Paint sprayer distributed control and output volume monitoring architectures
A sprayer for spraying fluid includes a pump, a motor that drives the pump, a drive cycle indicator, a wireless module configured to send and receive information, and control circuitry. The drive cycle indicator outputs an indication of cycle status of the pump. The control circuitry is configured to receive the plurality of cycle status indications of the pump, determine a plurality of output values representing paint spray fluid output volume over a plurality of time windows based on the plurality of cycle status indications of the pump, store the plurality of output values in memory, and cause the wireless module to transmit one or more of the stored plurality of output values externally from the sprayer.
1. A spray system for spraying paint and remotely monitoring part wear, the spray system comprising:
a hand portable paint sprayer comprising:
a spray gun configured to spray paint as an atomized spray fan, the spray gun comprising a trigger that actuates the spray gun to spray the paint and a tip nozzle configured to atomize the paint;
a hose that connects to the spray gun;
a frame that permits the hand portable paint sprayer to be moved by hand to job sites;
a pump supported by the frame, the pump having a reciprocating piston that outputs paint under pressure to the spray gun via the hose;
a replaceable part that contacts paint;
a motor supported by the frame, the motor configured to drive the pump;
a wireless module supported by the frame, the wireless module configured to wirelessly send and receive information; and
control circuitry supported by the frame, the control circuitry configured to generate data indicative of paint spray volume output by the hand portable paint sprayer through the tip nozzle and cause the wireless module to transmit the data indicative of the paint spray volume;
one or more computing devices remote from the sprayer, the one or more computing devices configured to receive the data indicative of the paint spray volume, update a spray volume log indicative of wear of the replaceable part based on the data indicative of the paint spray volume, and generate an output based on the spray volume log, the one or more computing devices configured to store the spray volume log in memory of the one or more computing devices.
2. The spray system of claim 1 , further comprising a user interface in communication with the one or more computing devices, wherein the output generated based on the spray volume log is a command that causes the user interface to display an indication of wear of the replaceable part.
3. The spray system of claim 2 , wherein the one or more computing devices are configured to:
compare the spray volume log to a first threshold and cause a first notification to be generated on the user interface based on the first threshold being exceeded,
compare the spray volume log to a second threshold and cause a second notification to be generated on the user interface based on the second threshold being exceeded, the second threshold representing a greater volume of paint being sprayed through the replaceable part than the first threshold.
4. The spray system of claim 1 , wherein the one or more computing devices are configured to track a plurality of spray volume logs corresponding to different wear components of the spray system that contact paint, the plurality of spray volume logs including the spray volume log for the replaceable part.
5. The spray system of claim 2 , wherein the indication of wear is an alert to one or both of inspect or replace the replaceable part.
6. The spray system of claim 1 , wherein the one or more computing devices are configured to generate the output based on the spray volume log exceeding a threshold.
7. The spray system of claim 1 , wherein the one or more computing devices comprises a cellular phone and a network server.
8. The spray system of claim 1 , wherein the one or more computing devices are configured to receive an input indicating a new replaceable part, and, based on the input, either reset the spray volume log or start a new spray volume log.
9. The spray system of claim 1 , wherein the data indicative of the paint spray volume the spray volume log is a value representing cumulative motor operation.
10. The spray system of claim 1 , wherein, to generate the data indicative of paint spray volume output by the pump through the tip nozzle, the control circuitry is configured to:
determine whether the hand portable paint sprayer is operating in a fluid atomizing spray mode or a non-atomizing flushing mode; and
generate the data indicative of the paint spray volume output corresponding to when the hand portable paint sprayer is operating in the fluid atomizing spray mode while excluding indications representing pump operation from when the hand portable paint sprayer is operating in the non-atomizing flushing mode.
11. The spray system of claim 10 , wherein the control circuitry is configured to determine whether the hand portable paint sprayer is operating in the fluid atomizing spray mode or the non-atomizing flushing mode based on an output setting input by a user.
12. The spray system of claim 10 , wherein the control circuitry is configured to determine whether the hand portable paint sprayer is operating in the fluid atomizing spray mode or the non-atomizing flushing mode based on an output from a pressure sensor measuring output pressure of the pump.
