Autonomous hydroponic seed germination system, components thereof and method of operation thereof

Abstract

The present invention relates to an autonomous hydroponic seed germination system (AHSGS) for hydroponically germinating seeds into tender shoot products in a seed germination tray. The AHSGS comprises: a climate-controlled automated hydroponic seed germination box having a hydroponic seed germination chamber and at least one shuttle; the working unit comprises at least one robot, and the at least one robot is provided with a hinge arm used for firmly clamping the seed germination tray; and the work station is used for enabling an operator to set the operation parameters of the AHSGS and monitor the operation of the AHSGS.

Description

Technical Field

[0001] The invention relates to an automated hydroponic seed germination system. Background Art

[0002] The automated hydroponic seed germination system makes germinating seeds into sprout products for human consumption and / or livestock consumption cost-effective, space-effective, labor-effective and environmentally considerate. Summary of the invention

[0003] The present invention relates to an autonomous hydroponic seed germination system, components thereof, and methods of operation thereof for hydroponically germinating seeds in seed germination trays into sprout products for human and / or livestock consumption.

[0004] The autonomous hydroponic seed germination system uses a seed germination tray to germinate fresh seeds into a sprout product. The seed germination tray is optionally substantially rectangular in shape and 1m×1m square. The seed germination tray is configured to be securely clamped by the articulated arm of the robot and the shuttle of the automated hydroponic seed germination box for manipulation. The seed germination tray is optionally divided into at least four seed germination tray sub-areas and includes a drainage arrangement for draining excess irrigation water from the seed germination tray. The drainage arrangement is optionally configured as a series of through holes.

[0005] The autonomous hydroponic seed germination system includes: a climate-controlled automated hydroponic seed germination box, similar to an automated storage and retrieval system (AS / RS), for hydroponically germinating seeds in seed germination trays into sprout products; a work unit, the work unit including at least one robot; and a workstation, the workstation being used to enable an operator to set operating parameters of the autonomous hydroponic seed germination system and monitor the operation of the autonomous hydroponic seed germination system, the workstation including a controller for simultaneously controlling the automated hydroponic seed germination box and the work unit.

[0006] A climate controlled automated hydroponic seed germination box includes a hydroponic seed germination chamber having at least a pair of spaced apart parallel seed germination tray racks having at least four shelves in height and configured to receive a plurality of seed germination trays there along. The automated hydroponic seed germination box includes at least one shuttle slidably displaceable along a shuttle track between the seed germination tray racks to place seed germination trays with fresh seeds on the seed germination tray shelves and, after a predetermined seed germination period, to remove seed germination trays with sprouted products from the seed germination tray shelves. The seed germination chamber includes the following arrangements: an illumination arrangement for illuminating the seed germination trays; an irrigation arrangement for irrigating the seed germination trays; and a drainage arrangement for draining excess irrigation water from the seed germination trays. The seed germination room maintains the following climate parameters to achieve optimal seed germination: temperature of about 20°C to about 25°C, humidity of about 65% to about 90%, CO2 concentration of about 500 ppm to about 1,500 ppm and wind speed along it of about 0.5 msec -1 to about 2msec -1 .

[0007] The work unit includes at least one robot having an articulated arm for firmly gripping a seed germination tray for manipulation. The robot transfers the seed germination tray with fresh seeds to an automated hydroponic seed germination box for seed germination. The seed germination tray with fresh seeds may be prepared in advance or alternatively prepared on-site at the work unit. The robot preferably empties the seed germination tray of the sprout product by inverting the seed germination tray, at which point the sprout product of the seed germination tray is emptied from the seed germination tray by gravity due to its weight. The robot preferably inserts the seed germination tray emptied of the sprout product into a cleaning station for cleaning and disinfection, thereby reloading with fresh seeds.

[0008] For optimal efficiency, the robot preferably continuously and securely grips the seed sprouting tray and performs the following steps: lifting the seed sprouting tray with the sprouted product, inverting the seed sprouting tray to empty the seed sprouting tray of the sprouted product by gravity at the sprouted product station, inserting the seed sprouting tray into a cleaning station for cleaning and sterilization, removing the cleaned and sterilized seed sprouting tray from the cleaning station, holding the seed sprouting tray under a fresh seed dispenser to dispense at least one fresh seed dose on the seed sprouting tray, and repeatedly and rapidly agitating the seed sprouting tray in an XY horizontal plane to flatten the at least one fresh seed dose so that the fresh seeds are evenly spread throughout the seed sprouting tray. The time the robot spends handling the seed sprouting tray is relatively insignificant compared to the seed germination period for hydroponically sprouting seeds into sprouted products.

[0009] The autonomous hydroponic seed germination system preferably includes a seed germination tray buffer located between the automated hydroponic seed germination box and the work unit for facilitating the transfer of seed germination trays therebetween. The seed germination tray buffer may be implemented by, for example, a motorized inbound conveyor for transporting seed germination trays with fresh seeds from the work unit to the automated hydroponic seed germination box and a motorized outbound conveyor for transporting seed germination trays with sprouted products from the automated hydroponic seed germination box to the work unit; a motorized conveyor belt similar to an airport baggage conveyor belt; a seed germination tray rack for holding a stack of seed germination trays, etc.

[0010] The autonomous hydroponic seed germination system preferably includes a fresh seed station for preparing seed germination trays with fresh seeds on site. The fresh seed station includes a fresh seed dispenser for dispensing a fresh seed dose of a predetermined weight. The fresh seed dose typically has a mound-like appearance. The robot securely clamps the seed germination tray under the fresh seed dispenser and agitates the seed germination tray repeatedly and rapidly, preferably in an XY horizontal plane, to flatten the fresh seed dose, thereby evenly spreading the fresh seeds throughout the seed germination tray.

