Segmented Spray Calibration Target for Coating Line Nozzle Accuracy
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Solution Overview
Problem
Existing coating production line systems face challenges in calibrating spray nozzles effectively, as weight target methods and virtual target methods require additional measurement equipment and do not accurately represent the real-world spray process, especially when the nozzle is in motion.
Innovation Solution
A spray process calibration target with a plurality of target detection areas arranged around a central area, connected by webs, which can be attached to a conveyor unit, allowing for calibration outside the production line system and providing a more accurate representation of the coating process by allowing airflow to traverse unoccupied areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a static flat target surface is used for calibration, then the calibration process is simple, but the spray distribution is distorted due to gas pressure buildup in front of the target
Solution Approach 1:
The target surface is segmented into multiple discrete target areas (first, second, third target areas) arranged in a triangular pattern, allowing spray material to pass through the gaps between areas rather than accumulating on a continuous flat surface. This segmentation resolves the gas pressure buildup issue while maintaining calibration simplicity.
Solution Approach 2:
The target structure functions as a porous configuration where the spaces between the discrete target areas allow spray material and gas flow to pass through. This prevents the gas pressure accumulation that occurs on solid flat surfaces, thereby improving spray distribution accuracy without complicating the calibration process.
2Measurement precision
If weight target methods or virtual target methods are used, then measurement capability is provided, but additional measurement equipment and complexity are required in the production line system
Solution Approach 1:
The target board serves its own measurement function through its geometric design. The known triangular arrangement of target areas with connecting webs creates a self-referential calibration pattern that can be analyzed without external measurement equipment. The target structure itself provides the measurement reference, eliminating the need for additional sensors or measurement devices in the production line.
Solution Approach 2:
The target board creates a simplified geometric representation (copy) of the spray pattern distribution. By projecting the spray onto the known geometric structure of target areas and connecting webs, the complex spray distribution is captured as a pattern on this simplified model, which can then be analyzed without requiring complex measurement equipment.
3Device complexity
If a continuous flat target surface is used, then the target structure is simple, but the airflow cannot traverse the target area causing distorted spray results
Solution Approach 1:
The continuous flat surface is divided into discrete segmented areas (first, second, third target areas) connected by webs. This segmentation allows airflow to pass through the gaps between areas while maintaining a relatively simple overall target structure. The segmented design ensures reliable spray calibration by preventing the airflow blockage that occurs with continuous surfaces.
Solution Approach 2:
Different regions of the target have different properties: the target areas provide measurement surfaces while the spaces between them provide airflow paths. The connecting webs provide minimal structural connection. This local differentiation of qualities allows the target to simultaneously maintain structural simplicity and enable reliable airflow traversal for accurate calibration.
Data Source
AI summary
A spray process calibration target (10) of a coating production line system for coating work pieces comprises a plurality of target detection areas (12) positioned around a central target detection area (62); a plurality of connecting webs (13, 13′, 13″); and at least one attachment means (11, 14, 62″); wherein each of the plurality of target detection areas (12) is connected via at least one of the plurality of connecting webs (13, 13′, 13″) directly or via one or more of further target detection areas (12) to at least one attachment means (11, 14, 62″) allowing to obtain coatings on the plurality of target detection areas (12) for calibration of a spray nozzle directed onto the central target detection area (62).