Optical Spray Pattern Monitoring for Nozzle Blockage Detection
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Solution Overview
Problem
Spray nozzles in agricultural sprayers often produce non-uniform sprays due to blockages or wear, leading to over- or under-application of materials, which existing technologies fail to consistently monitor and correct in real-time.
Innovation Solution
A spray sensor system using optical sensors to emit directional light and determine the presence or absence of a liquid spray by receiving reflections, providing real-time data on spray status and quality to adjust nozzle operation accordingly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional spray monitoring methods are used, then device complexity is reduced, but measurement precision and reliability of spray detection deteriorate
Solution Approach 1:
The patent replaces mechanical or electrical sensors with optical sensors that use light emission and detection to monitor spray patterns. The optical sensor system emits light through the spray path and detects light scattering or absorption changes caused by droplets, providing precise spray detection without mechanical contact or complex electrical components.
Solution Approach 2:
The patent introduces light as an intermediary medium between the spray nozzle and the detection system. By using light emission and detection of optical property changes (scattering, absorption, refraction) as the spray passes through the light path, the system achieves high measurement precision while maintaining relatively simple device architecture.
2Productivity
If real-time spray monitoring is implemented, then productivity and material application accuracy are improved, but device complexity and cost increase
Solution Approach 1:
The optical monitoring system replaces complex mechanical sensing arrangements with non-contact optical detection. The system uses light sources and photodetectors to continuously monitor spray characteristics in real-time, enabling high productivity through rapid detection without the mechanical complexity of traditional sensor systems.
Solution Approach 2:
The patent implements real-time feedback by continuously monitoring spray optical properties and providing immediate detection of spray deviations. This enables prompt correction of spray application issues, improving overall productivity and material application accuracy while the optical system keeps device complexity manageable through its non-contact measurement approach.
3Reliability
If optical sensors are used for spray detection, then measurement precision and reliability are improved, but use of energy increases
Solution Approach 1:
The optical sensor system can operate in periodic or pulsed modes rather than continuous operation. By emitting light in periodic pulses and detecting spray characteristics during these intervals, the system maintains high detection reliability while significantly reducing overall energy consumption compared to continuous illumination.
Solution Approach 2:
The use of optical fields instead of mechanical or electrical sensing systems provides inherent reliability advantages. Optical sensors are not subject to wear, contamination, or electrical interference that plague other sensor types, delivering superior reliability with relatively low energy consumption through efficient light source and detector design.
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
The system ensures uniform spray distribution by instantly detecting blockages or malfunctions, preventing over- or under-application and allowing for precise tracking of spray patterns, thereby improving application accuracy and efficiency.
Implementation Method 1
at least one optical sensor configured to emit and receive directional light
Data Source
AI summary
A spray pattern monitoring system includes a spray sensor disposed proximate an outlet of a spray nozzle. The spray sensor has one or more optical sensors configured to emit directional light, such as laser pulses, towards the expected position of a liquid spray emitted from the nozzle. The spray sensor can detect the absence or presence of the liquid spray based on returns of the directional light to the optical sensor.