WO2017222666A1 - Détection de limite de piston et commande logicielle pour application de fluide - Google Patents

Détection de limite de piston et commande logicielle pour application de fluide Download PDF

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Publication number
WO2017222666A1
WO2017222666A1 PCT/US2017/032084 US2017032084W WO2017222666A1 WO 2017222666 A1 WO2017222666 A1 WO 2017222666A1 US 2017032084 W US2017032084 W US 2017032084W WO 2017222666 A1 WO2017222666 A1 WO 2017222666A1
Authority
WO
WIPO (PCT)
Prior art keywords
piston
controller
sensor
delivery system
liquid delivery
Prior art date
Application number
PCT/US2017/032084
Other languages
English (en)
Inventor
Daniel ZIENTARA
Lam Nguyen
Jonathan SCHAUMANN
Original Assignee
Wagner Spray Tech Corporation
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from US15/468,611 external-priority patent/US10941762B2/en
Application filed by Wagner Spray Tech Corporation filed Critical Wagner Spray Tech Corporation
Priority to CN201780037405.4A priority Critical patent/CN109475886B/zh
Priority to EP17815861.4A priority patent/EP3452228A4/fr
Publication of WO2017222666A1 publication Critical patent/WO2017222666A1/fr

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05B—SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
    • B05B12/00—Arrangements for controlling delivery; Arrangements for controlling the spray area
    • B05B12/08—Arrangements for controlling delivery; Arrangements for controlling the spray area responsive to condition of liquid or other fluent material to be discharged, of ambient medium or of target ; responsive to condition of spray devices or of supply means, e.g. pipes, pumps or their drive means
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05B—SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
    • B05B9/00—Spraying apparatus for discharge of liquids or other fluent material, without essentially mixing with gas or vapour
    • B05B9/03—Spraying apparatus for discharge of liquids or other fluent material, without essentially mixing with gas or vapour characterised by means for supplying liquid or other fluent material
    • B05B9/04—Spraying apparatus for discharge of liquids or other fluent material, without essentially mixing with gas or vapour characterised by means for supplying liquid or other fluent material with pressurised or compressible container; with pump
    • B05B9/0403—Spraying apparatus for discharge of liquids or other fluent material, without essentially mixing with gas or vapour characterised by means for supplying liquid or other fluent material with pressurised or compressible container; with pump with pumps for liquids or other fluent material
    • B05B9/0409—Spraying apparatus for discharge of liquids or other fluent material, without essentially mixing with gas or vapour characterised by means for supplying liquid or other fluent material with pressurised or compressible container; with pump with pumps for liquids or other fluent material the pumps being driven by a hydraulic or a pneumatic fluid
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
    • F04B1/00—Multi-cylinder machines or pumps characterised by number or arrangement of cylinders
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
    • F04B17/00—Pumps characterised by combination with, or adaptation to, specific driving engines or motors
    • F04B17/06—Mobile combinations
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
    • F04B49/00—Control, e.g. of pump delivery, or pump pressure of, or safety measures for, machines, pumps, or pumping installations, not otherwise provided for, or of interest apart from, groups F04B1/00 - F04B47/00
    • F04B49/02—Stopping, starting, unloading or idling control
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
    • F04B49/00—Control, e.g. of pump delivery, or pump pressure of, or safety measures for, machines, pumps, or pumping installations, not otherwise provided for, or of interest apart from, groups F04B1/00 - F04B47/00
    • F04B49/06—Control using electricity
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
    • F04B49/00—Control, e.g. of pump delivery, or pump pressure of, or safety measures for, machines, pumps, or pumping installations, not otherwise provided for, or of interest apart from, groups F04B1/00 - F04B47/00
    • F04B49/06—Control using electricity
    • F04B49/065—Control using electricity and making use of computers
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
    • F04B2201/00—Pump parameters
    • F04B2201/02—Piston parameters
    • F04B2201/0201—Position of the piston
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
    • F04B9/00—Piston machines or pumps characterised by the driving or driven means to or from their working members
    • F04B9/02—Piston machines or pumps characterised by the driving or driven means to or from their working members the means being mechanical
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F04—POSITIVE - DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS FOR LIQUIDS OR ELASTIC FLUIDS
    • F04B—POSITIVE-DISPLACEMENT MACHINES FOR LIQUIDS; PUMPS
    • F04B9/00—Piston machines or pumps characterised by the driving or driven means to or from their working members
    • F04B9/08—Piston machines or pumps characterised by the driving or driven means to or from their working members the means being fluid
    • F04B9/10—Piston machines or pumps characterised by the driving or driven means to or from their working members the means being fluid the fluid being liquid
    • F04B9/103—Piston machines or pumps characterised by the driving or driven means to or from their working members the means being fluid the fluid being liquid having only one pumping chamber
    • F04B9/105—Piston machines or pumps characterised by the driving or driven means to or from their working members the means being fluid the fluid being liquid having only one pumping chamber reciprocating movement of the pumping member being obtained by a double-acting liquid motor

Definitions

  • Liquid delivery systems are used to deliver fluid from a source location to a delivery location.
