Abstract:
A method is provided. In this method, a first tray positioned at a first end of a trough assembly at a selected tier is engaged. The first tray is then lifted and removed. A second tray is then engaged and moved vertically to the selected tiers. It is placed in the trough assembly at a second end. Other trays—which are positioned within the trough assembly between the first and second ends of the selected tier—are moved toward the first end of the trough assembly.

Description:
CROSS-REFERENCE 
       [0001]    This application claims priority to U.S. Provisional Patent Application No. 62/167,804 filed on May 28, 2015, which is hereby incorporated by reference in its entirety. 
     
    
     TECHNICAL FIELD 
       [0002]    The present application relates generally to hydroponic systems and, more specifically, to an automated hydroponics system that increases production. 
       BACKGROUND 
       [0003]    Indoor and outdoor controlled agricultural environments are used to increase crop production and reliability. Controlled agricultural environments, for example, protect crops from natural disasters and draught, more effectively utilize land, decrease water consumption, effectively grow crops normally out of season or in otherwise non-ideal environments, and reduce insects, birds, and micro-organisms from destroying crops while reducing the use of pesticides. Some controlled agricultural environments use hydroponic systems. Some examples of such systems and methods are: U.S. Pat. No. 4,486,977; PCT Publ. No. WO2004093527; and PCT Publ. No. WO2014009842. 
         [0004]    One type of hydroponic system, in particular, that is currently used is aquaponics. Typically, aquaponic systems utilize a symbiotic integration of aquaculture (such as raising aquatic animals including snails, fish, crayfish, prawns, or the like in tanks) and hydroponics (such as cultivating plants in water). In aquaponic systems, such as recirculating aquaponic (RA) systems, liquid effluent (such as a liquid rich in plant nutrients and derived from fish manure, decomposing organic matter, and nitrogenous waste excreted from fish fertilizes hydroponic bed) provides nourishing elements to grow plants. 
         [0005]      FIG. 1  illustrates a conceptual example of an RA system  100 . As illustrated, the system  100  includes a fish-rearing tank  105 , a suspended solids removal unit  110 , a biofilter  115 , a hydroponic subsystem  120 , and a sump  125 . Effluent liquid from the fish-rearing tank  105  is treated in the suspended solids removal unit  110 . The effluent liquid, now cultured water, is treated at the biofilter  115  using nitrification to remove ammonia and nitrite. The water then flows to the hydroponic subsystem  120  where some dissolved nutrients are taken up by plants and additional ammonia and nitrite are removed by bacteria growing on the sides of a tank in the hydroponic subsystem  120 . After exiting the hydroponic subsystem  120 , the water collects in the sump  125  and is returned to the fish-rearing tank  105 . 
         [0006]    To implement this, there are a variety of techniques that can also employed. Some examples of these techniques are:
       Deep water culture (DWC) where a floatation devices positions crops on the surface of a water basin (where the water can be recirculated);   Nutrient film technique (NFT) where a sloped basin drips or trickles liquid effluent or water to crops positioned along the basin;   Ebb and Flow (EB) (or a Flood Drain technique) where crop roots are suspended above the media bed containing nutrient rich water. When the nutrient rich water reaches the upper threshold height, the nutrient rich water drains from the media bed into a drainage bed positioned below the media bed until the height of the nutrient rich water falls to a lower threshold height;   Aeroponics where crop roots are suspended in a growing chamber with spray nozzles which spray nutrient rich water onto the roots;   Drip system where nutrient rich water is dripped onto the crops (similar to commonly used drip irrigation systems) and the waste water is recirculated; and   Wick system where nutrient rich water is introduced to growing trays through the use of a wick.
