Crop Sprayer Liquid Distribution with Recirculation and Bypass Valves
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Solution Overview
Problem
Conventional crop sprayers face inefficiencies in liquid distribution, leading to uneven application and waste of chemicals due to air bubbles and residual products, as the existing systems lack effective priming and flushing mechanisms to ensure consistent pressure and flow across the boom arm nozzles.
Innovation Solution
A liquid distribution system incorporating a recirculation line and a bypass line with on/off valves, allowing for the recirculation of liquid back to the tank to prime the system, remove air bubbles, and maintain pressure below the threshold for nozzle operation, while the bypass line controls pressure to prevent unintended spraying during priming.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If conventional series-connected nozzles are used with simple pipe or hose plumbing, then the device complexity is low, but the liquid distribution uniformity deteriorates due to air bubbles and residual products in the system
Solution Approach 1:
The patent segments the plumbing system into multiple independent parallel lines (first line with first nozzle, second line with second nozzle, etc.) instead of a single series line. Each line has its own pump and recirculation path, allowing independent control and eliminating the cumulative effect of air bubbles and residual products that plague series-connected systems, thereby improving liquid distribution uniformity without significantly increasing overall system complexity
Solution Approach 2:
The patent implements feedback mechanisms through recirculation lines that return liquid from each nozzle to its corresponding pump. This closed-loop feedback allows the system to continuously monitor and adjust liquid flow, ensuring consistent pressure and flow rates at each nozzle while eliminating air bubbles and residual products through repeated circulation before field application
2Manufacturing precision
If flushing and purging is performed before field application, then the liquid distribution uniformity is improved by removing air bubbles, but the loss of time and loss of substance increase due to dispensing several gallons of product
Solution Approach 1:
The system performs self-priming through the recirculation lines that automatically return liquid from nozzles to pumps. When the pump operates with valves open, liquid circulates through the entire system including all nozzles and return lines, eliminating air bubbles and residual products without requiring external intervention or manual flushing, thereby reducing both time and chemical waste
Solution Approach 2:
Instead of discarding flushed liquid as waste, the recirculation system recovers and reuses the same liquid multiple times, circulating it through the pump and nozzles repeatedly until air bubbles and residual products are eliminated. This recovery process reduces both time loss and chemical waste compared to single-use flushing methods
3Manufacturing precision
If recirculation line is added to prime the system, then the liquid distribution uniformity is improved, but the device complexity increases
Solution Approach 1:
The recirculation lines serve multiple functions: they prime the system by removing air bubbles, maintain pressure below nozzle threshold during priming, enable consistent liquid distribution during operation, and allow for system flushing. By making the recirculation system multi-functional, the patent justifies the added complexity through significant improvements in liquid distribution uniformity and operational efficiency
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 solution ensures consistent and accurate liquid application by eliminating air bubbles, reducing waste, and maintaining pressure below the nozzle threshold during priming, thereby optimizing the distribution of fertilizers, pesticides, and herbicides across the field.
Implementation Method 1
a pump in fluid communication with the product tank... circulating a first portion of a liquid through the pump, the nozzles, and a first on/off valve in a recirculation line to the product tank; circulating a second portion of the liquid through the pump and a second on/off valve in a bypass line to the product tank
Implementation Method 2
The recirculation line includes a first on/off valve configured to alternatively block or permit flow through the recirculation line. The bypass line includes a second on/off valve configured to alternatively block or permit flow through the bypass line
Implementation Method 3
a recirculation line connecting the plurality of nozzles to the product tank... circulating a first portion of a liquid through the pump, the nozzles, and a first on/off valve in a recirculation line to the product tank
Data Source
AI summary
A liquid distribution system for a crop sprayer includes a product tank configured to contain a liquid, a pump in fluid communication with the product tank, a plurality of nozzles carried by a boom and configured to receive the liquid from the pump, a recirculation line connecting the plurality of nozzles to the product tank, and a bypass line connecting the pump to the product tank. The recirculation line includes an on/off valve configured to alternatively block or permit flow through the recirculation line. The bypass line includes a second on/off valve configured to alternatively block or permit flow through the bypass line. Related crop sprayers and methods are also disclosed.