Electrostatic Atomizer Feedback Control for Consistent Spraying
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electrostatic atomizers lack effective monitoring and control mechanisms to optimize the spraying process and prevent errors, leading to inconsistent results and potential inefficiencies in liquid application.
Innovation Solution
The method involves using an electronic control system with sensors to detect voltage and current intensity at the atomizer nozzles and high-voltage source, allowing for real-time monitoring and intervention to improve the spraying process, including features like acoustic and haptic feedback, and adjustable parameters for optimal liquid delivery and nozzle alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If electrostatic atomization is used for liquid application, then spraying efficiency and coverage are improved, but lack of monitoring and control mechanisms leads to inconsistent results and potential errors
Solution Approach 1:
The patent implements feedback mechanisms by using sensors to detect voltage and current at the atomizer nozzles and high-voltage source, then feeding this information back to the control electronics. This allows the system to monitor spray conditions in real-time and make adjustments to maintain consistent operation, directly addressing the reliability issue while preserving the productivity benefits of electrostatic atomization.
Solution Approach 2:
The patent replaces manual monitoring and adjustment mechanisms with an automated electronic control system that uses sensors and electronic circuits to detect and respond to spray conditions. This substitution of mechanical/control systems with electronic automation enables consistent monitoring and control, improving reliability without sacrificing the efficiency of the electrostatic atomization process.
2Device complexity
If manual operation without monitoring is used, then device complexity is reduced, but error prevention and process optimization are compromised
Solution Approach 1:
The control electronics are designed to autonomously monitor spray parameters and automatically intervene to correct deviations or prevent errors. The system serves itself by using sensors to detect conditions and the control electronics to make adjustments without external intervention, thereby improving reliability while keeping the user interface simple and the overall device complexity manageable.
Solution Approach 2:
The patent incorporates feedback loops where sensors continuously monitor voltage, current, and other spray parameters, and the control electronics automatically adjust operating conditions based on this feedback. This self-regulating mechanism prevents errors and optimizes performance without requiring complex manual control systems, balancing reliability with acceptable device complexity.
3Reliability
If real-time monitoring with sensors is implemented, then spray process control and consistency are improved, but device complexity and cost increase
Solution Approach 1:
The control electronics are designed to perform multiple functions: monitoring voltage and current at different points, detecting spray conditions, making adjustments to maintain consistency, and providing user feedback. By consolidating these multiple functions into a single integrated control system, the patent improves spray consistency while avoiding the need for separate complex subsystems for each function, thereby managing overall device complexity.
Solution Approach 2:
The patent combines the monitoring and control functions into an integrated electronic control system where sensors, signal processing circuits, and actuation controls are merged into a unified architecture. This consolidation improves spray consistency through comprehensive monitoring while reducing the complexity that would arise from having separate independent systems for each function.
4Manufacturing precision
If intervention mechanisms are added to improve spray pattern, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The control electronics use feedback from sensors monitoring spray parameters to automatically adjust operating conditions and maintain precise spray patterns. This automated feedback control achieves manufacturing precision without requiring complex manual adjustment mechanisms, as the system self-corrects based on real-time sensor data.
Solution Approach 2:
The patent replaces complex mechanical adjustment mechanisms with electronic control that adjusts spray parameters through electrical signals to the electrostatic atomizer. This substitution achieves precise spray pattern control through electronic means rather than mechanical adjustments, improving precision while keeping the control system relatively simple and maintenance-free.
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 enables precise control and monitoring of the atomization process, enhancing the spraying result, preventing errors, and ensuring consistent and efficient application of liquids, such as cosmetics and paints, while minimizing material waste and maintaining hygiene standards.
Implementation Method 1
electrostatic atomization encompasses all atomization processes that atomize liquids by means of high-voltage effects
Implementation Method 2
In particular, electrohydrodynamic and electrokinetic effects are also included in this concept of atomization
Implementation Method 3
sensors in the control electronics to detect the voltage and/or current at at least one of the atomizer nozzles, and/or using sensors in the control electronics to detect the voltage and/or current at the high-voltage source
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention relates to a method for controlling an electrostatic atomiser (101) for liquids (103), the atomiser (101) comprising a liquid tank (110) and a device (111) for conveying liquid (103) out of the liquid tank (110), a high voltage source (109) and at least one atomiser nozzle (102b, 102d, 102g) for atomising liquid (103). The at least one atomiser nozzle (102b, 102d, 102g) is connected to the high voltage source (109). Sensor means (S102-1, S102-2) of control electronics (108) are used to detect voltage and/or current at at least one of the atomiser nozzles (102a - 102h) and/or sensor means (S109-1, S109-2) of the control electronics (108) are used to detect voltage and/or current at the high voltage source (109).