Blast machine system controller

A system for system for controlling functions of a multi-feed blasting apparatus is disclosed. Tank pressure, charge/discharge control, status of a vessel cover, total hours of pressurization or operation for the vessel and individual feed lines, ambient environmental or weather conditions, and abrasive material level inside the vessel may also be monitored and controlled by the disclosed system.

FIELD OF THE INVENTION

Aspects of the present disclosure deal with control systems for abrasive blasting machines.

BACKGROUND OF THE INVENTION

Pressure vessels or “blast pots” are used with various abrasive blasting materials for surface preparation applications. When closed and filled with the blasting material, the pressure vessel is pressurized and used in combination with an air feed line which receives abrasive material from the pressure vessel and then carries the material through a hose to a nozzle when used in a surface preparation application. Some larger blast pots feed multiple outputs, for example to supply material to different work stations. An embodiment of the present disclosure provides a control unit and data collection into which various functions relating to the blasting apparatus and surrounding environment are integrated.

SUMMARY

According to one aspect, the present disclosure provides a control system which integrates various functions of a multi-feed blasting apparatus. Tank pressure, charge/discharge control, status of the vessel cover, total hours of pressurization for the tank and individual feed ports, ambient conditions, and abrasive material level inside the tank are some of the functions and variables which may be monitored and controlled by the disclosed system.

According to another aspect, an abrasive blasting control system is disclosed, comprising an abrasive blasting device having a pressure vessel for storing blasting media and a plurality of individual blast outlet lines connected to the pressure vessel, a control housing associated with the abrasive blasting device, a controller located within the housing and having a processor and a memory, and a plurality of line duration displays mounted to the housing. Each line duration display is operable to display the duration of time that a corresponding one of the blast outlet lines has been in active use. A vessel duration display is mounted to the control housing and is operable to display the duration of time that the pressure vessel has been pressurized. The controller may be configured to receive input from a plurality of line sensors connected to the corresponding plurality of individual blast outlet lines to track the duration of time that the individual abrasive blasting lines have been in active use. The controller may also provide output signals to the individual line duration displays to display the duration information for the individual blasting lines. Reset inputs may also be provided for each of the line duration displays and vessel duration display. The control system may also comprise a hatch status display for indicating the status of the vessel hatch or a locking device connected to the hatch. A media level display may also be included which indicates the amount of blasting media remaining in the pressure vessel.

According to another aspect, an abrasive blasting system is disclosed, comprising a pressure vessel having a plurality of blast outlet lines, a plurality of line sensors operatively connected to the individual blast outlet lines, and a control panel having a plurality of line duration displays. The line duration displays are operable to display the duration of time that a corresponding one if the blast outlet lines has been in active use based on input received from the line sensors. A vessel duration display is mounted to the housing. The vessel duration display is operable to display the duration of time that the pressure vessel has been pressurized.

According to yet another aspect, a method for monitoring an abrasive blasting apparatus is disclosed, comprising receiving input from a plurality of line sensors connected to a corresponding plurality of individual blast outlet lines connected to the abrasive blasting apparatus, and automatically indicating the individual durations of use for each of the individual blast outlet lines based on the input.

DESCRIPTION OF PREFERRED EMBODIMENTS

The present disclosure provides a system for controlling and monitoring various functions of a blasting machine having multiple blast outlets. By integrating the functions in a single unit, the operator can gain better knowledge of the blast operations and any effects the surrounding environment might present. As a result, increased safety and operational efficiency may be achieved.

FIG. 1illustrates a blasting system10having a pressure vessel20for storing an abrasive blasting media, feed air inlet25, and a plurality of blast outlets30. As illustrated, four outlets30are provided (allowing four users to utilize the system10simultaneously), however more or less outlets30may be provided depending on the needs of the application. An optional moisture separator40may be provided for removing moisture from the incoming air before it reaches the pressure vessel20and/or blast outlets30. The pressure vessel20includes a hatch22which can be opened to add the blasting media to the vessel and/or for interior inspection and maintenance. The hatch22typically includes a locking device, such as the cam-lock closures23shown inFIG. 1.

