Distance Sensor Aerosol Filtering for Spray Coating
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Solution Overview
Problem
Spray coating technologies face challenges in accurately determining the distance between a spray gun and a surface due to interference from airborne particles, which can lead to inconsistent coating thickness and affect the reliability of sensors like proximity radar systems.
Innovation Solution
A method and device that utilize a distance sensor connected to a spray gun, processing data to filter out invalid distance values using a distance tolerance criterion, determining a base value for the distance between the sensor and the surface, and providing feedback for maintaining the desired distance during spray coating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a distance sensor is used to measure distance between spray gun and surface, then distance information can be obtained for coating control, but airborne particles cause false measurements reducing accuracy
Solution Approach 1:
The system collects multiple distance measurements over a predetermined time interval before processing them. By gathering data in advance and applying filtering algorithms to identify valid measurements versus false readings caused by particles, the system prepares reliable distance information before it is needed for coating control decisions.
Solution Approach 2:
The system continuously monitors distance measurements and uses feedback loops to distinguish between valid surface distance readings and false readings caused by airborne particles. By analyzing patterns in the feedback data and applying tolerance criteria, the system can identify and reject invalid measurements, improving overall measurement reliability in aerosol environments.
2Measurement precision
If multiple distance measurements are collected and processed with tolerance criteria, then accurate distance values can be determined, but processing complexity increases
Solution Approach 1:
The system transforms raw distance measurement data into processed distance information by applying tolerance criteria and statistical analysis. By changing the parameters of the data (from raw values to filtered valid values) and using predetermined time intervals, the system achieves accurate distance determination while managing processing complexity through structured approaches.
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
This solution effectively filters out noise from airborne particles, providing accurate distance measurements and enhancing the control and feedback of the spray coating process, ensuring consistent coating thickness and improved reliability of sensors.
Implementation Method 1
distance sensor...data values indicative of a distance between the sensor and a detected object
Data Source
AI summary
For determining distance between a spray gun (140) for applying a coating fluid to a surface, a distance sensor (100) may be placed on the spray gun (140). The sensor will provide values related to distance between the spray gun (140) and the surface, but also values related to distance between the spray gun (140) and aerosol particles. From all these values, the distance between the spray gun (140) and the surface is estimated by checking whether values received are valid for the distance to the surface by means of a distance tolerance criterion. The distance tolerance criterion may be based on previous values. Values meeting the criterion in a set are used for providing an estimate of the distance to the surface. for example by providing a median or average.