Recipient Organization
INNOVATIVE SCIENTIFIC SOLUTIONS, INC
7610 MCEWEN RD
DAYTON,OH 45459
Performing Department
(N/A)
Non Technical Summary
The product being commercialized is a system for optimizing spray system performance on agrochemical application aircraft, commonly known as "crop dusters". Current technology allows applicators to precisely control their location and flight path (GPS guidance), to deal with changing temperature, humidity and wind conditions (Aircraft Integrated Meteorological Measurement System modules), and to control important properties of their chemical mixes. However, it does not allow them to monitor and control a key application parameter, spray droplet size. If the droplets are too small, they drift to unintended locations; if they are too large, plant coverage is poor.The EPA estimates that chemical drift losses exceed $200M annually. Drift litigation claims are also a multi-million-dollar annual cost. Crop loss, environmental damage, and human health costs are other significant impacts of poor droplet size control.This program will provide the missing link: real-time, in-flight, droplet size feedback. It will enable applicators to adjust system pressure and airspeed, in flight, to achieve the desired droplet spectrum. It will allow them to verify the effectiveness of between flight changes such as nozzle settings and chemical mixes. They can now "close the loop" on the key droplet size parameter. Automation of the control process may be possible in future product versions.The savings achieved in chemicals, time, litigation avoidance, and flexibility in optimizing chemical mixes will afford a payback time of less than one year. The product will be sold as an add-on to new systems or as a retrofit to existing systems. It will not impact the design, usage, or cost of other spray system and aircraft components.It will open a $25M market, in the U.S. alone, for our product distributor, Transland LLC. It will provide an opportunity for Innovative Scientific Solutions, Inc. (ISSI) to double our current annual commercial sales, with a projected gross annual revenue of $1.3M. Because of the maturity of the fundamental measurement system, we are structuring the program to begin commercial sales immediately after Phase II.The program involves collaboration with the USDA Aerial Application Technology Research Unit (USDA AAT); Transland LLC, the leading US supplier of agrochemical dispersal equipment; Dynanav Systems Inc., a provider of Ag aircraft guidance systems; and evaluators such as Andy Deterding Ag Aviation.
Animal Health Component
40%
Research Effort Categories
Basic
(N/A)
Applied
40%
Developmental
60%
Goals / Objectives
The overall goal of the Phase II program is to improve the efficiency and accuracy of aerial spray application by providing applicators with real-time droplet size measurements in flight. Real-time droplet size feedback will enable applicators to make in-flight and between flight adjustments to achieve the desired droplet spectrum, regardless of the composition of the chemical mixture or environmental conditions. During the Phase II program, this prototype system must be refined for general deployment in the agrochemical industry. Processing of image data must be integrated into the in-flight system to provide real-time droplet size measurements. These droplet size measurements must be delivered to the pilot in a user-friendly fashion. Finally, optimum procedures that allow pilots to refine droplet size in flight must be established. Only then will the overall goals of this program be achieved. With these tasks in mind, the following technical objectives have been defined for the Phase II program:Redesign the Particle Shadow Imaging (PSI)system to minimize the size of the LED/camera components and simplify deployment of the system to a broad range of aircraft and spray boom hardware.Integrate on-board control, capture, and analysis of the PSI image data to generate a real-time stream of droplet size data.Establish the accuracy of the Phase II PSI system using wind tunnel testing.Enable delivery of real-time droplet size data to existing Ag aircraft GPS-based guidance system displays.Use the Phase II system on the USDA AirTractor 402b to investigate practical in-flight droplet size control procedures using existing spray system pressure and airspeed adjustment capabilities.Establish best operational practices for using droplet size feedback from the Phase II system to refine the delivered spray droplet size.
