A particle counter is used for monitoring and diagnosing particle contamination within specific clean media, including air, water, and chemicals. Particle counters are used to support clean manufacturing practices in a variety of industrial applications. Clean manufacturing is required for the production of many electronic components and assemblies, pharmaceutical drug products and medical devices, and industrial technologies such as oil and gas.
Technology Particle counters function primarily using the principles of light scattering, although other technologies may also be employed. Light scattering by particles use instrumentation comprising a high-intensity light source (a laser), a controlled media flow (air, gas or liquid) and highly sensitive light-gathering detectors (a photo detector). Laser optical particle counters employ five major systems:
Lasers and optics: A laser operates on a single wavelength, so the light source is consistent with constant power output to illuminate the particle sampling region. Controlled flow: The viewing volume is a small chamber illuminated by the laser. The sample medium (air, liquid or gas) is drawn into the viewing volume, the laser passes through the medium, the particles scatter (reflect) light, and a photodetector tallies the scattered light sources (the particles). Photodetector: The photodetector is an electric device that is sensitive to light, and when particles scatter light, the photodetector observes the flash of light and converts it to an electric signal, or pulse. An amplifier converts the pulses to a proportional control voltage. Pulse height analyzer (PHA): The pulses from the photodetector are sent to a pulse height analyzer (PHA). The PHA examines the magnitude of the pulse and places its value into an appropriate sizing channel, called a bin. The bins contain data about each pulse, and this data correlates to particle sizes. Black box: The black box, or support circuitry, looks at the number of pulses in each bin and converts the information into particle data. Light obscuration by particles works on the principle where the presence of particles blocks some of the light from the photodetector, typically through either absorbance or light scattering. The photodetector records the obscuration of light and converts this to an electrical signal, this signal is then correlated to a specific sized particle using a PHA as with the scattering description above. Direct imaging particle counting employs the use of a high-resolution camera and a light source to detect particles. Vision based particle sizing units obtain two dimensional images that are analyzed by computer software to obtain particle size measurement, images can be retained and replayed for additional analysis A Coulter counter is an apparatus for counting and sizing particles suspended in electrolytes. It is typically used for cellular particles. The Coulter principle, and the Coulter counter that is based on it, is the commercial term for the technique known as resistive pulse sensing or electrical zone sensing.
Detection methods There are several methods used for detecting and measuring particle size or size distribution — light blocking (obscuration), light scattering, Coulter principle and direct imaging. A high intensity light source is used to illuminate the particle as it passes through the detection chamber. The light blocking optical particle counter method is typically useful for detecting and sizing particles greater than 1 micrometre in size and is based upon the amount of light a particle blocks when passing through the detection area of the particle counter. This type of technique allows high resolution and reliable measurement. If light scattering is used, then the redirected light is detected by a photo detector. The light scattering method is capable of detecting smaller-sized particles. This technique is based upon the amount of light that is deflected by a particle passing through the detection area of the particle counter. This deflection is called light scattering. Typical detection sensitivity of the light scattering method is 0.05 micrometre or larger. However, employment of the condensation nuclei counter (CNC) technique would allow a higher detection sensitivity in particle sizes down to nanometre range. A typical application is monitoring of ultrapure water in semiconductor fabrication facilities. If light blocking (obscuration) is used the loss of light is detected. The amplitude of the light scattered or light blocked is measured and the particle is counted and tabulated into standardized counting bins. The light blocking method is specified for particle counters that are used for counting in hydraulic and lubricating fluids. Particle counters are used here to measure contamination of hydraulic oil, and therefore allow the user to maintain their hydraulic system, reduce breakdowns, schedule maintenance during no or slow work periods, monitor filter performance, etc. Particle counters used for this purpose typically use ISO Standard 4406:1999 as their reporting standard, and ISO 11171 as the calibration standard. Others also in use are NAS 1638 and its successor SAE AS4059D. If direct imaging is used, a halogen light illuminates particles from the back within a cell while a high definition, high magnification camera records passing particles. Recorded video is then analyzed by computer software to measure particle attributes. Direct imaging particle counting employs the use of a high resolution camera and a light to detect particles. Vision based particle sizing units obtain two dimensional images that are analyzed by computer software to obtain particle size measurement in both the laboratory and online. Along with particle size, color and shape analysis can also be determined. Direct imaging is a technique that uses the light emitted by a laser as a source to illuminate a cell where particles are passing through. The technique does not measure the light blocked by the particles, but rather measures the area of the particles functioning like an automated microscope. A pulsed laser diode freezes the particle motion. The light transmitted through the fluid is imaged onto an electronic camera with macro focusing optics. The particles in the sample will block the light, and the resulting silhouettes will be imaged onto the digital camera chip.
Matrices Applications of particle counters are separated into three primary categories:
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