Spray bar deflection tray
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for spraying contents from rail cars are inefficient, leading to waste and foaming issues due to direct spray and lack of effective containment systems.
Innovation Solution
A deflection tray system for spray bars, including a curved spray bar with pneumatic valves and a trough design with angled deflector trays, reduces waste and foaming by deflecting spray and allowing gravity-driven liquid evacuation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If spray is directed directly into the rail car contents, then application coverage is achieved, but waste and foaming increase
Solution Approach 1:
A deflection tray is introduced as an intermediary component between the spray bar and the rail car contents. The tray captures and redirects spray material, preventing direct wasteful contact with the contents while maintaining effective chemical application. This intermediary structure reduces foam generation and material loss.
Solution Approach 2:
The spray delivery system is modified by adding a three-dimensional deflection tray structure that changes the spatial dimension of spray delivery. Instead of direct linear spray contact, the tray creates a controlled intermediate space that redirects spray in a different dimensional path, improving efficiency and reducing waste.
2Reliability
If spray bar is permanently attached to trim chute, then structural stability is maintained, but adaptability and maintenance difficulty increase
Solution Approach 1:
The spray bar assembly is segmented into separate components that can be independently removed and replaced. The spray bar is detachably mounted to the trim chute, allowing the spray bar to be separated from the fixed structure for maintenance while the trim chute remains in place. This segmentation enables easy replacement without affecting overall system stability.
Solution Approach 2:
The mounting system transitions from a static permanent attachment to a dynamic removable connection. The spray bar can be easily detached and reattached, providing operational flexibility while maintaining structural stability during use. This dynamic mounting approach facilitates quick maintenance and adaptation.
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
The system efficiently applies chemicals to rail car contents, minimizing waste and foaming by directing spray into a trough for collection and evaporation, enhancing operational efficiency and reducing maintenance needs.
Implementation Method 1
allowing gravity-driven liquid evacuation
Implementation Method 2
for collection and evaporation
Data Source
AI summary
A spray trough is described herein, including a trough body, wherein the trough body has a bottom portion, a first side portion, a second side portion, a front portion, and a back portion, the bottom portion, the front portion, and the back portion each having a first end and a second end, a top plate having a first end and a second end, wherein the first end of the top plate is fixedly attached to the second end of the back portion, wherein the top plate extends substantially perpendicular from the second end of the back portion, and a deflector plate, wherein the deflector plate is attached to the second end of the front plate, wherein the deflector plate extends downwardly from the second end of the front plate, such that the deflector plate angles towards the front portion.