Magnetic Sensor Rotary Atomizer Speed Monitoring

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Solution Overview

Problem

Existing rotary atomizer speed monitoring systems using optical sensors are susceptible to contamination and corrosion, and are costly, with a risk of electrocorrosion on reflector disks.

Innovation Solution

The use of a magnetic sensor instead of an optical sensor for speed monitoring, which generates an electrical signal converted into an optical signal and transmitted through an optical waveguide, eliminating the need for a reflector disk and reducing the risk of contamination and corrosion, and allowing for potential isolation between high-voltage and grounded areas.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If an optical sensor with reflector disk is used for speed monitoring, then speed monitoring function is achieved, but the components are susceptible to contamination and corrosion

Engineering Contradiction:

Improvespeed monitoring reliabilityVSAvoidcontamination and corrosion susceptibility

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent replaces the optical sensing system with a magnetic sensing system. Instead of using optical sensors and reflector disks that are susceptible to contamination, the invention uses a magnetic sensor (such as a Hall effect sensor or magnetoresistive sensor) to detect the rotational speed of the rotary atomizer through magnetic field variations caused by a magnetic element on the rotating component. This substitution eliminates the harmful effects of contamination and corrosion on the sensing components while maintaining reliable speed monitoring functionality.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If an optical sensor system with reflector disk is used, then speed monitoring is possible, but the cost is relatively high

Engineering Contradiction:

Improvespeed monitoring capabilityVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent employs a magnetic sensor system that uses inexpensive magnetic elements (such as ferrite magnets or magnetizable material rings) and standard magnetic sensors that are significantly cheaper than optical sensor systems. The magnetic element can be integrated into the existing turbine wheel or bell cup structure, eliminating the need for expensive optical components like precision reflector disks and optical waveguides, thereby reducing the overall manufacturing cost while maintaining the speed monitoring capability.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Loss of information

If a reflector disk is used in the high-voltage area, then speed monitoring signal can be transmitted, but electrocorrosion risk occurs

Engineering Contradiction:

Improvespeed signal transmissionVSAvoidelectrocorrosion risk

Core Design Contradiction:

Loss of informationVSObject-affected harmful factors

Solution Approach 1:

The patent replaces the optical reflector disk system with a magnetic field-based sensing system. The magnetic sensor detects changes in the magnetic field caused by a magnetic element attached to or integrated with the rotating component (turbine wheel or bell cup). This magnetic field detection method does not require any reflective surfaces or optical components in the high-voltage area, thereby eliminating the risk of electrocorrosion on the reflector disk while still enabling accurate speed signal transmission from the high-voltage area to the control system.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 provides reliable speed monitoring without the drawbacks of optical sensors, such as contamination and corrosion, while maintaining potential isolation and reducing costs, and also enables the detection of rotation direction and speed, with the added benefit of using the signal for power supply and product identification.

Implementation Method 1

a magnetic sensor (6) which generates an electrical signal in dependence on changes in the magnetic field

Methodology Applied

Scientific EffectMagnetic field detection: Magnetic Field

Implementation Method 2

an optical waveguide (9) for transmitting the measurement signal of the first sensor from the high-voltage area to the electrically grounded area

Methodology Applied

Scientific EffectOptical signal transmission: Optical Fibre

Data Source

PatentUS20240173729A1Coating device, in particular rotary atomizer

Publication Date: 2024.05.30 DUERR SYST AG

AI summary

The disclosure relates to a coating device, in particular a rotary atomizer, for coating components, in particular motor vehicle body components, with an electrostatic coating agent charging system, so that the coating device comprises a high-voltage area and an electrically grounded area. Furthermore, the coating device comprises a sensor in the high-voltage area, in particular as a rotational speed sensor for measuring the rotational speed of the rotary atomizer, and an optical waveguide for transmitting a measurement signal of the sensor from the high-voltage area to the electrically grounded area, wherein the optical waveguide enables a potential separation between the high-voltage area and the electrically grounded area. The disclosure provides that the sensor is a magnetic sensor.