A rapid verification method applied to the development of drip irrigation emitters

Abstract

The application relates to the technical field of agricultural water-saving irrigation equipment processing, in particular to a rapid verification method applied to the development of drip irrigation waterers, which comprises an integrated process of early preparation, three-dimensional modeling and CFD simulation iteration, light-cured 3D printing prototype and post-processing, core structure precision assembly, water test iteration, mold precision machining, injection molding, finished product assembly and detection delivery. Based on the technical means of flow channel right-angle boss optimization, 3D printing integrated PE adapter, high-precision gap control of diaphragm and boss, tungsten-copper electrode wire cutting mold machining and whole-process test and feedback optimization process, the problems of existing processing methods, such as trial and error dependence on test models, low machining and assembly precision, poor prototype adaptability, poor performance consistency of mass-produced products, are solved, rapid verification and precision standardized production of the waterer processing are realized, development cost is reduced, the finished product qualification rate and core performances such as pressure compensation and backflow prevention are improved, and the method is suitable for large-scale production needs of field drip irrigation.

Description

Technical Field

[0001] This invention relates to the field of agricultural water-saving irrigation equipment processing technology, and in particular to a rapid verification method for the development of drip irrigation emitters. Background Technology

[0002] Currently, the industry's processing of pressure-compensating sprinklers mostly adopts the conventional mode of repeated trial and error with experimental molds, traditional mold processing combined with rough manual assembly. Although it can achieve the forming and assembly of the basic structure of the sprinkler, it is limited by factors such as imperfect processing technology design, lack of precise parameter control of core processes, and lack of early verification. The existing processing methods have many technical defects in terms of development efficiency, processing accuracy, and product performance consistency, and can hardly meet the needs of large-scale, industrialized production.

[0003] Firstly, the lack of early optimization stages in 3D modeling and fluid simulation, relying on reverse copying of experimental molds and verification of structural rationality through trial molds, not only results in a large waste of mold materials, high development costs and long cycles, but also leads to a large deviation between prototype verification results and actual mass production conditions.

[0004] Secondly, the core cavities such as the water emitter's flow channel and bosses are processed using traditional electrical discharge machining, resulting in low forming accuracy, poor edge regularity, and poor flow channel pressure balance, which directly affects the pressure compensation accuracy of the water emitter.

[0005] Third, the assembly of the elastic diaphragm and the lower shell boss lacks precise gap control technology, resulting in uncontrolled fitting accuracy. This leads to inaccurate setting of the water dispenser's starting pressure, poor normally closed sealing effect when not in use, and easy occurrence of backflow and backflow.

[0006] Fourth, the 3D printed prototype and the PE drip irrigation pipe do not have a dedicated matching structure, and additional adhesive parts are required for connection, which results in low assembly efficiency and easy sealing failure, making it difficult to guarantee the accuracy of water flow test.

[0007] The aforementioned defects directly result in 3D printed prototypes being unable to effectively replace experimental molds for performance verification. Multiple experimental molds still need to be developed for repeated trial and error adjustments, further exacerbating the problems of high development costs and long development cycles.

[0008] Fifth, the testing and feedback optimization process of the processing flow is imperfect, there is no unified judgment standard for performance verification between each process, and the consistency of manual assembly is poor. Ultimately, this leads to a low pass rate of mass-produced water dispensers, and core functions such as pressure compensation and backflow prevention are difficult to achieve the design specifications.

[0009] In summary, there is an urgent need for a processing method that integrates early simulation optimization, rapid prototype verification, precision mold processing, standardized assembly, and full-process testing and iteration for the manufacturing of pressure-compensated irrigation devices. By optimizing the core processes and precisely controlling the parameters, this method can solve the problems of high development costs, low processing accuracy, and poor product performance consistency of existing processing methods, thereby improving the core functional indicators and mass production efficiency of irrigation devices and meeting the needs of large-scale use in agricultural water-saving irrigation. Summary of the Invention

[0010] In view of this, the technical problem to be solved by the present invention is how to provide a rapid verification method for the development of drip irrigation emitters that features scientific process design, precise parameter control, and high development efficiency.

[0011] To address the aforementioned technical problem, a rapid verification method for developing drip irrigation emitters is provided. The emitter is assembled from a lower shell, an upper shell, and an elastic diaphragm. The method includes the following steps:

[0012] S1, Preliminary preparation: Prepare and debug the equipment, materials and tooling fixtures required for processing;

[0013] S2, 3D modeling and fluid simulation iteration: establish solid models of each component of the water emitter and optimize the flow channel structure of the model. Import the optimized model into the fluid simulation software to complete the simulation analysis. After the simulation verification is qualified, export the model file.

[0014] S3, Photopolymer 3D Printing Prototype and Elastic Membrane Preparation: After importing the model file into the slicing software and setting the parameters, the prototype of the water dispenser is printed by the photopolymer 3D printer.

[0015] S4. Prototype post-processing: Cleaning and polishing the 3D printed prototype to ensure its water permeability and assembly compatibility.

[0016] S5. The core structure is precisely assembled by fitting the elastic diaphragm with the prototype part, so that the diaphragm divides the inner cavity enclosed by the upper and lower shells into a sealed water inlet chamber and a water outlet chamber, forming a normally closed seal structure to prevent backflow.

