Patent Description:
The subject matter discussed in the background section should not be assumed to be prior art merely as a result of its mention in the background section. Similarly, a problem mentioned in the background section or associated with the subject matter of the background section should not be assumed to have been previously recognized in the prior art. The subject matter in the background section merely represents different approaches, which in and of themselves may also correspond to implementations of the claimed technology.

During the twentieth century, agriculture slowly began to evolve from a conservative industry to a fast-moving high-tech industry. Global food shortages, climate change and societal changes drove a move away from manually-implemented agriculture techniques toward computer-implemented technologies. In the past, and in many cases still today, farmers only had one growing season to produce the crops that would determine their revenue and food production for the entire year. However, this is changing. With indoor growing as an option and with better access to data processing technologies, the science of agriculture has become more agile. It is adapting and learning as new data is collected and insights are generated.

Advancements in technology are making it feasible to control the effects of nature with the advent of "controlled environment agriculture. " Improved efficiencies in space utilization, lighting, and a better understanding of hydroponics, aeroponics, crop cycles, and advancements in environmental control systems have allowed humans to better recreate environments conducive for agriculture crop growth with the goals of greater yield per square foot, better nutrition and lower cost.

<CIT> and <CIT>, both assigned to the assignee of the present disclosure, describe environmentally controlled vertical farming systems. The vertical farming structure (e.g., a vertical column) may be moved about an automated conveyance system in an open or closed-loop fashion, exposed to precision-controlled lighting, airflow and humidity, with ideal nutritional support. US Patent Pub. No. <CIT>") describes a system for continuous automated growing of plants. A vertical array of plant supporting arms extends radially from a central axis. Each arm includes pot receptacles which receive the plant seedling, and liquid nutrients and water. The potting arms are rotated beneath grow lamps and pollinating arms.

Various systems and machines for transplanting a plant or root-bound plug from a first container to a second container are known. For example, <CIT> discloses a transplanter assembly that includes grippers and various actuators for grasping a plant held in a first container and placing it in a second container. Generally, most known transplanting systems operate in a vertical orientation. In particular, the grippers are moved vertically up and down when performing transplanting operations. Furthermore, most known transplanting systems operate to transfer a plug or plant from a first container to a second, larger container that includes ample space for the plant root ball or plug. <CIT>) describes a gripping device comprising two blades adapted to be moved downwards and upwards by a jack and each guided by two guides, one being an outer guide and the other an inner guide, and each blade having an outer boss which brings the blades close to one another at the end of the downward movement in order to pinch the block which is to be gripped and transferred. <CIT>) relates to a method for picking up and delivering a plug of substrate having a plant incorporated therein.

<CIT> and <CIT>, both assigned to the assignee of the present disclosure, are Patent Applications falling under Article <NUM>(<NUM>) EPC. They disclose vertical farm production systems configured for high density growth and crop yield in which a transplanter station, in one implementation, may include one or more robotic arms, each having an end effector that is adapted to grasp a root-bound plug from a plug tray and inject the root bound plug into a grow site of a grow tower. The end effector includes a base and multiple picking heads extending from the base. The picking heads are each pivotable from a first position to a second position.

The present disclosure is directed to automated transplanter systems and subsystems. For example, the disclosure sets forth a plug gripper and assembly adapted to transplant plugs into tight-fitting plug holders. The disclosure also conveys a transplanter assembly useful in transplant operations where a plug holder is oriented at a non-perpendicular angle to the surface of a grow tower or other structure that contains the plug holder. The disclosure also provides a transplanter system useful in transplanting plugs into grow towers where the plug holders are oriented horizontally.

The present description is made with reference to the accompanying drawings, in which various example embodiments are shown. However, many different example embodiments may be used, and thus the description should not be construed as limited to the example embodiments set forth herein. Rather, these example embodiments are provided so that this disclosure will be thorough and complete. Various modifications to the exemplary embodiments will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other embodiments and applications without departing from the scope of the disclosure. Thus, this disclosure is not intended to be limited to the embodiments shown, but is to be accorded the widest scope consistent with the principles and features disclosed herein.

The present disclosure describes transplanter systems and subsystems. In one implementation, these systems and subsystems may be configured for use in automated crop production systems for controlled environment agriculture. Embodiments of the disclosure can be implemented in a vertical farm production system that includes grow towers as described herein. The present invention, however, is not limited to any particular crop production environment, which may be an automated controlled grow environment, an outdoor environment or any other suitable crop production environment. Furthermore, implementations of the invention may be used in systems that use other growth structures, instead of grow towers, such as grow walls, modular grow structures and the like.

For didactic purposes, the following describes a vertical farm production system configured for high density growth and crop yield. <FIG> and <FIG> illustrate a controlled environment agriculture system <NUM> according to one possible example. At a high level, the system <NUM> may include an environmentally-controlled growing chamber <NUM>, a vertical tower conveyance system <NUM> disposed within the growing chamber <NUM> and configured to convey grow towers <NUM> with crops disposed therein, and a central processing facility <NUM>. The crops or plants species that may be grown may be gravitropic/geotropic and/or phototropic, or some combination thereof. The crops or plant species may vary considerably and include various leaf vegetables, fruiting vegetables, flowering crops, fruits and the like. The controlled environment agriculture system <NUM> may be configured to grow a single crop type at a time or to grow multiple crop types concurrently.

The system <NUM> may also include conveyance systems for moving the grow towers in a circuit throughout the crop's growth cycle, the circuit comprising a staging area configured for loading the grow towers into and out of the vertical tower conveyance mechanism <NUM>. The central processing system <NUM> may include one or more conveyance mechanisms for directing grow towers to stations in the central processing system <NUM>-e.g., stations for loading plants into, and harvesting crops from, the grow towers. The vertical tower conveyance system <NUM>, within the growing chamber <NUM>, is configured to support and translate one or more grow towers <NUM> along grow lines <NUM>. Each grow tower <NUM> is configured for containing plant growth media that supports a root structure of at least one crop plant growing therein. Each grow tower <NUM> is also configured to releasably attach to a grow line <NUM> in a vertical orientation and move along the grow line <NUM> during a growth phase. Together, the vertical tower conveyance mechanism <NUM> and the central processing system <NUM> (including associated conveyance mechanisms) can be arranged in a production circuit under control of one or more computing systems.

The growth environment <NUM> may include light emitting sources positioned at various locations between and along the grow lines <NUM> of the vertical tower conveyance system <NUM>. The light emitting sources can be positioned laterally relative to the grow towers <NUM> in the grow line <NUM> and configured to emit light toward the lateral faces of the grow towers <NUM> that include openings from which crops grow. The light emitting sources may be incorporated into a water-cooled, LED lighting system as described in <CIT>. In such an embodiment, the LED lights may be arranged in a bar-like structure. The bar-like structure may be placed in a vertical orientation to emit light laterally to substantially the entire length of adjacent grow towers <NUM>. Multiple light bar structures may be arranged in the growth environment <NUM> along and between the grow lines <NUM>. Other lighting systems and configurations may be employed. For example, the light bars may be arranged horizontally between grow lines <NUM>.

The growth environment <NUM> may also include a nutrient supply system configured to supply an aqueous crop nutrient solution to the crops as they translate through the growth chamber <NUM>. As discussed in more detail below, the nutrient supply system may apply aqueous crop nutrient solution to the top of the grow towers <NUM>. Gravity may cause the solution travel down the vertically-oriented grow tower <NUM> and through the length thereof to supply solution to the crops disposed along the length of the grow tower <NUM>. The growth environment <NUM> may also include an airflow source configured to, when a tower is mounted to a grow line <NUM>, direct airflow in the lateral growth direction of growth and through an under-canopy of the growing plant, so as to disturb the boundary layer of the under-canopy of the growing plant. In other implementations, airflow may come from the top of the canopy or orthogonal to the direction of plant growth. The growth environment <NUM> may also include a control system, and associated sensors, for regulating at least one growing condition, such as air temperature, airflow speed, relative air humidity, and ambient carbon dioxide gas content. The control system may for example include such sub-systems as HVAC units, chillers, fans and associated ducting and air handling equipment. Grow towers <NUM> may have identifying attributes (such as bar codes or RFID tags). The controlled environment agriculture system <NUM> may include corresponding sensors and programming logic for tracking the grow towers <NUM> during various stages of the farm production cycle and/or for controlling one or more conditions of the growth environment. The operation of control system and the length of time towers remain in growth environment can vary considerably depending on a variety of factors, such as crop type and other factors.

As discussed above, grow towers <NUM> with newly transplanted crops or seedlings are transferred from the central processing system <NUM> into the vertical tower conveyance system <NUM>. Vertical tower conveyance system <NUM> moves the grow towers <NUM> along respective grow lines <NUM> in growth environment <NUM> in a controlled fashion, as discussed in more detail below. Crops disposed in grow towers <NUM> are exposed to the controlled conditions of growth environment (e.g., light, temperature, humidity, air flow, aqueous nutrient supply, etc.). The control system is capable of automated adjustments to optimize growing conditions within the growth chamber <NUM> to make continuous improvements to various attributes, such as crop yields, visual appeal and nutrient content. In addition, <CIT> and <CIT> describe application of machine learning and other operations to optimize grow conditions in a vertical farming system. In some implementations, environmental condition sensors may be disposed on grow towers <NUM> or at various locations in growth environment <NUM>. When crops are ready for harvesting, grow towers <NUM> with crops to be harvested are transferred from the vertical tower conveyance system <NUM> to the central processing system <NUM> for harvesting and other processing operations.

Central processing system <NUM>, as discussed in more detail below, may include processing stations directed to injecting seedlings into towers <NUM>, harvesting crops from towers <NUM>, and cleaning towers <NUM> that have been harvested. Central processing system <NUM> may also include conveyance mechanisms that move towers <NUM> between such processing stations. For example, as <FIG> illustrates, central processing system <NUM> may include harvester station <NUM>, washing station <NUM>, and transplanter station <NUM>. Harvester station <NUM> may deposit harvested crops into food-safe containers and may include a conveyance mechanism for conveying the containers to post-harvesting facilities (e.g., preparation, washing, packaging and storage) that are beyond the scope of this disclosure.

Controlled environment agriculture system <NUM> may also include one or more conveyance mechanisms for transferring grow towers <NUM> between growth environment <NUM> and central processing system <NUM>. In the implementation shown, the stations of central processing system <NUM> operate on grow towers <NUM> in a horizontal orientation. In one implementation, an automated pickup station <NUM>, and associated control logic, may be operative to releasably grasp a horizontal tower from a loading location, rotate the tower to a vertical orientation and attach the tower to a transfer station for insertion into a selected grow line <NUM> of the growth environment <NUM>. On the other end of growth environment <NUM>, automated laydown station <NUM>, and associated control logic, may be operative to releasably grasp and move a vertically-oriented grow tower <NUM> from a buffer location, rotate the grow tower <NUM> to a horizontal orientation and place it on a conveyance system for loading into harvester station <NUM>. In some implementations, if a grow tower <NUM> is rejected due to quality control concerns, the conveyance system may bypass the harvester station <NUM> and carry the grow tower to washing station <NUM> (or some other station). The automated laydown and pickup stations <NUM> and <NUM> may each comprise a six-degrees of freedom robotic arm, such as a FANUC robot. The stations <NUM> and <NUM> may also include end effectors for releasably grasping grow towers <NUM> at opposing ends.