13. The spray system of claim 1 , wherein the replaceable part that contacts paint is the tip nozzle.
14. The spray system of claim 1 , wherein the spray volume log is a value representing cycles of the motor.
15. The spray system of claim 1 , wherein the spray volume log is a value representing cycles of the pump.
16. A method of operating a spray system, the method comprising:
spraying paint with a hand portable paint sprayer, the hand portable paint sprayer comprising:
a spray gun configured to spray paint as an atomized spray fan, the spray gun comprising a trigger that actuates the spray gun to spray the paint;
a hose that connects to the spray gun;
a frame that permits the hand portable paint sprayer to be moved by hand to job sites;
a pump supported by the frame, the pump having a reciprocating piston that outputs paint under pressure to the spray gun via the hose;
a motor supported by the frame, the motor configured to drive the pump;
a replaceable part that contacts paint;
sprayer control circuitry supported by the frame; and
a wireless module supported by the frame, the wireless module configured to wirelessly send and receive information;
generating, with the sprayer control circuitry, data indicative of paint spray volume output by the hand portable paint sprayer, wherein the replaceable part that contacts paint is used to output the paint spray volume output;
wirelessly transmitting the data indicative of the paint spray volume output off of the hand portable paint sprayer with the wireless module;
receiving the data indicative of the paint spray volume with one or more computing devices that are remote from the hand portable paint sprayer;
updating a spray volume log indicative of wear of the replaceable part that contacts paint in memory of the one or more computing devices; and
generating an output with the one or more computing devices based on the spray volume log indicative of the wear of the replaceable part.
17. The method of claim 16 , wherein generating the output comprises displaying on a user interface an indication of the wear of the replaceable part that contacts paint.
18. The method of claim 16 , wherein generating the output comprises identifying the spray volume log indicative of the wear of the replaceable part exceeding a threshold and generating the output based on the threshold being exceeded.
19. The method of claim 16 , wherein the one or more computing devices comprises a cellular phone and a network server.
20. The method of claim 16 , further comprising:
receiving an input indicating installation of a new replaceable part that contacts paint; and
either resetting the spray volume log or starting a new spray volume log based on receiving the input indicating installation of the new replaceable part that contacts paint.
21. The method of claim 16 , wherein the spray volume log is either a value representing cumulative operation of the motor or a value of the paint spray volume that is pumped.
22. The method of claim 16 , wherein:
the hand portable paint sprayer comprises a plurality of replaceable parts that contact paint, the plurality of replaceable parts including the replaceable part that contacts paint,
the plurality of replaceable parts that contact paint are used to output the paint spray volume output;
the method comprises updating a plurality of spray volume logs indicative of wear of the plurality of replaceable parts that contact paint in memory of the one or more computing devices, the plurality of spray volume logs including the spray volume log; and
the method comprises generating a plurality of outputs with the one or more computing devices respectively based on the plurality of spray volume logs.
23. The method of claim 16 , wherein the replaceable part that contacts paint is a tip nozzle.
24. A spray system for spraying paint and remotely monitoring part wear, the spray system comprising:
a hand portable paint sprayer comprising:
a tip nozzle configured to spray paint as an atomized spray fan;
a hose that supplies paint for spraying from the tip nozzle;
a frame that permits the hand portable paint sprayer to be moved by hand to job sites;
a pump supported by the frame, the pump having a reciprocating piston that outputs paint under pressure to the tip nozzle via the hose;
a motor supported by the frame, the motor configured to drive the pump;
a wireless module supported by the frame, the wireless module configured to wirelessly send and receive information; and
control circuitry supported by the frame, the control circuitry configured to generate data indicative of paint spray volume output by the hand portable paint sprayer through the tip nozzle and cause the wireless module to transmit the data indicative of the paint spray volume;
one or more computing devices remote from the sprayer, the one or more computing devices configured to receive the data indicative of the paint spray volume, update a spray volume log indicative of wear of the tip nozzle based on the data indicative of the paint spray volume, and generate an output based on the spray volume log, the one or more computing devices configured to store the spray volume log in memory of the one or more computing devices.