SpraySense

Sprayer Demo.mp4

SpraySense was a capstone project sponsored by Tandem Grove Farms, focusing on automating existing agriculture sprayers to improve efficiency and precision. This project involved developing a sensor system that can be retrofitted onto any of our client's sprayers. The sensor system connects to a microcontroller, allowing for the automatic activation of the sprayers when necessary.

Designed on a $5,000 budget, this system will perform comparably to integrated automated solutions that typically cost upwards of $300,000. My contribution to this project focuses on creating a microcontroller-based control system, various software development, and project documentation.

This project is still in progress, but I've achieved significant milestones in developing the electrical and software components. Watch the video on the left to see one of the sprayers in action; is it clear why automation would make such a difference?

Problem Statement

Smaller farms and orchards often can't justify the high cost of automated equipment, like agricultural sprayers, due to lower yield quantities. As a result, manual operation requires greater attention to detail, increases working time, and leads to wasted consumables. SpraySense, a retrofittable automation package, addresses this challenge by enabling automation on any agriculture sprayer at a fraction of the cost.

This project originated from MECH 45X, and allowed me the opportunity to explore various disciplines. I worked with electromechanical components like ultrasonic sensors, electrical components like microprocessors and PCBs, and software like C-based Arduino. Additionally, I strengthened my teamwork skills by collaborating effectively with my peers to deliver promising results for our client.

My Role & Significant Contributions

My role within this project focused mostly on the software and electrical aspects. My two largest milestones were:

developing C-based firmware for an Arduino Uno R3 to function as a control system. This included:
- processing states of various manual inputs, like switches and rotary encoders.
- handling data from digital inputs, including multiple ultrasonic sensors and potentiometer dials.
- controlling the agricultural sprayers via solenoid valves and dynamically enabling/disabling LEDs based on sensor inputs and system logic.
technical writing and documentation for an effective handoff to our client. This included:
- an extensive proposal report outlining a market assessment, requirements and evaluation criteria, and a detailed work plan covering the project scope and budget.
- regular project update presentations, effectively communicating progress and next steps to the client.
- comprehensive technical documentation for handoff, such as visual work instructions for setup, operation, and disassembly, software specifications, and engineering design documents such as CAD files and drawings.

Current Work

Controller Demo.MOV

Currently, this project is in the rollout phase, with all deliverables handed to our client. By maintaining open communication, I can continue to refine the solution as he gains valuable feedback over time.

On the left is a video demonstrating the controller's current logic! Every time a new component gets integrated, we systematically test and verify its behavior within the overall control system. Real-world testing ensures that every scenario our client may encounter has been anticipated and addressed by our team.

Technical Details

SpraySense integrates mechanical, electrical, and software subsystems to automate agricultural sprayers. Here's how it works:

Mechanical Mounting: Sensor mounts are installed on the agricultural sprayers, ensuring stable positioning of the sensors without excessive displacement or angle variations. These mounts can be installed to detect various targets, such as crops or weeds.
Electrical Integration: The sensors and agricultural sprayers are electronically wired to a central controller, which houses the microcontroller and control logic. All electrical components share the tractor as a common power source, which is stepped up or down depending on the voltage needed.
Dynamic Control System: As the operator moves through the field, sensors detect for targets. Based on the system inputs and logic, the control system actuates the sprayer's solenoid valves, optimizing efficiency and precision. The operate can change the system parameters in real-time by adjusting knobs and switches on the central controller.
Automated Actuation: The control system will enable or disable the sprayer's valves based on multiple data points, such as the distance of the current detection and the amount of time elapsed since the last detection. This ensures that spraying occurs only when necessary, reducing consumables and improving accuracy.

This complex system demonstrates the integration of multiple engineering disciplines, showcasing real-time control, automation, and precise electromechanical design.

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