The present invention relates generally to a continuously-variable nozzle system (CVNS), and in particular to a system for interactively controlling operational variables in an automated or autonomous agricultural sprayer.
Liquid application systems have utilized a wide variety of nozzle configurations and spray operation controls, which are generally based on the liquids being sprayed, environmental factors and other operational considerations. Without limitation, an exemplary application of the present invention is in a mobile agricultural spraying system, which applies liquids to field crops. Such liquids can comprise herbicides, pesticides, liquid fertilizers, nutrients and other substances. Crop field spray operations generally have the objectives of optimizing crop yields, maximizing spray operation efficiency (e.g., material usage) and minimizing unintended spray operation consequences (e.g., spray drift onto neighboring fields).
Spraying system operating condition variables generally include liquid viscosities, pump pressures, discharge nozzle configurations and fluid flow rates. These and other aspects of a spraying system can be controlled to deliver more or less liquid to target surfaces. However, changing the operating pressures and the flow rates in spraying systems can have adverse effects on other operational variables, such as droplet sizes and spray fan angles. For example, if the droplets are too small, the spray can be more susceptible to drift, even in relatively light wind conditions. Unintended drift of agricultural chemicals onto neighboring fields, water supply sources, non-cultivated land, livestock and individuals is generally undesirable. For example, spray operations which may be desirable for a target crop could be harmful to other crops located in adjacent fields. Accidental applications of harmful agricultural chemicals can create financial liabilities for applicators.
Another potential problem with spray operations relates to coverage gaps. For example, decreasing pressure can shrink spray pattern coverage, resulting in unintended coverage gaps and compromising spray operation effectiveness. Environmental conditions can also affect agricultural spraying system performance. For example, temperature and humidity can affect the spray material droplets and alter plant absorption. Effective spraying systems, especially for agricultural applications, preferably provide selective and/or individual control of the spray nozzles. Such control functionality can minimize overlapping spray patterns. It can also enable sectional control of the equipment by independently controlling individual nozzles or equipment sections with multiple nozzles. Relatively accurate spray patterns and material application rates can thus be achieved. For example, varying amounts of chemicals can be applied at different locations, e.g., based on criteria such as equipment sensor readings and pre-determined field conditions. Equipment turns causing differential nozzle ground speeds can also be accommodated because nozzles located over the sprayer-swath outside edges have higher ground speeds than nozzles located over the inside edges of equipment turns. Still further, equipment with differential nozzle control capabilities can automatically compensate for reduced-flow conditions, e.g., caused by worn and defective nozzles.
Croplands, pastures and other fields can be effectively sprayed using appropriate guidance and navigation systems. Current state-of-the-art agricultural vehicles commonly use a Global Navigation Satellite System (GNSS), such as the U.S.-based Global Positioning System (GPS), for precision guidance, prescription farming and material placement.
US-2017/0036228 discloses an intelligent spray nozzle having an input pressure sensor, a flow sensor, a flow modulator, a nozzle pressure sensor and an output orifice modulator. An output from the flow sensor is used to control the flow modulator and the output orifice modulator to control an output spray rate. An ultrasonic-based sensor and “time of flight” principal is used to measure the fluid flow.
The continuously variable nozzle system of the present invention addresses these sprayer performance objectives, and overcomes many of the deficiencies with prior art nozzle and control systems. Heretofore there has not been available a continuously variable nozzle system with the features and elements of the present invention.
In accordance with an aspect of the present invention, a continuously-variable nozzle system (CVNS) is provided for a sprayer, such as an agricultural sprayer. The nozzle system is configured for connection to a spray liquid source and configured for continuously, variably controlling a spray characteristic. The nozzle system comprises a nozzle body with an inlet and an outlet, a conduit between the inlet and the outlet, and a flow meter disposed in the conduit. The flow meter comprises a chamber with internal helical splines configured to interact with a spray liquid passing through the chamber and create a cyclone-like effect, a sphere disposed inside the chamber for free movement along a circular path, and a sensor disposed outside the chamber and configured to detect motion of the sphere and generate an output signal in response to detected motion.
The invention delivers a “smart” nozzle system with a flow meter that has been found to be highly accurate when measuring very low flow rates or rapidly changing flow rates. This is due to the low friction and low inertia of the sphere arrangement. Furthermore the flow meter of the present invention is more reliable and robust compared to known flow meters for individual nozzles.
The nozzle system may be connected to a spray material source and configured to automatically control fluid pressures, discharge volume rates, droplet sizes and discharge spray patterns.
