Acoustic ignition monitor for thermal spray guns
This system uses microphones to listen to a thermal spray gun before it fires coating material, catching ignition problems before they cause defects. It analyzes the acoustic signature of the gas flow in real time, converts that sound into a frequency spectrum, and compares it against known-good patterns to decide whether ignition succeeded, failed, or was abnormal. If something is wrong, the system automatically halts or restarts the spray process before any coating material is introduced—preventing wasted material, contaminated parts, and potential equipment damage. It outputs alerts and visual spectrograms so operators can see exactly what the gun was doing at the moment of ignition.
What you could build
A bolt-on acoustic monitoring module for industrial thermal spray equipment that provides automated ignition verification and closed-loop fault response, sold to aerospace MRO shops, turbine component manufacturers, and industrial coating job shops that run HVOF or plasma spray systems.
Who in Virginia should care
Virginia-based aerospace and defense manufacturers—particularly those doing turbine blade and engine component coatings near the Rolls-Royce or Pratt & Whitney supply chain—would have direct operational use for this.
Readiness: Prototype likely
Concept — described but not yet demonstrated. Lab validated — supported by experimental results in the patent. Prototype likely — the text describes a built, working embodiment.
Readiness is inferred from the patent text, not from a lab visit.
The record
- Inventors
- Michael Cybulsky, Raymond J. Sinatra, Roy Peter McIntyre, Taylor K. Blair, Gary Pickrell, Romesh Batra, Mark Hudson
- Granted
- March 26, 2019
- Status
- Granted patent
- Patent number
- 10241091
Ready to talk?
Virginia Tech Intellectual Properties handles licensing for this technology.
Prosim summaries are generated from public patent text and are not legal advice.