[0011] The climate-controlled automated hydroponic seed germination box optionally includes a separate climate-controlled seed imbibition station. The seed imbibition station includes a seed germination tray rack for accommodating seed germination trays with fresh seeds for imbibition of seeds ready for transfer to the hydroponic seed germination chamber. The seed imbibition station includes a spray device for generating a nearly 100% wet mist in a nearly sealed closed environment to absorb water equivalent to soaking fresh seeds in water. The seed germination tray is placed on the seed germination tray rack in the seed imbibition station and is removed from the seed germination tray rack by a shuttle in the same manner as in the hydroponic seed germination chamber.

[0012] The shuttle optionally includes one or more climate sensors for monitoring climate conditions at different locations in the hydroponic seed germination chamber so as to be able to detect possible failures of the lighting arrangement, irrigation arrangement, etc. The climate sensors include one or more of the following: humidity sensor, temperature sensor, CO2 sensor, and anemometer. The shuttle optionally includes a photometer for monitoring light at different locations in the hydroponic seed generation chamber.

[0013] The autonomous hydroponic seed germination system preferably includes a weighing machine for weighing the sprout product of the seed germination tray. The weighing machine preferably records the weight of the sprout product of each seed germination tray at the workstation for monitoring.

[0014] The autonomous hydroponic seed germination system may optionally include one or more cameras for imaging the sprout product to monitor seed germination. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] In order to understand the invention and see how it may be carried out in practice, preferred embodiments will now be described, by way of non-limiting example only, with reference to the accompanying drawings in which like parts are numbered alike and in which:

[0016] Figure 1 It is a schematic diagram of the autonomous hydroponic seed germination system;

[0017] Figure 2 It is a schematic diagram of the autonomous hydroponic seed germination system;

[0018] Figure 3 It is a schematic diagram of the fresh seed station;

[0019] Figure 4 It is a schematic diagram of an automated hydroponic seed germination box;

[0020] Figure 5 is along Figure 4 Longitudinal cross section of the automated hydroponic seed germination box of the middle AA line;

[0021] Fig. 6A is a schematic diagram of the seed germination tray rack and shuttle;

[0022] Figure 6B is an end view of a pair of spaced apart seed germination tray racks and shuttles;

[0023] Figure 7 is a close-up schematic diagram of a section of a seed germination tray shelf;

[0024] Figure 8 is a schematic diagram of a shuttle including a seed germination tray carriage;

[0025] Fig. 9is a schematic diagram of a seed swelling station of an automated hydroponic seed germination box;

[0026] Fig.10 is a schematic diagram of a work cell including a robot, an inbound conveyor, an outbound conveyor, a sprout product station, and a washing station;

[0027] Fig.11 is a schematic diagram of a robot in a work cell;

[0028] Fig.12 It is a front view schematic diagram of the cleaning station of the work unit;

[0029] Fig.13A It is a top view schematic diagram of a seed germination tray;

[0030] Fig. 13B yes Fig.13A A bottom view of a seed germination tray;

[0031] Fig.14 yes Fig.13A A partially exploded bottom view of a seed germination tray;

[0032] Fig.15 yes Fig.11 Schematic diagram of the robot firmly holding the seed germination tray;

[0033] Fig.16A yes Fig.11 Schematic diagram of a robot securely holding a seed germination tray with four fresh seed doses;

[0034] Fig. 16B yes Fig.11 The robot stirs firmly, repeatedly and quickly in the XY plane Fig.16A Schematic diagram of a seed germination tray to evenly distribute four fresh seed doses;

[0035] Fig. 16C yes Fig.11 schematic diagram of a robot inverting a seed germination tray to empty it of its sprout product by gravity; and

[0036] FIG. 17A to FIG. 17G is a series of schematic top views showing a shuttle slidingly pulling a seed germination tray thereon from an inbound conveyor and slidingly pushing the seed germination tray onto a seed germination tray shelf. DETAILED DESCRIPTION

[0037] Autonomous hydroponic seed germination system

[0038] Figure 1 and Figure 2An autonomous hydroponic seed germination system (AHSGS) 100 for hydroponically germinating fresh seeds into sprout products is shown, along with Cartesian coordinate systems X, Y, and Z axes, wherein the X and Y axes define an XY horizontal plane. The AHSGS 100 includes a controller 101 for controlling the following subsystems: a fresh seed station 200, a climate-controlled automated hydroponic seed germination box (AHSGE) 300, and a work unit 400. The work unit 400 is typically housed in a closed environment to protect it from the prevailing weather conditions.

[0039] The AHSGS 100 includes a workstation 102 that instructs the controller 101 to enable an operator to set the operating parameters of the AHSGS 100 and monitor the operation of the AHSGS. The workstation 102 is preferably in the form of a computerized human-machine interface (HMI). The workstation 102 is preferably operated by a touch screen. The workstation 102 can be interfaced with a smartphone installed with a dedicated application for operating the AHSGS 100 and monitoring its operation.

[0040] AHSGS100 adopts the following reference Figure 13 and Fig.14 The described seed germination tray 500 is used to hydroponically germinate fresh seeds into sprout products. The seed germination tray 500 is preferably 1m×1m square and 10cm deep. The seed germination tray 500 is preferably made of polypropylene or similar plastic material. The seed germination tray 500 preferably each has a unique tray identifier 501. Suitable tray identifiers 501 include barcodes, QR codes, etc. in particular. The seed germination tray 500 includes at least four seed germination tray sub-areas 508, so that fresh seeds are evenly spread throughout them for germination, and then the sprout products are taken out for further processing. The seed germination tray 500 includes a drainage arrangement 511 for draining excess irrigation. The drainage arrangement 511 is optionally implemented by an array of through holes in the form of holes, slits, etc.

