Method and device to detect clogged nozzles

Abstract

The nozzle clog detection device, system, and method detect if a liquid flows through a nozzle via conduction of electricity. The clog detector provides an open circuit at an opening between two conductors. The two conductors are placed in the flow path of a liquid flowing from a nozzle. The liquid from the nozzle conducts electricity. The liquid flowing through the opening between the conductors closes the circuit. An alert system notifies the user whether liquid is flowing through the nozzle. The system detects flow of liquid from multiple nozzles and identifies the nozzles from which liquid flows. A break in the circuit at the opening between the conductors indicates that the liquid is not flowing sufficiently enough to close the circuit.

Claims

1. A device for detecting the flow of a fluid from at least one nozzle wherein the device detects the presence of the fluid in a flow path from the nozzle wherein the flow path defines a longitudinal axis, the device comprising: a first conductor placed in the flow path of the fluid exiting the nozzle wherein the first conductor conducts electricity; a second conductor placed in the flow path of the fluid exiting the nozzle wherein the second conductor conducts electricity wherein the second conductor does not contact the first conductor; a power source electrically connected to the first conductor and the second conductor; an opening extending laterally between the first conductor and the second conductor wherein the opening creates an open circuit with the power source wherein the first conductor and the second conductor extend laterally inwards towards the opening into the flow path; a flow indicator electrically connected to the first conductor and the second conductor, the flow indicator providing a flow detected output indicating that the fluid is flowing from the nozzle, the flow indicator providing a clog detected output indicating that the fluid is not detected as flowing from the nozzle; a housing attachable adjacent the nozzle wherein the first conductor and second conductor extend radially inward from opposite sides of the housing towards the opening such that the first conductor approaches the second conductor towards the opening.

2. The device of claim 1 wherein the flow indicator is secured to the housing.

3. A system for detecting the flow of a fluid from a first nozzle and a second nozzle wherein the system detects the presence of the fluid in a flow path from the nozzles wherein the flow path defines a longitudinal axis, the device comprising: a housing configured to be secured to the first nozzle; a housing aperture located in the flow path of the fluid exiting the first nozzle; a first conductor placed in the flow path of the fluid exiting the first nozzle wherein the first conductor conducts electricity; a second conductor placed in the flow path of the fluid exiting the first nozzle wherein the second conductor conducts electricity wherein the second conductor does not contact the first conductor; a power source electrically connected to the first conductor and the second conductor; an opening between the first conductor and the second conductor wherein the opening creates an open circuit with the power source; wherein the first conductor and second conductor extend laterally inward from different sides of the housing such that the first conductor approaches the second conductor towards the opening without contacting the second conductor; and a flow indicator electrically connected to the first conductor and the second conductor, the flow indicator providing a flow detected output indicating that the fluid is flowing from the first nozzle to conduct electricity between the first conductor and the second conductor across the opening between the first conductor and the second conductor, the flow indicator providing a clog detected output indicating that the fluid is not detected as flowing from the first nozzle.

4. The system of claim 3 wherein the first conductor extends laterally inward from the housing into the housing aperture; and wherein the second conductor extends laterally inward from the housing into the housing aperture, the first conductor extending laterally towards the opening and the second conductor extending laterally inward towards the opening wherein the first conductor approaches the second conductor towards the opening, wherein the opening extends laterally between an end of the first conductor and an end of the second conductor wherein the flow path of the fluid exiting the nozzle travels through the opening.

5. The system of claim 4 wherein the flow indicator is a light that indicates that sufficient fluid is flowing from the first nozzle to complete the circuit at the opening wherein the light is powered on for the flow detected output to indicate that the fluid is completing the circuit.

6. The system of claim 4 further comprising: the flow indicator placed adjacent the first nozzle to indicate a status of the first nozzle identifying if fluid is flowing from the first nozzle.

