External By-Pass Circuit for Sprayer Pressure Regulation
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Solution Overview
Problem
Current sprayer systems face issues with chemical contamination, waste, and operational complexity due to the need to empty and clean tanks between different pesticide applications, and they struggle with variable pressure delivery that can damage equipment.
Innovation Solution
A sprayer system with a separable chemical tank and diluent tank, featuring a mixing manifold and positive displacement pump with a pressure by-pass circuit, allowing for adjustable concentration mixing and pressure regulation without recycling mixed fluid to the diluent tank, enabling easy tank replacement and minimizing contamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single tank is used to store both diluent and chemical concentrate, then the system structure is simple, but chemical contamination and waste occur when switching between different pesticide applications
Solution Approach 1:
The single tank is divided into two separate tanks: a diluent tank and a chemical concentrate tank. This segmentation prevents chemical contamination when switching between different pesticide applications, as each tank stores only one type of fluid. The separate tanks can be independently cleaned or replaced without affecting the other tank.
Solution Approach 2:
The chemical concentrate is extracted from the single tank and stored separately in a dedicated chemical tank. This extraction eliminates the risk of chemical contamination in the diluent tank and allows for precise metering of chemical concentrate into the spray stream without contaminating the main diluent supply.
2Device complexity
If a single tank system is used, then fewer components need cleaning, but time is lost emptying and cleaning tanks between applications
Solution Approach 1:
By segmenting the tank system into separate diluent and chemical tanks, the cleaning process can be optimized. The diluent tank only requires rinsing with water, while the chemical tank can be emptied and cleaned separately. This segmentation reduces the overall time required for tank maintenance between different pesticide applications.
Solution Approach 2:
The system allows for efficient discarding of remaining chemicals in the chemical tank and recovery/cleaning of the diluent tank. The separate chemical tank can be quickly emptied and replaced or cleaned, while the diluent tank can be rapidly rinsed and refilled, minimizing downtime between applications.
3Stress or pressure
If mixed fluid is recycled to the diluent tank during low flow applications, then pump pressure is regulated, but the diluent tank becomes contaminated with chemical
Solution Approach 1:
The recirculation path for excess pump fluid is extracted from the diluent tank and redirected to discharge directly to the spray stream or to a separate waste outlet. This extraction prevents chemical-contaminated mixed fluid from returning to the clean diluent tank, eliminating contamination while maintaining pump pressure regulation through the by-pass circuit.
Solution Approach 2:
A by-pass circuit acts as an intermediary pathway for excess pump fluid during low flow applications. Instead of recycling directly to the diluent tank, the by-pass circuit provides an alternative route that maintains pressure regulation while preventing contamination of the diluent supply.
4Object-affected harmful factors
If complex plumbing regimes are used to segregate chemical and water tanks, then contamination is minimized, but the system becomes difficult to use and clean
Solution Approach 1:
The system uses simple segmentation into two tanks with dedicated outlets rather than complex interconnections. The diluent tank connects to the pump inlet, and the chemical tank connects to the spray stream downstream of the pump. This simple segmented architecture minimizes contamination while maintaining ease of operation and cleaning, as each tank has straightforward connections without complex plumbing.
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 effectively segregates chemicals from diluents, reduces waste and contamination risks, and simplifies operation by allowing for tool-less tank removal and replacement, while maintaining consistent fluid pressure and concentration across different spraying applications.
Implementation Method 1
a positive displacement pump with a pressure by-pass circuit, and coupled to the mixing manifold
Implementation Method 2
pressure by-pass circuit configured to regulate a fluid pressure of the mixed solution being delivered to the spray device
Data Source
AI summary
An external by-pass circuit for a positive displacement pump includes a flow diverter valve coupled to the pressure port of the pump. The flow diverter has an end coupled with a high flow output and another end coupled with a low flow output. The low flow end includes a by-pass arm coupled to and input flow fitting. The flow diverter valve further includes a ball valve to direct fluid to either the high flow or low flow output. The input flow fitting is coupled to the suction port of the pump at the one end and couples with a fluid source at the other end. The input flow fitting includes a flow control arm which includes a needle valve to selectively control flow within the flow control arm. The flow control arm also includes a by-pass fitting fluidly coupled with the by-pass arm of the flow diverter valve.