Configurable Nozzle Assembly for Consistent Spray Patterns
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Solution Overview
Problem
Agricultural sprayers face challenges in achieving consistent spray patterns and droplet sizes due to variations in flow rates and pressures, leading to inefficient application of agricultural products across irregular field shapes and contours.
Innovation Solution
A configurable nozzle assembly that dynamically adjusts its orifice size and shape to maintain specified spray patterns and droplet sizes, coupled with a localized injection system for instantaneous mixing of injection products with carrier fluids at the nozzle level, allowing for real-time adjustment based on flow rates and pressures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a static nozzle is used, then the device complexity is reduced, but the spray pattern and droplet size vary with pressure and flow rate changes
Solution Approach 1:
The nozzle transitions from a static configuration to a dynamic one by incorporating movable orifices that can adjust their position and orientation in response to varying flow conditions. This allows the spray pattern and droplet size to be maintained consistently across different pressure and flow rate levels, resolving the contradiction between simplicity and precision.
Solution Approach 2:
The nozzle system changes physical parameters (orifice position, orientation, and effective size) dynamically based on operating conditions. By adjusting these parameters in response to pressure and flow rate variations, the system maintains consistent spray characteristics without requiring a complex fixed design.
2Productivity
If the flow rate varies, then the productivity is improved, but the droplet size and spray pattern become inconsistent
Solution Approach 1:
The nozzle system incorporates feedback mechanisms where sensors detect changes in flow rate and pressure, and this information is used to automatically adjust orifice configuration. This closed-loop control maintains consistent droplet size and spray pattern even as productivity increases through variable flow rates.
Solution Approach 2:
The movable orifices dynamically reconfigure themselves based on real-time flow conditions, allowing the system to maintain precision across a wide range of productivity levels. The orifices can shift position and orientation to compensate for changes in flow rate, ensuring uniform droplet size regardless of application speed.
3Productivity
If pressure increases, then the productivity is improved, but the spray pattern and droplet size deviate from specifications
Solution Approach 1:
The nozzle system adjusts physical parameters including orifice orientation and effective opening size in response to pressure changes. By changing these parameters dynamically, the system maintains specified spray patterns and droplet sizes even when operating pressure varies to meet different productivity requirements.
4Measurement precision
If a localized injection system is implemented, then the mixing precision is improved, but the device complexity increases
Solution Approach 1:
The injection mixing system is merged directly with the nozzle assembly, combining two functions (mixing and spraying) into a single integrated component. This reduces overall system complexity while maintaining precise injection product distribution, as the mixing occurs within the nozzle structure itself rather than as a separate upstream system.
Data Source
AI summary
A configurable nozzle includes a nozzle body having a reception chamber configured to receive an application mixture. The nozzle body includes a nozzle orifice. At least one orifice assembly is coupled with the nozzle body, the at least one orifice assembly includes an orifice plate movably coupled with the nozzle body. The orifice plate extends along at least a portion of the nozzle orifice, and movement of the orifice plate changes one or more of the size or shape of the nozzle orifice. An orifice actuator is coupled with the orifice plate, and the orifice actuator is configured to move the orifice plate.