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Optical Patternation in Quality Assurance: An Overview

Learn about optical patternation, its applications, and how it enhances quality assurance processes. Explore various types and potential errors, featuring SETScan technology with high-speed CATscan capabilities. Discover performance highlights and quality control insights.

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Optical Patternation in Quality Assurance: An Overview

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  1. 765-497-3269 765-463-7004 The SETScan Patternator An Overview En’Urga Inc. 1201 Cumberland Ave., West Lafayette, IN 47906, USA http://www.enurga.com

  2. 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

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

  4. 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

  5. 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

  6. 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

  7. Laser Sheet Imaging（Cont‘d） Potential Errors • Laser extinction 激光消光 • Signalattenuation 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

  8. Spray Beam expander Beam stop Cylindrical lens Laser sheet CCD Camera Nd: YAG laser 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

  9. Planar Laser Induced Fluorescence (Cont‘d) Spray Beam expander Beam stop Cylindrical lens Laser sheet CCD Camera Nd: YAG laser Potential Errors • Laser extinction 激光消光 • Signalattenuation 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

  10. SETScan Patternator Spray cross-section Array detector Laser Source Laser sheet

  11. 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

  12. q Field of interest X-ray source Detector array Primer on TomographyX光断层摄影术 Product

  13. Primer on Tomography(Cont’d) Product Technique • 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

  14. 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%)

  15. 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

  16. 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

  17. Why surface area density • The rate of fuel or liquid evaporation is proportional to surface area densityin 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

  18. Comparison with Competitive Technology SETscan: Only quantitativeoptical 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

  19. Sample Applications

  20. Aircraft Engine Nozzle • Struts signature 结构凹凸特征 • Hollow cone 空心锥体 • Drip 喷滴 • 1100 lbs perhour 每小时1100 lbs Drop Surface Area Map Only optical patternator for high obscuring sprays

  21. 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

  22. Automotive Injector Reliable data with multiple orifice injectors

  23. Flat Fan Paint Nozzle Summary Report: Major angle Minor angle Deviation from center Unsteadiness Y-Integral Custom parameters

  24. Quality Assurance of Nozzles

  25. 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

  26. X Sample QC parameter (1): Spray Angle Nozzle Measurement plane

  27. Sample QC parameter (2): Angular Distribution • Maximum distance • L2 Norm

  28. Sample QC Parameter (3): Radial Uniformity • Maximum distance • L2 Norm

  29. Optical Patternator Quality Audit System Configuration Spray gun SQL Database Control Unit Data Acquisition/ Processing/Display

  30. Sample QC Report Generated by SETscan

  31. 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

  32. 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

  33. Selected Patternator Customers

  34. 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”

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