ISBN 9783843957731

978-3-8439-5773-1, Reihe Apparatedesign

Inga Burke-Oeing
Development of a Smart Process Sensor for Emulsion Characterization Using Artificial Intelligence

232 Seiten, Dissertation Technische Universität Dortmund (2026), Softcover, A5

Zusammenfassung / Abstract

Recent advances in artificial intelligence (AI)-driven image analysis enable fast and automated droplet detection and thus open new possibilities for real-time monitoring of liquid-liquid processes. This work presents the development of an intelligent, integrated sensor for emulsification process characterization by measuring the droplet size distribution. The sensor was designed for application in both laboratory and industrial environments and required the close interconnection of optical analysis and AI-based image processing. The work focused on three main design steps: developing an optical flow cell to obtain 2D information on dispersed droplets, investigating AI-based image processing methods for process analysis, and integrating and adapting both elements into a sensor capable of operation in industrial environments.

The results highlight both the potential and the limitations of AI-based droplet detection: performance strongly depends on representative training data, consistent imaging conditions, and input parameters such as the confidence score. Reliable operation therefore requires systematic validation against reference methods whenever process conditions change, along with documentation of all acquisition and model parameters to ensure reproducibility. Synthetic datasets can further improve robustness under challenging imaging conditions.

The final prototype of the integrated optical AI-based sensor shows potential for real-time process characterization and monitoring. It represents a crucial step toward intelligent, flexible, and sustainable process design and control, enabling more cost- and resource-efficient process management through optimized plant utilization.