An Overview
En’Urga Inc.
1201 Cumberland Ave., West Lafayette, IN 47906, USA
765-497-3269
765-463-7004
http://www.enurga.com
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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
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Background on Optical Patternation
激光喷雾分布仪的背景介绍
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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
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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
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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
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Laser Sheet Imaging （Cont‘d）
Potential Errors Source: Brown et al., ILASS - 2003
 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
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Planar Laser Induced Fluorescence
 Excited with laser sheet
由激光切面激发
Nd: YAG
Beam
expander
Spray
laser
 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
Cylindrical
lens
Beam
stop
Laser sheet
CCD
Camera
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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
Source: Pastor et al., Opt. Express, 2002
Nd:
YAG
laser
Beam
expand
er
Cylindr
ical
lens
CCD
Camer
a
Sp
ray
Beam
stop
Laser
sheet
Implication: Difficult to get for quantitative patternation
不能提供定量的喷雾分布检测
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SETScan Patternator
Spray cross-section
Laser
Source
Array
detector
Laser sheet
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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
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Primer on Tomography X光断层摄影术
Product
q
Field of interest
X-ray source
Detector array
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Primer on Tomography (Cont’d)
Product
Technique
Boundary Measurement
边界测量
Internal Structure
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
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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%)
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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
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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
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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
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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
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Sample Applications
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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 lbs
Drop Surface Area Map
Only optical patternator for high obscuring sprays
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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
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Automotive Injector
Mean plume
angles (deg.)
10.89
5.73
11.53
10.48
11.51
9.35
% area in
plume
19.32
4.69
21.71
17.91
23.06
12.93
Mean centroid
(x, mm)
3.26
-4.84
-22.13
-29.04
-15.37
0.10
Mean centroid
(y, mm)
-5.69
14.28
1.97
-10.75
-18.49
-20.01
Reliable data with
multiple orifice injectors
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Flat Fan Paint Nozzle
Summary Report:
Major angle
Minor angle
Deviation from center
Unsteadiness
Y-Integral
Custom parameters
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Quality Assurance of Nozzles
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Quality Control Objectives
 Define QC parameters
 Set tolerance limits
定义质量控制参数
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
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Sample QC parameter (1): Spray Angle
Nozzle
X
Measurement plane
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Sample QC parameter (2): Angular Distribution
Maximum distance
Normalized surface area density (%/degree)
0.36
Test Nozzle
Master template
0.34
Max  Sit  Sim
0.32
0.30
L2 Norm
0.28
0.26
0.24
1 N i i 2
L2 
 (St Sm )
N i 1
0.22
0.20
0.18
0
50
100
150
200
250
300
350
Angle (degrees)
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Sample QC Parameter (3): Radial Uniformity
Maximum distance
X Max  S it  S mi
L2 Norm
1 N i i 2
L2 
 (St Sm )
N i 1
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Quality Audit System Configuration
Spray gun
SQL Database
Control
Unit
Data Acquisition/
Processing/Display
Optical
Patternator
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Sample QC Report Generated by SETscan
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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
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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
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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
United Technologies
Aerosapce System
Toyota
Dow Agrosciences
Laboratories
Bosch LLC.
Vertex
Pharmaceuticals
3M
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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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