Briefly describe the diagnosis and solutions of common faults in aerosol particle generators

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Date: 2025-08-21Read: 2

In environmental monitoring, air purifier testing, respiratory health research, and biosafety laboratories, aerosol particle generators are responsible for generating stable, controllable concentrations and particle size distributions of aerosol particles (such as NaCl, DOP, PSL microspheres, oil mist, etc.). It is widely used in filter efficiency testing (HEPA/ULPA), instrument calibration, exposure experiments, and aerodynamic research.

In practical operation, aerosol particle generators often encounter problems such as unstable concentration, particle size deviation, and blockage due to improper operation, consumable issues, or insufficient equipment maintenance. Mastering the diagnosis and solution methods of common faults is the guarantee to ensure the authenticity and reliability of experimental data.

Problem 1: Low particle concentration or inability to establish

Cause: insufficient air source pressure, spray liquid depletion, atomization nozzle blockage or scaling of ultrasonic atomizer.

Solution: Check if the compressed air or nitrogen source pressure meets the equipment requirements (usually 2-6 bar); Timely supplement atomized liquid (such as salt water, DOP oil); Soak the nozzle in clean water or specialized cleaning solution to remove crystals or impurities; The ultrasonic generator is regularly cleaned to prevent the deposition of calcium and magnesium from affecting vibration efficiency.

Problem 2: Particle size distribution deviates from the set value

Reason: Unstable atomization pressure, changes in liquid concentration, voltage drift in classifiers (such as DMA), or imbalance in airflow ratio.

Solution: Stabilize the flow rates of carrier gas and dispersion gas, and use a mass flow meter for precise control; Ensure accurate concentration of atomized liquid and no precipitation; Regularly calibrate the particle size grading voltage and sheath gas ratio; Real time verification of output particle size using an optical particle size analyzer (such as OPC).

Problem 3: Blockage of nozzle or pipeline

Reason: Residual high concentration solution, particle deposition, or precipitation after liquid evaporation.

Solution: Immediately rinse the atomization system with pure water or solvent after the experiment is completed; Avoid prolonged use of high concentration or easily crystallizable solutions; Run the "cleaning mode" or blow the pipeline with clean gas before stopping the machine.

Problem 4: Excessive noise or noticeable vibration during generator operation

Reason: Turbulent airflow, loose nozzle, poor contact of ultrasonic head or fan failure.

Solution: Check if the air circuit connection is tight to avoid air leakage and whistling; Fasten the spray assembly; Ensure that the ultrasonic atomizer head is in full contact with the liquid; Check the fan bearings and fixing devices.

Problem 5: Large concentration fluctuations or slow response

Reason: Fluctuations in gas source pressure, changes in temperature and humidity, control system failures, or sensor drift.

Solution: Install a pressure regulator valve and a dry filter to ensure a clean and stable air source; Operate in a constant temperature and humidity environment; Restart the device or update the control program; Calibrate concentration monitoring sensors (such as light scattering sensors).

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