  • liquid delivery systems include a pump system configured to provide the liquid at a desired operational pressure.
  • Liquid delivery systems are useful for a variety of fluids, for example paints, primers, and other exemplary fluids.
  • a liquid delivery system comprises a source of fluid coupled to an outlet.
  • the liquid delivery system also includes a hydraulic cylinder coupled to the source of fluid.
  • the hydraulic cylinder has a piston movable between a first limit position and a second limit position during an operational cycle.
  • the hydraulic cylinder is configured to pressurize fluid received from the source of fluid, and deliver the pressurized fluid to the outlet.
  • the liquid delivery system also comprises a rod connected to the piston and extending out of the cylinder.
  • the liquid delivery system also comprises a sensor configured to sense a position of the rod to provide a signal indication of the piston with respect to the first positon or the second position. An indication of the sensed position is provided to a controller, and the controller is configured to send a control signal to initiate a normal operation loop based on the sensed position.
  • FIG. 1 depicts a painting system in accordance with an embodiment of the present invention.
  • FIGS. 2A-2B depict a pump assembly in accordance with an embodiment of the present invention.
  • FIG. 3 depicts an exploded view of a pump assembly in accordance with an embodiment of the present invention.
  • FIGS. 4A-4B depict a cylinder with a limit sensing system in accordance with n embodiment of the present invention.
  • FIGS. 5A-5B depict exploded and assembled views of an planetary roller screw drive in accordance with an embodiment of the present invention.
  • FIGS. 6A-6B depict a planetary roller screw drive with a limit sensing system in accordance with an embodiment of the present invention.
  • FIG. 7 depicts a hydraulic circuit in accordance with an embodiment of the present invention.
  • FIG. 8 depicts a system diagram for a liquid dispensing system in accordance with an embodiment of the present invention.
  • FIG. 9 depicts a diagram of a pump system control in accordance with an embodiment of the present invention.
  • FIG. 10 depicts a flow diagram of a method for start-up of a pump control system in accordance with an embodiment of the present invention.
  • the present disclosure relates to liquid pumps, and more specifically, to a limit sensing system used to determine the position of a piston in a liquid delivery system.
  • Position sensing can provide instantaneous analog or digital electronic position feedback information about the piston within a cylinder.
  • aspects of the present disclosure relate to hydraulic powered liquid pumps, more particular aspects relate to a limit sensing system used to determine the position of a piston in a liquid delivery system, and control thereof. While the present disclosure is not necessarily limited to such applications, various aspects of the disclosure may be appreciated through a discussion of various examples using paint as context.
  • the liquid delivery system can include a hydraulic cylinder.
  • the hydraulic cylinder can be a mechanical actuator that distributes a force on a liquid using reciprocating piston strokes.
  • the piston is connected to a piston rod or other suitable structure and movement of the piston causes the reciprocal movement of the piston rod.
  • the cylinder is closed on one end by a cylinder top (hereinafter referred to as the head) and on the other end by a cylinder bottom (hereinafter referred to as the base) where the piston rod comes out of the cylinder.
  • the hydraulic cylinder derives its power from a pressurized hydraulic fluid.
  • an actuator e.g., a solenoid valve
  • a first port e.g., a port near the head hereinafter referred to as the head port
  • pressure builds in the cylinder to force the piston to move from the head, through the cylinder, and to the base.
  • a limit sensing system can be used to detect that the piston has reached the end of its stroke.
  • the limit sensing system can include a magnet and reed switches.
  • the magnet and reed switches may be controlled by a MOSFET (metal-oxide semiconductor field-effect transistor) and flip-flop integrated circuit system, in one example.
  • the limit sensing system is controlled by a processor and integrated software.
  • One advantage of software-based control, with hydraulic pump systems, is the ability to verify sensor functionality and detect a piston location prior to start-up.
  • Integrated software may be configured to start a normal operational loop based on a detected location of the piston within the loop.
  • software-based control also allows for other additional software control features, for example a total cycle counter, real-time cycle rate tracking, real-time gallons-per-minute tracking, total gallons pumped, and / or run-time tracking. Information concerning such features may be downloadable to a separate computing device, for example, allowing for parameter tracking over the lifetime of a system.
  • Software-based control may also comprise live cycle rate counting, which may enable tracking and updating of pump cycles per minute. This may enable performance tracking without additional hardware configured to manually count cycles.
  • the magnet is located on this portion of the piston rod (on the opposite side of the base of the cylinder as the piston), enabling the magnet to remain outside the cylinder as well.
  • the magnetic field created by the magnet causes the reed switch to change state.