[0017] S6. Water flow performance test and iteration: The water flow performance of the assembled prototype is tested. If the test is qualified, it proceeds to the next process. If the test is unqualified, it returns to S2 to adjust the model parameters.

[0018] S7. Precision machining of molds: Machining injection molds for water dispensers based on the model after successful simulation, completing the forming, post-processing and overall assembly of the mold cavity;

[0019] S8. Injection molding: Make a test mold to complete the injection molding verification. After the verification is qualified, make a formal mold for large-scale injection molding to obtain the water dispenser plastic parts.

[0020] S9. Precision assembly of mass-produced finished products: The elastic diaphragm and injection-molded plastic parts are assembled according to the assembly requirements of S5 to achieve a sealed connection between the water emitter and the drip irrigation pipe.

[0021] S10. Finished Product Inspection and Delivery: Sampling performance tests are conducted on mass-produced finished products. Qualified finished products are packaged and shipped out of the factory, while unqualified products are returned to S9 for reassembly.

[0022] In a preferred embodiment, the optimization of the model flow channel structure in S2 is to optimize the tooth tip angle of the traditional flow channel into a right-angled rectangular boss structure.

[0023] The inlet pressure in the fluid simulation is set based on the design requirements of the irrigation device, and the simulation criterion is that the drip irrigation flow rate remains constant.

[0024] In a preferred embodiment, when the three-dimensional model is established in S2, a PE adapter connector adapted to the drip irrigation pipe is integrally designed on the water inlet side of the lower shell.

[0025] The elastic diaphragm in S3 is prepared by compression molding using an elastic material.

[0026] In a preferred embodiment, the prototype post-processing of S4 includes,

[0027] The prototype was ultrasonically cleaned with organic solvents to remove residual molding material from the flow channels. The outer wall of the connecting joint and the inner wall of the flow channels of the prototype were polished with wet sandpaper.

[0028] In a preferred embodiment, the precision assembly of the core structure of S5 includes:

[0029] Clean the mating surfaces of the lower shell boss and the elastic diaphragm, attach the diaphragm to the boss surface, install a sealing ring at the joint of the upper and lower shells and apply a fastening force to complete the sealing and fixation, so that the diaphragm and the boss are tightly fitted to form a normally closed seal when water is not flowing.

[0030] In a preferred embodiment, the water flow performance test of S6 includes setting up a water flow test platform to test the core performance of the prototype, including starting pressure, drip irrigation flow rate, anti-backflow performance and anti-clogging performance.

[0031] In a preferred embodiment, the precision machining of the mold in S7 uses mold steel as the cavity base material, the flow channel cavity is formed by a conductive alloy electrode and a wire cutting machining equipment, and the cavities of the boss, filter plate and upper and lower shell fitting structure are all formed by CNC machining.

[0032] In a preferred embodiment, the injection molding in S8 uses water-pressure resistant and aging-resistant engineering plastics as raw materials. After the test mold injection is completed, the plastic parts are first inspected for size. Plastic parts that pass the size inspection are then tested for water flow performance on the machine.

[0033] In a preferred embodiment, the mass-produced finished product of S9 is precision assembled using automated equipment to complete the fitting and sealing of the upper and lower shells and the diaphragm.

[0034] In a preferred embodiment, the finished product sampling performance test in S10 is performed in batches, the sampling ratio of each batch meets the quality inspection specifications, the testing standard is consistent with the water flow performance test standard in S6, and the qualified finished products are labeled with relevant product information and then packaged and shipped.

[0035] According to the present invention, the tooth tip angle of the traditional flow channel is optimized into a right-angled rectangular boss structure, and the core cavity of the flow channel is processed by using tungsten copper alloy electrode with slow wire EDM, which significantly improves the cavity forming accuracy and edge regularity, reduces the difficulty of mold processing, ensures the flow channel pressure balance effect, realizes the stability of drip irrigation flow when the inlet water pressure fluctuates, and improves the accuracy of pressure compensation.

[0036] By precisely controlling the gap between the diaphragm and the boss, the starting pressure of the water dispenser can be accurately set, ensuring the normal closed sealing effect of the diaphragm and the boss when the water is not flowing, solving the problems of backflow and backflow, and improving the anti-clogging performance.

[0037] Through systematic optimization of the above geometric parameters, the flow index of the emitter is reduced to below 0.05, maintaining a constant outflow rate within an inlet pressure fluctuation range of 0.05 to 0.4 MPa.

[0038] Prototype water emitters are prepared by photopolymerization 3D printing, and a special connector that is compatible with PE drip irrigation pipes is integrally formed during the 3D modeling stage. The prototype can be sealed to the drip irrigation pipe without the need for additional adapter parts, ensuring the accuracy of water flow test.

[0039] It can directly verify core performance through 3D printed prototypes, replacing the traditional development mode of repeated trial and error with multiple sets of experimental molds, greatly reducing mold material consumption, shortening product development cycle, and reducing early R&D costs. Attached Figure Description

[0040] The embodiments of the present invention are described in detail below with reference to the accompanying drawings.

[0041] Figure 1 This is a flowchart illustrating the overall process of a rapid verification method according to an embodiment of the invention.