[0041] The fresh seed station 200 includes a seed silo 201 , a fresh seed dispenser 202 for dispensing a fresh seed dose of a predetermined weight, and a seed delivery pipe 203 connecting the seed silo 201 to the fresh seed dispenser 202 .

[0042] The AHSGE 300 includes a front wall 301, a rear wall 302, opposing side walls 303 and 304, and a top 306. The front wall 301 includes a front window 301A, and a pair of spaced-apart front wall hatches 307 and 308. The front wall hatches 307 and 308 are provided with cold room-like partitions for minimizing free air passage between the AHSGE 300 and its external environment. The AHSGE 300 includes a front seed germination tray processing chamber 309 and a rear hydroponic seed germination chamber 311 adjacent to and distal to the front wall 301, respectively. The front seed germination tray processing chamber 309 generally occupies a smaller portion of the AHSGE 300 than the rear hydroponic seed germination chamber 311. The AHSGE 300 may optionally include a cold room-like partition between the front seed germination tray handling chamber 309 and the rear hydroponic seed germination chamber 311 to minimize free air passage therebetween, thereby facilitating maintaining the rear hydroponic seed germination chamber 311 at optimal climate conditions for seed germination.

[0043] The seed germination tray processing chamber 309 includes a seed swelling station 312 for swelling the seeds during a predetermined seed swelling period. The hydroponic seed germination chamber 311 includes a lighting arrangement 313, an irrigation arrangement 314, and a drainage arrangement 316 for germinating the seeds during a predetermined seed germination period. The AHSGE 300 includes a shuttle 317 for traveling between the seed germination tray processing chamber 309 and the hydroponic seed germination chamber 311.

[0044] The work cell 400 preferably includes a robot 401, a motorized inbound conveyor 402, a motorized outbound conveyor 403, a sprout product station 404, and a cleaning station 406. The inbound conveyor 402 has an inbound conveyor start end 402A adjacent to the robot 401 and an inbound conveyor end end 402B located inside the AHSGE 300. The outbound conveyor 403 has an outbound conveyor start end 403A located inside the AHSGE 300 and an outbound conveyor end end 403B adjacent to the robot 401, the sprout product station 404, and the cleaning station 406.

[0045] The robot 401 is used to securely clamp the seed sprouting tray 500 under the fresh seed dispenser 202 so that the seeds are evenly spread on the seed sprouting tray, place the seed sprouting tray 500 on the inbound conveyor 402 for transportation to the AHSGE 300 for an initial predetermined seed imbibition period and a subsequent predetermined seed germination period, remove the seed sprouting tray 500 with the sprouted product from the outbound conveyor 403 for transportation from the AHSGE 300, invert the seed sprouting tray 500 to empty the sprouted product from the seed sprouting tray 500 by gravity at the sprouted product station 404, and insert the empty seed sprouting tray 500 into the cleaning station 406 for cleaning and disinfection for reuse.

[0046] The AHSGS100 can be easily expanded to provide a wide range of daily sprout products. For example, the AHSGE 300 can be designed to provide 5 tons of feed biscuits per day for livestock consumption. Seed germination usually increases the weight by 5 times, so that in a 6-day seed germination period, 15kg of fresh seeds germinate into 75kg of sprout products. Producing 5 tons of feed biscuits per day requires about 70 seed germination trays, each of which will harvest 75kg of sprout products per day: 75kg x 70 seed germination trays = 5,250kg of sprout products per day.

[0047] Assuming that each seed germination tray rack has 7 shelves in height, 70 seed germination trays occupy 5 shelves in length along a pair of spaced parallel seed germination tray racks, i.e., 7 shelves high × 5 shelves long × 2 seed germination tray racks = 70 seed germination trays. Therefore, in order to provide 5 tons of feed biscuits per day during the 6-day seed germination period, the seed germination tray rack is required to be 5 shelves long × 6 days seed germination period = 30m long.

[0048] Fresh Seed Station

[0049] Figure 3 A fresh seed station 200 is shown in communication with the workstation 102 for dispensing a predetermined weight of fresh seed dose onto the seed germination tray 500. The fresh seed station 200 includes a seed silo 201 containing loose seeds, a fresh seed dispenser 202 for dispensing the predetermined weight of fresh seed dose, and a pipe 203 connecting the seed silo 201 and the fresh seed dispenser 202. The seed silo 201 includes an outlet valve 204, such as an Exair Line Vac outlet valve, which uses a venturi effect to draw the loose seeds from the seed silo 201 to the fresh seed dispenser 202. The fresh seed dispenser 202 includes an outlet valve 206 for handling the predetermined weight of fresh seed dose. The fresh seed dose typically has a mound-like appearance.

[0050] Automated hydroponic seed germination box

[0051] Figure 4 The external dimensions of the AHSGE 300 are shown: length L, width W and height H. Typical dimensions for producing 5 tons of feed biscuits per day are L=10m, W=4m and H 4m. The inbound conveyor end 402B extends through the front wall hatch 307 into the seed germination tray processing chamber 309. The outbound conveyor start 403A extends through the front wall hatch 308 into the seed germination tray processing chamber 309 opposite the inbound conveyor start 402A. The shuttle 317 usually stops in the seed germination tray processing chamber 309.

[0052] Figure 5 AHSGE 300 is shown to include a double wall construction for maintaining a highly controlled climate for hydroponic germination of seeds into sprout products. AHSGE 300 includes standard HVAC equipment for maintaining the following climate parameters: temperature of about 20°C to about 25°C, humidity of about 65% to about 90%, CO2 concentration of about 500ppm to about 1,500ppm and wind speed along the standard HVAC equipment of about 0.5msec -1 to about 2msec -1 .

