Self-Cleaning Sprayer Filter Using a Plunger to Clear Debris
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Solution Overview
Problem
Agricultural sprayer systems face challenges in identifying and addressing clogs in nozzles due to their distributed nature and susceptibility to debris, which impede fluid flow and impact efficiency and efficacy.
Innovation Solution
The implementation of a sprayer system that includes self-cleaning nozzle apparatuses and a nozzle monitoring system using sensors and neural networks to detect clogs, and a plunger assembly in the filter apparatus for debris removal, allowing for automated cleaning events and improved fluid distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional filter apparatuses are used without self-cleaning mechanisms, then device complexity is reduced, but productivity decreases due to manual cleaning requirements and fluid flow impediment from debris accumulation
Solution Approach 1:
The filter apparatus employs a self-cleaning mechanism where a plunger assembly automatically removes debris from the filter screen during operation. The plunger is driven by pressure differential created during normal fluid flow, eliminating the need for external cleaning systems or manual intervention while maintaining continuous productivity.
Solution Approach 2:
The self-cleaning mechanism operates periodically rather than continuously. The plunger accumulates debris during normal filtration, then automatically reverses to discharge the accumulated debris at intervals when pressure differential indicates sufficient accumulation, optimizing between cleaning frequency and energy consumption.
2Reliability
If nozzle apparatuses operate without self-cleaning capability, then device complexity remains low, but reliability deteriorates due to clog formation from debris accumulation
Solution Approach 1:
The nozzle apparatus integrates a self-cleaning feature where the plunger assembly extends into the nozzle to automatically clear debris from nozzle openings. The system uses the existing pressure differential during operation to drive the plunger, enabling the nozzle to clean itself without external intervention or complex additional systems.
Solution Approach 2:
The cleaning function is merged with the existing nozzle structure rather than being a separate system. The plunger assembly is integrated into the nozzle body, combining filtration, spraying, and cleaning functions into a single unified apparatus, reducing overall system complexity while improving reliability.
3Loss of time
If manual monitoring and cleaning of nozzles is performed, then device complexity is minimized, but loss of time increases due to inspection and maintenance interruptions
Solution Approach 1:
The system incorporates pressure sensors that continuously monitor pressure differential across the filter and nozzle apparatus. When the differential exceeds a threshold indicating debris accumulation or clog formation, the system automatically triggers the plunger assembly to perform cleaning actions, eliminating the need for manual inspection and reducing operational interruptions.
Solution Approach 2:
The automated monitoring and cleaning system enables the apparatus to detect and address clogs independently without human intervention. The pressure-sensitive plunger assembly automatically responds to debris accumulation by discharging debris, allowing continuous operation and minimizing time loss.
4Productivity
If self-cleaning mechanisms are implemented in filter and nozzle apparatuses, then productivity is maintained through continuous operation, but device complexity increases due to additional components
Solution Approach 1:
The cleaning mechanism is integrated into the existing filter and nozzle structures rather than being a separate system. The plunger assembly utilizes the same pressure differential and fluid flow paths already present in the apparatus, combining multiple functions (filtration, spraying, cleaning) into unified components to minimize overall complexity.
Solution Approach 2:
The plunger assembly serves multiple functions: it acts as a debris discharge mechanism for the filter, a cleaning element for the nozzle, and a pressure-regulated valve. This multi-functionality reduces the need for separate components for each function, offsetting the complexity increase from adding self-cleaning capability.
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
Enhances the ability to identify and clear clogs in real-time, maintaining efficient fluid distribution and improving agricultural yields by ensuring consistent operation of the sprayer system.
Implementation Method 1
the pressure in the piston hollow and slot causes a lower pressure in a localized area of the media and back flushing of trapped material
Implementation Method 2
a friction element of the plunger assembly engages the interior surface of the screen device to dislodge debris within the screen device
Data Source
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AI summary
A self-cleaning filter apparatus (120) for a sprayer system (102) is disclosed. The self-cleaning filter apparatus (120) comprising: a filter unit (250) comprising: a screen device (320) defining a first screen device end and a second screen device end; and a filter unit housing (260) that houses the screen device (320) and includes a fluid inlet (268) and a fluid outlet (270) such that a fluid enters the filter unit (250) through the fluid inlet (268), is directed through the screen device (320), and exits the filter unit (250) through the fluid outlet (270); and a plunger unit (200) comprising: a rod end housing (150) coupled to the filter unit housing (260); a plunger rod (180) with a first plunger rod end (152) positioned within the rod end housing (150) and a second plunger rod end (154) within the filter unit housing (260); and a plunger assembly (200) secured to the second plunger rod end (154), wherein, during a first filter cleaning event segment of a filter cleaning event, the plunger rod (180) is configured to translate within the screen device (320) between a nominal position in which the plunger assembly (200) is proximate the first screen device end and a cleaning position in which the plunger assembly (200) is proximate the second screen device end, wherein, during a second filter cleaning event segment of the filter cleaning event, the plunger rod (180) is further configured to translate from the cleaning position to the nominal position, and wherein the plunger rod (180) is configured to dislodge, at least in part, debris from within the screen device (320) during at least the first filter cleaning event segment. Further, a sprayer system (102) with such self-cleaning filter apparatus (120) is disclosed.