Non-Invasive Agricultural Sprayer Nozzle Blockage Detection
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Solution Overview
Problem
Existing methods for detecting nozzle blockages in agricultural sprayers are invasive and disrupt fluid flow, requiring large sensors within the nozzle that can be difficult to replace.
Innovation Solution
A system using flow rate sensors placed upstream and downstream of the nozzle inlet, with an electrical processing circuit to compare flow rates and issue an alarm if a predetermined threshold of flow rate decrease is detected, allowing for non-invasive blockage detection without disrupting fluid flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a flow rate sensor is placed within the nozzle to detect blockages, then blockage detection capability is improved, but the sensor disrupts fluid flow and is difficult to replace
Solution Approach 1:
The flow rate sensor is extracted from the nozzle interior and relocated to the fluid conduit upstream of the nozzle. This allows the sensor to measure fluid flow rate without being physically present in the nozzle, thereby eliminating disruption to fluid flow while maintaining blockage detection capability through comparison of upstream flow rate with expected nozzle flow characteristics
Solution Approach 2:
The upstream flow rate sensor serves as an intermediary measurement point that indirectly detects nozzle blockages. Instead of placing a sensor inside the nozzle that would directly interfere with flow, the system uses an upstream sensor to measure flow rate as an intermediate parameter, which then indicates nozzle status through comparison with expected values
2Measurement precision
If a large sensor is placed within the small nozzle to detect blockages, then blockage detection capability is improved, but the sensor becomes difficult to replace if it fails
Solution Approach 1:
The sensor is extracted from the confined nozzle interior and relocated to the larger fluid conduit upstream. This extraction makes the sensor physically accessible and easily replaceable while maintaining its function of detecting blockages through upstream flow rate measurement
Solution Approach 2:
The detection system is segmented into separate functional components: the upstream flow rate sensor in the fluid conduit, the nozzle as a separate spray component, and the control system. This segmentation allows the sensor to be independently replaced without affecting the nozzle or requiring disassembly of the narrow nozzle interior
3Device complexity
If no blockage detection system is used, then device complexity is reduced, but make-up runs are required generating additional fuel and labor costs
Solution Approach 1:
The system implements feedback by continuously monitoring upstream flow rate through the sensor and comparing it with expected values. When a blockage is detected (flow rate deviation exceeds threshold), the system provides feedback to the operator via alarm or display, enabling timely nozzle replacement and preventing productivity losses from make-up runs
Solution Approach 2:
The sprayer system performs self-diagnosis of nozzle blockages through the upstream flow rate sensor and control system comparison logic. This self-service capability allows the system to automatically detect and alert operators to blockages without requiring external monitoring equipment or complex intervention systems
Data Source
AI summary
An agricultural sprayer arrangement includes a chassis; a ground engaging traction member carried by the chassis; a liquid tank carried by the chassis; a boom carried by the chassis; a conduit associated with the boom in fluid communication with the liquid tank that acts as a fluid flow path; a nozzle having an inlet in fluid communication with the conduit; a first flow sensor placed upstream of the inlet in the fluid flow path that provides a first flow signal; a second flow sensor placed downstream of the inlet in the fluid flow path that provides a second flow signal; and an electrical processing circuit coupled to the first flow sensor and the second flow sensor that is configured to compare the first and second flow signals to determine a flow rate decrease and issue an alarm if the flow rate decrease is less than a predetermined threshold level.