Patent Document

RELATED APPLICATIONS 
       [0001]    This application is related to commonly-owned U.S. patent application Ser. No. 14/339,015, submitted Jul. 23, 2014, by Kent Kernahan, which is incorporated herein by reference in its entirety, herein after “the &#39;015 disclosure”. This application is also related to commonly owned U.S. patent application Ser. No. 14/341,774 submitted Jul. 25, 2014, by Kent Kernahan, which is incorporated herein by reference in its entirety, herein after “the &#39;774” disclosure. 
     
    
     BACKGROUND 
       [0002]    Aeroponics is the technique of growing plants by providing droplets of water, and possibly water with nutrients, to plant roots, wherein the droplets are smaller than the pore size of the roots. 
         [0003]    An aeroponic growth system generally comprises a system for delivery of nutrient-rich water to one or more plants, light, and fresh air. The system may be outdoors, in a green house, or may be within a facility that includes the provision of light for plant growth, and centralized delivery of water and electrical power. 
         [0004]    Such facilities may be constructed on a large scale, covering thousands of square feet. The facility may be configured to produce a variety of crops, or just one. Between setup (planting) and harvest time there is little need for human attendance save for checking to insure that all is well. However sometimes the crop is very valuable, and may be lost if certain problems persist for a fairly short time. Due to the power requirements for light and distribution of water a significant amount of heat may be generated. Such heat may be generally removed by the proper use of fans, for example, but heat that is localized in a small area may destroy some amount of a valuable crop in spite of the general heat-removal system. Likewise if light is lost to a localized area the crop in that area may under-produce its expected value. 
         [0005]    A large aeroponic facility may be constructed using growing systems that are much smaller than the facility, for example just a few feet on a side. These systems generally include some automated means for periodically providing water or mist to the plant roots, refilling a reservoir, and managing light cycles and intensity. In a facility that may include thousands of growing systems it can be labor intensive to monitor for proper operation of each one. Such systems may also be inflexible. 
         [0006]    What is needed is a facility-wide system to control and monitor the facility at large as well as each growing system to insure proper operation and safety. It would be advantageous to also report status and various operational conditions to a central location within or away from the facility. It would also be desirable to provide for remotely altering the control programs of the growing systems. 
       SUMMARY 
       [0007]    The present disclosure describes a system for a control system for a single growth system, expandable to a large facility comprising an essentially unlimited number of growth systems. It is assumed that all growth systems are provided with adequate water from a central supply and power external to an individual growth system. A system comprises a removable sensor system and supporting power collar (or “cradle”); electronics instantiated within the growth system; an uninterruptable power supply (“UPS”); a link server for system wide control; a lighting system including monitoring of power and fire detection; wired communications between systems in a common enclosure; and a wireless infrastructure, for example a Wi-Fi system including transceivers, access points, router, gateway and internet access. There may also be optional equipment also capable of wireless communications. 
         [0008]    The apparatus required for one embodiment of the present disclosure will be disclosed, followed by a disclosure of the various connectivity paths and control systems. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0009]    The accompanying drawings, which are incorporated herein and constitute part of this specification, illustrate exemplary aspects of the invention, and, together with the general description given above and the detailed description given below, serve to explain features of the invention. 
           [0010]      FIG. 1  shows all major systems for a complete aeroponic growth system and the communications paths between them. 
           [0011]      FIG. 2  shows the various pumps and valves being controlled. 
           [0012]      FIG. 3  is a detail of an electronic control subsystem. 
           [0013]      FIG. 4  is a diagram of an LEF system. 
           [0014]      FIG. 5  shows a water and nutrient distribution system. 
           [0015]      FIG. 6  is a list of symbols used in  FIG. 5 . 
       
    
    
     DETAILED DESCRIPTION 
       [0016]    The various embodiments will be described in detail with reference to the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts. References made to particular examples and implementations are for illustrative purposes, and are not intended to limit the scope of the invention or the claims. 
       Apparatus 
       [0017]    An aeroponic growth system will be referred to as an “atrium”  190 , which includes the electronics and various mechanical systems embodied in an enclosure including a water reservoir and a top, wherein the plants being grown generally are kept in a basket-type device with the roots extending down towards the bottom of the reservoir. In some systems there is little water; the box is to provide a volume for the roots to occupy. The systems providing the present invention may comprise a portable, wireless sensor system  160  and a collar  170  affixed to a container for the water, nutrients, and various pumps and other equipment  180  for growing plants according to the aeroponic methodology  190 . A system referred to as a “LEF”  110 , or Lights, Exhaust gas temperature, and Fan control includes lighting equipment, a wireless communications device, temperature sensor, fire detector, fan, and input terminals for mains power. Some number of access points  102  are connected to a router  101  connected to a LAN/WAN  103  and may also connect to a local console  104  and another router providing firewall protection  015  and eventually connection to the internet  107 . A link server  150  may include wireless capability, and be in communication with all other appliances on the network, whether via Wi-Fi or wired via a wireless node. 
