Boom-Mounted Vision System for Nozzle Blockage Detection
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Solution Overview
Problem
Existing fluid application systems, such as sprayers, face challenges in accurately monitoring and adjusting the application of chemicals like herbicides and fertilizers, as they lack effective methods to detect nozzle blockages, spray pattern uniformity, and drift, leading to inefficiencies and potential environmental impact.
Innovation Solution
Integration of cameras and lights on boom arms of sprayers to capture spray patterns, analyze them using artificial intelligence, and adjust nozzle operation based on real-time imaging, enabling detection of blockages and ensuring uniform application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional fluid application systems are used without monitoring devices, then the system structure remains simple, but the ability to detect nozzle blockages and maintain spray uniformity deteriorates
Solution Approach 1:
The patent replaces mechanical monitoring methods with optical imaging systems. Cameras capture spray patterns and AI algorithms analyze the images to detect nozzle blockages, substituting physical sensors and mechanical measurement devices with vision-based detection that achieves higher precision without proportionally increasing mechanical complexity
Solution Approach 2:
The patent introduces cameras as intermediary devices between the nozzles and the monitoring system. The cameras capture optical information of spray patterns, which then serves as an intermediary data source for AI analysis, enabling indirect but accurate detection of nozzle conditions without direct contact with the spray fluid
2Measurement precision
If real-time imaging and AI analysis are implemented, then spray pattern monitoring precision improves, but energy consumption and system complexity increase
Solution Approach 1:
The system implements periodic imaging rather than continuous monitoring. Cameras capture spray patterns at intervals during operation, and AI analysis is performed on these discrete images. This periodic approach maintains adequate monitoring precision while significantly reducing energy consumption compared to continuous real-time processing
Solution Approach 2:
The AI analysis focuses on detecting specific blockage conditions rather than analyzing all aspects of spray patterns. The system processes only the necessary features in the images required to identify nozzle issues, performing partial analysis that achieves the required monitoring precision without the excessive energy cost of comprehensive spray characterization
3Measurement precision
If multiple cameras with different fields of view are used, then detection coverage and accuracy improve, but device complexity and cost increase
Solution Approach 1:
The camera system is segmented into multiple units, each with a specific field of view targeting different portions of the spray pattern. One camera captures the central spray area while another captures peripheral regions. This segmentation allows comprehensive coverage and accurate detection of blockages at different positions without requiring a single complex high-resolution system
Solution Approach 2:
The multiple cameras serve universal functions of capturing spray pattern information from different angles and regions. Each camera performs the same basic function of image capture, but their combined data provides comprehensive monitoring. This multi-functionality approach achieves enhanced detection accuracy through simple, identical components rather than complex specialized devices
Data Source
AI summary
A system comprising a boom, a plurality of nozzles disposed along the boom, a light disposed on the boom to illuminate a spray pattern from at least one nozzle, a camera disposed on the boom to capture a first image of a spray from the at least one nozzle at a first time and a second image of no spray from the at least one nozzle at a second time, and a processor to calculate a difference between the first time and second time to determine a pulse width modulation of the at least one nozzle.