"Multifunctional modular technological system for construction and operation of vertical farms"

A multifunctional modular technological system for growing all types of photocultures, seed lings, mushrooms, medicinal and ornamental plants under indoor conditions on mats, in pots, trays, in suspension, placed horizontally or vertically, on organic or artificial substrates and soils or without them, implemented by a specialised workflow process and a software and hardware complex.

According to the International Patent Classification, the invention relates to Section A01 “Agriculture” and crop growing, in particular, to the equipment for growing crops, plants and mushrooms. The following patents are the closest counterparts: No. RU 2391812 C2, No. RU 194725 U1 (No. RU 142236 U1), which have similar characteristics to the current invention. All of them cover only certain issues of technological equipment designs or methods of growing a certain list of agricultural crops in vertical complexes of protected ground. However, this trend of development of greenhouse facilities requires a more serious and comprehensive approach, since it boosts the development of the entire industry — industrial food production in the immediate vicinity of a consumer: in megalopolises, large cities, regions of the Far North, remote, inaccessible and unfavourable areas for traditional methods of growing. In recent years, a dynamic invention of this type of agricultural production methods has developed into a new concept of “urban farm”, “urban farming”, and has taken an important place in solving issues of food safety for the population.

Within the framework of the claimed invention, a highly effective universal technological system has been developed, which differs from known counterparts in that its solutions cover a whole range of problems that arise during the placement and operation of vertical farms of different formats, and it allows an unlimited access to operators regarding all existing ways and methods of growing greenhouse photocultures, seedlings, mushrooms, medicinal and ornamental plants, regardless of their species differences and size characteristics. These technical solutions are implemented in the form of a specialised technological process carried out within the framework of a multifunctional software and hardware complex from transformable modular units and structures that are assembled into block modules of the required area and volume in any room, regardless of its technical condition. The ability of certain modules to quickly transform provides operators with the technical capabilities to switch throughout the day, for example, from cultivating strawberries to mushrooms, from tomatoes to flowers, from salads to tuberous, and so on. Each assembled complex has a special integrated thermal housing that fully protects the plants inside from environmental in fluences. An automatic system is provided for the emergency support of the vital activity of plants during a temporary (12-24 hours) power outage. At the same time, the reserves of water and nutrient mixtures for plants are designed for 1 -3 days. In most cases, such a time lag is sufficient to preserve the growing crops. The entire functionality of the technological system is controlled by a single software package, and all units and components are unified. This makes it possible for a batch production of systems of any scale and various levels of automation: both with manual and semi-automatic, or maximum robotic control of work processes. In addition, the transition from a lower to a higher level is simple and inexpensive. This opportunity provides for a significant economic flexibility and maximises a range of potential customers.

The core of the complex system is the “Smart Garden” module called “3D SmartGarden.” These particular units of the system are responsible for the process of vegetation of plants of any species groups, for which purpose various mechanisms of life support, nutrition and control are built into them. Each bed module is equipped with a specially designed universal distributor communicator. The operation algorithm of this node makes it possible to freely use various methods of supplying food to plants: direct irrigation, drip system, oxygen enrichment, hydroponics, aeroponics, aquaponics, bioponics. Possibility of simultaneous use of several of the above methodsis provided. Studies prove that the alternation and I or combination of different methods of plants’ nutrition at different stages of their vegetation give a significant increase in yield and acceleration of ripening. In addition, the “3D SmartGarden” module has an integrated mechanism for metered point delivery of carbon dioxide directly to the leaves of the cultivated crop. This method of supplying the component, which is essential for plant photosynthesis, significantly reduces the volume of its consumption and creates a positive economic effect. All known systems, installations and devices do not have the ability to use such functions.

Each 3D SmartGarden module is equipped with a system of regulated supply of prepared air through perforated tubes placed along the stem zone of the cultivated plants. Air intake and its return to the microclimate control system occurs through special passages in the lower part of the above bed. All parameters of the local microclimate, taking into account the requirements for each specific cultivated crop, as well as the quality and composition of the supplied air, are automatically controlled by a special unit. Its control algorithm makes it possible to redistribute excess thermal energy between neighbouring block modules, which allows saving on total energy costs. The entire system is monitored using built-in sensors and controlled by a software package. Compared with all known methods, this method of creating and maintaining a microclimate is economically more profitable due to the significantly lower volume of processed air.

A high degree of versatility of the entire technological system is achieved, among other things, by integrating multispectral adaptive lamps into the 3D SmartGarden module. The combination of the principle of calculating the modular grid and technical solutions when placing the lamps made it possible to illuminate the side foliage down to the lower tiers without using additional light sources. Some of the design features of the bed also provide an additional opportunity to use the reflective surface of a part of the module to illuminate the foliaceous tiers from below. The applied design of lamps with built-in watercooling makes it possible to transfer excess heat energy to the microclimate control unit for its redistribution. The economic effect achieved in this way from reducing energy costs can be up to 15 percent.

3D SmartGarden modules are placed in vertical tiers on special racks, which are located at an equal distance from each other to form the necessary passages. The design of the beds’ connection units with the racks and outgoing communications ensures quick assembly and disassembly of all components. Each tier is provided with a special drive for moving the beds in the horizontal plane and in a staggered tiered manner so that they occupy the entire height and area of the room. The 3D SmartGarden is in this position for the entire vegetation period, except for the plant maintenance period, routine maintenance, or harvesting. For such a period, the beds of a certain vertical row (or rows), according to the programmed algorithm, return to the dimensions of their rack opening the desired passage. In this way, the planting density of cultivated plants reaches up to 100 percent of the occupied area and volume of the room. The number of tiers in the racks is limited by the height of a particular room and is governed by the dimensional characteristics of a particular cultivated crop, and the number of racks is limited by the area occupied by the complex. The basis of the racks’ structure are tube modules, which are interconnected with a single interval for each measurement, i.e. height, length, and width. This provides great opportunities for optimising the process and maximising the use of both the area and the height of the space provided. The calculation of the placement of structures at the facility for their further assembly is based on a modular grid that is uniform for all projects using a special installation program. This approach eliminates the need to develop a special project for each new facility, making this process a routine, non-time-consuming procedure. None of the known systems can provide for the possibility of using the area and volume of premises with such high efficiency.

When developing a multifunctional modular technological system, the issues of cost-effective industrial production of all its components were especially taken into account. As a result of the design, almost all parts, units and assemblies used to form complexes of any format can be produced on traditionally widespread equipment, without the use of special and expensive processes. All required raw materials, materials and finished components from third-party manufacturers used are commercially available. A special software product has been created for logistics solutions in managing the manufacturing process of components. Calculations show that the industrial implementation of the developed system will be cost effective. At the development stage, the issues of optimising and simplifying the design process of potential facilities, completing them with the tools and equipment necessary for installation were formulated and resolved. The basic principles of methodological and training materials have been developed for the assembly teams of the complexes in the field, as well as for the development of service centres in the future.