WO2019056057A1 - Automated vertical farming apparatus and methods - Google Patents

Abstract

An apparatus (10) for sequential carriage of growth trays (40) around and through a mechanised, multi-level farming structure (20) having an entry side or path (30) and an exit side or path (50) for said growth trays of a crop, the carriage apparatus including: an inward transporter (200) disposed along the entry side of the farming structure for transporting at least one tray (40) containing growth media from a seeding station (100); an upstanding elevator (300) for elevating said at least one tray to a selected level of the farming structure (20) and inserting said tray into entry side (30) of the farming structure; an automatic controller (1001) for coordinating movement of the trays into the entry side and/or out of the exit side of the farming structure (20); an upstanding receiver (350) for receiving and lowering said at least one tray containing a mature crop from the exit side of the farming structure; an outward transporter (250) disposed along the exit side (50) of the farming structure (20) for transporting said at least one tray to a harvesting station (500); a growth media remover (600) for removing growth media from each said at least one tray (40); and a tray washer (750) for emptying and washing empty trays. Also disclosed is a method (1100) for sequential carriage of growth trays around and through the multi-level farming structure (20).

Description

AUTOMATED VERTICAL FARMING APPARATUS

AND METHODS

TECHNICAL FIELD

This invention relates to automation of multi-layer horticultural structures and associated crop handling equipment, which together may be referred to as vertical farm systems. In particular, although not exclusively, the invention relates to a vertical farming apparatus and methods for the mechanized transport of trays for holding growth media and seed or a mature crop in relation to one or more climate controlled cells comprising such multi-layer horticultural structures.

BACKGROUND Vertical farm systems of the prior art may employ a vertical structure supporting one or more stacks of trays for containing soil and/or growth media for growth of plants in horizontal arrays, which trays are conveniently arranged in layers. Each stack of trays may be provided with water, plant nutrients and light which are suitably controlled to optimize plant growth to maturity. Space efficiency and parsimonious use of scarce resources whilst maximizing crop output are important drivers for vertical farming.

In patent publication WO 2012/040776 A1 , Applicant describes a watering and drainage arrangement for a multilayer horticultural structure, wherein plant trays are arranged in rows and columns provided within a supporting framework that includes a watering and drainage arrangement. The plant trays are inserted into or removed from the structure with the aid of a lift truck or similar lifting equipment or, on a smaller scale, manually. In patent publication WO 2014/1 13838 A1 , Applicant describes a plant cultivation installation including a number of plant growth nutrient solution conduits and light assemblies arranged relative to opposed support members for horizontal growth trays containing seeds or growing plants of a crop.

Prior art vertical farming systems may also involve additional environmental controls, for example by disposing the vertical support structure in an enclosure, such as a conventional greenhouse or even a modified ISO shipping container, and installing an environmental monitoring and control system. A controlled environment of this kind can obviate the need for use of pesticides and in some cases also herbicides. US Patent No. 4,068,405 to Campbell et al. describes an apparatus for maintaining a controlled environment for the growth of plants, including an enclosure with a plurality of artificial light sources positioned over a growing region. Trays containing the growing plants are carried through the enclosure by an endless chain drive coupled to a tray support structure, and are accessible at an end of the enclosure for manual planting, weeding, harvesting and like activities.

However, manual handing of trays is labour intensive and use of handling equipment such as scissor lifts or fork-lift trucks, can be dangerous and may involve wear of enclosures where less robust structures are employed, adding to construction and operating costs. A processing bottleneck is caused by the entry and exit of trays from a common end of a support structure, as for example in Campbell. Furthermore, additional floor area may be required to accommodate lift truck operations, space that would be better utilized for cropping.

Any references to methods, apparatus or documents of the prior art are not to be taken as constituting any evidence or admission that they formed, or form part of the common general knowledge.

