Patent Application
20230278055
A fluid spraying system may be used by an operator to deliver a fluid from a fluid source to an application area. For example, paint may be sprayed, or otherwise applied, by an applicator, such as a spray gun, to an application area, such as a surface of a wall. In order to deliver the different fluids from the fluid source to the application area, a conveyance system, such as a pump, can be used to convey the fluid from the fluid source, under pressure, through a fluid passageway and out of an outlet of the applicator to be applied to the application area.
The discussion above is merely provided for general background information and is not intended to be used as an aid in determining the scope of the claimed subject matter. The claimed subject matter is not limited to implementations that solve any or all disadvantages noted in the background.
A handheld fluid spraying system includes a pump assembly configured to provide a pressurized liquid and a handheld fluid sprayer. The handheld fluid sprayer comprises a fluid inlet configured to receive the pressurized liquid, a spray tip having an outlet through which the pressurized liquid exits the handheld fluid sprayer to be applied to a surface, a trigger configured to control flow of the liquid through the handheld fluid sprayer, and a sensor configured to detect the liquid and to generate sensor data indicative thereof, the sensor being selected from the group consisting of an infrared (IR) sensor, a thermal imager, and a UV sensor. The handheld fluid spraying system further comprises a controller configured to determine a characteristic of the liquid based on the sensor data and to generate a control output based on the determined characteristic.
For the sake of illustration, but not by limitation, aspects of the present disclosure relate to liquid applicators. While examples below are illustrated in the context of paint, it is noted that the present features can also be applicable to systems that apply other types of liquids as well. Additionally, while examples below are illustrated in the context of spray pumps, it is noted that the present features can also be applicable to paint brushes, rollers, etc.
Many fluid delivery systems employ spray pumps that are designed to pressurize a fluid, such as paint, to spray a coating of the fluid onto a desired surface. Typically, spray pumps pressurize the fluid and an applicator, such as a spray tip, sprays the fluid onto the surface at varying spray angles which determine the area of the surface that gets applied with fluid. In operation, it is difficult to determine the spray edges and spray coverage of the applied fluid apart from visual observation, such as visual observation by an operator. This becomes increasingly difficult as more fluid is applied, especially in cases where the surface and fluid have the same or similar features (e.g., color, finish). Further, spray pumps often are used in the application of other types of fluids onto surfaces of interest. For example, disinfectants are often coated onto surfaces in order to neutralize possible contaminants. Due to the transparent appearance of these disinfectants, it is difficult to observe the spray edges and/or spray coverage by eyesight or camera view alone. Therefore, it is desired to have a system that allows a user or operator to determine spray characteristics, such as spray edges (e.g., locations of spray edges) and the spray coverage, of a liquid applied by the fluid delivery system to provide, for example, a desired coating of liquid onto the surface.
Spraying system 200 illustratively includes one or more controllers 212 configured to control subsystems 214. Subsystems 214 may include, for example, one or more pumps 216, one or more valves 218, etc. Additionally, subsystems 214 may include other types of subsystems as well, such as various actuators (some examples of which are described elsewhere herein) as indicated by block 222. Controller 212 is configured to identify characteristics based on the spray characteristics detected by sensors 202. For example, controller 212 may receive information by sensors 202 relating to liquid application, spray edges (e.g., locations of spray edges), spray density (e.g., thickness), spray angles, etc. In operation, controller 212 identifies characteristics of the spray produced by system 200 based on sensors 202 and responsively generates an output. The output may be, for example, an indication to an operator to move closer or further from the surface. In another example, the output may be providing an indication of the spray edges (e.g., locations of spray edges) of the liquid to the operator. Alternatively, the output may be a signal provided to controllers 212 to adjust controllable subsystems 214 based on the spray characteristics detected by sensors 202. In one example, controller 212 is or includes a microprocessor.
Additionally, spraying system 200 may include one or more applicators, such as a sprayer (e.g., a spray tip, a spray gun having a spray tip, etc.) some examples of which are provided herein. Spraying system 200 can include various other items as well, as indicated by block 213.
