Ground marking bead flow sensor

Abstract

A bead flow sensor for a ground marking system is configured to sense flow of beads for application on a ground surface. The bead flow sensor includes a sensor assembly that is mountable to a housing through which the beads flow. The sensor assembly includes a beam cantilevered from an assembly body. The beam projects into the flow of beads and the beads impact on the beam to cause deflection of the beam. One or more sensors sense the beam deflection and generate information corresponding to bead flow based on the sensed beam deflection.

Description

[0001]

[0002] GROUND MARKING BEAD FLOW SENSOR

[0003] CROSS-REFERENCE TO RELATED APPLICATION(S)

[0004] This application claims priority to U.S. Provisional Application No. 63 / 714,329 filed October 31, 2024 and entitled “GROUND MARKING BEAD FLOW SENSOR,” and claims priority to U.S. Provisional Application No. 63 / 770,607 filed March 12, 2025 and entitled “GROUND MARKING BEAD FLOW SENSOR,” the disclosures of which are hereby incorporated by reference in their entireties.

[0005] BACKGROUND

[0006] The present disclosure relates generally to line striping systems. More specifically, the present disclosure relates to a monitoring system for bead dispensing.

[0007] Line striping systems, which can be vehicle-mounted, are used for painting stripes on roadways, runways, parking lots, and other ground surfaces. Line striping systems typically comprise pushed and / or gas or clcctric-propcllcd platforms that dispense materials used to mark ground surfaces. The systems typically include a gas or electric motor for driving a pump. The pump is fed a flowable material, such as paint, from a container and pumps the fluid to spray nozzles mounted to discharge the fluid toward the ground surface. While paint is used herein as an exemplar, it is understood that paint is merely one example and that other solutions (e.g., water, oil, solvents, beads, flowable solids, pellets, etc.) can be applied in addition to or instead of paint. In some cases, ground markings can be thermally applied instead of sprayed as a paint.

[0008] Striping systems are typically mounted on a vehicle. For example, the striping systems can be mounted on the bed of a truck. Such a striping system has the advantage of being used in a common truck, such as a pickup truck, without the need of a specialized vehicle. The striping systems can be palletized such that they can be loaded, lifted, placed, and unloaded by a conventional pallet jack or forklift in the same manner as a conventional pallet. When mounted on a vehicle, one or more dispense outlets are mounted on an extension that extends away from the vehicle to dispense the striping material as the vehicle drives. In most cases, the extension is on the lateral side of the vehicle to apply one or more stripes to the side of the vehicle as the vehicle drives forward. Such a system can apply a large volume of striping material to the ground due to the carrying capacity of the vehicle, both in terms of material to be applied and the pumping, mixing, and dispensing equipment, and due to the distance that such a vehicle can efficiently cover, particularly along a long stretch of roadway.

[0009] Beads may be applied to line stripes to increase their reflectivity. Beads are three-dimensional and can be highly reflective along many orientations. Wet paint or other coating applied to the ground surface can have beads dropped or shot on the paint or other coating to embed or otherwise adhere the beads to the paint or other coating. The paint or other coating will rapidly dry and the beads can become permanently part the line stripe, increasing the visibility, and in particular the reflectivity, of the stripe.

[0010] SUMMARY

[0011] According to an aspect of the present disclosure, a bead flow sensor module includes a housing defining a flow channel between a channel inlet and a channel outlet; a diaphragm located within the housing; a beam supported by the diaphragm in an orientation such that the beam extends into the flow channel in which beads impacts on the beam to cause deformation of the diaphragm; and one or more sensors that respectively output one or more signals indicative of deformation of the diaphragm due to the beads impacting on the beam.

[0012] According to an additional or alternative aspect of the present disclosure, a bead flow sensor assembly includes an assembly body; a diaphragm located within the assembly body; a beam supported by the diaphragm and extending from the diaphragm away from the assembly body along a beam axis; and one or more sensors that respectively output one or more signals indicative of deformation of the diaphragm due to the beads impacting on the beam, the one or more sensors disposed within the assembly body.

[0013] According to another additional or alternative aspect of the present disclosure, a bead flow sensor module includes a cross-flow housing defining a flow channel between a channel inlet and a channel outlet; and a sensor assembly. The sensor assembly includes an assembly body; a diaphragm located within the assembly body; a beam supported by the diaphragm in an orientation such that the beam extends into the flow channel in which beads impact on the beam to cause deflection of the beam and deformation of the diaphragm; and one or more sensors that respectively output one or more signals indicative of deformation of the diaphragm due to the beads impacting on the beam.

[0014] BRIEF DESCRIPTION OF THE DRAWINGS

[0015] FIG. 1 is an isometric view of a striping system that includes a bead dispensing system. FIG. 2 is a schematic view of an exemplary bead dispensing system of the striping system that includes a bead flow sensor module.

[0016] FIG. 3A is an isometric view of a bead flow sensor module.

[0017] FIG. 3B is an exploded view of the bead flow sensor module of FIG. 3 A.

[0018] FIG. 3C is an isometric view of a bead flow sensor assembly.

[0019] FIG. 3D is an exploded view of a bead flow sensor assembly.

[0020] FIG. 4 is a cross-sectional view taken along line 4-4 in FIG. 3A.

[0021] FIG. 5 A is a cross-sectional view of a bead flow sensor module taken along line A-A in FIG. 5B.

[0022] FIG. 5B is a second cross-sectional view of a bead flow sensor module taken along line B-B in FIG. 5A.

[0023] DETAILED DESCRIPTION

[0024] The present disclosure relates generally to ground marking. More specifically, the present disclosure is directed to bead flow sensing for ground marking systems. Bead flow sensor assemblies according to aspects of the disclosure include a sensor module that is mountable to a housing. The sensor module includes sensing components that are configured to generate information regarding bead flow through the sensor assembly.

[0025] Bead flow sensors according to aspects of the disclosure include a beam that extends into a flow channel within a housing. The flow channel is configured to convey ground marking beads through the sensor assembly. The beam is connected to sensor components that are configured to generate information based on deflection of the beam. The beam deflection provides information indicative of the volumetric bead flow through the sensor assembly.

[0026] According to aspects of the disclosure, a ground marking system includes a compressed air source, a bead hopper, a bead dispenser, a flow pathway between the bead hopper and the bead dispenser, and a bead flow sensor module. The compressed air source supplies a flow of compressed air to the bead hopper. A flow of beads carried within the flow of compressed air exits the bead hopper through the flow pathway to the bead dispenser. The bead flow sensor module is positioned along the flow pathway and comprises a housing, a beam, and a sensor. The beam extends into a flow channel of the housing. The sensor outputs a signal indicative of bead impact on the beam.

[0027] Bead flow sensors according to various aspects of the disclosure include a beam that is cantilevered from a module body and extends into the bead flow passage. The beam can extend from a diaphragm that flexes in response to deflection of the beam. Sensor components are disposed on an opposite side of the diaphragm from the beam. In some examples, the beam and the diaphragm are formed as a single component, such as monolithically. The diaphragm can include an outer ring and a center shelf with an inner ring disposed between the outer ring and center shelf. The beam can extend from the center shelf. The inner ring can be thinner than the outer ring and center shelf. The sensing components can be aligned with the flex portion to sense distortions of the flex portion.

[0028] Bead flow sensors according to various aspects of the disclosure include a beam that has a main portion and an impact portion. The main portion extends from structure that supports the beam. The impact portion can be disposed at an opposite end of the beam from the support structure. The impact portion can be disposed at a distal end of the beam. In some examples, the main portion can be formed as a cylindrical body while the impact portion can include one or more flat faces. The impact portion is configured to be disposed in the bead flowpath such that the beads impinge on the impact portion.

[0029] The present disclosure uses multiple examples to demonstrate various inventive aspects. The inventive scope of this disclosure is not necessarily limited to any one of these embodiments, nor to all of them in just the manner shown and / or described. Rather, the inventive aspects demonstrated herein can be implemented in various other manners. One aspect or feature shown or described from one embodiment could be implemented on another embodiment in this disclosure even if not shown or described for that embodiment, or various embodiments not illustrated herein. The embodiments illustrated and / or discussed are intended to be illustrative and not limiting, and the described and / or illustrated features can be mixed and matched between different embodiments but including and excluding various features amongst the embodiments.

