In-situ control system for atomization

Melt atomizing apparatus comprising a melt supply orifice for supplying the melt for atomization and gas supply orifices proximate the melt supply orifice for supplying atomizing gas to atomize the melt as an atomization spray. The apparatus includes a sensor, such as an optical and/or audio sensor, for providing atomization spray data, and a control unit responsive to the sensed atomization spray data for controlling at least one of the atomizing gas pressure and an actuator to adjust the relative position of the gas supply orifice and melt supply in a manner to achieve a desired atomization spray.

The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows:

1. Atomizing apparatus, comprising:

atomizing means including melt supply means for supplying melt for atomization, gas supply means disposed about the melt supply means for supplying atomizing gas to atomize the melt as an atomization spray, and actuator means for relatively moving said gas supply means and said melt supply means,

sensor means for providing an image of said atomization spray, and

control means for controlling said actuator means in response to the sensed image of said atomization spray to adjust the relative position of said gas supply means and said melt supply means in a manner to modify said atomization spray.

2. The apparatus of claim 1 wherein said melt supply means includes a melt discharge orifice and said gas supply means includes a gas discharge orifice and wherein said actuator means moves said gas supply means relative to said melt supply means to vary the relative position of the melt and gas discharge orifices.

3. The apparatus of claim 1 wherein said actuator means is disposed in said atomization chamber to move said gas supply means relative to said melt supply means.

4. The apparatus of claim 1 wherein said control means includes means for storing an image of the atomization spray generated using known relative positions of said gas supply means and said melt supply means and means for comparing the sensed image with the stored image to determine an adjusted relative position of said gas supply means and said melt supply means.

5. The apparatus of claim 4 wherein said sensor means comprises an optical sensor for providing optical image of the atomization spray.

6. The apparatus of claim 4 wherein said sensor means comprises an audio sensor for providing an audio image of the atomization spray.

7. Melt atomizing apparatus, comprising:

atomizing means including melt supply means for supplying melt for atomization and gas supply means disposed about the melt supply means for supplying atomizing gas to atomize the melt as an atomization spray,

sensor means for providing an image of said atomization spray, and

control means for controlling said gas supply means in response to the sensed image of said atomization spray to adjust the atomizing gas pressure in a manner to modify said atomization spray.

8. The apparatus of claim 7 wherein said gas supply means includes a dome loaded static gas pressure regulator and wherein said control means comprises means for varying the dome load and hence the flow rate and pressure of the atomizing gas.

9. The apparatus of claim 7 wherein said control means includes means for storing an image of the atomization spray generated using known atomizing gas pressures and means for comparing the sensed image with the stored image to determine an adjusted atomizing gas pressure.

10. The apparatus of claim 9 wherein said sensor means comprises an optical sensor for providing an optical image of the atomization spray.

11. The apparatus of claim 9 wherein said sensor means comprises an audio sensor for providing an audio image of the atomization spray.

12. Melt atomizing apparatus, comprising:

atomizing means having melt supply means for supplying melt for atomization, gas supply means disposed about the melt supply means for supplying atomizing gas to atomize the melt as an atomization spray, and actuator means for relatively moving said gas supply means and said melt supply means,

sensor means for providing an image of said atomization spray, and

control means responsive to the sensed image of said atomization spray for controlling said atomizing gas pressure to adjust the atomizing gas pressure and said actuator means to adjust the relative position of said gas supply means and said melt supply means in a manner to modify said atomization spray.

13. The apparatus of claim 12 wherein said control means includes means for storing an image of said atomization spray generated using known relative positions of said gas supply means and said melt supply means and means for comparing the sensed image with the stored image to determine an adjusted relative position of said gas supply means and said melt supply means.

14. The apparatus of claim 13 wherein said control means includes means for storing an image of said atomization spray generated using known atomizing gas pressures and means for comparing the sensed image with the stored image to determine an adjusted atomizing gas pressure.