Recipient Organization
APPLICATION INSIGHT, LLC
2519 WILSON AVE
LANSING,MI 489062737
Performing Department
(N/A)
Non Technical Summary
Aerial application is limited in its productivity by the inability to produce low-drift sprays above certain speeds. Regardless of the nozzle, higher airspeeds result in finer droplets and more spray drift, both highly undesirable. Airplanes could apply spray faster in many conditions if such hardware existed, which would increase profit and improve the productivity of each airplane.The ultimate vision of this project is to reduce spray drift from aerial applications while significantly increasing the efficiency and profitability of aerial applicators. Our product will do this by decreasing the drift potential of sprays, allowing faster application rates, increasing the productivity within weather windows in which spray can be applied, and improving the precision of applications. These improvements could yield 15% increases in productivity and revenue per aircraft.This project will achieve these objectives through the development of a scalable, multi-pump, electric drive, high-pressure aerial chemical delivery system (HPACDS), designed to mount on piloted, fixed-wing or rotary-wing aircraft, and potentially larger unmanned aerial vehicles. This system will give an applicator superior operational control over droplet size by delivering higher spray pressures than anything currently commercially available in aerial spray application systems. The designed flow range will be appropriate for the application rates of most, if not all, aerial agricultural and forestry spray applications.
Animal Health Component
50%
Research Effort Categories
Basic
(N/A)
Applied
50%
Developmental
50%
Goals / Objectives
This project will develop a scalable, multi-pump, electric drive, high-pressure aerial chemical delivery system (HPACDS) that is designed to mount on piloted, fixed-wing or rotary-wing (helicopter) aircraft, and potentially larger unmanned aerial vehicles (UAVs). This system will give an applicator superior operational control over droplet size by delivering higher spray pressures than anything currently commercially available in aerial spray application systems. It will be able to maintain flow ranges appropriate to the application rates of most, if not all, aerial agricultural and forestry spray applications.Objective 1:Discussions with potential CPs and numerous in-person applicator interviews concluded that the Phase I system required modifications in Phase II to meet market expectations, including:Common spray nozzles supplied with new spray aircraft require a maximum total flow of up to 100 gpm on larger aircraft. This is higher than assumed in Phase I. Given a five pump system on a large aircraft, each pump would require approximately 20 gpm each. The Phase I design yielded approximately 18 gpm while over-speeding the motor from design specifications. Larger pumps of a similar style are available and those designs will be used to meet the required commercial flow rate.The preferred power supply is the onboard system 24V DC. Conversations with numerous applicators and potential CPs affirmed the strong dislike of adding hot swappable 44V auxiliary batteries, a phase 1 design objective. Connecting the pumping system to the on-board power systems will require an Electrical Usage Study to meet FAA compliance requirements. Commercial prototype systems will be designed carefully to be able to meet FAA safe power draw and other engineering requirements.Suck-back capability must be part of the final design. Vacuum on the spray booms minimizes the chances of off-target drips during between-pass turns and transport between the target and airport and is required by applicators.Control interface between the computer rate controller and the pump stack needs to be developed.Objective 2:Optimize the electronic control strategies, configurations and parameters necessary to meet the spray application and running performance requirements of third-party control systems.There are two levels of system control that need to be optimized. The primary level, mentioned in TO 1, is the actual internal control of the motors that drive the pumps to provide optimal spray performance and high-precision applications. These are divided out as control phases below. The secondary level is the interface between the third-party onboard rate controller (such as Capstan or Insero's control systems) and the HPACDS.Objective 3:Is the pump module system sufficiently robust to meet user expectations? How frequent will maintenance or break-downs occur with the pump module system? Can maintenance be minimized, deferred, or eliminated until regular annual aircraft maintenance occurs?Annual aircraft maintenance is an FAA requirement and good common sense. A well-designed modular pump system would operate without failure and not require maintenance until routine maintenance is carried out on the aircraft itself. An appropriate design goal would be for the pumping system to operate for one "spray application-year" with more than 99% uptime between regular annual maintenance on the aircraft. Technical Objective #3 seeks to quantify the long-term performance of the system through repetitive cycle tests under simulated field application conditions and resolve any design or component limitations that would result in system failures between routine annual aircraft maintenance.
