Electric current based automatic classification and operation of EHDA modes

Electrohydrodynamic Atomization (EHDA), often called electrospray, is a way to disintegrate a liquid into droplets by exposing it to a strong electric field. In this technique, it is possible to set different spraying modes by changing the physicochemical properties of the atomized liquids and the configuration of the experimental setup. There are four known modes in EHDA: dripping, intermittent, cone-jet, and multi-jet mode. Controlling the electrospray mode is crucial, as each mode has distinct operating flow rates, potential characteristics, and droplet properties. Current classifications rely on optical verification, which is often impractical in explosive or confined environments. In this work, a real-time EHDA mode classification system based on Verdoold et al. (2014) approach was developed. The system uses the spray electric current as the main classification parameter and uses several threads working in parallel to optimize its computational performance. The first results have shown a good performance of the system in classifying EHDA modes for various liquids. This work presents the first EHDA mode classification algorithm capable of automatically classifying three EHDA modes and detecting corona discharge. This new system has significant potential for implementation in various industrial applications. © 2025 The Authors