Coaxial Collection Tubes for Spray Nozzle Distribution Testing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for testing spray nozzle distribution patterns in additive manufacturing, such as directed energy deposition, lack precision in measuring particle distribution and flow rates, leading to deposition defects like voids, inclusions, and uneven material incorporation.
Innovation Solution
A system comprising multiple coaxial collection tubes with varying diameters and angles, fluidically connected to receptacles, allows for precise measurement of particle size and weight distribution as a function of radial position and distance from the spray nozzle, reducing collision with collection tube walls and gas flow backpressure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional testing methods are used for spray nozzle distribution patterns, then the testing process is simple, but measurement precision of particle distribution and flow rates deteriorates
Solution Approach 1:
The collection system is divided into multiple separate collection tubes, each corresponding to different radial zones of the spray pattern. Each tube collects particles from a specific angular sector, allowing independent measurement of particle distribution in different regions. This segmentation enables precise mapping of the spray nozzle distribution pattern while maintaining a relatively simple overall system architecture.
Solution Approach 2:
The invention transitions from conventional two-dimensional spray pattern visualization to three-dimensional particle collection by using multiple collection tubes arranged in specific spatial configurations. Each tube captures particles from a unique angular and radial position, creating a three-dimensional measurement dataset that provides comprehensive characterization of the spray distribution pattern.
2Measurement precision
If collection tubes are positioned close to the spray nozzle for accurate measurement, then measurement accuracy improves, but collision with collection tube walls increases
Solution Approach 1:
Each collection tube is designed with specific local geometric characteristics, including optimized entry angles and internal surface properties, to minimize particle-wall collisions while maintaining effective particle collection. The tubes are positioned at specific radial distances and angular orientations that match the local spray pattern characteristics, allowing accurate measurement without excessive particle impact.
Solution Approach 2:
The collection tubes serve as intermediary structures that capture particles from the spray plume without requiring direct contact between the spray nozzle and the measurement detection system. This intermediary approach allows particles to be collected and measured after they have naturally dispersed through a portion of the spray pattern, reducing collision effects while maintaining measurement representativeness.
3Measurement precision
If multiple collection tubes are used to measure distribution patterns, then measurement comprehensiveness improves, but gas flow back pressure increases
Solution Approach 1:
The gas flow path is segmented into multiple independent channels, each leading to a separate collection tube. This segmentation allows the total gas flow to be distributed across multiple parallel pathways, reducing the back pressure in each individual channel while maintaining comprehensive particle collection capability across all spray zones.
Solution Approach 2:
The system utilizes pneumatic principles to design the collection tubes with optimized internal geometries and flow paths that minimize flow resistance. The tubes are configured to allow smooth gas flow with minimal turbulence and pressure drop, enabling multiple tubes to operate simultaneously without excessive back pressure affecting the spray nozzle operation.
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
Enables direct measurement of spray nozzle distribution patterns, improving the accuracy of material delivery and reducing defects in additive manufacturing components by analyzing particle size, flow rate, and composition distribution.
Implementation Method 1
A system comprising multiple coaxial collection tubes with varying diameters and angles, fluidically connected to receptacles, allows for precise measurement of particle size and weight distribution
Data Source
Figure 1
Figure 2
Figure 3
AI summary
An example spray nozzle distribution pattern testing system (10) may include coaxial collection tubes (14) extending substantially parallel to a major axis (16), where each coaxial collection tube includes a first end (18) defining an orifice (20), where the first end is disposed at a first position (22) on a plane substantially orthogonal to the major axis, a second end (24) coupled to an end of a respective outlet tube (42), and a collection tube wall (28) extending from the first end to the second end, where the collection tube wall at the first end includes a first diameter, where the collection tube wall at a second position between the first end and the second end includes a second diameter greater than the first diameter, where the collection tube wall extending from the second position to the first position tapers toward the major axis at a first angle.