Smart Backpack Sprayer with Segregated Mixing Manifold
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Solution Overview
Problem
Current sprayer systems face issues such as waste of chemicals, cross-contamination, and inefficiency due to the need to completely empty and clean tanks between applications, and lack of control over chemical/diluent ratios, especially in backpack sprayers.
Innovation Solution
A sprayer system with a separable chemical and diluent tank configuration, incorporating a mixing manifold and positive displacement pump that allows for adjustable dilution and pressure regulation, along with smart controls for efficient operation and minimal chemical exposure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single tank is used for storing both chemical and diluent, then the device complexity is reduced, but cross-contamination and chemical waste increase due to the need to empty and clean the tank between applications
Solution Approach 1:
The sprayer system divides the storage function into separate tanks: a first tank for diluent and a second tank for chemical concentrate. This segmentation prevents cross-contamination between different chemicals while maintaining operational efficiency. The separate tanks eliminate the need to empty and clean a single tank between applications of different chemicals.
2Ease of operation
If a single tank system is used, then ease of operation is improved, but loss of time increases due to the need to empty, clean, and refill tanks between applications
Solution Approach 1:
By separating the chemical storage from the diluent storage into distinct tanks, the system eliminates the time-consuming process of emptying and cleaning a single tank between applications. The chemical tank can be quickly disconnected and replaced without affecting the diluent tank, significantly reducing operational downtime.
Solution Approach 2:
The chemical concentrate is extracted from the main water tank system into a separate, dedicated tank. This allows the chemical to be isolated and easily replaced without disturbing the large volume of diluent in the first tank, thereby saving time on cleaning and refilling operations.
3Object-affected harmful factors
If chemical is stored in a separate smaller tank, then cross-contamination is reduced, but device complexity increases due to complex plumbing and interconnectivity requirements
Solution Approach 1:
A mixing manifold serves as an intermediary device that receives diluent from the first tank and chemical concentrate from the second tank, then combines them in controlled proportions. This intermediary mixing mechanism simplifies the plumbing by providing a centralized mixing point rather than requiring complex distribution systems throughout the tank.
Solution Approach 2:
The system incorporates a metering device that automatically controls the proportion of chemical concentrate added to the diluent flow. This self-regulating mechanism eliminates the need for manual measurement and mixing, reducing operational complexity while maintaining precise chemical dosing.
4Productivity
If variable pressure spray is used with multiple nozzles, then productivity is improved, but device complexity increases and chemical waste occurs due to recirculation requirements
Solution Approach 1:
The system incorporates a variable pressure pump that can dynamically adjust output pressure based on operational needs. This dynamic pressure control enables the system to switch between high-pressure operation for multiple nozzles (increasing productivity) and low-pressure operation for single nozzle application (reducing complexity and waste).
Solution Approach 2:
The pump system can change its operating parameters (pressure and flow rate) to match the requirements of different spray configurations. When multiple nozzles are attached, the pump increases pressure to deliver adequate flow to each nozzle. When a single nozzle is used, the pump reduces pressure to prevent waste and reduce the need for recirculation.
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 efficient and controlled application of chemicals with reduced waste and cross-contamination, allowing for easy switching between different chemical solutions without emptying and refilling the tank, and provides smart operation features for improved usability.
Implementation Method 1
a positive displacement pump that delivers a fixed amount of diluent from the first tank and a selectively adjustable amount of liquid concentrate from the second tank
Data Source
AI summary
A backpack sprayer system includes a mounting bracket having a battery receiving fixture to receive a battery. A first tank is mounted to the mounting bracket and holds a diluent. A second tank is mounted to the mounting bracket and holds a liquid concentrate. A mixing manifold is mounted to the mounting bracket and has a first inlet fitting to receive a fixed amount of diluent and a second inlet to receive an adjustable amount of liquid concentrate. The fixed amount of diluent and adjustable amount of concentrate are combined to form a mixed solution and the mixing manifold includes a mixed solution outlet. A positive displacement pump is mounted to the mounting bracket and a suction port coupled to the mixed solution outlet and a pressure port fluidly coupled with a spray device. A control unit is mounted on the mounting bracket and receives power from the battery.