Spray Nozzle Assembly with Pre-Orifice Flow Control for Drift Reduction
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Spray devices used in agriculture face issues with spray drift due to the production of fine particles and pressure changes during vehicle movement, which affect droplet size and distribution, especially when using pulse width modulation.
Innovation Solution
A spraying system with a spray nozzle assembly and tip design that produces large droplet sizes and uniform distribution, incorporating a pulse width modulation assembly to adjust flow rates without pressure changes, and a flow control element with a pre-orifice and discharge orifices to maintain consistent spray patterns across varying flow capacities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If pulse width modulation is used to adjust flow rate without pressure changes, then flow rate control is improved, but air entrapment stops and spray performance degrades
Solution Approach 1:
The nozzle is pre-configured with multiple orifices of different sizes and air entrainment features that are activated in advance based on the selected flow rate setting. This allows the nozzle to maintain proper air-liquid mixing and spray performance across different flow rates without degradation during PWM operation.
Solution Approach 2:
The nozzle design incorporates multiple orifices with different flow capacities that change the flow parameters based on the selected setting. By providing pre-configured orifice options, the system adjusts the flow characteristics to maintain consistent spray performance while enabling flow rate control through PWM.
2Productivity
If vehicle speed increases, then productivity is improved, but liquid pressure must increase leading to smaller droplets and more spray drift
Solution Approach 1:
The nozzle system dynamically adapts to changing vehicle speeds by using PWM control to adjust the effective flow rate while maintaining constant pressure. The multiple orifice design allows the system to select appropriate flow capacities that maintain optimal droplet size across varying operational conditions, preventing spray drift even at higher speeds.
Solution Approach 2:
The system uses periodic PWM switching to control the average flow rate to the nozzle while maintaining constant pressure. This periodic on-off action allows the pump to operate at constant pressure while the effective delivery to the nozzle is modulated, preventing the pressure increase that would cause smaller droplets and drift.
3Object-generated harmful factors
If air induction is used to produce larger droplets, then spray drift is reduced, but rapid flow changes cause inconsistent air entrapment and poor spray distribution
Solution Approach 1:
The nozzle is pre-configured with multiple orifices and air entrainment features designed to work together from the start. This preliminary configuration ensures that when PWM control is applied, the air and liquid flow paths are already established and coordinated, allowing consistent air entrapment and stable spray distribution even during rapid flow changes.
Solution Approach 2:
The multi-orifice design allows the system to change flow parameters while maintaining the air induction mechanism's effectiveness. By providing pre-configured orifice options with different flow capacities, the system can adjust to different flow rates while maintaining the proper air-liquid mixing ratios needed for consistent spray distribution and drift reduction.
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 achieves minimal spray drift, consistent droplet size, and uniform spray distribution, even with pulse width modulation, while being simple in design and adaptable for different flow capacities.
Implementation Method 1
Air induction spray nozzles utilize air passages that draw air into the nozzle body with the liquid which slows the flow of liquid allowing larger liquid drops to form
Implementation Method 2
Spray nozzles equipped with pulse width modulation alternate very quickly between open and closed flow conditions. Changing the amount of time the pulse width modulation equipped nozzle is open or closed allows the rate of flow to be adjusted without changing the pressure
Data Source
AI summary
A spray tip including a spray tip body and flow control element is provided. The flow control element includes a pre-orifice through which fluid can enter a primary fluid passage of the spray tip body. First and second discharge orifices are provided in a dome-shaped end wall of the spray tip body with each of the first and second discharge orifices being arranged on a respective one of opposing first and second sides of an apex of the dome-shaped end wall. Each of the first and second discharge orifices having an elongated slot-like configuration that maintains a substantially constant width as the respective discharge orifice extends from a first end to a second end and each and each extending a substantially equal distance to either side of the apex of the dome-shaped end wall.