Project Methods
Redesign the PSI system to minimize the size of the LED/camera components and simplify deployment of the system to a broad range of aircraft and spray boom hardware: The overall system, including the camera, data acquisition, LED, LED driver, and pulse generator, will be integrated into the mounting brackets and reside near the selected spray boom nozzle. A micro-PC will be located with the camera for data acquisition and processing. The LED driver will be paired with a pulse generator and mounted near the LED. This compact design will be made possible by redesigning the pulse generator, LED driver, and data acquisition system using compact modern electronics. The mounting hardware system will be redesigned to support deployment on any commercial boom with only the need for boom-specific mounting clips.Integrate on-board control, capture, and analysis of the PSI image data to generate a real-time stream of droplet size data: Data acquisition requires collection of camera image data at 10-30 Hz over GigE or USB3. Conversion of image data to droplet size in real-time is slightly more computationally intensive. Image processing includes a series of linear algebra processes such as computing a running average of images, subtracting this average from individual images, setting a threshold, detecting edges of in-focus particles, and blob analysis to estimate droplet size. The Jetson TK1 is a low-cost micro-PC that would support our requirements, having Ethernet and USB3 for communication and an array of GPUs for data processing. Custom software for the controller will be developed to communicate with the camera, collect data, and convert the data to droplet size distributions. Finally, the processed data will be streamed to the guidance system over Ethernet, wireless network, or Bluetooth.Establish the accuracy of the Phase II PSI system using wind tunnel testing: The accuracy and resolution of the Phase II system will be evaluated and established by acquiring droplet size data on several spray units in a wind tunnel at the USDA AAT facility. Here, data can be compared to several well-established measurements acquired using their "gold standard" Phase Doppler Particle Analyzer. It is noted that the PSI system will acquire data over a limited region of the spray pattern, and repositioning of the sensor in flight is not possible. The spray pattern from several nozzles at a range of operating conditions can be mapped out in the wind tunnel and the optimum position for in-flight data acquisition will be determined. This should also identify any potential interactions between the PSI system and the spray nozzle and reveal any potential aerodynamics issues associated with the in-flight system.Enable delivery of real-time droplet size data to existing Ag aircraft GPS-based guidance system displays: Aerial applicators already use combined GPS and spray control systems to paint targeted fields with a specific quantity of material. For maximum benefit, the droplet size system must be integrated into these existing GPS/spray systems to provide visual feedback to the pilot, who can then adjust the spray pressure and airspeed as needed to tune the droplet size. Integration of the system into the aircraft guidance and control system will be accomplished through a cooperative agreement between Dynanav and ISSI. Dynanav currently manufactures and sells the Vektor series of light bar guidance systems and has offered to collaborate with ISSI in the integration of the droplet size measurement system into their guidance system. While the initial integration procedure will focus on the Vektor package, the development process will be expanded later to allow integration into any commercial guidance system.Use the Phase II system on the USDA AirTractor 402b to investigate practical in-flight droplet size control procedures using existing spray system pressure and airspeed adjustment capabilities: The prototype Phase II system will be deployed at the USDA AAT research station on the AirTractor 402b. Droplet size data will be acquired over a matrix of test conditions, already established by the USDA AAT, including airspeed, spray pressure, and chemical composition, that simulate real-world application of agrochemicals. Several rounds of testing will be conducted by the USDA team.Establish best operational practices for using droplet size feedback from the Phase II system to refine the delivered spray droplet size: Using the data from both existing and new wind tunnel testing, as well as data collected in flight from this program, it should be possible to establish correlations between airspeed, spray pressure, and droplet size. This relationship is already well-established for wind tunnel testing; the goal here is to incorporate this existing knowledge with in-flight measurement of droplet size, to allow the pilot to tune droplet size between passes over the field. We envision a simple initial input from the applicator, for example, a target droplet size (Dv10, Dv50, Dv90) distribution that is fed to the guidance system or PSI system. Using these targets, combined with the airspeed/pressure/droplet size correlations, a refined operating point can be fed to the pilot. The data can then be refined on each pass toachieve the targeted droplet distribution.Product marketing: Aerial applicator acceptance will be significantly enhanced by USDA AAT involvement in the development of the droplet measurement system. Applicators consider this group their "dedicated" research team. It is completely appropriate for the USDA research team to produce technical reports describing best practices for using in-flight droplet measurements. This team cannot, however, participate in direct marketing and sales of the commercial system. This role will largely belong to Transland LLC and their dealer network. For product introduction and initial marketing, Transland will emphasize the use of Fly-Ins. These events will include the measurement system mounted on an aircraft, spray pattern demonstrations, presentations by industry experts, and often CEUs for applicator participants. In addition, Transland and ISSI will utilize our websites, product brochures, and trade show participation as marketing and sales tools. Once the effectiveness of the system is demonstrated, ISSI and Transland will approach chemical manufacturers and insurance providers to include this technology in their recommended "best practice guidelines". A chemical label statement such as the following would serve to incentivize sales: "One means to ensure compliance with our droplet size recommendation is use of an in-flight droplet measurement system." Marketing activities and expenses will be borne by ISSI and Transland, outside of the SBIR funding.