[0030] Components with common reference numbers can be structurally and functionally equivalent except to the limited extent specifically shown and / or described to be different. As such, aspects discussed and / or shown in connection with one embodiment can be present in another embodiment even if not discussed and / or shown for the other embodiment, particularly when common reference numbers are used.

[0031] Components can be considered to radially overlap when those components are disposed at common axial locations along an axis. A radial line extending 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 the axially overlapping components. Components can be considered to circumferentially overlap when aligned about the axis, such that a circle centered on the axis passes through the circumferentially overlapping components.

[0032] FIG. 1 is an isometric view of striping system 10. Striping system 10 includes vehicle surface 12, pumping module 14, user interface 16, liquid reservoirs 17, compressor 18, bead hopper 19, support frame 20, hoses 21, beam mount 22, beam 24, dispense arm 26, carriage 28, and seat 30. Pumping module 14 includes pumps 32 and motor 34. Beam mount 22 includes beam clamps 36. Dispense arm 26 includes boom 38, lateral arm 40, wheels 42, and dispensing modules 44. Dispensing modules 44 include gun arms 46, spray outlets 48, and bead dispensers 49. Carriage 28 includes carriage motor 50.

[0033] Striping system 10 is a system for applying stripes of a marking material, such as paint, water, oil, solvents, beads, reflective glass beads, flowable solids, pellets, etc., to a ground surface, such as a roadway, runway, parking lot, or other desired surface. While the term “stripes” is used herein as an example, it will be understood that the scope of this disclosure includes dispensing fluid and / or material on any surface in any pattern, and is not limited to the marking of stripes.

[0034] Vehicle surface 12 is a surface of a self-propelled vehicle that supports other components of striping system 10. For example, vehicle surface 12 can be the bed of a truck, such as a pickup truck, a pallet or other structure mounted to a truck, or another vehicle surface. Liquid reservoirs 17 are disposed on vehicle surface 12 and are configured to store the marking material prior to application to the ground surface. The marking material can be any desired material suitable for creating the stripes, such as paint, flowable solids such as beads, plural component materials, or any other suitable material. In some examples, system 10 can include bead hopper 19 to store beads apart from a liquid component (e.g., paint) of the marking material contained in liquid reservoirs 17. A compressor 18 pressurizes bead hopper 19 and generates an airflow to carry the beads out of bead hopper 19 via hoses 21 to bead dispensers 49.

[0035] Support frame 20 is disposed on vehicle surface 12 and supports various components of striping system 10. Support frame 20 is configured to mount to vehicle surface 12 and can either rest on vehicle surface 12 or be connected to vehicle surface 12. In some examples, support frame 20 is removably connected to vehicle surface 12, such as by fasteners, such as bolts, or straps. In other examples, support frame 20 is permanently connected to vehicle surface 12, such as by welding. Pumping module 14 is supported by support frame 20 and configured to drive the marking material from liquid reservoirs 17 to dispense arm 26. Pumps 32 are supported by support frame 20 and are fluidly connected to liquid reservoirs 17 by one or more of a pipe, a conduit, and a hose. Motor 34 is also supported by support frame 20 and is configured to power pumps 32. In some examples, motor 34 powers a variable displacement pump that drives pumps 32, such as in examples in which pumps 32 are hydraulically powered. In some examples, motor 34 can also power an air compressor 18 to power pumps 32, where pumps 32 are pneumatic, to draw a liquid component of the marking material from reservoir 17 and discharge the liquid component of the marker material through spray outlets 48. In some examples, air compressor 18 also pressurizes bead hopper 19 to drive reflective glass beads to and out of glass bead dispensers 49. It is understood, however, that pumps 32 can be driven in any desired manner, such as mechanically, electrically, or hydraulically, and motor 34 can be of any suitable configuration for powering pumps 32. While pumping module 14 is shown as including two pumps 32, it is understood that pumping module 14 can include fewer or greater number of pumps 32. Moreover, pumping module 14 can include any desired configuration of pump 32 suitable for driving the marking material from liquid reservoirs 17 to dispense module 44, such as piston pumps, diaphragm pumps, gerotor pumps, lobe pumps, rotary vane pumps, peristaltic pumps, and plunger pumps, among other options.

[0036] Seat 30 is supported by support frame 20. A user is typically seated in seat 30 during operation. The position of seat 30 allows the user to monitor the placement of the stripe by striping system 10 and adjust the location of dispense arm 26 as needed. User interface 16 extends from seat 30 and provides controls to the user to allow the user to actuate carriage 28 and adjust the position of dispense arm 26 along the Y-axis. User interface 16 is operatively connected to carriage motor 50 to control operation of carriage motor 50. User interface 16 can provide information to the user regarding bead flow through sensor module 58.

[0037] Beam mount 22 extends from support frame 20. Beam mount 22 is directly or indirectly connected to support frame 20, such as by bolts or intermediate structural plates and / or tubes. Beam 24 is mounted on beam mount 22 and is secured to beam mount 22 by beam clamps 36. Beam clamps 36 prevent movement of beam 24 relative to beam mount 22 and support frame 20. Beam 24 is cantilevered from beam mount 22 with a free end of beam 24 spaced from vehicle surface 12. Beam 24 extends laterally along the Y- axis from vehicle surface 12 so that the free end of beam 24 is positioned to the left side of vehicle surface 12 and the remainder of the vehicle.

[0038] Camage 28 rides on beam 24. Carriage 28 is movable along the entire length of beam 24. Specifically, carriage 28 can move laterally along the Y-axis. Carriage motor 50 is configured to drive carriage 28 laterally along beam 24 on the Y-axis.

[0039] Dispense ami 26 is connected to beam 24 by carriage 28. Boom 38 is attached to and extends from carriage 28. Lateral arm 40 extends laterally from boom 38 along the Y-axis. Wheels 42 are disposed at the ends of boom 38 and are configured to support dispense arm 26 relative to the ground. Wheels 42 support the weight of dispense aim 26 on the ground surface. Wheels 42 typically bracket the ground surface being marked by striping system 10. While dispense arm 26 is shown as including two wheels 42, it is understood that dispense arm 26 can include any desired number of wheels 42 to support dispense arm 26 on the ground surface, such as one, three, four, or any other desired number of wheels 42. Lateral translation of carriage 28 along beam 24 likewise causes lateral movement of dispense ami 26.

[0040] Gun arms 46 extend from boom 38 and dispensing modules 44 are disposed on gun arms 46. Dispensing modules 44 are fluidly connected to pumps 32 to receive marking material from pumps 32 and apply the marking material to the ground surface. Gun arms 46 are disposed generally orthogonal to lateral arm 40. While dispense arm 26 is shown as including five gun arms 46, it is understood that dispense arm 26 can include as many or as few gun arms 46 as desired, such as one, two, three, or any desired number. Spray outlets 48 and bead dispensers 49 are typically positioned above the surface being marked, such as by one or more inches (i.e., by 2.54 or more centimeters). Spray outlets

[0041] 48 and bead dispensers 49 eject the marking material, in separate liquid and bead components, onto the ground surface. Specifically, for each stripe, the spray outlet 48 is positioned in front of each bead dispenser 49 such that the spray outlet 48 passes over a surface and sprays the surface with paint or other liquid coating and then the bead dispenser

[0042] 49 passes over the freshly sprayed liquid coating and drops, blows, or otherwise dispenses the beads onto the liquid coating to adhere the beads to the stripe. Spray outlets 48 and bead dispensers 49 are moved along the surface being marked by forward motion of the vehicle, which motion is translated to spray outlets 48 and bead dispensers 49 by support frame 20, beam mount 22, beam 24, carriage 28, and dispense arm 26. In some examples, spray outlets 48 and bead dispensers 49 are positioned relative to one another so as to eliminate any gaps between the stripes generated by spray outlets 48 and bead dispensers 49. Two variations of dispense modules 44 are shown, spray nozzles 48 and bead dispensers 49, but it is understood that dispense arm 26 can include as few or as many varieties of spray outlets

[0043] 48 and bead dispensers 49 as desired. Moreover, dispense arm 26 can include additional variations of spray outlets 48 and bead dispensers 49 in addition to the spray nozzles and bead dispensers shown.

