Controller-Based Nozzle Cleaning via Flow Rate Adjustment
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Solution Overview
Problem
The existing rotary mixer systems face inefficiencies due to clogged spray nozzles, requiring tedious manual or physical unclogging methods, which are time-consuming and disrupt operations.
Innovation Solution
A method and system that automatically determine which nozzles need cleaning, increase the fluid flow rate to enhance cleaning, and then decrease it once the nozzles are clear, using a controller and monitoring devices to manage the process, applicable to various machines with nozzles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual or physical unclogging methods are used to clear clogged nozzles, then the nozzles can be cleaned, but the process becomes tedious and time-consuming
Solution Approach 1:
The system enables nozzles to clean themselves by automatically increasing fluid flow rate through detected clogged nozzles, eliminating the need for manual intervention. The controller monitors nozzle performance and autonomously initiates cleaning by adjusting flow rates, allowing the system to service itself without operator involvement.
Solution Approach 2:
The patent replaces manual mechanical unclogging operations with an automated fluid-based cleaning system. Instead of physically removing or manipulating clogged nozzles, the system uses increased fluid flow pressure to clear obstructions automatically, substituting mechanical labor with a controlled fluid dynamics approach.
2Reliability
If high fluid flow rate is used to clean nozzles, then cleaning effectiveness is improved, but excess fluid usage increases
Solution Approach 1:
The system applies high fluid flow rate selectively only to specific nozzles that are detected as clogged, rather than increasing flow through all nozzles uniformly. The controller identifies individual problematic nozzles and directs enhanced cleaning flow only where needed, maintaining local quality of cleaning action while minimizing overall fluid consumption.
Solution Approach 2:
The cleaning process operates periodically based on detected nozzle conditions rather than continuously. The controller monitors nozzle performance and initiates high flow rate cleaning only when clogging is detected, then returns to normal operation once cleaning is complete, creating a periodic action pattern that reduces total fluid usage compared to continuous high-flow operation.
3Reliability
If all nozzles are cleaned continuously, then all nozzles remain clear, but operational efficiency decreases due to unnecessary cleaning cycles
Solution Approach 1:
The system incorporates a feedback mechanism where the controller continuously monitors nozzle performance and identifies which nozzles are clogged based on fluid flow measurements. This feedback information allows the controller to selectively clean only the nozzles that require it, rather than cleaning all nozzles uniformly, thereby maintaining productivity while ensuring nozzle reliability.
Solution Approach 2:
Instead of applying cleaning action to all nozzles, the system applies partial cleaning action only to the subset of nozzles that are actually clogged. This partial action approach avoids the excessive cleaning of already-clear nozzles, maintaining operational efficiency while still achieving the necessary cleaning effect on problematic nozzles.
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 automated process reduces the need for manual unclogging, improves efficiency by minimizing excess fluid usage, and ensures accurate cleaning of obstructed nozzles, maintaining operational continuity and soil moisture control.
Implementation Method 1
determine a first flow rate of the fluid through the first subset of nozzles; increasing, based on determining that the first subset of nozzles is to be cleaned, the first flow rate of the fluid through the first subset of nozzles to a second flow rate
Data Source
AI summary
A controller associated with a machine may determine that a first subset of nozzles, of a plurality of nozzles of the machine, is to be cleaned. The controller may determine a first flow rate of the fluid through the first subset of nozzles and increase, based on determining that the first subset of nozzles is to be cleaned, the first flow rate of the fluid through the first subset of nozzles to a second flow rate of the fluid through the first subset of nozzles. The controller may decrease the second flow rate of the fluid through the first subset of nozzles to the first flow rate of the fluid through the first subset of nozzles when the first subset of nozzles is cleaned.