[0042] Figure 2 This is a sub-flowchart of a rapid verification method according to an embodiment of the invention.

[0043] Figure 3 This is a sub-flowchart of a rapid verification method according to an embodiment of the invention.

[0044] Figure 4 This is a sub-flowchart of a rapid verification method according to an embodiment of the invention.

[0045] Figure 5 Structural view of an embedded pressure-compensating irrigation device according to an embodiment of the invention Figure 1 .

[0046] Figure 6 Structural view of an embedded pressure-compensating irrigation device according to an embodiment of the invention Figure 2 .

[0047] Figure 7 This is a structural view of an embodiment of the on-pipe pressure compensating irrigation device of the present invention. Figure 1 .

[0048] Figure 8 This is a structural view of an embodiment of the on-pipe pressure compensating irrigation device of the present invention. Figure 2 .

[0049] Figure 9 This is a structural view of an embodiment of the on-pipe pressure compensating irrigation device of the present invention. Figure 3 . Detailed Implementation

[0050] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, the specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings.

[0051] Please see Figures 1 to 4 This invention provides a rapid verification method for the development of drip irrigation emitters. The emitter is assembled from an upper shell, a lower shell, and an elastic diaphragm. Its core technical indicators are: starting pressure of 0.1 MPa, rated drip irrigation flow rate of 2 L / h when the inlet pressure fluctuates between 0.05 and 0.4 MPa, and features anti-backflow, anti-clogging, and pressure compensation functions. The rapid verification method adopts an integrated processing flow of preliminary preparation, design simulation, 3D printing verification, mold processing, injection molding, and assembly testing.

[0052] The following section provides a detailed explanation of the rapid verification method.

[0053] Step 1 (S1), preliminary preparation, is the starting point of the processing flow. This involves preparing and debugging the necessary equipment, materials, tooling, and fixtures.

[0054] Regarding the processing equipment, including 3D modeling software, fluid simulation software, photopolymer 3D printer, slicing software, CNC ultrasonic cleaner, slow wire EDM machine, CNC milling machine, horizontal injection molding machine, and electronic flow meter, all equipment should be turned on and debugged to normal working condition;

[0055] Regarding the processing materials, these include tough photosensitive resin, tungsten copper alloy, pre-hardened mold steel, silicone rubber, and nitrile rubber sealing rings;

[0056] Regarding tooling and fixtures, including feeler gauges, wet sandpaper, and customized silicone rubber molding dies, all fixtures have been cleaned and their accuracy verified.

[0057] Step two (S2) involves iterative 3D modeling and CFD simulation to design the 3D model of the irrigation device and optimize it for fluid simulation, providing an accurate model for subsequent 3D printing and mold processing.

[0058] S2a, establish a three-dimensional CAD model (optimize the right-angled rectangular boss), use three-dimensional modeling software to establish three-dimensional solid models of the upper shell, lower shell and elastic diaphragm, and optimize the tooth tip angle of the traditional flow channel into a right-angled rectangular boss structure to address the problems of high processing difficulty and poor pressure balance effect of the existing flow channel.

[0059] The upper shell is designed as an arc-shaped rectangle, with the curvature of the arc surface fitting well with the wall of the PE16 drip irrigation pipe. The lower shell is designed as a rectangle with a groove, in which a matrix filter plate, an inlet, and a first flow channel are installed. The upper shell is designed as a continuous tortuous second flow channel, a pressure relief chamber, and an outlet.

[0060] In this embodiment, the right-angled rectangular boss structure is arranged in a single row or multiple rows in an alternating pattern;

[0061] The elastic diaphragm has a thickness of 0.3~0.8mm and a Shore hardness of A35~A50. The drainage channel between the inlet and outlet chambers has a width of 0.2~0.5mm, a depth of 0.1~0.3mm, and an outlet hole diameter of 0.8~1.2mm, located in the central area of ​​the upper shell's arc surface.

[0062] S2b, Fluid Simulation Analysis, imports the 3D model from S2a into fluid simulation software;

[0063] In this step, the simulation boundary conditions are: inlet chamber pressure 0.05~0.1MPa, outlet chamber connected to the atmosphere, to simulate the flow velocity and pressure distribution of water in the flow channel, and to obtain the outlet flow rate data under different inlet pressures;

[0064] S2c, simulation result judgment and iteration, to determine whether the simulation results meet the design specifications (flow rate stable at 2L / h±0.02L / h under an inlet water pressure of 0.05~0.4MPa).

[0065] If the result is unqualified, return to step S2a to adjust parameters such as the gap of the right-angled rectangular boss and the length of the flow channel, and remodel and simulate.

[0066] If the model is deemed acceptable, the final 3D model will be exported as an STL file for subsequent photopolymerization 3D printing.

[0067] Step 3 (S3): Photopolymerization 3D printing prototype.

[0068] S3a, Model slicing parameter settings: Import the STL format model obtained in step S2c into the slicing software for slicing processing. Addressing the fusion defects between the UV-cured resin and the PE drip irrigation pipe, an integrated PE adapter joint is designed in the model for the water inlet side of the lower shell.

[0069] In this step, the core process parameters include: layer thickness 0.03mm, single layer exposure time 1.6s, number of bottom layers 10, bottom layer exposure time 30s, and connector dimensions of outer diameter 20mm, inner diameter 16mm, and length 30mm, which are compatible with PE16 drip irrigation pipes.