7. The system of claim 4 further comprising: a second set of conductors placed in the flow path of the fluid from the second nozzle wherein the second set of conductors form an open circuit with the power source such that the second set of conductors do not contact each other, the second set of conductors connected in parallel with the first set of conductors; a second flow indicator electrically connected to the second set of conductors, the second flow indicator providing a flow detected output indicating that the fluid is flowing from the second nozzle wherein the fluid conducts electricity across an opening between the second set of conductors, the flow indicator providing a clog detected output indicating that the fluid is not detected as flowing from the second nozzle wherein the second flow indicator detects whether electricity flows across the open circuit between the second set of conductors.

8. The device of claim 7 further comprising: a monitor providing the flow indicators wherein the monitor provides a status of the two nozzles.

9. The device of claim 4 further comprising: a first detection body providing the first conductor and two additional conductors wherein the conductors of the first detection body are electrically connected to each other, the first detection body electrically connected to the power source; a second detection body providing the second conductor and two additional conductors wherein the conductors of the second detection body are electrically connected to each other, the second detection body electrically connected to the power source; and the opening located between the conductors of the first detection body and the conductors of the second detection body wherein the opening creates the open circuit such that the conductors of the first detection body do not contact the conductors of the second detection body.

10. The device of claim 4 wherein the flow indicator is secured to the housing.

11. A method of detecting a flow of fluid from a first nozzle and a second nozzle, the method comprising: attaching a housing adjacent the nozzle; installing a first conductor in a flow path of said fluid exiting said first nozzle; installing a second conductor in the flow path of the fluid exiting said first nozzle wherein the first conductor does not contact the second conductor, wherein the first conductor and second conductor extend radially inward from opposite sides of the housing; connecting the first conductor and the second conductor to a power source; creating an open circuit in the flow path of the fluid exiting from the first nozzle wherein the flow of the fluid in the flow path conducts electricity across the open circuit between the first conductor and the second conductor; electrically connecting a flow indicator to the first conductor and the second conductor, the flow indicator providing a flow detected output indicating that the fluid is flowing from the first nozzle to conduct electricity across the open circuit, the flow indicator providing a clog detected output indicating that the fluid is not detected as flowing from the first nozzle.

12. The method of claim 11 further comprising: installing a third conductor in a flow path of the fluid exiting the second nozzle; installing a fourth conductor in the flow path of the fluid exiting the second nozzle wherein the third conductor does not contact the fourth conductor; connecting the third conductor and the fourth conductor to the power source; creating an open circuit in the flow path of the fluid from the second nozzle wherein the flow of the fluid in the flow path conducts electricity across the open circuit between the third conductor and the fourth conductor; electrically connecting a second flow indicator to the third conductor and the fourth conductor, the second flow indicator providing a flow detected output indicating that the fluid is flowing from the second nozzle, the second flow indicator providing a clog detected output indicating that the fluid is not detected as flowing from the second nozzle.

13. The method of claim 11 wherein the fluid flowing from said first nozzle completes the open circuit between the first conductor and the second conductor.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) In the following drawings, which form a part of the specification and which are to be construed in conjunction therewith, and in which like reference numerals have been employed throughout wherever possible to indicate like parts in the various views:

(2) FIG. 1 is an environment view showing one embodiment of the present invention;

(3) FIG. 2 is a circuit view showing one embodiment of the present invention;

(4) FIG. 3 is a circuit view showing one embodiment of the present invention;

(5) FIG. 4 is a circuit view showing one embodiment of the present invention;

(6) FIG. 5 is a circuit view showing one embodiment of the present invention;

(7) FIG. 6 is a circuit view showing one embodiment of the present invention;

(8) FIG. 7 is a circuit view showing one embodiment of the present invention;

(9) FIG. 8 is a schematic view showing one embodiment of the present invention;

(10) FIG. 9 is a schematic view showing one embodiment of the present invention;

(11) FIG. 10 is a schematic view showing one embodiment of the present invention;

(12) FIG. 11 is a schematic view showing one embodiment of the present invention;

(13) FIG. 12 is a schematic view showing one embodiment of the present invention;

(14) FIG. 13 is a schematic view showing one embodiment of the present invention;

(15) FIG. 14 is a top view of a monitor of one embodiment of the present invention;

(16) FIG. 15 is a bottom view of a flow detection device of one embodiment of the present invention; and

(17) FIG. 16 is a bottom view of a flow detection device of one embodiment of the present invention.

