Atomizer With Sensor-Based Condition Monitoring
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Solution Overview
Problem
The inefficiency and difficulty in monitoring and maintaining fluid atomizers, especially at high electrical potentials, lead to reduced availability and quality issues due to undetected defects, making frequent periodic maintenance necessary.
Innovation Solution
An atomizer equipped with a measurement module featuring sensors and an electronic control module that monitors parameters such as electrical potential, acceleration, temperature, and noise levels, allowing for real-time diagnostics and reduced maintenance needs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the atomizer operates at high electrical potential to improve fluid projection efficiency, then atomizer efficiency is improved, but the difficulty of monitoring and maintaining the atomizer increases
Solution Approach 1:
The patent replaces mechanical monitoring methods with electronic sensing technology. Sensors (accelerometers, temperature sensors, noise sensors) are integrated into the atomizer to electronically detect operational parameters, enabling monitoring at high voltages without physical intervention or complex mechanical measurement systems.
Solution Approach 2:
The patent introduces sensors as intermediary elements between the high-voltage atomizer components and the monitoring system. These sensors act as mediators that can withstand high electrical potentials and transmit operational data (vibration, temperature, noise) to external monitoring systems, enabling indirect observation of the atomizer state without direct exposure to high voltage risks.
2Reliability
If periodic maintenance is performed frequently to ensure atomizer reliability, then reliability is improved, but device availability decreases
Solution Approach 1:
The patent implements continuous feedback through integrated sensors that monitor atomizer operation in real-time. Accelerometers detect vibrations indicating component wear, temperature sensors monitor thermal conditions, and noise sensors identify abnormal operational patterns. This feedback enables condition-based maintenance, allowing intervention only when actual degradation is detected rather than following fixed schedules.
Solution Approach 2:
The patent performs preliminary detection of defects through continuous monitoring before they lead to failures. By detecting early signs of wear, imbalance, or abnormal operation, the system enables proactive maintenance planning, allowing replacement or adjustment of components before they cause downtime or quality issues.
3Object-affected harmful factors
If the atomizer is equipped with minimum necessary components and electrical insulation to prevent arcing, then safety is improved, but the complexity of monitoring components increases
Solution Approach 1:
The patent makes the sensors serve multiple functions: they monitor operational parameters (vibration, temperature, noise) while simultaneously providing data for predictive maintenance, quality control, and safety monitoring. This multi-functionality reduces the need for separate dedicated monitoring systems, managing complexity through consolidation rather than proliferation of components.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enhances atomizer availability and quality by enabling early detection of defects, reducing the frequency of maintenance and improving operational efficiency.
Implementation Method 1
a measurement module, with at least one sensor configured to measure values of at least one atomizer parameter
Implementation Method 2
monitors parameters such as electrical potential, acceleration, temperature, and noise levels
Implementation Method 3
the difference in electrical potential between the part to be coated with the fluid and the atomizer tends to favor the projection of the fluid droplets projected to the part, since the droplets tend to become electrically charged at the atomizer and follow the electric field lines
Implementation Method 4
follow the electric field lines between the atomizer and the part
Data Source
AI summary
An atomizer having an atomizer head configured to atomize a first fluid. The atomizer includes, in addition, a measurement module including at least one sensor configured to measure the values of at least one parameter of the atomizer, an electronic control module configured to receive the measured values, and a power supply configured to electrically supply the control module with a power supply voltage.