Growth environment <NUM> may also include automated loading and unloading mechanisms for inserting grow towers <NUM> into selected grow lines <NUM> and unloading grow towers <NUM> from the grow lines <NUM>. In one implementation, the load transfer conveyance mechanism <NUM> may include a powered and free conveyor system that conveys carriages each loaded with a grow tower <NUM> from the automated pickup station <NUM> to a selected grow line <NUM>. Vertical grow tower conveyance system <NUM> may include sensors (such as RFID or bar code sensors) to identify a given grow tower <NUM> and, under control logic, select a grow line <NUM> for the grow tower <NUM>. Particular algorithms for grow line selection can vary considerably depending on a number of factors and is beyond the scope of this disclosure. The load transfer conveyance mechanism <NUM> may also include one or more linear actuators that pushes the grow tower <NUM> onto a grow line <NUM>. Similarly, the unload transfer conveyance mechanism <NUM> may include one or more linear actuators that push or pull grow towers from a grow line <NUM> onto a carriage of another powered and free conveyor mechanism, which conveys the carriages <NUM> from the grow line <NUM> to the automated laydown station <NUM>. <FIG> illustrates a carriage <NUM> that may be used in a powered and free conveyor mechanism. In the implementation shown, carriage <NUM> includes hook <NUM> that engages hook <NUM> attached to a grow tower <NUM>. A latch assembly <NUM> may secure the grow tower <NUM> while it is being conveyed to and from various locations in the system. In one implementation, one or both of load transfer conveyance mechanism <NUM> and unload transfer conveyance mechanism <NUM> may be configured with a sufficient track distance to establish a zone where grow towers <NUM> may be buffered. For example, unload transfer conveyance mechanism <NUM> may be controlled such that it unloads a set of towers <NUM> to be harvested unto carriages <NUM> that are moved to a buffer region of the track. On the other end, automated pickup station <NUM> may load a set of towers to be inserted into growth environment <NUM> onto carriages <NUM> disposed in a buffer region of the track associated with load transfer conveyance mechanism <NUM>.

Grow towers <NUM> provide the sites for individual crops to grow in the system. As <FIG> illustrate, a hook <NUM> attaches to the top of grow tower <NUM>. Hook <NUM> allows grow tower <NUM> to be supported by a grow line <NUM> when it is inserted into the vertical tower conveyance system <NUM>. In one implementation, a grow tower <NUM> measures <NUM> meters long, where the extruded length of the tower is <NUM> meters, and the hook is <NUM> meters long. The extruded rectangular profile of the grow tower <NUM>, in one implementation, measures <NUM> x <NUM> (<NUM>" x <NUM>"). The hook <NUM> can be designed such that its exterior overall dimensions are not greater than the extruded profile of the grow tower <NUM>. The foregoing dimensions are for didactic purposes. The dimensions of grow tower <NUM> can be varied depending on a number of factors, such as desired throughput, overall size of the system, and the like. For example, the grow tower <NUM> may be up to <NUM> meters long or greater, for example.

Grow towers <NUM> may include a set of grow sites <NUM> arrayed along at least one face of the grow tower <NUM>. In the implementation shown in <FIG>, grow towers <NUM> include grow sites <NUM> on opposing faces such that plants protrude from opposing sides of the grow tower <NUM>. Transplanter station <NUM> may transplant seedlings into empty grow sites <NUM> of grow towers <NUM>, where they remain in place until they are fully mature and ready to be harvested. In one implementation, the orientation of the grow sites <NUM> are perpendicular to the direction of travel of the grow towers <NUM> along grow line <NUM>. In other words, when a grow tower <NUM> is inserted into a grow line <NUM>, plants extend from opposing faces of the grow tower <NUM>, where the opposing faces are parallel to the direction of travel. Although a dual-sided configuration is preferred, the invention may also be utilized in a single-sided configuration where plants grow along a single face of a grow tower <NUM>.

<CIT> discloses an example tower structure configuration. In the implementation shown, grow towers <NUM> may each consist of three extrusions which snap together to form one structure. As shown, the grow tower <NUM> may be a dual-sided hydroponic tower, where the tower body <NUM> includes a central wall <NUM> that defines a first tower cavity 54a and a second tower cavity 54b. <FIG> provides a perspective view of an exemplary dual-sided, multi-piece hydroponic grow tower <NUM> in which each front face plate <NUM> is hingeably coupled to the tower body <NUM>. In <FIG>, each front face plate <NUM> is in the closed position. The cross-section of the tower cavities 54a, 54b may be in the range of <NUM> inches by <NUM> inches to <NUM> inches by <NUM> inches (<NUM> x <NUM> to <NUM> x <NUM>) where the term "tower cavity" refers to the region within the body of the tower and behind the tower face plate. The wall thickness of the grow towers <NUM> maybe within the range of <NUM> to <NUM> inches (<NUM>,<NUM> to <NUM>,<NUM>). A dual-sided hydroponic tower, such as that shown in <FIG>, has two back-to-back cavities 54a and 54b, each preferably within the noted size range. In the configuration shown, the grow tower <NUM> may include (i) a first V-shaped groove 58a running along the length of a first side of the tower body <NUM>, where the first V-shaped groove is centered between the first tower cavity and the second tower cavity; and (ii) a second V-shaped groove 58b running along the length of a second side of the tower body <NUM>, where the second V-shaped groove is centered between the first tower cavity and the second tower cavity. The V-shaped grooves 58a, 58b may facilitate registration, alignment and/or feeding of the towers <NUM> by one or more of the stations in central processing system <NUM>. <CIT> discloses additional details regarding the construction and use of towers. Another attribute of V-shaped grooves 58a, 58b is that they effectively narrow the central wall <NUM> to promote the flow of aqueous nutrient solution centrally where the plant's roots are located. Other implementations are possible. For example, a grow tower <NUM> may be formed as a unitary, single extrusion, where the material at the side walls flex to provide a hinge and allow the cavities to be opened for cleaning. <CIT> discloses an example grow tower <NUM> formed by a single extrusion.

As <FIG> illustrate, grow towers <NUM> may each include a plurality of cut-outs <NUM> for use with a compatible plug holder <NUM>, such as the plug holder disclosed in any one of co-assigned and co-pending <CIT>, <CIT> and <CIT>. As shown, the plug holders <NUM> may be oriented at a <NUM>-degree angle relative to the front face plate <NUM> and the vertical axis of the grow tower <NUM>. It should be understood, however, that tower design disclosed in the present application is not limited to use with this particular plug holder or orientation, rather, the towers disclosed herein may be used with any suitably sized and/or oriented plug holder. As such, cut-outs <NUM> are only meant to illustrate, not limit, the present tower design and it should be understood that the present disclosure is equally applicable to towers with other cut-out designs. Plug Holder <NUM> may be ultrasonically welded, bonded, or otherwise attached to tower face <NUM>.

The use of a hinged front face plate simplifies manufacturing of grow towers, as well as tower maintenance in general and tower cleaning in particular. For example, to clean a grow tower <NUM> the face plates <NUM> are opened from the body <NUM> to allow easy access to the body cavity 54a or 54b. After cleaning, the face plates <NUM> are closed. Since the face plates remain attached to the tower body <NUM> throughout the cleaning process, it is easier to maintain part alignment and to insure that each face plate is properly associated with the appropriate tower body and, assuming a double-sided tower body, that each face plate <NUM> is properly associated with the appropriate side of a specific tower body <NUM>. Additionally, if the planting and/or harvesting operations are performed with the face plate <NUM> in the open position, for the dual-sided configuration both face plates can be opened and simultaneously planted and/or harvested, thus eliminating the step of planting and/or harvesting one side and then rotating the tower and planting and/or harvesting the other side. In other embodiments, planting and/or harvesting operations are performed with the face plate <NUM> in the closed position.

Other implementations are possible. For example, grow tower <NUM> can comprise any tower body that includes a volume of medium or wicking medium extending into the tower interior from the face of the tower (either a portion or individual portions of the tower or the entirety of the tower length. For example, <CIT> discloses a grow tube having a slot extending from a face of the tube and a grow medium contained in the tube. The tube illustrated therein may be modified to include a hook <NUM> at the top thereof and to have slots on opposing faces, or one slot on a single face.

<FIG> illustrates a portion of a grow line <NUM> in vertical tower conveyance system <NUM>. In one implementation, the vertical tower conveyance system <NUM> includes a plurality of grow lines <NUM> arranged in parallel. As discussed above, automated loading and unloading mechanisms <NUM>, <NUM> may selectively load and unload grow towers <NUM> from a grow line <NUM> under automated control systems. As <FIG> shows, each grow line <NUM> supports a plurality of grow towers <NUM>. In one implementation, a grow line <NUM> may be mounted to the ceiling (or other support) of the grow structure by a bracket for support purposes. Hook <NUM> hooks into, and attaches, a grow tower <NUM> to a grow line <NUM>, thereby supporting the tower in a vertical orientation as it is translated through the vertical tower conveyance system <NUM>. A conveyance mechanism moves towers <NUM> attached to respective grow lines <NUM>.

<FIG> illustrates the cross section or extrusion profile of a grow line <NUM>. The grow line <NUM> may be an aluminum extrusion. The bottom section of the extrusion profile of the grow line <NUM> includes an upward facing groove <NUM>. As <FIG> shows, hook <NUM> of a grow tower <NUM> includes a main body <NUM> and corresponding member <NUM> that engages groove <NUM> as shown in <FIG> and <FIG>. These hooks allow the grow towers <NUM> to hook into the groove <NUM> and slide along the grow line <NUM> as discussed below. Conversely, grow towers <NUM> can be manually unhooked from a grow line <NUM> and removed from production. This ability may be necessary if a crop in a grow tower <NUM> becomes diseased so that it does not infect other towers. In one possible implementation, the width of groove <NUM> (for example, <NUM>) is an optimization between two different factors. First, the narrower the groove the more favorable the binding rate and the less likely grow tower hooks <NUM> are to bind. Conversely, the wider the groove the slower the grow tower hooks wear due to having a greater contact patch. Similarly, the depth of the groove, for example <NUM>, may be an optimization between space savings and accidental fallout of tower hooks.

