Dynamic Spray Pattern Control for Non-Rectangular Objects
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Solution Overview
Problem
Spraying systems face inefficiencies in coating non-rectangular objects, resulting in significant material wastage and increased labor costs due to overspray, as conventional systems struggle to precisely control the spray pattern on irregularly shaped items moving on a conveyor belt.
Innovation Solution
A spraying system with dynamically varying spray guns that adjust their pattern in real-time based on the shape and movement of non-rectangular objects, utilizing a control system and computer-readable medium to ensure precise coverage without substantial overspray, by altering the fan air, atomizing air, and liquid pressures to match the object's dimensions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a conventional spray gun is used to coat non-rectangular objects on a conveyor belt, then the coating process can be automated and labor costs are reduced, but significant material wastage occurs due to overspray on the conveyor belt and support structures
Solution Approach 1:
The spray gun incorporates adjustable components that allow dynamic modification of the spray pattern width and angle during operation. The spray pattern can be widened or narrowed based on the presence and dimensions of objects on the conveyor belt, enabling the system to adapt to different coating requirements and minimize overspray on surrounding areas.
Solution Approach 2:
The system changes physical parameters of the spray output by adjusting the spray pattern width and angle. By modifying these parameters in response to object detection, the system optimizes material deposition on the target object while reducing wastage on the conveyor belt and support structures.
2Ease of operation
If a fixed spray pattern is used for all objects, then the spray system is simple to operate, but it cannot adapt to varying object shapes and sizes, resulting in overspray and material wastage
Solution Approach 1:
The system incorporates sensors that detect the presence, position, and dimensions of objects on the conveyor belt. This feedback information is used to automatically adjust the spray pattern parameters, allowing the system to adapt to varying object shapes and sizes without requiring complex manual configuration or programming.
Solution Approach 2:
The spray system automatically adjusts its own parameters based on sensor input, eliminating the need for manual intervention to configure spray patterns for different objects. The system self-regulates the spray width and angle to match the detected object dimensions, maintaining ease of operation while achieving precise coating.
3Area of stationary object
If the spray pattern width is increased to cover larger objects, then coverage is improved, but overspray increases on the conveyor belt and surrounding areas
Solution Approach 1:
The spray pattern width is made dynamically adjustable rather than fixed. The system can widen the spray pattern when large objects are detected and narrow it when smaller objects are present, optimizing coverage area while minimizing overspray on the conveyor belt and surrounding areas for each specific coating operation.
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 approach minimizes material wastage and labor costs by ensuring precise coating of non-rectangular objects, maintaining productivity by reducing the need for manual cleaning and halting production lines, while maintaining consistent coverage density across varying object widths.
Implementation Method 1
a spray gun or nozzle operable for discharging a spray pattern of liquid material
Implementation Method 2
spray pattern of liquid material atomized into particles
Data Source
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AI summary
A system and method for spray gun or nozzle control wherein the spray gun liquid discharge pattern is dynamically varied to correspond to the dimensions of a moving target object or a portion of the moving target. The spray gun includes inputs for fan air, atomizing air, and liquid, as well as cylinder air. Upon detection of a target object approaching, such as on a conveyor belt, the fan air pressure, atomizing air pressure, liquid pressure, and cylinder air pressure are varied according to predefined or contemporaneously generated curves to provide a spray pattern that corresponds to the shape of the target object or portion of the target object, thus minimizing waste and inefficiency due to overspray.