Fluid Level Indicator in Airless Fluid Sprayer
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Solution Overview
Problem
Airless fluid sprayers lack an effective method to indicate the fluid level in the container, leading to potential sputtering or uneven spray when the fluid runs low, as conventional liquid level sensors can be inaccurate and hard to read.
Innovation Solution
A controller with a fluid level indication module that generates an indication of the fluid level by counting current pulses applied to an electromagnetic actuator, allowing for accurate monitoring of the fluid level without the need for liquid level sensors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional liquid level sensors are used to indicate fluid level, then the system can detect fluid level, but the measurement is inaccurate and hard to read
Solution Approach 1:
The patent replaces conventional mechanical liquid level sensors with an electromagnetic pulse counting system. The controller counts electromagnetic pulses generated by the electromagnetic actuator during pump operation to calculate fluid consumption, thereby determining fluid level. This substitution eliminates the need for direct liquid contact sensors and their associated readability and accuracy issues.
Solution Approach 2:
The patent introduces an intermediary measurement approach by using electromagnetic pulse counting as a mediator to infer fluid level. Instead of directly measuring liquid level with a sensor, the system counts electromagnetic pulses from the actuator and correlates them to fluid consumption through a counter module, providing indirect but accurate level indication.
2Reliability
If the sprayer operates without fluid level indication, then the device complexity is reduced, but the sprayer cannot detect low fluid levels leading to sputtering and uneven spray
Solution Approach 1:
The patent implements a feedback mechanism where the controller continuously monitors the counter value representing fluid consumption and compares it against thresholds to detect low fluid levels. When the counter indicates low fluid remaining, the system can alert the user or adjust operation to maintain spray consistency and prevent sputtering, ensuring reliable performance throughout the container's usage cycle.
Solution Approach 2:
The patent performs preliminary action by proactively monitoring fluid consumption and detecting low fluid levels before the container is completely empty. The counter tracks fluid usage in advance, allowing the system to warn users or adjust operation before sputtering occurs, thereby maintaining spray reliability without requiring complex real-time detection systems.
3Measurement precision
If electromagnetic pulse counting is used to indicate fluid level, then measurement accuracy is improved, but the device complexity increases due to controller and counter integration
Solution Approach 1:
The patent makes the controller multi-functional by having it perform both electromagnetic actuator control and fluid level indication through pulse counting. The same controller that manages pump operation also counts electromagnetic pulses and calculates fluid level, eliminating the need for separate dedicated level sensing hardware and simplifying the overall system architecture.
Solution Approach 2:
The patent merges the fluid level indication function with the existing electromagnetic actuator control system. By combining the counter module with the controller and using the same electromagnetic pulses for both actuation and measurement, the system achieves accurate level indication without adding separate operational complexity for the user.
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
The solution provides a reliable and user-friendly method to prevent the sprayer from running dry, reducing the risk of sputtering and ensuring consistent performance by alerting the user when the fluid level is low, thus maintaining efficient and uniform fluid delivery.
Implementation Method 1
applying a plurality of current pulses to an electromagnetic actuator that drives a fluid pump mechanism
Data Source
AI summary
The present disclosure generally relates to systems and devices for spraying fluid materials such as paints, stains, and the like, and more specifically, but not by limitation, to a fluid level indicator for an airless fluid sprayer. In one example, an airless fluid sprayer is provided and includes a fluid container, a controller, and a fluid level indication module implemented by the controller to generate an indication of a level of fluid material in the fluid container.