Spray tools with multi-nozzle-arrays are used in a wide variety of applications. Monitoring the functionality of complex spraying tools with a large number of individual nozzles is a great challenge. For this purpose, we have developed a measurement technique based on the wetting pattern, which forms on a surface during spray impingement. To investigate the performance of this measurement technique we applied a spraying tool with nine external mixing air-water nozzles, the geometric alignment of which can be freely adjusted. In the first test series, the precision of the evaluation of the nozzle alignment is determined. The second test series focuses on the individual sizes of the wetted areas. Here the reproducibility, the influences of the operating modes and the nozzle type were evaluated. Subsequently, the functionality is tested in an exemplary test case in which two of nine nozzles were readjusted in a defined manner. Finally, the wetting pattern resulting from injecting a full spray is discussed and the necessary image processing steps are provided. In summary, this measuring system allows efficient, fast and cost-effective control and documentation of the alignment and functionality of spraying tools, thereby avoiding production downtime and related costs.
In casting technology spraying tools are used for cooling and cleaning purposes. Its heavy use is often accompanied by contamination and misalignment of the nozzles, which leads to the production of rejects and to production downtime. Therefore, control systems are necessary to check the function of the nozzles and in case of a problem to find the defect. From this starting point, we develop a new robust measuring technique. This measurement technic is based on the optical visualisation of the spray impingement on a frosted pane. A camera detects the resulting characteristic wetting pattern. From the camera recordings, conclusions can be drawn about the alignment and the mass flow of individual nozzles. To test the capabilities of the measurement method, we used a spray tool with 9 nozzles and equipped with different nozzles as shown in Figure 1. For this we have measure the position of spray impact and the size of the wetted area of the individual spray plumes on the frosted pane surface. As a result, we are able to show that the measurement results are reproducible and the measurement method achieves high sensitivity.
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