DETAILED DESCRIPTION

(18) The clog detection device shown generally as 100 in FIG. 1 detects clogs in spray nozzles 102. The clog detection device 100 provides housing 104 that attaches around the nozzles 102 to detect whether liquid 110 is flowing from the nozzle 102. Detection bodies 105, 107 each provide at least one conductor, such as conductors 106, 108. In another embodiment, the detection bodies 105, 107 may provide multiple conductors, such as three conductors, spaced throughout the flow path of the spray from the nozzle.

(19) Conductors 106, 108, such as prongs, provide an open circuit within the flow path of the spray from the nozzle. The liquid 110, such as water, a water based solution, an agrochemical spray, a liquid solution, a liquid compound, or other liquid, flows through the nozzle 102. The liquid 110 completes the opening 120 between conductors 106, 108 to complete the circuit. The clog detection device 100 operates due to the electric conductivity of the liquid 110.

(20) Water that is not pure will conduct electricity due to the presence of ions. Almost all water sources such as tap water, sea water, and groundwater contain a certain amount of ions that cause the water to conduct electricity. Water-based agrochemicals require mixing with water as a solvent before spraying. Groundwater or tap water normally serves as the water source for such a solvent. Therefore, such an agrochemical spray solution is potentially able to conduct electricity.

(21) The clog detection device 100 and method detects clogs due to the conductive nature of the liquid 110 passing through the nozzle 102. The clog detection device 100 provides two conductors 106, 108 extending from the housing 104 with an opening 120 to form an open electrical circuit. The spray liquid 110 exiting nozzle 102 contacts the two conductors 106, 108 allowing the current to flow across the conductors 106, 108 and the spray liquid 110.

(22) The clog detection device 100 (NCDD) is constructed from a housing 104, such as a cylindrical plastic body, with the water sensor circuit (henceforth referred to as NCDD circuit or the circuit) built into it. The housing 104 attaches to a nozzle body at the top to become one assembly. The circuit components install into the housing 104 with two conductor apertures on the housing with the two conductors 106, 108, such as the two prongs (naked metallic wires relatively more rigid than the remaining wires used in the circuit) piercing from outside of the housing 104 on opposite sides radially toward the center of the housing 104.

(23) The conductors 106, 108, such as the prongs, of one embodiment are collinear and separated by a small opening 120 with their axis being perpendicular to the axis of the nozzle's orifice. When the nozzle 102 is spraying, a small opening 120 between the prongs and the nozzle tip allows the developing liquid spray 110 (initial portion of the water exiting from the nozzle), which is conical in shape for a circular orifice and continuous, to make contact with the conductors 106, 108 (FIG. 1). Since the developing liquid spray 110 is continuous, the liquid 110 closes the circuit allowing the flow of current.

(24) An indicator, such as a light emitting diode (an LED), a light, a visual alert, an audio alert, an alarm, or other indicator, can be included in the circuit to indicate the presence or absence of water. The liquid 110 contacts the conductors 106, 108 to complete the circuit. As the liquid 110 fails to close the circuit, the clog detection system 100 detects the open circuit. The end result is a water sensor that detects the flow of liquid 110 across the opening 120 between conductors 106, 108.

(25) Contact of the two conductors 106, 108 to each other produces a short circuit that eventually damages the LED. The water is a relatively poor conductor of electricity that acts as a resistor to minimize the current that passes through the prongs. The water reduces the likelihood of a short circuit.

(26) In most practical applications, the user applies the liquid through multiple nozzles. The user installs a clog detection system constructed from a clog detection device placed at each nozzle. Such a system requires multiple clog detection devices.