 
Additionally, the following documents and standards descriptions are hereby incorporated by reference herein: James E. Rakocy, Michael P. Masser, and Thomas M. Losordo, “Recirculating Aquaculture Tank Production Systems: Aquaponics—Integrating Fish and Plant Culture,” November 2006 Revision, Southern Regional Aquaculture Center (SRAC) Publication No. 454 (REF 1); Fox, B. K., Tamaru, C. S., Hollyer, J., Castro, L. F., Fonseca, J. M., Jay-Russell, M., &amp; Low, T. (2012). A Preliminary Study of Microbial Water Quality Related to Food Safety in Recirculating Aquaponic Fish and Vegetable Production Systems. University of Hawai&#39;i at Manoa (REF 2); Burden, D. Agricultural Marketing Resource Center. Agricultural Marketing Resource Center. July 2013 (REF 3); Wire, B. Research and Markets: 2012 Report Analyzing the Fertilizer Industry in United States 2011-2016. March 16, 2012. (REF 4); United States Government Publishing Office—Public Law 111-353-January 4, 2011, 124 STAT. 3885 (REF 5).
       
 
         [0013]    There is, however, one common issue that plagues hydroponics and agriculture in general, and that is labor. Agriculture is (in general) labor intensive in that it often requires the touch of human hands. Therefore, there is a need for a method and/or apparatus for automating hydroponics. 
       SUMMARY 
       [0014]    An embodiment is accordance with the disclosure provides an apparatus. The apparatus comprises: a frame having a plurality of tiers; a plurality of trough assemblies, wherein each trough assembly is secured to the frame and positioned in at least one of the tiers, and wherein each trough assembly includes at least one reservoir dimensioned by first and second end plates with at least one trough segment secured therebetween; a load assembly that is secured to the frame, wherein the load assembly is secured to the frame and is configured to access each of the tiers, and wherein the load assembly includes first and second arm that are spaced apart at a predetermined distance dimensioned so as to load or unload at least one tray from at least one of the trough assemblies; a plurality of conveyor assemblies, wherein each conveyor assembly is secured to the frame and is associated with at least one tier, and wherein each conveyor assembly is configured to engage and transfer at least one tray across its associated trough assembly; a feed assembly that is configured to provide nutrient laden water to the plurality of trough assemblies. 
         [0015]    An embodiment is accordance with the disclosure provides the trough assembly further comprising first and second tracks that are configured to engage at least one tray. 
         [0016]    An embodiment is accordance with the disclosure provides the frame further comprising: a plurality of frame sections, wherein each frame section includes a plurality of vertical support members interconnected to a plurality of cross support members; and a plurality of horizontal support members, wherein each horizontal support member is secured to at least two frame sections, and wherein each horizontal support member spans the distance between its associated frame sections, and wherein the plurality of horizontal support members are divided into a plurality of sets of horizontal frame members, and wherein each set of horizontal frame members forms at least one of the tiers. 
         [0017]    An embodiment is accordance with the disclosure provides that each of the first and second arms of the load assembly further comprises a lift assembly, wherein each lift assembly is secured to at least one of the vertical support members so as to allow its arm to access each of the tiers. 
         [0018]    An embodiment is accordance with the disclosure provides that the first and second tracks further comprise low-friction skid tracks. 
         [0019]    An embodiment is accordance with the disclosure provides that each of the first and second tracks further comprises: a u-shaped channel; and a plurality of roller bearings, wherein the roller bearings are secured within the u-shaped channel. 
         [0020]    An embodiment is accordance with the disclosure provides that each conveyor assembly further comprises: an engagement assembly that is adapted to engage at least one tray; a pulley assembly; and a belt that is secured to the engagement and pulley assemblies. 
         [0021]    An embodiment is accordance with the disclosure provides a method. The method comprises: engaging a first tray having a first set of plants positioned therein, wherein the first tray is positioned at a first end of a trough assembly secured at a selected tier; lifting and removing the first tray from the trough assembly; moving a plurality of third trays positioned within the trough assembly toward the first end of the trough assembly; engaging a second tray having a plurality of plants positioned therein; moving the second tray vertically to the selected tiers; and placing the second tray in the trough assembly, wherein the second tray is positioned at a second end. 
         [0022]    An embodiment is accordance with the disclosure provides that the step of engaging the first tray further comprises engaging first and second ends of the first tray with first and second load arms, respectively. 
