Dosing Valve Calibration for Wide-Range Agricultural Spraying
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Solution Overview
Problem
Existing spraying systems struggle to provide a wide range of fluid flow rates, particularly between high and extremely low flow rates, limiting their ability to selectively apply chemicals to specific areas in a field, leading to inefficiencies and waste.
Innovation Solution
The implementation of pulse width modulation (PWM) dosing valves and a calibration method that allows for fluid flow rates to vary between high (4 gallons per minute) and extremely low (0.0004 GPM) rates, achieving ratios of up to 10,000:1, enabling precise application of chemicals to both entire fields and targeted spots using a sprayer system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional spraying systems are used, then the system can apply chemicals to the field, but the system cannot provide a wide range of fluid flow rates between high and extremely low rates
Solution Approach 1:
The dosing valve is designed with dynamic adjustability, allowing the valve opening to be varied continuously to control fluid flow rate. The valve mechanism enables smooth transition between fully open (high flow) and nearly closed (extremely low flow) positions, providing a wide adjustable range without requiring multiple fixed-position valves or complex switching systems.
Solution Approach 2:
The system changes the flow rate parameter by adjusting the valve opening degree rather than changing the entire system configuration. By modifying this single parameter (valve opening from near-closed to fully open), the system achieves flow rate ratios of at least 100:1, simplifying the overall system design while expanding operational versatility.
2Quantity of substance
If the dosing valve is adjusted for high flow rate, then high volume chemical application is possible, but extremely low flow rates cannot be achieved
Solution Approach 1:
The dosing valve provides continuous dynamic control over the fluid passage cross-section. The valve mechanism allows incremental adjustments from nearly closed (for extremely low flow rates delivering precise small quantities) to fully open (for high volume application), enabling operators to precisely control chemical quantity delivered to targeted spots versus broad field coverage.
3Loss of substance
If selective chemical application to specific spots is implemented, then waste is minimized, but the system requires precise flow control capability
Solution Approach 1:
By enabling continuous adjustment of the valve opening parameter, the system can precisely control the flow rate to match the exact chemical quantity needed for targeted spot treatment. This precise parameter control ensures that only the necessary amount of chemical is applied to specific locations, minimizing waste while maintaining ease of operation through a single adjustable valve rather than complex multi-component systems.
Data Source
AI summary
A method of calibrating dosing valves of a sprayer system of an agricultural implement comprises initiating calibration by filling a calibrating tube with fluid having a fluid from an auxiliary tank of the sprayer system, measuring a volume of the fluid filled into the calibration tube, pumping the fluid in the calibration tube to the dosing valves to calibrate the dosing valves with respect to flow characteristics of the fluid with the dosing valves being capable of a high fluid flow rate to a low fluid flow rate ratio of at least 100:1 for the fluid. The method also includes pumping, during a pump from concentration tank mode, the fluid in the concentration tank to the dosing valves and then to a mixing apparatus with the fluid to be mixed with a carrier fluid from a primary tank of the sprayer system.