Hooks <NUM> may be injection-molded plastic parts. In one implementation, the plastic may be polyvinyl chloride (PVC), acrylonitrile butadiene styrene (ABS), or an Acetyl Homopolymer (e.g., Delrin® sold by DuPont Company). The hook <NUM> may be solvent bonded to the top of the grow tower <NUM> and/or attached using rivets or other mechanical fasteners. The groove-engaging member <NUM> which rides in the rectangular groove <NUM> of the grow line <NUM> may be a separate part or integrally formed with hook <NUM>. If separate, this part can be made from a different material with lower friction and better wear properties than the rest of the hook, such as ultra-high-molecular weight polyethylene or acetal. To keep assembly costs low, this separate part may snap onto the main body of the hook <NUM>. Alternatively, the separate part also be over-molded onto the main body of hook <NUM>.

As <FIG> and <FIG> illustrate, the top section of the extrusion profile of grow line <NUM> contains a downward facing t-slot <NUM>. Linear guide carriages <NUM> (described below) ride within the t-slot <NUM>. The center portion of the t-slot <NUM> may be recessed to provide clearance from screws or over-molded inserts which may protrude from the carriages <NUM>. Each grow line <NUM> can be assembled from a number of separately fabricated sections. In one implementation, sections of grow line <NUM> are currently modeled in <NUM>-meter lengths. Longer sections reduce the number of junctions but are more susceptible to thermal expansion issues and may significantly increase shipping costs. Additional features not captured by the Figures include intermittent mounting holes to attach the grow line <NUM> to the ceiling structure and to attach irrigation lines. Interruptions to the t-slot <NUM> may also be machined into the conveyor body. These interruptions allow the linear guide carriages <NUM> to be removed without having to slide them all the way out the end of a grow line <NUM>.

At the junction between two sections of a grow line <NUM>, a block <NUM> may be located in the t-slots <NUM> of both conveyor bodies. This block serves to align the two grow line sections so that grow towers <NUM> may slide smoothly between them. Alternative methods for aligning sections of a grow line <NUM> include the use of dowel pins that fit into dowel holes in the extrusion profile of the section. The block <NUM> may be clamped to one of the grow line sections via a set screw, so that the grow line sections can still come together and move apart as the result of thermal expansion. Based on the relatively tight tolerances and small amount of material required, these blocks may be machined. Bronze may be used as the material for such blocks due to its strength, corrosion resistance, and wear properties.

In one implementation, the vertical tower conveyance system <NUM> utilizes a reciprocating linear ratchet and pawl structure (hereinafter referred to as a "reciprocating cam structure or mechanism") to move grow towers <NUM> along a path section 202a, 202b of a grow line <NUM>. In one implementation, each path section 202a, 202b includes a separate reciprocating cam structure and associated actuators. <FIG> and <FIG> illustrate one possible reciprocating cam mechanism that can be used to move grow towers <NUM> across grow lines <NUM>. Pawls or "cams" <NUM> physically push grow towers <NUM> along grow line <NUM>. Cams <NUM> are attached to cam channel <NUM> (see below) and rotate about one axis. On the forward stroke, the rotation is limited by the top of the cam channel <NUM>, causing the cams <NUM> to push grow towers <NUM> forward. On the reserve or back stroke, the rotation is unconstrained, thereby allowing the cams to ratchet over the top of the grow towers <NUM>. In this way, the cam mechanism can stroke a relatively short distance back and forth, yet grow towers <NUM> always progress forward along the entire length of a grow line <NUM>. A control system, in one implementation, controls the operation of the reciprocating cam mechanism of each grow line <NUM> to move the grow towers <NUM> according to a programmed growing sequence. In between movement cycles, the actuator and reciprocating cam mechanism remain idle.

The pivot point of the cams <NUM> and the means of attachment to the cam channel <NUM> consists of a binding post <NUM> and a hex head bolt <NUM>; alternatively, detent clevis pins may be used. The hex head bolt <NUM> is positioned on the inner side of the cam channel <NUM> where there is no tool access in the axial direction. Being a hex head, it can be accessed radially with a wrench for removal. Given the large number of cams needed for a full-scale farm, a high-volume manufacturing process such as injection molding is suitable. ABS is suitable material given its stiffness and relatively low cost. All the cams <NUM> for a corresponding grow line <NUM> are attached to the cam channel <NUM>. When connected to an actuator, this common beam structure allows all cams <NUM> to stroke back and forth in unison. The structure of the cam channel <NUM>, in one implementation, is a downward facing u-channel constructed from sheet metal. Holes in the downward facing walls of cam channel <NUM> provide mounting points for cams <NUM> using binding posts <NUM>.

Holes of the cam channel <NUM>, in one implementation, are spaced at <NUM> intervals. Therefore, cams <NUM> can be spaced relative to one another at any integer multiple of <NUM>, allowing for variable grow tower spacing with only one cam channel. The base of the cam channel <NUM> limits rotation of the cams during the forward stroke. All degrees of freedom of the cam channel <NUM>, except for translation in the axial direction, are constrained by linear guide carriages <NUM> (described below) which mount to the base of the cam channel <NUM> and ride in the t-slot <NUM> of the grow line <NUM>. Cam channel <NUM> may be assembled from separately formed sections, such as sections in <NUM>-meter lengths. Longer sections reduce the number of junctions but may significantly increase shipping costs. Thermal expansion is generally not a concern because the cam channel is only fixed at the end connected to the actuator. Given the simple profile, thin wall thickness, and long length needed, sheet metal rolling is a suitable manufacturing process for the cam channel. Galvanized steel is a suitable material for this application.

Linear guide carriages <NUM> are bolted to the base of the cam channels <NUM> and ride within the t-slots <NUM> of the grow lines <NUM>. In some implementations, one carriage <NUM> is used per <NUM>-meter section of cam channel. Carriages <NUM> may be injection molded plastic for low friction and wear resistance. Bolts attach the carriages <NUM> to the cam channel <NUM> by threading into over molded threaded inserts. If select cams <NUM> are removed, these bolts are accessible so that a section of cam channel <NUM> can be detached from the carriage and removed.

Sections of cam channel <NUM> are joined together with pairs of connectors <NUM> at each joint; alternatively, detent clevis pins may be used. Connectors <NUM> may be galvanized steel bars with machined holes at <NUM> spacing (the same hole spacing as the cam channel <NUM>). Shoulder bolts <NUM> pass through holes in the outer connector, through the cam channel <NUM>, and thread into holes in the inner connector. If the shoulder bolts fall in the same position as a cam <NUM>, they can be used in place of a binding post. The heads of the shoulder bolts <NUM> are accessible so that connectors and sections of cam channel can be removed.

In one implementation, cam channel <NUM> attaches to a linear actuator, which operates in a forward and a back stroke. A suitable linear actuator may be the T13-B4010MS053-<NUM> actuator offered by Thomson, Inc. of Redford, Virginia; however, the reciprocating cam mechanism described herein can be operated with a variety of different actuators. The linear actuator may be attached to cam channel <NUM> at the off-loading end of a grow line <NUM>, rather than the on-boarding end. In such a configuration, cam channel <NUM> is under tension when loaded by the towers <NUM> during a forward stroke of the actuator (which pulls the cam channel <NUM>) which reduces risks of buckling. <FIG> illustrates operation of the reciprocating cam mechanism. In step A, the linear actuator has completed a full back stroke; as <FIG> illustrates, one or more cams <NUM> may ratchet over the hooks <NUM> of a grow tower <NUM>. Step B of <FIG> illustrates the position of cam channel <NUM> and cams <NUM> at the end of a forward stroke. During the forward stroke, cams <NUM> engage corresponding grow towers <NUM> and move them in the forward direction along grow line <NUM> as shown. Step C of <FIG> illustrates how a new grow tower <NUM> (Tower <NUM>) may be inserted onto a grow line <NUM> and how the last tower (Tower <NUM>) may be removed. Step D illustrates how cams <NUM> ratchet over the grow towers <NUM> during a back stroke, in the same manner as Step A. The basic principle of this reciprocating cam mechanism is that reciprocating motion from a relatively short stroke of the actuator transports towers <NUM> in one direction along the entire length of the grow line <NUM>. More specifically, on the forward stroke, all grow towers <NUM> on a grow line <NUM> are pushed forward one position. On the back stroke, the cams <NUM> ratchet over an adjacent tower one position back; the grow towers remain in the same location. As shown, when a grow line <NUM> is full, a new grow tower may be loaded and a last tower unloaded after each forward stroke of the linear actuator. In some implementations, the top portion of the hook <NUM> (the portion on which the cams push), is slightly narrower than the width of a grow tower <NUM>. As a result, cams <NUM> can still engage with the hooks <NUM> when grow towers <NUM> are spaced immediately adjacent to each other. <FIG> shows <NUM> grow towers for didactic purposes. A grow line <NUM> can be configured to be quite long (for example, <NUM> meters) allowing for a much greater number of towers <NUM> on a grow line <NUM> (such as <NUM>-<NUM>). Other implementations are possible. For example, the minimum tower spacing can be set equal to or slightly greater than two times the side-to-side distance of a grow tower <NUM> to allow more than one grow tower <NUM> to be loaded onto a grow line <NUM> in each cycle.

Still further, as shown in <FIG>, the spacing of cams <NUM> along the cam channel <NUM> can be arranged to effect one-dimensional plant indexing along the grow line <NUM>. In other words, the cams <NUM> of the reciprocating cam mechanism can be configured such that spacing between towers <NUM> increases as they travel along a grow line <NUM>. For example, spacing between cams <NUM> may gradually increase from a minimum spacing at the beginning of a grow line to a maximum spacing at the end of the grow line <NUM>. This may be useful for spacing plants apart as they grow to increase light interception and provide spacing, and, through variable spacing or indexing, increasing efficient usage of the growth chamber <NUM> and associated components, such as lighting. In one implementation, the forward and back stroke distance of the linear actuator is equal to (or slightly greater than) the maximum tower spacing. During the back stroke of the linear actuator, cams <NUM> at the beginning of a grow line <NUM> may ratchet and overshoot a grow tower <NUM>. On the forward stroke, such cams <NUM> may travel respective distances before engaging a tower, whereas cams located further along the grow line <NUM> may travel shorter distances before engaging a tower or engage substantially immediately. In such an arrangement, the maximum tower spacing cannot be two times greater than the minimum tower spacing; otherwise, a cam <NUM> may ratchet over and engaging two or more grow towers <NUM>. If greater maximum tower spacing is desired, an expansion joint may be used, as illustrated in <FIG>. An expansion joint allows the leading section of the cam channel <NUM> to begin traveling before the trailing end of the cam channel <NUM>, thereby achieving a long stroke. In particular, as <FIG> shows, expansion joint <NUM> may attach to sections 604a and 604b of cam channel <NUM>. In the initial position (<NUM>), the expansion joint <NUM> is collapsed. At the beginning of a forward stroke (<NUM>), the leading section 604a of cam channel <NUM> moves forward (as the actuator pulls on cam channel <NUM>), while the trailing section 604b remains stationary. Once the bolt bottoms out on the expansion joint <NUM> (<NUM>), the trailing section <NUM> of cam channel <NUM> begins to move forward as well. On the back stroke (<NUM>), the expansion joint <NUM> collapses to its initial position.