  • the reed switch can be connected to an electrical circuit that can feed logic gates that enable the actuator to direct the hydraulic fluid through the valve into a second port (e.g., a port near the base hereinafter referred to as the rod port) located on the cylinder.
  • the reed switch can also be connected, in another example, to a controller, such that data concerning piston location, reed switch state, and magnetic field can be reported and / or stored over time, allowing for system performance tracking.
  • a controller such that data concerning piston location, reed switch state, and magnetic field can be reported and / or stored over time, allowing for system performance tracking.
  • pressure builds in the cylinder to force the piston to move from the base, through the cylinder, and to the head.
  • the hydraulic fluid is forced into the head port, back into the actuator, and returned to a hydraulic fluid reservoir.
  • the magnetic field applied to the reed switch decreases and the reed switch will change its state (open if application of the magnetic field forced it to close and close if application of the magnetic field forced it to open).
  • the piston draws near the head and approaches the second reed switch, its magnetic field causes the second reed switch to change its state.
  • the magnet since the magnet is located on the portion of the piston rod that is outside of the cylinder, the magnet is not exposed to the pressurized hydraulic fluid inside the cylinder. This may protect the magnet from damage and corrosion that could occur from exposure to the hydraulic fluid if the magnet was located in the cylinder (e.g., on the piston). Moreover, if the magnet becomes damaged (e.g., cracked or has depleted magnetic properties), it may need to be repaired or replaced. However, because the magnet is located outside the cylinder, the hydraulic pump does not need to be disassembled to repair or replace the magnet.
  • the reed switches may also be located outside the cylinder.
  • the reed switches, reed switch connectors, and an electrical circuit board may be exposed to paint.
  • the reed switches and the reed switch connectors can be hermetically sealed and the electrical circuit board can be enclosed to protect them from damage, corrosion, and depletion of sensor properties that may be caused from exposure to the paint.
  • a controller may be located proximate the cylinder, in one example, and may be responsible for control of the piston rod. In another example, the controller may be located elsewhere within the pump system, such that commands are generated by the controller, and received by a receiving component proximate the piston rod.
  • FIG. 1 depicts a painting system in accordance with an embodiment of the present invention.
  • Paint system 100 that includes an upper shroud 126, a frame 128, wheels 130, a lower shroud 132, a motor system 102, a solenoid valve (not shown in FIG. 1) under the lower shroud 132, a pump assembly 106, a hydraulic motor 136, and a paint reservoir (not shown).
  • Motor system 102 can be electrically powered, gas powered, etc. and can include a hydraulic pump 140 under lower shroud 132 and a hydraulic fluid reservoir (not shown in FIG. 1) also under lower shroud 132.
  • the hydraulic pump delivers hydraulic fluid (e.g., oil) from the hydraulic fluid reservoir to the solenoid valve.
  • hydraulic fluid e.g., oil
  • the solenoid valve can be an electromechanical device that includes a solenoid, a head port on the valve body and a rod port on the valve body.
  • the head port on the valve body and the rod port on the valve body can be controlled by an electric current through the solenoid.
  • the solenoid can alternate the flow from the head port on the valve body and the rod port on the valve body.
  • the solenoid is coupled to a controller 140.
  • the controller comprises a MOSFET and flip-flop integrated circuit system.
  • the solenoid is controlled by a computer processor and integrated software, for example a circuit board.
  • the circuit board may be communicably coupled, directly to the solenoid.
  • the controller is also coupled to a memory, such that the controller can report, or store, collected information from a cycle counter and / or a run-time tracker. The controller may be useful to measure performance of the pump system without manual cycle counting.
  • pump assembly 106 includes a hydraulic cylinder 114 and a paint pump 1 16.
  • the solenoid valve directs the hydraulic fluid, generated by the hydraulic pump, through the head port on the valve body to a head port 122 of hydraulic cylinder 114.
  • pressure builds in the cylinder and forces the hydraulic piston to move.
  • the hydraulic piston moves through cylinder, the hydraulic fluid is forced through a rod port 124 of hydraulic cylinder 114, into the solenoid valve through the rod port on the valve body, and returned to the hydraulic fluid reservoir.
  • a hydraulic piston rod (not shown in FIG.
  • a magnet is connected to the hydraulic piston rod.
  • at least two sensors are located outside the cylinder that correspond to the two limit positions of the hydraulic piston at each end of its stroke, hereinafter referred to as a stroke limit position.
  • the sensor can be a reed switch.
  • a reed switch is an electrical switch operated by an applied magnetic field. It may consist of a pair of contacts on reeds in a hermetically sealed airtight envelope constructed from a suitable material, such as glass or plastic.
  • the contacts can be open, making no electrical contact. The switch can be closed by bringing the magnet near the switch. Once the magnet is pulled away, the reed switch will open again. In other embodiments, the contacts can be closed and the switch can be opened by bringing the magnet near the switch. Once the magnetic field is removed, the reed switch closes.
  • one or more limit sensors are coupled to a controller (not shown in FIG. 1).