It is an object of the present invention to provide a growth tray carriage apparatus and method for multi-layer horticultural structures that addresses the problems of the prior art or at least provides the horticultural industry with a useful choice. SUMMARY OF THE INVENTION

According to a first aspect of the present invention there is provided an apparatus for sequential carriage of growth trays in a mechanised, multi-level farming structure having an entry side and an exit side for said trays of a selected crop, the carriage apparatus including:

an inward transporter disposed along the entry side of the farming structure for transporting at least one tray containing growth media from a seeding station;

an upstanding elevator for elevating said at least one tray to a selected level of the farming structure and inserting said tray into the into the entry side of said farming structure;

an automatic controller for coordinating movement of the trays into the entry side and/or out of the exit side of said farming structure;

an upstanding receiver for receiving and lowering said at least one tray containing a mature crop from the exit side of the farming structure;

an outward transporter disposed along the exit side of the farming structure for transporting said at least one tray to a harvesting station;

a growth media remover for removing growth media from each tray; and

a tray washer for washing empty trays.

Preferably, the inward transporter includes guide wheels for movably supporting a tray and a drive for propelling the trays. The guide wheels may be rotatably mounted in two parallel sets on respective longitudinal rails. Suitably the drive includes a drive motor coupled to a friction drive roller arranged for engagement with a tray. If required, the inward transporter comprises a plurality of modules arranged in longitudinal alignment with one another. The inward transporter preferably further includes at least one presence sensor for detecting the location of a tray. The presence sensor suitably comprises a signal transceiver and reflector pair. Preferably the upstanding elevator includes an elevator carriage for said trays that is horizontally alignable with the inward transporter or at least a module thereof, and is selectively vertically alignable with any level of the multi-level farming structure.

Most preferably, the elevator carriage further includes a pusher mechanism for pushing a tray into a selected level of the multi-level structure, suitably laterally with respect to the carriage. Suitably, where the upstanding elevator services a plurality of rows of trays in the multi-level structure, the elevator carriage is also movable along the structure, preferably for indexed alignment with individual transporter modules.

Preferably the upstanding receiver includes a receiver carriage for said trays that is horizontally alignable with the outward transporter or at least a module thereof, and is selectively vertically alignable with any level of the multi-level farming structure. Suitably, where the upstanding receiver services a plurality of rows of tray supports in a multi-level structure, the receiver carriages are movable along the structure, preferably for indexed alignment with individual transporter modules.

Suitably, lateral movement of carriages in the upstanding elevator and upstanding receiver is effected by provision of a movable frame including columns supporting the carriages for vertical movement of said at least one tray. Preferably the movable frame includes a drive coupled to a carriage for selectively raising and lowering of the trays thereon.

The automatic controller may further include a plurality of local sub-controllers co-located with each of the transporters, elevator, receiver, growth media remover and tray washer in a modular arrangement, each sub-controller coupled to a central control processor via a communications link. Handover of control between local sub-controllers is triggered by tray or bench presence sensors associated with respective modules of the carriage apparatus.

Preferably, the multi-level farming structure is contained within one or more enclosures whereby a growing environment for the crop is controllable. Most preferably each level of the structure provides for support of a row of trays in side-by-side relation, the row extending from the entry side to the exit side of the structure. Suitably, the automatic controller is further configured to control the growing environment within the farming structure and/or nutrient supply to the crop until maturity.

Preferably, the outward transporter includes guide wheels for movably supporting a tray and a drive for propelling the trays. The guide wheels may be rotatably mounted in two parallel sets on respective longitudinal rails. Suitably the drive includes a drive motor coupled to a friction drive roller arranged for engagement with a tray. If required, the outward transporter comprises a plurality of modules arranged in longitudinal, end-to-end alignment with one another. The outward transporter preferably further includes at least one presence sensor for detecting the location of a tray. The presence sensor suitably comprises a signal transceiver and reflector pair. Suitably, the growth media remover includes a vacuum apparatus and a screen for separating growth media pebbles from debris. Preferably, the vacuum apparatus includes a cyclone separator and the screen comprises a trommel.

Preferably, the tray washer includes a tray inversion apparatus for inverting the trays prior to liquid pressure washing.

The seeding station may be located prior to the inward transporter, the seeding station having a seed hopper and pneumatic seed dispenser.

The tray carriage apparatus may further include at least one turn-table module for rotating said at least one tray between either the inward transporter or the outward transporter and an auxiliary module path disposed at an angle to said transporters. The auxiliary module path can include one or more of the growth media remover, the tray washer, a growth media loading conveyor and a tray stacker for storage of said one or more trays.