Other implementations for moving vertical grow towers <NUM> may be employed. For example, a lead screw mechanism may be employed. In such an implementation, the threads of the lead screw engage hooks <NUM> disposed on grow line <NUM> and move grow towers <NUM> as the shaft rotates. The pitch of the thread may be varied to achieve one-dimensional plant indexing. In another implementation, a belt conveyor include paddles along the belt may be employed to move grow towers <NUM> along a grow line <NUM>. In such an implementation, a series of belt conveyors arranged along a grow line <NUM>, where each belt conveyor includes a different spacing distance among the paddles to achieve one-dimensional plant indexing. In yet other implementations, a power-and-free conveyor may be employed to move grow towers <NUM> along a grow line <NUM>. Still further, although the grow line <NUM> illustrated in the various figures is horizontal to the ground, the grow line <NUM> may be sloped at a slight angle, either downwardly or upwardly relative to the direction of tower travel. Still further, while the grow line <NUM> described above operates to convey grow towers in a single direction, the grow line <NUM> may be configured to include multiple sections, where each section is oriented in a different direction. For example, two sections may be perpendicular to each other. In other implementations, two sections may run parallel to each other, but have opposite directions of travel.

<FIG> illustrates how an irrigation line <NUM> may be attached to grow line <NUM> to supply an aqueous nutrient solution to crops disposed in grow towers <NUM> as they translate through the vertical tower conveyance system <NUM>. Irrigation line <NUM>, in one implementation, is a pressurized line with spaced-apart holes disposed at the expected locations of the towers <NUM> as they advance along grow line <NUM> with each movement cycle. For example, the irrigation line <NUM> may be a PVC pipe having an inner diameter of <NUM> inches (<NUM>) and holes having diameters of <NUM> inches (<NUM>,<NUM>). The irrigation line <NUM> may be approximately <NUM> meters in length spanning the entire length of a grow line <NUM>. To ensure adequate pressure across the entire line, irrigation line <NUM> may be broken into shorter sections, each connected to a manifold, so that pressure drop is reduced.

As <FIG> shows, a funnel structure <NUM> collects aqueous nutrient solution from irrigation line <NUM> and distributes the aqueous nutrient solution to the cavity(ies) 54a, 54b of the grow tower <NUM> as discussed in more detail below. <FIG> illustrate that the funnel structure <NUM> may be integrated into hook <NUM>. For example, the funnel structure <NUM> may include a collector <NUM>, first and second passageways <NUM> and first and second slots <NUM>. As <FIG> illustrates, the groove-engaging member <NUM> of the hook may disposed at a centerline of the overall hook structure. The funnel structure <NUM> may include flange sections <NUM> extending downwardly opposite the collector <NUM> and on opposing sides of the centerline. The outlets of the first and second passageways are oriented substantially adjacent to and at opposing sides of the flange sections <NUM>, as shown. Flange sections <NUM> register with central wall <NUM> of grow tower <NUM> to center the hook <NUM> and provides additional sites to adhere or otherwise attach hook <NUM> to grow tower <NUM>. In other words, when hook <NUM> is inserted into the top of grow tower <NUM>, central wall <NUM> is disposed between flange sections <NUM>. In the implementation shown, collector <NUM> extends laterally from the main body <NUM> of hook <NUM>.

As <FIG> shows, funnel structure <NUM> includes a collector <NUM> that collects nutrient fluid and distributes the fluid evenly to the inner cavities 54a and 54b of tower through passageways <NUM>. Passageways <NUM> are configured to distribute aqueous nutrient solution near the central wall <NUM> and to the center back of each cavity 54a, 54b over the ends of the plug holders <NUM> and where the roots of a planted crop are expected. As <FIG> illustrates, in one implementation, the funnel structure <NUM> includes slots <NUM> that promote the even distribution of nutrient fluid to both passageways <NUM>. For nutrient fluid to reach passageways <NUM>, it must flow through one of the slots <NUM>. Each slot <NUM> may have a V-like configuration where the width of the slot opening increases as it extends from the substantially flat bottom surface <NUM> of collector <NUM>. For example, each slot <NUM> may have a width of <NUM> millimeter at the bottom surface <NUM>. The width of slot <NUM> may increase to <NUM> millimeters over a height of <NUM> millimeters. The configuration of the slots <NUM> causes nutrient fluid supplied at a sufficient flow rate by irrigation line <NUM> to accumulate in collector <NUM>, as opposed to flowing directly to a particular passageway <NUM>, and flow through slots <NUM> to promote even distribution of nutrient fluid to both passageways <NUM>.

In operation, irrigation line <NUM> provides aqueous nutrient solution to funnel structure <NUM> that even distributes the water to respective cavities 54a, 54b of grow tower <NUM>. The aqueous nutrient solution supplied from the funnel structure <NUM> irrigates crops contained in respective plug containers <NUM> as it trickles down. In one implementation, a gutter disposed under each grow line <NUM> collects excess water from the grow towers <NUM> for recycling.

Other implementations are possible. For example, the funnel structure may be configured with two separate collectors that operate separately to distribute aqueous nutrient solution to a corresponding cavity 54a, 54b of a grow tower <NUM>. In such a configuration, the irrigation supply line can be configured with one hole for each collector. In other implementations, the towers may only include a single cavity and include plug containers only on a single face <NUM> of the towers. Such a configuration still calls for a use of a funnel structure that directs aqueous nutrient solution to a desired portion of the tower cavity but obviates the need for separate collectors or other structures facilitating even distribution.

As discussed above, the stations of central processing system <NUM> operate on grow towers <NUM> in a horizontal orientation, while the vertical tower conveyance system <NUM> conveys grow towers in the growth environment <NUM> in a vertical orientation. In one implementation, an automated pickup station <NUM>, and associated control logic, may be operative to releasably grasp a horizontal grow tower from a loading location, rotate the tower to a vertical orientation and attach the tower to a transfer station for insertion into a selected grow line <NUM> of the growth environment <NUM>. On the other end of growth environment <NUM>, automated laydown station <NUM>, and associated control logic, may be operative to releasably grasp and move a vertically-oriented grow tower <NUM> from a buffer location, rotate the grow tower <NUM> to a horizontal orientation and place it on a conveyance system for processing by one or more stations of central processing system <NUM>. For example, automated laydown station <NUM> may place grow towers <NUM> on a conveyance system for loading into harvester station <NUM>. The automated laydown station <NUM> and pickup station <NUM> may each comprise a six-degrees of freedom (six axes) robotic arm, such as a FANUC robot. The stations <NUM> and <NUM> may also include end effectors for releasably grasping grow towers <NUM> at opposing ends.

<FIG> illustrates an automated laydown station <NUM>. As shown, automated laydown station <NUM> includes robot <NUM> and end effector <NUM>. Unload transfer conveyance mechanism <NUM>, which may be a power and free conveyor, delivers grow towers <NUM> from growth environment <NUM>. In one implementation, the buffer track section <NUM> of unload transfer conveyance mechanism <NUM> extends through a vertical slot <NUM> in growth environment <NUM>, allowing mechanism <NUM> to convey grow towers <NUM> attached to carriages <NUM> outside of growth environment <NUM> and towards pick location <NUM>. Unload transfer conveyance mechanism <NUM> may use a controlled stop blade to stop the carriage <NUM> at the pick location <NUM>. The unload transfer conveyance mechanism <NUM> may include an anti-roll back mechanism, bounding the carriage <NUM> between the stop blade and the anti-roll back mechanism.

As <FIG> illustrates, receiver <NUM> may be attached to a swivel mechanism <NUM> allowing rotation of grow towers <NUM> when attached to carriages <NUM> for closer buffering in unload transfer conveyance mechanism <NUM> and/or to facilitate the correct orientation for loading or unloading grow towers <NUM>. In some implementations, for the laydown location and pick location <NUM>, grow towers <NUM> may be oriented such that hook <NUM> faces away from the automated laydown and pickup stations <NUM>, <NUM> for ease of transferring towers on/off the swiveled carriage receiver <NUM>. Hook <NUM> may rest in a groove in the receiver <NUM> of carriage <NUM>. Receiver <NUM> may also have a latch <NUM> which closes down on either side of the grow tower <NUM> to prevent a grow tower <NUM> from sliding off during acceleration or deceleration associated with transfer conveyance.

<FIG> illustrates an end effector <NUM> that provides a pneumatic gripping solution for releasably grasping a grow tower <NUM> at opposing ends. End effector <NUM> may include a beam <NUM> and a mounting plate <NUM> for attachment to a robot, such as robotic arm <NUM>. A top gripper assembly <NUM> and a bottom gripper assembly <NUM> are attached to opposite ends of beam <NUM>. End effector <NUM> may also include support arms <NUM> to support a grow tower <NUM> when held in a horizontal orientation. For example, support arms <NUM> extending from a central section of beam <NUM> mitigate tower deflection. Support arms <NUM> may be spaced ~<NUM> meters from either gripper assembly <NUM>, <NUM>, and may be nominally <NUM> offset from a tower face, allowing <NUM> of tower deflection before the support arms <NUM> catch the tower.

Bottom gripper assembly <NUM>, as shown in <FIG> and <FIG>, may include plates <NUM> extending perpendicularly from an end of beam <NUM> and each having a cut-out section <NUM> defining arms 1708a and 1708b. A pneumatic cylinder mechanism <NUM>, such as a guided pneumatic cylinder sold by SMC Pneumatics under the designation MGPM40-40Z, attaches to arms 1708a of plates <NUM>. Arms 1708b may include projections <NUM> that engage groove 58b of grow tower <NUM> when grasped therein to locate the grow tower <NUM> in the gripper assembly <NUM> and/or to prevent slippage. The gripper assembly <NUM>, in the implementation shown, operates like a lobster claw-i.e., one side of the gripper (the pneumatic cylinder mechanism <NUM>) moves, while the other side (arms 1708b) remain static. On the static side of the gripper assembly <NUM>, the pneumatic cylinder mechanism <NUM> drives the grow tower <NUM> into the arms <NUM>, registering the tower <NUM> with projections <NUM>. Friction between a grow tower <NUM> and arms 1708b and pneumatic cylinder mechanism <NUM> holds the tower <NUM> in place during operation of an automated laydown or pick up station <NUM>, <NUM>. To grasp a grow tower <NUM>, the pneumatic cylinder mechanism <NUM> may extend. In such an implementation, pneumatic cylinder mechanism <NUM> is retracted to a release position during a transfer operation involving the grow towers <NUM>. In one implementation, the solenoid of pneumatic cylinder mechanism <NUM> is center-closed in that, whether extended or retracted, the valve locks even if air pressure is lost. In such an implementation, loss of air pressure will not cause a grow tower <NUM> to fall out of end effector <NUM> while the pneumatic cylinder mechanism <NUM> is extended.