In one embodiment, prior to the operation of spraying system 200, environmental characteristic data indicative of environmental conditions can be utilized as a calibrating factor. For example, in the case where fluid application occurs outdoors, environmental characteristic data may be acquired pertaining to, for example, temperature, wind, humidity, etc. In one embodiment, spraying system 200 may comprise an ambient temperature sensor (not shown—but may be part of other sensors 210). However, in other embodiments, other temperature sensors may be utilized as well. For example, a temperature sensor could be placed externally in the environment to gather environmental characteristic data and could wirelessly communicate the characteristic data to system 200. In another embodiment, a user interface (UI) included in system 200 (not shown) could include a temperature sensor for obtaining the environmental characteristic data.
During operation, sensor 510 gathers sensor data at the spray site, which is received and processed by controller 522 to identify spray characteristics based on the received sensor data. Spray characteristics may include, for example, a determination of the spray edges (e.g., locations of spray edges). Additionally, the identified characteristics may include spray angle, spray density (e.g., spray thickness), spray coverage, etc. Upon identification of the characteristics of interest, a control signal may be sent by controller 522 to control operation of system 500. For example, the control signal may include an indication to change location, in which controller 522 causes propulsion system 516 to rotate wheels 504 or cause actuator(s) 515 to drive movement of robotic arm 506 and sprayer 508, or both. Additionally, the control signal may include, in one example, a signal provided to the other controllable subsystems to adjust their operation. For example, a control signal may be sent to pump(s) 512 or valve(s) 514, or both, to alter their operation. Additionally, it is expressly contemplated that other control signals may be sent by controllers 522 as well. In one embodiment, the control signal may include controlling subsequent passes of sprayer 500 based on detected spray edges. For example, the control signal may indicate to sprayer 500 to, in a subsequent pass, overlap the spray edges of a previous pass, with an additional spray to ensure adequate fluid coverage on the surface. In operation, various conditions may impact the straightness of the spray edges. For example, wind conditions may result in the spray edge not being in a uniform line. Additionally, the spray tip may be blocked, resulting in an irregular spray edge. Thus, by detecting the spray edges (e.g., detecting the locations of spray edges), sprayer 500 can undergo subsequent passes and achieve the necessary overlap to ensure a proper fluid coat is applied. For example, it may be desired to overlap 50% (or half) of a previous pass with a subsequent pass. In this way, each portion of the surface gets double coated. Other desired overlap parameters (e.g., other percentage overlaps) are contemplated herein.
As illustrated in
In one example, spray sensing application 708 can interact with an imaging sensor (e.g., camera) on device 700, as represented by input mechanism 710. Input mechanism 710 may comprise, for example, a camera application that allows a user to access and control a camera associated with device 700. The camera may be, for example, an IR camera. However, in other embodiments, a thermal or UV camera may be utilized as well. A user, using the spray sensing application 708, can, in one example, scan and/or capture an image of a surface of interest (e.g., a wall) on which a liquid spray has been recently applied. Application 708 can, based on the scan and/or captured image, detect spray characteristics via the camera and identify the spray characteristics (e.g., via controller(s), etc.). The spray characteristics may include, for example, an indication of spray edges (e.g., locations of spray edges). In another example, the spray characteristics may include an indication of the spray angle, spray coverage, spray density (e.g., spray thickness), etc. Spray sensing application 708 can include and/or display various display elements and/or user input mechanisms. For example, application 708 can include user input mechanisms that allow a user to view spray edges on the surface in real time (or near real time), and/or provide recommendations to the user based on the identified spray characteristics. In another example, spray coverage, spray density (e.g., spray thickness), spray angle, etc. may be viewed. The recommendations may include, for example a suggestion to move location, provide an additional spray coating, etc.
Additionally, in other embodiments, sensing application 708 can interact with imaging sensor 700 to detect fluid edges of a liquid applied on a surface in operations other than spraying. For example, device 700 may detect the edges of a fluid applied by, for example, a paint roller. In another example, device 700 may detect the edges of a fluid applied by a brush.