[0053] Fig. 6A , Figure 6B and Figure 7 The seed germination chamber 311 is shown to include a pair of spaced apart parallel seed germination tray racks 318. Each of the seed germination tray racks 318 has seven seed germination tray shelves 319 in height. The seed germination tray shelves 319 are configured to hold eight seed germination trays 500 along them. The seed germination tray shelves 319 have a pair of spaced apart parallel seed germination tray supports 321 for snugly receiving the seed germination trays 500 therebetween. The lighting arrangement 313 for illuminating the seed germination trays 500 is preferably in the form of elongated LEDs 322 extending along the length of the seed germination tray shelves 319. The irrigation arrangement 314 for irrigating the seed germination trays 500 is preferably in the form of a spray device 323 for spraying on each seed germination tray quadrant 508. The drain arrangement 316 includes a drain tube 324 extending along the underside of each seed germination shelf 319, with a drain port 326 aligned in registration with the drain arrangement 511 of the seed germination tray for collecting excess irrigation water therefrom.

[0054] Figure 8 The shuttle 317 is shown to include a seed germination tray carriage 327, the size and shape of which are similar to the size and shape of the seed germination tray 500 for carrying the seed germination tray. The shuttle 317 travels along a shuttle double track 328, which extends between a pair of spaced parallel seed germination tray racks 318 to shift along the X axis. Shock absorbers 329 are provided at the opposite ends of the shuttle double track 328 for softly stopping the seed germination tray carriage 327 there. The shuttle 317 enables the seed germination tray carriage 327 to shift along the Z axis.

[0055] The seed germination tray carriage 327 includes a pair of spaced apart parallel belts 331, i.e., a left belt 331A and a right belt 331B, each belt being provided with a pair of equally spaced displacement hooks 332 and 333, such that the pair of spaced apart parallel belts 331 has a first pair of spaced apart displacement hooks 332 for uniformly engaging the seed germination tray 500 and a second pair of spaced apart displacement hooks 333 for uniformly engaging the seed germination tray 500. The belts 331 are driven to rotate counterclockwise relative to each other, i.e., one belt 331 is driven clockwise and the other belt 331 is driven counterclockwise, to displace the seed germination tray 500 laterally horizontally in the Y direction relative to the seed germination tray carriage 327. The belts 331 are preferably step-driven, i.e., the belts 331 are driven only when it is necessary to displace the seed germination tray 500 laterally horizontally. The belt 331 can rotate bi-directionally, ie, clockwise and counterclockwise, depending on the relative position between the seed germination tray carriage 327 and the seed germination tray bearing surface (ie, the inbound conveyor 402, the outbound conveyor 403 and the seed germination tray shelf 319).

[0056] The seed germination tray carriage 327 includes one or more climate sensors for monitoring climate conditions at different locations in the hydroponic seed germination chamber 311 so as to be able to detect failures of the lighting arrangement 313 and the irrigation arrangement 314. Exemplary failures include LED burnout, clogged spray devices, etc. The climate sensors include one or more of the following: humidity sensor 334, temperature sensor 336, CO2 sensor 337, and anemometer 338. The shuttle 317 optionally includes a photometer 339 for monitoring light at different locations in the seed generation chamber 311.

[0057] Fig. 9A climate controlled seed swelling station 312 is shown in communication with the workstation 102 for operation and monitoring. The seed swelling station 312 includes a seed suction station housing 341 having a seed swelling station housing front surface 342 and housing a seed germination tray rack 343 for holding a seed germination tray 500 for swelling fresh seeds ready for transfer to the hydroponic seed germination chamber 311. The seed swelling station housing front surface 342 has an array of apertures 344 aligned with the seed germination tray rack 343. The seed swelling station 312 is connected to a water source 346 and a drain port 347 for drainage, the water source being used to supply water to a spray device (not shown) to produce a nearly 100% wet mist therein. The seed swelling station 312 optionally includes a control panel 348 for controlling its operation. The seed swelling station housing 341 includes a brush-like cover 349 similar to a cold room divider for covering the array of apertures 344 to facilitate maintaining nearly 100% humidity. The shuttle 317 places the seed germination tray 500 on the seed germination tray rack 343 and takes the seed germination tray out of the seed germination tray rack 343 in the same manner as on the seed germination tray shelf 319 .

[0058] Work Unit

[0059] Fig.10 A work cell 400 is shown in communication with the work station 102 for operation and monitoring. The work cell 400 includes a robot 401, an inbound conveyor 402, an outbound conveyor 403, a sprout product station 404, and a cleaning station 406 for cleaning and sanitizing the seed sprouting trays 500 for reuse. The inbound conveyor 402 and the outbound conveyor 403 optionally include sensors for detecting the presence of the seed sprouting trays 500 for intermittent operation. Alternatively, the inbound conveyor 402 and the outbound conveyor 403 can operate continuously.

[0060] Fig.11The robot 401 is shown to be preferably a commercially available robot, such as ABB IRB6620, with a maximum payload of 150 kg and a working range of 2200 mm. The robot 401 is firmly anchored on a supporting surface, i.e., the robot 401 is fixed in the XY horizontal plane. Such a firm anchoring is required so that the robot 401 can support 150 kg×2.2 m working range=3.3 kNm. The robot 401 includes an articulated arm 407 terminating in a square U-shaped 3-point clamp 408 for firmly clamping the seed sprouting tray 500 for handling and transportation. The articulated arm 407 can rotate 360° to invert the seed sprouting tray 500 so as to empty the seed sprouting tray 500 of the sprout product by gravity at the sprout product station 404. The square U-shaped 3-point clamp 408 includes a crossbeam 409 and a pair of opposing side arms 411. The crossbeam 409 has a central joint assembly 412. The central engagement assembly 412 is preferably comprised of an array of pins 413. The side arms 411 each have a pair of pneumatic piston clamps 414 therealong.

