Spray Gun Control via Laser Light Barrier
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Solution Overview
Problem
Traditional spraying systems for hides and similar materials face challenges in efficiently controlling the activation of spray guns due to irregular shapes and dimensions, leading to waste and increased maintenance, with calibration difficulties caused by varying switching times and interference from rebound vortices, resulting in unsatisfactory quality and economic losses.
Innovation Solution
A control apparatus using a light source to generate a laser beam that illuminates the spray pattern, combined with an image sensor to capture and process images, allowing for continuous monitoring and automatic adjustment of spray gun operation, enabling quick identification of malfunctions and preventive maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If photocells or sensors are used to measure switching time of spray guns, then switching time can be detected, but the calibration becomes laborious and unreliable due to positioning difficulties and interference from rebound vortices
Solution Approach 1:
A light barrier is introduced as an intermediary element between the spray gun and the sensor. The light barrier converts the difficult-to-detect spray pattern presence into a clean optical interruption signal, eliminating the need for complex photocell positioning and making the switching time measurement reliable and easy to calibrate.
Solution Approach 2:
The mechanical/sensor-based detection of spray pattern presence is replaced with an optical detection system. Instead of using photocells that require precise positioning near the spray pattern, a light barrier with optical sensor provides contactless, interference-free detection of the spray gun activation timing.
2Measurement precision
If periodic calibration is performed to compensate for wear and fouling of spray guns, then measurement accuracy is maintained, but production time is lost and labor costs increase
Solution Approach 1:
The system performs automatic self-calibration by using the light barrier to detect the actual switching time of each spray gun during normal operation. The control unit automatically adjusts the timing parameters based on detected deviations, eliminating the need for manual calibration interventions and maintaining continuous production without downtime.
Solution Approach 2:
The light barrier provides continuous feedback on the actual switching time of spray guns. The control unit processes this feedback and automatically adjusts timing parameters to compensate for wear and fouling, enabling real-time adaptation without stopping production or requiring manual calibration.
3Adaptability or versatility
If spray guns are operated with anticipated activation commands, then the irregular shape of hides can be accommodated, but switching time variations cause inconsistent spray patterns and quality defects
Solution Approach 1:
The system dynamically adjusts the switching time of each spray gun based on real-time detection from the light barrier. Instead of using fixed anticipated activation commands, the control unit modifies timing parameters on-the-fly to account for variations in spray gun performance, ensuring consistent spray patterns while maintaining adaptability to irregular hide shapes.
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
The apparatus ensures reliable and efficient operation of spray guns, reduces waste, and provides real-time monitoring and certification of the spraying process, facilitating easier calibration and maintenance while maintaining high-quality results.
Implementation Method 1
a light source (30) arranged to face towards said spray pattern (22) and generate at least one light beam (32) directed to cross said spray pattern (22) thus defining an intersection zone (31)
Implementation Method 2
an image sensor (24) arranged to face towards said intersection zone (31) of said spray pattern (22) and obtain at least an image of said intersection zone (31) of said spray pattern (22)
Data Source
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AI summary
Improved control apparatus (1) for a plant (100) or a spraying device, said plant (100) or device comprising at least one spray gun (14) configured to spray a treatment liquid on at least one product (8) to be treated by generating a corresponding spray pattern (22), said apparatus comprises: - at least one light source (30) arranged to face towards said spray pattern (22) and configured to generate at least one electromagnetic radiation beam (32) directed to cross said spray pattern (22) thus defining an intersection zone (31); - at least one image sensor (24) arranged to face towards said intersection zone (31) of said spray pattern (22) and configured to acquire at least an image of said intersection zone (31) of said spray pattern (22), - a processing unit in data link with said image sensor (24) which receives said at least one image captured by said at least one image sensor (24), said processing unit being configured to process the image (24) thus received, preferably so as to calculate and / or define the characteristics and / or the quality of said spray pattern (22) and / or to send the received and / or processed image to a display device in which it is presented to the operator; characterized by the fact that said laser beam generated by said light source (30) comprises a first wavelength and by the fact that said image sensor (24) comprises at least one optical filter adapted to prevent the detection of electromagnetic radiation comprising second wavelength different from said first wavelength of said laser beam.