Top gripper assembly <NUM>, in one implementation, is essentially a mirror image of bottom gripper assembly <NUM>, as it includes the same components and operates in the same manner described above. Catch plate <NUM>, in one implementation, may attach only to bottom gripper assembly <NUM>. Catch plate <NUM> may act as a safety catch in case the gripper assemblies fail or the grow tower <NUM> slips. Other implementations are possible. For example, the gripper assemblies may be parallel gripper assemblies where both opposing arms of each gripper move when actuated to grasp a grow tower <NUM>.

Robot <NUM> may be a <NUM>-axis robotic arm including a base, a lower arm attached to the base, an upper arm attached to the lower arm, and a wrist mechanism disposed between the end of the upper arm and an end effector <NUM>. For example, robot <NUM> may <NUM>) rotate about its base; <NUM>) rotate a lower arm to extend forward and backward; <NUM>) rotate an upper arm, relative to the lower arm, upward and downward; <NUM>) rotate the upper arm and attached wrist mechanism in a circular motion; <NUM>) tilt a wrist mechanism attached to the end of the upper arm up and down; and/or <NUM>) rotate the wrist mechanism clockwise or counter-clockwise. However, modifications to end effector <NUM> (and/or other elements, such as conveyance mechanisms and the like) may permit different types of robots and mechanisms, as well as use of robots with fewer axes of movement. As <FIG> illustrates, robot <NUM> may be floor mounted and installed on a pedestal. Inputs to the robot <NUM> may include power, a data connection to a control system, and an air line connecting the pneumatic cylinder mechanism <NUM> to a pressurized air supply. On pneumatic cylinder mechanism <NUM>, sensors may be used to detect when the cylinder is in its open state or its closed state. The control system may execute one or more programs or sub-routines to control operation of the robot <NUM> to effect conveyance of grow towers <NUM> from growth environment <NUM> to central processing system <NUM>.

When a grow tower <NUM> accelerates/decelerates in unload transfer conveyance mechanism <NUM>, the grow tower <NUM> may swing slightly. <FIG> and <FIG> illustrate a tower constraining mechanism <NUM> to stop possible swinging, and to accurately locate, a grow tower <NUM> during a laydown operation of automated laydown station <NUM>. In the implementation shown, mechanism <NUM> is a floor-mounted unit that includes a guided pneumatic cylinder <NUM> and a bracket assembly including a guide plate <NUM> that guides a tower <NUM> and a bracket arm <NUM> that catches the bottom of the grow tower <NUM>, holding it at a slight angle to better enable registration of the grow tower <NUM> to the bottom gripper assembly <NUM>. A control system may control operation of mechanism <NUM> to engage the bottom of a grow tower <NUM>, thereby holding it in place for gripper assembly <NUM>.

The end state of the laydown operation is to have a grow tower <NUM> laying on the projections <NUM> of the harvester infeed conveyor <NUM>, as centered as possible. In one implementation, a grow tower <NUM> is oriented such that hook <NUM> points towards harvester station <NUM> and, in implementations having hinged side walls, and hinge side down. The following summarizes the decisional steps that a controller for robot <NUM> may execute during a laydown operation.

The Main program for the robot controller may work as follows:.

The Pick Tower program may work as follows:.

The Place Tower program may work as follows:.

<FIG> and <FIG> illustrate an automated pickup station <NUM>. As shown, automated pickup station <NUM> includes robot <NUM> and pickup conveyor <NUM>. Similar to automated laydown station <NUM>, robot <NUM> includes end effector <NUM> for releasably grasping grow towers <NUM>. In one implementation, end effector <NUM> is substantially the same as end effector <NUM> attached to robot <NUM> of automated laydown station <NUM>. In one implementation, end effector <NUM> may omit support arms <NUM>. As described herein, robot <NUM>, using end effector <NUM>, may grasp a grow tower <NUM> resting on pickup conveyor <NUM>, rotate the grow tower <NUM> to a vertical orientation and attach the grow tower <NUM> to a carriage <NUM> of loading transfer conveyance mechanism <NUM>. As discussed above, loading transfer conveyance mechanism <NUM>, which may include be a power and free conveyor, delivers grow towers <NUM> to growth environment <NUM>. In one implementation, the buffer track section <NUM> of loading transfer conveyance mechanism <NUM> extends through a vertical slot in growth environment <NUM>, allowing mechanism <NUM> to convey grow towers <NUM> attached to carriages <NUM> into growth environment <NUM> from stop location <NUM>. Loading transfer conveyance mechanism <NUM> may use a controlled stop blade to stop the carriage <NUM> at the stop location <NUM>. The loading transfer conveyance mechanism <NUM> may include an anti-roll back mechanism, bounding the carriage <NUM> between the stop blade and the anti-roll back mechanism.

The following summarizes the decisional steps that a controller for robot <NUM> may execute during a pickup operation.

The Main program for the robot controller may work as follows for robot <NUM>:.

As discussed above, central processing system <NUM> may include harvester station <NUM>, washing station <NUM> and transplanter station <NUM>. Central processing system <NUM> may also include one or more conveyors to transfer grow towers <NUM> to or from a given station. For example, central processing system <NUM> may include harvester outfeed conveyor <NUM>, washer infeed conveyor <NUM>, washer outfeed conveyor <NUM>, transplanter infeed conveyor <NUM>, and transplanter outfeed conveyor <NUM>. These conveyors can be belt or roller conveyors adapted to convey grow towers <NUM> laying horizontally thereon. As described herein, central processing system <NUM> may also include one or more sensors for identifying grow towers <NUM> and one or more controllers for coordinating and controlling the operation of various stations and conveyors.

<FIG> illustrates an example processing pathway for central processing system <NUM>. As discussed above, a robotic picking station <NUM> may lower a grow tower <NUM> with mature crops onto a harvester infeed conveyor <NUM>, which conveys the grow tower <NUM> to harvester station <NUM>. <FIG> illustrates a harvester infeed conveyor <NUM>. Harvester infeed conveyor <NUM> may be a belt conveyor having a belt <NUM> including projections <NUM> extending outwardly from belt <NUM>. Projections <NUM> provide for a gap between belt <NUM> and crops extending from grow tower <NUM>, helping to avoid or reduce damage to the crops. In one implementation, the size the projections <NUM> can be varied cyclically at lengths of grow tower <NUM>. For example, projection 2004a may be configured to engage the end of grow tower <NUM>; top projection 2004d may engage the opposite end of grow tower <NUM>; and middle projections 2004b, c may be positioned to contact grow tower <NUM> at a lateral face where the length of projections 2004b, c are lower and engage grow tower <NUM> when the tower deflects beyond a threshold amount. The length of belt <NUM>, as shown in <FIG> can be configured to provide for two movement cycles for a grow tower <NUM> for each full travel cycle of the belt <NUM>. In other implementations, however, all projections <NUM> are uniform in length.

As <FIG> shows, harvester outfeed conveyor <NUM> conveys grow towers <NUM> that are processed from harvester station <NUM>. In the implementation shown, central processing system <NUM> is configured to handle two types of grow towers: "cut-again" and "final cut. " As used herein, a "cut-again" tower refers to a grow tower <NUM> that has been processed by harvester station <NUM> (i.e., the crops have been harvested from the plants growing in the grow tower <NUM>, but the root structure of the plant(s) remain in place) and is to be reinserted in growth environment <NUM> for crops to grow again. As used herein, a "final cut" tower refers to a grow tower <NUM> where the crops are harvested and where the grow tower <NUM> is to be cleared of root structure and growth medium and re-planted. Cut-again and final cut grow towers <NUM> may take different processing paths through central processing system <NUM>. To facilitate routing of grow towers <NUM>, central processing system <NUM> includes sensors (e.g., RFID, barcode, or infrared) at various locations to track grow towers <NUM>. Control logic implemented by a controller of central processing system <NUM> tracks whether a given grow tower <NUM> is a cut-again or final cut grow tower and causes the various conveyors to route such grow towers accordingly. For example, sensors may be located at pick position <NUM> and/or harvester infeed conveyor <NUM>, as well as at other locations. The various conveyors described herein can be controlled to route identified grow towers <NUM> along different processing paths of central processing system <NUM>. As shown in <FIG>, a cut-again conveyor <NUM> transports a cut-again grow tower <NUM> toward the work envelope of automated pickup station <NUM> for insertion into grow environment <NUM>. Cut-again conveyor <NUM> may consist of either a single accumulating conveyor or a series of conveyors. Cut-again conveyor <NUM> may convey a grow tower <NUM> to pickup conveyor <NUM>. In one implementation, pickup conveyor <NUM> is configured to accommodate end effector <NUM> of automated pickup station <NUM> that reaches under grow tower <NUM>. Methods of accommodating the end effector <NUM> include either using a conveyor section that is shorter than grow tower <NUM> or using a conveyor angled at both ends as shown in <FIG>.

Final cut grow towers <NUM>, on the other hand, travel through harvester station <NUM>, washing station <NUM> and transplanter <NUM> before reentering growth environment <NUM>. With reference to <FIG>, a harvested grow tower <NUM> may be transferred from harvester outfeed conveyor <NUM> to a washer transfer conveyor <NUM>. The washer transfer conveyor <NUM> moves the grow tower onto washer infeed conveyor <NUM>, which feeds grow tower <NUM> to washing station <NUM>. In one implementation, pneumatic slides may push a grow tower <NUM> from harvester outfeed conveyor <NUM> to washer transfer conveyor <NUM>. Washer transfer conveyor <NUM> may be a three-strand conveyor that transfers the tow to washer infeed conveyor <NUM>. Additional pusher cylinders may push the grow tower <NUM> off washer transfer conveyor <NUM> and onto washer infeed conveyor <NUM>. A grow tower <NUM> exits washing station <NUM> on washer outfeed conveyor <NUM> and, by way of a push mechanism, is transferred to transplanter infeed conveyor <NUM>. The cleaned grow tower <NUM> is then processed in transplanter station <NUM>, which inserts seedlings into grow sites <NUM> of the grow tower. Transplanter outfeed conveyor <NUM> transfers the grow tower <NUM> to final transfer conveyor <NUM>, which conveys the grow tower <NUM> to the work envelope of automated pickup station <NUM>.

