The sensor systems of the SpraySpy® ProcessLine are developed for inline quality monitoring and process automation of industrial coating processes — this is what makes them so unique.
SpraySpy® ProcessLine instruments measure and digitize the most important spray quality parameters. This data is processed by AI-based SprayAI® algorithms to automatically detect even the smallest anomalies in the spray. This is essential for the digital coating process and an intelligent, state-of-the-art paint shop.
Stop reacting to product failure. Start acting on the spray!
Spray monitoring with SpraySpy® helps prevent the most common coating defects inline, in the spray coating process, and in real time.
The sensor systems can be integrated inline into the production line, providing automated 24/7 quality monitoring of the production process. The integrated SprayAI® software analyzes the data in real time and classifies the process as OK or NOK throughout the running process.
Saving the monitoring data gives you a log file of the quality level. In addition, the data can be further processed, for example for smart maintenance or closed-loop spray applications. SpraySpy® data is also an essential input for a digital twin of your coating process or spray application.
Different patented innovations are implemented in SpraySpy® technology. This makes SpraySpy® products easy to use and a reliable addition to your quality monitoring and process automation.
SpraySpy® demonstration video:
SpraySpy® on a Bell Atomizer – example for real time spray monitoring in the process:
SpraySpy® highlights:
- Checking the spray quality by monitoring different spray parameters, for example:
- droplet size
- droplet velocity
- volume flow / transfer efficiency
- spray angle
- Suitable for explosive atmospheres (ATEX) & High-Voltage Application
- Suitable for clean-room environments
- IP67 measurement probe
- Detection of spray anomalies >2% variation from the set point
- Over 90% certainty in the failure root identification
- Component for a digital coating line and smart factory
- Patented SprayAI® software technology, based on artificial intelligence
- Applicable for all kind of atomizers and all kind of liquid sprays
- Relays status signals in real time to process control system
- Automated process documentation
- Digitalization of the spray process (AI-ready)
- Monitoring of the process quality, instate of just the product quality
SpraySpy® savings examples:
- Forecasting when equipment will wear out and when the nozzle will become contaminated helps optimize maintenance services. Services are therefore carried out directly before a defect occurs, rather than too early or too late. This minimizes service and downtime, as well as costs for spare parts.
- A reliable forecast of the production process leads to an OK or NOK classification and separates defective parts throughout the process. This increases your first-run rate.
- Real-time, inline monitoring of the spray jet allows the volume flow per unit area – and thus the coating application (film thickness) – to be monitored. This means, for example, that a minimum film thickness on the component can be ensured during the coating process itself, as opposed to an end-of-line inspection. Consequently, the safety factor for the layer thickness (buffer layer) can be radically reduced. This saves up to 15% of the paint used, and end-of-line inspection can also be reduced to a minimum.
- By integrating SpraySpy® into the system, the system’s operating parameters can be correlated with error patterns and assigned to a spray pattern. Any process fault can thus be attributed to a specific cause with over 90% certainty. In the event of a fault, this allows it to be rectified immediately without a lengthy troubleshooting process. It is then possible to take corrective action in real time while the coating is being applied (control loop).
Further Information: