To address the technical problems of broad droplet size spectrum, insufficient atomization uniformity, and spray drift in plant protection unmanned aerial vehicle (UAV) applications, this study developed a novel two-stage aerial electrostatic spraying device based on the coupled mechanisms of hydraulic atomization and electrostatic induction, and, through the integration of three-dimensional numerical simulation and additive manufacturing technology, a new two-stage inductive charging device was designed on the basis of the traditional hydrodynamic nozzle structure, and a synergistic optimization study of the charging effect and atomization characteristics was carried out systematically. With the help of a charge ratio detection system and Malvern laser particle sizer, spray pressure (0.25–0.35 MPa), charging voltage (0–16 kV), and spray height (100–1000 mm) were selected as the key parameters, and the interaction mechanism of each parameter on the droplet charge ratio (C/m) and the particle size distribution (Dv50) was analyzed through the Box–Behnken response surface experimental design. The experimental data showed that when the charge voltage was increased to 12 kV, the droplet charge-to-mass ratio reached a peak value of 1.62 mC/kg (p < 0.01), which was 83.6% higher than that of the base condition; the concentration of the particle size distribution of the charged droplets was significantly improved; charged droplets exhibited a 23.6% reduction in Dv50 (p < 0.05) within the 0–200 mm core atomization zone below the nozzle, with the coefficient of variation of volume median diameter decreasing from 28.4% to 16.7%. This study confirms that the two-stage induction structure can effectively break through the charge saturation threshold of traditional electrostatic spraying, which provides a theoretical basis and technical support for the optimal design of electrostatic spraying systems for plant protection UAVs. This technology holds broad application prospects in agricultural settings such as orchards and farmlands. It can significantly enhance the targeted deposition efficiency of pesticides, reducing drift losses and chemical usage, thereby enabling agricultural enterprises to achieve practical economic benefits, including reduced operational costs, improved pest control efficacy, and minimized environmental pollution, while generating environmental benefits.

The electrostatic spray technology can significantly improve the utilization rate of liquid medicine under the operation characteristics of unmanned aerial vehicles (UAVs) with small load and low spray volume. To explore the settlement law of electrostatic droplets, further improve the amount of droplets deposited in target crops, and reduce the loss of missing target, this study adopted the method of combining numerical simulation and high-speed photography to study the movement characteristics of electrostatic droplets of UAV induction conical electrostatic nozzle. Based on the droplet spatial dynamics theory, a user-defined function and volume of fluid (UDF-VOF) multiphase spray model is established to simulate the trajectory of electrostatic droplet. TEMA software is used to analyze the droplet motion image under electrostatic field, and the characteristic parameters, such as trajectory and velocity are obtained. Theoretical analysis and spray test results show that the main factors affecting electrostatic droplet settlement are charging voltage, droplet falling distance, and airflow velocity. The optimal charging voltage of electrostatic droplet is 14 kv, the maximum charge-mass ratio is 1.04 mC/kg, and the average particle size is 209.77 μm. The numerical simulation results show that spray height, charging voltage, and lateral wind speed have significant effects on droplet sedimentation. The results of high-speed camera analysis show that the induced electric field causes the droplet to adsorb the target crop, resulting in the droplet movement trajectory deflection.

Spraying is currently one of the main methods of pesticide application worldwide. It converts the pesticide solution into fine droplets through a sprayer, which then deposit onto target plants. Therefore, in the process of pesticide application, improving the effectiveness of spraying while minimizing or preventing crop damage has become a key issue. Combining the advantages of electrostatic spraying technology with the characteristics of ground boom sprayers, a contact-type electrostatic boom spraying system based on a rod–plate electrode structure was designed and tested on a self-propelled boom sprayer. The charging chamber was designed based on the characteristics of the rod–plate electrode and theoretical analysis. The reliability of the device was verified through COMSOL numerical simulations, charge-to-mass ratio, droplet size, and droplet size spectrum measurements, and a droplet size prediction model was established. The deposition characteristics in soybean fields were analyzed using the Box–Behnken experimental design method. The results showed that the rod–plate electrode structure demonstrated its superiority with a maximum spatial electric field of 2.31 × 10⁶ V/m. When the spray pressure was 0.3 MPa and the charging voltage was 8 kV, the droplet size decreased by 26.6%, and the charge-to-mass ratio reached 2.88 mC/kg. Field experiments showed that when the charging voltage was 8 kV, the spray pressure was 0.3 MPa, the traveling speed was 7 km/h, and the number of deposited droplets was 8517. This study provides some basis for the application of electrostatic spraying technology in large-scale field operations.

