing instructions that, when executed by the processor, cause the processor to perform acts comprising: identifying a part connected to the powder coating system upon connection of the part to a device controller communicatively coupled to the system controller; monitoring parameters associated with the part; storing part parameter information for the part; upon detecting a login to an administrator profile stored in the memory, displaying on the GUI the administrator profile; receiving a request via the administrator profile to access the part parameter information; and displaying the requested part parameter information via the administrator profile displayed on the GUI.

16. The system controller of claim 15, wherein the identifying the part is performed based on at least one of: part numbers stored in a database or assigned by an administrator; and part serial numbers detected through a system part interface or entered by an administrator.

117. The system controller of claim 15, wherein the part parameter information comprises at least one of: part usage time; part service or maintenance events; part fault information; and part descriptors.

18. The system controller of claim 17, wherein the part parameter information comprises the part descriptors, wherein the part descriptors comprise at least one of: part type; part number; serial number; and part service period.

19. The system controller of claim 15, wherein the part connected to the powder control system comprises one of a powder spray gun, powder pump, and a valve.

20. The system of claim 19, wherein the part connected to the powder control system comprises the powder pump, wherein the powder pump comprises one of a venturi powder pump and a high density (HD) powder pump.

21. A powder coating system, comprising: a plurality of device controllers, each device controller being coupled to a spray gun powder pump assembly; a system controller that is communicatively coupled to the plurality of device controllers; wherein the system controller comprises: a processor; and memory storing instructions that, when executed by the processor, cause the processor to perform acts comprising: transmitting to the plurality of device controllers a single powder recipe.

22. The powder coating system of claim 21, wherein the system controller controls the plurality of device controllers synchronously.

23. The powder coating system of claim 21, further comprising a programmable logic controller (PLC) configured to push powder recipes to the corresponding spray gun powder pump assembly of one or more of the plurality of device controllers, and to initiate a powder color change purge at the corresponding spray gun powder pump assembly synchronously or asynchronously.

24. The powder coating system of claim 21, wherein the system controller controls the plurality of device controllers asynchronously.

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