[0061] Fig.12 Shown is a cleaning station 406 communicated with the workstation 102 for operation and monitoring. The cleaning station 406 includes a cleaning station housing 416 with upright slots 417, for enabling the robot 401 to insert the seed germination tray 500 therein and remove the seed germination tray therefrom. The cleaning station 406 is connected to a water source 418 and an outlet 419 for draining, and the water source is used to supply water and disinfectant to a spray device (not shown). The cleaning station 406 may optionally include a control panel 421 for controlling its operation. The cleaning station 406 may optionally include a hot air device (not shown) for blowing hot air to dry the seed germination tray 500.

[0062] Return to Fig.10 The inbound conveyor end 402B may optionally include an inbound conveyor elevator 422 for lifting the seed germination tray 500 with fresh seeds from the inbound conveyor 402 to help transfer the seed germination tray to the seed germination tray slide 327. Similarly, the outbound conveyor start end 403A may optionally include an outbound conveyor elevator 423 for lifting the seed germination tray 500 to help transfer the seed germination tray from the seed germination tray slide 327 to the outbound conveyor start end 403A. The outbound conveyor elevator 423 rises so that the seed germination tray 500 can be pushed onto it from the seed germination tray slide 327, and then the outbound conveyor elevator is lowered so that the seed germination tray 500 is placed on the outbound conveyor start end 403A.

[0063] The outbound conveyor 403 may optionally include a load cell weighing machine 424 for weighing the sprout product of the seed sprouting tray 500 for monitoring. The load cell weighing machine 424 preferably records the weight of the sprout product of each seed sprouting tray 500 at the workstation 102.

[0064] Seed germination tray

[0065] Fig.13A , Fig. 13B and Fig.14 A seed germination tray 500 is shown, which is configured to be firmly clamped by the robot's 3-point clamp 408 and can be slidably horizontally displaced by the shuttle 317 for manipulation. The seed germination tray 500 has a unique tray identifier 501. The seed germination tray 500 includes a 1m square base 502, a first pair of opposing side walls 503 and 504, and a second pair of opposing side walls 506 and 507 transverse to the first pair of opposing side walls 503 and 504. The base 502 has a base top surface 502A and a base bottom surface 502B. The seed germination tray 500 is made of a suitable plastic material, such as polypropylene. The base top surface 502A is divided into four seed germination tray quadrants 508. The base 502 has an inverted pyramid shape, converging to a lowest center 509 formed together with a drainage arrangement 511 for draining excess irrigation from the four seed germination tray quadrants 508. The drainage arrangement 511 is optionally configured as an array of through-going apertures in the form of holes, slits, or the like.

[0066] For repeated releasable engagement by the 3-point clamp 408, the side walls 503 and 504 each have a center engagement component 512 complementary to the center engagement component 412 of the 3-point clamp 408 to enable them to engage so as to center the seed germination tray 500 relative to the articulated arm 407. The center engagement component 512 is thus comprised of an array of recesses 513 for receiving the array of pins 413. Providing both side walls 503 and 504 with the same center engagement component 512 enables the seed germination tray 500 to be indexed relative to the robot's 3-point clamp 408. The side walls 506 and 507 each have a piston clamp recess arrangement 514 configured for sliding insertion of a pneumatic piston clamp 414 thereinto, thereby enabling the seed germination tray 500 to be securely clamped by the robot's 3-point clamp 408 in both an upright orientation and an inverted orientation. The pneumatic piston clamp 414 is slidingly withdrawn from the piston clamp recess arrangement 514 for releasing the seed germination tray 500 from the robotic 3-point clamp 408 .

[0067] For repeated detachable engagement by the shuttle 317, the seed germination tray 500 is configured to be engaged by a pair of spaced-apart shift hooks 332 and 333. The seed germination tray 500 includes a pair of spaced-apart elongated plates 516 and 517 attached to the base bottom surface 502B adjacent to the side walls 503 and 504, respectively, and located on the side of the piston clamp recess arrangement 514. The elongated plates 516 and 517 include a pair of spaced-apart inverted L-shaped protrusions 518 protruding beyond the side wall 506. The elongated plates 516 and 517 include a pair of spaced-apart inverted L-shaped protrusions 519 protruding beyond the side wall 507.

[0068] Such a seed germination tray 500 can be easily placed on the inbound conveyor 402 and the outbound conveyor 403 by the robot 401, wherein the side walls 506 and 507 of the seed germination tray are in the same direction as the inbound conveyor 402 and the outbound conveyor 403, whereby the seed germination tray 500 can be easily engaged by the shuttle 317.

[0069] Alternatively, the pair of spaced apart elongated plates 516 and 517 may be attached to the base bottom surface 502B adjacent the side walls 506 and 507 , respectively, such that the pair of spaced apart inverted L-shaped protrusions 518 and 519 of the elongated plates protrude beyond the side walls 506 and 507 .

[0070] Robotic Operation

[0071] Fig.15 The robot 401 is shown securely clamping the seed germination tray 500 with its pin array 413 having been initially inserted into the recess array 513 of the seed germination tray and subsequently its pneumatic piston clamp 414 being inserted into the piston clamp recess arrangement 514 of the seed germination tray.

