Stainless Steel Spray Boom With Thermally Formed Couplings
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Solution Overview
Problem
Conventional spray boom systems require manual retrofitting of couplings, which are prone to cracking and deformation due to stress and pressure, leading to aesthetically malformed and inefficient manufacturing processes.
Innovation Solution
The spray boom includes couplings thermally formed from the stainless steel housing using a carbide tool, eliminating the need for pilot holes and welding, with couplings being unitary with the housing and less likely to crack.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If manual retrofitting of couplings is used, then the manufacturing process is simple, but the couplings are prone to cracking and deformation under stress and pressure
Solution Approach 1:
The coupling is merged with the spray boom housing by thermally forming the coupling directly from the housing material, creating a unitary structure. This eliminates separate coupling components that would otherwise be manually attached, thereby improving durability while maintaining manufacturing efficiency through a streamlined thermal forming process.
Solution Approach 2:
The material parameters of the coupling are changed through thermal forming, where the housing material is heated and molded into the coupling shape. This creates a coupling with optimized structural properties that resists cracking and deformation, while the process remains efficient due to the direct forming method.
2Ease of manufacture
If manual retrofitting of couplings is used, then the manufacturing process requires multiple steps, but the process becomes complex and time-consuming
Solution Approach 1:
The coupling shape is preliminarily formed during the thermal forming process itself, rather than requiring separate steps for creating pilot holes, molding individual couplings, and welding. The housing material is directly molded into the final coupling shape with integrated threading, streamlining the entire manufacturing process.
Solution Approach 2:
Multiple manufacturing operations are merged into a single thermal forming process: the housing material is heated, molded into the coupling shape, and threaded in one continuous operation. This eliminates the need for separate steps of forming pilot holes, molding couplings, and welding, thereby improving productivity.
3Productivity
If couplings are thermally formed from the housing, then the manufacturing process is streamlined, but the housing material must be heated to high temperatures
Solution Approach 1:
Heating is applied locally at specific locations along the housing where couplings are needed, rather than heating the entire housing uniformly. This localized thermal forming approach improves manufacturing efficiency by targeting only the necessary areas while minimizing overall temperature exposure and energy consumption.
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
This method streamlines manufacturing, enhances coupling durability, and reduces deformation, providing an efficient and long-lasting spray boom system.
Implementation Method 1
The application of a rotational movement of the carbide tool at a speed of at least 2500 revolutions per minute (RPM) against the elongate housing may generate friction, thereby generating heat at a temperature ranging between 1900° F. and 2100° F.
Data Source
AI summary
The present disclosure is directed to spray boom for aerial spraying comprising an elongate housing operable to be mounted to an underside of an aircraft, the elongate housing defining a hollow cavity, and a plurality of couplings positioned along at least a portion of a length of the elongate housing, wherein each of the plurality of couplings comprises a cylindrical boss that is unitary with and thermally formed from the elongate housing.