[0070] S3b, Model Slicing: Based on the process parameters set in S3a, the STL format model is sliced ​​layer by layer to generate slice files adapted to the SLA-600 photopolymer 3D printer, and the slice files are verified and exported.

[0071] S3c, prototype part printing and molding: import the verified slice file into the photopolymer 3D printer, add tough photosensitive resin, start the printing program, and mold the upper shell, lower shell and PE adapter prototype parts respectively.

[0072] In this step, the prototype is immediately removed from the printer platform after printing is completed, and the prototype is manually separated from the printing support column to obtain a rough prototype to be cleaned.

[0073] Furthermore, this step avoids the problem of traditional 3D printed prototypes not being able to have additional adapters glued on by printing the PE adapter in one piece, ensuring the sealing and reliability of the pipeline connection during subsequent water flow testing, and directly completing performance verification through the prototype.

[0074] S3d, elastic diaphragm compression molding, uses a customized silicone rubber compression molding die to prepare a silicone rubber elastic diaphragm with a Shore hardness of A40;

[0075] Weigh the raw silicone rubber according to the mold cavity volume × 1.03 (with an upward float of 3% to compensate for flash loss), and cut it into blanks that match the diaphragm cavity;

[0076] Preheat the mold to 150℃, apply water-based release agent, place the blank in, close the mold and apply pressure to 10MPa, and vulcanize at a constant temperature for 20 minutes.

[0077] After vulcanization, the film is demolded and the flash is removed to obtain an elastic diaphragm.

[0078] Step 4 (S4): Post-processing of 3D printed prototypes. Place the upper and lower shell prototypes printed by S3c into a CNC ultrasonic cleaner for ultrasonic cleaning for 15 minutes to remove residual photosensitive resin from the inner wall and surface of the flow channel.

[0079] The elastic diaphragm prepared by S3d is trimmed to ensure that the edges of the diaphragm are flat and free of burrs;

[0080] Step 5 (S5): Precision assembly of the core structure.

[0081] The first step is to clean the bonding surface. Clean the outer edge of the water inlet of the lower shell and the bonding surface of the elastic diaphragm, remove surface oil, burrs and impurities, and ensure that the bonding surface is flat and free of foreign objects.

[0082] The second step, diaphragm positioning and gap control, involves clamping the silicone rubber elastic diaphragm in the mating area between the upper and lower shells, ensuring high-precision surface bonding between the diaphragm and the lower shell protrusion.

[0083] In this step, a feeler gauge is used to check the fit clearance, and an elastic diaphragm divides the inner cavity enclosed by the upper and lower shells into an independent, sealed water inlet chamber and a water outlet chamber.

[0084] The third step is to fit and seal the upper and lower shells together using a snap-fit ​​structure to ensure that the elastic diaphragm fits the protrusion when the water is not flowing through it.

[0085] In this step, 3D printing resin is applied to the mating surfaces of the upper and lower shells, and then placed in the UV curing unit of the 3D printer for curing to complete the normally closed seal.

[0086] Step Six (S6): Water flow performance testing and iteration.

[0087] The first step is to set up the test platform. The 3D printed prototype of the S5 assembly is connected to the water conservancy test equipment (including water supply, flow monitoring and pressure monitoring equipment) through PE adapter connectors. The pipeline sealing is checked to prevent water leakage from affecting the test results.

[0088] The second step is performance testing. The inlet water pressure is gradually increased in the range of 0.05~0.4MPa. The flow rate of the prototype is tested under different pressures, pressure-flow curves are plotted, and its hydraulic performance is evaluated. At the same time, it is observed whether there is backflow, blockage, or leakage in the prototype.

[0089] The third step is to determine and iterate the test results to see if the test results meet the design specifications.

[0090] If it is determined to be unqualified, return to step two S2a to adjust parameters such as the gap of the right-angle rectangular boss and the length of the flow channel, then conduct re-modeling, simulation, printing, assembly and testing;

[0091] If it is determined to be qualified, proceed to the subsequent precision mold processing procedure;

[0092] In this step, the 3D printed prototype can be directly used to complete the full-performance water passing verification, there is no need to develop multiple test molds for verification, and only one test mold is required to be developed for the final injection molding process verification after the prototype verification is qualified, which effectively reduces the number of mold development times and material waste;

[0093] Step seven (S7), precision mold processing,

[0094] S7a, processing of mold cavity base material: cutting pre-hardened mold steel into blanks according to the mold design dimensions, and sequentially processing through rough milling, finish milling and grinding to obtain the mold cavity base material;

[0095] S7b-1, processing of flow channel cavity: adopting tungsten-copper alloy to process the flow channel forming electrode, and the electrode size is adapted to the optimized right-angle rectangular boss type flow channel obtained in S2a;

[0096] clamping the electrode on a low-speed wire cut electrical discharge machine, performing wire cut processing on the mold cavity to form the cavities of the first flow channel and the second flow channel;

[0097] In this step, the processing parameters are: wire traveling speed 2m / s, processing current 3A, the corners and edges are regular without curved surface deviation;

[0098] S7b-2, processing of boss and matrix filter plate: adopting a numerical control milling machine to process the boss cavity of the lower shell water inlet;

