Agricultural Sprayer Thermal Imager Nozzle Plugging Detection

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Solution Overview

Problem

Agricultural sprayers face challenges in detecting full or partial plugging of spray nozzles, leading to uneven distribution of fertilizers or pesticides, resulting in wasted resources and reduced crop yields due to over- or under-application.

Innovation Solution

The implementation of a system using radio-frequency (RF) transmissions and thermal imaging to diagnose nozzle plugging by monitoring changes in RF signal attenuation and thermal reactions on the agricultural field, providing real-time indications for operator intervention.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If traditional spray monitoring methods are used, then the system complexity is low, but the detection precision of nozzle plugging is insufficient

Engineering Contradiction:

Improvenozzle plugging detection precisionVSAvoidmonitoring system complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent replaces traditional mechanical or visual inspection methods with thermal imaging technology to detect nozzle plugging. The thermal imager captures temperature variations in the spray pattern, providing non-contact, automated detection of plugging conditions without requiring physical intervention or complex mechanical sensors at each nozzle location.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system monitors temperature parameters of the spray pattern using thermal imaging. By detecting changes in temperature distribution across the spray field, the system identifies plugging conditions through thermal signature analysis, transforming the detection approach from mechanical measurement to thermal parameter monitoring.

Inventive Principle:

Principle #35Parameter changes

2Productivity

If manual inspection of spray nozzles is performed, then the equipment cost is low, but the productivity and response time are reduced

Engineering Contradiction:

Improvespray application efficiencyVSAvoidtime for nozzle detection and correction

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The thermal imaging system operates continuously during spray application, providing real-time monitoring of nozzle performance. This eliminates interruptions for manual inspection and enables continuous detection of plugging conditions, maintaining uninterrupted spray operations and immediate identification of problems.

Inventive Principle:

Principle #20Continuity of useful action

Solution Approach 2:

The system provides immediate feedback through visual display of thermal images showing spray pattern anomalies. Operators can see real-time temperature variations indicating plugging conditions and respond promptly, creating a closed-loop monitoring system that enhances productivity through rapid detection and correction.

Inventive Principle:

Principle #23Feedback

3Loss of substance

If spray application continues with undetected plugging, then operational time is maximized, but the loss of substance increases due to uneven distribution

Engineering Contradiction:

Improveagricultural product wasteVSAvoidspray operation continuity

Core Design Contradiction:

Loss of substanceVSProductivity

Solution Approach 1:

The thermal imaging system detects plugging conditions before they cause significant spray distribution problems. By identifying temperature anomalies early in the spray pattern, the system alerts operators to correct issues before uneven distribution leads to substantial product waste or crop yield reduction.

Inventive Principle:

Principle #10Preliminary action

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

Ensures even distribution of agricultural products by quickly identifying and correcting plugged nozzles, preventing waste and maintaining optimal crop yields through real-time monitoring and diagnostic capabilities.

Implementation Method 1

A thermal imager operably coupled to the agricultural sprayer has a field of view behind the agricultural sprayer. The thermal imager is configured to provide an indication of a thermal reaction of the agricultural field in response to application of the atomized liquid.

Methodology Applied

Scientific EffectThermal radiation: Thermal Radiation

Data Source

PatentEP3574756B1Agricultural sprayer and method of operating an agricultural sprayer

Publication Date: 2023.07.05 DEERE & CO

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AI summary

An agricultural sprayer (162, 500, 510, 900) is disclosed. The agricultural sprayer (162, 500, 510, 900) comprising: at least one nozzle (176, 210, 215, 240, 310, 360, 410, 412, 414, 610, 802, 904, 926) configured to receive a liquid and direct atomized liquid to an agricultural field (180, 922) in a dispersal area; a thermal imager (906) operably coupled to the agricultural sprayer (162, 500, 510, 900) and having a field of view (910) behind the agricultural sprayer (162, 500, 510, 900), the thermal imager (906) being configured to provide an indication of a thermal reaction of the agricultural field (180, 922) in response to application of the atomized liquid; and wherein an output of the thermal imager (906) is used to characterize operation of the at least one nozzle (176, 210, 215, 240, 310, 360, 410, 412, 414, 610, 802, 904, 926). Furthermore, a method of operating an agricultural sprayer (162, 500, 510, 900) is disclosed.