The present invention relates generally to irrigation machines and, more particularly, to a system, method and apparatus for filter and overhang plugging detection.
Modern field irrigation machines are combinations of drive systems and sprinkler systems. Common irrigation machines most often include an overhead sprinkler irrigation system consisting of several segments of pipe (usually galvanized steel or aluminum) joined together and supported by trusses, mounted on wheeled towers with sprinklers positioned along its length. These machines move in a circular pattern (if center pivot) or linear and are fed with water from an outside source (i.e., a well or water line). The essential function of an irrigation machine is to transport water (and other applicants) from a water source to a given location.
A critical issue with irrigation machines is the need to filter out sand, debris (wood, dirt, fish, etc.) and oxidized organics found in some water supplies. To address this issue, filters are often incorporated at various points in the irrigation system. Commonly, large, in-line pressure filters are attached between the water supply and the main irrigation riser of a given irrigation machine. These pressure filters are commonly fitted with internal screen brush systems which act to physically separate sand and other sediment from the water before it enters the main irrigation spans. Additionally, sand traps are commonly located along the main irrigation spans to further separate and trap sediment as it settles within the spans.
Because of the large volumes of water processed by the irrigation machine, each of the filters within the system require regular flushing. The amount of flushing required generally depends on the sediment load of the irrigation water, the flow rate of the machine and the hours of use. If the filters are not regularly flushed, the restriction of flow to the pivot will result in increased pumping costs and/or decreased uniformity of application.
Most commonly, growers have relied on expensive flowmeters to ensure the proper flow rate through the irrigation system. In addition to being expensive, flowmeters are often prone to clogging and failure when used with water having high levels of sediment. Because of this, growers have generally resorted to cleaning out filters according to a fixed schedule. This type of scheduling is imprecise and results in both under-maintenance and over-maintenance of the filter systems.
In order to overcome the limitations of the prior art, a system is needed which is able to reliably provide growers with filter status information in a timely manner.
To minimize the limitations found in the prior art, and to minimize other limitations that will be apparent upon the reading of the specifications, the present invention provides a system, method and apparatus for monitoring and providing maintenance updates for irrigation filters.
According to a first preferred embodiment, the present invention may preferably include one or more load cells at one or more of the mounting feet of an in-line filter to actively measure the increased weight of the filter during irrigation operations. The weight sensor preferably sends its data to a processing unit (e.g., a controller within a pivot control panel) where the weight is compared to one or more stored weight values. Preferably, when the detected weight exceeds a threshold level, the system may trigger notices and/or remedial actions as discussed further herein.
According to a second preferred embodiment, the present invention may preferably include a differential pressure transducer that measures the pressure differential across a given filter screen. Preferably, the detected levels of pressure differentials are compared to stored threshold levels indicating a filter maintenance issue requiring remedial action.
According to a third preferred embodiment, the present invention may further include a load cell mounted in one or more of the overhang cables. Preferably, when the detected weight exceeds a threshold level, the system may trigger notices and/or remedial actions as discussed further herein.
For the purposes of promoting an understanding of the principles of the present invention, reference will now be made to the embodiments illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the present invention is hereby intended and such alterations and further modifications in the illustrated devices are contemplated as would normally occur to one skilled in the art. The descriptions, embodiments and figures used are not to be taken as limiting the scope of the claims.
Where the specification describes advantages of an embodiment or limitations of other prior art, the applicant does not intend to disclaim or disavow any potential embodiments covered by the appended claims unless the applicant specifically states that it is “hereby disclaiming or disavowing” potential claim scope. Moreover, the terms “embodiments of the invention”, “embodiments” or “invention” do not require that all embodiments of the invention include the discussed feature, advantage or mode of operation, nor that it does not incorporate aspects of the prior art which are sub-optimal or disadvantageous.
As used herein, the word “exemplary” means “serving as an example, instance or illustration.” The embodiments described herein are not limiting, but rather are exemplary only. It should be understood that the described embodiments are not necessarily to be construed as preferred or advantageous over other embodiments. Additionally, any examples or illustrations given herein are not to be regarded in any way as restrictions on, limits to, or express definitions of, any term or terms with which they are utilized. Instead, these examples or illustrations are to be regarded as illustrative only.
As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. Additionally, the word “may” is used in a permissive sense (i.e., meaning “having the potential to”), rather than the mandatory sense (i.e., meaning “must”). Further, it should also be understood that throughout this disclosure, unless logically required to be otherwise, where a process or method is shown or described, the steps of the method may be performed in any order (i.e., repetitively, iteratively, or simultaneously) and selected steps may be omitted. It will be further understood that the terms “comprises,” “comprising,” “includes” and/or “including”, when used herein, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.
With reference now to
As further shown in
Additionally, the in-line filter 204 is preferably equipped with one or more load cells 214 (i.e., weight sensors) which are capable of sensing the weight of the in-line filter 204. According to a preferred embodiment, the load cells of the present invention may preferably be incorporated into the feet of the in-line filter 204. Additionally, the load cells 214 are preferably linked to one or more wireless reporting devices for transmitting load cell 214 sensor readings to the central control device 222 as discussed further herein.
