Diagnosis of thermal spray gun ignition
First Claim
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1. A system comprising:
- at least one acoustic sensor configured to generate at least one acoustic data signal indicative of an acoustic signal generated by a thermal spray system comprising a flowstream;
a computing device comprising at least one processor;
an acoustic data signal processing module operable by the at least one processor to determine an ignition attribute of the thermal spray system by analyzing at least a pre-ignition window of the acoustic data signal received by the computing device by at least;
transforming the at least one acoustic data signal associated with the pre-ignition window to a frequency-domain spectrum, and comparing a peak intensity within a selected frequency band of the frequency-domain spectrum with a predetermined intensity range for the selected frequency band to determine the ignition attribute of the thermal spray system; and
an output device configured to output at least one of an alert or a representation of at least one of the at least one acoustic data signal, the ignition attribute, or a spectrogram associated with the pre-ignition window, wherein the computing device is configured to, in response to determining that the ignition attribute is indicative of ignition failure or improper ignition, stop or restart a thermal spray process performed by the thermal spray system by sending a control signal to the thermal spray system before introducing spray material into the flowstream.
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Abstract
An example system includes at least one acoustic sensor configured to generate at least one acoustic data signal indicative of an acoustic signal generated by a thermal spray system comprising a flowstream, a computing device, and an acoustic data signal processing module operable by the computing device to determine an ignition attribute of the thermal spray system by analyzing at least a pre-ignition window of the acoustic data signal received by the computing device.
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Citations
16 Claims
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1. A system comprising:
- at least one acoustic sensor configured to generate at least one acoustic data signal indicative of an acoustic signal generated by a thermal spray system comprising a flowstream;
a computing device comprising at least one processor;
an acoustic data signal processing module operable by the at least one processor to determine an ignition attribute of the thermal spray system by analyzing at least a pre-ignition window of the acoustic data signal received by the computing device by at least;
transforming the at least one acoustic data signal associated with the pre-ignition window to a frequency-domain spectrum, and comparing a peak intensity within a selected frequency band of the frequency-domain spectrum with a predetermined intensity range for the selected frequency band to determine the ignition attribute of the thermal spray system; and
an output device configured to output at least one of an alert or a representation of at least one of the at least one acoustic data signal, the ignition attribute, or a spectrogram associated with the pre-ignition window, wherein the computing device is configured to, in response to determining that the ignition attribute is indicative of ignition failure or improper ignition, stop or restart a thermal spray process performed by the thermal spray system by sending a control signal to the thermal spray system before introducing spray material into the flowstream. - View Dependent Claims (2, 3, 4, 5, 6, 7)
- at least one acoustic sensor configured to generate at least one acoustic data signal indicative of an acoustic signal generated by a thermal spray system comprising a flowstream;
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8. A method comprising:
- receiving, by a computing device, from at least one acoustic sensor, at least one acoustic data signal indicative of an acoustic signal generated by a thermal spray system comprising a flowstream;
determining, by the computing device, an ignition attribute of the thermal spray system by analyzing at least a pre-ignition window of the acoustic data signal by at least;
transforming the at least one acoustic data signal to a frequency-domain spectrum, and comparing a peak intensity within a selected frequency band with a predetermined intensity range for the selected frequency band;
causing, by the computing device, an output device to output at least one of an alert or a representation of at least one of the at least one acoustic data signal, the ignition attribute, or a spectrogram; and
causing, by the computing device, in response to determining that the ignition attribute is indicative of ignition failure or improper ignition, stop or restart a thermal spray process performed by the thermal spray system by sending a control signal to the thermal spray system before introducing spray material into the flowstream. - View Dependent Claims (9, 10, 11, 12, 13, 14)
- receiving, by a computing device, from at least one acoustic sensor, at least one acoustic data signal indicative of an acoustic signal generated by a thermal spray system comprising a flowstream;
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15. A non-transitory computer readable storage medium comprising instructions that, when executed, cause at least one processor to:
- receive, from at least one acoustic sensor, at least one acoustic data signal indicative of an acoustic signal generated by a thermal spray system comprising a flowstream;
determine an ignition attribute of the thermal spray system by analyzing at least a pre-ignition window of the acoustic data signal by at least;
transforming the at least one acoustic data signal associated with the pre-ignition window to a frequency-domain spectrum, and comparing a peak intensity within a selected frequency band of the frequency-domain spectrum with a predetermined intensity range for the selected frequency band to determine the ignition attribute of the thermal spray system;
cause an output device to output at least one of an alert or a representation of at least one of the at least one acoustic data signal, the ignition attribute, or a spectrogram; and
cause, in response to determining that the ignition attribute is indicative of ignition failure or improper ignition, stop or restart a thermal spray process performed by the thermal spray system by sending a control signal to the thermal spray system before introducing spray material into the flowstream. - View Dependent Claims (16)
- receive, from at least one acoustic sensor, at least one acoustic data signal indicative of an acoustic signal generated by a thermal spray system comprising a flowstream;
Specification