Project Methods
Determine Pump Design: The pump must achieve 20 gpm at 150 psi and be lightweight. The Phase I roller pump configuration meets the mechanical design requirements, but does not meet the updated flow requirement and is not optimized for weight. Successful completion of this step may occur by either of the two following methods:Sourcing the motor: A 24 or 30 pole motor would provide an output speed better matched to the needs of the pump. That would possibly eliminate the need for gears or belts and pulleys, however, these power transmission devices still may be desirable to optimize motor placement in the mechanical design. An ESC will be selected to match the motor performance specifications, with emphasis placed on current draw and efficiency. During this design step we will also work with the commercialization partners to make sure that the input-output capabilities are compatible with their control system needs.Initial electrical performance estimations of the system will be shared with CPs and Turbine Conversions so they may begin the work associated with the FAA power consumption studies. Success Criterion: Components meeting the engineering needs are sourced and or designed and internally manufactured. Successful completion of Task 1 will partially address Technical Objective 1 by yielding a pump, gearing ratio, motor, and speed control combination that meets all performance requirements.Task 2: Design & construct the modular system?All design work will be completed using Solidworks CAD/FEA/CFD software. Designs will be evaluated internally and cooperatively with Turbine Conversions and CPs prior to manufacturing the prototype system.Success Criterion: Remaining design integration details from Technical Objective 1 are resolved yielding the mechanical electrical and fluid systems that make up the complete individual modular pump assembly and multi-module pumping system. The system design is ready for fabrication/construction.Task 3: Construct prototype systemControl system tuning, performance evaluation, and durability tests cannot occur without a functional prototype. In Task 3, the mechanical design, as determined by Tasks 1 and 2, will be manufactured and assembled into a functional prototype. Initially, a single, five module prototype system will be produced. This will allow for tuning and initial evaluation of performance. Additional multi-module systems may be assembled to expedite testing in Tasks 4 and 5 if deemed necessary.Success criterion: a fully functional modular pump system prototype satisfying the parameters and requirements identified in TO 1.Task 4: Optimize the control cycleAs discussed in Technical Objective 2, for each operating phase during a spray cycle, the appropriate control strategy must be selected. To accomplish this, the following test steps will be utilized:For each phase, multiple control strategies will be testedFor each control strategy, the time required to achieve steady-state will be measured, as will be the pump and motor performance. Measured parameters include response time, steady-state time, motor and pump rpm, pressure, flow, voltage, current, fluid power, electrical power, and system efficiency. Measurement methodologies will be replicated from those used in Phase I, with the exception of improved rpm, flow, and pressure sensors. These will be measured using speed controller parameters, a high speed camera system to measure system response, and an independent data collector for external rpm, pressure, and flow sensors.The performance results will be evaluated using operational parameters as would be seen if used in the expected commercial application strategy to determine which control method best satisfies the requirements of each control phase.A series of pump control algorithms will be developed to reflect 3 primary modes of operation, each of which having unique use parameters:single spray pass,turns between passes,transport to and from the application site.Each algorithm will utilize a sequential series of control methods for each phase of the pump operation, accordingly. These algorithms will reside in a custom-designed, pump control system to operate and monitor the entire modular pump system.? Success Criterion: Completion of the following: an optimized control algorithm for the high-performance operation of individual pump modules and, cumulatively, as a complete modular pumping system. This satisfies Technical Objective 2.Task 5: The pump module will be connected to a laboratory mock-up of the aircraft spraying systemAn rpm sensor, flowmeter, and one or more pressure sensors will be mounted on the system to monitor system performance. As in Task 4, the sensors will be selected and installed in a manner to minimize influences or disturbances compared to the commercial installation.An algorithm will be developed to synchronize data collection efforts with the control system. The algorithm will simulate spray passes as experienced in application, including periods of no spray, spray, and suck-back. The algorithm may also be developed to utilize real-world data, such as that recorded by a spray rate controller and played back to the pump control system. This data may be provided by one or more of our commercial partners.?Data will be analyzed to determine if and how the system performance changed over time. This will include changes in pressure, flow, and system responsiveness. Any mechanical or control system failures will be evaluated to determine the root cause and improvements iterated, if deemed necessary.A review of the performance and design improvement recommendations will determine if the modifications are critical for success. If so, the modifications will be implemented and lifecycle testing will be resumed or restarted, depending on the level of modification. Once the design achieves the goal of more than 1 year of mean time between failure, the design will be approved for production, as coordinated with CPs.?Task 6: Integrate into an aircraft for in-situ testing.The system design will include:A mechanical system to support multiple pump modules on the aircraft structure in an aerodynamic housingPlumbing to connect the existing tank supply to the pumping system input and plumbing from the pumping system output to the multiple independent spray bars across the wingspan.An electrical power connection system to supply power to the pump control system components based on the demands developed over the course of the projectIntegration into their existing controller wiring.Once installed, the system will undergo mechanical, electrical, and safety evaluations by Turbine Conversions then will undergo test flights and subsequent evaluations.In situ testing will include:synchronized and timed high speed video to determine the in-situ lag between system actuation and actual release of spray.Instrumentation of the boom to log pressure over time during the swaths. Variation between boom and system pressure will be logged, and lag time if necessary.Visual inspection of the structure and components after flights. If failures occur, iterate and re-test.Success Criterion: The Prototype is installed in the airplane and missions are flown with successful spray application. No major failures occur in operation. on/off lag times are similar to those seen in bench testing. Simultaneously, Application Insight will begin preparations for the manufacturing and assembly of the modular pump systems for delivery to the CPs. This will involve working with partners and in-house efforts to manufacture the electrical and mechanical components. During the transitions, Application Insight will develop assembly, programming, testing, and quality control steps. When complete, a manufacturing work plan will be developed and executed to deliver fully assembled, field-ready modular pumps to the CPs.