As an innovative plant protection method in precision agriculture, electrostatic spray technology can increase the droplet coverage area by over 30% coMpared to conventional spraying. This technology not only achieves higher droplet deposition density and coverage but also enables water and pesticide savings while reducing environmental pollution. This study, combining theoretical analysis with experimental validation, reveals the critical role of electrode material selection in induction-based electrostatic spray systems. Theoretical analysis indicates that the Fermi level and work function of electrode materials fundamentally determine charge transfer efficiency, while corrosion resistance emerges as a key parameter affecting system durability. To elucidate the effects of different electrode materials on droplet charging, a coMparative study was conducted on nickel, copper, and brass electrodes in both pristine and moderately corroded states based on the corrosion classification standard, using a targeted mesh-based charge-to-mass measurement device. The results demonstrated that the nickel electrode achieved a peak charge-to-mass ratio of 1.92 mC/kg at 10 kV, which was 8.5% and 11.6% higher than copper (1.77 mC/kg) and brass (1.72 mC/kg), respectively. After corrosion, nickel exhibited the smallest reduction in the charge-to-mass ratio (19.2%), significantly outperforming copper (40.2%) and brass (21.6%). Droplet size analysis using a Malvern Panalytical Spraytec spray particle analyzer (measurement range: 0.1–2000 µm) further confirmed the atomization advantages of nickel electrodes. The volume median diameter (Dv50) of droplets produced by nickel was 4.2–8 μm and 6.8–12.3 um smaller than those from copper and brass electrodes, respectively. After corrosion, nickel showed a smaller increase in droplet size spectrum inhomogeneity (24.5%), which was lower than copper (30.4%) and brass (25.8%), indicating superior droplet uniformity. By establishing a multi-factor predictive model for spray droplet size after electrode corrosion, this study quantifies the correlation between electrode characteristics and spray performance metrics. It provides a theoretical basis for designing weather-resistant electrostatic spray systems suitable for agricultural pesticide application scenarios involving prolonged exposure to corrosive chemicals. This work offers significant technical support for sustainable crop protection strategies.

To optimize the flow stability and improve application accuracy of the PWM intermittent variable-rate spraying system, which suffers from insufficient flow stability and response delays during changes in travel speed, this study proposes an intelligent control method based on an improved Adaptive Neural Fuzzy Inference System (ANFIS). Flow characteristic data of the solenoid valve were collected under four pressure conditions (0.2–0.5 MPa), drive frequencies (5–20 Hz), and duty cycles (10–90%) using an indoor test system. An ANFIS controller architecture was constructed with target flow rate and actual travel speed as input variables and PWM frequency-duty cycle combinations as output variables. This controller enhances the traditional single-output mode of ANFIS by achieving multi-output collaborative optimization through shared premise parameters, thereby strengthening the system’s nonlinear modeling and control capabilities. To validate the system’s practical performance, a field simulation test platform based on a spraying robot was constructed. By analyzing preset prescription map information, the system achieved precise variable-rate spraying operations during movement. Test results demonstrate that the steady-state error remains within 5.03% under various speed-varying conditions. This research provides a high-precision intelligent control solution for variable-rate spraying systems, holding significant implications for reducing pesticide application rates and advancing precision agriculture.

Air induction nozzle (AIN) has a special Venturi structure that has been widely used in the field of reducing the probability of drift of pesticide droplets and realizing precise application. The present research mainly adopts the method of comparative test and analyzes the difference between AIN and standard fan nozzle. However, the research on internal flow characteristics and air–liquid ratio (ALR) of AIN is very limited. In order to detect the air-liquid transient flow distribution and the influence of the geometric parameter structure of Venturi on the air–liquid ratio in the air induction nozzle, numerical simulation and air-liquid ratio prediction model of AIN combined with TD (Turbo Drop series) type Venturi tubes and ST110 (standard nozzle series) type fan nozzles are used. Based on the VOF (volume of fluid) model and Realizable k-ε turbulence control method, the TD-ST combined AIN is simulated numerically using open input and exit boundary conditions. The results show that the transient flow characteristic of the combined AIN is determined by the geometric structure of the Venturi tube, and the internal velocity and pressure change significantly at the Venturi angle. Under the same ST110 fan nozzle, the size of the larger TD Venturi tube will decrease the air phase content in the air–liquid flow. TD03-ST06 combined AIN has a maximum volume flow of 0.0092 (L/min) under 0.6 MPa. The air–liquid ratio regression model is established by designing the intake volume measurement system. According to this model, the influence law of tube size and spray parameters on the air–liquid ratio can be clarified. After variance analysis, it is proved that this model is suitable for air–liquid ratio prediction of TD-ST combined AIN. This study clarifies the air–liquid coupling law inside AIN and provides some reference for the quantitative analysis of the relationship between the geometric parameters, spray parameters, and the air–liquid ratio.