Golf Ball Spray System with Real-Time Pattern Feedback Control
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Solution Overview
Problem
Conventional golf ball painting systems lack efficient monitoring and feedback control, leading to inconsistent paint coverage, material waste, and production inefficiencies.
Innovation Solution
A golf ball painting system that includes a spray system with adjustable spray guns and a spray control system featuring a spray detection system and feedback mechanism to monitor and adjust spray patterns in real-time, ensuring consistent paint coverage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual visual monitoring and adjustment of spray parameters is used, then operational flexibility is maintained, but manufacturing precision and consistency of paint coverage deteriorate
Solution Approach 1:
The system employs a detector positioned between the spray gun and application area that continuously monitors spray pattern parameters and feeds this information back to a control device. The control device automatically adjusts spray gun settings based on the detected parameters, creating a closed-loop feedback system that maintains consistent paint coverage without manual intervention.
Solution Approach 2:
The patent replaces manual visual monitoring and mechanical adjustment with an automated detection and control system. The detector uses optical or electromagnetic fields to monitor spray patterns, and the control device uses electronic signals to adjust spray parameters, substituting human operators with automated sensing and control mechanisms.
2Manufacturing precision
If spray parameters are frequently adjusted to maintain quality, then manufacturing precision improves, but productivity deteriorates due to line downtime
Solution Approach 1:
The automated detection and control system operates continuously during production without requiring line shutdowns. The detector continuously monitors spray patterns in real-time, and the control device makes continuous automatic adjustments, eliminating the need to stop production for routine measurements and parameter adjustments.
Solution Approach 2:
The spray system performs self-diagnosis and self-adjustment through the automated feedback control loop. The detector monitors spray parameters and the control device automatically corrects deviations without external intervention, enabling the system to maintain precision while operating autonomously throughout the production cycle.
3Device complexity
If spray gun is not monitored, then device complexity is reduced, but loss of substance increases due to improper coating and material waste
Solution Approach 1:
The detector continuously monitors spray pattern parameters and provides feedback to the control device, which automatically adjusts spray gun settings to maintain optimal coating application. This ensures that paint is applied efficiently and consistently, preventing waste from improper coating, overspray, or malfunctioning spray guns.
Solution Approach 2:
The detector acts as an intermediary between the spray gun and the control device, translating physical spray parameters into electrical signals that the control device can process. This intermediary enables automatic monitoring and adjustment without requiring direct complex integration between the spray gun and control systems.
4Measurement precision
If operator manually monitors and adjusts spray parameters, then measurement precision can be maintained, but loss of time increases due to routine measurements and adjustments
Solution Approach 1:
The system replaces manual measurement and adjustment operations with automated detection and control. The detector continuously measures spray parameters with high precision using optical or electromagnetic sensing, and the control device automatically adjusts parameters based on detected values, eliminating the time required for manual measurement cycles and adjustments.
Solution Approach 2:
The automated detection system operates continuously without interruption to measure spray parameters, whereas manual monitoring requires periodic stopping of the production line. This continuous measurement capability maintains measurement precision while eliminating the time loss associated with routine manual measurements and adjustments.
Data Source
AI summary
A golf ball painting system encompassing a spray system having a spray gun configured to spray paint in a spray pattern toward an application area having one or more golf balls to be painted. The spray gun has one or more spray gun settings configured to be adjusted to thereby change the spray pattern of the sprayed paint. A spray control system is connected to the spray system. The spray control system has a spray gun control system configured to adjust or signal for adjustment of at least one of the one or more spray gun settings and a spray detection system having a detector positioned between the spray gun and the application area and configured to non-invasively monitor the spray pattern and collect data indicative of at least one spray pattern parameter. A device is configured to receive the at least one spray pattern parameter from the spray detection system and compare the at least one spray pattern parameter to a target value, and, if the at least one spray pattern parameter is outside of the target value, perform a corrective action.