Spray Gun Status Display for Real-Time Fluid Ratio Monitoring
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Solution Overview
Problem
In fluid delivery systems like Spray Polyurethane Foam (SPF) systems, operators lack real-time access to critical system information and control due to the remote location of proportioning systems, leading to potential errors in fluid ratio, temperature, and pressure, which can result in suboptimal foam quality and increased downtime.
Innovation Solution
A status indicator system with a processor that provides visualization of system status to the operator via a display, integrated with the spray gun, allowing for real-time monitoring and control of fluid ratio and temperature, using a proportioner system connected via smart hoses with embedded sensors and actuators, and wearable displays for immediate feedback.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the proportioner system is located at a distance from the spray gun to improve workspace accessibility, then the operator can access the work area more easily, but the operator loses real-time access to system status information and control
Solution Approach 1:
The patent introduces an intermediary communication system consisting of smart hoses with embedded sensors and wireless transmitters that relay system status information (fluid ratio, temperature, pressure) from the remote proportioner system to the operator's spray gun or wearable display, allowing the operator to monitor and control parameters without being physically present at the proportioner system
Solution Approach 2:
The patent replaces the mechanical/physical presence requirement with an electronic information transmission system, where wireless communication and display technologies substitute for the operator needing to physically access the proportioner system to obtain status information
2Object-affected harmful factors
If the proportioner system is located remotely to improve safety and separation, then operator safety is improved, but response time for detecting and correcting system errors increases
Solution Approach 1:
The patent implements a real-time feedback system where sensors in the smart hoses continuously monitor fluid ratio, temperature, and pressure parameters, and immediately transmit status information to the operator via wireless communication or wearable displays, enabling rapid detection and correction of system errors without compromising operator safety through physical separation
Solution Approach 2:
The system provides self-monitoring capabilities through embedded sensors and automatic status reporting, allowing the remote proportioner system to actively communicate its own status without requiring operator presence, thus maintaining both safety and rapid response time
3Manufacturing precision
If real-time monitoring and control systems are added to provide immediate status information, then operator awareness and foam quality are improved, but system complexity increases
Solution Approach 1:
The patent integrates multiple functions into the smart hose assembly, which serves as both a fluid delivery conduit and a monitoring platform with embedded sensors for temperature, pressure, and flow rate measurement, eliminating the need for separate monitoring equipment and reducing overall system complexity
Solution Approach 2:
The patent combines the display and control interface directly with the spray gun or wearable device, merging the monitoring and control functions into tools the operator already has in hand, rather than requiring separate stationary display systems at the proportioner location
Data Source
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AI summary
A fluid delivery system (10) includes a status indicator (70, 72) and control system (36) comprising a processor (40). The processor is configured to receive a first signal indicative of a first status of operations of a spray application system. The processor is further configured to provide to an operator of a spray gun (28), via a display system (70, 72), a visualization representative of the first status of operations, and techniques to control the fluid delivery system, wherein the spray application system is configured to deliver at least one fluid (A, B) to the spray gun during operations.