(27) A clog detection device of one embodiment will be installed at each nozzle to detect sprayed liquid 110 from the nozzle. The conductors 106, 108 install adjacent to each nozzle 102. The installation of the conductors 106, 108 places each opening 120 in the path of liquid 110 through the respective nozzle. The system monitors the flow of liquid 110 through each nozzle 102.

(28) In one embodiment, the system provides an alert system that detects flow of the liquid through each nozzle. The alert system may be an audible alert, such as an alarm, a beep, or other audio signal. The alert system may also be a visual alert, such as a light, LED, status update on a screen, or other visual alert. Another embodiment may provide both an audible alert and a visual alert.

(29) The system monitors each nozzle. The alert system indicates which nozzle is clogged. The user can then identify the clogged nozzle and repair the nozzle. The alert system identifies the clogged nozzle so that the user can quickly locate and repair the nozzle without losing significant time.

(30) As indicated above, multiple clog detection devices of one embodiment will be working concurrently at different nozzle locations. These clog detectors may share some resources such as a power source. Consequently, the circuit on the clog detection device must be completed by connecting to that external resource. As such, henceforth, the term Nozzle Clogging Detection System (NCDS) will be used to refer to the entire setup and NCDS circuit will refer to the circuit on the NCDD in connection with the rest of the system.

(31) FIGS. 2-13 show different embodiments of the clogged nozzle detection system 100. Six NCDS circuit designs are established based on two circuit types (A and B) of three applicable configurations (1, 2, and 3) of the NCDD. The circuit designs are summarized in Table 1.

(32) TABLE-US-00001 TABLE 1 Nozzle clogging detection system (NCDS) circuit design details. Circuit Type B: Circuit provides an A: Circuit provides a BJT NPN transistor and 330- resistor shown in 330- resistor as shown FIGS. 2, 4, 6, 8, 10, in FIGS. 3, 5, 7, 9, 11, Configuration and 12 and 13 1: Single device Constructed from a 9- Constructed from a 9- configuration volt power source, a volt power source, a constructed from a 330-ohm resistor, an 330-ohm resistor, a standalone NCDD LED and two prongs 2N222A NPN transistor, with an LED on it (See FIGS. 2 and 8). an LED, and two prongs that operates (See FIGS. 3 and 9). independently with its own individual power source. 2: Multiple device Constructed from a Constructed from a configuration shared 12-volt power shared 12-volt power constructed from a source, a 330-ohm source, a 330-ohm connectible NCDD resistor, an LED, and resistor, a 2N222A NPN with an LED that two prongs (See FIGS. 4 transistor, an LED, and connects to a power and 10). two prongs (See FIGS. 5 source shared by and 11). additional devices in parallel. 3: Multiple device Constructed from a Constructed from a configuration shared 12-volt power shared 12-volt power constructed from a source, a switch, a 330- source, a switch, a connectible NCDD ohm resistor, two LEDs, 2N222A NPN transistor, with an LED that and two prongs (See a 330-ohm resistor, two connects to a power FIGS. 6 and 12). LEDs, and two prongs source shared by (See FIGS. 7 and 13). additional devices in parallel and a second LED on a monitoring panel, in order to be operational.

(33) FIGS. 2 and 8 show one embodiment with a resistor in the circuit with the flow indicator 118. The flow indicator 118 may be a light, an LED, a visual alert, or audible alert as indicated above. Power source 112, such as a battery, solar panel, power from the agricultural equipment, or other power source, provides power to the flow indicator 118. Opening 120 creates an open circuit 114. The liquid flows through the housing 104, across conductors 106, 108. The liquid capable of conducting electricity closes the circuit 114 as the liquid flows through opening 120. The liquid closes the circuit 114 allowing electricity to flow across the flow indicator 118 to indicate that nozzle is not clogged. If the flow is not sufficient to complete the circuit at opening 120, electricity is not supplied to flow indicator 118 such that flow indicator 118 is not powered.