  • the controller may, using the one or more limit sensors, detect a position of the piston rod. Detecting a position of the piston rod, during start-up for example, may be helpful to start a normal operation loop. In some previous systems, uncertainty in piston-location can make starting a normal operation loop difficult.
  • the piston may be mid-stroke, topped out, bottomed out, etc.
  • the software-controlled controller may be able to detect a location of the piston, and engage a corresponding operation loop.
  • the controller may also be configured to track cycles, for example by updating a cycle-rate count after each completed cycle, and run-time for the pump system. This may allow for calculation of performance parameters without adding additional hardware to the pump system to manually count cycles.
  • the electrical circuit can provide a voltage or other suitable indication that activates a set of metal oxide semiconductor field effect transistors (MOSFETs) and flip-flop integrated circuit, or other suitable switching devices, to change the state of the solenoid.
  • the controller comprises integrated software configured to change the state of the solenoid.
  • the hydraulic fluid can now be released from the rod port on the valve body, into the cylinder through rod port 124 of hydraulic cylinder 1 14.
  • the magnetic field strength with respect to the first reed switch, decreases and the first reed switch opens.
  • the hydraulic fluid can be pushed back through head port 122 of hydraulic cylinder 1 14, into the solenoid valve through the head port on the valve body, and returned to the hydraulic fluid reservoir.
  • the paint piston rod can then move through paint pump 116 and continue to pump paint from the paint reservoir.
  • the magnetic field causes a second reed switch to close, thereby completing the electrical circuit, and reverse the hydraulic fluid flow from the solenoid valve.
  • a hall-effect sensor system can be used to determine when the hydraulic piston has reached the end of a piston stroke.
  • a hall-effect sensor system can include a magnet and a sensor.
  • the hall-effect sensor system can be hermetically sealed or enclosed.
  • the sensor can be a transducer that varies its output voltage in response to an applied magnetic field produced by the magnet.
  • the magnet When the hydraulic piston has reached a stroke limit position, the magnet is located at a position such that its magnetic field is perpendicular with respect to the sensor. The perpendicular magnetic field can induce the output voltage from the sensor that enables the solenoid valve to alternate the flow of the hydraulic fluid.
  • the hall-effect sensor is communicably coupled to a controller, such that the controller can detect a current position of the piston within an operational loop, during start-up, for example.
  • a photoelectric sensor is used to determine that the hydraulic piston has reached a stroke limit position.
  • a photoelectric sensor is a device used to detect the distance, absence, or presence of an object by using a light transmitter and a photoelectric receiver.
  • other sensors can be used that include, but are not limited to, mechanical sensors, base active transducer sensors, eddy-current sensors, inductive position sensors, photodiode array sensors, and proximity sensors.
  • the sensor systems can be hermetically sealed or enclosed to protect them from exposure to the paint.
  • the photoelectric sensor is communicably coupled to a controller, such that the controller can detect a current position of the piston within an operational loop.
  • AMR anisotropic magneto-resistive
  • GMR giant magneto-resistive
  • FIGS. 2A-2B depict a pump assembly in accordance with an embodiment of the present invention.
  • FIG. 2A depicts an outside view of pump assembly 106
  • FIG. 2B depicts an inside view of pump assembly 106.
  • pump assembly 106 includes head port 122 of hydraulic cylinder 1 14, rod port 124 of hydraulic cylinder 1 14, a hose outlet 206, a paint piston rod 208, a paint pump cavity 210, a hydraulic piston rod 212, a hydraulic piston 214, a paint intake 216, a hydraulic cylinder cavity 218, a first reed switch 220, a second reed switch 222, and a magnet 224.
  • An actuator e.g., solenoid valve
  • An actuator directs a hydraulic fluid into hydraulic cylinder cavity 218 through head port 122 of hydraulic cylinder 114.
  • the hydraulic fluid forces hydraulic piston 214 to move down through hydraulic cylinder cavity 218.
  • paint piston rod 208 moves down through paint pump cavity 210 and pushes the paint out hose outlet 206.
  • hydraulic fluid is forced back through rod port 124 of hydraulic cylinder 114, into the solenoid valve and returned to a hydraulic fluid reservoir.
  • magnet 224 when hydraulic piston 214 is at a stroke limit position, magnet 224 causes first reed switch 220 to close and complete an electrical circuit (not shown in FIG. 2B).
  • the electrical circuit provides a voltage or other suitable indication that reverses the state of the solenoid valve and causes the hydraulic fluid to flow into hydraulic cylinder cavity 218 through rod port 124 of hydraulic cylinder 1 14, thereby reversing the direction of piston 214.
  • the hydraulic fluid As piston 214 travels up, the hydraulic fluid is forced back through head port 122 of hydraulic cylinder 114, into the solenoid valve and returned to the hydraulic fluid reservoir. Paint piston rod 208 also moves up through paint pump cavity 210 and draws the paint through paint intake 216.