In the implementation shown in <FIG>, harvester station <NUM> comprises crop harvester machine <NUM> and bin conveyor <NUM>. Harvester machine <NUM> may include a rigid frame to which various components, such as cutters and feed assemblies, are mounted. Harvester machine <NUM>, in one implementation, includes its own feeder mechanism that engages a grow tower <NUM> and feeds it through the machine. In one implementation, harvester machine <NUM> engages a grow tower <NUM> on the faces that do not include grow sites <NUM> and may employ a mechanism that registers with grooves 58a, 58b to accurately locate the grow tower and grow sites <NUM> relative to harvesting blades or other actuators. In one implementation, harvester machine <NUM> includes a first set of rotating blades that are oriented near a first face <NUM> of a grow tower <NUM> and a second set of rotating blades on an opposing face <NUM> of the grow tower <NUM>. As the grow tower <NUM> is fed through the harvester machine <NUM>, crop extending from the grow sites <NUM> is cut or otherwise removed, where it falls into a bin placed under harvester machine <NUM> by bin conveyor <NUM>. Harvester machine <NUM> may include a grouping mechanism, such as a physical or air grouper, to group the crops at a grow site <NUM> away from the face plates <NUM> of the grow towers <NUM> in order to facilitate the harvesting process.

Bin conveyor <NUM> may be a u-shaped conveyor that transports empty bins the harvester station <NUM> and filled bins from harvester station <NUM>. In one implementation, a bin can be sized to carry at least one load of crop harvested from a single grow tower <NUM>. In such an implementation, a new bin is moved in place for each grow tower that is harvested. In one implementation, grow towers <NUM> enter the harvester machine <NUM> full of mature plants and leave the harvester machine <NUM> with remaining stalks and soil plugs to be sent to the next processing station.

<FIG> is a top view of an example harvester machine <NUM>. Circular blades <NUM> extending from a rotary drive system <NUM> harvest plants on opposing faces 101a of grow towers <NUM>. In one implementation, rotary drive system <NUM> is mounted to a linear drive system <NUM> to move the circular blades <NUM> closer to and farther away from the opposing faces 101a of the grow towers <NUM> to optimize cut height for different types of plants. In one implementation, each rotary drive system <NUM> has an upper circular blade and a lower circular blade (and associated motors) that intersect at the central axis of the grow sites of the grow towers <NUM>. Harvester machine <NUM> may also include an alignment track <NUM> that includes a set of rollers that engage groove <NUM> of the grow tower <NUM> as it is fed through the machine. Harvester machine <NUM> may also include a tower drive system that feeds grow towers through the machine at a constant rate. In one implementation, the tower drive system includes two drive wheel and motor assemblies located at opposite ends of harvester machine <NUM>. Each drive wheel and motor assembly may include a friction drive roller on the bottom and a pneumatically actuated alignment wheel on the top. As <FIG> illustrates, harvester machine <NUM> may also include a gathering chute <NUM> that collects harvested crops cut by blades <NUM> as it falls and guides it into bins located under the machine <NUM>. In another implementation, the harvester station <NUM> may include a track including an alignment feature and one or more engagement actuators, as discussed above, to align the grow tower <NUM> relative to harvesting blades that are moved across a stationary grow tower <NUM>. In another implementation, the harvesting blades may be replaced by another harvest mechanism, such as a picker assembly adapted to harvest different types of crops.

Washing station <NUM> may employ a variety of mechanisms to clean crop debris (such as roots and base or stem structures) from grow towers <NUM>. To clean a grow tower <NUM>, washing station <NUM> may employ pressurized water systems, pressurized air systems, mechanical means (such as scrubbers, scrub wheels, scrapers, etc.), or any combination of the foregoing systems. In implementations that use hinged grow towers (such as those discussed above), the washing station <NUM> may include a plurality of substations including a substation to open the front faces <NUM> of grow towers <NUM> prior to one or more cleaning operations, and a second substation to close the front faces <NUM> of grow towers after one or more cleaning operations.

Transplanter station <NUM>, in one implementation, includes an automated mechanism to inject root-bound plugs into grow sites <NUM> of grow towers <NUM>. In one implementation, the transplanter station <NUM> receives plug trays containing root-bound plugs including seedlings to be transplanted into the plug holders <NUM> of the grow towers <NUM>. In one implementation, transplanter station <NUM> includes a robotic arm and an end effector that includes one or more plug grippers that grasps root-bound plugs from a plug tray and inserts them into plug holders <NUM> of grow tower <NUM>. For implementations where grow sites <NUM> extend along a single face of a grow tower, the grow tower may be oriented such that the single face faces upwardly or laterally. For implementations where grow sites <NUM> extend along opposing faces of a grow tower <NUM>, the grow tower <NUM> may be oriented such that the opposing faces having the grow sites <NUM> face laterally (horizontally). In other implementations, as <FIG> shows, the front face plates <NUM> of grow towers <NUM> may be decoupled and rotated such that the grow sites <NUM> face generally upwardly for transplant operations.

<FIG>, <FIG> and <FIG> illustrate an example transplanter station <NUM> according to one possible implementation. Transplanter station <NUM> may include a plug tray conveyor <NUM> that positions plug trays <NUM> within the working envelope of a robotic arm <NUM> and associated end effector. Transplanter station <NUM> may also include a feed mechanism that loads a grow tower <NUM> into place for transplanting. Transplanter station <NUM> may include one or more robotic arms <NUM> (such as a six-axis robotic arm), each having an end effector <NUM> and one or more plug grippers <NUM> each adapted to grasp a root-bound plug from a plug tray and inject the root bound plug into a grow site <NUM> of a grow tower <NUM>.

<FIG> illustrates an example end effector <NUM> that includes a carriage <NUM> and multiple plug grippers <NUM> extending from the carriage <NUM>. The plug grippers <NUM> are attached to carriage <NUM> and are each pivotable from a first angular orientation to a second angular orientation. In a first angular orientation (top illustration of <FIG>), plug grippers <NUM> extend perpendicularly relative to the carriage <NUM>. In one implementation, plug grippers <NUM> are positioned in this first angular orientation when picking plugs from a plug tray <NUM>. In the second angular orientation shown in <FIG>, each plug gripper <NUM> extends at a <NUM>-degree (or other desired) angle relative to the carriage <NUM>. The <NUM>-degree angle may be useful for injecting plugs into the plug containers <NUM> of grow towers <NUM> that, as discussed above, extend at a <NUM>-degree angle relative to the injection plane or front face <NUM> of a grow tower <NUM>. Other implementations are possible. For example, the second angular orientation will generally conform to the angular orientation of plug containers <NUM>. For example, the plug containers <NUM> illustrated in the various drawings are oriented ~<NUM> degrees relative to the front face <NUM> (injection plane) of a given grow tower <NUM>. Therefore, the second angular orientation is also ~<NUM> degrees, matching the angular orientation of the plug containers <NUM>. Accordingly, the second angular orientation will generally vary with the targeted or designed angular orientation of the plug container and may vary depending on design goals and engineering constraints. Furthermore, the spacing of plug grippers <NUM> generally conforms to the spacing of the plug containers <NUM>.

A pneumatic actuator system may control the pivoting of the plug grippers <NUM> between the first angular orientation and the second angular orientation. For example, a common bar or other member <NUM> may attach to each of the plug grippers <NUM> as shown in <FIG>. The common bar <NUM> may also be attached to or otherwise guided by features of carriage <NUM> and slidable there along. As shown in <FIG>, one or more actuators <NUM> attached to the common bar <NUM> may move from a retracted position to an extended position, moving common bar <NUM> and causing each of plug grippers <NUM> to rotate about their respective attachment points to carriage <NUM>. In operation, the plug grippers <NUM> may be in the first position when picking up root-bound plugs from a plug tray, and then may be moved to the second position prior to insertion of the plugs into plug containers <NUM>. In such an insertion operation, the robotic arm <NUM> can be programmed to insert the plug grippers in a direction of motion parallel with the orientation of the plug container <NUM>, generally along a path having the second angular orientation relative to the insertion plane.

Using the end effector <NUM> illustrated in <FIG>, multiple plug containers <NUM> may be filled in a single operation. In addition, the robotic arm <NUM> may be configured to perform the same operation at other regions on one or both sides of a grow tower <NUM>. As <FIG> shows, in one implementation, several robotic arms <NUM>, each having an end effector <NUM>, may be used to lower processing time for a given grow tower <NUM>. After grow sites <NUM> are filled, the grow tower <NUM> is ultimately conveyed to automated pickup station <NUM>, as described herein, and ultimately inserted into the controlled growth environment <NUM>. In the implementation shown, an infeed mechanism (see below) moves a grow tower <NUM> in a single operation into transplanter station where multiple robotic arms <NUM> (and associated end effectors <NUM>) operate to fill all grow sites <NUM> of a grow tower before an outfeed mechanism moves the tower <NUM> from the station <NUM>. Other implementations are possible. For example, transplanter station <NUM> may be configured to move a robotic arm <NUM> along a grow tower <NUM> to reduce the number of robotic arms <NUM> required. Alternatively, the transplanter station <NUM> may be configured to convey sections of a grow tower <NUM> to a robotic arm <NUM> in successive transplant operations. In other implementations, a single end effector <NUM> may correspond to a section and side of a grow tower <NUM>. In such an implementation, the robotic or other actuation systems for moving the end effector <NUM> may be simplified.

<FIG> illustrates an example plug gripper <NUM> in a retracted position. <FIG> illustrates an example plug gripper <NUM> in an extended position. In the implementation shown, plug gripper <NUM> includes a base <NUM>, a stripper plate assembly <NUM>, an actuator <NUM>, and opposing gripper arms 2608a, 2608b. Base <NUM> rotatably attaches to carriage <NUM> of end effector <NUM> as shown in <FIG>. As <FIG> shows, stripper plate assembly <NUM> comprises extension member <NUM> extending from base <NUM> and stripper plate <NUM> extending from extension member <NUM>. Extension member <NUM> holds stripper plate <NUM> at a desired distance from base <NUM>. Actuator <NUM> is operative to move gripper arms 2608a,b from a retracted position (<FIG>) to an extended position (<FIG>). Gripper arms 2608a, 2608b extend through slots <NUM> of stripper plate <NUM> when the plug gripper is moved from the retracted to the extended position. In the implementation shown, stripper plate <NUM> has an overall U-shape and extends substantially over the entire area (or at least over the entire width in one dimension) defined by the top of the plug container <NUM> of a plug tray <NUM> (see <FIG>). In other implementations, the stripper plate <NUM> may have a substantially rectangular overall configuration. As <FIG> show, each gripper arm 2608a, 2608b may include two prongs; however, each gripper arm 2608a, 2608b may include fewer or more prongs. In the implementation shown, when actuator <NUM> is in the retracted position, the ends of gripper arms 2608a, 2608b are substantially at the same level as stripper plate <NUM> with ends engaged in respective slots <NUM>. When actuator <NUM> is in the extended position, gripper arms 2608a, 2608b extend past stripper plate <NUM> through slots <NUM>. Additionally, when the gripper arms 2608a, 2608b are extended, they may be configured to extend at an angle toward one another to hold a plug securely. This slight interference forces gripper arms 2608a and 2608b to pinch together slightly as they extend, creating a secure hold on the seedling plug. In one implementation, the gripper arm material is a tempered stainless steel to provide adequate spring force while maintaining corrosion resistance and cleanability. In one implementation, the width of gripper arms 2608a, 2608b are narrowed at the top region <NUM> under the screws <NUM> to act as a flexure and concentrate the majority of the bending at that location. Other implementations are possible. The dimensions and overall configuration of the gripper arms will depend on the application, as well as the shape and configuration of the plugs and plug trays. In addition, stripper plate <NUM> may not include slots. In such an implementation, gripper arms 2608a, 2608b extend along opposing outside edges of the plate. In one implementation, the stripper plate <NUM> may include features near the ends of what would otherwise be complete slots <NUM> to help guide the 2608a, 2608b.