[0044] During operation, the vehicle that vehicle surface 12 is a part of is driven across the ground surface in the longitudinal direction, along the X-axis. A user separate from the driver is seated in seat 30 and controls the position of dispense arm 26 along the Y-axis via user interface 16. As such, the user can monitor the application of the stripes and the lateral position of dispense arm 26 independent from steering of the vehicle. Pumps 32 draw the marking material from liquid reservoirs 17 and drive the marking material to dispensing modules 44. Hopper 19 is pressurized by compressor 18 to drive beads downstream from hopper 19 to bead dispensers 49. Spray outlets 48 and bead dispensers

[0045] 49 eject the marking material, in separate liquid and bead components, onto the ground surface.

[0046] FIG. 2 shows a schematic view of the bead dispensing system 11 of the striping system 10. Controller 62 is shown. Controller 62 includes control circuitry 64 and memory 66. The bead dispensing system 11 includes a compressor 18 or other source of compressed air, such as a tank of compressed air. The compressor 18 generates a flow of compressed air. The flow of compressed air is routed, such as by hose, pipe, or conduit, to a bead hopper 19. The bead hopper 19 includes an internal chamber into which beads can be placed. The quantity of beads can number in the hundreds of thousands or millions within a bead hopper 19. The bead hopper 19 is sealed such that the inflow of compressed air circulates within the bead hopper to pressurize the area around the beads and flows out of the bead hopper 19 via hose 21, carrying the beads. Multiple hoses 21 may flow out of the bead hopper 19 or a manifold may attach to multiple hoses 21. One or more hoses 21 can fluidly communicate with a lower portion of bead hopper 19, or other region of bead hopper 19 where beads collect. The beads are small and light enough that they are entrained in the flow of compressed air to flow through the interior of the hose with the airflow. It is noted that the flow can be dry such that the only fluid is compressed air flowing and the beads themselves. Hose 21 connects with the bead dispenser 49 which can spread the beads out laterally to fall on the freshly sprayed line from the spray outlet 48. During operation, the beads can fully fill the one or more hoses 21 such that the beads flow together as a fluid that is urged through the one or more hoses 21 by the compressed air flow. A position of sensor module 58 can be anywhere along the bead flow path between an outlet of bead hopper 19 and an outlet of bead dispenser 49. In some embodiments, sensor module 58 can be located anywhere along hose 21 between an outlet of the bead hopper 19 and an inlet of bead dispenser 49. In this embodiment, the sensor module 58 is located close to the bead dispenser 49 and relatively far away from the bead hopper 19, however the sensor module 58 can be placed anywhere along the How path of beads. For instance, sensor module 58 can be adjacent to bead dispenser 49 as shown in FIG. 2. In this example, sensor module 58 connects to bead dispenser by a short length of hose 21, for example, by a length less than one meter. In other examples, the short length of hose 21 is less than half a meter, or less than one fourth of a meter. In still other examples, the short length of hose 21 between sensor module 58 and bead dispenser 49 can be omitted, connecting sensor module 58 directly to a fitting operatively associated with bead dispenser 49, or integrated into bead dispenser 49. In other examples, the sensor module 58 can be directly attached to an outlet of the bead hopper 19. While in other examples, the sensor module 58 can be intermediate of the bead hopper 19 and the bead dispenser 49. Bending, flexing, expansion, and / or contracting of hose 21 can introduce differences between the bead flow sensed by sensor module 58 and the bead flow discharged from bead dispenser 49. Placing sensor module 58 closer to bead dispenser 49 and relatively far away from hopper 19 improves accuracy of bead flow volume measurements by reducing or minimizing a length of hose 21 between sensor module 58 and bead dispenser 49.

[0047] Controller 62 is operatively connected to various components of striping system 10, electrically or communicatively, to control operation of components of striping system 10. Controller 62 can be of any desired configuration for controlling operation of striping system 10. Controller 62 is operatively connected to sensor module 58 to receive information from sensor module 58.

[0048] Memory 66 is configured to store software that, when executed by control circuitry 64, can generate parameter information regarding the bead flow through sensor module 58. For example, control circuitry 64 can include one or more of a microprocessor, a controller, a digital signal processor (DSP), an application specific integrated circuit (ASIC), a field-programmable gate array (FPGA), a graphics processing unit (GPU), a system-on-module (SOM), or other equivalent discrete or integrated logic circuitry.

[0049] Memory 66, 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 66 is a temporary memory, meaning that a primary purpose of memory 66 is not long-term storage. Memory 66, in some examples, is described as volatile memory, meaning that memory 66 does not maintain stored contents when power to controller 62 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. Memory 66, in one example, is used by software or applications running on control circuitry 64 to temporarily store information during program execution. Memory 66, in some examples, also includes one or more computer-readable storage media. Memory 66 can further be configured for longterm storage of information. Memory 66 can be configured to store larger amounts of information than volatile memory. In some examples, memory 66 includes non-volatile storage elements. Examples of such non-volatile storage elements can include magnetic hard discs, optical discs, floppy discs, flash memories, or forms of electrically programmable memories (EPROM) or electrically erasable and programmable (EEPROM) memories.

[0050] User interface 16 can be any graphical and / or mechanical interface that enables user interaction with controller 62. For example, user interface 16 can implement a graphical user interface displayed at a display device of user interface 16 for presenting information to and / or receiving input from a user. User interface 16 can include graphical navigation and control elements, such as graphical buttons or other graphical control elements presented at the display device. User interface 16, in some examples, includes physical navigation and control elements, such as physically actuated buttons or other physical navigation and control elements. In general, user interface 16 can include any input and / or output devices and control elements that can enable user interaction with controller 62.

[0051] A data line 60 extends from the sensor module 58 and is configured to provide a signal to controller 62, the signal indicating a measure of bead flow volume. The data line 60 is shown as a wire in this embodiment, but the data line 60 could be a wireless signal communication between the sensor module 58 and the controller 62. The user interface 16 can output a value representing the volume of the flow based on the signal communicated along the data line 60 from the sensor module 58. In typical use, one sensor module 58 will be provided for each hose 21. Each bead dispenser 49 is supplied by a respective hose 21. Therefore, there may be one sensor module 58 for each bead dispenser 49. For example, a plurality of sensor modules 58 can be provided for a plurality of bead dispensers 49, respectively. It is understood, however, that each sensor module 58 can be associated with one or more bead dispensers 49.

[0052] FIG. 3A is an isometric view of sensor module 58. FIG. 3B is an exploded view of sensor module 58. FIG. 3C is an isometric view of sensor assembly 70. FIG. 3D is an exploded view of sensor assembly 70. FIGS. 3A-3D are discussed together. Housing 68 of sensor module 58 is shown. Sensor module 58 includes sensor assembly 70 and cross-channel housing 72. Sensor assembly 70 includes assembly body 74, beam 76, diaphragm 78, connector 80, sensors 82, sensor board 84, inner board 86, flexible printed circuit 88, outer board 90, sealant 92, and seals 94. Assembly body 74 includes sensor housing 96 and inner housing 98. Sensor housing 96 includes mount 100, retainer 102, and cap 104. Beam 76 includes main portion 106 and impact portion 108. Cross-channel housing 72 includes channel inlet 110, channel outlet 112, flow channel 114, and side channel 116.

[0053] Sensor module 58 is configured to generate information regarding the flow of beads. The beads are configured to flow through cross-channel housing 72 between bead hopper 19 and bead dispenser 49. The sensor module 58 measures the volume of beads traveling with a flow of compressed air, and outputs a signal indicative of the volume of beads traveling with the flow of compressed air. Sensor module 58 can be operatively connected to controller 62 to provide the bead flow information to the controller 62.

[0054] Sensor assembly 70 is mountable to cross-channel housing 72. Sensor assembly 70 can be mounted to and dismounted from cross-channel housing 72 such as for repair, replacement, maintenance, etc. Assembly body 74 of sensor assembly 70 is configured to interface with cross-channel housing 72 to mount sensor assembly 70 to cross-channel housing 72. Assembly body 74 and cross-channel housing 72 together form a housing 68 of the sensor module 58.

[0055] Cross-channel housing 72 defines a flow channel 114 through which the beads flow. The flow channel 114 extends between channel inlet 110 and channel outlet 112. Flow channel 114 extends along channel axis CA. Flow channel 114 is configured to be pressurized by compressor 18 along with bead hopper 19, hose 21, and bead dispenser 49. Flow channel 114 is not an open channel but is instead a closed, pressurized channel that conveys beads for dispensing by bead dispenser 49. In some examples, flow channel 114 is a cylindrical passage with a constant cross-section that extends through cross-channel housing 72 from channel inlet 110 to channel outlet 112. In other examples, flow channel 114 can have a different cross- sectional shape, such as rectangular or polygonal, and may have include regions that have decreasing, increasing, or both decreasing and increasing cross-sectional area.