  • magnet 224 causes second reed switch 222 to close, thereby completing an electrical circuit and reversing the hydraulic fluid flow into hydraulic cylinder cavity 218 through head port 122 of hydraulic cylinder 114.
  • the integrated software controller may allow for parameter-tracking of performance metrics of pump assembly 106.
  • the integrated software controller may comprise a cycle counter configured to track total cycles and run-time over the operational lifetime of assembly 106.
  • FIG. 3 depicts an exploded view of a pump assembly in accordance with one embodiment of the present invention.
  • Pump assembly 106 includes hydraulic cylinder 114, paint pump 116, and sensor cover assembly 304.
  • Sensor cover assembly 304 can prevent paint from entering the area where the paint piston rod (e.g., paint piston rod 208, from FIG. 2) and hydraulic piston rod 212 are coupled together and can prevent paint from reaching magnet 224 and reed switches 220 and 222.
  • sensor cover assembly 304 can include first reed switch 220, second reed switch 222, and a circuit board 330.
  • hydraulic cylinder 114 can include hydraulic cylinder fasteners 306, cylinder 308, piston head wear ring 310, piston head seal 312, hydraulic piston 214, hydraulic piston rod 212, magnet 224, hydraulic piston coupler 318, piston rod seal 324, jam nut 332, and a fluid section block 334.
  • Hydraulic cylinder fasteners 306 securely attaches cylinder 308 to fluid section block 334.
  • Cylinder 308 can include hydraulic cylinder cavity 218, from FIG. 2, head port 122 of hydraulic cylinder 1 14, from FIG. 2, and rod port 124 of hydraulic cylinder 114, from FIG. 2.
  • Piston head wear ring 310 is a ring that fits into a groove on the outer diameter of hydraulic piston 214.
  • Piston head seal 312 can be a dynamic seal. It can be single acting or double acting and it can be made from nitrile rubber, polyurethane, fluorocarbon viton, etc.
  • Jam nut 332 can lock the hydraulic piston coupler onto piston rod 212 and hydraulic piston coupler 318 can attach hydraulic piston rod 212 to a paint piston rod (e.g., paint piston rod 208, from FIG. 2).
  • FIGS. 4A-4B depict a cylinder with a limit sensing system in accordance with an embodiment of the present invention.
  • FIG. 4A depicts a pump assembly 400 that includes hydraulic cylinder 402 in a first position with a limit sensing system, consistent with embodiments of the present disclosure.
  • Hydraulic cylinder 402 can include piston 404, piston rod 406, head 408, base 410, head partition 412, base partition 414, magnet 416, first reed switch 420, and second reed switch 418.
  • the limit sensing system may be coupled to an integrated software controller (not shown in FIG. 4A), in one example, which may serve to detect and control movement of piston rod 406, for example by controlling an on / off state of the solenoid valve.
  • piston 404 is initially located at a stroke limit position, near head 408 and magnet 416 causes first reed switch 420 to change state and complete an electrical circuit (not shown in FIG. 4A).
  • the electrical circuit provides a voltage or other suitable signal to reverse the state of an actuator (e.g., a solenoid valve) and direct hydraulic fluid into cylinder 402 through head partition 412 (as shown by arrow 422).
  • an actuator e.g., a solenoid valve
  • piston 404 is forced away from head 408.
  • first reed switch 420 changes state and the hydraulic fluid is forced back into the actuator through base partition 414 (as shown by arrow 424).
  • FIG. 4B depicts hydraulic cylinder 402 in a second position with a limit sensing system, consistent with embodiments of the present disclosure.
  • Magnet 416 is positioned on piston rod 406 such that when piston 404 moves through cylinder 402 and approaches base 410, magnet 416 approaches second reed switch 418 and causes second reed switch 418 to change state. This will complete an electrical circuit and provide a voltage or other suitable signal to reverse the state of the solenoid valve and thus, reverse the flow of the hydraulic fluid and move piston 404 away from base 410.
  • information about an operation loop is collected by an integrated software controller (not shown in FIG. 4B). Parameter tracking, such as cycle counters and run-time tracking may allow for evaluation of the performance of assembly 400 over time. Additionally, an integrated software controller may allow for determination of a piston location within an operational loop prior to pump start-up.
  • FIGS. 5A-5B depict exploded and assembled views of a planetary roller screw drive in accordance with an embodiment of the present invention.
  • FIG. 5A depicts an exploded view of a planetary roller screw drive 600
  • FIG. 5B depicts an assembled view of the planetary roller screw drive 600, consistent with embodiments of the present disclosure.
  • Planetary roller screw drive 600 includes rod 602, cog 604, rollers 606, roller retainer 608, and tube 610.
  • planetary roller screw drive 600 can be used in place of, or in combination with, a hydraulic cylinder (e.g., hydraulic cylinder 400).
