Spray Bar Pressure Sensing for Clogged Nozzle Detection

Solution Overview

Problem

Nozzles in spray systems of work machines like cold planers and rotary mixers often become clogged during operation, leading to inefficiencies and potential damage, as existing methods such as high-pressure air cleaning are not always effective or convenient.

Innovation Solution

A system comprising a pressure sensor and controller that detects excessive liquid pressure in the spray bar, determining if nozzles are clogged by comparing actual pressure to pre-determined thresholds, allowing for real-time clog detection and either alerting the operator or activating automatic cleaning.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If high pressure air is used to remove clogging of spray nozzles, then nozzle clogging is cleared, but the system complexity increases and operation convenience decreases

Engineering Contradiction:

Improvenozzle clogging clearanceVSAvoidsystem complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent implements a feedback mechanism by using a pressure sensor to continuously monitor liquid pressure in the spray bar and comparing it against a predetermined threshold. When the pressure exceeds the threshold, indicating nozzle clogging, the controller automatically activates the high-pressure air source to clear the clog. This closed-loop feedback system automates the clogging detection and clearance process, maintaining reliability while reducing operational complexity.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system performs self-service by automatically detecting nozzle clogging through pressure monitoring and autonomously activating the high-pressure air source to clear clogs without requiring manual intervention. The controller continuously monitors pressure readings and triggers the cleaning mechanism when needed, allowing the spray system to maintain itself during operation.

Inventive Principle:

Principle #25Self-service

2Reliability

If high pressure air is used to remove clogging of spray nozzles, then nozzle clogging is cleared, but ease of operation deteriorates

Engineering Contradiction:

Improvenozzle clogging clearanceVSAvoidoperation convenience

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The system performs self-service by automatically detecting nozzle clogging through pressure monitoring and autonomously activating the high-pressure air source to clear clogs without requiring manual intervention. The controller continuously monitors pressure readings and triggers the cleaning mechanism when needed, allowing the spray system to maintain itself during operation.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent implements a feedback mechanism by using a pressure sensor to continuously monitor liquid pressure in the spray bar and comparing it against a predetermined threshold. When the pressure exceeds the threshold, indicating nozzle clogging, the controller automatically activates the high-pressure air source to clear the clog. This closed-loop feedback system automates the clogging detection and clearance process, maintaining reliability while reducing operational complexity.

Inventive Principle:

Principle #23Feedback

3Measurement precision

If continuous monitoring of spray bar pressure is implemented, then clogged nozzles are detected in real-time, but device complexity increases

Engineering Contradiction:

Improveclog detection accuracyVSAvoidsystem complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent implements a feedback mechanism by using a pressure sensor to continuously monitor liquid pressure in the spray bar and comparing it against a predetermined threshold. When the pressure exceeds the threshold, indicating nozzle clogging, the controller automatically activates the high-pressure air source to clear the clog. This closed-loop feedback system automates the clogging detection and clearance process, maintaining reliability while reducing operational complexity.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent replaces complex mechanical monitoring systems with a simple pressure sensor and electronic controller. Instead of using mechanical flow meters or visual inspection systems, the invention uses electronic pressure sensing to detect nozzle clogging, simplifying the overall system while maintaining high measurement precision.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 operation of work machines by promptly identifying and addressing clogged nozzles without interrupting the machine, ensuring optimal performance and preventing damage from clogging.

Implementation Method 1

a pressure sensor to detect a pressure of a liquid within the spray bar

Methodology Applied

Scientific EffectPressure detection:

Data Source

PatentUS11612906B2Clogged nozzle detection

Publication Date: 2023.03.28 CATERPILLAR PAVING PROD INC

AI summary

A work machine can include a frame; a spray system couple to the frame and including a spray bar having a plurality of nozzles; a pressure sensor to detect a pressure of a liquid within the spray bar; and a controller to determine whether the detected pressure of the liquid within the spray bar has exceeded a pre-determined pressure threshold.