In another aspect of the invention, there is provided a method for sequential carriage of growth trays in a multi-level farming structure having an entry side and an exit side for said trays, the method including the mechanised steps of:

transporting from a seeding station and along the entry side of the farming structure at least one tray containing growth media for growth of a selected crop;

elevating said at least one tray to a selected level of the farming structure and inserting said tray into the structure;

automatically controlling movement of the trays into the entry side and/or out of the exit side of the multi-level structure; receiving and lowering said at least one tray containing the mature crop from the exit side of the farming structure;

transporting said at least one tray along the exit side of the farming structure to a harvesting station; and

removing growth media from the tray and washing the tray.

Preferably the method further includes the step of automatically controlling a growing environment within the farming structure and/or nutrient supply to the crop until maturity. Suitably, the controlling step operates at least between the tray inserting and receiving steps. BRIEF DESCRIPTION OF THE DRAWINGS

Preferred features, embodiments and variations of the invention may be discerned from the following Detailed Description which provides sufficient information for those skilled in the art to perform the invention. The Detailed Description is not to be regarded as limiting the scope of the preceding Summary of the Invention in any way. The Detailed Description will make reference to a number of drawings as follows:

Figure 1 is a schematic diagram depicting a preferred operating sequence for a horticultural apparatus according to a method of an embodiment of the invention;

Figure 2A is a top plan view drawing of a horticultural apparatus of a preferred embodiment of the invention;

Figure 2B is a rear or "outbound" elevational view of the horticultural apparatus of Fig. 2A;

Figure 2C is an end elevational view of the horticultural apparatus of Fig. 2A;

Figure 2D is a top perspective view of the horticultural apparatus of Fig. 2A;

Figure 3A is a top plan view drawing of a seeder 100 for the preferred horticultural apparatus;

Figure 3B is a front elevational view of the seeder of Fig. 3A;

Figure 3C is a top perspective view of the seeder of Fig. 3A;

Figure 3D is a front perspective photographic view of the seeder of Fig. 3A;

Figure 4A is a top plan viewing drawing of an outward transporter 250 for the preferred horticultural apparatus;

Figure 4B is a rear elevational view of the transporter of Fig. 4A;

Figure 4C is a top perspective view of the transporter of Fig. 4A;

Figure 4D is a top perspective photographic view of an input end of an inward transporter

200;

Figure 5A is a top perspective view of an inward elevator 300 for the preferred horticultural apparatus; Figure 5B is an enlarged top perspective view of a tray loader sub-assembly for the inward elevator 300;

Figure 6A is a top perspective view of an enclosure 400 for the preferred horticultural apparatus;

Figure 6B is a sectional rear elevational view of the enclosure of Fig. 6A;

Figure 6C is a front photographic view of the enclosure 400 of Fig. 6A with the tray loader of inward elevator 300 of Fig. 5B in foreground;

Figure 6D is a front photographic view of the enclosure 400 of Fig. 6A with the tray loader of inward elevator 300 of Fig. 5B in the middle ground and the inward transporter 200 in the foreground;

Figure 7A is a top plan view drawing of a harvester for the horticultural apparatus of the embodiment;

Figure 7B is a top perspective view of the harvester 500 of Fig. 7A;

Figure 7C is a rear elevational drawing of the harvester of Fig. 7A;

Figure 7D is a rear perspective photographic view of a tray leaving an outward transporter module 250 and entering the harvester module of Fig. 7A;

Figure 7E is a front perspective view of a turntable assembly 650 associated with the outward transporter of Fig. 4A and harvester of Fig. 7A;

Figure 7F is a front perspective view of a turntable assembly 600 associated the inward transporter of Fig. 4D and seeder of Fig. 3C;

Figure 8A is an end elevational drawing of a medium recovery assembly 700, a tray washing module 750 and a medium loading assembly 800 for the horticultural apparatus of the embodiment;

Figure 8B is a partial top plan view drawing of the tray washing module of Fig. 8A;

Figure 8C is an enlarged fragmentary view of a position sensor in the tray washing module of Fig. 8B;

Figure 8D is a side elevational view of a vacuum device of the medium recovery assembly of Fig. 8A;

Figure 8E is a top perspective view of the vacuum device of Fig. 8D with a medium transfer conveyor and hopper of the medium loading assembly of Fig 8A;

Figure 8F is a top perspective view of the tray washing module of Fig. 8A;

Figure 9A is a rear elevational view of a tray stacker apparatus 900 of the preferred horticultural apparatus;

