Sprayer Nozzle Plugging Detection Using RF Spray Attenuation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing agricultural sprayer nozzle monitoring systems are prone to false readings due to ambient noise, vibrations, and environmental factors, making them costly and inefficient in detecting full or partial plugging of spray nozzles, which can lead to uneven product distribution and reduced crop yields.
Innovation Solution
The implementation of a radio-frequency (RF) based system that uses RF transmitters and receivers to detect changes in signal attenuation as the RF signal passes through the atomized fluid, allowing for real-time monitoring and diagnosis of nozzle plugging without relying on optical techniques, which are susceptible to dirt, dust, or light conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If acoustic sensors and microphones are used to detect nozzle plugging, then nozzle monitoring capability is provided, but the system becomes highly sensitive to ambient noise and requires complex signal filtration
Solution Approach 1:
The patent replaces acoustic sensors and microphones with optical sensors (cameras) to detect nozzle plugging. This substitution eliminates the sensitivity to ambient noise inherent in acoustic systems while providing visual detection capability through image processing, thereby reducing the need for complex signal filtration procedures.
Solution Approach 2:
The system creates visual copies (images) of the spray pattern using cameras instead of acoustic copies. These images can be processed and analyzed to detect plugging conditions without being affected by ambient noise, simplifying the detection process compared to acoustic signal filtration.
2Reliability
If vibration sensors are used to monitor spray nozzle operation, then operational information is provided, but the system becomes highly sensitive to ambient vibrations and movements from uneven ground
Solution Approach 1:
The patent replaces vibration sensors with optical cameras to monitor spray nozzle operation. This substitution eliminates sensitivity to ambient vibrations and ground movements, as optical detection is not affected by mechanical vibrations in the same way acoustic and vibration sensors are.
Solution Approach 2:
The patent introduces light as an intermediary medium for detection instead of direct mechanical vibration sensing. The camera captures light reflected from or transmitted through the spray, providing information about nozzle operation without being directly affected by mechanical vibrations from uneven ground.
3Reliability
If digital cameras and image processing are used to analyze spray patterns, then nozzle monitoring is achieved, but the system becomes costly and requires complex analyzing algorithms
Solution Approach 1:
The patent replaces complex image processing algorithms with simpler optical detection methods using cameras in specific configurations. By positioning cameras to capture images of nozzles against controlled backgrounds and using basic image analysis, the system achieves reliable detection without requiring complex analyzing algorithms.
4Reliability
If optical techniques are used to detect nozzle plugging, then spray pattern visualization is provided, but the system becomes susceptible to dirt, dust, and limited light conditions
Solution Approach 1:
The patent uses periodic illumination (flash lamps) to provide controlled lighting conditions for optical detection. This periodic action overcomes limitations of ambient light conditions and ensures consistent detection capability regardless of external lighting variations.
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
This RF-based system provides accurate and real-time detection of nozzle plugging, reducing the need for complex signal filtration and minimizing false positives, thereby ensuring even product distribution and maintaining optimal crop yields by identifying and addressing plugged nozzles promptly.
Implementation Method 1
A radio-frequency (RF) transmitter is disposed to generate an RF signal that passes through the dispersal area. The RF signal is detectably changed when interacting with droplets of the atomized fluid.
Data Source
Figure 1
Figure 2A
Figure 2B~2C
AI summary
An agricultural sprayer (162) is disclosed. The agricultural sprayer (162) comprising: at least one nozzle (176, 210, 215, 310, 360, 412, 414, 610, 802) configured to receive a fluid and direct atomized fluid to an agricultural surface (180); a radio-frequency (RF) transmitter (312, 430, 620, 804) disposed to generate an RF signal (315) that passes through a dispersal area (350), wherein the RF signal (315) is detectably changed when interacting with droplets of the atomized fluid; a first RF receiver (314, 510, 560, 570) disposed to receive the RF signal (315) after the RF signal (315) passes through the dispersal area (320), the first RF receiver (314) providing an output indicative of the RF signal (315); and a controller (317) coupled to the first RF receiver (314, 510, 560, 570) and configured to detect plugging of the at least one nozzle (210) based on the output of the first RF receiver (314, 510, 560, 570). Furthermore, a method of detecting plugging in a nozzle (176, 210, 215, 310, 360, 412, 414, 610, 802) is disclosed.