[0056] Hoses or other components along the flow path of beads can connect with channel inlet 1 10 and channel outlet 112. The direction of bead flow through the flow channel 114 from channel inlet 110 to channel outlet 112 along channel axis CA is in flow direction FD1 as indicated in FIGS. 3B and 4.

[0057] Side channel 116 is in fluid communication with flow channel 114 and extends outward from flow channel 114. The side channel 116 can extend directly radially outward from the flow channel 1 14. Side channel 116 can, in some examples, extend orthogonal to flow channel 114. In the example shown, the flow channel 114 together with the side channel 116 can form a T shape. In other examples, side channel 116 intersects flow channel 114 at an oblique angle such that cross-channel housing 72 forms a Y shape. Side channel 1 16 can be a dead end in which air and beads do not flow through. Side channel 116 can be considered to form a closed channel that has a single opening at one end of the channel while flow channel 114 has both channel inlet 110 and channel outlet 112 to allow flow through flow channel 114.

[0058] Cross-channel housing 72 includes receiver 120 that extends outward relative to a main body 1 18 portion of the cross-channel housing 72. Receiver 120 defines a receiving chamber 122 within which the sensor assembly 70 is at least partially disposed when mounted to cross-channel housing 72. Receiver 120 can form an annular ring. Receiver 120 can interface with assembly body 74 to secure sensor assembly 70 to crosschannel housing 72. For example, receiver 120 can include interior threading that interfaces with exterior threading of assembly body 74 to connect sensor assembly 70 to cross-channel housing 72.

[0059] Assembly body 74 includes inner housing 98 that is configured to interface with cross-channel housing 72 to secure sensor assembly 70 to cross-channel housing 72. In various examples, inner housing 98 is movable relative to other components of assembly body 74. Inner housing 98 can be movable relative to sensor housing 96. Inner housing 98 can be configured to rotate about sensor axis SA relative to other components of assembly body 74. Inner housing 98 can be configured to shift lengthwise (e.g., axially along sensor axis SA) relative to other components of assembly body 74. It is understood, however, that not all examples are so limited.

[0060] Sensor housing 96 supports other components of sensor assembly 70. Sensor housing 96 can enclose various electrical elements of sensor assembly 70. Sensor housing 96 defines a sensor chamber 124 within which various sensing components of sensor assembly 70 can be disposed. Diaphragm 78 is supported by sensor housing 96. Beam 76 extends from diaphragm 78 and away from sensor housing 96. Beam 76 is supported by sensor housing 96. Beam 76 can be considered to be cantilevered away from sensor housing 96.

[0061] In the example shown, sensor housing 96 is formed from multiple components that are connected together, though it is understood that not all examples are so limited. Mount 100 supports various sensing components of the sensor assembly 70. Mount 100 is disposed at least partially within inner housing 98. The beam 76 is supported by mount 100 and extends away from mount 100 and into the flow channel 114. Retainer 102 is connected to mount 100. In the example shown, the retainer 102 is connected to the mount 100 by interfaced threading, though it is understood that not all examples are so limited. Retainer 102 is disposed at least partially within inner housing 98. In the example shown, retainer 102 and mount 100 are fixed together while the inner housing 98 is movable relative to retainer 102 and mount 100. The retainer 102 and mount 100 can define sensor chamber 124 within which the electrical sensing components (e.g., sensors 82, inner board 86, outer board 90, flexible printed circuit 88) are disposed. Cap 104 is disposed at an opposite end of sensor assembly 70 from beam 76. Cap 104 is connected to retainer 102 and is configured to hold connector 80 on retainer 102. Connector 80 extends through cap 104. Connector 80 can include one or more electrical terminals that can connect to a complementary connector to convey power and / or electric signals (e.g., for, or output by, sensors), amongst other options.

[0062] It will be understood that while one construction of the housing 68 is shown, various other options are possible within the scope of this disclosure, including unifying what are illustrated as separate components and / or dividing single components into two or more components. As such, various embodiments are not limited to the particular embodiment shown.

[0063] In the example shown, sensor housing 96 retains inner housing 98 on sensor housing 96. Sensor housing 96 is configured to overlap with inner housing 98 to prevent inner housing 98 from shifting axially off of sensor housing 96 along sensor axis SA. In the example shown, the inner housing 98 is retained by lip 126 and shoulder 128.

[0064] In the example shown, cap 104 includes lip 126 that projects radially outward, relative to sensor axis SA, beyond the outer edge of the retainer 102. The lip 126 extends to axially overlap with inner housing 98 along sensor axis SA. In this way, the lip 126 can interface with the inner housing 98 and prevent the inner housing 98 from slipping off of sensor assembly 70 in axial direction ADI along the sensor axis SA. In the examples shown, mount 100 includes shoulder 128 that projects radially outward, relative to sensor axis SA, from other portions of mount 100. Shoulder 128 can, in some examples, extend fully annularly around mount 100. Shoulder 128 extends to axially overlap with inner housing 98 along sensor axis SA. In this way, the shoulder 128 can interface with the inner housing 98 and prevent the inner housing 98 from slipping off of sensor assembly 70 in axial direction AD2 along the sensor axis SA.

[0065] Assembly body 74 includes locator 130. In the example shown, locator 130 is formed as a portion of the sensor housing 96. In the example shown, locator 130 is formed as a portion of mount 100. The locator 130 is formed at the end of sensor housing 96 in axial direction AD2. Cross-channel housing 72 includes recess 132. Tocator 130 is configured to extend into recess 132 with sensor assembly 70 mounted to cross-channel housing 72. In the example shown, the locator 130 interfaces with the recess 132 to form a keyed interface that prevents rotation of the locator 130 relative to the recess 132 on the sensor axis SA. The keyed interface prevents rotation of the sensor housing 96, and thus of beam 76, during installation of sensor assembly 70 on cross-channel housing 72. The keyed interface maintains the beam 76 in a desired orientation relative to flow channel 114 during threading of inner housing 98 into cross-channel housing 72.

[0066] In the example shown, locator 130 includes flat 134 on an outer side of the locator 130 and recess 132 includes wall 136 that is formed as a flat wall. The flat 134 interfacing with the wall 136 inhibits rotation of the sensor housing 96. Such a configuration allows for the sensing components (e.g., beam 76) to be properly positioned and aligned relative to bead flow through the flow channel 114 while the inner housing 98 is threaded into the receiver 120 to connect the sensor assembly 70 to the cross-channel housing 72.

[0067] Beam 76 projects from assembly body 74. Beam 76 is supported by sensor housing 96 and extends from sensor housing 96. Beam 76 is configured to extend into the bead flow through the cross-channel housing 72. The beam 76 is configured to extend into the flow channel 114. Beam 76 can extend such that a near end of the beam 76 (e.g., an end connected to diaphragm 78) is not exposed to direct bead impacts within the flow channel 114 while a far end of the beam 76 (e.g., end opposite diaphragm 78) is exposed to direct bead impacts within the flow channel 114.

[0068] Beam 76 is connected to diaphragm 78. Diaphragm 78 is disposed in the sensor chamber 124 of the assembly body 74. The beam 76 is connected to diaphragm 78 such that deflection of the beam 76 distorts the diaphragm 78. In various examples, the diaphragm 78 and beam 76 can be formed as a single contiguous component (e.g., monolithically). In other examples, diaphragm 78 is formed separately from beam 76 and the beam 76 is connected to diaphragm 78. The diaphragm 78 and the beam 76 can be coaxial, such as along beam axis BA. The beam axis BA can be disposed coaxial with the sensor axis SA. Beam 76 is cantilevered from diaphragm 78 and sensor housing 96.

[0069] Diaphragm 78 is held between retainer 102 and mount 100. In the example shown, brace rings 138 arc disposed within the sensor chamber 124. The retainer 102 interfaces with the brace rings 138 to bias the brace rings 138 into diaphragm 78 and pinch diaphragm 78 between retainer 102 and mount 100.

