# US 8,465,792 B2 · Monitor system for coating apparatus > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 8,465,792 B2 - Document ID: US8465792B2 - Status: Granted - Kind: B2 - Application number: 11/620,379 - Filed: 2007-01-05 - Published: 2007-06-07 - Granted: 2013-06-18 - Earliest claimed: 2004-07-16 - Assignees: Arcelormittal Dofasco, Inc. - Applicants: Douglas Marriott; Robert Eric Mueller - Inventors: Douglas Marriott; Robert Eric Mueller - Web page: https://patentgrep.com/patent/US8465792B2 ## CPC - G01N 21/95: characterised by the material or shape of the object to be examined (G01N21/89 - G01N21/91, G01N21/94 take precedence) - B05B 12/004: {comprising sensors for monitoring the delivery, e.g. by displaying the sensed value or generating an alarm (B05B12/08 takes precedence; registering or indicating the condition or the working of machines or other apparatus in general G07C3/00)} - B05D 1/02: performed by spraying - G01N 21/47: Scattering, i.e. diffuse reflection (G01N21/25, G01N21/41 take precedence {G01N21/55 takes precedence}) - G05B 23/0229: {knowledge based, e.g. expert systems; genetic algorithms} - B05B 12/082: {responsive to a condition of the discharged jet or spray, e.g. to jet shape, spray pattern or droplet size} - B05B 15/50: Arrangements for cleaning; Arrangements for preventing deposits, drying-out or blockage; Arrangements for detecting improper discharge caused by the presence of foreign matter - B05B 15/658: the spraying apparatus or its outlet axis being perpendicular to the flow conduit - G01N: INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES (measuring or testing apparatus or processes other than immunoassay, involving enzymes or microorganisms C12M, C12Q) - B05B: SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES (spray-mixers with nozzles B01F25/72; processes for applying liquids or other fluent materials to surfaces by spraying B05D) - B05D: PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL (conveying articles or workpieces through baths of liquid B65G, e.g. B65G49/02) - G05B: CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS (systems for controlling or regulating non-electric variables G05D; systems for regulating electric or magnetic variables G05F; control devices or systems insofar as characterised by mechanical features only G05G) ## Abstract A spray monitoring device analyzes images obtained from a beam passing through a spray pattern applying a spray to a substrate, and identifies discontinuities in the image as indicative of a discontinuity in a spray pattern. The spray pattern is produced by a plurality of nozzles spaced apart across the substrate for applying a suitable coating thereto. The beam is produced by a laser, that preferably has a collimator for distributing the beam intensity. The beam is imaged by a camera that provides a constant image to a computers where the scattering of beam light by the spray pattern is processed by image processing software and optionally provided to a user interface for analysis. Discontinuities detected by the user or software indicate faulty spray nozzles and may trigger remedial action. ## Claims ### Claim 1 A method of monitoring the application of a coating to a substrate from a plurality of nozzles spaced apart along at least one dimension of the substrate, the method comprising the steps of projecting a beam of coherent radiation horizontally through a spray of coating comprising overlapping spray patterns from said plurality of nozzles, said spray patterns overlapping between adjacent separate nozzles in said plurality of nozzles, obtaining an image of the beam as it propagates through said overlapping spray patterns and processing said image to identify a horizontal band in the image, the horizontal band representative of the beam as scattered by the spray, and determining discontinuities in the horizontal band in the image indicative of discontinuities of said overlapping spray patterns between separate nozzles. ### Claim 2 (depends on 1) A method according to claim 1 wherein discontinuities in the horizontal band in the image in excess of a predetermined value are utilized to identify discontinuities of said spray. ### Claim 3 (depends on 1) A method according to claim 1 wherein said beam of coherent radiation is a laser beam generated by a laser. ### Claim 4 (depends on 3) A method according to claim 3 wherein said laser includes a collimator to produce a non-Gaussian, substantially uniform intensity line from said laser beam. ### Claim 5 (depends on 1) A method according to claim 1 wherein said image is obtained by a camera, said camera transmitting said image to a computing device to perform said processing. ### Claim 6 (depends on 5) A method according to claim 5 wherein said computing device is connected to an interface, said interface permitting a user to interact with said image. ### Claim 7 (depends on 1) A method according to claim 1 wherein said image is obtained by a smart camera and said processing of said image occurs within said smart camera. ### Claim 8 (depends on 1) A method according to claim 1 wherein determination of said discontinuities in the horizontal band in the image triggers a step of initiating remedial action. ### Claim 9 (depends on 1) A method according to claim 1 wherein said plurality of nozzles are spaced along a plurality of sprayheads to produce a plurality of sprays, a beam of coherent radiation is projected through each spray, said image represents at least two of said beams, and said step of processing said image determines discontinuities in at least two horizontal bands in the image representing each of said at least two beams. ### Claim 10 (depends on 1) A method according to claim 1 wherein said processing comprises identifying blobs indicative of regions of continuous brightness in the horizontal band in the image, said method identifying a discontinuity by counting the number of said blobs wherein two or more blobs indicates at least one discontinuity. ### Claim 11 (depends on 10) A method according to claim 10 wherein said blobs are identified based on a predetermined threshold of said brightness, said threshold determined using an intensity distribution of said pixels.