Method and apparatus for detecting a plugged nozzle of a sprayer

1. For use with a nozzle of an agricultural sprayer that dispenses a fluid from a fluid source onto an application surface, the improvement comprising:

a thermal flow sensor disposed within the nozzle at a location upstream of an outlet orifice of the nozzle and substantially within a fluid flow path defined by and within the nozzle, the thermal flow sensor:

including upstream and downstream flow sensor elements for measuring the temperatures of the fluid flowing therepast; and

generating an output signal in response to the difference between the temperatures measured by the upstream and downstream flow sensor elements;

a heating element disposed between the upstream and downstream flow sensor elements for heating the fluid flowing therepast;

an alert remote from and communicatively linked with the thermal flow sensor, and configured to convey a status of the thermal flow sensor as fluid is being dispensed from the outlet orifice; and

wherein the alert provides an indication notifying an operator that the flow through the nozzle is obstructed in response to the output signal varying from a threshold.

2. The improvement of claim 1 wherein the sensor is made of a metal.

3. The improvement of claim 2 wherein the sensor is made of a rust-resistant, corrosion-resistant material.

4. The improvement of claim 3 wherein the sensor is made of stainless steel.

5. The improvement of claim 1 wherein the alert is located in an operator cab.

6. The improvement of claim 5 wherein the alert illuminates when the velocity of fluid through the nozzle is below the preset limit.

7. The improvement of claim 1 wherein the sensor and the alert are configured to determine and indicate a plugged nozzle without requiring operator inspection of the orifice outlet.

8. A nozzle for an agricultural sprayer, comprising:

a nozzle body having an inlet for receiving fluid from a fluid source and an outlet for spraying fluid onto an application surface, and wherein a fluid path is defined between the inlet and the outlet;

a thermal flow sensor aligned in the nozzle body and in the fluid path, the thermal flow sensor including first and second flow sensor elements for monitoring fluid flow through the nozzle body and providing a clogged nozzle output signal when fluid flow through the nozzle body falls below a preset velocity; and

a heating element disposed between the first and second flow sensor elements for heating the fluid flowing therepast.

9. The nozzle of claim 8 wherein the sensor has an output lead connected to a remote alert system, and wherein the sensor transmits the clogged nozzle output signal on the output lead to the remote alert system.

10. The nozzle of claim 9 wherein the sensor is made from a corrosion-resistant material.

11. The nozzle of claim 10 wherein the sensor is made from stainless steel.

12. The nozzle of claim 9 wherein the sensor is free of moving parts.

13. A plugged flow warning system for a farm implement having a sprayer that sprays a fluid through a nozzle onto a surface, the system comprising:

an alert in the operator cab that changes states in response to an output signal;

a thermal flow sensor located within the nozzle, the thermal flow sensor:

including first and second flow sensor elements for monitoring fluid flow through the nozzle; and

being operative to output a flow condition signal in response to the fluid flow through the nozzle as determined by the first and second flow sensor elements;

a heating element disposed between the flow sensor elements for heating the fluid flowing therepast; and

a switch that provides the output signal in response to the flow condition signal.

14. The plugged flow warning system of claim 13 wherein the alert is an audible alert that is sounded in response to the output signal.

15. The plugged flow warning system of claim 13 wherein the alert is a light that illuminates in response to the output signal.

16. The plugged flow warning system of claim 13 wherein the thermal flow sensor is free of moving parts.

17. The plugged flow warning system of claim 13 wherein the thermal flow sensor is formed of stainless steel.

18. The plugged flow warning system of claim 13 wherein the thermal flow sensor is made from corrosion-resistant material.