Acoustic Sensor Thermal Spray Diagnostics
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Solution Overview
Problem
Thermal spray systems face challenges in accurately monitoring process attributes, leading to unsatisfactory coating characteristics due to variances in process parameters and component wear, which existing monitoring methods like flow meters and voltmeters may not effectively address.
Innovation Solution
A system incorporating acoustic sensors to generate time-dependent acoustic data signals, which are analyzed by a computing device to transform into frequency-domain spectra, allowing for the determination of process attributes such as nozzle wear and powder pulsing, enabling real-time monitoring and feedback.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If acoustic sensors and frequency-domain analysis are implemented, then measurement precision of process attributes is improved, but device complexity increases
Solution Approach 1:
The patent replaces traditional mechanical monitoring devices (flow meters, voltmeters) with acoustic sensing and signal processing. Acoustic sensors capture sound waves from the thermal spray process, and frequency-domain analysis transforms these signals to extract process attributes, substituting mechanical measurement systems with acoustic-field-based monitoring that provides higher precision without significant physical complexity increase
Solution Approach 2:
The patent introduces frequency-domain spectrum analysis as an intermediary between the acoustic sensor output and process attribute determination. The Fast Fourier Transform (FFT) converts time-domain acoustic signals into frequency-domain spectra, where characteristic frequencies and their intensities serve as intermediaries that reveal process attributes like nozzle wear and powder pulsing, enabling indirect but accurate measurement of difficult-to-access parameters
2Reliability
If real-time acoustic analysis is performed, then reliability of process monitoring is improved, but loss of time in signal processing increases
Solution Approach 1:
The patent performs preliminary action by continuously capturing and pre-processing acoustic signals in real-time during the thermal spray operation. The acoustic sensor continuously monitors the process, and the signal processing system is prepared to immediately transform and analyze incoming signals, ensuring that process attribute changes are detected as they occur without significant time delay
Solution Approach 2:
The patent uses efficient Fast Fourier Transform (FFT) algorithms to rapidly convert time-domain acoustic signals into frequency-domain spectra, rushing through the signal processing step. This mathematical transformation method enables quick extraction of characteristic frequencies and their intensities, minimizing processing time while maintaining high reliability in process attribute determination
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach provides more accurate and real-time analysis of thermal spray system operations, improving coating quality by identifying deviations in process attributes and component conditions, thus enhancing the overall performance and reliability of the thermal spray process.
Implementation Method 1
at least one acoustic sensor configured to generate at least one time-dependent acoustic data signal indicative of an acoustic signal. The acoustic signal is generated by a thermal spray system performing a process
Implementation Method 2
The acoustic data signal processing module may be configured to receive the at least one time-dependent acoustic data signal, and transform the at least one time-dependent acoustic data signal to a frequency-domain spectrum
Data Source
AI summary
An example system includes at least one acoustic sensor configured to generate at least one time-dependent acoustic data signal indicative of an acoustic signal generated by a thermal spray system performing a process possessing a plurality of process attributes, and a computing device including an acoustic data signal processing module configured to receive the at least one time-dependent acoustic data signal, and transform the at least one time-dependent acoustic data signal to a frequency-domain spectrum, wherein each process attribute of the plurality of process attributes is associated with at least one respective frequency band, and a correlation module configured to determine a process attribute of the plurality of process attributes by identifying at least one characteristic of the frequency-domain spectrum.