[0070] In various examples, the beam 76 is supported only by the diaphragm 78, such that the beam 76 does not contact any other components of sensor module 58. However, in the example shown, sealant 92 is in contact with the beam 76, as discussed in more detail below.

[0071] In the example shown, beam 76 includes main portion 106 and impact portion 108. Main portion 106 extends from diaphragm 78. Impact portion 108 is disposed at a distal end of the beam 76 opposite the diaphragm 78. The impact portion 108 is disposed at a far end of the beam 76. Beam 76 is configured such that impact portion 108 is disposed in flow channel 114 in the flowpath of the beads through flow channel 114.

[0072] Impact portion 108 includes impact surface 148. Impact surface 148 is formed as a flat face in the example shown, though it is understood that other surface profiles are possible. The flat surface is only part of the impact portion 108, such that, in this embodiment, the sides of the beam 76 along the impact portion 108 are round similar to the shape of the main portion 106. The impact surface 148 is orientated to face upstream along the flow channel 114 such that beads will impact the impact surface 148. The impacting of the beads on the impact surface 148 deflects the cantilevered beam 76.

[0073] One or more sensors 82 are connected to the diaphragm 78. It is understood that some examples can include multiple sensors 82 while other examples can have a single sensor 82. Each sensor 82 can be mounted on the diaphragm 78. Distortion of the diaphragm 78 by deflection of the beam 76 is sensed by the sensors 82, resulting in output of signals to controller 62 which identify and measure the degree of deflection and relate that to a metric of bead flow.

[0074] Each sensor 82 can be a strain gauge, amongst other options. Sensor 82 can measure the degree of distortion of the diaphragm 78. The sensor 82 outputs a signal proportional to the degree of bending or other type of strain of the diaphragm 78. The sensor 82 may be adhered to the diaphragm 78 with adhesive (e.g., epoxy) and / or laminated onto the diaphragm 78 under a coating, among other options.

[0075] The signal output by the sensor 82 can be correlated to a known volume of bead flow to establish a relationship between the signal output by the sensors 82 and bead flow volumes. It is noted that a bead flow volume can relate to weight per unit time or another metric of bead flow. The sensor 82 may be a resistor whose resistance increases as the resistor is strained (e.g., by narrowing and / or lengthening a resistor wire within the sensor 82 when strained). The change in resistance can be measured by a change in current flow through the resistor, and different amounts of change in current flow can be correlated to different known flow rates of beads. After calibration, the current or other metric of the signal output by the sensors 82 can be compared to establish relationship to correlate the measured signal to the known flow rate of beads. The flow rate of beads can then be output on the interface 16.

[0076] Sensors 82 can be connected to a sensor board 84. The sensor board 84 can be any kind of board such as a printed circuit board. Sensor board 84 may be supported by the diaphragm 78 by way of the sensors 82. Also within the assembly body 74 is an inner board 86, a flexible printed circuit 88, and an outer board 90. The flexible printed circuit 88 connects between the inner board 86 and the outer board 90. These electrical components can help manage the power and handling of signals to and from the sensors 82. These electrical components electrically connect with the terminals of the connector 80.

[0077] Seals 94 are disposed between various components of sensor module 58. In the example shown the seals 94 are disposed between components of sensor assembly 70. The seals 94 can be formed as O-ring seals, among other options. The seals 94 can be used for sealing and / or retaining by maintaining force due to compression resistance. In the example shown, one of seals 94 is disposed between diaphragm 78 and a portion of mount 100. In the example shown, one of seals 94 is disposed between connector 80 and mount 100. In the example shown, one of seals 94 is disposed between inner housing 98 and shoulder 128 of mount 100. In the example shown, one of seals 94 is disposed between cap 104 and connector 80. In the example shown, one of seals 94 is disposed between connector 80 and retainer 102. The seals 94 can seal the sensor chamber 124 to prevent the compressed gas flowing through cross-channel housing 72 from leaking into sensor chamber 124, which can affect operation of the sensing components.

[0078] During operation, sensor module 58 is configured to generate information regarding bead flow through cross-channel housing 72. Sensor assembly 70 is mounted to cross-channel housing 72. During mounting, the locator 130 is aligned with the recess 132 and sensor assembly 70 is shifted into receiver 120. Locator 130 enters into recess 132 such that flat 134 is aligned with wall 136, preventing rotation of sensor housing 96, and thus of components fixed to sensor housing 96, about the sensor axis SA. Inner housing 98 is connected to receiver 120 to secure sensor assembly 70 to cross-channel housing 72. For example, inner housing 98 can be threaded to receiver 120.

[0079] With sensor assembly 70 mounted to cross-channel housing 72, the beam 76 projects through the side channel 116 and into the flow channel 114. The beam 76 can extend to axially overlap with the channel axis CA along the channel axis CA such that the channel axis CA extends through a portion of the beam 76. For example, the channel axis CA can extend through the impact portion 108 of the beam 76.

[0080] Striping system 10 is operated and compressed air carries beads from hopper 19 to bead dispenser 49. The beads flow through sensor module 58 between hopper 1 and bead dispenser 49. The beads create drag on the portion of the beam 76 extending into the flow channel 114, causing a slight deflection and strain, and that strain value can then be correlated to a mass flow rate of beads. Air, having a lower viscosity, will have less of an effect on the strain value such as to be negligible, and because of the viscous boundary layer in the air near the surface of each bead, the air velocity would be nearly the same as the bead velocity.

[0081] Controller 62 (e.g., as part of interface 16) may receive a plurality of outputs from a plurality of sensors 82 from a plurality of sensor modules 58 that monitor a plurality of bead flow lines supplying a plurality of bead dispensers 49. The controller 62 can correlate the plurality of signals to a plurality of bead flow values and display the values on a screen of interface 16 and / or save the values to memory 66. This can be used to ensure balance in bead dispense, and allow adjustment if one bead line is supplying more than another. The controller 62 can aggregate the values to calculate a total flow rate, representing the total or average outflow of beads from the bead hopper 19 and / or dispensed on the ground surface.

[0082] The bead hopper 19 may be the only source of beads for the bead dispensers 49. The compressor 18 may be the only source of the flow of compressed air.

[0083] While the sensor module 58 has been discussed in connection with bead flow monitoring for ground marking, the sensor module 58 or other sensor modules within the scope of this disclosure may not be associated with beads for ground marking. The beads may not be for marking. The beads may be physical objects. The beads may be food. The beads may be particles used in making things.

[0084] Sensor module 58 provides significant advantages. Sensor module 58 includes beam 76 that projects from assembly body 74 and into the bead flow. The beam 76 is cantilevered from the assembly body 74. Such a configuration provides for a compact and efficient sensing configuration.

[0085] The electrical components of sensor module 58 are not exposed to the bead flow or the compressed air flow through cross-channel housing 72. Isolating the sensors 82 and other electrical components from the bead and compressed air flow protects such components and provides for more accurate sensing by sensor assembly 70.

[0086] FIG. 4 is a cross-sectional view taken along line 4-4 in FIG. 3A. FIG. 5A is an isometric cross-sectional view of sensor assembly 70 taken along line A-A in FIG. 5B. FIG. 5B is an isometric cross-sectional view of sensor assembly 70 taken along line B-B in FIG. 5A. FIGS. 4-5B are discussed together.

[0087] The sensor module 58 is configured to measure the volume of beads traveling with a flow of compressed air, and outputs a signal indicative of the volumetric flow of beads traveling with the flow of compressed air.

[0088] The sensor module 58 includes housing 68. The housing 68 can be a unitary body. As shown, the housing 68 can be composed of multiple components. One such component is the cross-channel housing 72. Cross-channel housing 72 includes a flow channel 114. The flow channel 114 can be axially aligned with the flow of compressed air and beads along a channel axis CA. Flow channel 114 is pressurized by compressor 18 along with bead hopper 19, hose 21, and bead dispenser 49.

[0089] Flow channel 114 is not an open channel but is instead a closed, pressurized channel that conveys beads for dispensing by bead dispenser 49. In some examples, flow channel 114 is a cylindrical passage with a constant cross-section that extends through cross-channel housing 72 from channel inlet 1 10 to channel outlet 112. In other examples, flow channel 114 can have a different cross-sectional shape, such as rectangular or polygonal, and may have include regions that have decreasing, increasing, or both decreasing and increasing cross-sectional area. Hoses or other components along the flow path of beads can connect with channel inlet 110 and channel outlet 1 12 to provide bead flow to and receive bead flow from cross -channel housing 72.