In the illustrated embodiment, pressurized air, from either an external source or a compressor integrated with the system10, enters the moisture separator40via inlet25and is then directed through multiple outlets to air lines42via air control valves45. A main inlet shutoff valve26may also be provided to isolate the system10from the pressurized air source. The blasting media is fed from the bottom of the pressure tank20through feed lines55and enters metering valves50. Each metering valve50receives the blasting media from a media feed line55and pressurized air from an air line42. As the blasting media enters a metering valve50, it is propelled by the pressurized air toward the corresponding metering valve outlet30. Blast hoses (not shown) may be connected to one or more of the metering valve outlets30and typically include a nozzle for directing the blast media toward the object being blasted. When a outlet or feed line55is not in use, it may be secured with a cap or plug to prevent air and/or blast media from escaping. It shall be understood that the valve26may be operated manually or operated remotely by electrical, pneumatic, or mechanical actuators. Valves45and50may be operated remotely by electrical or pneumatic actuators. In one embodiment, the valves26,45and50may comprise electromechanically actuated ball valves, although other types of valves may also be used.

The operation of the various valves and other components of the system10is monitored and controlled using control station60, which may be mounted to the pressure tank20as shown or mounted in a remote location. As shown in schematic form inFIG. 2and illustrated inFIG. 3, the control station60monitors several conditions and/or variables related to the system20including, but not limited to, internal pressure of the pressure tank20, total time the pressure tank20is pressurized, cycle time of each blast outlet30when pressurized, state (open, closed, etc.) of the hatch22, and ambient weather conditions.

The control station60comprises a controller65for receiving input from monitoring devices and outputting data for display. The controller65may also provide outputs for controlling various devices related to the control and operation of the system10, including regulation and maintenance of the pressure level within the pressure vessel20, regulation of the mixture of air and blasting media through the system, and regulation of other material flow rates through the system10. The controller65preferably includes a computer processor70and a memory75for processing and storing information during operation of the system10. In a preferred embodiment, the control station60is configured to operate using12volt direct current as the supply power, although other suitable power levels and types may be used, depending on the needs of the particular application.

In one embodiment, a vessel pressure sensor80is operatively attached to the pressure vessel10in a location which allows the sensor80to accurately measure the pressure level inside the pressure vessel10. The pressure sensor80transmits a signal indicative of the pressure level to the controller65as shown. The controller60receives the signal from the sensor80and outputs a corresponding signal to the vessel pressure display85, which displays the pressure in pounds per square inch or other appropriate units. The vessel pressure display85may comprise any suitable electronic display known in the art, such as a liquid crystal display (LCD), light emitting diode (LED) display, or the like. The displays may also take the form of other types of displays, such as dials, gauges, needle indicators, and color-coded lamps. In addition, it shall be understood that still other types of displays may be used to indicate the vessel pressure or other system parameters, including analog, mechanical, and pneumatic displays. It shall also be understood that the signal from the pressure sensor80may be connected directly to the display85, as opposed to being routed through the controller65.

The control station60may also be configured to monitor and/or display the total hours that the pressure vessel20is pressurized. In one embodiment, a separate pneumatic switch82is attached to the pressure vessel10and is triggered whenever the pressure inside the vessel20rises above a predetermined level (e.g., 1 psi). The switch82is also connected to the controller65. When the switch is triggered, the controller65begins to log and display the total hours that the vessel20has been pressurized on display90. In other embodiments, the controller65may further track and display the total hours that the pressure vessel is pressurized and at least one blast outlet line is in active use. In other embodiments, the display90may be incremented when any one of the individual blast outlets is in use or when a corresponding individual display for that outlet or line is being incremented. The total hours displayed may be expressed in increments of one tenth of an hour or any other appropriate units. A reset button, such as keyed reset95, may be provided to reset the total displayed hours to zero as desired.

In addition to total vessel hours, cycle times for the individual blast outlets30(i.e., when blast media is being propelled through the blast line during active use) may be monitored and displayed using the control station60. In one embodiment, individual pneumatic switches100(e.g., 1 thru N, if N lines42are provided) are installed in a location which causes the switches to be activated when the pressure inside a corresponding individual air line42or a hose connected to an individual blast outlet30, rises above a predetermined pressure. When one of the switches100is activated, the controller65begins to log and display the total usage hours for that line on the corresponding display105. In other embodiments, the controller increases the total usage hours based on a switch which is actuated when the operator activates a trigger located near the nozzle of a hose connected to a blast outlet30. Reset buttons110may be provided to reset the individually displayed cycle times as desired.