[0099] adopting a split tungsten-copper electrode to process the matrix filter plate cavity by electric discharge machining;

[0100] S7b-3, processing of chimeric structure: adopting numerical control turning to process the curved surface cavity of the upper shell, and the curvature of the curved surface matches the inner wall of the PE16 drip irrigation pipe;

[0101] adopting numerical control milling to process the groove cavity of the lower shell, so as to ensure no water leakage at the chimeric position of subsequent injection molded parts;

[0102] S7c, polishing and rust prevention treatment of mold cavity: performing polishing treatment on all mold cavities processed in S7a, S7b-1, S7b-2 and S7b-3, polishing the inner wall of the flow channel to Ra≤0.4μm, and polishing the surface of the cavity to Ra≤0.8μm;

[0103] performing rust prevention treatment on the mold parting surface and the exhaust groove;

[0104] S7d, mold assembly, complete the overall assembly of mold guide pillars, guide sleeves, ejection mechanism and other accessories. After assembly, check the mold closing clearance to ensure that there is no looseness or offset when the mold is closed.

[0105] Step 8 (S8): Injection molding of the test mold and the final mold.

[0106] S8, test mold injection molding: Based on the mold cavity processed in S7, make a test mold, clamp the test mold in a horizontal injection molding machine, use water pressure resistant and aging resistant engineering plastic as raw material, start the injection molding machine, and mold the upper shell and lower shell plastic parts.

[0107] The test mold is subjected to water flow test. The dimensions of the plastic parts injected from the test mold are checked to ensure that the dimensional deviation of all plastic parts is ≤ ±0.01mm and there are no defects such as missing glue, flash, or bubbles. After the qualified plastic parts are assembled with the silicone rubber diaphragm according to the S5 process, the water flow test is carried out to verify the fitting and sealing, flow channel flow, and pressure compensation performance of the plastic parts.

[0108] If the test fails, return to S7 to optimize the mold cavity machining parameters;

[0109] If the test is passed, the formal injection molding process will proceed to the mass injection molding stage. Based on the test results of the experimental mold, routine optimization of the mold cavity will be performed, a formal injection mold will be made, and mass injection molding will be carried out according to the injection molding process parameters of S8.

[0110] Step 9 (S9): Precision assembly of mass-produced finished products.

[0111] S9a, cleaning and removing impurities from the upper and lower shells of the injection-molded parts: the upper and lower shells of the injection-molded parts of S8 are cleaned by an automated cleaning device to remove surface dust and burrs, ensuring that there are no impurities in the mating surfaces and flow channels;

[0112] S9b, the silicone rubber diaphragm and the boss are precisely fitted. The silicone rubber elastic diaphragm with a Shore hardness of A40 is fitted with the water inlet boss of the lower shell with high precision. The fit gap is checked with a feeler gauge to ensure that the gap meets the design requirements. The diaphragm separates the upper and lower shells into a sealed water inlet chamber and a water outlet chamber.

[0113] S9c features a sealed upper and lower shell with a 1mm diameter nitrile rubber sealing ring installed at the groove where the upper and lower shells fit together. An automated snap-fit ​​assembly device is used for the sealing and fixing, and a snap-fit ​​force of 5N is applied to ensure that there is no leakage or loosening after assembly.

[0114] S9d, the PE adapter is inserted and sealed with the PE pipe. The assembled water emitter is inserted into the PE16 drip irrigation pipe through the PE adapter to achieve a sealed connection.

[0115] Step 10 (S10): Sampling performance testing and shipment of finished products.

[0116] For finished product sampling performance testing, finished products are randomly selected according to the production scale of each batch and the quality inspection specifications. The test items include starting pressure, anti-backflow performance, and anti-clogging performance. The test standards are consistent with S6.

[0117] If the test fails, return to step S9 to reassemble the finished product;

[0118] If the inspection is passed, the qualified batch of finished products will be packaged and labeled to complete the finished product shipment and delivery.

[0119] Furthermore, the rapid verification method for the pressure-compensated emitter developed in this embodiment can be applied to non-pressure-compensated emitters. In practical applications, when implementing the method, the processing of the diaphragm in steps S2~S5 and S8~S9 can be eliminated, thus achieving the processing of conventional upper and lower shell emitters.

[0120] Please see the appendix Figure 1 To be continued Figure 6 As another embodiment of the present invention, an embedded pressure-compensating water emitter processed using the rapid verification method in the above embodiments is provided. The water emitter is prepared through the entire process of three-dimensional modeling and CFD simulation iteration, photopolymerization 3D printing prototype verification, mold precision processing and standardized assembly in the aforementioned embodiments, and includes an upper shell 100, a lower shell 200 and an elastic diaphragm 300.

[0121] The elastic diaphragm 300 is sealed and clamped between the upper shell 100 and the lower shell 200, and divides the inner cavity enclosed by the upper shell 100 and the lower shell 200 into an independent water inlet chamber and a water outlet chamber.

[0122] The water inlet chamber corresponds to the water inlet side of the lower shell 200, and the water outlet chamber corresponds to the water outlet side of the upper shell 100.