[0072] Fig.16A and Fig. 16B The operation of the robot 401 for preparing a seed germination tray 500 having fresh seeds ready for transfer to the AHSGE 300 is shown. The robot 300 securely grips the seed germination tray 500 and positions the seed germination tray under the fresh seed dispenser 200 to dispense four fresh seed doses correspondingly onto its four seed germination tray quadrants 508 (see FIG. Fig.16A ). The robot 300 repeatedly and rapidly agitates the seed germination tray 500 in the XY horizontal plane to flatten the fresh seed dose so that the fresh seed is evenly spread throughout the four seed germination tray quadrants 508 (see Fig. 16B ).

[0073] Fig. 16CArticulated arm 407 is shown as being able to rotate 360° to invert seed sprouting tray 500 to gravity empty the seed sprouting tray 500 of sprout product at sprout product station 404 .

[0074] The robot 300 continues to firmly hold the seed germination tray 500 to perform the following steps:

[0075] a) Lift the seed germination tray 500 from the outbound conveyor 403 at the end 403B of the outbound conveyor

[0076] b) Inverting the seed sprouting tray 500 to empty the seed sprouting tray 500 of the sprout product by gravity at the sprout product station 404

[0077] c) Insert the empty seed germination tray 500 into the cleaning station 406 for cleaning and disinfection

[0078] d) Remove the seed germination tray 500 from the cleaning station 406

[0079] e) placing the seed germination tray 500 below the fresh seed dispenser 202 to dispense fresh seed doses onto the seed germination tray

[0080] f) repeatedly and rapidly agitating the seed germination tray 500 in the XY horizontal plane to flatten the fresh seed dose, thereby evenly spreading the fresh seeds and

[0081] g) Placing the seed germination tray with fresh seeds on the inbound conveyor 402 at the inbound conveyor start end 402A for transfer to the AHSGE 300

[0082] Shuttle Operation

[0083] FIG. 17A to FIG. 17G The operation of the seed germination tray slide 327 is shown, which is used to initially slide and pull the seed germination tray 500 with fresh seeds thereon horizontally from the end end 402B of the inbound conveyor, and then slide and push the seed germination tray 500 on the seed germination tray shelf 319 horizontally for germinating the seeds into sprout products. The seed germination tray 500 with the sprout product is pulled horizontally from the seed germination tray shelf 319 to the seed germination tray slide 327 and the seed germination tray 500 is pushed horizontally from the seed germination tray slide 327 to the start end 403A of the outbound conveyor. FIG. 17A to FIG. 17G The operation is reversed. According to the relative orientation of the seed germination tray 500 and the seed germination tray carriage 327, the seed germination tray 500 hides part of the belts 331A and 331B, the displacement hook 332 and the displacement hook 333, as shown by the dotted lines.

[0084] FIG. 17A to FIG. 17G The operation is as follows:

[0085] Fig.17A The seed germination tray carriage 327 is shown in its parked position juxtaposed with the inbound conveyor end 402B. The belt 331 is fixed. The shift hook 332 is in its initial non-engaged position. The seed germination tray 500 is located on the inbound conveyor end 402B with its pair of spaced apart inverted L-shaped projections 518 adjacent to the seed germination tray carriage 327.

[0086] Fig. 17B The left belt 331A is shown starting to rotate in a counterclockwise direction and the right belt 331B is shown starting to rotate in a clockwise direction. The shift hook 332 engages the inverted L-shaped protrusion 518 for pulling the seed germination tray 500 laterally and horizontally onto the seed germination tray carriage 327 as shown by arrow A.

[0087] Fig. 17C The left belt 331A is shown continuing to rotate counterclockwise and the right belt 331B continues to rotate clockwise to further pull the seed germination tray 500 laterally and horizontally onto the seed germination tray carriage 327.

[0088] Fig.17D It is shown that after the seed germination tray 500 is fully placed on the seed germination tray carriage 327, the shift hooks 332 of the left belt 331A and the shift hooks 332 of the right belt 331B are rotated outwardly beyond their corresponding inverted L-shaped protrusions 518. The belts 331 are fixed. The seed germination tray carriage 327 can now move along the shuttle double track 328, as shown by arrow B and rise to the desired seed germination tray shelf 319.

[0089] Fig.17E Seed germination tray carriage 327 is shown carrying seed germination tray 500 juxtaposed with seed germination tray shelf 319, ready to be pushed horizontally and slidingly onto a pair of spaced apart parallel seed germination tray supports 321. Belt 331 is fixed. Left belt 331A is ready to be driven in a counterclockwise direction, and right belt 331B is ready to be driven in a clockwise direction.

[0090] Fig.17F Counterclockwise rotation of left belt 331A and clockwise rotation of right belt 331B are shown to push seed germination tray 500 laterally and horizontally from seed germination tray slide 327 to seed germination tray shelf 319 by a pair of spaced-apart displacement hooks 333 pushing against side wall 507, as shown by arrow C.

[0091] Figure 17GIt is shown that after the seed germination tray 500 is fully pushed from the seed germination tray carriage 327 onto the seed germination tray shelf 319 , the shift hooks 333 of the left belt 331A and the shift hooks 333 of the right belt 331B are rotated outwardly beyond the side wall 507 .

[0092] A belt 331 having only a pair of spaced apart shift hooks 332, i.e., without a pair of spaced apart shift hooks 333, can perform the same FIG. 17A to FIG. 17G The same operation is performed, but the belt 331 will need to be additionally driven so that a pair of spaced apart shifting hooks 332 function instead of a pair of spaced apart shifting hooks 333 .

[0093] AHSGS Operation

[0094] The controller instructs the robot to firmly clamp the empty seed germination tray under the fresh seed dispenser. The fresh seed dispenser dispenses four doses of fresh seeds on the four sections of the seed germination tray.

