Electrostatic Spray Module Tool-Free Nozzle and Voltage Adjustment
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Solution Overview
Problem
Existing electrostatic spray modules face issues with high-voltage current leakage, difficulty in changing nozzle orifice sizes without tools, and suboptimal high-voltage power supply levels, leading to inefficiencies and increased time for reconfiguration and maintenance.
Innovation Solution
The design includes a sturdy, liquid-impermeable, electrically insulative base and cover forming a protective enclosure with quick access, removable nozzle assemblies, and a variable high-voltage power supply that can be adjusted without tools, along with snap-on connectors for easy assembly and maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If nozzles extend through the shell or casing to deliver high voltage signal, then high voltage signal can be delivered to nozzles, but high-voltage current leakage occurs
Solution Approach 1:
The nozzle system is segmented into conductive nozzles for signal delivery and insulative seals for isolation. The seals are positioned where nozzles pass through the shell, creating distinct functional zones that prevent current leakage while maintaining electrical connectivity where needed.
Solution Approach 2:
Electrically insulative seals are introduced as intermediary elements between the conductive nozzles and the shell casing. These seals act as mediators that allow the nozzles to pass through the shell while blocking the harmful electrical current, thus preventing leakage without compromising signal delivery.
2Manufacturing precision
If nozzle orifice sizes are fixed during manufacturing, then manufacturing precision is maintained, but difficulty in changing nozzle orifice sizes without tools increases
Solution Approach 1:
The nozzle system transitions from a static, fixed configuration to a dynamic, changeable one. Nozzle inserts with different orifice sizes can be exchanged in the field without tools, allowing the system to adapt to different spraying requirements while maintaining manufacturing precision through pre-fabricated precision components.
Solution Approach 2:
Multiple nozzle inserts with different orifice sizes are pre-prepared and can be quickly exchanged. The preliminary preparation of various nozzle inserts allows users to select and install the appropriate nozzle for specific applications without requiring tools or complex reconfiguration procedures.
3Device complexity
If high voltage power supply is fixed at a single level, then device complexity is reduced, but adaptability for different applications decreases
Solution Approach 1:
The power supply system transitions from a fixed voltage output to a variable voltage output. The high voltage power supply can be adjusted to different voltage levels to match different application requirements, providing adaptability while maintaining relatively simple device architecture through a single adjustable power supply unit.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration reduces high-voltage leakage, allows for tool-free nozzle adjustments and optimal voltage settings, and streamlines the process of reconfiguring the sprayer system for different applications, enhancing efficiency and reducing maintenance time.
Implementation Method 1
The electrical charge in the spray leads to better dispersal of the spray due to the droplets in the spray repelling from each other, and further improves the adherence of the spray to crops which attract the charged droplets.
Data Source
AI summary
In an example, an electrostatic spray module includes a base unit formed of a sturdy, rigid, liquid impermeable, electrically insulative material and a cover formed of a sturdy, rigid, liquid impermeable, electrically insulative material and sized for covering the base unit. The base unit and the cover configured for mating engagement together so as to form a liquid impermeable, electrically insulative, protective enclosure when the module is in a closed state to keep the internal components clean and dry and prevents high voltage shorting and prevents leakage of current by inhibiting a high voltage from establishing a return path to ground. The spray module includes a quick access latch and gasket system—with no tools required to open for maintenance. The module includes integral place holders for components including air supply manifold and variable voltage supply to provide a selectable high voltage level to accommodate various spraying application.