Abstract:
A method and apparatus for continuous automated growing of plants utilizes a vertical array of plant supporting arms extending radially from a central axis. Each arm has a plurality of pot receptacles which receive the plant seedling and liquid nutrients and water. The potting arms are rotated beneath grow lamps and pollinating arms. The frequency of feeding is increased as the plants grow. CO 2  iched air may also be provided. Once the plants are ready to harvest, they are manually exchanged for new seedlings and packaged.

Description:
CROSS REFERENCE TO RELATED APPLICATION 
       [0001]    The present application claims the benefits, under 35 U.S.C.§119(e), of U.S. Provisional Application Ser. No. 61/942,500 filed Feb. 20, 2014 entitled “Method and Apparatus for Automated Vertical Horticulture and Agriculture” which is incorporated herein by this reference. 
     
    
     TECHNICAL FIELD 
       [0002]    The invention relates to the fields of horticulture, hydroponics and agriculture and particularly apparatus and methods for automated commercial growth and production of plants in controlled environments. 
       BACKGROUND 
       [0003]    Traditionally the commercial horticultural and agricultural growth of plants has been carried out in nurseries and greenhouses, where the plants are arranged horizontally and are stationary. More efficient methods have more recently been developed, some of which are referred to as ‘vertical farming’ The present inventor, for example, in U.S. Pat. No. 7,415,796, 7,533,494, 7,559,173, 7,818,917 and 7,984,586 disclosed methods of growing plants using a rotating vertical carousel of rotating spheres, each having a central light source around which rows of plants are rotated, to thereby increase the productivity of plant growth in a given area. However harvesting of mature plants from such systems can be complicated and time consuming. 
         [0004]    The foregoing examples of the related art and limitations related thereto are intended to be illustrative and not exclusive. Other limitations of the related art will become apparent to those of skill in the art upon a reading of the specification and a study of the drawings. 
       SUMMARY 
       [0005]    The following embodiments and aspects thereof are described and illustrated in conjunction with systems, tools and methods which are meant to be exemplary and illustrative, not limiting in scope. In various embodiments, one or more of the above-described problems have been reduced or eliminated, while other embodiments are directed to other improvements. 
         [0006]    The present invention provides a method and apparatus for continuous automated growing of plants. A vertical array of plant supporting arms extends radially from a central axis. Each arm has a plurality of pot receptacles which receive the plant seedling and liquid nutrients and water. The potting arms are rotated beneath grow lamps and pollinating arms. The frequency of feeding is increased as the plants grow. CO 2  enriched air may also be provided. Once the plants are ready to harvest, they are manually exchanged for new seedlings and packaged. 
         [0007]    In addition to the exemplary aspects and embodiments described above, further aspects and embodiments will become apparent by reference to the drawings and by study of the following detailed descriptions. 
     
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
         [0008]    Exemplary embodiments are illustrated in referenced figures of the drawings. It is intended that the embodiments and figures disclosed herein are to be considered illustrative rather than restrictive. 
           [0009]      FIG. 1  is a perspective view of a growing unit for carrying out the method of the invention, with light bulbs removed for ease of illustration; 
           [0010]      FIG. 2  is a perspective view of the growing unit shown in  FIG. 1  with lighting fixtures swung out of operating position; 
           [0011]      FIG. 3  is a front view of the growing unit shown in  FIG. 1 ; 
           [0012]      FIG. 4  is a side view of the growing unit shown in  FIG. 1 ; 
           [0013]      FIG. 5  is a front view of the growing unit shown in  FIG. 1  with lighting fixtures swung out of operating position; and 
           [0014]      FIG. 6  is a detail of the perspective view shown in  FIG. 1 . 
       
    
    
