Abstract: A method and apparatus for efficiently applying liquid coatings to a workpiece. The apparatus is a compressed air spray system tailored to achieve a desired transfer efficiency (TE) by controlling atomization. Liquid and pressurized air are supplied to a spray applicator. The atomized spray is applied to the workpiece. Atomization and TE, as well as associated fluid flow parameters, are measured at various gas pressures while maintaining a constant liquid flow rate. A graphical representation of the relationship between atomization and TE is produced. An optimized atomization corresponding to a desired TE is determined from the graphical representation of atomization and TE. The fluid flow parameters corresponding to the optimized atomization are set and regulated to produce the optimized atomization, thereby optimizing transfer efficiency.

Abstract: The invention relates to a method and apparatus for optimizing the transfer efficiency of a compressed air system used to apply liquid coatings (e.g., paint) while producing a high quality film coating. The invention uses a laser measuring system to determine the atomization of a spray produced by a compressed air spray system. The system also monitors and measures the liquid and air being supplied to the spray applicator to determine the settings required for optimization.