         [0018]    In some embodiments there is optional equipment, some, all or none of which may be utilized at a given installation. Examples include a smart tablet or phone  120 , a camera  130 , and a roving sensor  140 . The atrium  190  may be contained in a single enclosure, which may include some overhead support structures. The system  190  may include a QR code conveniently placed where the tablet or smart phone  120  or camera  130  may read the QR code and report it to the link server  150 , thereby making an association of a specific system  190 . An electronic serial number (“ESN”) in the collar  170  makes a logical association between the system  190  and the instant WAND  170 . A QR code emblem in the LEF  110  may be used in the same manner. 
         [0019]    A system referred to as a “WAND”  160 , an acronym for Water, Air, Network Device, may be provisioned with a variety of sensors according to the system designer&#39;s need. In some embodiments of the instant disclosure the WAND  160  comprises air sensors for CO2, CO, and O2, and a sensor for ambient light. The WAND  160  may also comprise water sensors, for sensing pH, temperature, TDS (total dissolved solids) or resistivity. 
         [0020]    The WAND  160  may be completely devoid of internal power, instead be inserted into a collar  170  wherein the collar induces power into the WAND  160  via proximate coils. Such an arrangement enables a system to be built and used wherein the WAND  160  is easily removable for a variety of reasons. Examples include replacement due to failure or changing the sensor complement of a given WAND  160 , therefore growth system  190 . 
         [0021]    WANDs  160  may be configured with wireless communications capability, thereby acting as a gateway. Wired communications are sometimes provided by inductively communicating between the WAND and the collar  170 , the collar  170  in turn connected to other devices within the growth system  190  by any means. The collar  170  includes an ESN, which may then be used to identify a given growth system  190  to the link server  150 . Further details regarding the WAND  160  and the collar  170  may be found in the ‘ 774  disclosure. 
         [0022]    Looking to  FIG. 2 , detailing the subsystems  180  associated with the atrium  190 , an RS-485 bus  205  provides for communication between the atrium electronics  181  and the collar  170 . 
         [0023]    Looking to  FIG. 3 , the ACE (atrium chamber electronics)  181  comprises a mister system  235 ; a pump for mixing and siphon priming  240 ; a valve to a water source  245 ; two pumps to water misters, one for a first bank  255  and one for a second bank  260 ; and five canister dispensing pumps with check valves. The canisters may be for the following nutrients ( FIG. 2 ): phosphate  265 ; nitrogen  270 ; potassium  275 ; acid for pH decreasing  280 ; and a base for increasing pH  285 . The ACE  181  also includes a status/warning light  350 . 
         [0024]    An MCU  310  manages the various sensors and drivers in order to control the hardware systems within the atrium  190 . Mains power  302  is provided to the system from the facility in which it is operated. The mains  302  provide high voltage, for example 120 VAC to a 24 VDC converter  303 . The 24 VDC converter  303  provides operating power to the downstream pumps. A UPS  345  senses the output of the mains  302 , and under certain conditions, for example power failure, takes over and provides  120  VAC to the  24  VDC supply, which continues to operate until either power is restored to the mains  302  or the UPS  345  unit&#39;s battery fails, and which time the entire atrium  190  fails. The UPS  345  system provides a unique safety backup similar to how data centers are configured to be failure resistant. 
         [0025]    The UPS  345  may communicate with the MCU  310  via a USB line  330 , providing data as to the condition of the mains  302  level and the state of the UPS  345  backup battery. 
         [0026]    Consider an atrium  190  comprising nine plant locations in nine plant baskets. Each plant is provided with two transducers to generate mist for the roots from two small reservoirs holding the water or water enriched with nutrients. In one embodiment eighteen mister drivers  315  provide control signals to the eighteen transducers. Signals from the mister drivers are provided to an analog front end  305 , wherein the signals are converted to digital versions of the analog signals and provided to the MCU on a bus  306 . The data is used by the MCU to determine if a transducer has gone bad or a reservoir gone dry, causing the transducer to shut down. 