[0090] Branching from the flow channel 114 is a side channel 116. Side channel 116 can be orientated orthogonal to the flow channel 114, however other orientations are possible. The flow channel 114 together with the side channel 1 16 can form a T shape. In other examples, side channel 116 intersects flow channel 114 at an oblique angle such that cross-channel housing 72 forms a Y shape. Side channel 116 can be a dead end in which air and beads do not flow through.

[0091] Returning to the housing segments of the housing 68, the housing 68 can include an inner housing 98. The inner housing 98, in this example, threads into the crosschannel housing 72. In the example shown, the inner housing 98 is configured to thread into the receiver 120 of cross-channel housing 72. The inner housing 98 can secure assembly body 74 to cross-channel housing 72.

[0092] Beam 76 extends from assembly body 74 and into cross-channel housing 72. In the example shown, the beam 76 extends within the side channel 116 and into the flow channel 114. Beam 76 can be located at least partially within side channel 116. In the example shown, beam 76 is disposed partially within side channel 116 and projects into flow channel 114 relative to centerline axis CA. More specifically, a majority of the beam 76 is located within the side channel 116 but a portion of the beam 76 extends beyond the side channel 116 into the flow channel 114 towards channel axis CA.

[0093] In the example shown, the beam 76 extends to the channel axis CA such that the beam 76 intersects the channel axis CA. The beam 76 extends to the channel axis CA such that the channel axis CA passes through the beam 76. As such, the beam 76 can extend to, and in some cases beyond, the center of the flow channel 114. In some examples, a majority portion of beam 76 may extend into flow channel 114 towards or through channel axis CA from side channel 116.

[0094] Beam 76 is cantilevered into flow channel 1 14 in the example shown. The beam 76 is connected to diaphragm 78. Diaphragm 78 is disposed within sensor chamber 124 in assembly body 74. In various embodiments, the beam 76 is formed from a piece of material contiguous with the diaphragm 78. For example, beam 76 and diaphragm 78 can be formed by a continuous metallic piece. However, in other embodiments, the diaphragm 78 is formed separately from the beam 76, and the beam 76 is connected to the diaphragm 78. The diaphragm 78 and the beam 76 can be coaxial, such as along beam axis BA. In various embodiments, the beam 76 is supported only by the diaphragm 78, such that the beam 76 does not contact any other components. In the example shown, sealant 92 is in contact with the beam 76. In the example shown, the beam 76 is cantilevered such that a majority of an axial length of the beam 76 is not in contact with any other component of the sensor module 58.

[0095] The beam 76 extends from diaphragm 78 and through side channel 1 16. Beam 76 is spaced from the walls defining side channel 116 by gap 140. The gap 140 can extend fully annularly around the beam 76 to provide an annular gap 140 between beam 76 and the portion of cross-channel housing 72 defining side channel 116. Gap 140 provides space for beads to enter into and flow around the beam 76 within side channel 116. The gap 140 is sized to prevent beads from becoming stuck between the wall defining side channel 116 and beam 76 as such sticking can affect the deflection of the beam 76 and thus affect the information generated by sensor assembly 70. In some examples, the gap 140 is sized based on the size of the beads. For example, gap 140 can be sized such that gap 140 is at least twice as large as the diameter of the beads.

[0096] The beam 76 includes a main portion 106 and impact portion 108. The main portion 106 can be cylindrical and elongate, however other options are possible, such as rectangular, hexagonal, or other shapes. Impact portion 108 extend from main portion 106. Impact portion 108 can include an impact surface 148. The impact surface 148 is flat in this example, however other surface profiles are possible for the impact surface 148. The flat surface is only part of the impact portion 108 in the example shown, such that, in this example, the sides of the beam 76 along the impact portion 108 are round similar to the shape of the main portion 106. The impact surface 148 is orientated to face upstream (in direction FD2 along channel axis CA) along the flow channel 114 such that beads will impact the impact surface 148. The impacting of the beads on the impact surface 148 deflects the cantilevered beam 76.

[0097] Beam 76 is connected to diaphragm 78. Diaphragm 78 can be formed as a disk, among other options. Deflection of the beam 76 distorts the diaphragm 78. Sensors 82 are connected to the diaphragm 78. It is understood that, while multiple sensors 82 are shown, various embodiments can have a single sensor 82. Each sensor 82 can be mounted on the diaphragm 78. Distortion of the diaphragm 78 by deflection of the beam 76 is sensed by the sensors 82, resulting in output of signals to controller 62 that identify and measure the degree of deflection and relate that to a metric of bead flow.

[0098] Each sensor 82 can be a strain gauge, amongst other options. Sensor 82 can measure the degree of distortion of the diaphragm 78. The sensor 82 outputs a signal proportional to the degree of bending or other type of strain of the diaphragm 78. The diaphragm 78 may be formed from a resilient material. For example, the diaphragm 78 may be formed from metal. The diaphragm 78 may be formed from polymer. The sensor 82 may be adhered to the diaphragm 78 with adhesive (e.g., epoxy) and / or laminated onto the diaphragm 78 under a coating.

[0099] The diaphragm 78 can include various portions. In the example shown, diaphragm 78 includes outer rim ring 142, inner recess ring 144, and center shelf 146. Outer rim ring 142 is used for mounting of the diaphragm 78 and the beam 76. Specifically, the outer rim ring 142 is pinched between the mount 100 and the retainer 102, which holds the diaphragm 78 in place and thereby also holds the beam 76 in place. The outer rim ring 142 is coaxial with the beam axis BA. In the example shown, brace rings 138 are disposed between outer rim ring 142 and retainer 102. The brace rings 138 are biased into outer rim ring 142 by retainer 102 such that the diaphragm 78 is pinched directly between brace rings 138 and retainer 102.

[0100] Center shelf 146 is part of the diaphragm 78. The center shelf 146 is the portion of the diaphragm 78 to which the beam 76 is directly attached and / or from which the beam 76 extends from the diaphragm 78. In the example shown, the center shelf 146 is wider than the main portion 106 of the beam 76. The center shelf 146 can have a larger diameter than the main portion 106. The beam 76 can be disposed coaxially with the center shelf 146 on the beam axis BA.

[0101] Inner recess ring 144 extends between and connects outer rim ring 142 and center shelf 146. Inner recess ring 144 can extend fully annularly about the beam axis BA. In the example shown, the inner recess ring 144 is thinner relative to the outer rim ring 142 and the center shelf 146. It is understood, however, that the inner recess ring 144 may not be thinner than the outer rim ring 142 and / or the center shelf 146 in various other examples (e.g., the outer rim ring 142 and / or the center shelf 146 may not be thicker than the inner recess ring 144). Having a relatively thin part of diaphragm 78 at the inner recess ring 144 can concentrate the deformation of the diaphragm 78 along the thinned inner recess ring 144, making deformation of the diaphragm 78 easier to measure by locating the sensors 82 over the thinner inner recess ring 144 relative to the thicker (and less likely to deform) outer rim ring 142 and / or the center shelf 146. In the example shown, the sensors 82 overlap the inner recess ring 144 (e.g., overlap axially with respect to the beam axis BA).

[0102] In various examples, a plurality of sensors 82 can be configured to sense deformation of diaphragm 78. For example, sensor assembly 70 can include three sensors 82. In various other examples, there can be four sensors 82. In various examples, there can be two sensors 82. In various examples, there can be more than four sensors 82. The sensors 82 can be arrayed around the beam axis BA. The sensors 82 can be evenly arrayed around the beam axis BA in various examples. Diaphragm 78 does not include a hole through the diaphragm 78 in the example shown. Wires or other signal transmitting components are not disposed in the flow channel 114 and do not extend through the diaphragm 78.

[0103] The sensors 82 can be connected to a sensor board 84. The sensor board 84 can be any kind of board such as a printed circuit board. Sensor board 84 may be supported by the diaphragm 78, such as by way of the sensors 82. Also within the assembly body 74 is an inner board 86 connected to the sensor board 84, an outer board 90 connected to the connector 80, and a flexible printed circuit 88 extending between and connecting the inner board 86 and outer board 90. These electrical components can help manage the power and handling of signals to and from the sensors 82. Such electrical components can electrically connect with the terminals of the connector 80.

