Rapidly Actuating Spray Nozzles for Avian Vaccine Delivery
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Solution Overview
Problem
Existing inline spray applicators for avian animals face challenges in regulating vaccine delivery due to varying conveyor speeds, leading to inefficiencies and waste, as changing pressure affects droplet size and actuatable nozzles' effectiveness in maintaining desired droplet sizes is unknown.
Innovation Solution
An automated inline spray applicator system with rapidly actuating automatic nozzles, using Pulse Width Modulation (PWM) technology and Precision Spray Control, allows for rapid cycling between open and closed positions to control flow rate and maintain constant pressure and droplet size, accommodating varying conveyor speeds and conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If pressure is increased or decreased to regulate vaccine delivery, then delivery amount is controlled, but droplet size changes away from desirable range
Solution Approach 1:
The system dynamically adjusts the duty cycle of actuatable nozzles to regulate vaccine delivery amount while maintaining constant pressure and droplet size. The duty cycle varies from 1% to 100% based on conveyor speed and vaccination requirements, allowing precise control of vaccine quantity without affecting droplet characteristics.
Solution Approach 2:
The actuatable nozzles operate in periodic on-off cycles rather than continuously. By controlling the duration of on-periods relative to off-periods (duty cycle), the system delivers precise amounts of vaccine while maintaining stable pressure and droplet size during active spray periods.
2Productivity
If conventional nozzles are used, then continuous spray is achieved, but vaccine waste increases and delivery precision decreases
Solution Approach 1:
The system uses periodic activation of nozzles with adjustable duty cycles (1%-100%) to deliver vaccine only when needed. This eliminates continuous spraying and associated waste, while maintaining high vaccination throughput by rapidly cycling nozzles on and off during conveyor operation.
Solution Approach 2:
The system incorporates feedback control where conveyor speed sensors and spray pattern monitors adjust the duty cycle in real-time. This ensures optimal vaccine delivery quantity without over-spraying, reducing waste while maintaining productivity across varying operational conditions.
3Adaptability or versatility
If pressure is changed to accommodate varying conveyor speeds, then delivery rate is adjusted, but droplet size and spray pattern become inconsistent
Solution Approach 1:
The system dynamically adjusts duty cycle based on real-time conveyor speed feedback rather than changing pressure. This allows adaptation to varying conveyor speeds (0.5-2.0 meters per second) while maintaining constant pressure and consistent droplet size and spray pattern characteristics throughout operation.
Solution Approach 2:
Instead of changing pressure to adapt to conveyor speed variations, the system changes the temporal parameter (duty cycle) of nozzle activation. This parameter change allows full adaptability to different conveyor speeds while preserving pressure stability and spray consistency.
Data Source
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AI summary
The invention relates to spray applicator devices and methods of use for vaccinating, or administering probiotics to, avian animals. Said automated spray applicator device comprises a housing, at least one rapidly actuatable automatic spray nozzle, a programmable spray module, for controlling the automatic spray nozzle(s), and optionally a source of pressurized air for supplying pressure to the fluid prior to its entry into the spray nozzles; wherein the programmable spray module is in electrical, pneumatic or hydraulic connection with the at least one automatic spray nozzle; wherein the automatic spray nozzle(s) is(are) in fluid communication with a fluid reservoir/tank; and wherein the automatic spray nozzle comprises an electrical, pneumatic or hydraulic actuator and a nozzle tip.