Highlights Electric air assist system was developed with electric fans, pulse width modulation (PWM) controllers, a custom-designed air channel, and a battery. Adjusting PWM duty cycles from 0% to 100% achieved average exit air velocities from 0 to 11.3 m s^-1. Spray applications with the system at 50% and 70% power achieved canopy pass through spray coverages from 4.1% to 19.9% and 14.2% to 24.2%, respectively. A multivariable regression model was developed to adjust air assist outputs based on tree canopy density and off-target loss. Abstract. Air assist for apple orchard spray applications is a necessity to deliver pesticides to target crops. However, conventional orchard sprayers use axial fans to provide air assists which are generally designed for tall crops. Thus, these systems have very limited capabilities to control airflows to match canopy densities. An electric air assist system (EAAS) was developed with an electric fans, pulse width modulation (PWM) controllers, a custom-design air channel, and a 400-Ah LiFePO₄ battery to address such limitations. The system could ramp up its airflow to nearly 80% of its maximum in 2.5 s, while it took approximately 4 s to reach 100% airflow from no air assist. The EAAS provided airflow of 11.3 and 5.3 m s^-1 at the fan outlet and 1 m away, respectively, with 100% duty cycles (DC) of PWM. It was capable of modulating its average air velocities from 0 to 11.3 ms^-1 by changing DCs. Spray coverage samples of constant rate applications with different air assist levels were collected from the behind apple tree canopies throughout the 2023 growing season to characterize the potential for off-target spray drift. A multivariable regression model for controlling DCs was developed with the spray coverage data and leaf area index (LAI) to minimize the off-target drift. The EAAS was a promising approach to developing more advanced air assist spraying systems to enable the adjustment of both air and liquid flows based on canopy characteristics to maximize spray depositions on intended targets while minimizing spray drift. Keywords: Air assisted sprayer, Automation, Crop protection, Fan, Penetration, Pesticide, Pulse width modulation, Variable air assistance.

Electrostatic spraying systems can improve the pesticide application efficiency by enhancing droplet deposition and coverage within crop canopies. This study evaluated the droplet size spectra and charge-to-mass ratio (CMR) of five electrostatically charged hollow-cone nozzles and one flat-fan nozzle paired with an electrode. Each nozzle was mounted on a moving boom in a wind tunnel and operated with the electrode and voltage that produced the highest CMR. Their effects on the spray coverage and deposition inside boxwood shrubs at wind speeds of 0 and 2.24 m s⁻¹ were assessed. The nozzles operated with the optimized electrode had average improvements in the canopy deposition and canopy coverage of 1.33 µg cm⁻² and 4.4% at a wind speed of 0 m s⁻¹ and 0.26 µg cm⁻² and 0.9% at a wind speed of 2.24 m s⁻¹. The airborne drift measurements at various heights above the wind tunnel floor showed an average 0.50 µg cm⁻² reduction in the drift at 0.1 m, variable results at 0.35 m, and minimal changes at heights of 0.7 m and above at a downwind distance of 2 m. These findings highlighted the potential of optimized electrostatic spraying systems to enhance pesticide deposition inside the crop canopy under various wind speeds while reducing the spray drift potential.

Although a pulse-width modulation (PWM) technique controls nozzle flow rate with minimal pressure variation, its effects on droplet size distribution and flow regulation when combined with low-drift nozzle designs are still not well documented. Therefore, the objective of this research was to investigate the effects of PWM on droplet size distribution and flow rate of low-drift nozzles used in pesticide application systems. Experiments were conducted under controlled laboratory conditions to evaluate eight flat-fan nozzles with different designs to increase spray droplet sizes. Each nozzle was coupled with a PWM valve, and tested at duty cycles (DUC) from 20% to 100% in 20% increments, and operating pressures of 276 and 414 kPa. Droplet size distribution was determined using a laser diffraction technique, and nozzle flow rate was evaluated to assess the effects of DUC on spray characteristics. PWM operation showed a strong linear relationship between DUC and flow rate (R² ≥ 0.99). In addition, measured flow rates showed good agreement with theoretical values at DUCs ≥ 60%, whereas substantial deviations were observed at lower DUCs. The effects of DUC on droplet size characteristics varied by nozzle design, pressure, and the parameter evaluated. Low DUCs tended to increase droplet size heterogeneity and the proportion of drift-prone droplets (<150 µm), although these effects were dependent on nozzle type and operating pressure and were not observed consistently across all nozzles. Overall, excessively low DUCs may compromise flow accuracy and spray quality in PWM systems.