® innovations in quality control An Overview En’Urga Inc. 1201 Cumberland Ave., West Lafayette,...

®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


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


Background on Optical Patternation激光喷雾分布仪的背景介绍


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


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


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


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


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


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


SETScan Patternator

Laser sheet

Laser Source

Array detector

Spray cross-section


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


Primer on Tomography X 光断层摄影术 Product

X-ray source

Detector array

Field of interest


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


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%)


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


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


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


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


Sample Applications


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


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


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


Flat Fan Paint Nozzle

Summary Report:

Major angle Minor angle Deviation from center Unsteadiness Y-Integral Custom parameters


Quality Assurance of Nozzles


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


Sample QC parameter (1): Spray Angle

Measurement plane

Nozzle

X


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)


Sample QC Parameter (3): Radial Uniformity

2im

N

1i

it2 )SS(

N

1L

im

itMax SSX

Maximum distance

L2 Norm


Quality Audit System Configuration

Data Acquisition/Processing/Display

Control Unit

SQL Database

OpticalPatternator

Spray gun


Sample QC Report Generated by SETscan


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


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


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


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”

® innovations in quality control An Overview En’Urga Inc. 1201 Cumberland Ave., West Lafayette,...

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