Spray Nozzle Deposit Detection via Digital Image Comparison
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Solution Overview
Problem
Current spray drying and spray cooling systems lack automated monitoring for nozzle performance changes, leading to potential product quality issues, deposit buildup, and safety risks such as overheating and fires, requiring manual operator attention which is time-consuming and inefficient.
Innovation Solution
A method using digital optical cameras to record reference and process images of spray nozzles, detecting pixel differences and issuing notifications when predetermined thresholds of error pixels are reached, allowing for automated detection and alerting of nozzle performance changes, including deposit buildup, thereby reducing manual monitoring needs and ensuring safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual monitoring by operators is used to detect nozzle performance changes, then operator awareness of nozzle issues is maintained, but time consumption and labor requirements increase significantly
Solution Approach 1:
The system enables self-service monitoring where the nozzle performance detection is automated through image capture and processing. The computer automatically captures images, processes them to detect deposit buildup, and generates alerts without requiring operator intervention, thus maintaining reliability while eliminating time consumption.
Solution Approach 2:
The patent replaces the mechanical/manual monitoring system with an automated image processing system. Instead of operators visually inspecting nozzles, the system uses cameras to capture images and computer algorithms to automatically detect performance changes, substituting human labor with automated technological means.
2Object-affected harmful factors
If traditional temperature monitoring systems are used to detect fires and explosions, then safety against thermal hazards is provided, but early detection of nozzle performance degradation is not achieved
Solution Approach 1:
The system performs preliminary detection of nozzle performance degradation by capturing images and detecting deposit buildup before thermal hazards occur. By monitoring nozzle condition in advance and alerting operators to performance changes, the system enables preventive action before fires or explosions can develop.
Solution Approach 2:
The system establishes a feedback loop where nozzle performance is continuously monitored through image capture and processing. The computer analyzes images to detect changes in nozzle appearance or spray patterns, provides feedback through alerts when degradation is detected, and enables corrective action to prevent safety incidents.
3Loss of time
If automated image processing is implemented to detect nozzle deposit buildup, then early warning of nozzle performance changes is achieved, but system complexity increases
Solution Approach 1:
The system uses optical copying by capturing images of the nozzle and its spray pattern. Instead of directly measuring physical parameters, the system creates visual copies through imaging and processes these copies to detect deposit buildup, simplifying the measurement approach while maintaining detection effectiveness.
Solution Approach 2:
The patent introduces an intermediary image processing system between the nozzle and the operator. The camera captures images and the computer processes them to extract information about nozzle performance, acting as an intermediary that translates physical nozzle conditions into detectable visual signals without requiring direct physical measurement.
4Reliability
If continuous manual observation of nozzle spraying performance is performed, then real-time detection of spraying issues is achieved, but operational efficiency decreases due to operator workload
Solution Approach 1:
The monitoring system performs self-service by automatically capturing images, processing them to detect spray performance issues, and generating alerts without operator involvement. This maintains reliable monitoring of spray performance while freeing operators to focus on other value-added tasks, thereby improving operational efficiency.
Solution Approach 2:
The patent replaces manual visual inspection with automated image processing technology. The system uses cameras and computer algorithms to monitor spray performance continuously, substituting human observation with automated technological means that maintain reliability while eliminating the productivity loss associated with manual monitoring workload.
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
The system enables automated and efficient monitoring of nozzle performance, reducing the risk of product quality issues and safety hazards by promptly alerting operators to changes, thus enhancing operational efficiency and safety.
Implementation Method 1
obtaining and recording a reference image by use of one or more digital optical cameras
Data Source
Figure 1
Figure 2a~2c
Figure 3a~3b
AI summary
There is provided a method for monitoring deposit build-up on spray nozzles in a spray drying or spray cooling chamber. The method comprises feeding drying air or cooling air into the chamber, and feeding a feed material to be spray dried or spray cooled into the chamber through one or more spray nozzles, thereby obtaining one or more sprays of feed material in contact with drying or cooling air. A digital reference image is obtained, which reference image has an image area comprising a first area of interest covering at least part of a spray nozzle and/or part of a feed material spray corresponding to a spray nozzle. A number of process images are obtained and recorded, where the process images cover the same image area as the reference image, and at least part of the recorded process images are compared with the reference image, and a difference, if any, is detected for the first interest area between the reference image and the process images being compared to the reference image. A notification or error notification may be issued based on the detected differences. The notification may be issued when a predetermined minimum difference is detected for each of a predetermined number of recorded process images. The present invention also provides a system for monitoring spray nozzles in a spray drying or spray cooling chamber.