<FIG> is a perspective view of an alternative plug gripper <NUM>. As <FIG> illustrates, plug gripper <NUM> comprises actuator <NUM>, guide bracket <NUM>, and arm assembly <NUM>. Actuator <NUM>, in one implementation, is a pneumatic linear actuator that attaches to guide bracket <NUM> and arm assembly <NUM>. Arm assembly <NUM> includes two laterally opposing palm sections <NUM> extending from base section <NUM>. Arms <NUM> extend from the palm sections <NUM>, as shown in <FIG>. Expansion and retraction of actuator <NUM> causes arm assembly <NUM> to move relative to guide bracket <NUM>, as shown in <FIG>. Guide bracket <NUM> includes first and second guide members <NUM> that extend upwardly from a stripper plate <NUM>. As <FIG> show, similar to gripper <NUM>, arms <NUM> extend through slots <NUM> of stripper plate <NUM> as the actuator <NUM> moves between the retracted and extended positions. In the implementation shown, stripper plate <NUM> has an overall U-shape and extends substantially over the entire area (or at least over the entire width in one dimension) defined by the top of the plug container <NUM> of a plug tray <NUM> (see <FIG>). In other implementations, the stripper plate <NUM> may have a substantially rectangular overall configuration.

In the implementation shown, guide members <NUM> and stripper plate <NUM> are configured to include a substantially U-shaped configuration. In one implementation, the inner surfaces of guide members <NUM> are configured to contact and guide arms <NUM> as the extend and retract. In one implementation, the inner surfaces of guide members <NUM> can be coated to mitigate mechanical wear due to frictional contact with arm assembly <NUM>. The location of slots <NUM> are configured to cause arms <NUM> to bend inwardly to facilitate gripping of a plug as they extend beyond stripper plate <NUM>. In one implementation, arms <NUM> may be reinforced relative to palm sections <NUM> to promote arm assembly <NUM> to bend at palm sections <NUM> leaving the arms <NUM> substantially straight. In one implementation, arms <NUM> may be reinforced by configuring them to have a slight arc as shown in <FIG> to resist bending.

Guide members <NUM> also have the advantage of deflecting away from the arms <NUM> leaves or other parts of a plant extending from the plug being gripped. In addition, the outer surfaces of guide members <NUM> may also be configured to facilitate insertion of the gripper <NUM> into a plug site <NUM> of a grow tower <NUM>. For example, the contour of the outer surface of guide members <NUM> can be configured to guide the gripper <NUM> into plug containers <NUM> as they are inserted.

<FIG> is a perspective view of yet another alternative plug gripper. Plug gripper <NUM> comprises actuator <NUM>, bracket <NUM>, arm assembly <NUM> and stripper plate <NUM>. Plug gripper <NUM> differs from grippers <NUM> and <NUM> in that the actuator <NUM> attaches directly to and moves the stripper plate <NUM>, instead of arm assembly <NUM>. Arm assembly <NUM> attaches to bracket <NUM>; otherwise, arm assembly <NUM> is substantially the similar to the arm assembly <NUM> discussed above. As actuator <NUM> retracts, it causes stripper plate <NUM> to move arms <NUM> inwardly, as discussed above, to grip a plug. As actuator extends, arms <NUM> move outwardly.

The configuration of plug gripper <NUM> requires the robotics associated with transplanter <NUM> to operate somewhat differently. In particular, because arms <NUM> do not move relative to stripper plate <NUM>, the robotic arm connected to the plug gripper <NUM> must move during plug pickup and insertion operations. For example, during an insertion operation, the robotics inject the gripper <NUM> holding a plug into a plug site <NUM>. When stripper plate <NUM> is moved to a programmed distance relative to the plug site <NUM>, the robotics must move gripper away from the plug site <NUM> at the same speed and angular orientation as the actuator extends. In this manner, stripper plate <NUM> remains in the same place relative to the plug site <NUM> and pushes the plug away into plug site <NUM>, as the robotic arm extracts arms <NUM> from the plug site <NUM>. Conversely, during a plug pickup operation, the robotic arm must move the arms <NUM> toward the plug to be grasped at the same speed that the actuator retracts. Otherwise, plug gripper <NUM> is substantially interchangeable with plug gripper <NUM> or <NUM>.

<FIG> shows an example plug tray <NUM> that is configured to hold a plurality of root-bound plugs to be inserted into respective grow sites <NUM> of a grow tower <NUM>. Plug tray <NUM> contains a two-dimensional array of plug containers <NUM>. <FIG> illustrates an example shape of a root-bound plug <NUM> that a plug container <NUM> may hold. In one implementation, the number of plug containers <NUM> in a given row can match the number of plug grippers <NUM> attached to end effector <NUM>. In other implementations, the number of plug containers <NUM> in a given row can be a multiple of the number of plug grippers <NUM> attached to end effector <NUM>. In one implementation, gripper arms 2608a, 2608b are configured to spear into the plug medium and pinch the plug <NUM> to grasp a plug <NUM> substantially near its outer surface. Similarly, the inner dimensions of plug holder <NUM> of a grow tower <NUM> are also configured to substantially match the dimension of plug container <NUM> and the corresponding plug <NUM>. Accordingly, when a plug gripper <NUM> holds a plug, gripper arms 2608a, 2608b hold it in place relatively firmly from the outer surface of the plug <NUM>. In addition, the gripper arms 2608a, 2608b and plug <NUM> are dimensioned, in one implementation, to essentially achieve a press fit with respect to the plug holder <NUM>. As discussed below, stripper plate <NUM>, spanning the entire width of a plug <NUM> in at least one dimension, prevents a plug <NUM> from sliding back out of the plug holder <NUM> when gripper arms 2608a, 2608b are retracted.

<FIG> illustrates an infeed mechanism <NUM> that facilitates insertion of a grow tower <NUM> into transplanter station <NUM>. In one implementation, transplanter station <NUM> includes a track (discussed below) that guides and aligns grow tower <NUM> for transplanting operations. In the implementation shown, infeed mechanism <NUM> may include a drive wheel and motor assembly to feed a grow tower <NUM> into transplanter station <NUM>. In one implementation, the drive wheel and motor assembly may include a friction drive roller <NUM> that engages the grow tower <NUM> from the bottom and a pneumatically-actuated alignment wheel <NUM> that engages top groove <NUM> of grow tower <NUM>, pressing it against friction drive roller <NUM>. Infeed mechanism <NUM> may further include a lead-in feature <NUM> to guide the grow tower <NUM> into infeed mechanism <NUM> to correct for gross misalignment of the grow tower <NUM>. In one implementation, a control system drives infeed mechanism <NUM> to operate until an entire grow tower <NUM> is inserted into transplanter station <NUM>. As discussed, infeed mechanism <NUM> drives a grow tower <NUM> causing it to slide along a track <NUM> of transplanter station <NUM> (see <FIG>). Other implementations for feeding towers <NUM> into transplanter station <NUM> are possible. For example, in other implementations, the groove region <NUM> of a grow tower <NUM> may include a row of teeth extending along the length of the tower. In such an implementation, a friction drive wheel can be replaced by a toothed wheel that positively engages the teeth in grove region <NUM>. Such an implementation would allow the infeed mechanism to track the position of the grow tower as it moves through the transplanter <NUM>.

After transplanter station <NUM> completes one or more transplanting operations for a given grow tower <NUM>, a control system drives outfeed mechanism <NUM> to translate the grow tower <NUM> out of transplanter station <NUM> where it can be eventually injected into growth environment <NUM>. <FIG> illustrates an outfeed mechanism <NUM>. Similar to infeed mechanism <NUM>, outfeed mechanism <NUM> includes a drive wheel and motor assembly. In the implementation shown, friction drive roller <NUM> engages the bottom of grow tower <NUM>, while a pneumatically-actuated alignment wheel <NUM> engages groove <NUM> from the top of grow tower <NUM> driving the grow tower <NUM> against friction drive roller <NUM>. In one implementation, outfeed mechanism <NUM> may include an actuated stop to accurately locate grow tower <NUM> relative to the station <NUM>.

<FIG> and <FIG> illustrate a track <NUM> that may be used to guide a grow tower <NUM> within and along a transplanter station <NUM>. As <FIG> illustrates, as infeed mechanism <NUM> translates a grow tower <NUM>, track <NUM> acts as a guide. <FIG> illustrates an example profile for track <NUM>. The track profile may include a base section <NUM>, side ridges <NUM> and guide projection <NUM>. Ridges <NUM> and guide projection <NUM> run substantially the length of track <NUM>. <FIG> illustrates a track section <NUM>, a plurality of which may be aligned and attached to transplanter station <NUM> to form track <NUM>. For example, track section <NUM> may be one meter in length. In such an implementation, five track sections may be used to form a <NUM>-meter track <NUM>. Track section <NUM> may be made of plastic (such as high-density polyethylene (HDPE), ultra-high molecular weight (UHMW) polyethylene, Delrin® offered by DuPont®, etc.) or some other low-friction, wear-resistant material. The profile of guide projection <NUM> substantially matches, and is the inverse form, of at least a section of groove <NUM> of grow tower <NUM>. As shown in <FIG>, grow tower <NUM> contacts and slides along ridges <NUM> as it moves in and out of transplanter station <NUM>, guided by projection <NUM>. In the implementation shown, the modeled distance between groove <NUM> and projection <NUM> is approximately <NUM>-<NUM> millimeters.

A variety of configurations involving groove <NUM> and projection <NUM> are possible. <FIG> illustrates that the cross-section profile of grow tower <NUM> includes a substantially V-shaped section define a groove <NUM> along the length of grow tower <NUM> and that the cross-section profile of track <NUM> includes a matching, substantially V-shaped section defining projection <NUM>. In other implementations, the profile sections defining these features can be semi-circular, triangular or any other suitable shape. Furthermore, the profile sections associated with groove <NUM> and projection <NUM> need not be perfectly complimentary. In general, projection <NUM> can be any suitable shape that guides a grow tower <NUM> along groove <NUM> during transfer operations, and that centers grow tower <NUM> along the alignment feature provided by projection <NUM> when one or more engagement actuators (see below) exert a force to press the grow tower <NUM> against the track <NUM>.