In one example operation, a user may use a sensor-based fluid sprayer to spray a surface of interest and additionally receive characteristics relative to the applied area detected by the one or more sensors described above. For example, as shown in image 800, spray characteristics may be obtained by the one or more sensors to indicate the edge of the fluid applied onto the surface. Additionally, information relating to fluid coverage, fluid density (e.g., fluid thickness), and fluid angle may also be obtained via the information collected from image 800.
In operation, the sensor may obtain data relative to the area applied with fluid by the roller and/or brush. In this way, fluid edges, coverage (e.g., area of coverage), density (e.g., thickness), etc. may be identified, indicative of fluid rolled and/or brushed on the surface. For example, the sensor may be disposed within a mobile device, wherein a user operates the mobile device to obtain a sensor image after applying fluid onto the surface. Additionally, it is expressly contemplated that other modes of fluid sensing may be utilized as well.
The operation proceeds at block 310 where one or more characteristics of the fluid are identified based on the sensor data. Characteristics of the fluid (e.g., spray characteristics) may include, for example, a determination of the edges 312 (e.g., spray edges (e.g., locations of spray edges)). For example, in the case where an IR sensor is utilized, the edges (e.g., locations of edges) may be identified based on a temperature difference in the sensor data between the applied (e.g., sprayed) fluid and the surface of interest. Additionally, or alternatively, the identified characteristics may include one or more of application (e.g., spray) angle 314, application (e.g., spray) density 316 (or application (e.g., spray) thickness), or application (e.g., spray) coverage 318. Further, it is expressly contemplated that other characteristics of the fluid may be identified as well, as indicated by block 320.
The operation proceeds at block 330 where one or more control signals are generated based on the identified characteristics. The control signal(s) may include, in one example, a signal provided to one or more subsystems 332 to adjust their operation. For example, a control signal may be sent to a pump of the spraying system to alter its operation. Additionally, the control signal may include controlling movement of the spraying system, as indicated by block 334. This example is particularly useful in cases where the spraying system utilizes robotic (or autonomous or semi-autonomous) operation. Further, the control signal may include providing an indication to a user, as indicated by block 336. The indication may be, for example, a display of the identified characteristics of the spray. Additionally, the control signals may include user recommendations 338, indicating to a user or operator how to adjust operation in order to improve spray characteristics. For example, the control signal may be a recommendation to the operator to move closer to or further from the surface. In another example, the control signal may include a recommendation to the operator to change the spray tip. Additionally, the generated control signals may include some other type of signal as well, as indicated by block 340. In one embodiment, the control signal may include controlling subsequent passes of the sprayer based on detected spray edges (e.g., locations of spray edges). For example, the control signal may control the position or movement, or both, of the sprayer to control the overlap of a previous pass with a subsequent pass.
At least some examples are described herein in the context of applying a coating material, such as paint, to a surface. As used herein, paint includes substances composed of coloring matter or pigment suspending in a liquid medium as well as substances that are free of coloring matter or pigment. Paint can also include preparatory coatings, such as primers. Paint can be applied to coat a surface as a liquid or a gaseous suspension, for example, and the coating provided can be opaque, transparent, or semi-transparent. Some particular examples include, but are not limited to, latex paint, oil-based paint, stain, lacquers, varnish, inks, and the like. At least some examples can be applied in plural components systems.
Additionally, while a particular order of steps has been described for the sake of illustration, it is to be understood that some or all of these steps can be performed in any number of orders.
It should also be noted that the different examples described herein can be combined in different ways. That is, parts of one or more examples can be combined with parts of one or more other examples. All of this is contemplated herein.
Although the subject matter has been described in language specific to structural features and/or methodological acts, it is to be understood that the subject matter defined in the appended claims is not necessarily limited to the specific features or acts described above. Rather, the specific features and acts mentioned above are disclosed as example forms of implementing the claims.
The present application is based on and claims the benefit of U.S. provisional patent application Ser. No. 63/315,139, filed Mar. 1, 2022, the content of which is hereby incorporated by reference in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 63315139 | Mar 2022 | US |
