Field Sprayer with Application Rate Control Using Fast Response Proportional Valves under Variable Speed Conditions

Abstract

In modern agriculture, which is characterised by dynamic field environments, challenges are faced in maintaining consistent application rates due to varying tractor speeds, field conditions, and certain calibration errors. Conventional control systems, which rely on slower valves, have difficulty adapting to these dynamic field conditions. By contrast, the integration of fast-acting proportional valves improves the precision and flexibility of flow rate adjustment during spraying applications. This research focused on evaluating the accuracy of spraying applications under different tractor speed conditions through field experiments and data analysis. This study involves a field sprayer with boom wings divided into right and left sections, where the flow rate of the liquid to each section is controlled by proportional valves with a 3 s full opening and closing time, dependent on speed information. Using a closed-loop control system consisting of a flow meter, proportional valve, and PLC, the valves are controlled by the PLC’s internal PID blocks. Observations reveal that as the tractor speed increases to a certain level, the system effectively adjusts the application rate close to the target value and maintains control against the changing ground speed during all field tests. The study included five different application tests, with target application rates of 100, 150, 200, 250, and 300 L ha⁻1, with each repeated three times, resulting in a total of 15 field tests at different ground speeds. During these tests, the data were meticulously recorded every second, covering the tractor speed, flow rate, and pressure values for both right and left boom sections, along with regulator pressure, proportional valve opening rates, and application rates. The durations for each application rate were documented alongside instances within specified periods where error boundaries of ±10% were exceeded. During the total test duration of 9734 s, the actual application rate value exceeded error boundaries during only 209 s. Within the application durations, the speed variation intervals ranged from 5.10 to 10.23 km h−1, 4.64 to 9.91 km h−1, 3.68 to 7.89 km h−1, 4.80 to 8.21 km h−1, and from 4.90 to 8.69 km h−1. The absolute percentage mean application errors were recorded as 2.81%, 2.68%, 2.28%, 2.14%, and 2.51% for respective application rates. Furthermore, statistically significant correlations (p < 0.01) were identified among the variables (speed, valve opening rate, flow rate, pressure) in both the right and left boom sections across all application rates.