  • Planetary roller screw drive 600 is a mechanical device for converting rotational motion to linear motion.
  • threaded rod 602 provides a helical raceway or thread 612 for multiple rollers 606 radially arrayed around rod 602 and encapsulated by threaded tube 610.
  • the lead for thread 612 is the axial travel for a single revolution.
  • the pitch of thread 612 is defined as the axial distance between adjacent threads of thread 612.
  • Thread 612 of rod 602 typically has the same pitch or corresponding features to the internal thread of tube 610.
  • Rollers 606 spin in contact with, and serve as transmission elements between rod 602 and tube 610.
  • Rollers 606 typically have a single-start thread where a single helical thread is along their length and the lead and pitch are equal. This can limit the friction as rollers 606 contact rod 602 and tube 610.
  • Rollers 606 orbit rod 602 as they spin and rotation of tube 610 results in rod 602 travel, and rotation of rod 602 results in tube 610 travel.
  • FIGS. 6A-6B depict a planetary roller screw drive with a limit sensing system in accordance with an embodiment of the present invention.
  • FIG. 6A depicts a planetary roller screw drive 700 in a first position with a limit sensing system, consistent with embodiments of the present disclosure.
  • Planetary roller screw drive 700 can include a rod 702, rollers 704, tube 706, head 708, base 710, magnet 712, first reed switch 714, and second reed switch 716.
  • rod 702 is initially located at a stroke limit position, near head 708 and magnet 712 causes first reed switch 714 to change state and complete an electrical circuit (not shown in FIG. 6A).
  • an electrical circuit provides a voltage or other suitable signal to reverse the rotation of rollers 704 and move rod 702 away from head 708.
  • first reed switch 714 changes state.
  • control of the solenoid valve- is provided by an integrated software controller (not shown in FIG. 6A).
  • the integrated software controller may be configured to detect the presence of magnet 712, in one embodiment, using reed switches 714 and 716.
  • FIG. 6B depicts planetary roller screw drive 700 in a second position with a limit sensing system, consistent with embodiments of the present disclosure.
  • Magnet 712 is positioned on rod 702 such that when rod 702 moves through tube 706 and approaches base 710, magnet 712 approaches second reed switch 716 and causes second reed switch 716 to change state. This will complete an electrical circuit and provide a voltage or other suitable signal to reverse the rotation of rollers 704 and move rod 702 away from base 710.
  • FIG. 7 depicts a hydraulic circuit in accordance with an embodiment of the present invention.
  • hydraulic circuit 500 can include a hydraulic reservoir 502, a hydraulic pump 504, a solenoid 506, a head port 508, a rod port 510, a hydraulic cylinder 512, a paint cylinder 514, a paint reservoir 516, and a spray gun 518.
  • hydraulic pump 504 can pump hydraulic fluid from hydraulic reservoir 502 to solenoid 506.
  • solenoid 506 is illustrated as a directional control valve.
  • Directional control valves can allow fluid to flow into different paths from one or more sources. They can consist of a spool inside a cylinder and can be mechanically, electrically, and hydraulically controlled.
  • an electromechanical solenoid is used to operate a 4-way, 2 position valve since there are 2 spool positions and 4 valve ports.
  • the 4-way, 2 position valve combined with the reed switch sensor (not shown in FIG. 7) enables fast switching between the down stroke and the up stroke of hydraulic cylinder 512. This allows hydraulic circuit 500 to achieve a consistent paint pressure.
  • head port 508 is the pressure port which is connected to hydraulic pump 504 and the rod port is connected to hydraulic reservoir 502.
  • the reed switch sensor can provide a voltage that activates a set of MOSFETs and flip-flop integrated circuit (not shown in FIG. 7), causing solenoid 506 to slide the spool to its second position.
  • rod port 510 is the pressure port which is connected to hydraulic pump 504 and the head port is connected to hydraulic reservoir 502.
  • the pressure inside hydraulic cylinder 512 forces the hydraulic piston to move up through hydraulic cylinder 512 and the hydraulic fluid is pushed out the head port and back to hydraulic reservoir 502.
  • the paint piston also moves up through paint cylinder 514 and paint from paint reservoir 516 can be drawn up into paint cylinder 516.
  • solenoid 506 is controlled by an integrated software controller (not shown in FIG. 7), communicably coupled to solenoid 506.
  • An integrated software controller may be useful to locate a position of the piston is detectable prior to start-up of the pump assembly.
  • FIG. 8 depicts a system diagram for a liquid dispensing system in accordance with an embodiment of the present invention.
  • Fluid dispensing system 800 may be useful, for example, for dispensing paint, or other exemplary fluids such as primers, coatings, plural components, etc.
  • System 800 may comprise a fluid source 810 operably coupled to a pump 820 within fluid dispensing system 800.
  • Pump 820 may comprise, for example, a planetary roller screw pump such as that presented in FIGs. 5A and 5B, or a hydraulic pump such as that presented in FIG. 3.
