"Detection and avoiding of unmelted wire pieces during wire arc spraying"

A real-time measuring system has been developed to record and analyze the fluctuations of burner voltage and current. The objective is to identify the occurrence of stripping unmelted wire pieces (cold shuts) and to detect corresponding spraying conditions.

To identify voltage and current fluctuations causing cold shuts, high speed camera shots are synchronized with electrical measurements to analyze spraying parameters which were assumed leading to cold shuts. As a result, different cold shut conditions could be identified, some of which could clearly be correlated with electrical measurement.

The electrical cold shut identification then triggers a camera system, to capture online the size and velocity of cold shuts. Based on electrical measurements it is intended to detect wear of spraying equipment which leads to enhanced cold shuts appearance during industrial spraying process.