Electronic Spray Drive Modulation for Consistent Performance
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Solution Overview
Problem
Electronic spray devices face challenges in delivering repeatable performance due to manufacturing variations and the need for precise control of power and frequency to ensure consistent spray quality, especially in consumer products where cost and portability are concerns.
Innovation Solution
The electronic spray device incorporates a spray controller that modulates the drive signal based on measured operational parameters, such as impedance and power consumption, to set a target power level and adjust the drive signal frequency and amplitude, ensuring consistent spray performance across different cartridges and devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a fixed drive signal is used for the spray generator, then the device is simpler to manufacture and operate, but spray performance varies due to manufacturing tolerances and device-specific characteristics
Solution Approach 1:
The spray controller pre-stores optimal drive signal parameters (frequency, amplitude, pulse width) for different spray generator types in its memory. Before operation, the controller identifies the spray generator type and retrieves the corresponding pre-optimized parameters, eliminating the need for complex real-time adjustments while ensuring consistent spray performance across manufacturing variations.
Solution Approach 2:
The system measures operational parameters such as impedance and power consumption of the spray generator, compares these measurements against stored reference values, and automatically modulates the drive signal parameters to compensate for manufacturing tolerances and device-specific variations, thereby maintaining consistent spray performance.
2Manufacturing precision
If the drive signal parameters are manually adjusted for each device, then spray performance can be optimized, but the ease of operation is reduced and time is lost during setup
Solution Approach 1:
The spray controller automatically performs device characterization by measuring impedance and power consumption, retrieves appropriate drive signal parameters from its stored library, and configures the optimal spray settings without user intervention. This self-configuration capability eliminates manual adjustment requirements while ensuring consistent spray performance.
Solution Approach 2:
Optimal drive signal parameters for various spray generator configurations are pre-calculated and stored in the controller's memory during manufacturing. At runtime, the controller simply retrieves the appropriate pre-optimized parameters based on device identification, eliminating the need for users to perform time-consuming manual adjustments.
3Manufacturing precision
If the power level is not controlled, then the device is simpler to manufacture, but spray performance repeatability deteriorates due to power variations
Solution Approach 1:
The spray controller continuously monitors power consumption of the spray generator and dynamically modulates the drive signal parameters (amplitude, pulse width, frequency) to maintain a target power level. This closed-loop power control compensates for manufacturing variations and ensures repeatable spray performance without requiring complex hardware power regulation circuits.
Solution Approach 2:
The system maintains consistent spray power delivery by dynamically adjusting drive signal parameters such as amplitude, frequency, and pulse width based on measured power consumption and impedance. This parameter modulation approach achieves precise power control through software algorithms rather than complex hardware regulation mechanisms.
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 approach significantly reduces variation in spray performance, improving repeatability and reliability by accounting for device-specific characteristics and manufacturing tolerances, leading to a more consistent flow rate and improved user experience.
Implementation Method 1
The spray generator includes a perforate membrane which vibrates ultrasonically in response to a drive signal
Implementation Method 2
means for measuring at least one operational parameter of the spray generator
Implementation Method 3
such spray generators often have a resonant frequency at which energy is efficiently transferred to the perforate membrane and hence to the liquid
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
An electronic spray device comprising a spray generator and a spray controller for providing a drive signal to the spray generator, wherein the spray generator includes a perforate membrane which vibrates ultrasonically in response to the drive signal, said vibration causing liquid droplets to be ejected from one side of the perforate membrane, wherein the spray controller is adapted to modulate the drive signal sent to the spray generator, wherein such modulation of the drive signal is arranged to set the mean power level supplied to the spray generator to a target level.