A hatch sensor112may be provided to monitor the state of the hatch22. In one embodiment, the hatch sensor112monitors the state of a locking device (e.g., cam-lock closures23and/or other additional hatch locking devices, such as a detent collar securing the cam-lock closures in a closed position) connected to the hatch22to determine whether the locking device is actively locked or inactive and potentially unlocked. In other embodiments, the hatch sensor112may simply monitor whether the hatch is open or secured, or whether it is safe for the operator to open the hatch22. The hatch information is transmitted to the controller65, which displays the hatch status using display115.

In certain preferred embodiments, the control station60may include a weather condition display120which displays data relating to ambient weather conditions around the system10. The displayed data may include ambient temperature, relative humidity, dew point, barometric pressure, wind conditions, and the like. In one embodiment, the weather information is obtained using various weather sensors125which are in operative communication with the controller65, either through wired or wireless mediums. The weather sensors may be mounted within or external to the control station60. The controller65receives the signals from the sensors125and translates the information for display on weather display120. The controller65may also receive weather information from independent weather reporting services, such as the National Weather Service. The displayed information allows the operator to assess how local weather conditions may affect operation of the system10and/or whether the conditions may affect the surface of the item being treated.

A remote pressurization control switch87may also be provided which allows the operator to control an associated valve actuator (e.g., inlet valve26) or other control device to remotely pressurize or depressurize the vessel20. In one embodiment, the switch87is implemented as a two position double pole/double throw (DPDT) toggle switch. In addition to total tank pressurization or depressurization, additional switches may be included within the control station60to allow selective pressurization or depressurization of the individual blast outlets30. Additional switches may provided to control the state of the various valves and control devices of the system, including air control valves45, feed valves50, or other pressure control valves (indicated collectively as88inFIG. 2) during operation of the system10. In certain embodiments, the control station60may also receive input from valve position sensors92connected to the valves88at appropriate locations.

In certain embodiments, the system10may also include a display86for indicating the amount of blasting media remaining in the vessel20. The display86is fed (either directly or via controller65) by a media sensor89operatively connected to the vessel10. The media sensor89may comprise any material level or quantity sensor known in the art, including, but not limited to, ultrasonic sensors, laser/light sensors, mechanically-actuated sensors, and the like.

It shall be understood that while a single controller65is described above as managing and/or translating the various input signals for output on the individual displays, other processor or signal routing configurations are contemplated to be within the scope of the present disclosure. For example, certain signals, such as those received from pressure switches82and100, may bypass the controller65and be connected directly to the displays90and105respectively, when the displays are implemented with built-in circuitry to monitor the state of the switches and cause the hour display to be incremented.

In certain embodiments, the control station60may incorporate a data logging system which monitors and records information relating to operation of the system10in memory for future reference. Examples of such recorded data include, but are not limited to, total vessel hours, individual outlet hours, usage trends, hatch status, weather data and weather tracking, maintenance interval data, and the like. In still further embodiments, the control station60may include a communication module for transferring data from the logging system to a computer, memory device, or handheld mobile device located near the control station60, through either a wired (e.g., USB, Ethernet, Firewire, or the like) or short range wireless medium (e.g., Bluetooth, RFID, and the like). The control station60may also comprise a remote reporting device, such as a cellular network or Wi-Fi transmitter/receiver, for electronically reporting the operational data to a remote location. The control station60may also include a global positioning satellite (GPS) receiver/transmitter for recording or reporting the location of the system10or for selecting a location for a desired local weather report, such as when the system10is implemented on a movable platform or trailer.

FIG. 3illustrates a perspective view of one embodiment of the control station60. As shown, the control station60includes a housing160, a main control panel165, and a weathertight enclosing door170for protecting the panel165from the elements. The door170may be optionally secured to the housing160by hinge175and releasable locks180. The various indicators and remote operator controls described above are preferably arranged within the panel165as shown, although other suitable arrangements may be used.