[0095] The controller instructs the robot to repeatedly and rapidly agitate the seed germination tray in the XY horizontal plane to flatten the fresh seed dose so that the fresh seed is evenly spread throughout its corresponding four seed germination tray quadrants.

[0096] The controller instructs the robot to place the seed germination tray with fresh seeds on the starting end of the inbound conveyor, and drives the inbound conveyor to transport the seed germination tray to the front seed germination tray processing room, and then the controller stops the inbound conveyor.

[0097] The controller raises the inbound conveyor elevator to raise the seed germination tray with fresh seeds and instructs the shuttle to remove the seed germination tray from the inbound conveyor elevator.

[0098] The controller instructs the shuttle to push the seed germination tray with fresh seeds onto a designated seed germination tray shelf in the seed imbibition station to allow the seeds to imbibition.

[0099] The controller instructs the shuttle to pull the seed germination tray out of the seed imbibition station and push the seed germination tray onto a designated seed germination tray shelf in the hydroponic seed germination chamber for a predetermined seed germination period to form a sprout product.

[0100] At the end of the seed germination period, the controller instructs the shuttle to retrieve the seed germination tray with the sprouted product from the seed germination tray shelf.

[0101] The controller causes the outbound conveyor elevator to rise and instructs the shuttle to push the seed sprouting tray with the sprouted product thereon.

[0102] The controller causes the outbound conveyor elevator to descend so that the seed sprouting tray with the sprouted product is positioned on the start end of the outbound conveyor.

[0103] The controller drives the outbound conveyor to transport the seed sprouting trays to the sprout product station.

[0104] The controller stops the output conveyor and instructs the robot to securely grip the seed sprouting tray and invert the seed sprouting tray to gravity empty the seed sprouting tray of sprout product at the sprout product station.

[0105] The controller instructs the robot to insert the empty seed germination tray into the cleaning station to be cleaned and sanitized for reuse.

[0106] While the invention has been described with respect to a limited number of embodiments, it will be appreciated that numerous variations, modifications and other applications of the invention are possible within the scope of the appended claims.

Claims

1. An autonomous hydroponic seed germination system for hydroponically germinating seeds into sprout products in a seed germination tray, the autonomous hydroponic seed germination system comprising: (a) A climate-controlled automated hydroponic seed germination box, the climate-controlled automated hydroponic seed germination box comprising: i) a hydroponic seed germination chamber having at least one pair of spaced-apart parallel seed germination tray racks, each of the seed germination tray racks having at least four seed germination tray shelves in height and configured to receive a plurality of seed germination trays therethrough, and ii) at least one shuttle slidably displaceable along a shuttle track between the at least one pair of spaced-apart parallel seed germination tray racks to initially place a seed germination tray having fresh seeds on the at least one pair of spaced-apart parallel seed germination tray racks and subsequently remove the seed germination tray from the at least one pair of spaced-apart parallel seed germination tray racks after a predetermined seed germination period to hydroponically germinate the seeds into a sprouted product; (b) a working unit comprising at least one robot that is fixed in an XY horizontal plane, The at least one robot comprises an articulated arm for securely gripping a seed germination tray; and (c) a workstation for enabling an operator to set operating parameters of the autonomous hydroponic seed germination system and monitor the operation of the autonomous hydroponic seed germination system, The workstation includes a controller that simultaneously controls the automated hydroponic seed germination box and the working unit.

2. The system of claim 1, wherein the at least one robot continuously and securely holds the seed sprouting tray with the sprout product to perform the following steps: a) lifting the seed germination tray with the sprout product, b) inverting the seed sprouting tray to empty the seed sprouting tray of sprout product by gravity at a sprout product station, c) inserting the empty seed germination tray into the cleaning station for cleaning and sanitization, and d) Removing the cleaned and sterilized seed germination tray from the cleaning station.

3. The system according to claim 2, and further comprising a fresh seed dispenser in communication with the workstation, the fresh seed dispenser for dispensing a predetermined weight of fresh seed dosage on the seed germination tray, The robot holds the seed germination tray below the fresh seed dispenser to dispense at least one fresh seed dose onto the seed germination tray, The robot repeatedly and rapidly agitates the seed germination tray in the XY horizontal plane to evenly flatten the at least one fresh seed dose throughout the seed germination tray.

4. The system of any of the preceding claims, further comprising a seed germination tray buffer located between the at least one robot and the at least one shuttle, a robot of the at least one robot securely gripping a seed germination tray having fresh seeds and placing the seed germination tray on the seed germination tray buffer, a shuttle of said at least one shuttle securely clamping said seed germination tray with fresh seeds on said seed germination tray buffer for placement on said at least one pair of spaced-apart parallel seed germination tray racks, A shuttle of the at least one shuttle securely clamps the seed sprouting tray with sprouted product to the at least one pair of spaced-apart parallel seed sprouting tray racks for placement on the seed sprouting tray buffer, A robot of the at least one robot securely clamps the seed sprouting tray with the sprout product on the seed sprouting tray buffer and removes the seed sprouting tray and thereafter inverts the seed sprouting tray to empty the seed sprouting tray of the sprout product by gravity at the sprout product station.

5. The system of claim 4, wherein the seed germination tray buffer is comprised of at least one motorized conveyor extending between the work unit and the automated hydroponic seed germination box.

6. The system of any one of the preceding claims, wherein the automated hydroponic seed germination chamber comprises a climate controlled seed imbibition station in communication with the workstation, The seed swelling station has a seed swelling station housing that allows a seed germination tray with fresh seeds to be swollen in a nearly 100% humid environment. A shuttle of the at least one shuttle initially places a seed germination tray with fresh seeds in the seed imbibition station for a predetermined seed imbibition period and subsequently removes a seed germination tray from the seed imbibition station.