As further shown in
Referring now to
In addition, the span of the present invention may also include one or more tension sensors 230. According to a preferred embodiment, the tension sensor(s) 230 may preferably sense the amount of tension applied to one or more support cables 232 (e.g., back cables, overhang cables and the like) and report the tension level(s) to the controller 222 (or other processing device). In this way, the system of the present invention may receive and process data from one or more tension sensors 230, and may use the data to signal weight levels and to open selected valves in response to detected weights exceeding predetermined levels. Preferably, the selected predetermined weight levels may be adjusted and calibrated based on detected water pressures and other factors as discussed further herein.
With reference now to
At a next step 308, the system may then receive system sensor data from one or more sensors within the irrigation system. According to the present invention, such sensor data may include data such as: inlet water pressure (IP); outlet water pressure (Op); in-line filter weight; and overhang/sand trap weight sensor data.
At a next step 310, the system may calculate the IP:Op ratio(s) for detected pressures. At a next step 312, the system may compare the calculated IP:Op ratio to stored ranges of ratios to identify a pre-calculated, associated sediment rate for the calculated IP:Op ratio.
At a next step 314, the system may preferably further compare the determined sediment rate to a pre-set sediment threshold which indicates a cut-off level for required filter maintenance. Where the determined sediment rate exceeds the pre-set sediment threshold, the system at a next step 316 may transmit maintenance notices or provide a visual/audial notice of the maintenance notice. According to a further preferred embodiment, different pre-set sediment thresholds may be determined, stored and used depending on other detected factors such as: needed watering pressures, pump duty cycles, pump/motor temperatures, well water levels, filter types, and the like. Additionally, the sediment thresholds may be adjusted based on detected crop irrigation needs (e.g., growing status, health indicators, ground moisture, weather). Additionally, the sediment thresholds may be adjusted based on other factors such as: whether chemigation/fertigation is active; whether the minimum machine pressure for proper water application is available downstream of the filter; and the like. Preferably, the system of the present invention may work with the water supply system (i.e., pump) and end of machine or pivot pressures to: ensure the system is providing the minimum required pressure for proper water application; and to predict, based on the rate of change of the Ip/Op ratio and ratio of the pump supply pressure to maximum pump pressure, when flushing or filter maintenance would need to occur. Preferably, the system may include preset ratios and/or threshold levels for each of these data points to trigger specific alerts and warnings. Preferably, each of these ratios may further be adjusted based on specific tasks performed by the irrigation system (e.g., chemigation/fertigation, water, specific applicant mixes, and the like.).
According to preferred embodiments, in step 316 (and steps 322, 328 discussed below), the system of the present invention may perform a number of possible pre-programmed actions in response to a detected threshold condition. Accordingly, the system may trigger an alert (e.g., “filter flush required,” and/or “machine flush required” (in the case of sediment overload in the overhang or at the end of the machine)) to be displayed on a control panel. Additionally, a notice may be sent via the remote monitoring and control system to the operator or grower. Still further, the system may stop the pump and/or irrigation machine and record or transmit an error code or the like. As another alternative, the system may also trigger an automatic flushing system to clear the filter and to allow the machine to restart. For example, an overhang flush valve may be opened to allow the debris or sand to be removed from the machine. Preferably, the flushing would only be permitted when irrigating, not when chemigation or fertigating. In addition, the machine would preferably temporarily stop while any flushing action was taking place to ensure no under-watering occurred.
Referring now to
Referring now to
According to alternative embodiments, the system of the present invention may further include the step of comparing the calculated sediment rates from one or more of steps 312, 318 and 324 to provide a further degree of confidence in the calculated sediment rates of a given filter system. Accordingly, exemplary embodiments of the present invention may further average two or more of the calculated sediment rates together before analyzing the sediment rates against stored sediment threshold values for any given filter.
While the above descriptions regarding the present invention contain much specificity, these should not be construed as limitations on the scope, but rather as examples. Many other variations are possible. For example, the processing elements of the present invention by the present invention may operate on a number of different frequencies, voltages, amps and BUS configurations. Further, the communications provided with the present invention may be designed to be duplex or simplex in nature. Further, the systems of the present invention may be used with any arrangement of drive towers including both linear and center pivot systems. Further, as needs require, the processes for transmitting data to and from the present invention may be designed to be push or pull in nature. Still, further, each feature of the present invention may be made to be remotely activated and accessed from distant monitoring stations. Accordingly, data may preferably be uploaded to and downloaded from the present invention as needed.
Accordingly, the scope of the present invention should be determined not by the embodiments illustrated, but by the appended claims and their legal equivalents.
The present application claims priority to U.S. Provisional Application No. 63/252,703 filed Oct. 6, 2021.
Number | Date | Country | |
---|---|---|---|
63252703 | Oct 2021 | US |