[0104] Between various components of the housing 68 are seals 94. The seals 94, which can be O-ring seals among other options, may be used for sealing and / or retaining by maintaining force due to compression resistance.

[0105] Sealant 92 is disposed around a portion of the beam 76. The sealant 92 fills into space radially (relative to beam axis BA) outward of the beam 76. In the example shown, the sealant 92 fills into a gap between the beam 76 and the assembly body 74 and into area defined by diaphragm 78. The sealant 92 can fill into the space between the outer rim ring 142 and center shelf 146 of the diaphragm 78. Sealant 92 can be formed as an adhesive, such as glue, among other options. The sealant 92 filling into the area around the beam 76 prevents beads from entering into that area. Such a configuration prevents the beads from becoming stuck between beam 76 and assembly body 74, which could affect deflecting of the beam 76 thereby affecting sensing by sensor module 58. Further, the sealant 92 prevents the beads from traveling to and directly impacting on the diaphragm 78. As such, the sealant 92 isolates the diaphragm 78 from the bead flow such that diaphragm 78 deflects based on bead impact on beam 76, not based on beam impact directly on diaphragm 78. In the example shown, the beam 76 extends from the diaphragm 78 and through the side channel 116 into the flow channel 114. A portion of the beam 76 is surrounded by sealant 92 and a portion of the beam 76 is surrounded by gap 140 such that the portion surrounded by gap 140 is not in contact with other structure of the sensor module 58. The portion of the beam 76 surrounded by gap 140 can be contacted by the beads flowing through cross-channel housing 72. The portion of the beam 76 surrounded by sealant 92 can have an axial length (along beam axis BA) less than the portion of beam 76 surrounded by gap 140.

[0106] In one manner of operation, the beads create drag on the portion of the beam 76 extending into the flow channel 114, causing a slight deflection and strain, and that strain value can then be correlated to a mass flow rate of beads. As discussed above, the beads can fill the flow channel 114 and be carried in mass by the compressed air. The flowing air, having a lower viscosity, will have less of an effect on the strain value such as to be negligible, and because of the viscous boundary layer in the air near the surface of each bead, the air velocity would be nearly the same as the bead velocity.

[0107] The signal output by the sensor 82 can be correlated to a known volume of bead flow to establish a relationship between the signal output by the sensors 82 and bead flow volumes. It is noted that a bead flow volume can relate to weight per unit time or another metric of bead flow. The sensor 82 may be a resistor whose resistance increases as the resistor is strained (e.g., by narrowing and / or lengthening a resistor wire within the sensor 82 when strained). The change in resistance can be measured by a change in cunent flow through the resistor, and different amounts of change in current flow can be correlated to different known flow rates of beads. After calibration, the current or other metric of the signal output by the sensors 82 can be compared to establish relationship to correlate the measured signal to the known flow rate of beads. The flow rate of beads can then be output on the interface .

[0108] Sensor module 58 provides significant advantages. Electrical components of sensor module 58 are disposed in sensor chamber 124 within assembly body 74. The sensor chamber 124 is fluidly isolated from the compressed air and bead flow through flow channel 114. Such a configuration protects the sensing components and prevents the compressed air and / or beads from acting directly on the sensing components.

[0109] Beam 76 extends from diaphragm 78 and through sealant 92 to project into the passages within cross-channel housing 72. Sealant 92 surrounds beam 76 and is disposed between diaphragm 78 and the flow within cross-channel housing 72. The sealant 92 isolates the diaphragm 78 from the bead and compressed air flow within the crosschannel housing 72. Such a configuration prevents the beads and / or compressed air flow from acting directly on the diaphragm 78, providing for more accurate sensing. In the example shown, the sealant 92 surrounds a portion of the beam 76 which prevents beads from becoming stuck between beam 76 and assembly body 74, thereby providing for a more robust configuration of sensor assembly 70.

[0110] Beam 76 is cantilevered into the flow channel 114 from diaphragm 78. The beads impact on the beam 76 to cause deflection of the beam 76. Deflection of the beam 76 causes distortion of the diaphragm 78. The sensors 82 that are configured to sense distortion of the diaphragm 78 are disposed on an opposite side of the diaphragm 78 from the beam 76. The sensors 82 are isolated from the bead flow and not directly exposed to the bead flow within cross-channel housing 72. Isolating the sensors 82 from the bead flow provides for a more robust configuration and improved operating life.

[0111] It is understood that components that arc described as connected arc not necessarily in contact with each other without an intermediary component, unless it is specified that they are directly connected, in which case the two components are in contact with each other. Although not necessarily stated, any two materials that are contacting in any of the figures can be described (e.g., specifically claimed) as directly connected, and any two components described herein as being connected can be described (e.g., specifically claimed), optionally, as directly connected.

[0112] Optional language is used herein describing what “can” or “may” be present, or what “various” embodiment may include, not what is or must necessarily be present. Therefore, if in reference to an embodiment, it is stated that an aspect “may” or “can” be present, then the option can be included, or left out, of the embodiment, particularly in a claim. Each sentence or paragraph can refer to multiple, independent aspects. A claim can be amended with a select word or phrase from a sentence or paragraph without taking the whole sentence or paragraph.

[0113] The present disclosure is made using several embodiments to highlight various inventive aspects. Modifications can be made to the embodiments presented herein without departing from the scope of the invention. It is intended that someone can mix various aspects from the presented embodiments and remain within the scope of this disclosure. For example, this disclosure contemplates that a single element disclosed in part of a sentence of a paragraph can be implemented in a different embodiment (or claimed) apart from the other aspects of the rest of the sentence and paragraph. Likewise, an aspect of part of an embodiment shown in a figure can be implemented in a different embodiment (or claimed) apart from the rest of the embodiment shown in the figure. The scope of the disclosure is not limited to the specific embodiments shown herein. Rather, this disclosure is presented in an illustrative manner to demonstrate several of many possibilities within the scope of this disclosure. The scope of the invention is not limited to the particular embodiments disclosed herein.

[0114] 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 bead flow sensor module, comprising: a housing defining a flow channel between a channel inlet and a channel outlet; a diaphragm located within the housing; a beam supported by the diaphragm in an orientation such that the beam extends into the flow channel in which beads impacts on the beam to cause deformation of the diaphragm; and one or more sensors that respectively output one or more signals indicative of deformation of the diaphragm due to the beads impacting on the beam.

2. The bead flow sensor module of claim 1, wherein the diaphragm is a disc.

3. The bead flow sensor module of claim 2, wherein the diaphragm does not have a hole through the diaphragm.

4. The bead flow sensor module of any one of claims 4-6, wherein the one or more sensors are disposed on an opposite side of the diaphragm from the beam.

5. The bead flow sensor module of any one of claims 2-4, wherein the diaphragm includes an outer rim ring and an inner recess ring.

6. The bead flow sensor module of claim 5, wherein the one or more sensors overlap the inner recess ring.

7. The bead flow sensor module of claim 6, wherein the one or more sensors axially overlap with the inner recess ring relative to a beam axis along which the beam extends.

8. The bead flow sensor module of any one of claims 5-7, wherein the inner recess ring is thinner than the outer rim ring.

9. The bead flow sensor module of any one of claims 5-8, wherein the diaphragm includes a center shelf.

10. The bead flow sensor module of claim 9, wherein the beam is mounted to the center shelf.

11. The bead flow sensor module of any one of claims 9 and 10, wherein the inner recess ring is thinner than the center shelf.

12. The bead flow sensor module of any one of claims 1-11, wherein the diaphragm and the beam are both formed from a contiguous piece of metal.

13. The bead flow sensor module of any one of claims 1-12, wherein the one or more sensors are arrayed around a center of the diaphragm.

14. The bead flow sensor module of any one of claims 1-13, wherein the beam includes a main portion which is cylindrical.

15. The bead flow sensor module of any one of claims 1-14, wherein the beam includes an impact portion having a flat surface positioned to be directly impacted by beads.

16. The bead flow sensor module of claim 15, wherein the impact portion is disposed at an end of the beam opposite the diaphragm.

17. The bead flow sensor module of any one of claims 1-16, wherein the beam extends into the flow channel such that a near end of the beam is not exposed to direct bead impacts within the flow channel while a far end of the beam is exposed to direct bead impacts within the flow channel.

