Variable-Orifice Spray Nozzle for Independent Flow and Droplet Control
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Solution Overview
Problem
Conventional spray nozzle systems face challenges in independently controlling flow rate and droplet size, leading to issues like spray drift, inefficiencies in pesticide application, and the need for frequent nozzle tip changes, which are costly and time-consuming.
Innovation Solution
A variable-orifice spray nozzle system with a flexible nozzle orifice opening and an actuator mechanism that adjusts the orifice size and shape, controlled by a controller using data from pressure sensors to achieve desired flow rates and droplet sizes, and a weather control system to adjust settings based on weather conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If system pressure is adjusted to change flow rate, then flow rate is improved, but droplet size changes adversely
Solution Approach 1:
The patent employs a variable-orifice mechanism that dynamically adjusts the orifice size in response to pressure changes. This allows the system to maintain consistent droplet size across different flow rates by adapting the orifice geometry to compensate for pressure variations, resolving the contradiction between flow rate adjustment and droplet size consistency.
Solution Approach 2:
The patent changes the physical parameter of the orifice size dynamically. By varying the orifice dimensions based on operating conditions, the system can decouple the relationship between flow rate and droplet size, enabling independent control of these parameters and eliminating the adverse effect where pressure changes simultaneously affect both flow and droplet characteristics.
2Manufacturing precision
If nozzle tips are changed frequently to achieve required droplet size or application rate, then spray quality is improved, but time consumption and cost increase
Solution Approach 1:
The patent creates a universal nozzle design that can perform multiple functions by varying the orifice size dynamically. A single nozzle body can accommodate different orifice configurations, allowing the system to achieve different droplet sizes and application rates without physical nozzle tip changes, thereby eliminating time loss and reducing operational costs.
Solution Approach 2:
The variable-orifice mechanism allows the nozzle to dynamically adapt its characteristics during operation. This dynamic capability enables the single nozzle to replace multiple fixed-orifice nozzles, providing the flexibility to adjust spray parameters on-demand without manual intervention for nozzle tip changes.
3Adaptability or versatility
If fixed orifice nozzles operate at different droplet sizes by adjusting pressure, then droplet size versatility is improved, but application rate control becomes impractical
Solution Approach 1:
The patent implements a dynamic orifice adjustment mechanism that responds to pressure changes by modifying the orifice size. This allows the system to maintain consistent application rate control across different droplet sizes, as the variable orifice compensates for pressure variations that would otherwise require impractical travel speed adjustments.
Solution Approach 2:
By dynamically changing the orifice size parameter, the system decouples the relationship between droplet size and application rate. This enables independent control of both parameters, providing operational simplicity while achieving versatile droplet size ranges without requiring impractical adjustments to travel speed or other external factors.
Data Source
AI summary
A variable-orifice spray nozzle system includes at least one variable-orifice spray nozzle including a nozzle body with a flexible nozzle orifice opening and a mechanism that controls the physical size and shape of the orifice opening. An actuator can set and change the position of the orifice control mechanism. A mount attaches to a spray boom. The actuator has a home position. A pressure sensor senses fluid pressure delivered to the nozzle body. A controller can control the actuator to set a requested nozzle flow rate and/or droplet size based upon data from the pressure sensor via positioning of the actuator. The controller tracks the actuator position relative to its home position via open loop control. A weather control system senses weather conditions and is configured to adjust the requested nozzle flow rate and/or droplet size of the controller according to sensed weather conditions.