Speed-Based Pressure Controller for Agricultural Spray Systems
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Solution Overview
Problem
Agricultural spraying is inefficient due to susceptibility to wind drift, overspray, and inaccurate placement of spray materials, exacerbated by large-scale operations and varying ambient conditions, which affect the uniformity and efficiency of spray application.
Innovation Solution
A spray system that includes a tank, conduit, pump, flow controller, and electrically actuated nozzle assemblies, where the flow rate is regulated based on travel speed to maintain a constant upstream nozzle pressure, ensuring consistent spray application despite changes in travel speed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the spray liquid pressure is adjusted to control the application rate, then the application rate is controlled, but the droplet size is altered which affects deposition and susceptibility to spray drift and evaporation
Solution Approach 1:
The system separates the control of application rate and droplet size into independent functions. The flow controller regulates application rate by controlling overall flow, while the pressure controller maintains constant spray pressure to ensure consistent droplet size. This segmentation allows both parameters to be optimized independently without the trade-off that previously existed when pressure adjustment was the sole method of controlling application rate.
Solution Approach 2:
The system changes the control parameters from a single pressure-based control to a dual-parameter control system. By introducing flow rate as a separate controllable parameter and maintaining pressure as a constant parameter, the system can adjust application rate through flow control while preserving droplet size consistency through pressure stabilization. This parameter separation resolves the contradiction between application rate control and droplet size consistency.
2Productivity
If larger spraying equipment covering wider swaths and high speed vehicles are used to increase efficiency, then productivity is improved, but the problems of wind drift, overspray, and inaccurate placement are exacerbated
Solution Approach 1:
The system incorporates feedback control through sensors that monitor spray pressure and flow rate, with controllers that continuously adjust system parameters to maintain optimal performance. The pressure controller receives feedback on actual pressure conditions and adjusts the spray system to maintain constant pressure, while the flow controller monitors and regulates flow rate to achieve the desired application rate. This feedback mechanism ensures precise spray placement and consistent droplet characteristics even at high speeds and wide swath widths, resolving the contradiction between productivity and placement accuracy.
3Adaptability or versatility
If variable ambient conditions such as wind, humidity levels, and temperature are present, then spraying operations can continue in diverse environments, but the uniformity and efficiency of spray application are reduced
Solution Approach 1:
The feedback control system continuously monitors actual spray conditions and adjusts system parameters to compensate for environmental variations. By maintaining constant spray pressure through active control, the system ensures consistent droplet size and distribution regardless of ambient conditions such as wind, humidity, or temperature changes. This allows the system to operate effectively across diverse environments while maintaining spray uniformity, resolving the contradiction between environmental adaptability and spray consistency.
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 maintains a consistent upstream nozzle pressure, improving the uniformity and efficiency of spray application by adjusting flow rates and nozzle assembly parameters in response to travel speed, reducing drift and evaporation, and enhancing droplet size consistency.
Implementation Method 1
a pump in fluid communication with the conduit for generating a pressure in the conduit and a flow of the product through the conduit
Implementation Method 2
The plurality of nozzle assemblies is configured to dispense the product such that an upstream nozzle pressure is established within the conduit
Data Source
AI summary
Spray systems and control systems for use with spray systems are provided. A spray system generally includes a tank configured to hold a product, a conduit in fluid communication with the tank, a pump in fluid communication with the conduit, a flow controller, a plurality of electrically actuated nozzle assemblies in fluid communication with the conduit, and a pressure controller. The flow controller is configured to regulate a flow rate of product through the conduit based on a travel speed of the system. The plurality of nozzle assemblies is configured to dispense the product such that an upstream nozzle pressure is established within the conduit. The pressure controller is configured to control at least one operating parameter of at least one of the nozzle assemblies based at least in part on speed information indicative of the travel speed of the system to maintain a substantially constant upstream nozzle pressure.