The flow meter preferably comprises an upper section, wherein the upper section comprises an outer wall of the chamber, and wherein the helical splines are provided on an inner surface of the outer wall. The flow meter may further comprise a lower section comprising a cone that projects from the base into the chamber, wherein the cone is aligned on a central axis, and wherein the circular path is disposed between the cone and the outer wall. In one preferred embodiment the upper section comprises a transparent material and the sensor is a photodiode that ‘looks’ through the transparent material at the sphere. A light source may be provided outside the chamber to illuminate the sphere and improve detection reliability by the photodiode.
In one embodiment an automated control system includes a microprocessor configured for receiving input signals representing operating condition variables and providing output signals for controlling adjustable sprayer parameters. The control system includes a feedback loop functions for interactively modifying sprayer parameters in real-time, responding to field, weather, crop and other conditions.
In a preferred embodiment the nozzle system further comprises a flow control valve disposed in the conduit, and an actuator for controlling the flow control valve. Advantageously, the flow control valve permits nozzle-by-nozzle regulation of the flow rate of spray liquid. The flow control valve is preferably a needle valve although other types of valve are viable. The actuator may be provided by a stepper motor for example. Alternatively, a voice coil (or non-commutated DC linear) actuator may be employed.
In another preferred embodiment the nozzle system may further comprise an electronic controller that is in communication with the sensor and the actuator for control of the flow control valve, wherein the controller is configured to compute a flow rate from the output signal and control the actuator in dependence upon the flow rate.
A pressure sensor may be mounted in the conduit downstream of the flow meter and configured to generate a pressure signal, wherein the controller is in communication with the pressure sensor and configured to receive the pressure signal. In one example of the system in operation a supply pressure of the spray liquid source and the flow control valve is controlled in dependence upon the measured flow rate and the nozzle pressure so as to maintain a desired flow rate and spray pattern.
The nozzle system may further comprise an impinging valve disposed in the conduit downstream of the flow control valve, and a further actuator for controlling the impinging valve, wherein the impinging valve serves to modify a mean droplet size of a spray output. Advantageously, the provision of an impinging valve in addition to a flow control valve permits a high degree of nozzle-by-nozzle control of the output spray characteristics, especially with regard to droplet size and flow rate.
The nozzle system can be embodied, by way of example only, in a sprayer that can be configured as a self-propelled vehicle, a mounted or a towed implement, or an unmanned aerial vehicle.
The CVNS of the present invention is adaptable for retrofitting in aftermarket installations, and for original equipment manufacturing (OEM) applications. The modular design accommodates such various applications.
Further advantages of the invention will become apparent from reading the following description of specific embodiments with reference to the accompanying drawings. The drawings constitute a part of this specification and include exemplary embodiments of the present invention illustrating various objects and features thereof.
I. Introduction and Environment
As required, detailed aspects of the present invention are disclosed herein, however, it is to be understood that the disclosed aspects are merely exemplary of the invention, which may be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art how to variously employ the present invention in virtually any appropriately detailed structure.
Certain terminology will be used in the following description for convenience in reference only and will not be limiting. For example, up, down, front, back, right and left refer to the invention as orientated in the view being referred to. The words, “inwardly” and “outwardly” refer to directions toward and away from, respectively, the geometric center of the aspect being described and designated parts thereof. Forwardly and rearwardly are generally in reference to the direction of travel, if appropriate. Said terminology will include the words specifically mentioned, derivatives thereof and words of similar meaning.
II. Sprayer 2
In the practice of an aspect of the present invention, a CVNS 4 is shown in a sprayer 2. Without limitation on the generality of useful applications of the present invention, the sprayer 2 can be configured for agricultural sprayer applications, e.g., either self-propelled, mounted or towed behind a tractor. As shown in
Each CVNS 4 comprises a nozzle body 5 having an input 7 and an output 9 shown diagrammatically in
The fluid enters an impinging valve 20 controlled by another linear stepper motor 22 connected to the microprocessor 12. Depending on the impinging valve 20 open/closed condition, fluid either discharges from the impinging valve 20 or is diverted to an optional discharge valve 24. A fluid-conveying conduit is thus provided between the input 7 and output 9 a series connected plurality of components including the flow meter 10, needle valve 14 and impinging valve 20.
