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Diagnosis of thermal spray gun ignition

  • US 10,241,091 B2
  • Filed: 06/03/2016
  • Issued: 03/26/2019
  • Est. Priority Date: 06/04/2015
  • Status: Active Grant
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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