         [0023]    An embodiment is accordance with the disclosure provides that the step of lifting and removing the first tray further comprises: activating first and second lift assemblies to so as raise the first tray with the first and second load arms; and moving the first tray from a first horizontal position to a second horizontal position with the first and second load arms. 
         [0024]    An embodiment is accordance with the disclosure provides that the step of engaging the second tray further comprises engaging first and second ends of the second tray with third and fourth load arms, respectively. 
         [0025]    An embodiment is accordance with the disclosure provides that the step of moving the second tray further comprises activating third and fourth lift assemblies to so as raise the second tray with the third and fourth load arms to the selected tier. 
         [0026]    An embodiment is accordance with the disclosure provides an apparatus. The apparatus comprises: a frame having a plurality of tiers; a plurality of trough assemblies, wherein each trough assembly is secured to the frame and positioned in at least one of the tiers, and wherein each trough assembly includes: a first end plate; a plurality of trough segments that are secured to one another in a sequence, wherein the first end plate is secured to the first trough segment of the sequence; and a second end plate that is secured to the last trough segment of the sequence; a plurality of sets of trays, wherein each set of trays is positioned within at least one of the trough assemblies and extends across the approximate length of its trough assembly; a first and second load assemblies that are secured to the frame at first and second ends, wherein each load assembly is configured to access each of the tiers, and wherein the assembly includes first and second arm that are spaced apart at a predetermined distance dimensioned so as to load or unload at least one of the trays from at least one of the trough assemblies; a plurality of conveyor assemblies, wherein each conveyor assembly is secured to the frame and is associated with at least one tier, and wherein each conveyor assembly is configured to engage and transfer at least one tray across its associated trough assembly; a feed assembly that is configured to provide nutrient laden water to the plurality of trough assemblies. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0027]    For a more complete understanding of the present disclosure and its advantages, reference is now made to the following description taken in conjunction with the accompanying drawings, in which like reference numerals represent like parts: 
           [0028]      FIG. 1  illustrates a conceptual example of a conventional recirculating aquaponics system; 
           [0029]      FIG. 2  is an example of a portion of an aquaponics automation system in accordance with the disclosure; 
           [0030]      FIGS. 3 and 4  are magnified views of alternative examples of the trough assembly of  FIG. 2 ; 
           [0031]      FIG. 5  is a magnified view of the conveyor assembly of  FIG. 2 ; 
           [0032]      FIG. 6  is a cross-sectional view of an in situ trough assembly of  FIG. 2  with a tray in place; 
           [0033]      FIG. 7  is an isometric view of an example of a tray shown in  FIG. 2 ; 
           [0034]      FIG. 8  is an isometric view of an example of a trough segment; and 
           [0035]      FIG. 9  is a view depicting the load assembly of  FIG. 2  is greater detail. 
       
    
    
     DETAILED DESCRIPTION 
       [0036]    Refer now to the drawings wherein depicted elements are, for the sake of clarity, not necessarily shown to scale and wherein like or similar elements are designated by the same reference numeral through the several views. 
         [0037]    To preface, hydroponic systems have several advantages over conventional agriculture techniques. For example, soil-based vegetable farms draw overhead irrigation water from non-potable, highly exposed water sources such as rivers, lakes, ditches, and hillside ponds. Because hydroponic systems do not apply water and nutrients directly to edible portion of the crop, microbial contamination is reduced. Hydroponic systems also use approximately 10% of the land area and 5% of the water volume of conventional crop cultivation systems and thus are suitable for urban gardening and gardening in special environmental conditions (such as drought, infertile soil, relatively low exposure to sunlight, and the like). Hydroponic systems can also operate year round regardless of ambient conditions and can produce non-native crops. Hydroponic systems operate in controlled environments that are more resistant to man-made and natural disasters and sustain rare and endangered crop species. Hydroponic systems can also reduce crop production time. For example, butterhead lettuce varieties can be produced in about 30 days, rather than a 60-day growing period needed for conventional butterhead lettuce cultivation systems. Hydroponic systems are adaptable to concentrate crop production on particular crops to meet specific demands. Hydroponic systems allow agriculture to take large innovative steps toward environmental sustainability. Because hydroponic systems are mostly-closed-loop systems, nutrient effluent leaving the facility is greatly reduced. Additionally, fish, plant, and other waste solids may be captured and converted into value-added fertilizer products for wholesale or retail sale. 
