Spray Nozzle Monitoring With Real-Time Networked Pattern Feedback
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Solution Overview
Problem
Current spray pattern monitoring and management systems are expensive and complex, making them unsuitable for field configurations in various applications, as they require offline testing and optimization in controlled settings, which is time-consuming and not feasible for many spraying applications.
Innovation Solution
A network-based spray application management system that includes a spray scan data server and a spray nozzle monitoring apparatus, which sends process variable data via a network interface for storage and analysis, enabling real-time feedback and optimization of spray nozzle configurations and material properties in the field.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If high precision measuring devices are used for spray pattern monitoring, then measurement precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent uses a camera to capture images of the spray pattern, creating a visual copy of the spray distribution. This optical copying approach replaces complex mechanical measuring devices while maintaining measurement capability through image analysis of the spray pattern geometry and distribution.
2Manufacturing precision
If offline testing and optimization are conducted in controlled settings, then manufacturing precision is improved, but loss of time increases
Solution Approach 1:
The system provides real-time visual feedback of spray patterns through captured images, allowing immediate assessment and adjustment of spray configurations. This feedback loop eliminates the need for lengthy offline testing by enabling on-the-spot optimization decisions based on actual spray pattern observations.
Solution Approach 2:
The system captures and analyzes spray pattern images before final application decisions are made, allowing preliminary assessment and optimization of spray configurations. This preliminary visualization enables users to evaluate spray patterns and make adjustments before committing to particular spray settings or material applications.
3Measurement precision
If complex testing procedures are implemented, then measurement precision is improved, but ease of operation deteriorates
Solution Approach 1:
The camera creates a visual copy of the spray pattern that can be directly observed and analyzed without complex measurement procedures. Users can visually assess spray distribution, coverage, and pattern geometry from the captured images, eliminating the need for complicated testing protocols while maintaining analytical capability.
Data Source
AI summary
A networked spray application management arrangement is described herein. The spray application management arrangement includes a spray scan data server and a spray application. The spray scan application, in turn, includes: a spray nozzle monitoring apparatus that renders a process variable data indicative of a current status of a spray nozzle system; and a first network interface that sends a message comprising a data payload comprising information corresponding to the process variable data to the spray scan data server. The spray scan data server includes: a second network interface for receiving the message; a spray scan database for storing the information corresponding to the process variable data; and a spray scan data analysis engine.