Spray Gun Air Pressure Measurement via Membrane Sensor
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Solution Overview
Problem
Existing spray guns, particularly hand-held pressurized air atomization paint spray guns, are unable to accurately measure the actual spray pressure, leading to suboptimal painting results due to approximate pressure measurements.
Innovation Solution
Incorporating a device, such as a pressure sensor, to detect and display the air pressure within the air chamber of the spray gun, which can be connected to a control or feedback system to adjust and maintain target pressure values, and using a method to determine the air pressure by measuring variances between internal and external pressures to calculate the precise air pressure within the air chamber.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional pressure measurement methods are used in spray guns, then the device structure remains simple, but the measurement precision of air pressure is insufficient
Solution Approach 1:
A membrane element is introduced as an intermediary between the air chamber and the pressure sensor. The membrane transmits pressure changes from the air chamber to the sensor while maintaining structural integrity and enabling accurate measurement without direct contact between the sensor and the high-pressure air flow
Solution Approach 2:
The patent replaces conventional mechanical pressure measurement methods with a sensor-based detection system. The pressure sensor, connected through the membrane element, converts mechanical pressure into electrical signals for precise measurement and electronic display, eliminating the need for complex mechanical gauge mechanisms
2Measurement precision
If pressure sensor and membrane element are added to measure internal air pressure, then measurement precision improves, but device complexity increases
Solution Approach 1:
The pressure sensor and membrane element are integrated directly into the air chamber structure. The sensor is positioned to detect pressure changes within the air chamber through the membrane, combining multiple functions (pressure detection, signal conversion, and display) into a unified system that minimizes additional components
Solution Approach 2:
The system automatically detects and displays pressure values without requiring manual intervention. The sensor continuously monitors the air pressure in the air chamber and the control unit processes and displays the data in real-time, enabling self-regulating operation that simplifies user interaction despite the added complexity of the measurement system
3Manufacturing precision
If accurate pressure measurement is implemented, then atomization quality improves, but manufacturing complexity increases
Solution Approach 1:
The membrane element and pressure sensor are pre-positioned and integrated into the air chamber structure during manufacturing. The control unit is pre-programmed with the characteristics of the membrane-sensor system, allowing the complete pressure measurement and control system to be assembled as a integrated unit, thereby reducing assembly complexity despite the enhanced manufacturing precision achieved
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 allows for precise determination and display of the air pressure within the spray gun, enhancing the quality of atomization and painting results by ensuring accurate pressure control, thereby improving the efficiency and consistency of the spraying process.
Implementation Method 1
a device for detecting an air pressure, in particular a pressure sensor
Implementation Method 2
The atomization air, which in the nozzle assembly described above generates a negative pressure on the end face of the paint nozzle, as a result of which the material to be sprayed is suctioned out of the paint nozzle
Implementation Method 3
The material to be atomized is fed to the atomization air and shredded so as to form threads and strips. These threads and strips disintegrate by virtue of their hydrodynamic instability, the interaction between the rapidly flowing compressed air and the ambient air, as well as by virtue of aerodynamic disturbances, to form droplets
Implementation Method 4
the so-called horn air exiting the horn air bores can influence the air that has already exited the annular gap, or the paint jet or the paint mist which has already been at least partially created, respectively. As a result, the paint jet, or else the spray jet, with an originally circular cross section (round jet) is compressed on the sides of said jet that face the horns and is elongated in the direction perpendicular thereto
Data Source
AI summary
A spray gun, in particular a pressurised air atomisation paint spray gun, in particular a hand-held pressurised air atomisation paint spray gun has at least one material nozzle for discharging a material to be sprayed, at least one air nozzle for outputting air, in particular air for atomising a material to be sprayed, air for changing the shape of a spray jet, and/or air for transporting an atomised spraying medium, and at least one air chamber, in particular an air chamber adjoining the air nozzle or at least one air outlet opening of the air nozzle in the upstream direction, for supplying the air nozzle with air. The spray gun also has at least one device for inputting and/or adjusting and/or detecting and/or determining and/or displaying the air pressure in the air chamber during operation of the spray gun.