Automated Spray Automated Spray PatternatorPatternator

Kevin M. Agnew Greg BarberKevin M. Agnew Greg Barber

David RubinDavid Rubin

Team 14Team 14

Design Concept ReviewDesign Concept Review

• BackgroundBackground

• Customers:Customers:

– wants, constraints

• Mission StatementMission Statement

• Benchmarking:Benchmarking:

– system

– functional

• Metrics / Target ValuesMetrics / Target Values

• Generated ConceptsGenerated Concepts

• Concept SelectionConcept Selection

• BudgetBudget– material and equipment

– engineering hours

BackgroundBackground

• Spray nozzles are used to apply a fluid onto a Spray nozzles are used to apply a fluid onto a surfacesurface

• Each nozzle has a certain distribution patternEach nozzle has a certain distribution pattern

Spray Nozzle

Fluid

BackgroundBackground• Spray patterns of adjacent nozzles overlap Spray patterns of adjacent nozzles overlap

• This overlap region can be used to provide This overlap region can be used to provide a more uniform spray distributiona more uniform spray distribution

• A spray patternator allows the spray A spray patternator allows the spray distribution to be observeddistribution to be observed

Spray Nozzle Spray Nozzle

FluidFluid

Project InformationProject Information• Customers :Customers :

– Larry Gaultney

– Ted Lang Dupont Agricultural Research Team

– James Davis

• Mission StatementMission Statement– To develop and test an automatic spray patternator with high

accuracy, improved resolution, a minimal amount of human error, test reset time, and allowing superior flexibility.

System InformationSystem Information

• VideoVideo

• System ComponentsSystem Components– nozzle

– spray table

– collection tubes

• Deficiencies of current DuPont Patternator:Deficiencies of current DuPont Patternator:– Low Accuracy - High Reset Times

– Insufficient Resolution - Human Error

– Limited To One Nozzle (insufficient size)

Prioritized WantsPrioritized Wants

1. Provide All Desired 1. Provide All Desired OutputsOutputs

2. Automated Data 2. Automated Data Collection SystemCollection System

3. Observe interaction of 3. Observe interaction of 2 or more Nozzles2 or more Nozzles

4. Comply with 4. Comply with Hardware/Software Hardware/Software StandardsStandards

5. High Accuracy and 5. High Accuracy and ResolutionResolution

6. Run on Tap Water6. Run on Tap Water

7. Be able to test 110° 7. Be able to test 110° nozzlesnozzles

8. Modular Design8. Modular Design

9. Accurately Locate 9. Accurately Locate Nozzle PositionNozzle Position

10. Mobile within Lab10. Mobile within Lab

ConstraintsConstraints

• 54” Door Width54” Door Width

• Safety Guidelines - OSHASafety Guidelines - OSHA– Allowable Weight:

• 200 lbs./person (Max. Push/Pull Weight)

• Senior Design Project ScheduleSenior Design Project Schedule

System BenchmarksSystem Benchmarks

• Current DuPont Spray PatternatorCurrent DuPont Spray Patternator• Hardi Inc.Hardi Inc.

– Field Patternator

– Laboratory Patternator

• Transportable Spray PatternatorTransportable Spray Patternator– (Patent)

• Spray Systems Co.Spray Systems Co. – Laboratory Patternator Hardi Field Patternator

Functional BenchmarkingFunctional Benchmarking

Collection SoftwareCollection SoftwareLabView

Measure

Image Pro Plus

Fluid SupplyFluid SupplyPressure Regulator

Pressure Transducer

Solenoid Valves

Reservoir

Data Collection MethodData Collection MethodLaser Imaging

Flow Rate

Float Level Sensor

Water Sensitive Paper

Table DesignTable Design Current DuPont table design

V-grooved table

Quality Metrics / Target ValuesQuality Metrics / Target Values

Initial Design ConceptsInitial Design ConceptsData Collection DesignData Collection Design

FunctionFunction: : To measure water distributionTo measure water distribution

• Level Detection (Using graduated cylinders)Level Detection (Using graduated cylinders)– Manual Reading– Pressure Sensors– Laser Imaging

