The sensor systems of the SpraySpy® ProcessLine are developed for the (inline) quality monitoring and process automation of industrial coating processes, this makes them so unique.
SpraySpy® ProcessLine instruments measure and digitize the most important spray quality parameters. Those data are processed by artificial intelligence (AI) based SprayAI® algorithms to detect automated even smallest anomalies in the spray. This is essential for the digital coating process and an intelligent state of the art paint shop.
Spray monitoring with SpraySpy® can help to prevent the most common paint coating defects inline in the spray coating process and in real time.
The sensor systems can be integrated inline in the production line, doing so you have an automated 24/7 quality monitoring of the production process. The integrated SprayAI® Software analysis the data in real time and classifies the process into 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. The SpraySpy® data is as well an essential piece of data for a digital twin of your coating process or spray application.
Different patented innovations are implemented into the SpraySpy®-technology. This makes SpraySpy® products easy to use and a reliable expansion for your quality monitoring and process automation.
SpraySpy® demonstration video:
SpraySpy® on a Sames Bell Atomizer – example for real time spray monitoring in the process:
SpraySpy® highlights:
- Checking of the spray quality by monitoring different spray parameters, for example:
- drop size,
- drop velocity,
- Volume flow rate,
- spray angle
- Measurement under explosive conditions (ATEX) and for electrostatic applications
- Clean room suitable
- IP 67 measurement probe
- Detection of spray anomalies >2%
- Component for a digital coating line and smart factory
- Patented SprayAI® software technology, based on artificial intelligence
- Inline monitoring of the spray quality in the production process
- Real time detection the most common coating defects
- The cause of paint defects can be identified with over 90% certainty
- Works inline with common atomizers, including bell atomizers
SpraySpy® savings examples:
- Forecasting when equipment will wear out and when the nozzle will get contaminated helps to optimise maintenance services. Services are therefore carried out directly before a defect, rather than too early or too late. This minimises 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 pieces with defects 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 the SpraySpy® into the system, the system’s operating parameters can be correlated with error patterns and assigned to a spray pattern. Any process faults can thus be attributed to a specific cause with over 90% certainty. In the event of a fault, this allows the fault to be rectified immediately without a lengthy troubleshooting process. In the next step, it is then possible to take corrective action in real time whilst the coating is being applied (control loop).
Further Information: