Multi-plane Grow System with Continuous Conveyor Flow
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Solution Overview
Problem
Controlled Environment Agriculture (CEA) systems face inefficiencies in workflow and waste management due to batch methods, leading to poor productivity and excess inventory, particularly when batch sizes are suboptimal or when there are significant differences in productivity across operations, resulting in significant 'work in progress' and perishable inventory waste.
Innovation Solution
A multi-layer hydroponics grow system with a continuous flow design that uses conveyor systems and elevators to transport crop carriers through vertically stacked planes with varying spacing and air flow management, optimizing plant growth conditions and minimizing labor by ensuring only what is needed is produced when needed, utilizing concepts like the Toyota Way and Lean production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If batch methods are used in CEA systems, then flexibility in managing variations in raw materials and environmental conditions is improved, but workflow efficiency deteriorates due to poor workflow and excess inventory buildup
Solution Approach 1:
The system divides the grow space into multiple independent vertical planes, each capable of operating autonomously. This segmentation allows different batches to be processed simultaneously in different planes, eliminating workflow bottlenecks while maintaining the flexibility to adjust each plane independently based on specific crop needs and variations in raw materials or environmental conditions.
Solution Approach 2:
The patent implements continuous flow systems within each vertical plane where plants progress continuously through different growth stages rather than being processed in discrete batches. This continuous action eliminates idle time and work-in-progress inventory buildup, improving workflow efficiency while the multi-plane configuration maintains adaptability by allowing simultaneous continuous flows of different crop types.
2Quantity of substance
If multiple levels of large trays are used, then plant density is improved, but labor and material handling requirements worsen due to excessive manual activity and equipment needs
Solution Approach 1:
The system transitions from horizontal tray arrangements to vertical stacking of grow planes, utilizing the vertical dimension to achieve high plant density. This vertical configuration allows plants to be grown at multiple levels without increasing the horizontal footprint, and eliminates the need for excessive manual handling by enabling automated vertical transport between levels through integrated conveyor systems and elevators.
Solution Approach 2:
The vertical planes are designed as multi-functional units that combine planting, growing, harvesting, and material handling capabilities within a single integrated structure. Each plane can independently perform multiple operations, reducing the need for separate equipment and manual intervention for each function, thereby maintaining high plant density while simplifying operation.
3Productivity
If automated operations are implemented, then productivity is improved, but system complexity worsens due to excessive software development and equipment coordination needs
Solution Approach 1:
The automation system is divided into independent control modules for each vertical plane, allowing each plane to be automated separately with its own simplified control logic. This segmentation reduces overall system complexity by avoiding the need for complex centralized coordination, while still achieving high productivity through parallel automated operations across multiple planes.
Solution Approach 2:
Each vertical plane is designed with self-sufficient automated capabilities, including integrated sensors, actuators, and control systems that can autonomously manage planting, monitoring, and harvesting operations within that plane. This self-service approach eliminates the need for complex inter-plane coordination software, reducing system complexity while maintaining high automated productivity.
Data Source
AI summary
A controlled environment agriculture system maximizes high quality yield, plant or organism density, and life cycle productivity. A combined structure contains automated conveyance and more than two vertically stacked planes of horizontal track that plants traverse throughout their life cycle. Nutritional support, controlled lighting, controlled climate and air flow are managed at each plane and coordinated across all planes as a system for optimized life cycle productivity. Plant or organism growth carriers are conveyed and connected to multiple planes with controlled elevators that enable continuous movement of plants throughout their lifecycle from seedling to harvest in a serpentine, carousel, or straight path configuration. Plants enjoy a variety of controlled environmental conditions including lighting, airflow, CO2, temperature and humidity configured to their organism type and optimized by life cycle stage. The ongoing movement provides an optimal environment for robust plant growth, eliminates the opportunity for pests to settle and lay eggs, and enables the ability to course correct organisms to higher yields.