Spray Gun Sensor Kit for Real-Time Coating Thickness Control
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Solution Overview
Problem
Spray painting requires significant skill to achieve consistent layer thickness, and existing technologies do not effectively assist in optimizing the application process for varying coating properties and environmental conditions.
Innovation Solution
A sensor kit for a spray gun that includes a housing with a connection module, a sensor module to obtain spray job parameter values, a processing unit to compare these values to reference parameters, and a user feedback module to provide real-time adjustments, utilizing proximity, orientation, and movement sensors to optimize coating application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If spray painting is performed manually by an operator, then the coating application can be completed, but the layer thickness consistency deteriorates due to lack of skill
Solution Approach 1:
The patent implements real-time feedback through optical sensors that monitor the distance between the spray gun and the work surface. This feedback is processed to provide visual indications to the operator, enabling continuous adjustment of spraying parameters to maintain consistent layer thickness without requiring extensive operator skill.
Solution Approach 2:
The patent replaces manual skill-based control with an automated optical measurement and feedback system. The mechanical judgment and manual adjustment previously required from skilled operators are substituted by an automated system using optical sensors, processors, and visual feedback mechanisms.
2Manufacturing precision
If optical sensors and processing systems are added to the spray gun, then coating application precision is improved, but device complexity increases
Solution Approach 1:
The patent combines multiple functional components (optical sensors, processing unit, memory, and visual feedback mechanisms) into an integrated sensor kit that attaches to the spray gun. This merging of functions into a single modular unit reduces the overall system complexity compared to having separate independent components.
Solution Approach 2:
The patent introduces a processing unit as an intermediary between the optical sensors and the visual feedback display. This intermediary component simplifies the system architecture by centralizing data processing, comparison with reference values, and control signal generation in a single dedicated unit.
3Manufacturing precision
If real-time visual feedback is provided to the operator, then coating quality is improved, but information processing requirements increase
Solution Approach 1:
The patent implements partial processing by comparing only the measured distance values against reference values stored in memory, rather than processing all possible parameters. The visual feedback provides selective information about distance compliance with predetermined criteria, rather than displaying all raw sensor data.
Solution Approach 2:
The patent performs preliminary action by storing reference values in memory before the spraying operation begins. This allows the processing unit to quickly compare real-time measurements against pre-stored standards without requiring complex real-time calculations, reducing the information processing load during actual coating application.
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 sensor kit enables less skilled operators to achieve consistent and high-quality coatings by providing real-time feedback, adapting to different coating properties and environmental conditions, and allows for data analysis to improve spraying techniques.
Implementation Method 1
The proximity sensor may comprise an optical transmitter arranged to emit an emitted optical signal and an optical receiver for receiving a reflected optical signal as a reflection of the emitted optical signal
Implementation Method 2
a user feedback module, arranged to generate a user feedback signal based on at least part of the comparison data signal
Data Source
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AI summary
A sensor kit (100) is provided to be used with a spray gun (200). The sensor kit (100) may acquire relevant data while the spray gun (200) is being used, and provide feedback to the user of the spray gun (200) on particular parameters of the spray job such that the user in real-time can adjust his method of spraying. Furthermore, the feedback may be adjusted for different types of coatings using pre-determined data related to a specific coating. Even further, the obtained data during spraying may be sent to a remote server where data may be collected of a plurality of spray jobs using a particular type of coating. Using the obtained data during spraying, it may be possible to reconstruct what the applied coating looks like, and/or what the surface looked like on which the coating has been applied.