• Flow DetectionFlow Detection– In-Line Flow Meters

• Image AcquisitionImage Acquisition– Filter Paper

Flow Meter

Initial Design ConceptsInitial Design ConceptsTable and Water Collection DesignTable and Water Collection Design

FunctionFunction: : To capture water being sprayed from nozzle and To capture water being sprayed from nozzle and separate into measurable quantitiesseparate into measurable quantities

• 2-Dimensional Design2-Dimensional Design– V-Grooved Table Top– Square Channels (dividing walls)

• 3-Dimensional Design3-Dimensional Design– Flat Table (Filter Paper design) – Honeycomb

Initial Design ConceptsInitial Design ConceptsWater Supply SystemWater Supply System

• ReservoirReservoir– Water Tank– Tap

• Pressure SystemPressure System– Water Pump– Air Pressure Source with Regulator

• Test Stop SystemTest Stop System– Solenoid Valves– Cylinder Covers

FunctionFunction: To supply pressurized water to the nozzles: To supply pressurized water to the nozzles

Concept SelectionConcept Selection• Water Pressure SystemWater Pressure System

– Pressure Pot• air readily available• pressure can be regulated

– Solenoid Valves• acts as automatic shut-off• eliminates residual spray

– Dial Pressure Gauge• inexpensive• simplifies design

Concept SelectionConcept Selection• Table/Frame Design:Table/Frame Design:

– Square Channels With Aluminum Dividing Walls• 2.5cm spacing of walls gives desired resolution• low cost for HDPE table material• narrower, square channels reduce splashing

– 2’ PVC Collection Tubes (0.602” ID)• allows for the use of pressure sensors• holds >100ml of fluid• clear piping allows user to see fluid level

– Aluminum C-Channel / Square Stock• Provides structural support

Concept SelectionConcept Selection

• Data Acquisition SystemData Acquisition System– Pressure Sensors (80)

• high accuracy (0.5mL)• relatively inexpensive ($17.45/ea.)• allows for simpler design of water

supply system

Concept SelectionConcept Selection• Collection SoftwareCollection Software

– LabView• compliant with DuPont software/hardware standards

Test ResultsTest Results

• Continuity/Sensor Integrity Checks: Continuity/Sensor Integrity Checks: SatisfactorySatisfactory• Calibration Check of Pressure Sensors: Calibration Check of Pressure Sensors: .5ml .5ml• Collection Tube Leakage Test: Collection Tube Leakage Test: No leakageNo leakage• Software Operation: Software Operation: SatisfactorySatisfactory• Pattern Check:Pattern Check: SatisfactorySatisfactory• Test Reset TimeTest Reset Time :: 3 min (est)3 min (est)• Water Supply System Operability:Water Supply System Operability: SatisfactorySatisfactory

BudgetBudget• Shop ExpensesShop Expenses

– Time(40 man-hrs)– Materials

• Data Acquisition SystemData Acquisition System– National Instruments hardware

and software– Pressure Sensors

• Structural MaterialsStructural Materials– aluminum C-channel/square

stock– HDPE sheet

• Water SystemWater System– Reservoir– Regulator/Gauges– Solenoids Valves– Tubing

$2,400.00$2,400.00

$10,759.81$10,759.81

$2330.08$2330.08

$269.29$269.29

Total = $15,759.18Total = $15,759.18

Team Engineering HoursTeam Engineering Hours

Task Man - HoursTable Design 440

Software Design 90

DAQ System Setup 120

Sensor Calibration 8

Table Construction 25

Final Table Assembly 30

Sensor Installation 3 (est)

SummarySummary• Final DesignFinal Design

– 80 graduated cylinders w/pressure sensors– Square collection channels– Pressure pot water supply w/solenoid valves– LabView for data acquisition

• Total CostTotal Cost– $15,759.18

• Remaining TasksRemaining Tasks– Attach remaining components to frame– Test reset time

Question and AnswerQuestion and Answer