The guidance and control microprocessor 12 receives inputs from the flow meter 10, the pressure sensor 18 and, optionally, from an external data connection 26. The external data connection 26 can comprise a variety of resources, such as the Internet (e.g., via the “Cloud”) an operator, a smart device, a LAN, a WAN, electronic storage media, etc. Moreover, multiple vehicles and equipment pieces with CVNSs can be linked and their operations coordinated. Such vehicles and equipment pieces can be assigned individual operators, or can operate autonomously.
III. Continuously-Variable Nozzle System (CVNS) 4
As shown in
As shown in
As shown in
A needle valve seat 58 acts as a seal against the needle valve 14 as the needle valve closes down to restrict flow. As the fluid passes through the CVNS 4, the pressure of the fluid is read by the pressure sensor 18, which is covered by a gasket 19 preventing fluid from directly contacting the sensor 18 and the PCB 54. The positions of the needle valve 14 and the impinging valve 20 are monitored with a magnet 60, which is pressed into a magnet holder 62 mounted on and sliding with respective motor shafts 64, 66. The magnets 60 interact with magnet sensors (not shown) in the enclosure 30, which provide output signals to the controller 12 for monitoring and controlling the positions of the valves 14, 20, e.g., through an appropriate feedback loop. The needle valve 14 (
As shown in
With reference to
A fluid passage is defined through the chamber 83 from an inlet side 102 to an outlet side 104 between the inside surface of upper section 80 and an external surface of cone portion 85. Helical splines 82 are provided on an inner surface of the outer wall and serve to interact with the fluid to create a cyclone-like effect, which spins the flow meter sphere 52 inside the flow meter 10, along a circular path 106. The speed of revolution of the sphere 52 is proportional to the fluid flow allowing the flow rate of fluid running through the CVNS 4 to be measured. In a preferred embodiment of the flow meter 10, it comprises a clear material so that the motion of the sphere 52 inside can easily be read. In an alternative embodiment, magnetic sensors, acoustic sensors or ultrasonic sensors can be used.
An important characteristic of this particular flow meter design is its ability to measure very low flow rates and rapidly changing flow rates with high accuracy. This is due to the low friction and low inertia of the sphere arragement. In a preferred embodiment, the density of the sphere material should match that of the spraying liquid. For example, acrylic material, or plexiglass, with a density of 1.17-1.20 g/cm3, is particularly suited to spraying liquids with a density close to 1.0 g/cm3.
As shown in
For many agricultural operations the discharge from the CVNS 4 will be through the impinging valve or nozzle subassembly 20. Alternatively, a lower discharge tube 88 can be provided and can include lugs 90 for removably mounting a cap 92 for closing the discharge tube 88. Alternatively, the cap 92 can be replaced with or connected to a suitable spray discharge nozzle (not shown) for bypassing the impinging valve or nozzle subassembly 20 in operation.
Alternative flow meters include, without limitation, thermal mass flow meters, ultrasonic flow sensors, electromagnetic flow meters, acoustic material flow meters and sensors, impeller flow meters, axial turbine flow meters, paddlewheel flow sensors, and a standalone flow meter spray system component that is unconnected to the needle and impinging valves 14, 20.
Although the spraying system is particularly suited for agricultural applications, various other applications for flexibly controlling and managing the flow of liquid material can be accommodated. For example, prescription farming operations can benefit from such control measures. Farmers and other machine users can thus place water, chemicals, liquid fertilizers, or any other liquid material, as well as controlling quantities deposited. Such control provides a solution to the issues such as over-application and underapplication of liquid material.
Other undesirable consequences, which can be mitigated with the present invention, include drift with airborne droplets, issue is exacerbated with smaller droplet sizes. Application on unintended target areas can thus be mitigated. Moreover, the present invention can communicate with a control system on a machine, such as a vehicle, for navigating and controlling precision farming operations. Such navigational and positioning systems can include a global navigation satellite system (GNSS), e.g., the U.S.-based global positioning system (GPS). Real-time kinematic (RTK), inertial and other navigational/positional procedures can also be used. Interactive communication with vehicles and other equipment and machines can coordinate and control other aspects of precision farming and other operations. For example, multiple CVNSs 4 can be selectively and individually controlled, or can be controlled collectively in sections or on entire implements.
It is to be understood that the invention can be embodied in various forms, and is not to be limited to the examples discussed above. The range of components and configurations which can be utilized in the practice of the present invention is virtually unlimited.
Filing Document | Filing Date | Country | Kind |
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PCT/US2019/026600 | 4/9/2019 | WO |
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WO2019/204085 | 10/24/2019 | WO | A |
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Number | Date | Country | |
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62660895 | Apr 2018 | US |