Powder Feed Valve Timing Control for Consistent Coating Delivery
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Solution Overview
Problem
Existing powder conveying devices for coating systems experience fluctuations in powder delivery, leading to deviations from the desired quantity, resulting in inconsistent coating processes.
Innovation Solution
A powder conveying device with a setpoint generator for specifying the opening time of the powder outlet valve, a sensor to determine the actual opening time, and an evaluation unit to calculate deviations, ensuring precise control and accurate powder delivery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a powder outlet valve is used to control powder delivery quantity by repeatedly opening and closing, then powder can be conveyed to the powder applicator, but the actual quantity of powder conveyed deviates from the desired quantity
Solution Approach 1:
The patent implements a feedback control system where a sensor detects the actual opening duration of the powder outlet valve, compares it with the target opening duration, and adjusts the valve control accordingly. This closed-loop feedback mechanism ensures that the actual powder delivery quantity matches the desired quantity, resolving the deviation problem between target and actual delivery rates.
Solution Approach 2:
The patent replaces purely mechanical valve control with an electronically controlled system that uses sensors and evaluation units to monitor and adjust the valve opening duration. This substitution of mechanical control with electronic measurement and control systems enables precise measurement and adjustment of powder delivery quantity, eliminating the inaccuracies of manual or simple mechanical timing.
2Measurement precision
If the sensor is arranged in the immediate vicinity of the powder outlet valve, then the measurement system inertia is reduced and disturbances not attributable to the outlet valve are minimized, but the sensor must operate in a harsh environment with powder flow
Solution Approach 1:
The patent positions the sensor in the immediate vicinity of the powder outlet valve rather than directly in the powder stream, using the valve housing or surrounding structure as an intermediary medium. This allows the sensor to detect vibrations or acoustic signals related to valve opening duration without being directly exposed to harmful powder flow conditions, thus maintaining measurement accuracy while protecting the sensor.
Solution Approach 2:
The patent employs non-contact sensing methods such as acoustic sensors or vibration sensors that detect valve operation through sound waves or mechanical vibrations transmitted through the valve housing. This substitution of direct mechanical contact sensing with remote or indirect sensing techniques allows accurate measurement of opening duration without exposing the sensor to harsh powder flow environments.
3Stability of the object's composition
If the sensor is designed as an influence sensor for non-contact measurement, then the powder flow in the powder channel is not affected by the measurement, but the measurement system becomes more complex
Solution Approach 1:
The patent employs influence sensors such as acoustic sensors, vibration sensors, or capacitive sensors that detect valve operation through physical fields (sound waves, mechanical vibrations, or electrical fields) rather than direct mechanical contact. These non-contact sensing methods measure opening duration without physically interfering with the powder flow, maintaining flow stability while providing accurate measurements through field-based detection techniques.
Solution Approach 2:
The patent designs the influence sensor system to serve multiple functions: detecting valve opening duration, monitoring powder flow conditions, and potentially detecting other operational parameters. This multi-functionality reduces the need for separate dedicated sensors for each measurement task, thereby offsetting the increased complexity of using influence sensors with additional versatile capabilities.
Data Source
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AI summary
The powder conveying device according to the invention for coating powder comprises a powder conveyor (110) with a powder outlet channel (51.1) and a powder outlet valve (13) for opening or closing the powder outlet channel (51.1). Furthermore, a setpoint generator (200) for specifying a target opening duration (Ttarget) of the powder outlet valve (13) and a sensor (210) for determining the actual opening duration (Tactual) of the powder outlet valve (13) are provided. The powder conveying device also includes an evaluation unit (220) for determining the deviation (ΔT) between the target opening duration (Ttarget) and the actual opening duration (Tactual).