         [0038]    Turning to  FIGS. 2-9 , an example automated hydroponics system  200  according to this disclosure can be seen. As shown in this example, the system  200  includes a frame  202  with tiers. For example, eight tiers are shown. The frame  202  is generally comprised of frame sections, which themselves are generally comprised of vertical supports  210  and cross supports  216 . Between the frame sections, there can be horizontal supports  212  (which are typically secured to vertical supports  210 ). The horizontal supports  212  generally form the tiers. 
         [0039]    Within these tiers, trough assemblies  203  are typically secured. The trough assemblies  203  are generally formed such that there is a reservoir of water. This water is typically nutrient rich water (selected for the chosen plants) and recirculated. Feed systems for performing this recirculation are well known and are associated with the description of  FIG. 1 . The trough assemblies  203  are typically formed of end plates  302  (one on each end, for example) trough segment  305 . The trough segment  305 , for example, has a general horizontal bottom  504  with two generally upright sides  506 . Along each edge the trough segment  305  are bolt surfaces  508  (which allow additional trough segments  305  or end plates  302  to be bolted thereto). As a result, the length of the trough assemblies  203  is variable. Additionally, along the generally upright edges of the trough assemblies  203 , tracks  304  can be used. These tracks  304  generally provide a low-friction engaging surface for trays  208  and can take the form of a generally flat skid track  304 - 1  or a roller bearing track  304 - 2  (which includes a general u-shaped channel with roller bearings secured therein). 
         [0040]    A conveyor assembly  214  can also be secured to the frame  202  instead of simply pushing the trays  208  with the load assembly  206 . The conveyor assembly  214  can, for example, include an engagement assembly  406 , belt  404 , and pulley assembly  402 . The engagement assembly is, typically, able to engage trays  208  placed in a trough assembly  203  such that it is able to move the tray by action of the belt  404  and pulley assembly  402 . Such an arrangement allows for a “conveyor belt” of sorts for trays  208  of plants—allowing for substantially continuous removal of trays  208  with more mature plants and addition of new trays  208  (e.g. with seedlings). Trays  208  of plants can be placed in the trough assemblies  203  and migrated from one end of the trough assembly  203  to the other as trays  208  of matured plants are removed. Additionally, each end of each tray  208  can include a rigid block to provide separation between trays. 
         [0041]    Typically, the trays  208  have openings  502  in the bottom to allow the roots access to the nutrient rich water or fluid. The tray  208 , for example, is 94.5 inches wide, 6 inches long, and 4.1 inches deep and extends across the width of the trough assembly  203 . As an example, the trough segment  305  is 94 inches wide, 48 inches long, and 12 inches deep. 
         [0042]    To move the trays  208  between tiers (or on and off tiers), a load assembly  206  can be employed. The load assembly  206  is typically comprised of opposing load arms  602  and lift assemblies  604 , which can both lift and push trays  208 . Typically, the lift assemblies  604  are secured to move along vertical supports  210 . The load arms  602  can engage the ends of trays  208  and move the trays laterally, while the lift assemblies  604  can move the load arms  603  vertically. That way, the load assemblies  206  can move trays  208  with more mature plants off and trays  208  with fresh plants (e.g., seeds or seedlings) onto the tiers—allow for a substantially continuous conveyor system of plants. 
         [0043]    As will be understood by those skilled in the art, the hydroponics automation system described herein can be utilized with components of aquaponic systems discussed herein. Although the present disclosure has been described with an exemplary embodiment, various changes and modifications may be suggested to one skilled in the art. It is intended that the present disclosure encompass such changes and modifications as those that fall within the scope of the appended claims.