From research to customer value

Research becomes a controllable spraying system

FSG develops more than a nozzle: patented effects, laboratory measurements, practical trials and digital monitoring form a transferable system for industrial use.

VOCMATIC system with FSG nozzle, cleaners, monitoring dashboard and practical accessories

Protected technical effects

Patents protect the functional interaction of geometry, atomisation and control – the basis for differentiation and reliable application.

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Research partnership

Together with Münster University of Applied Sciences, flow, acoustics and droplet behaviour are measured and transferred into practical designs.

Open research project

Measurable customer benefit

More stable wetting, less avoidable media use and clearer commissioning create value directly in production.

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Development and Optimization

the Sonic Two-Phase Nozzle

Can the functionality of nozzles used to apply solvents in the edge-banding manufacturing process be further improved? In particular, improved predictive maintenance and partial automation would be desirable. With this goal in mind, FSGSchäferGmbH is developing new nozzle designs in close cooperation with Münster Universityof Applied Sciences and characterizing their performance through detailed laboratory tests and real-world measurements.

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Figure B - Sonic Two-Phase Nozzle
Figure B - Sonic two-phase nozzle for applying solvents in edge-banding machines

sonic two-phase nozzle

for minimal VOC consumption

Based on this research, a sonic two-phase nozzle has been developed that is highly efficient and minimizes the consumption of organic chemicals (VOCs). In particular—and this is a first in the industry—the mass flow of the solvent phase can be controlled via the working pressure of the compressed air phase, with the velocity of the phase mixture in the nozzle being sonic. Although earlier generations of such high-pressure nozzles of various designs are widely available commercially and have been used for decades in the day-to-day production of the furniture industry, operations are often based on the “more is better” principle rather than being optimized for efficiency. Although solvent consumption is generally economically insignificant, new guidelines for the industrial use of organic chemicals, as well as higher quality expectations for modern interior furnishings, require a shift in thinking. The new sonic two-phase nozzle addresses this need.

Optimized nozzle geometry

reduces the amount of solvent to a minimum

The nozzle geometry of the new sonic two-phase nozzle was optimized using these parameters, thereby reducing the amount of solvent to the minimum required for the manufacturing process. This is a key advantage of the new design in meeting future, stricter regulatory requirements. Furthermore, it has been demonstrated that the mass flow of the solvent phase can be controlled via the working pressure of the compressed air phase. This makes it conceivable to use sensors with such nozzle types to control the components individually and automatically. The insights gained into the flow physics within the nozzle and the spray cone also lay a necessary foundation for the long-term transition to water-based solvents and the complete elimination of VOCs.

Optimized nozzle geometry
Münster University of Applied Sciences Technology Campus in Steinfurt

NRW-Funded Collaboration

Developed jointly at the Steinfurt Technology Campus

The development and efficiency characterization of the novel nozzle design were carried out by a multidisciplinary research team as part of a collaboration funded by the state of North Rhine-Westphalia at the Steinfurt Technology Campus of Münster University of Applied Sciences. This involved the use of state-of-the-art measurement techniques such as laser and sonospectroscopy, as well as scientific approaches from basic research. Recordings of the sound spectrum of the nozzle jet noise using ultrasonic-sensitive microphones enabled noninvasive velocity measurements of the compressed air phase. Time-resolved velocity profiling of the jet cone upstream of the nozzle using laser illumination made it possible to determine the exit velocities of droplets of different sizes in the liquid phase. Both methods were used in this context for the first time. The mixing of organic solvents into the sonic compressed air flow within the new nozzle, the transport of this phase mixture through the nozzle channel, and the subsequent atomization in the jet cone after exit from the nozzle were theoretically elucidated.Using this approach, we were able to successfully understand the velocity profile of the flow within the nozzle as well as the uniformity of the spray mist as a function of nozzle parameters such as operating pressure, orifice diameter, or solvent volume. In addition, the impact velocities of individual solvent droplets were determined as a function of their size.

 

Research in Practice

Our Nozzle Patent

High-Pressure Nozzle Mixing System with Sensors

For the purposes of process automation, reducing material wear, and complying with strict regulations on the emission of volatile organic solvents, the design and functionality of a smart high-pressure nozzle are patented.

Patent Description
European Patent Application No. 20 205 885.5

Patent Sketch No. 20 205 885.5
Nozzle design and, above it, the pressure and velocity profile (bar, Mach number)
Note: alternative representation.

Das theoretisch untersuchte und mit Prototypen vermessene Design nutzt die Ultraschallgeschwindigkeit der Hochdruckluft im Düsenkörper um Lösungsmittel anzusaugen und homogen in den Jetstrahl einzubringen. Die Strahlhomogenität und der Lösungsmittelmassenfluss werden mit akustischen Sensoren erfasst und mit elektronischer Datenverarbeitung analysiert und mit Optimalreferenzen verglichen. 

Eine integrierte Feedbackloop kontrolliert das Nadelventil der Lösungsmittelzufuhr um den optimalen Betrieb zu erreichen und aufrecht zu halten. 

Das Patent antizipiert die zu erwartenden technologischen Entwicklungen in der maschinellen Hochleistungsherstellung von Möbeln und Inneneinrichtungen.

Advantages of the new

Sonic two-phase nozzle

Kontinuierliche Selbstansaugung der Flüssigphase

Der Betrieb der Düse garantiert minimal notwendigen, gleichmässigen Auftrag des Produktes.

Sonische Druckluftgeschwindigkeit im Düsenkörper

Stabiler, wirbelfreier Transport der Flüssigphase im Düsenkörper und kontroliierte Tröpfchenvernebelung beim Düsenaustritt.

Effizienter Betrieb

Nur die minimal notwendigen Menge des Produktes wird versprüht, im Sinne moderner Richtlinien zur Minimierung von VOCs.

Arbeitsdruckabhängiger Massenfluss des Produktes

Eine gewünschte Veränderung des Produktauftrags benötigt keine Stellschraubenkorrektur, sondern kann über den Arbeitsdruck erreicht werden.

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With over 30 years of experience in the production of chemical products for the furniture and exhibition stand construction industries,
we have built up a wealth of expertise.