7. A system according to any one of the preceding claims, further comprising a weighing device in communication with the workstation, The weighing device weighs the seed sprouting tray with sprout products before the sprout products of the seed sprouting tray are emptied at the sprout product station to record the weight of the sprout products of the seed sprouting tray at the workstation.

8. A system according to any of the preceding claims, wherein a shuttle of the at least one shuttle includes at least one climate sensor in communication with the workstation, the at least one climate sensor being used to monitor climate conditions at a location in the climate-controlled automated hydroponic seed germination box.

9. The system of claim 8, wherein the at least one climate sensor comprises at least one of: a humidity sensor for sensing humidity at the location, a temperature sensor for sensing temperature at the location, a CO2 sensor for sensing CO2 at the location, an anemometer for sensing wind speed at the location, and a photometer for sensing light intensity at the location.

10. A robot configured to be used in the autonomous hydroponic seed germination system according to any one of the preceding claims 1 to 9.

11. A shuttle configured for use in an autonomous hydroponic seed germination system according to any one of the preceding claims 1 to 9.

12. An autonomous hydroponic seed germination method for hydroponically germinating seeds into sprout products in a seed germination tray, the autonomous hydroponic seed germination method comprising the following steps: (a) providing an automated hydroponic seed germination system according to any one of the preceding claims; (b) transporting the seed germination trays to the climate-controlled automated hydroponic seed germination box; (c) horizontally slidingly displacing the seed germination tray from the shuttle to the seed germination tray shelf; (d) allowing fresh seeds to germinate into sprout products in the seed germination tray within a predetermined seed germination period; (e) horizontally slidingly displacing the seed germination tray from the seed germination tray shelf onto the shuttle; (f) transporting the seed germination tray from the automated hydroponic seed germination box; (g) inverting the seed sprouting tray to empty the seed sprouting tray of sprout product at a sprout product station; and (h) cleaning and disinfecting the seed germination tray.

13. A seed germination tray for hydroponically germinating seeds into sprout products, the seed germination tray being configured for use with a robot and a shuttle, The robot includes a square U-shaped clamp for firmly clamping the seed germination tray, the square U-shaped clamp having a crossbeam and a pair of opposing side arms, and the pair of opposing side arms each having at least one pneumatic piston clamp along it, The shuttle comprises a pair of spaced apart parallel belts having at least a pair of spaced apart displacement hooks, The seed germination tray comprises: (a) a generally rectangular base having a drainage arrangement for allowing excess irrigation water to drain from the seed germination tray; (b) a first pair of opposing side walls; (c) a second pair of opposing side walls, the second pair of opposing side walls being transverse to the first pair of side walls; (d) a pair of opposing side walls of the first pair of opposing side walls and the second pair of opposing side walls, the pair of opposing side walls having a pair of opposing piston clamp recess arrangements, the pair of opposing piston clamp recess arrangements being configured to be removably securely clamped by the square U-shaped clamp, whereby the U-shaped clamp is capable of securely clamping the seed germination tray in both an upright orientation and an inverted orientation; as well as (e) a pair of opposing side walls among the first pair of opposing side walls and the second pair of opposing side walls, the pair of opposing side walls having a pair of spaced-apart inverted L-shaped protrusions, the pair of spaced-apart inverted L-shaped protrusions being configured to be selectively engaged by the at least one pair of spaced-apart shifting hooks to horizontally slideably shift the seed germination tray.

14. A tray according to claim 13, wherein the crossbar of the square U-shaped clamp has a center joint assembly, and the seed germination tray has a center joint assembly along at least one of the pair of opposite side walls transverse to the pair of opposite side walls having the piston clamp recess arrangement, whereby the seed germination tray is securely clamped by the square U-shaped clamp initially inserting its center joint assembly into the center joint assembly and subsequently inserting its pneumatic piston clamp into the pair of opposite piston clamp recess arrangements.

15. A pallet according to claim 13 or claim 14, wherein the first pair of opposing side walls comprises the pair of opposing piston clamp recess arrangements and the pair of spaced apart inverted L-shaped projections.

16. A tray according to any one of the preceding claims 13 to 15, wherein the base has an inverted pyramidal shape converging to a lowest centre formed with the drainage arrangement.

17. A tray according to any one of the preceding claims 13 to 16, wherein the base is divided into at least four seed germination tray sub-areas.

18. A climate-controlled automated hydroponic seed germination box for germinating fresh seeds on seed germination trays into sprout products, the climate-controlled automated hydroponic seed germination box comprising: (a) a climate controlled hydroponic seed germination chamber having at least one pair of spaced apart parallel seed germination tray racks, each of the seed germination tray racks having at least four shelves in height and configured to receive a plurality of seed germination trays therethrough; and (b) at least one shuttle slidably displaceable along a shuttle track between the at least one pair of spaced-apart parallel seed germination tray racks to initially place a seed germination tray having fresh seeds on the at least one pair of spaced-apart parallel seed germination tray racks and subsequently remove the seed germination tray from the pair of spaced-apart parallel seed germination tray racks for harvesting after a predetermined germination period for hydroponically germinating the seeds into a sprouted product, A shuttle of the at least one shuttle includes at least one climate sensor for sensing climate conditions at a location in the climate controlled hydroponic seed germination chamber.

19. A box according to claim 18, wherein the at least one climate sensor includes at least one of the following: a humidity sensor for sensing humidity at the location, a temperature sensor for sensing temperature at the location, a CO2 sensor for sensing CO2 at the location, an anemometer for sensing wind speed at the location, and a photometer for sensing light intensity at the location.

20. A shuttle configured for use in a climate controlled automated hydroponic seed germination box according to claim 18 or claim 19.

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