(34) FIGS. 3 and 9 show another embodiment that includes resistor 116 and transistor 122. As indicated above, housing 104 secures near the nozzle to place opening 120 in the flow path of the liquid from the nozzle. The liquid flows into opening 120 to close circuit 114. Power source 112 powers the flow indicator 118. The liquid closes the circuit 114 allowing electricity to flow across the flow indicator 118 to indicate that the nozzle is not clogged. If the flow is not sufficient to complete the circuit at opening 120, electricity is not supplied to flow indicator 118 such that flow indicator 118 is not powered.

(35) FIGS. 4 and 10 show another embodiment that includes resistor 116 similar to FIGS. 2 and 8. As indicated above, housing 104 secures near the nozzle to place opening 120 in the flow path of the liquid from the nozzle. The liquid flows into opening 120 to close circuit 114. The liquid capable of conducting electricity closes the circuit 114 as the liquid flows through opening 120. The liquid closes the circuit 114 allowing electricity to flow across the flow indicator 118 to indicate that the nozzle is not clogged. If the flow is not sufficient to complete the circuit at opening 120, electricity is not supplied to flow indicator 118 such that flow indicator 118 is not powered.

(36) FIGS. 4 and 10 show a system of clog detection devices 130, 132, 134 providing multiple indicators 118 placed at different nozzles. Each clog detection device 130, 132, 134 attaches in parallel with the power source 112. Each detection device 130, 132, 134 signals whether sufficient liquid flows across each opening 120 between the conductors 106, 108.

(37) FIGS. 5 and 11 show another embodiment that includes resistor 116 and transistor 122. As indicated above, housing 104 secures near the nozzle to place opening 120 in the flow path of the liquid from the nozzle. The liquid flows into opening 120 to close circuit 114. Power source 112 powers the flow indicator 118. The liquid closes the circuit 114 allowing electricity to flow across the flow indicator 118 to indicate that the nozzle is not clogged. If the flow is not sufficient to complete the circuit at opening 120, electricity is not supplied to flow indicator 118 such that flow indicator 118 is not powered.

(38) FIGS. 5 and 11 show a system of clog detection devices 136, 138, 140 providing multiple indicators 118 placed at different nozzles. Each clog detection device 136, 138, 140 attaches in parallel with the power source 112. Each detection device 136, 138, 140 signals whether sufficient liquid flows across each opening 120 between the conductors 106, 108. The power source 112 powers the alert to signal that sufficient liquid is flowing across the opening 120 to complete the circuit such that nozzle is not clogged.

(39) FIGS. 6-7 and 12-13 show additional embodiments of the system. Multiple flow detection devices 142, 144, 146, 148, 150, 152 install at different nozzles. The flow detection devices 142, 144, 146, 148, 150, 152 connect in parallel on circuit 114. These systems provide an indicator, such as indicators 118, 124, to indicate whether sufficient liquid is flowing through opening 120 to complete the circuit.

(40) One flow indicator 118, such as an LED, is placed near the nozzle 102. Another indicator 124 is placed on a monitor system 154 as shown in FIG. 14. Such a monitor system 154 provides a switch 126 that turns the system on and off. The monitor system 154 also provides a power indicator, such as a power light, pilot light, indicating that the system is turned on or off.

(41) As discussed above, the flow detection devices are placed to locate the opening between conductors 106, 108 in the flow path of the liquid from the nozzle. The indicators 118, 124 indicate whether sufficient liquid is flowing through the opening 120 at conductors 106, 108. These flow detection devices 142, 144, 146, 148, 150, 152 provide the resistor. Flow detection devices 148, 150, 152 provide the transistor in addition to the resistor.

(42) Each flow detection device installs on a nozzle. The flow detection devices detect whether the liquid flows from the nozzle to which the flow detection device is attached. In one embodiment, each flow detection device detects clogs on a single nozzle.

(43) Flow indicator 118 alerts the user whether or not sufficient liquid is flowing from the nozzle to complete the circuit. In one embodiment, the indicator is a visual indicator, such as a light or LED. The flow indicator 118 may be positioned on a monitor, on the housing, or within the housing.