Grow tower <NUM>, as discussed above, may be a relatively long structure (e.g., ~<NUM>-<NUM> meters) composed of an extruded plastic. Accordingly, the relative locations of grow sites <NUM> may vary over the length of a grow tower <NUM>. For example, a slight curvature or other variation of a grow tower <NUM> may cause the grow sites <NUM> to vary in one or two dimensions in addition to the longitudinal axis along which the grow sites <NUM> are spaced. This variation may prevent challenges to the transplant operations described herein. For example, the attachment of plug grippers <NUM> to a common carriage <NUM> requires that the front face plate <NUM> is substantially uniform across the length of the carriage <NUM>. Accordingly, to facilitate the transplant operations described herein, it may be advantageous to reduce spatial variation across grow sites <NUM>. As <FIG> illustrates, in one implementation, transplanter station <NUM> includes tower registration actuators <NUM> disposed above track <NUM>. After a grow tower <NUM> is inserted into transplanter station <NUM>, actuators <NUM> are controlled to press down on grow tower <NUM> at defined points along and above track <NUM>. The force exerted by actuators <NUM> deflects grow tower <NUM>, causing groove <NUM> to register against projection <NUM> and centering the grow tower along track <NUM>. Registering the surface of groove <NUM> against projection <NUM> reduces variation of grow sites <NUM> along grow tower <NUM> in two dimensions. In particular and with reference to a grow tower <NUM> disposed on track <NUM>, if the length of a grow tower <NUM> is considered the x-axis, the width or face of a grow tower <NUM> the y-axis and the height the z-axis, then registration of the grow tower <NUM> against profile section <NUM> and track <NUM> generally reduces variation of the grow sites <NUM> relative to each other in the y- and z-axes. Accordingly, transplanter station <NUM> may include cameras or other sensors to locate grow sites <NUM> in the remaining x-axis dimension to facilitate insertion of plugs at plug holders <NUM>. Still further, such an implementation allows relaxation of manufacturing tolerances for grow towers <NUM> and/or reduces the number of sensors required to locate the plug holders <NUM> for transplant operations.

<FIG> illustrates an example tower registration actuator <NUM>. In the implementation shown, tower registration actuator <NUM> includes a linear actuator <NUM> (e.g., a pneumatic actuator), a ball and swivel joint <NUM>, and an engagement member <NUM> mounted to the end of the actuator. As <FIG> illustrates, the profile of engagement member <NUM> may substantially match the outer, upper surface of grow tower <NUM>. The profile of engagement member <NUM> can be an extruded, molded or machined part and may vary in length depending on a variety of engineering and other design considerations. For example, engagement member <NUM> may be <NUM>-<NUM> centimeters in length. In other implementations, engagement member may be <NUM> meters in length. As <FIG> illustrates, multiple actuators <NUM> may be disposed along track <NUM> to facilitate registration of various sections of grow tower <NUM> relative to an operator, such as robotic arm <NUM>. Other implementations are possible. For example, as <FIG> demonstrate, engagement member <NUM> may be have a disc shape with a flat profile configured to engage the upper surfaces of grow tower <NUM>, as opposed to groove <NUM>. In both configurations, ball and swivel joint <NUM> allows for misalignment when pressing the grow tower <NUM> against projection <NUM> of track <NUM>.

The following description sets forth an example process flow and operation for transplanter station <NUM>. Infeed mechanism <NUM> feeds a grow tower <NUM> into transplanter station along track <NUM> until it hits a defined stop location. As <FIG> illustrates, transplanter station <NUM> contains the entire grow tower <NUM>. The grow tower <NUM> is oriented such that the opposing tower faces <NUM> with plug holders <NUM> face horizontally. Actuators <NUM> press grow tower <NUM> onto track <NUM> reducing variation in two dimensions of the location of plug holders <NUM> along grow tower <NUM>, as discussed above. A control system operates robotic arms <NUM> and respective end effectors <NUM> to pick up rows of plugs from a plug tray <NUM> and insert them into plug holders <NUM>, as discussed below. In the implementation shown in <FIG>, a given robotic arm <NUM> may be cycled through four insertion operations to inject plugs at two regions and on each side of grow tower <NUM>. After transplanter station <NUM> fills all plug holders <NUM> of grow tower <NUM>, actuators <NUM> release the tower <NUM>, allowing outfeed mechanism <NUM> to feed the grow tower <NUM> from transplanter station <NUM>.

During a transplant operation, plug grippers <NUM> are positioned over respective plug containers <NUM> of a plug tray <NUM>. In some implementations, robotic arm <NUM> positions plug grippers <NUM> such that stripper plate <NUM> is positioned substantially adjacent to the top surface of a root-bound plug contained in plug container <NUM> and/or at the top surface of plug container <NUM>. Actuators <NUM> are then controlled to drive gripper arms 2608a, 2608b into the lateral sides of plug container <NUM> to engage a plug. Robotic arm <NUM> then moves end effector <NUM> vertically upward to lift the plugs out of their respective plug containers <NUM>. Robotic arm <NUM> then moves the end effector <NUM> such that the plugs are in a horizontal orientation near the insertion plane of the grow tower <NUM> and facing the horizontally-arranged plug holders <NUM> of grow tower <NUM>. Pneumatic controls cause plug grippers <NUM> to rotate to the desired insertion angle (in one embodiment, <NUM> degrees). Robotic arm <NUM> then moves the end effector <NUM> at the desired insertion angle causing plug grippers <NUM> to insert the plugs into respective plug holders <NUM>. Actuators <NUM> are then controlled to retract grippers 2608a, 2608b along the insertion angle. Stripper plate <NUM> may cause a plug to remain in plug holder <NUM>. Robotic arm <NUM> then moves end effector <NUM> away from grow tower <NUM> and back to plug tray <NUM> to begin another transplant cycle.

A variety of implementations are possible. A single robotic arm can be used in connection with an assembly that moves robotic arm along the grow tower <NUM>. Alternatively, the grow tower <NUM> could be incrementally moved relative to the robotic arm. Plug trays may be oriented vertically instead of horizontally. In such a configuration, a robotic arm may need not operate in six degrees of freedom to effect the plug insertion operations described herein. Still further, grow towers <NUM> may be opened prior to transplanting operations, as discussed above. In such an implementation, the faces <NUM> of grow tower <NUM> may be oriented horizontally, eliminating the need for robotic arm to orient the plug grippers <NUM> horizontally. Still further, other actuators, such as a cartesian gantry system, may be used in lieu of robotic arms.

One or more of the controllers discussed above, such as the one or more controllers for central processing system <NUM> (or one or more stations therein), may be implemented as follows. <FIG> illustrates an example of a computer system <NUM> that may be used to execute program code stored in a non-transitory computer readable medium (e.g., memory) in accordance with embodiments of the disclosure. The computer system includes an input/output subsystem <NUM>, which may be used to interface with human users or other computer systems depending upon the application. The I/O subsystem <NUM> may include, e.g., a keyboard, mouse, graphical user interface, touchscreen, or other interfaces for input, and, e.g., a LED or other flat screen display, or other interfaces for output, including application program interfaces (APIs). Other elements of embodiments of the disclosure, such as the controller, may be implemented with a computer system like that of computer system <NUM>.

Program code may be stored in non-transitory media such as persistent storage in secondary memory <NUM> or main memory <NUM> or both. Main memory <NUM> may include volatile memory such as random-access memory (RAM) or non-volatile memory such as read only memory (ROM), as well as different levels of cache memory for faster access to instructions and data. Secondary memory may include persistent storage such as solid-state drives, hard disk drives or optical disks. One or more processors <NUM> reads program code from one or more non-transitory media and executes the code to enable the computer system to accomplish the methods performed by the embodiments herein. Those skilled in the art will understand that the processor(s) may ingest source code, and interpret or compile the source code into machine code that is understandable at the hardware gate level of the processor(s) <NUM>. The processor(s) <NUM> may include graphics processing units (GPUs) for handling computationally intensive tasks.

The processor(s) <NUM> may communicate with external networks via one or more communications interfaces <NUM>, such as a network interface card, WiFi transceiver, etc. A bus <NUM> communicatively couples the I/O subsystem <NUM>, the processor(s) <NUM>, peripheral devices <NUM>, communications interfaces <NUM>, memory <NUM>, and persistent storage <NUM>. Embodiments of the disclosure are not limited to this representative architecture. Alternative embodiments may employ different arrangements and types of components, e.g., separate buses for input-output components and memory subsystems.

Those skilled in the art will understand that some or all of the elements of embodiments of the disclosure, and their accompanying operations, may be implemented wholly or partially by one or more computer systems including one or more processors and one or more memory systems like those of computer system <NUM>. In particular, the elements of automated systems or devices described herein may be computer-implemented. Some elements and functionality may be implemented locally, and others may be implemented in a distributed fashion over a network through different servers, e.g., in client-server fashion, for example.

Although the disclosure may not expressly disclose that some embodiments or features described herein may be combined with other embodiments or features described herein, this disclosure should be read to describe any such combinations that would be practicable by one of ordinary skill in the art. Unless otherwise indicated herein, the term "include" shall mean "include, without limitation," and the term "or" shall mean non-exclusive "or" in the manner of "and/or.

Those skilled in the art will recognize that, in some embodiments, some of the operations described herein may be performed by human implementation, or through a combination of automated and manual means. When an operation is not fully automated, appropriate components of embodiments of the disclosure may, for example, receive the results of human performance of the operations rather than generate results through its own operational capabilities.

Claim 1:
A transplanter for injecting plugs at non-perpendicular angles relative to an injection plane of a container (<NUM>), comprising
a carriage (<NUM>);
one or more plug grippers (<NUM>), wherein each plug gripper (<NUM>) is attached to the carriage (<NUM>) and rotatable about an axis from a first angular orientation to a second angular orientation;
a first actuator operably attached the one or more plug grippers (<NUM>) and operative to rotate each of the one or more plug grippers (<NUM>) about a respective axis from the first angular orientation to the second angular orientation;
a second actuator attached to the carriage (<NUM>) and operative to position the one or more plug grippers (<NUM>) proximal to the injection plane and move the carriage (<NUM>) along a path having the second angular orientation relative to the injection plane, wherein the injection plane is defined by a surface associated with a container (<NUM>) that includes one or more plug holders (<NUM>) having the second angular orientation relative to the injection plane; and
a control system operative to control the first and second actuators to effect transplant operations,
wherein each plug gripper comprises
a base (<NUM>);
a plug gripper actuator (<NUM>) attached to the base (<NUM>) and having a first end, the plug gripper actuator (<NUM>) operative to move the first end along a first direction from a retracted position to an extended position;
first and second opposing gripper arms (2608a, 2608b) extending substantially parallel the first direction;
a stripper plate (<NUM>) extending between the first and second gripper arms (2608a, 2608b) and in a perpendicular orientation relative to the first direction,
wherein the stripper plate or the first and second gripper arms are operably attached to the first end of the plug gripper actuator.