|
| Abstract No.: |
|
Scheduled at:
|
Friday, May 06, 2022, Hall K2 1:40 PM
Process Diagnostics, Sensors & Controls
|
|
| Title: |
Improvement of in-flight particle diagnostic system to monitor process stability in thermal spray processes
|
|
| Authors: |
Wania Jibran* / Tecnar Automation Ltée, Canada
Wania Jibran / Tecnar Automation Ltee, Canada
Alexandre Nadeau/ Tecnar Automation Ltee, Canada
Christian Desmarais/ Tecnar Automation Ltee, Canada
|
|
| Abstract: |
In the past 25 years, we have seen thermal spray processes such as Atmospheric Plasma Spray (APS), High Velocity Oxygen Fuel Spray (HVOF) and Suspension Plasma Spraying (SPS) transition from research and development towards key production technology. Since thermal spraying is a multiparameter and multiresponse process, it is susceptible to process instabilities. Consistency and repeatability is of utmost importance in production lines that spray high volumes of coatings. Since process parameters such as feed rates, particle velocity, temperature, electrode wear and nozzle blockages can dramatically affect the coating properties, monitoring and controlling these parameters can significantly improve the process repeatability. An online process monitoring sensor such as the Accuraspray 4.0 is a powerful tool that can help ensure repeatable coatings. In an effort to make process monitoring more production friendly, the Accuraspray 4.0 was upgraded in 2021 to include a process stability measurement. This new sensor platform takes advantage of its individually validated data captured 25 times per second to supplement its average measurements of in-flight spray parameters with robust standard deviation criteria. The sensor now compares the live deviation of different spray parameter measurements in a particular spray process to their reference deviations in order to produce a process stability reading. The targeted reference standard deviations are found through statistical data analysis by characterizing a stable process for any spray process. The platform allows the user to define tolerance windows for the stability measurement depending on the level of confidence desired. Since the Accuraspray 4.0 is designed around Industry 4.0 principles, the new process stability measurement can be used to trigger the spray cell robot for Go/No-Go decisions to ensure seamless, automated spraying. This upgrade brings the Accuraspray 4.0 one step closer to becoming the industry standard for thermal spray production facilities.
|
|