[0123] The elastic diaphragm 300 adapts to the pressure difference between the inlet and outlet chambers, adjusting the flow area of ​​the outlet channel by changing the outlet chamber volume to stabilize the outlet chamber pressure and achieve pressure compensation.

[0124] Regarding the upper shell 100, it is set as a rectangular body, and its end face away from the lower shell 200 is machined into an arc surface that matches the curvature of the inner wall of the PE16 drip irrigation pipe.

[0125] A water outlet 101 is provided through the upper shell 100, and a pressure relief chamber 103 is provided in the water outlet cavity at the position corresponding to the water outlet 101. The pressure relief chamber 103 is directly connected to the water outlet 101.

[0126] The water outlet cavity is also provided with a second flow channel 102. The second flow channel 102 is continuously tortuous, and the inner wall of the flow channel adopts the right-angled rectangular boss structure in the aforementioned embodiment. It is formed by tungsten copper alloy electrode combined with slow wire cutting process, and the corner regularity deviation is ≤0.01mm.

[0127] Regarding the lower shell 200, it is configured as a rectangular body with a groove on one side. The groove is used to accommodate the elastic diaphragm 300 and the upper shell 100. The upper shell 100 and the lower shell 200 are fitted and sealed by the groove.

[0128] The lower shell 200 is provided with an inlet 201 on the end face away from the upper shell 100. A filter plate 201-2 is integrally formed around the inlet 201. The filter plate 201-2 is composed of several filter blocks arranged in a matrix.

[0129] A boss 201-1 is provided on the inner side of the lower shell 200 and on the outer edge of the water inlet 201. In the non-water-flow state, the elastic diaphragm 300 is attached to the boss 201-1, and the gap between the two is controlled to be 0.01~0.03mm by the precision assembly process of the aforementioned embodiment.

[0130] The lower shell 200 has a first flow channel 202 inside, which together with the elastic diaphragm 300 forms a flow guiding structure for the water inlet cavity;

[0131] The water inlet side of the lower shell 200 is integrally molded with a PE adapter connector that is compatible with PE16 drip irrigation pipe, which is achieved through photopolymerization 3D printing integral molding process and subsequent injection molding process;

[0132] Regarding the elastic diaphragm 300, it is made of silicone rubber with a Shore hardness of A40 through a compression molding process, with a thickness of 0.5mm. Its size is adapted to the fitting area of ​​the upper shell 100 and the lower shell 200, and it can fill the assembly gap between the upper shell 100 and the lower shell 200 to achieve water flow isolation and elastic pressure compensation.

[0133] Normal usage status:

[0134] Irrigation water first flows through the filter plate 201-2 of the lower shell 200, filtering out impurities such as mud, sand, and grass roots. Afterward, it enters the interior of the lower shell 200 through the inlet 201. The water flows directionally along the first flow channel 202, gradually filling the primary pressure-stabilizing cavity formed by the elastic diaphragm 300 and the lower shell 200. The elastic diaphragm 300 undergoes elastic deformation under the pressure of the water flow, absorbing the pressure impact and completing primary pressure stabilization. The water that has completed primary pressure stabilization then flows around the edge of the elastic diaphragm 300 and enters the outlet cavity. The water flows through the continuous and tortuous second flow channel 102 and undergoes gradual deceleration and pressure release. After secondary pressure release, the water flows into the pressure release chamber 103. At this time, the elastic diaphragm 300 is subjected to water pressure from the primary pressure stabilizing chamber and the pressure release chamber 103 on both sides. Based on the pressure difference between the two sides, it adaptively generates elastic deformation and dynamically adjusts the flow channel cross-sectional area to keep the pressure in the outlet chamber stable. After multiple stages of pressure stabilization and pressure compensation, the water finally drips out of the outlet 101 at a uniform speed and in a quantitative manner.

[0135] Please see the appendix Figure 1 To be continued Figure 4 Appendix Figure 7 To be continued Figure 9 As another embodiment of the present invention, a pipe-mounted anti-drip pressure compensating sprinkler processed using the rapid verification method described in the foregoing embodiments is provided. This sprinkler is manufactured through a complete process including 3D modeling and CFD simulation iteration, photopolymerization 3D printing prototype verification, precision mold machining, and standardized snap-fit ​​assembly as described in the foregoing embodiments. It includes a cylindrical upper shell 200, a cylindrical lower shell 100, and an elastic diaphragm 300.

[0136] The upper shell 200 is embedded inside the lower shell 100, and the elastic diaphragm 300 is mounted on the mounting boss 301 inside the upper shell 200.

[0137] The elastic diaphragm 300 divides the interior of the upper shell 200 into two independent water chambers, the first water chamber being connected to the water inlet 101 of the lower shell 100 and having a higher pressure than the second water chamber.

[0138] The outer wall of the upper shell 200 is provided with a first water hole 202 and a second water hole 204. The first water hole 202 and the second water hole 204 are arranged alternately along the axial direction of the upper shell 200. The outer wall of the upper shell 200 is provided with a continuous bent flow channel 203. The two ends of the flow channel 203 are respectively connected to the first water hole 202 and the second water hole 204.