     DESCRIPTION 
       [0015]    Throughout the following description specific details are set forth in order to provide a more thorough understanding to persons skilled in the art. However, well known elements may not have been shown or described in detail to avoid unnecessarily obscuring the disclosure. Accordingly, the description and drawings are to be regarded in an illustrative, rather than a restrictive, sense. 
         [0016]    With reference to  FIG. 1 , a growing unit for automated vertical cultivation and harvesting of plants is designated generally as  10 . It has a frame  12  including a horizontal beam  14  and vertical posts  16 , the lower ends of which have flanges or feet  18  fixed to the floor of the growing facility. 
         [0017]    Rotating planter assembly  20  ( FIG. 3 ) is suspended from beam  14 . It includes a central drainage tube  22  from which a plurality of potting arms  24  are attached and extend radially. As shown in  FIG. 3 , central drainage tube  22  may comprise three tubing sections  26 ,  28 ,  30  secured together. Such sections may be PVC. In the embodiment shown there are 8 horizontal levels of potting arms  24  with 9 potting arms per level. 
         [0018]    Potting arms  24  are each preferably PVC pipes, 6 inches in diameter and 2 feet or 4 feet long, closed at end  32  and attached to central drainage pipe  22  at the opposite end so that liquid flows from the interior of potting arms  24  into central drainage pipe  22  and out the bottom  34  of central drainage pipe  22  through a drainage outlet (not shown). Each potting arm  24  is provided with a plurality of pot receptacles  36 , six per potting arm as shown, which are each sized to receive a seedling plant in a soil cylinder. Each pot receptacle is perforated to permit the flow of fluids from recess  36  into the interior of potting arm  24 . Potting arms  24  are supported on brackets  38  and connect to central drainage pipe  22  by a fluid sealed pipe fitting. 
         [0019]    Horizontal light fixtures  40 , shown in  FIG. 2 , are hingedly connected to vertical posts  16  at hinge  42  to permit them to swing into operational position shown in  FIG. 1  and out of operational position as shown in  FIG. 2 . Fixtures  40  each have a frame formed of inner arc  44 , outer arc  46  and radial frame members  48 . Each fixture may carry ballasts and electrical connections for 10 T5 HO fluorescent bulbs, with electricity provided through connections  42  from vertical posts  16 , controlled by a remotely controlled electrical switch. While fluorescent lamps are preferred, other growth promoting lights can be used, such as light emitting diodes (LEDs), high pressure sodium lamps, metal halide lamps or incandescent light bulbs. The electrical control switches may be programmed to provide a coordinated light cycle (photoperiod) for the plants at each growth stage and depending on the particular plant. 
         [0020]    Attached to the central radial frame member  48  of each fixture  40  is a mechanical pollinator arm  50 , formed of a suspended strip of micro-fibre strands  52  (see  FIG. 6 ). Fixtures  40  can be individually raised or lowered on posts  16  by electrically powered activators, and activators may also provide power to swing each fixture  40  into and out of operating position as described above. Preferably the mechanical pollinator is kept at a height whereby the bottom 2 inches of the strands  52  brush over plants carried by the potting arms  24 . Since the length of the strands  52  will typically be 4 or 5 inches, and the plants may reach a height of as much as 10 inches, there should be a clearance of about 14 inches between the fixture  40  and potting arms  24 . As the plants grow, the fixtures  40  are elevated higher on post  16 . An ultrasonic vibrator on or connected to each fixture  42  can also be provided to enhance the pollination activity of the mechanical pollinators  50 . Also provided on the frame members  48  of each fixture  40  is an air emitting nozzle arm (not shown) which emits CO 2 -enriched air onto the potting arms  24 . Preferably compressed air is provided through an air line extending up vertical post  16  and through hinge element  42  and emits CO 2 -enriched air onto the plants in potting arms  24 . 
         [0021]    With reference to  FIG. 6 , water and food is provided to plants in pot receptacles  36  by drip emitters  70  connected to and supplied by feed line  72 . Drip emitters  70  are of the usual type used in greenhouses, hydroponics and other horticultural applications to provide a slow drip feed. Liquid feed lines  72  thus supply liquid nutrient solution to the pot receptacles  36  on each level through drip emitters  70 . Liquid nutrient is delivered to the liquid feed lines  72  from feed tanks (not shown). 
         [0022]    With reference to  FIG. 6 , drive system  60  has an electric motor  62 , driving sprocket  64  which drives chain  66  which in turn drives sprocket  68  attached to central drainage pipe  22 . Drive system  60  thus when activated rotates central drainage pipe  22  and attached potting arms  24  at a slow rate of rotation. Depending on the stage of growth and types of plants a typical rate of rotation is 4 rotations per hour. Rotation can be in either direction. 