Figure 9B is a top perspective view of the tray stacker of Fig. 9 A;

Figure 10 is a block diagram of an automatic controller 1000 for coordinating operations of the modules of the horticultural apparatus 10 of the embodiment; Figure 1 1 A is a flow chart of a first portion of an operating method of an embodiment of the present invention;

Figure 1 1 B is a flow chart of a second portion of the operating method introduced in Fig. 1 1 A; and

Figure 1 1 C is a flow chart of a third portion of the operating method introduced in Fig. 1 1 A.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

Referring now to Figure 1 , there is depicted a schematic view of a horticultural apparatus installation of a preferred embodiment of the invention which installation 10 provides for the sequential carriage of trays 40, also referred to as "benches" that are of generally rectangular configuration for holding growth media, seeds and/or plants. A suitable growth media has been found to be kiln fired clay pebbles or light expanded clay aggregate (LECA). The trays are propelled in a cyclical fashion around via roller-ways and through one or more multi-level vertical farming structures 20, such as shown in Figs. 6A-6C. In the present embodiment, the multi-level structures are housed in enclosures 400 referred to herein as "climate cells" in view of the automatic control of the climate or environment provided therein, which may for example include the watering, drainage and/or LED lighting sub-systems described in the Applicant's earlier patent applications. The multiple climate cells 400.1 , 400.2, 400.3 of the embodiment conveniently allow for the growth of different crops in a respective cell under specific environmental conditions, as desired. The climate cell enclosures are disposed in a row, here three (3) climate cells 400.1 , 400.2, and 400.3 (see also Figs 2A-2D), each having in inward or entry side 402 and an outward or exit side 404 whereby each level of the structure 20 include racks that allow for movement of trays 40 from entry to exit within each enclosure 400. Along the entry side 402 of the climate cells there is provided an inward transporter 200, which here includes a line of three (3) inward transporter modules 200.1 , 200.2, 200.3 which carry the trays 40 horizontally relative to the climate cells along an entry path 30. The entry path originates at a seeder station 100 and associated tray stacker 900. Similarly, an outward transporter 250 is provided along the exit side 404 of the enclosures 400, including a line of three (3) outward transporter modules 250.3, 250.2, 250.1 arranged to form an exit path 50, which line terminates at a harvester station 500. A push path 70 is also provided between the inward VRC 300 and outward VRC 350.

It will be appreciated from at least Figs 2D and 6C, that the enclosures 400 include openings on both entry and exit sides 402, 404 corresponding to respective levels defined by cross bars 22 of the internal tray support structure 20. In order to elevate (or if required lower) an individual tray 40 to a selected level for insertion (or extraction), there is further provided, an upstanding elevator 300 in the form of a vertical reciprocating conveyor ("VRC") that is mounted to travel along the entry side 402 for receiving trays from any of the inward transporter modules 200.1 , 200.2, 200.3, and similarly on the exit side 404 an extractor or receiver 350, also in the form of a VRC, and mounted to travel along the exit side 404 for delivering trays from any of the climate cell enclosures 400.3, 400.2, 400.1 to a respective outward transporter module 250.3, 250.2, 250.1 . Each of the VRC apparatus are arranged to stop in horizontal alignment with a selected transporter module 200, 250 to enable transfer to and from a particular transporter to a vertically movable lifting carriage 310, 360 of the associated VRC-type conveyor 300, 350 (see also Figs 5A-5B).

Linking the linear paths passing the climate cells 400, including entry path 30 and exit path 50, is a return path 60 which, in the embodiment, is parallel with tray movement in push path 70 on supporting racks providing at each level of the multi-level structure 20, within and through the enclosures 400 from entry 402 to exit 404. Turntable devices 600, 650 (see Fig. 2A and in detail Figs 7E-7F) are provided for turning the trays 40, here through an angle of 90°, to and from the return path 60. The return path 60 of the embodiment incorporates a growth media recovery station 700, a tray wash station 750 and a growth media re/loading station 800, each described further below.