         [0027]    A motor driver  325  includes seven outputs for driving pumps, for example peristaltic pumps. For backup, the nine misters comprising two small water reservoirs per plant are refilled by two different pumps  255 ,  260  such that if one side fails to all nine mister reservoirs the other pump will likely still be operable. The other five motor driver  325  output signals control individual canister pumps wherein each canister contains a liquid or gel nutrient. For example, in one embodiment the five canister pumps are assigned to canisters holding phosphate  265 ; nitrogen  270 ; potassium  275 , an acid to decrease pH  280 ; and a base to raise the pH. 
         [0028]    A water level sensor  320 , for example an eTape Water Level Sensor, provides a signal voltage that varies with how much water the sensor  320  is covered by. The water level sensed is the main water reservoir of the atrium  190 . 
         [0029]    The status light system  350  provides different color lights which may be turned on by the system to identify status or problems. An example component is a QLight St56ECF-BZ-1, available from QLight, 185-25, Mukbang-ro, Sangdong-myeon, Gimhae-si, Gyeongsangnam-do 621-812 Korea. The light  350  may signal such conditions as good, a warning that the water level is low but useable, or an out of service condition such as failure of the mister pumps ( 255 ,  260 ). 
         [0030]    A solenoid controller  335  controls a valve for adding water  245  and another valve for priming the draining tube  240 . There is also a pump control for operating a circulation/draining pump  250 . 
         [0031]      FIG. 4  is an example of a system referred to as a Lights, EGT, and Fan system or “LEF”  110 . The LEF  110  performs several functions wirelessly other than the mains power  405  provided by the facility in which it is installed. 
         [0032]    AC power is delivered  405  to a relay  440  for turning on lights  470 . The lights  470  maybe be any suitable lighting technology. A controller system  415  includes components for rectification and voltage reduction as needed. The controller  415  may comprise an MCU for controlling the system  110  and an analog front end or other ADC functionality. A contactless AD voltage and current sensor  410  provides signals to the ADC within the controller  415 . AC mains power  405  may also be provided to a fan  450 , enabled or disabled by a relay  430  under the control of the controller  415 . A temperature sensor  460  for sensing the local temperature provides its signal to the ADC of the controller  415 . 
         [0033]    A two-way wireless device  420 , for example a Wi-Fi transceiver, may be connected to the controller  415 , thereby enabling the controller  415  to report the LEF  110  status to the link server  150  or to receive a recipe or commands from the link server  150 . A QR sticker  480  may be viewed by the smart device  120  or camera  130  to associate the instant LEF with a particular atrium  190  or position in the facility. 
         [0034]    The controller may perform several functions beyond energizing and de-energizing relays. For example, the controller  415  may read the temperature from sensor  460  and if the temperature is above a predetermined value turn on the fan  450  until the temperature returns to a desirable value. The controller may also have a predetermined cycle of turning the lights  470  ON and OFF per instructions from the link server  150 . In some embodiments other sensors may be provided, for example a CO detector or fire detector for protection of the atrium, facility, or human staff. 
       Communication and Control 
       [0035]    The system of  FIG. 1  may be related to just one atrium in service. However it may be deployed in a large plant growing facility, thereby providing efficiency by amortizing the cost of some components over a larger number of atriums  190 . The key component in the system  100  is a link server  150 . The link server may support any wireless technology, such as Wi-Fi or a proprietary technology. In some embodiments all of the communication equipment is off the shelf components, configured as a unique command and control system. 
         [0036]    A key component of the system  100  is a link server  150 . The link server may be designed in a variety of ways, for example a programmed Raspberry Pi. Strictly for the purpose of illustration, a Wi-Fi based system has been arbitrarily selected to be an example for the instant disclosure. 
         [0037]    The link server performs a variety of functions. In some embodiments the link server  150  collects data from other wireless components of the system, connecting via one or more access points  102 , wherein the access points  102  are deployed throughout the growth facility so that there are no “blind spots” for data and control. For example the link server may receive requested air or water sensor data from the WAND  160 . The WAND  160  is coupled to the collar  170  for data from ACE  181  on an RS-485 bus  205  ( FIG. 2 ) enabling data, status and such related to the entire atrium  190  via the WAND Wi-Fi link. 
         [0038]    When a WAND  160  is installed in a collar  170  a pairing procedure may command the WAND  160  to interrogate an ESN in the collar, thereby matching the WAND  160  with the collar  170 , thereby the atrium  190  for which the WAND  160  provides data. In some embodiments a controller in the WAND  160  has been set up by the link server  150  to report various sensor data per a schedule. In other embodiments the link server  150  requests sensor data when it wants it, which may be in place of or in addition to the schedule in place in the WAND. 
