SprayQuantAI® is used for real-time monitoring of sprays and particle flows, for example to observe the position and stability of a spray cone, the relative particle density, and typical process deviations. To get started, first position the measurement head so that the measurement volume covers the relevant region of the flow, such as the spray cone axis, the core zone, or the peripheral region. Ensure a safe distance from hot surfaces, moving parts, and direct liquid contact, and make sure that optical windows and protective covers are clean.
Next, connect SprayQuantAI® to the power supply and, if applicable, to the process computer or HMI. Then start the software and check in the live view whether a stable input signal is present. If the display shows strong drift or excessive noise, first correct the alignment by adjusting the measurement head in small steps until the signal quality becomes uniform and the measurement zone is reproducibly detected. Once the basic signal is stable, select the appropriate measurement profile in the software for your application, either spray monitoring or particle-flow monitoring. In many cases, it is useful to start the measurement briefly in a baseline state under stable process conditions, so that SprayQuantAI® can establish a clean reference for later comparison.
After that, activate the measurement and observe the key parameters in real time. For spray monitoring, pay particular attention to the position of the spray cone (for example, whether the cone drifts or tilts), to the distribution or density indicators (which reflect fluctuations in atomization), and to stability metrics (such as periodic changes caused by pulsations, clogging, or pressure fluctuations). For particle flows, focus on density or intensity indicators and on characteristic signature changes that may indicate agglomeration, varying particle loading, or flow instabilities. When deviations occur, process parameters such as pressure, feed rate, nozzle position, or carrier-gas flow can be adjusted, and their effects can be observed immediately in the trends.
Once the measurement is running stably, data recording can be started to document process behavior over minutes or hours. For documentation and analysis, it is recommended to annotate significant events, such as pressure steps, nozzle cleaning, or changes in feed rate, so that the causes of signal variations can be clearly identified later. After the measurement, trend data, screenshots, or measurement reports can be exported as needed and used for quality assurance, process optimization, or troubleshooting.
To finish, stop the measurement in the software, save the data, and shut down the system in a controlled manner. Finally, clean the optical surfaces and protective windows and check for deposits, especially when working with sticky media, high solid loads, or varying temperature conditions. This ensures that SprayQuantAI® will deliver reproducible monitoring results again immediately during the next operation.