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®innovations in quality control
An Overview
En’Urga Inc.1201 Cumberland Ave., West Lafayette, IN 47906, USA
765-497-3269 765-463-7004
http://www.enurga.com
®innovations in quality control
Outline
Background on optical patternation
激光喷雾分布仪的背景介绍
Sample applications
应用案例
Quality assurance using optical patternator
采用激光喷雾分布仪的质量保证过程
®innovations in quality control
Background on Optical Patternation激光喷雾分布仪的背景介绍
®innovations in quality control
Why Optical Patternation Fast, capable of obtaining transient data
快速 , 有能力获取瞬态数据 Greater reproducibility and spatial resolution than
mechanical devices
远胜机械式分布仪的可重复性和空间分辨率 Does not interfere with the spray
对喷雾没有扰动 Low maintenance and operational cost
极低的维护和运行成本
®innovations in quality control
Principal Types of Optical Patternators
Laser sheet imaging 激光切面成像法
Planar Laser Induced Fluorescence 平面激光感生荧光喷雾检测法 Extinction based systems 基于消光的喷雾分布检测系统
®innovations in quality control
Laser Sheet Imaging
Laser sheet to illuminate spray
采用激光切面照亮喷雾 Image taken using a CCD
camera at an oblique angle
通过侧方向安装的 CCD 摄像机获取图像
Intensity proportional to drop surface area per unit volume
每单位体积的液滴表面积与亮度成对比
®innovations in quality control
Laser Sheet Imaging ( Cont‘d )Potential Errors Laser extinction
激光消光 Signal attenuation
信号衰减 Secondary emission
多次散射
Implication: Difficult to get for quantitative patternation
不能提供定量的喷雾分布检测
Source: Brown et al., ILASS - 2003
®innovations in quality control
Planar Laser Induced Fluorescence
Excited with laser sheet
由激光切面激发
Fluorescence observed with CCD array
用 CCD 阵列获取荧光
Intensity proportional to fuel volume fraction
亮度正比于燃油容积率
Nd: YAG laser
Beam expander
Cylindrical lens
Spray
Laser sheet
CCD Camera
Beam stop
®innovations in quality control
Planar Laser Induced Fluorescence (Cont‘d)Potential Errors Laser extinction
激光消光 Signal attenuation
信号衰减 Shot-to-shot variation
每次投射强度的变化
Implication: Difficult to get for quantitative patternation
不能提供定量的喷雾分布检测
Source: Pastor et al., Opt. Express, 2002
Nd: YAG laser
Beam expander
Cylindrical lens
Spray
Laser sheet
CCD Camera
Beam stop
®innovations in quality control
SETScan Patternator
Laser sheet
Laser Source
Array detector
Spray cross-section
®innovations in quality control
Principle of the SETScan Patternator Path integrated extinction of laser sheets
Multiple view angles and multiple slices to obtain high spatial resolution
Local extinction coefficients obtained by statistical tomography (MLE method)
For liquid sprays, the local extinction coefficients is linearly proportional to the drop surface areas per unit volume 单位体积内液滴表面积
Major characteristics of spray can be obtained by analyzing the drop surface area distribution
®innovations in quality control
Primer on Tomography X 光断层摄影术 Product
X-ray source
Detector array
Field of interest
®innovations in quality control
Primer on Tomography (Cont’d) Technique Product
Boundary Measurement Internal Structure
边界测量 内部结构Non-invasive
无创性检测CATscan : most successful medical diagnostic device
CATscan :最成功的医疗设备SETscan = Laser-Based Ultra-High-Speed CATscan
SETscan 可被认做成基于激光的超高速 CATscan
®innovations in quality control
Performance Highlights of the SETScan Fast Up to 10 K frame per second
transient patternation of fuel injector sprays
快速 最高到 10,000 帧 / 秒 瞬态的分布扫描燃油喷嘴的喷雾
Extinction Well developed theory and technique
消光 完备发展的理论和技术 MLE Deconvolution Accurate (+/- 2%)
MLE 反卷积 精度 (+/- 2%)
®innovations in quality control
Performance Highlights (cont'd) High repeatability (+/- 1% on patternation number)
高可重复性 质量保证 (+/- 1%)
Six line-scan cameras (six axes), 512 pixels per axis
Angular resolution up to 5 degrees
Spatial resolution up to 0.2 mm
六台线扫描相机(分别位于六个轴) , 每轴 512 像素
角度分辨率最高到 5 度
空间分辨率最高到 0.2 mm
®innovations in quality control
Basic Information for Quality Control
Mean, RMS, and RMS/Mean of drop surface area density
uniformity, steadiness, drop size variations, presence of streaks and voids液滴表面浓度的均值,均方根,和均值 / 均方根
均匀性,稳定性,液滴大小的变化
®innovations in quality control
Why surface area density
The rate of fuel or liquid evaporation is proportional to surface area density in combustion
Correlation coefficient (R) of different parameters with total fuel evaporated
Mass flux R = 0.903 Velocity R = -0.239
Diameter R = 0.681
Surface area density R = 0.961 For combustion and urea dosing applications,
using surface area density is the best choice of evaluating nozzles
®innovations in quality control
Comparison with Competitive Technology
SETscan: Only quantitative optical patternator
+/- 2% on absolute values, +/- 1% repeatability
Reliable 100% quality assurance of nozzles Quick design verification tool Laser extinction Immune to environmental lighting
Diode lasers Class II, No safety issues
Monolithic Out-of-box factory floor deployment
Adaptive grids Alignment of nozzle not critical
®innovations in quality control
Sample Applications
®innovations in quality control
Aircraft Engine Nozzle
Struts signature
结构凹凸特征Hollow cone
空心锥体Drip
喷滴1100 lbs per
hour
每小时 1100 lbsOnly optical patternator for high obscuring sprays
Drop Surface Area Map
®innovations in quality control
Interpretation of Data The data is the ensemble average of drop surface area
per unit volume
Differs from mechanical patternator (which is time average of mass flux)
High surface area indicates streaks
Low surface area indicates voids
95% ring typically used for spray angle
®innovations in quality control
Automotive InjectorMean plume angles (deg.)
% area in plume
10.89 19.325.73 4.6911.53 21.7110.48 17.9111.51 23.069.35 12.93
Mean centroid (x, mm)
Mean centroid (y, mm)
3.26 -5.69-4.84 14.28-22.13 1.97-29.04 -10.75-15.37 -18.490.10 -20.01
Reliable data with multiple orifice injectors
®innovations in quality control
Flat Fan Paint Nozzle
Summary Report:
Major angle Minor angle Deviation from center Unsteadiness Y-Integral Custom parameters
®innovations in quality control
Quality Assurance of Nozzles
®innovations in quality control
Quality Control Objectives
Define QC parameters 定义质量控制参数 Set tolerance limits 设置公差限值 Generate master template 产生主模板 Compare each nozzle with master template
每个喷嘴与主模板进行对比 Accept/reject nozzle based on patternation result
基于分布测量结果,接受 / 拒绝喷嘴
®innovations in quality control
Sample QC parameter (1): Spray Angle
Measurement plane
Nozzle
X
®innovations in quality control
Sample QC parameter (2): Angular Distribution
2im
N
1i
it2 )SS(
N
1L
im
itMax SS
Maximum distance
L2 Norm
0 50 100 150 200 250 300 3500.18
0.20
0.22
0.24
0.26
0.28
0.30
0.32
0.34
0.36
Test Nozzle Master template
Norm
aliz
ed s
urf
ace
area
den
sity
(%
/deg
ree)
Angle (degrees)
®innovations in quality control
Sample QC Parameter (3): Radial Uniformity
2im
N
1i
it2 )SS(
N
1L
im
itMax SSX
Maximum distance
L2 Norm
®innovations in quality control
Quality Audit System Configuration
Data Acquisition/Processing/Display
Control Unit
SQL Database
OpticalPatternator
Spray gun
®innovations in quality control
Sample QC Report Generated by SETscan
®innovations in quality control
Sample Installation (OP-600)
2 computer QA system
Automatic nozzle mounts
Booth by Alsmatik
QA software by En’Urga
Mulitple types of nozzles
Typical output: 1000/day
Photograph: Courtesy Danfoss S/A
®innovations in quality control
Product Quality Implications
SETscan: On-line 100% inspection of nozzles enabled
Critical in aero-engine urea dosing nozzle tests
Traceable and warehoused data
Sorting of already manufactured nozzles
®innovations in quality control
Selected Patternator Customers
Abbott General Motors Hitachi
Bend Research Cummins AVL
Pfizer Emcom Technologies FEV
S.C. Johnson & Son Faurecia Nordson
Catalytica Energy Donaldson Delavan
Delphi Proctor & Gamble Woodward
Ricardo Honeywell Tenneco
Continental Bombardier Synerject
Eaton Rolls Royce Danfoss
Columbian Chemical General Electric Boston Scientific
Toyota Bosch LLC. 3M
United Technologies Aerosapce System
Dow Agrosciences Laboratories
Vertex Pharmaceuticals
®innovations in quality control
Selected Customer Comments
“We purchased the patternator and in six months we approached our customer with a request to tighten tolerances on the nozzles we produce”
“The SETscan patternator has given us an order of magnitude return on investment within one year after we purchased it”
“The first time I saw the patternation results obtained with our nozzles on the SETscan, I was amazed. I did not realize what was possible with current technology”
“Our department will most probably win the improved productivity award of our company, thanks in a large measure to the SETscan patternator”