Nozzle Spray Width Measurement Using Cylindrical Optical Sensing
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Solution Overview
Problem
Current methods for measuring nozzle parameters, such as spraying width, are inaccurate due to expansion of the spraying diameter caused by high-pressure gas and delays in signal transmission, leading to unreliable digital twin simulations.
Innovation Solution
A nozzle parameter measuring device that projects the spraying width onto a lateral horizontal plane, using a hollow cylinder with a light sensor to detect the coating material's position, allowing for accurate calculation of diameter, height, and angle, and accounts for spraying delay time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the overhead projection measuring method is used to measure spraying width, then the measurement process is simple, but the measurement precision deteriorates due to diameter expansion caused by high-pressure gas and atomization
Solution Approach 1:
The patent transitions from measuring spraying width on a horizontal reference plane (2D overhead projection) to measuring coating material deposition on the inner wall surface of a hollow cylinder (3D lateral surface). This dimensional change allows the coating material to be deposited vertically along the cylinder wall, preventing the horizontal expansion and atomization issues that occur in traditional overhead projection methods.
Solution Approach 2:
The hollow cylinder serves as an intermediary structure between the nozzle and the measurement surface. Instead of measuring directly on a reference plane, the coating material is deposited on the cylinder's inner wall, which acts as a mediator that captures the spraying pattern without being affected by high-pressure gas expansion. The light sensor then detects the deposition pattern on this intermediary surface.
2Productivity
If high-pressure gas is used to continuously spray coating material, then the spraying process is efficient, but the measurement accuracy deteriorates due to airflow pushing material outward and increasing spraying width over time
Solution Approach 1:
The patent changes the measurement geometry from horizontal projection to vertical deposition on a cylindrical surface. The hollow cylinder's inner wall provides a vertical surface where coating material accumulates from top to bottom, converting the horizontal spreading problem into a vertical deposition problem that is not affected by radial airflow forces.
Solution Approach 2:
The hollow cylinder is pre-positioned around the nozzle before spraying begins, creating a confined space that directs and contains the coating material deposition. This preliminary setup ensures that the coating material is deposited in a controlled manner on the cylinder wall, preventing uncontrolled outward expansion during the spraying process.
3Extent of automation
If electrical signals and high-pressure gas transmission are used to control spraying, then the system is automated, but the measurement accuracy deteriorates due to delays in signal transmission and gas compressibility
Solution Approach 1:
The patent replaces the traditional overhead projection measurement system with an optical detection system using a light sensor. The light sensor emits light through the hollow cylinder and detects the deposition pattern of coating material on the inner wall, providing direct optical measurement that is not affected by electrical signal transmission delays or gas compressibility effects.
Solution Approach 2:
The light sensor acts as an intermediary detection device that directly measures the coating material deposition on the cylinder wall. This optical intermediary provides real-time measurement data without being affected by the delays inherent in electrical signal transmission and high-pressure gas dynamics, thereby improving timing accuracy.
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 precise measurement of spraying parameters, enhancing the accuracy of digital twin simulations by establishing a reliable spraying behavior model, improving predictability and simulation fidelity.
Implementation Method 1
a light sensor disposed directly facing a direction of the nozzle, wherein the light sensor is configured for detecting a covering time when an emitted light is covered by the coating material
Data Source
Figure 1
Figure 2A
Figure 2B
AI summary
Nozzle parameter measuring device is used for measuring a spraying width of a nozzle to be measured when the nozzle sprays a coating material and includes a connection part (21), a measuring kit (22), and a sensing part (23). The connection part (21) is connected to the nozzle (1) and the measuring kit (22). The measuring kit (22) is a hollow cylinder with an inner wall (223). The nozzle (1) sprays a coating material (12) toward the inside of the measuring kit (22) so that the coating material (12) is coated on the inner wall (223) of the measuring kit (22). The sensing part (23) is connected to another side of the measuring kit (22) relative to the connection part (21) and has a light sensor (231) disposed in the direction of the nozzle (1). The light sensor (231) is configured for detecting a time when an emitted light being covered, and a spraying width of the nozzle (1) is calculated.