[0139] The elastic diaphragm 300 undergoes adaptive elastic deformation under the water pressure difference between the first water chamber and the second water chamber, adjusting the chamber volume and the flow state of the flow channel 203 to achieve pressure compensation;

[0140] Regarding the lower shell 100, it is set to a cylindrical shape, and an inlet 101 is integrally formed at the end away from the upper shell 200. The inlet 101 is a tapered anti-detachment round tube, and the tapering of the outer wall gradually decreases in the direction away from the lower shell 100. The insertion-type anti-detachment sealing connection with the irrigation pipe is achieved through the injection molding process of the aforementioned embodiment.

[0141] The inlet 101 has an integrally formed filter screen 101-1 inside, which is used to filter impurities such as mud, sand and grass roots in the water flow.

[0142] A top abutment protrusion 501 is provided inside the lower shell 100 and on the outer edge of the output end of the water inlet 101. In the non-water-flow state, the elastic diaphragm 300 is attached to the top abutment protrusion 501, and the gap between the two is controlled to be 0.01~0.03mm by the precision assembly process of the aforementioned embodiment.

[0143] The inner wall of the lower shell 100 is provided with an installation groove 401 corresponding to the installation protrusion 400 of the upper shell 200, so as to realize the snap-fit ​​and fixation of the upper and lower shells;

[0144] Regarding the upper shell 200, it is set as a cylinder adapted to the lower shell 100, and its top end is integrally formed with a drain outlet 201, which is connected to the second water cavity.

[0145] The inner wall of the upper shell 200 is provided with an annular mounting boss 301 for mounting the elastic diaphragm 300;

[0146] The outer wall of the upper shell 200 is provided with a first water hole 202 and a second water hole 204, which are arranged alternately along the axial direction to avoid direct water flow.

[0147] The continuous bending flow channel 203 on the outer wall of the upper shell 200 adopts the right-angled rectangular boss structure optimized in the aforementioned embodiment, and is formed by tungsten copper alloy electrode combined with slow wire cutting process, with a corner regularity deviation ≤0.01mm;

[0148] An annular mounting protrusion 400 is provided on the outer side of the upper shell 200 and on the side of the flow channel 203 away from the lower shell 100. It adopts an elastic convex rib structure and engages and seals with the mounting groove 401 of the lower shell 100, replacing the traditional ultrasonic welding process.

[0149] Inside the upper shell 200, on one side corresponding to the drain outlet 201, there is a water outlet pressure compensation protrusion 500, which is used to cooperate with the elastic diaphragm 300 for dynamic pressure adjustment.

[0150] Regarding the elastic diaphragm 300, it is made of silicone rubber with a Shore hardness of A40 through the molding process described in the aforementioned embodiment. The thickness is 0.5mm, and its size is adapted to the mounting boss 301 inside the upper shell 200. It can fill the assembly gap to achieve water flow isolation and elastic pressure compensation.

[0151] The elastic parameters of the elastic diaphragm 300 are matched with the height and contact area of ​​the top protrusion 501, which together determine the starting pressure of the water emitter.

[0152] Normal usage status:

[0153] During the water supply phase, irrigation water flows into the irrigator through the inlet 101 of the tapered anti-detachment circular pipe structure. After being filtered by the internal filter screen 101-1, it flows into the first water chamber. The high-pressure water flow pushes open the elastic diaphragm 300 attached to the top protrusion 501, quickly filling the first water chamber. The water flows through the first water hole 202 into the continuous bend channel 203 on the outer wall of the upper shell 200. The right-angled rectangular protrusion structure of the channel decelerates, releases pressure, and buffers the water flow step by step, eliminating water pressure impact and pressure pulsation. After the pressure is released, the water flows through the second water hole 204 into the second water chamber. At this time, the elastic diaphragm 300 is subjected to the water pressure of the first water chamber and the second water chamber on both sides. It generates elastic deformation in real time according to the water pressure difference, dynamically adjusting the cavity volume and the flow state of the channel 203. With the help of the pressure compensation protrusion 500 at the outlet end, the internal water pressure is further balanced. After pressure stabilization and compensation, the water flows out uniformly and quantitatively through the drain outlet 201 at the top of the upper shell 200.

[0154] During the water outage self-locking stage, after the drip irrigation system stops water, the water pressure inside the first water chamber disappears rapidly. The elastic diaphragm 300 rebounds under its own elasticity and re-fits tightly against the top protrusion 501, sealing the water inlet channel and forming a normally closed self-locking structure, which effectively prevents backflow of water and impurities in the irrigation pipe from causing blockage of the flow channel.

[0155] Compared with the prior art, the present invention has the following characteristics:

[0156] The toothed corners of the traditional flow channel are optimized into a right-angled rectangular boss structure. Tungsten copper alloy electrodes are used in conjunction with slow wire EDM to process the core cavity of the flow channel, which significantly improves the forming accuracy and edge regularity of the cavity, reduces the difficulty of mold processing, ensures the pressure balance effect of the flow channel, realizes the stability of drip irrigation flow when the inlet water pressure fluctuates, and improves the accuracy of pressure compensation.

[0157] By precisely controlling the gap between the diaphragm and the boss, the starting pressure of the water dispenser can be accurately set, ensuring the normal closed sealing effect of the diaphragm and the boss when the water is not flowing, solving the problems of backflow and backflow, and improving the anti-clogging performance.