         [0023]    As an alternate embodiment (not shown), central discharge pipe  22  can be replaced with a circular array of chains, hanging downwardly from a circular drive plate attached to sprocket  68 . Potting arms  24  are clipped onto brackets bolted onto the chains, one per chain. For example 16 arms can be attached per level, with 13 levels of arms and 4 pots per arm. Drainage may be carried through pipes on each chain as well as air lines and feed lines. 
         [0024]    In operation seeded germination pucks are prepared in a separate location and each plant goes through a first germination stage prior to being placed in growing unit  10 . After a sufficient germination period, and once the plants are ready to be transferred to the growing unit  10 , a wheeled scissor lift is used to load the plants into the pot receptacles  36  on each level of potting arms  24 . This is done manually on each scissor lift. One end of a conveyor is connected to the scissor lift and the plants are loaded on the other end of the conveyor. Scissor lifts are motorized to permit the scissor lifts to service a number of growing units  10 . The plants remain on each growing unit  10  until they are ready to harvest. Once the plants are sufficiently mature, they are manually removed from each level onto a scissor lift and loaded onto a conveyor. Preferably new seedlings replace each harvested plant at the same time the plants are harvested. 
         [0025]    The plants can also be packaged at the time of harvesting on the scissor lift before being placed in the conveyor, and then stored in cold storage. 
         [0026]    The growing facility may house a large number of growing units  10  and may also include the germination area, a packaging area, cold storage, cleaning area, seeding area and a feed tank storage area. In the example shown, each growing unit  10  handles 432 plants on a floor space of about 144 square feet for 4 foot potting arms  24 . 
       EXAMPLE 
     Strawberries 
       [0027]    An example of application of the invention to the production of strawberries is described as follows. The preferred liquid nutrient solution mixes are: 
         [0028]    i) a Bacterial Compost Tea mixed by, for each 20 L of filtered water adding 
         [0029]    1.5 pounds (700 g) bacterial compost or vermicompost 
         [0030]    3-4 tablespoons (45-60 ml) liquid black strap molasses 
         [0031]    4 teaspoons (23 g) dry soluble kelp or 2 tablespoons of liquid kelp 
         [0032]    3-4 teaspoons (15-20 ml) fish emulsion 
         [0033]    ii) as a fertilizer/nutrient solution, PURA VIDA™ GROW produced by Technaflora Plant Products of Mission BC, Canada. EDTA Iron is added at 20 ppm to the final solution. 1 gallon of compost tea is added for each 50 gallons of the feed solution with each new batch mixture. 
         [0034]    In the germination stage, strawberry seeds are planted into Jiffy™ peat pucks (preferably Item #70000591), which are seed starting plugs. After about a week the plants are sprayed with the full strength compost tea solution at 5.8 pH. For the second week the media is soaked once per day with a 400 ppm fertilizer solution at 5.8 pH. After about 15 days the seedlings are transplanted into molded plastic pots 85 filled with 75% Botanicare™ Cocogro® Coir Fiber media to 25% perlite. Botanicare ZHO™ Root Inoculant is added according to the label directions and also added is 1 tbsp dolomite lime per gallon of media saturated in the same compost tea mix used in the seeding process. The pots are then placed in pot receptacles 36 on each level of growing unit 10. The temperature is maintained at 62 degrees F., the humidity is maintained at 68% and the light cycle is kept at 18 hours On, 6 hours Off. Rotation of the unit is 4 revolutions per hour. At days 15-30, the drip emitters are activated once a day with the fertilizer solution at 540 ppm at 5.8 pH. After about 30 days, the media is saturated at 1 EC (electrical conductivity) and plants are sprayed with the full strength compost tea solution brewed as above at 5.8 pH. From Days 30-45, the emitters are activated twice a day with the nutrient solution at 640 ppm at 5.8 pH. At day 45 the plants are harvested. 
         [0035]    Thus using the invention, a continuous automated and controlled production of plants can be obtained. Different lighting, temperatures, humidity and nutrition can be programmed for the different growth stages of a crop and also for different crops. This can be done remotely by computer. The land space required to produce a crop is dramatically reduced and can be further reduced by increasing the height of the growing units  10 . The entire process can be automated using robots to transfer the plants at different stages. 
         [0036]    While the present apparatus and method are well-suited for strawberry production, many other types of plants can also be effectively produced using the present apparatus and method, such as lettuce, spinach, herbs, grape seedlings and tomato seedlings 
         [0037]    While a number of exemplary aspects and embodiments have been discussed above, those of skill in the art will recognize certain modifications, permutations, additions and sub-combinations thereof. It is therefore intended that the invention be interpreted to include all such modifications, permutations, additions and sub-combinations as are within their true spirit and scope.