The Toyota painting laboratory at the Institute of Research for Technology Development (IR4TD), has several systems and tools uniquely developed to conducting critical spray atomization and atomizer-design research. These include a Phase Doppler Particle Analyzer (PDPA), a Particle Image Velocimetry (PIV) setup, and other equipment such as laser diagnostics, wet spray paint testing and high-temperature oven.
Laser diagnostic techniques have been proven to be invaluable tools for characterizing droplet sizes and size distributions. The understanding of sprays is critical to industries where coating is an essential part of their process. At IR4TD, Malvern Spraytech laser diffraction tool is used for droplet size measurements and analysis, including Sauter mean diameter, spray span, and specific outputs tailored to your industry needs.
Testing is conducted in a controlled environment within a booth, using paint applicators such as a high-speed rotary bell atomizer, inkjet nozzles and handheld air spray guns for coating experiments. We conduct paint overspray capturing performance study including scrubber design, optimization, and efficiency. Paint transfer efficiency optimization and booth airflow performance are the other areas of study here at IR4TD.
Our high-temperature oven is designed for high temperature applications up to 1500oC. The dimensions of the oven compartment are 15x 20 x 25cm; it has an opening through which air can be purged for cooling needed in applications such as sintering.
Surface inspection and flow visualization laboratory contains several systems used to conduct nondestructive testing and evaluation (NDT&E). Included in the equipment are infrared camera, high-resolution visual cameras, several heating applicators, and other items.
Infrared camera Model SC4000 MWIR (FLIR systems, Goleta, Ca.) with a 3.0-5.0 µm detection wavelength and an adjustable integration time. The camera is able to capture 400 frames per second at full frame resolution (320 x 256 pixels). The frames are captured using data acquisition software developed by FLIR systems, North Billerica, MA, and include:
• ThermaCAM Rtools
• ExaminIR
In addition, the camera has the capability to image at microscopic resolutions by using extension rings.
Extended Black Body Heater:
The extended area black body (Model IR-160/301, Infrared Systems Development, Orlando, FL) has an area of 30 x 30 cm (1 x 1 ft) coated with a high emissivity paint (ε = 0.96). The surface temperature of the heater can be varied from room temperature to 350oC by using a temperature control unit.
Visual Imaging:
Several state-of-the-art visual high speed cameras and detectors are available. The detectors are equipped with different lenses to enable microscopic and telescopic visualizations; filters are also available to enhance contrast and can be used for multispectral analysis.
Holographic Interferometry:
We have the capability to do holographic interferometry. In a double-exposure holographic interferometry, we obtain an interference pattern between two reconstructed images of the same object. A holographic recording is first made with the object in some reference state. The object is then moved or deformed as desired, and a second hologram is made on the same photographic film. During reconstruction, two waves are created and interfered in the space beyond the hologram. The resulting interference fringes record the local displacement of the surface of the object.
Schlieren Imaging:
The word schlieren is derived from the German word schliere, referring to a streak-like flow appearance. The concept of schlieren imaging rely on the physics of refraction. Light rays passing through a schliere gas will refract and appear as illuminance contrast in the image plane. With this setup, one can visualize the flow of transparent fluids clearly in the image plane using the naked eye or a high-speed camera. Using this technique for instance, we were able to visualize the effect of various rotary bell operating parameters on the shaping air alone, without introducing any liquid, which improved our understanding of droplets transport to the target.
Prototype Testing
The prototype testing laboratory contains several systems critical to conducting nondestructive testing and evaluation (NDT&E). Included in the equipment are a radiofrequency matching unit and wave generator, an ultrasonic wave generator, and biocoke and densified mass production unit.
Radio Frequency Generator:
The radio frequency generator produces energy at 13.56 MHz, with power ranging from 0-540 W.
Biocoke and Densified Biomass:
This equipment is used for densified biomass production: Retsch SM300 cutting mill. It uses a high torque 3 kW drive and has a capacity to reduce material from 60 x 80 mm to an output size as low as 0.25 mm.
Other equipment and testing devices are: a Thermo Scientific Precision drying oven; moisture analyzer; and specially design reaction cylinder and shop press. Ceramic electric tubular furnace with a thermo controller.
Computational Fluid Dynamic Simulation
Computational fluid dynamics (CFD), is a branch of fluid dynamics that uses numerical methods and algorithms to solve and analyze problems that involve fluid flows. When used properly, CFD can provide highly accurate results from the real-world problems without the need for expensive and complicated experimental testing systems.
IR4TD has extensive expertise and experience in using CFD to solve several practical industry problems such as:
Painting and coating related applications:
• Multiphase flow prediction
• Droplet atomization
• Paint booth airflow modelling
• Coat deposition modeling
• Overspray capturing
• Curing oven efficiency
• Assessment of wet scrubber energy utilization
Other Applications such as:
• CO2 capturing
• Heat exchanger performance analysis
• Combustion modelling
• Fire spread simulations
• Coke drum cycle prediction
• and other applications
Multi-Objective Optimization
The Multi-Objective Optimization (MOO) is the science of finding an optimal working solution values of the system with respect to more than one desired goal set for the system. In other words, this method involves more than one function to be optimized simultaneously. When used properly, it will lead to a set of different solutions that can provide the difference in the system condition with respect to multiple competing objectives. This is a helpful optimization methodology in many recent industrial problems such as incorporating renewable energy cycles into existing conventional power plants or expanding renewable energy systems’ penetration into the electrical grids.
At IR4TD, we have extensive experience working on projects addressing both types of renewable expansions, tackling the problems associated with each of them. We have developed and validated a computer code to simulate an actual power plant, then utilized linear-regression and artificial neural network multi-objective optimizations (MOO) to tune the operating parameters to integrate renewable energy to the cycle to enhance the performance of gas turbine power plants and reduce their greenhouse emissions and NOx pollutants.
Conducting Energy Assessments
Recent years have seen an increase in the number of renewable energy (RE) initiatives around the world that are based on broad frameworks which allow for regional assessment while taking into account the mismatch between supply and demand with pre-set goals to reduce energy costs and harmful emissions. Thus, developing a multi-faceted RE assessment framework is vital to achieving the transition to sustainable energy. AT IR4TD, we have the expertise and knowledge to assess the solar and wind resources potential in different areas using the mapping between the supply and the demand which can provide the most efficient utilization of these resources.
In addition, we can provide thorough onsite energy audits for different energy consumption processes such as HVAC, injection modeling, laser cutting, compressed air system, illumination, boilers and furnaces and etc. to achieve a more sustainable energy status in various industrial facilities. We can perform extensive utility analyses specific to the area and the provider, offer engineering guidelines, recommendations and best practices through using strong engineering fundamentals in thermal, fluid, mechanical, electrical, material and chemical engineering.
A summary of the services provided by IR4TD in this area are the following:
• Reduce energy demands and carbon emissions with the goal of a sustainable world in mind.
• Perform on-site walk throughs to identify energy conservation measures (mechanical) in commercial, institutional and industrial facilities and provide technical review/report/recommendations/best practices.
• Conduct energy audits and assessment to buildings and facilities.