Smart Nozzle Flow Control for Uniform Agricultural Spraying
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Solution Overview
Problem
Agricultural sprayers face challenges in achieving uniform distribution of agricultural products due to irregular field shapes and sprayer configurations, leading to waste and unpredictable application variations.
Innovation Solution
A nozzle control system with electronic control units (ECUs) at each nozzle, which adjusts flow rates based on inputs like nozzle position, boom length, yaw rate, target flow rate, sprayer speed, and product characteristics, and uses location fiducials for field-specific application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional agricultural sprayers are used with fixed nozzle configurations, then the sprayer structure remains simple and easy to manufacture, but the distribution uniformity of agricultural products deteriorates due to irregular field shapes and sprayer configurations
Solution Approach 1:
The sprayer system is divided into multiple independent nozzle units, each with its own control capabilities. Each nozzle can be individually controlled based on its position and the local field characteristics, allowing precise distribution uniformity without requiring complex centralized control for the entire sprayer system.
Solution Approach 2:
The nozzle system transitions from a static, fixed configuration to a dynamic system where nozzle flow rates can be adjusted in real-time based on sprayer speed, yaw rate, and field characteristics. This dynamic adjustment capability enables the system to adapt to irregular field shapes and maintain distribution uniformity throughout the spraying operation.
2Manufacturing precision
If individual nozzle flow rate control is implemented, then distribution uniformity improves, but the device complexity and manufacturing cost increase
Solution Approach 1:
The electronic control unit is designed as a universal component that can be installed in each nozzle position. This standardized, multi-functional unit handles multiple tasks including flow rate control, position tracking, and communication, simplifying the manufacturing process by using identical components throughout the system rather than custom-designed parts for each nozzle.
Solution Approach 2:
The system achieves precise application by changing the flow rate parameter of each nozzle based on operational conditions. By controlling the flow rate parameter dynamically rather than requiring complex mechanical adjustments, the system simplifies manufacturing while maintaining high application precision.
3Productivity
If the sprayer operates at varying speeds and orientations, then productivity increases, but the distribution uniformity deteriorates due to unpredictable variation in application
Solution Approach 1:
The system incorporates feedback from sensors that continuously monitor sprayer speed, yaw rate, and nozzle position. This real-time feedback is processed by the electronic control unit, which adjusts each nozzle's flow rate to compensate for variations in operating conditions, maintaining distribution uniformity even when productivity is increased through variable speed operation.
Solution Approach 2:
The system replaces mechanical flow control mechanisms with electronic control. Instead of using complex mechanical linkages to maintain constant flow rates during variable speed operation, the patent uses electronic sensors and control units to digitally regulate each nozzle's flow rate, achieving both high productivity and application uniformity.
Data Source
AI summary
Systems and methods may be used to perform nozzle control. For example, a system includes an overall system pressure valve, configured to adjust the pressure of an agricultural product within a boom. A master node is configured to receive an overall system flow rate measurement, an overall target flow rate, and an overall system pressure measurement. The master node is configured to adjust the overall system pressure valve to control the pressure of the agricultural product. A plurality of smart nozzles are configured to dispense the agricultural product, the plurality of smart nozzles each associated with an electronic control unit (ECU) and one or more individual nozzle. The smart nozzle is configured to control a nozzle flow rate of the associated one or more individual nozzles.