Rotary Sprayer Flow Segmentation for Clog Prevention
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Solution Overview
Problem
Conventional rotary sprayers face issues with discontinuous fluid discharge when the fluid amount is low, leading to irregular wetting of workpieces and clogging of pipe conduits due to impurities, which requires larger conduit sizes to prevent clogging but results in unnecessary fluid application.
Innovation Solution
A rotary sprayer design with a rotating disc that divides the fluid flow into a secondary and working flow using openings in the distribution plane, allowing the secondary flow to be discharged separately, preventing drop formation and clogging, while maintaining efficient fluid application to the workpiece.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the amount of fluid supplied to the rotating disc is reduced to achieve precise fluid application, then the fluid discharge becomes discontinuous and forms drops, but the wetting uniformity deteriorates
Solution Approach 1:
The fluid flow is segmented into two separate streams: a primary working flow that is sprayed onto the workpiece and a secondary flow that is extracted and discarded. This segmentation allows the primary flow to maintain continuous discharge for uniform wetting while the secondary flow compensates for the reduced total fluid supply, preventing drop formation and maintaining spray stability.
2Reliability
If the pipe conduit inner diameter is increased to prevent clogging, then the conduit can flush out impurities, but the fluid application efficiency deteriorates
Solution Approach 1:
The secondary flow containing impurities and excess fluid is extracted through openings in the distribution plane before reaching the spray edges. This extraction allows the use of larger diameter pipe conduits that can effectively flush out impurities without wasting excessive fluid, as the secondary flow is removed and discarded rather than being applied to the workpiece.
3Quantity of substance
If the amount of fluid supplied is reduced to avoid waste, then the fluid consumption decreases, but the continuous flow stability deteriorates
Solution Approach 1:
Different regions of the fluid flow are treated differently: the primary working flow maintains sufficient volume and continuous flow characteristics for stable spraying, while the secondary flow is extracted and discarded. This local differentiation allows reduced overall fluid consumption while preserving flow continuity in the critical spray application region.
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
Enables continuous and controlled fluid application to workpieces, preventing irregular wetting and clogging, by separating the fluid flow into a secondary flow for extraction and a working flow for application, using a larger conduit size without wasting the entire main flow.
Implementation Method 1
the fluid is centrifuged to the outside with a radial component due to the rotary motion of the disc
Implementation Method 2
a first spray edge for spraying the working fluid flow, and a second spray edge for spraying the secondary fluid flow
Data Source
AI summary
A rotary sprayer (10) for fluids (14), has a rotating disc (22), a drive (58) for the disc (22), and a supply device (28) for the application of fluid (14) onto the disc (22). The disc (22) has a distribution plane (30) for the fluid (14), and at least one opening (34) is provided in the distribution plane (30), via which a secondary flow (50) of the fluid (14) is separated from the main flow (48) to another plane (46). The disc (22) has a first spray edge (44) for spraying the working flow (52) of the fluid (14) and a second spray edge (54) for spraying the secondary flow (50) of the fluid (14). Since the main flow is divided into a secondary flow and a working flow, the effective amount of fluid that is used to moisten the workpiece can be reduced without having to therefore reduce the amount of fluid that is supplied e.g. via the pipe conduit. The formation of drops is thereby reliably prevented and a pipe conduit is used that has a cross-section of adequate size to prevent clogging.