Sensor for the Prognostics and Health Management of Multiple Impinging Jet Nozzles

The impinging jet technique is a critical process for enhancing mechanical properties. Sensors for the precise diagnosis of the nozzle status are necessary to maintain product quality and reduce cost. The application of commercial sensors for this purpose is difficult because sensors in the casting, rolling, and reheating processes should provide sensitivity to small impact variations, durability, anticorrosion, waterproofing, and high-temperature endurance. We developed a sensor module to satisfy these engineering requirements. The sensor monitored impact pressures based on the reduction in the collision force caused by abnormal impinging jet flows. Smart signal filtering based on a low-pass filter was employed to achieve a short CPU time, noise discrimination, and the preservation of signal characteristics. A method for nozzle position synchronization and a new performance index for impinging jets for multiple-nozzle sensing in practical applications were also developed. The developed sensor module was validated using artificial abnormal nozzles and tested in the field. The validations showed that the developed sensor with the smart filter and nozzle synchronization method could provide an individual jet status with a high precision. The developed sensor is expected to contribute to the improvement of machine health monitoring technology in various fields with jet nozzles.