         [0039]    In a similar fashion, the link server  150  may provide ON/OFF pattern data to the controller  310  in the ACE  181  for scheduling the operation of the water pumps  255 ,  260 ,  240 ,  245 ,  250  or the ON/OFF times for the mister transducers. As with the WAND, the ACE  181  controller  310  functions may be per patterns and schedules commanded by the link server, or a local function, or a combination of the two. 
         [0040]    Data from the link server, for example the status and other information of a given atrium  190  may be provided to a wireless tablet or smart phone  120 . The tablet or smart phone  120  may be used the other way as well. That is, to send commands to the link server. For example, the link server  150  could be commanded to turn all lights ON or OFF. A camera  130 , either dedicated or a camera that may be included in a smart tablet or phone  120  may interrogate a QR code sticker on an atrium  190  or a LEF  110 , thereby to cause an association with an atrium  190  and a newly installed WAND  160 . In some embodiments QR stickers are placed on various known positions in a facility and, again, making the location of the QR code known. For example, the camera  130  may be used to report the position of a portable sensor, such as a system for determining ambient temperature, by scanning the QR code sticker on a nearby atrium  190 . 
         [0041]    The access points  102  may connect to a router  101 , which would take care of such network duties as assignment of DNSs to all devices in the LAN. A factory console  104  may connect to the link server  150  through the router for the purpose of getting data, status, downloading recipes, and even insuring that the link server  150  is healthy. 
         [0042]    In some embodiments atriums  190  are installed adjacent to each other, for example nine in a row. This configuration is referred to as a “master/slave” arrangement. This may provide for several advantages. For example, each atrium may include a siphon tube between each atrium in line. Installation may be accomplished by filling two adjacent atrium units  190  with the desired amount of water, then priming the siphon tube with a mechanical priming tool. This would be done in sequence until the end of a row, for example nine atriums  190 , then the tube exiting the last atrium  190  may be returned to the water siphon input of the first atrium  190 , thereby completing a water circuit. A pump  245  may keep the water flowing between units, thereby keeping water from becoming stagnant or gross variations between atriums  190 . In some embodiments only one WAND  160  has water and air sensors, the other atriums  190  being equipped with WAND  160  units which are only for communication. 
         [0043]      FIG. 5  provides details of the master/slave configuration.  FIG. 6  is a table of the meaning of various symbols used by  FIG. 5   
         [0044]    When water from the pump  245  is to be directed to mix in nutrients and/or stir the tank  505  for measurements, the mixing/siphon break valve  240  is opened and the pump  245  is switched on. Since the siphon drain line  510  requires a higher water head than the mixing/siphon break line  515  and the check valve will prevent back flow, water flows through the open valve through the eddy jet and back into the tank  505 . 
         [0045]    When a water drain process is initiated, the mixing/siphon break valve  240  is closed and the pump  245  is switched on. A check valve will prevent back flow while the siphon primes. Falling water levels inside the tank, as measured by the water level sensor  320 , will confirm that the siphon drain  510  is primed and running. At this point the check valve will have opened and draining will continue with the pump switched off. 
         [0046]    If a drain operation is to be partial, the siphon may be interrupted by opening the mixing/siphon break valve  240 . Since the eddy jet  520  is always above the water line, the open valve will introduce air to the siphon, terminating the drain operation. 
         [0047]    In some embodiments the inlet filter and measurement channel and pump are inside a “pump bag” inside the main mixing tank. A pump bag is commonly used in swimming pools as a pre-filter for a pump. It is simply a bag made out of filter material. In one embodiment it is just a bag which is open at the top, above the water line that provides a filtered area of water within the main tank  505 . 
         [0048]    The siphon input picks up inside the tank  505  and the check valve is close to the pickup end of the Siphon input line. The siphon drain (top end of the siphon) rises over the edge of the tank  505 . 
         [0049]    Note that the siphon input is not inside the pump bag so that the tank can drain at max rate, even if the pump bag is fouled. The pump is inside the pump bag to protect the pump. The pump input and the siphon input are not the same line and the check valve is not in the pump input. Since the Siphon input tube is inside the tank, the mixing/siphon break valve is also inside the tank above the water line but below the edge of the tank and importantly BELOW the peak of the siphon drain tube. This is also true for the mixing/siphon break line  515 , the venturi and eddy jet  520 . 
         [0050]    The preceding description of the disclosed embodiments is provided to enable any person skilled in the art to make or use the present invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other embodiments without departing from the spirit or scope of the invention. Thus, the present invention is not intended to be limited to the embodiments shown herein but is to be accorded the widest scope consistent with the following claims and the principles and novel features disclosed herein.

Technology Category: 5