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. However, the spacing between plants appears to be fixed. <CIT> describes a hydroponic system comprising a plurality of seedbeds, a suspension section, and a conveyance mechanism. The suspension section suspends the seedbeds in a state in which the plurality of seedbeds are arrayed in a horizontal direction from a seedling planting side to a harvesting side. The conveyance mechanism conveys the plurality of seedbeds in a horizontal direction while widening the gaps between the seedbeds in the horizontal direction in a stepwise or continuous manner. <CIT> describes equipment for moving plant bodies, in which plural columns supporting culturing plants are movably supported by a support frame leaving a space in the direction of movement. A conveying mechanism set under a plant-supporting unit is equipped with a mobile frame, a drive frame, a coupling mechanism for coupling both the frames and a drive mechanism allowing the drive frame to perform a reciprocating motion in the direction of movement. The coupling mechanism occupies the holding position where the columns are held by the mobile frame and moved in the same direction only in a forward movement operation of the mobile frame while the mobile frame performs a reciprocating motion corresponding to a reciprocating motion of the drive frame. <CIT> describes a unit for plant culture comprising mobile modules suspended vertically so as to form lines of modules which receive the plants. The modules are driven with a rotary movement about their vertical axis and with a translation movement which makes it possible to displace the modules horizontally. <CIT> describes a light-weight, modular, adjustable vertical hydroponic growing system and method of Native American design for cultivation plants and beneficial soil organisms in symbiotic combination.

The present disclosure is directed to a vertical farming structure having vertical grow towers and associated funnel systems. A conveyance mechanisms for moving the vertical grow towers through a controlled environment, while being exposed to controlled conditions, such as lighting, airflow, humidity and nutritional support via the funnel, is provided. The present disclosure describes a reciprocating cam mechanism that provides a cost-efficient mechanism for conveying vertical grow towers in the controlled environment. The reciprocating cam mechanism can be arranged to increase the spacing of the grow towers as they are conveyed through the controlled environment to index the crops growing on the towers. The present disclosure also describes an irrigation system that provides aqueous nutrient solution to the vertical grow towers.

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.

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 embodiment of the invention. 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> <NUM>. 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>.

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 that can be used in connection with various embodiments of the invention. 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>×<NUM> (<NUM>,<NUM>×<NUM>,<NUM> inches) to 76mmx76mm (3x3 inches) 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> (<NUM>,<NUM> to <NUM>,<NUM> inches). 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 that may be used in embodiments of the invention. 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.

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 invention 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 unhinged (i.e., 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>, according to one possible implementation of the invention. 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 cam structure to move grow towers <NUM> along grow line <NUM>. <FIG> and <FIG> illustrate one possible reciprocating cam mechanism that can be used to move grow towers <NUM> across grow lines <NUM>. 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 according to one implementation of the invention. 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 engage 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> to an open position (<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. During the back stroke, the leading section 604a moves backward, while the trailing section remains stationary, until the expansion joint reaches the initial, collapsed 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 openings or 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> (<NUM>,<NUM> inches) and holes having diameters of <NUM> (<NUM>,<NUM> inches). 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 or aperture for each collector. In some implementations, an emitter structure or nozzle may be attached to each hole or aperture. 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.

Claim 1:
A funnel (<NUM>) for use in a vertical grow tower (<NUM>), comprising
a collector (<NUM>);
first and second passageways (<NUM>) in fluid communication with the collector (<NUM>);
a first slot disposed in the collector (<NUM>) and in the fluid communication path between the collector and the first passageway; and
a second slot disposed in the collector (<NUM>) and in the fluid communication path between the collector and the second passageway;
wherein the first and second slots (<NUM>) are arranged to cause fluid to accumulate in the collector (<NUM>) and distribute the fluid substantially evenly to the first and second passageways (<NUM>).