  • Pump 820 is operably coupled to a pump controller 830.
  • Pump 820 may be configured to pressurize, or otherwise deliver fluid from fluid source 810 to an outlet 802.
  • Controller 830 may be configured, in one example, to provide an output 804.
  • output 804 comprises storing detected parameters concerning operation of pump 820 in a memory of controller 830.
  • output 804 comprises delivery of detected parameters to a separate unit, for example downloading detected parameter information to a separate computing unit.
  • output 804 comprises an audio or visual output, for example an audible alert or a visual indication, such as a separate display unit.
  • Fluid dispensing system 800 in some embodiments, comprises other features 840 integral to the delivery of fluid from fluid source 810 to outlet 802.
  • other functionality 840 comprises a heater.
  • fluid may be transferred a significant distance from pump 820 to outlet 802.
  • Other functionality 840 may comprise a transport mechanism in such embodiments.
  • FIG. 9 depicts a diagram of a pump system control in accordance with an embodiment of the present invention.
  • Pump 910 of pump system 900 may, in one example, comprise a planetary roller screw pump system such as that presented in FIGS. 5A and 5B.
  • pump 910 comprises a hydraulic pump system, such as that presented in FIG. 3.
  • pump system 900 may also be useful with other exemplary pump configurations.
  • Pump 910 comprises, in one example, a fluid section piston 912 coupled to a hydraulic piston 914. Movement of hydraulic piston 914 is limited, in one example, by one or more switching mechanisms 918. Switching mechanisms 918 may comprise reed switches, for example. However, other switching mechanisms 918 may also be used. For example, an integrated software controller 920 may be configured to control a solenoid. Pump 910 may also include one or more limit sensors 916. Pump 910 may also comprise other components 928.
  • Controller 920 in one example, is configured to operably control and monitor pump 910.
  • Controller 920 in one embodiment, comprises a detector 922 configured to detect a position of fluid section piston 912 prior to operation of pump 910.
  • Detector 922 may receive a signal from limit sensor 916, for example, indicating a position of fluid section piston 912 within an operational loop.
  • fluid section piston 912 may be mid-stroke, topped out, bottomed out, or in another position within an operational loop. Knowing a detected position of fluid section piston 912 within an operational loop may allow for controller 920 to resume a normal operational loop of fluid section piston 912 based on its detected current position.
  • Controller 920 may also comprise other functionality 924.
  • controller 920 is responsible for controlling movement of fluid section piston 912 within a cylinder.
  • limit sensor 916 can send an indication, to detector 922, causing the controller to switch the direction of piston movement, for example using switching mechanism 918.
  • Switching mechanism 918 can comprise, for example, a reed switch, in one embodiment.
  • switching mechanism 918 comprises a solenoid coupled to the controller.
  • switching mechanism 918 comprises a solenoid coupled to a MO SFET and a flip- flop integrated circuit system.
  • Limit sensor 916 can comprise, in one embodiment, a hall-effect sensor. In another embodiment, limit sensor 916 comprises a photoelectric sensor. In another embodiment, limit sensor 916 comprises a mechanical sensor. In another embodiment, limit sensor 916 comprises a base active transducer sensor. In another embodiment, limit sensor 916 comprises an eddy- current sensor. In another embodiment, limit sensor 916 comprises an inductive position sensor. In another embodiment, limit sensor 916 comprises a photodiode array sensor. In another embodiment, limit sensor 916 comprises a proximity sensor. However, other suitable limit sensors 916 are also envisioned. For example, in one embodiment, limit sensor 916 comprises an anisotropic magneto-resistive (AMR). In another embodiment, limit sensor 916 comprises a giant magneto-resistive (GRM) magnetic sensor.
  • AMR anisotropic magneto-resistive
  • GEM giant magneto-resistive
  • Controller 920 may be coupled, in one example, to a memory 930.
  • Memory 930 is illustratively shown as part of pump system 900. However, in another example, at least some portions of memory 930 are stored remotely from pump system 900. For example, a start-up sequence 932 may be stored within an integrated memory coupled to controller 920 such that controller 920 can retrieve sequence 932 and engage pump 910.
  • historic data 936 may only be accessible when integrated controller 920 is coupled to a remote computing system 950, where current operational information 938 may be downloaded and compared to historic data 936 to track operational parameters related to operation of pump 910 over time.
  • Memory 930 may also store a counter 934. Counter 934 may be responsible for tracking a total cycle count of pump 910, a live cycle-rate counter, and / or track a run time of pump 910 for a given operation.
  • Memory 930 may also comprise other functionality 942.
  • Pump system 900 may also illustratively comprise a user interface 940.
  • User interface 940 may allow an operator to interact with controller 920.
  • User interface 940 may comprise an input / output mechanism, such as a set of buttons, keys, etc.
  • User interface 940 may comprise a display attached to pump system 900.