18. The bead flow sensor module of claim 17, wherein the beam is oriented orthogonal to the flow channel.

19. The bead flow sensor module of any one of claims 1-18, wherein the flow channel is formed in a cross-flow housing of the housing, and wherein an assembly body that supports the diaphragm and the beam is mounted to the cross-flow housing.

20. The bead flow sensor module of claim 19, wherein the cross-flow housing is T shaped.

21. The bead flow sensor module of any one of claims 1-20, wherein the beads are for ground marking.

22. The bead flow sensor module of any one of claims 1-21, wherein the bead is for an application other than for ground marking.

23. A system comprising: a source of a flow of compressed air; a bead hopper that is supplied with the flow of compressed air, the bead hopper storing a supply of beads configured to form a flow of beads carried by the flow of compressed air out of the bead hopper; a bead dispenser; a flow pathway between the bead hopper and the bead dispenser; and the bead flow sensor module of any one of claims 1-22 disposed between the hopper and the bead dispenser.

24. A bead flow sensor assembly comprising: an assembly body;a diaphragm located within the assembly body; a beam supported by the diaphragm and extending from the diaphragm away from the assembly body along a beam axis; and one or more sensors that respectively output one or more signals indicative of deformation of the diaphragm due to the beads impacting on the beam, the one or more sensors disposed within the assembly body.

25. The bead flow sensor assembly of claim 24, wherein the assembly body includes a sensor housing within which the one or more sensors and the diaphragm are disposed, and the assembly body includes an inner housing disposed around the sensor housing, wherein the inner housing is movable relative to the sensor housing.

26. The bead flow sensor assembly of claim 25, wherein the inner housing includes exterior threading.

27. The bead flow sensor assembly of any one of claims 25 and 26, wherein the inner housing is rotatable about the sensor housing and the inner housing is movable axially relative to the sensor housing.

28. 1'he bead flow sensor assembly of any one of claims 25-27, wherein the sensor housing includes a lip that axially overlaps with the inner housing and the sensor housing includes a shoulder that radially overlaps with the inner housing, the lip and the shoulder preventing the inner housing from shifting axially off of the sensor housing.

29. The bead flow sensor assembly of any one of claims 24-28, wherein the beam is disposed coaxially with the diaphragm.

30. The bead flow sensor assembly of any one of claims 24—29, wherein the diaphragm includes an outer rim ring and an inner recess ring, the inner recess ring thinner than the outer rim ring.

31. The bead flow sensor assembly of claim 30, wherein the one or more sensors are aligned wit the inner recess ring.

32. The bead flow sensor assembly of any one of claims 30 and 31 , wherein the one or more sensors axially overlap with the inner recess ring.

33. The bead flow sensor assembly of any one of claims 30-32, wherein the diaphragm includes a center shelf, the beam extends from the center shelf, and the center shelf is thicker than the inner recess ring.

34. The bead flow sensor assembly of claim 33, wherein a width of the center shelf is greater than a width of the beam.

35. The bead flow sensor assembly of claim 33, wherein a width of the center shelf is greater than a largest width of the beam.

36. The bead flow sensor assembly of any one of claims 24—35, wherein the beam and the diaphragm are monolithic.

37. The bead flow sensor assembly of any one of claims 24-36, wherein the beam includes a main portion extending from the diaphragm and an impact portion extending from the main portion.

38. The bead flow sensor assembly of claim 37, wherein the impact portion includes at least one flat face.

39. The bead flow sensor assembly of any one of claims 24-38, wherein the sensor body includes: a mount supporting the diaphragm; and a retainer connected to the mount such that the diaphragm is captured between the mount and the retainer; a cap connected to the retainer; and a connector extending through the cap.

40. The bead flow sensor assembly of claim 39, wherein the connector includes an electrical terminal.

41. The bead flow sensor assembly of any one of claims 24—40, further comprising: a sensor circuit board connected to the one or more sensors; an inner circuit board connected to the sensor circuit board; an outer circuit board; and a flexible printed circuit extending between and connecting the inner circuit board and the outer circuit board.

42. The bead flow sensor assembly of any one of claims 24—41, further comprising: sealant disposed around the beam and between the beam and the assembly body.

43. The bead flow sensor assembly of claim 42, wherein the sealant is disposed adjacent to the diaphragm.

44. A bead flow sensor module comprising: a cross-channel housing defining a flow channel between a channel inlet and the channel outlet; andthe bead flow sensor assembly of any one of claims 24-43 mounted to the cross-channel housing such that the beam extends into the flow channel.

45. The bead flow sensor module of claim 44, wherein the cross-channel housing includes a side channel extending from the flow channel, and wherein the beam extends through the side channel and into the flow channel.

46. The bead flow sensor module of any one of claims 44 and 45, wherein the assembly body is at least partially disposed in a receiver extending from a main body of the cross-channel housing.

47. The bead flow sensor module of any one of claims 44-46, wherein the assembly body includes a locator, the cross-channel housing includes a recess, and the locator is keyed to the recess.

48. The bead flow sensor module of any one of claims 44-47, wherein the beam extends to intersect with a channel axis along which the flow channel extends.

49. A system comprising: a source of a flow of compressed air; a bead hopper that is supplied with the flow of compressed air, the bead hopper storing a supply of beads configured to form a flow of beads carried by the flow of compressed air out of the bead hopper; a bead dispenser; a flow pathway between the bead hopper and the bead dispenser; and the bead flow sensor module of any one of claims 44—48 disposed between the hopper and the bead dispenser.

50. A bead flow sensor module comprising: a cross-flow housing defining a flow channel between a channel inlet and a channel outlet; and a sensor assembly comprising: an assembly body; a diaphragm located within the assembly body; a beam supported by the diaphragm in an orientation such that the beam extends into the flow channel in which beads impact on the beam to cause deflection of the beam and deformation of the diaphragm; andone or more sensors that respectively output one or more signals indicative of deformation of the diaphragm due to the beads impacting on the beam.

51. The bead flow sensor module of claim 50, wherein the assembly body is mounted to the cross-flow housing by a threaded interface.

52. The bead flow sensor module of any one of claims 50 and 51, wherein the cross-flow housing includes a receiver and wherein the assembly body is at least partially disposed in the receiver.

53. The bead flow sensor module of any one of claims 50-52, wherein the assembly body comprises: a sensor housing within which the at least one sensor is disposed; and an inner housing disposed around the sensor housing; wherein the inner housing connects with the cross-flow housing to hold the sensor housing on the cross-flow housing.

54. The bead flow sensor module of claim 53, wherein the inner housing is movable relative to the sensor housing.

55. The bead flow sensor module of any one of claims 53 and 54, wherein the inner housing is rotatable relative to the sensor body and wherein the inner housing is movable lengthwise relative to the sensor body.

56. The bead flow sensor module of any one of claims 53-55, wherein the sensor housing defines a sealed sensor chamber within which the one or more sensors is disposed.

57. The bead flow sensor module of any one of claims 53-56, wherein the sensor housing interfaces with the cross-channel housing at a keyed interface.

58. The bead flow sensor module of any one of claims 50-57, wherein the beam and the diaphragm are disposed coaxially.

59. The bead flow sensor module of any one of claims 50-58, wherein the flow channel extends along a channel axis, the beam extends along a beam axis, and the beam axis is transverse to the channel axis.

60. The bead flow sensor module of claim 59, wherein the beam axis is orthogonal to the channel axis.

61. The bead flow sensor module of any one of claims 59 and 60, wherein the beam extends to intersect with the channel axis.

62. The bead flow sensor module of any one of claims 50-61, wherein the beam and the diaphragm are formed from a continuous metallic piece.

63. The bead flow sensor module of any one of claims 50-62, wherein the diaphragm includes an outer rim ring and an inner recess ring, the inner recess ring thinner than the outer rim ring.

64. The bead flow sensor module of claim 63, wherein the one or more sensors are aligned wit the inner recess ring.

65. The bead flow sensor module of any one of claims 63 and 64, wherein the one or more sensors axially overlap with the inner recess ring.

66. The bead flow sensor module of any one of claims 62-65, wherein the diaphragm includes a center shelf, the beam extends from the center shelf, and the center shelf is thicker than the inner recess ring.

67. The bead flow sensor module of any one of claims 50-66, wherein a majority of a length of the beam is not in contact with a component of the bead flow sensor module.

68. The bead flow sensor module of any one of claims 50-67, wherein the assembly body interfaces with the cross-flow housing at a keyed interface.

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