Quick-Connect Spray Manifold for Clogged Mining Nozzles
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Solution Overview
Problem
Existing water spray systems in mining equipment, such as coal mining machines, often suffer from nozzle plugging due to coal, coal dust, and foreign matter, requiring frequent cleaning that disrupts mining production and poses safety risks.
Innovation Solution
A water spray assembly with a removable manifold and nozzle block design allows for easy cleaning and replacement of nozzles, featuring a manifold with a passageway connecting nozzle inlets to a pressurized water source, and optional quick connect fittings for efficient maintenance, along with a wire mesh basket to filter debris.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If nozzles are fixedly mounted to manifolds or blocks, then spray coverage is maintained, but nozzle cleaning and replacement becomes difficult and time-consuming
Solution Approach 1:
The spray system is divided into separate modular components: nozzles, manifolds, and blocks. Each component can be independently removed and replaced. The manifold contains internal passages that distribute water to nozzles, while the block provides mounting structure. This segmentation allows rapid replacement of clogged nozzles without disturbing the entire spray system.
Solution Approach 2:
The system transitions from fixed nozzle mounting to a dynamic, easily reconfigurable arrangement. Nozzles are designed to be quickly detached from manifolds and manifolds can be removed from blocks, enabling maintenance personnel to rapidly swap out clogged components during mining operations with minimal downtime.
2Reliability
If nozzles are continually cleaned for safety reasons, then safety is maintained, but mining production is reduced
Solution Approach 1:
The modular design allows nozzles to be pre-cleaned or pre-replaced in preparation for maintenance. Clogged nozzles can be identified and swapped out with clean replacement nozzles from inventory, eliminating the need for time-consuming on-site cleaning operations and maintaining continuous mining productivity while ensuring safety through regular nozzle replacement.
3Ease of operation
If manifolds are fixedly mounted, then structural stability is maintained, but maintenance access becomes difficult
Solution Approach 1:
The system separates the manifold from the block structure, allowing the manifold to be independently removed from the block for maintenance. The block remains fixedly mounted to the mining machine providing structural stability, while the manifold can be easily detached and replaced without disturbing the mounted structure, ensuring both stability and maintenance accessibility.
Data Source
AI summary
A water spray assembly especially adapted for control of dust suppression in mining machines has a manifold with one or a number of nozzles mounted thereon. The manifold provides communication between the nozzles and a manifold inlet, the manifold inlet being adapted to connect to a supply of water. The manifold with one half of a quick connect coupling cooperates with a nozzle block having a bore sized to receive at least a portion of the manifold and the other half of the quick connect coupling. The use of quick connect coupling half with the block allows easy removal and insertion of the manifold.