(44) FIG. 14 shows the monitor 154 with indicators, such as alert indicator 124 and power indicator 128. Monitor 154 provides multiple indicators to indicate that the system is powered on and whether a clog is detected.

(45) A power indicator indicates that the system is powered on. Alert indicator 124 indicates that an individual nozzle is properly functioning. The alert indicator 125 indicates that a nozzle is clogged and not functioning properly. The monitor 154 identifies any nozzles that are not functioning properly. The user can easily identify the nozzle to be examined. The user can then locate and repair the nozzle and continue spraying.

(46) FIG. 14 also shows that alert flow indicators 118, 124 are powered on to indicate no clog at detection devices attached to a particular nozzle. The nozzle is functioning properly and liquid is properly flowing.

(47) The monitor may have a wired connection with the flow detection devices. The monitor may also be a wireless monitor. The monitor has been shown with individual lights that alert the user. The system may also be implemented with a program that provides digital display with touch screen capabilities. A second monitor may also be connected to allow supervision of the system.

(48) FIGS. 15 and 16 show different embodiments of the nozzle detection device. One embodiment provides two conductors 106, 108 that form an incomplete circuit as shown in FIG. 15. The two conductors 106, 108 conduct electricity but do not contact each other. The conductors are stored within housing 156. The conductors 106, 108 extend radially inward towards housing aperture 158. Foam 160 located within the housing cushions the nozzle to reduce damage to the nozzle.

(49) Another embodiment shown in FIG. 16 provides a first detection body 162 providing a set of three conductors that contact each other and a second detection body 164 providing a set of three conductors that contact each other. The conductors of each detection body conduct electricity. The conductors of the first detection body do not contact the conductors of the second detection body. The conductors of the first detection and the conductors of the second detection body form an incomplete circuit with each other.

(50) The flow of the spray fluid completes the circuit between the two detection bodies. Similarly, the flow of the spray fluid completes the circuit between the two sets of conductors. The conductors are configured to detect clogs with minimum effect on the spray pattern and droplet size.

(51) The alert indicators indicate whether a clog is detected. The visual alert indicators alternate between a clog alert and an unclogged alert. To distinguish between the clog alert and the unclogged alert, the system may use a flashing light, different colored lights, power on the indicator, or power off the indicator. In one embodiment, the system lights the indicator if a clog is detected. In another embodiment, the system lights the indicator if no clog is detected. The system can be developed according to the user's preferences.

(52) The system has also been described with indicators, such as a visual or audible indicator. In another embodiment, a sensor may be implemented as the indicator. The sensor detects whether the circuit across opening 120 is open or closed. If the circuit across opening 120 is open, a clog has been detected as insufficient liquid flows across opening 120 between conductors 106, 108.

(53) The system may also provide data logging. Such data logging can include which nozzle clogged, position at which the nozzle clogged, position at which the nozzle was repaired. Such data logging allows the user to pin point the areas at which the liquid was not applied.

(54) The system may also provide real-time analysis of efficiency and economic impact.

(55) The clog detection system may also be implemented to automatically turn on and off with activation of the sprayer's pump.

(56) Future modifications and/or additions to the NCDD and NCDS will be implemented. These improvements will increase performance and efficiency, incorporate automation, and enhance user-friendliness. Such improvements, include but are not limited to: detecting partial clogging; and adopting a lightweight and durable power source for the standalone models (A1 and B1).

(57) From the foregoing, it will be seen that the present invention is one well adapted to obtain all the ends and objects herein set forth, together with other advantages which are inherent to the structure.

(58) It will be understood that certain features and sub-combinations are of utility and may be employed without reference to other features and sub-combinations. This is contemplated by and is within the scope of the claims.

(59) As many possible embodiments may be made of the invention without departing from the scope thereof, it is to be understood that all matter herein set forth or shown in the accompanying drawings is to be interpreted as illustrative and not in a limiting sense.