Abstract: 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.

Abstract: A method of regulating a temperature of a fluid within a hose of a fluid dispensing system includes passing the fluid through the hose and across a heating element. A temperature of the fluid in the hose is sensed by the heating element. The sensed temperature of the fluid in the hose is compared to a reference temperature. An input of the heating element is adjusted in response to the comparison of the sensed temperature of the fluid in the hose to the reference temperature such that the temperature of the fluid is adjusted towards the reference temperature.

Abstract: A method for pumping, tracking, and controlling a fluid includes the steps of producing a drive signal for driving a motor of a pump using a controller, driving the motor to pump a fluid based on the drive signal, sending a dispense signal from the controller to a sprayer for dispensing the fluid, determining a work piece count as a function of a work piece signal provided to the controller from the work piece sensor, detecting the position of a rod connected to the motor and the pump using a position sensor, creating a position signal as a function of the position of the rod using the position sensor, sending the position signal to the controller, and determining a volume usage as a function of the position of the rod using the controller.

Abstract: An adaptive hot melt feed system includes a melt system, a feed system, a gas control device, a sensor, and a controller. The melt system includes a heated vessel. The feed system is configured to deliver a solid material to the vessel of the melt system for melting. The gas control device is configured to control a supply of gas provided to the feed system to drive the solid material from the feed system to the melt system. The sensor can be configured to detect an amount of material in the vessel of the melt system. The controller is in electronic communication with the gas control device and is programmed to signal the gas control device to vary the supply of gas to the feed system based on a fill metric determined by the controller.

Abstract: 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.

Abstract: A method for pumping, tracking, and controlling a fluid includes the steps of producing a drive signal for driving a motor of a pump using a controller, driving the motor to pump a fluid based on the drive signal, sending a dispense signal from the controller to a sprayer for dispensing the fluid, determining a work piece count as a function of a work piece signal provided to the controller from the work piece sensor, detecting the position of a rod connected to the motor and the pump using a position sensor, creating a position signal as a function of the position of the rod using the position sensor, sending the position signal to the controller, and determining a volume usage as a function of the position of the rod using the controller.

Abstract: An adaptive hot melt feed system includes a melt system, a feed system, a gas control device, a sensor, and a controller. The melt system includes a heated vessel. The feed system is configured to deliver a solid material to the vessel of the melt system for melting. The gas control device is configured to control a supply of gas provided to the feed system to drive the solid material from the feed system to the melt system. The sensor can be configured to detect an amount of material in the vessel of the melt system. The controller is in electronic communication with the gas control device and is programmed to signal the gas control device to vary the supply of gas to the feed system based on a fill metric determined by the controller.

Abstract: A pump system for pumping a fluid includes a motor housing, a motor, a rod, a positive displacement pump, a position sensor, and a controller. The motor is located within the motor housing. The rod is connected to and driven by the motor and the positive displacement pump for moving a fluid is driven by the rod. The position sensor produces a rod position signal that is a function of a position of the rod, and the controller produces a drive signal for driving the motor as a function of the rod position signal.

Abstract: In one embodiment, a remote monitoring system for a fluid applicator system is disclosed. The fluid applicator system is disposed to heat and pump spray fluid, and to transmit reports including sensed temperatures, pressures, and other operational parameters of the fluid applicator system via a wireless network. The remote monitoring system comprises a data storage server, and an end user interface. The data storage server is configured to receive and archive the reports. The end user interface is configured to provide a graphical user interface based on the reports. The graphical user interface illustrates a status of the fluid handling system, sensed and commanded temperatures of the fluid handling system, sensed and commanded pressures of the fluid handling system, and usage statistics of the fluid handling system.

Abstract: A power distribution system for supplying AC power to loads includes an automatic wiring board that realigns voltages and determines a user-supplied wiring configuration. If an acceptable configuration is detected, an auto-wiring relay circuit closes relays to provide appropriate connections from a terminal block to power controllers that control delivery of AC power to loads, such as heating elements. If wiring configuration is incorrect or voltage is outside a safe voltage range, the auto-wiring relay circuit remains open to protect the controllers and loads.

Abstract: A pump system for pumping a fluid includes a motor housing, a motor, a rod, a positive displacement pump, a position sensor, and a controller. The motor is located within the motor housing. The rod is connected to and driven by the motor and the positive displacement pump for moving a fluid is driven by the rod. The position sensor produces a rod position signal that is a function of a position of the rod, and the controller produces a drive signal for driving the motor as a function of the rod position signal.

Abstract: A method includes delivering current in parallel to a first resistive heating element, a second resistive heating element and a third resistive heating element during a first operating mode of a hot melt dispensing system, and delivering current in parallel to the first resistive heating element, the second resistive heating element and third and fourth resistive heating elements during a second operating mode of a hot melt dispensing system where the third and fourth resistive heating elements are arranged in series.