  • User interface 940 in another example, may comprise a display on a separate computing unit 950, such that interaction with controller 920 and memory 930 is limited to a configuration where controller 920 is communicably coupled with separate computing unit 950, for example during or after a download of operational information 938 from memory 930.
  • FIG. 10 depicts a flow diagram of a method for start-up of a pump control system in accordance with an embodiment of the present invention.
  • a system controller such as controller 920, retrieves a start-up sequence, such as sequence 932, from an integrated memory 930.
  • Start-up sequence 932 may, for example, provide instructions for implementing method 1000.
  • Engaging the pump system may comprise turning on an associated motor, initiating priming operations, and / or other appropriate start-up operations.
  • a piston position is located.
  • a piston may be detected as mid-stroke, as indicated in block 1022, topped out, as indicated in block 1024, bottomed out, as indicated in block 1026, or in another position, as indicated in block 1028.
  • a controller knowing the location of a piston, may be able to start a normal operational loop from the present location, instead of having to estimate a position.
  • an operational loop is started.
  • the operational loop may be initiated, in part, based on a detected location of the piston, in one example.
  • Starting the operational loop in block 1030 may also comprise a controller retrieving and initiating one or more parameter tracking sequences.
  • the controller can retrieve and initiate a cycle counter, as indicated in block 1032.
  • a cycle counter may comprise a live operational cycle counter, for example starting at ⁇ cycles.
  • a cycle counter may comprise a lifetime cycle counter for a pump system, such that a controller retrieves a total cycle count, for example, comprising a cycle count at the end of a previous operation, and continue counting through a present operation, providing an ending cycle counter for the beginning of the next operation.
  • Starting an operational loop may also comprise the controller retrieving a runtime tracking sequence and starting a runtime counter, as indicated in block 1034, which may provide an ongoing indication of how long a current operation has been ongoing.
  • Starting an operational loop may also comprise starting other parameter tracking sequences, as indicated in block 1036.
  • data regarding an operation is stored.
  • runtime counter information, cycle counter information, or other parameter data can be tracked and stored for a given operation.
  • Such data may also be accumulated and stored over time, for example to provide diagnostic information.
  • Data can be stored, in one embodiment, in an onboard memory associated with the pump control system, as indicated in block 1042.
  • Data can also be stored, in one embodiment, in a remote memory component, as indicated in block 1044, for example associated with a separate computing unit.
  • Data can also be stored in other configurations, as indicated in block 1046.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Computer Hardware Design (AREA)
  • Reciprocating Pumps (AREA)
  • Control Of Positive-Displacement Pumps (AREA)

Abstract

L'invention concerne un système de distribution (900) de liquide. Le système de distribution (900) de liquide comprend une source de fluide accouplée à une sortie. Le système de distribution de liquide comprend également un vérin hydraulique (912) accouplé à la source de fluide. Le vérin hydraulique comporte un piston (914) mobile entre une première position limite et une deuxième position limite pendant un cycle de fonctionnement. Le vérin hydraulique (912) est conçu pour mettre sous pression un fluide reçu de la source de fluide et pour distribuer le fluide sous pression à la sortie. Le système de distribution (900) de liquide comprend également une tige reliée au piston et s'étendant hors du vérin. Le système de distribution (900) de liquide comprend également un capteur (916) conçu pour détecter une position de la tige afin de fournir une indication par signal du piston (914) par rapport à la première position ou à la deuxième position. Une indication de la position détectée est fournie à un dispositif de commande (920) et le dispositif de commande (920) est conçu pour envoyer un signal de commande afin d'initier une boucle de fonctionnement normal sur base de la position détectée.
PCT/US2017/032084 2016-06-22 2017-05-11 Détection de limite de piston et commande logicielle pour application de fluide WO2017222666A1 (fr)

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CN201780037405.4A CN109475886B (zh) 2016-06-22 2017-05-11 用于流体涂覆的活塞限位检测和软件控制
EP17815861.4A EP3452228A4 (fr) 2016-06-22 2017-05-11 Détection de limite de piston et commande logicielle pour application de fluide

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US201662353165P 2016-06-22 2016-06-22
US62/353,165 2016-06-22
US15/468,611 US10941762B2 (en) 2015-01-30 2017-03-24 Piston limit sensing and software control for fluid application
US15/468,611 2017-03-24

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US10969805B2 (en) 2013-02-11 2021-04-06 Graco Minnesota Inc. Paint sprayer distributed control and output volume monitoring architectures
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EP4144444A1 (fr) * 2018-09-24 2023-03-08 Graco Minnesota Inc. Architectures de commande et de surveillance de volume de sortie distribuées de pulvérisateur de peinture

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CN109475886B (zh) 2021-08-24
EP3452228A1 (fr) 2019-03-13
CN109475886A (zh) 2019-03-15
EP3452228A4 (fr) 2020-01-01

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