[0158] We have constructed a multi-stage testing and feedback optimization process, from simulation design, prototype water flow testing, experimental model verification to finished product sampling inspection. Combined with automated assembly processes, we have improved the pass rate and performance consistency of mass-produced finished products, and ensured that core functions such as pressure compensation, backflow prevention, and anti-clogging meet the design specifications.

[0159] Through the systematic optimization of the above geometric parameters, the flow index of the water emitter is reduced to below 0.05, and the outflow rate is kept constant within the range of inlet pressure fluctuation of 0.05 to 0.4 MPa.

[0160] The above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. The scope of protection of the present invention should be determined by the scope of the claims.

Claims

1. A rapid verification method for developing drip irrigation emitters, wherein the emitter is assembled from a lower shell, an upper shell, and an elastic diaphragm, characterized in that, The method includes the following steps: S1, Preliminary preparation: Prepare and debug the equipment, materials and tooling fixtures required for processing; S2, 3D modeling and fluid simulation iteration: establish solid models of each component of the water emitter and optimize the flow channel structure of the model. Import the optimized model into the fluid simulation software to complete the simulation analysis. After the simulation verification is qualified, export the model file. The optimization of the model flow channel structure involves transforming the tooth tip angle of the traditional flow channel into a right-angled rectangular boss structure. S3, Photopolymer 3D Printing Prototype and Elastic Membrane Preparation: After importing the model file into the slicing software and setting the parameters, the prototype of the water dispenser is printed by the photopolymer 3D printer. S4. Prototype post-processing: Cleaning and polishing the 3D printed prototype to ensure its water permeability and assembly compatibility. S5. The core structure is precisely assembled by fitting the elastic diaphragm with the prototype part, so that the diaphragm divides the inner cavity enclosed by the upper and lower shells into a sealed water inlet chamber and a water outlet chamber, forming a normally closed seal structure to prevent backflow. S6. Water flow performance test and iteration: The water flow performance of the assembled prototype is tested. If the test is qualified, it proceeds to the next process. If the test is unqualified, it returns to S2 to adjust the model parameters. S7. Precision machining of molds: Machining injection molds for water dispensers based on the model after successful simulation, completing the forming, post-processing and overall assembly of the mold cavity; S8. Injection molding: Make a test mold to complete the injection molding verification. After the verification is qualified, make a formal mold for large-scale injection molding to obtain the water dispenser plastic parts. S9. Precision assembly of mass-produced finished products: The elastic diaphragm and injection-molded plastic parts are assembled according to the assembly requirements of S5 to achieve a sealed connection between the water emitter and the drip irrigation pipe. S10. Finished Product Inspection and Delivery: Sampling performance tests are conducted on mass-produced finished products. Qualified finished products are packaged and shipped out of the factory, while unqualified products are returned to S9 for reassembly.

2. The rapid verification method as described in claim 1, characterized in that, The inlet pressure in the fluid simulation of S2 is set based on the design requirements of the irrigation device, and the simulation judgment criterion is that the drip irrigation flow rate remains constant.

3. The rapid verification method as described in claim 1, characterized in that, When establishing the three-dimensional model in S2, a PE adapter connector adapted to the drip irrigation pipe is integrally designed on the water inlet side of the lower shell. The elastic diaphragm in S3 is prepared by compression molding using an elastic material.

4. The rapid verification method as described in claim 1, characterized in that, The prototype post-processing of S4 includes, The prototype was ultrasonically cleaned to remove residual molding material from the flow channel. The outer wall of the connecting joint and the inner wall of the flow channel of the prototype were polished with wet sandpaper.

5. The rapid verification method as described in claim 1, characterized in that, The core structure precision assembly of the S5 includes: Clean the mating surfaces of the lower shell boss and the elastic diaphragm, attach the diaphragm to the boss surface, install a sealing ring at the joint of the upper and lower shells and apply a fastening force to complete the sealing and fixation, so that the diaphragm and the boss are tightly fitted to form a normally closed seal when water is not flowing.

6. The rapid verification method as described in claim 1, characterized in that, The water flow performance test of S6 includes setting up a water flow test platform to test the core performance of the prototype, including starting pressure, drip irrigation flow rate, anti-backflow performance and anti-clogging performance.

7. The rapid verification method as described in claim 1, characterized in that, The S7 uses mold steel as the cavity base material for precision machining. The flow channel cavity is formed by conductive alloy electrodes in conjunction with wire cutting equipment. The cavities of the boss, filter plate and upper and lower shell fitting structure are all formed by CNC machining.

8. The rapid verification method as described in claim 1, characterized in that, In the S8 injection molding process, water-pressure resistant and aging-resistant engineering plastics are used as raw materials. After the test mold injection is completed, the plastic parts are first inspected for size. Plastic parts that pass the size inspection are then tested for water flow performance on the machine.

9. The rapid verification method as described in claim 1, characterized in that, The mass-produced S9 is precision assembled using automated equipment to complete the fitting and sealing of the upper and lower shells and the diaphragm.

10. The rapid verification method as described in claim 1, characterized in that, The performance testing of the finished product in S10 is carried out by batch, and the sampling ratio of each batch meets the requirements of the quality inspection specifications. The testing standards are consistent with the water flow performance testing standards of S6. The finished products that pass the test are packaged and shipped out of the factory.

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