Sprayer Mixing Manifold With Recirculation Loop
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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 applications, and they require complex plumbing for segregating chemical and water tanks, which can lead to cross-contamination and equipment damage from high pressure.
Innovation Solution
A sprayer system with a separable chemical tank and diluent tank, featuring a mixing manifold and positive displacement pump that allows for adjustable concentrate dosing and a pressure by-pass recirculation loop to manage fluid pressure, preventing backflow and contamination, and enabling easy tank replacement without tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single tank is used to hold both diluent and chemical concentrate, then the system is simpler in structure, but cross-contamination and chemical 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 cross-contamination when switching between different pesticide applications, as each tank can be dedicated to specific chemicals or thoroughly cleaned independently. The separate tanks are connected through a mixing manifold system that combines them only during spraying operation.
2Reliability
If chemical and water tanks are segregated with complex plumbing, then cross-contamination is minimized, but the system becomes difficult to operate and clean
Solution Approach 1:
The mixing manifold serves as a common connection point where the separate diluent tank and chemical concentrate tank are temporarily merged during operation. This allows the tanks to remain separate for cleaning and chemical changes while functioning as an integrated system during spraying, simplifying operation compared to complex multi-component plumbing systems.
3Manufacturing precision
If high pressure is used to deliver fluid through multiple nozzles, then proper spraying is enabled at each nozzle, but the spray wand becomes damaged from high pressure
Solution Approach 1:
The spray system is segmented into two modes: a boom-and-nozzle arrangement that receives high pressure fluid for multiple nozzles, and a spray wand that receives low pressure fluid through a bypass line. This segmentation allows each component to operate at its optimal pressure level, preventing damage to the spray wand while maintaining proper spray distribution through the boom nozzles.
4Stress or pressure
If recirculation manifold is used to manage pressure for spray wand, then pressure control is achieved, but mixed fluid is recycled to the water tank contaminating it
Solution Approach 1:
The recirculation bypass line extracts the mixed fluid from the pump outlet and returns it directly to the pump inlet, removing it from the water tank circulation path. This extraction prevents contaminated mixed fluid from entering the water tank while still providing the necessary pressure control for spray wand operation through the bypass mechanism.
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 design reduces chemical waste, minimizes contamination risks, simplifies operation and cleaning, and prevents equipment damage by allowing adjustable concentrate dosing and controlled pressure management, enhancing user safety and efficiency.
Implementation Method 1
A mixing manifold is mounted to the mounting bracket and has a first inlet fitting configured to receive a fixed amount of diluent from the first tank and a second inlet configured to receive a selectively adjustable amount of liquid concentrate from the second tank. The fixed amount of diluent and selectively adjustable amount of concentrate are combined to form a mixed solution. The mixing manifold includes a mixed solution outlet and a positive displacement pump is mounted to the mounting bracket and has a suction port fluidly coupled to the mixed solution outlet.
Implementation Method 2
A pressure by-pass recirculation loop is configured to fluidly couple the pressure port to the suction port. The pressure by-pass recirculation loop is configured to selectively regulate a fluid pressure of the mixed solution being delivered to the spray device.
Data Source
AI summary
A sprayer system includes a diluent tank, a mounting bracket mounted to the diluent tank and a concentrate tank mounted to the mounting bracket and diluent tank. A mixing manifold is mounted to the mounting bracket and has a first inlet fitting to receive a fixed amount of diluent and a second inlet to receive a liquid concentrate. The diluent and concentrate are then combined to form a mixed solution. The mixing manifold includes an outlet. A positive displacement pump is mounted to the mounting bracket and has a suction port fluidly coupled to the mixed solution outlet. A pressure port may fluidly couple with a spray device. The second tank may be separable from the first tank and mounting bracket without requiring removal of the mixing manifold or positive displacement pump.