The operation of the return path 60 is facilitated by the turntables 600, 650, allowing the cycling of growth trays 40 from the seeder 100, along the entry path 30 via the inward transporters 200 and into a selected climate cell enclosure, such as 400.2, at a desired level with the aid of the inward VRC 300. A tray 40 exiting the climate cell 400.2 with be carried from the desired level by outward VRC 350, typically operating in a coordinated fashion with the inward VRC (as explained further below), transferred to the outward transport module 250.2 for on-forwarding along exit path 50 via the further outward transporter 250.1 to an outward turntable 650. Upon exiting the growth media loading station 800, inward turntable 600 redirects the tray 40 from return path 60 back into entry path 30, whereby the tray may re-enter the seeder 100 or be reversed into the stacker or racking module 900 for temporary storage (see Fig. 2A).

Seeder module

The seeder module 100 is illustrated in further detail in Figs 3A-3D, and includes a pair of elongate rails 102, 104 supported by posts 106 and held in spaced relation by cross-members 108. A lower end of the post 106 further includes a surface fixing bracket 107 to anchor the rails to a supporting surface. The rails 102, 104 each carry respective flanged guide wheels 1 12, 1 14 for movably supporting a tray (not shown). A hopper 1 10 for containing seed is located above the pair of rails 102, 104, seed being dispensed by a pneumatic distributer driven by hopper motor 1 1 1 under the control of a local sub-controller (121 , see Fig. 10), via a transverse array of dispensing tubes 1 16 visible under hopper 1 10 in Fig. 3D. A supply of nutrient 128 is also provided for optioned dosing the seeded growth media, as required. The sub-controller is housed in a control and communications cabinet 120. A remote monitor in the form of a video camera 122 is mounted on an upright 1 18 and coupled to an interface (not shown) within the cabinet 120.

Trays or benches are moved along the inward path 30 by a drive 130, here in the form of a digital stepper motor coupled to a frictional drive roller 132 which engages an under surface of a passing tray 40 that is also supported on the guide wheels 1 12, 1 14. A tray detection arrangement including a detector transceiver 124 and associated reflector 126 are provided at ends of the rails 102, 104, and is coupled to the control and communications cabinet 120. The tray detection arrangement is configured for detection of both the arrival and departure of a tray, and effect necessary control of the drive motor 130 which is also coupled to the sub-controller 121 .

Transporter modules - inward/outward

A transporter module, here an outward transporter 250, is further illustrated in detail by Figs. 4A- 4C. It should be noted at the outset, that the inward transporters 200 are of substantially the same configuration - see Fig. 4D and Figs 6C-6D, being a longitudinal mirror image of the outward transporter; as can be seen from the plan view of the horticultural installation 10 in Fig. 2A. The transporter modules 250 are raised roller ways having a pair of elongate rails 252, 254 supported by posts 256 and held in spaced relation by cross members 258. The rails 252, 254 each carry a series of flanged guide wheels 262, 264 for movably supporting a tray, and are aligned with rail and guide wheel arrangements of other modules in the installation 10, in order to facilitate substantially uninterrupted linear tray movements in travel paths.

Trays or benches 40 are moved along the transporter module 250 by independently controlled drives 280, 281 in the form of stepper motors coupled to respective friction drive rollers 282, 283 for engaging an under surface of a tray 40. The ends of the pair of rails 252, 254 are equipped with tray presence detectors for sensing the arrival and departure of each tray traversing the transporter longitudinally. The presence detectors include a first detector transceiver 272 and opposing first reflector 274, for tray arrival detection, at a first end of the rails, and a second detector transceiver 276 and opposing second reflector 278 at a second end, for tray departure detection. [Aside: A detailed view of a detector transceiver 222 and cooperating reflector 224 mounted on an arrival end of the transporter rails 202, 204 for an inward transporter module 200 is shown by way of further example in Figure 4D.] A third detector transceiver 273 and opposing third reflector 275 are also provided at a position intermediate the ends of the outward transporter module 250, and in order to facilitate lateral movement of a tray either inward to, or (in this case), outward through an exit opening 408 in a climate cell 400 and from the tray support structure 20 therein, via an intermediate vertical reciprocating conveyor or "VRC" as discussed further below, (see Fig. 6C). The intermediate tray position is arranged to correspond with openings provided on both the entry side 402 and the exit side 404 of a climate cell 400, and coordinated with each of the travelling VRCs (described further below in relation to Figs 6A-6D). The intermediate tray position on the transporter is further provided with a lifting mechanism 290, to facilitate lateral movement of the generally rectangular tray 40 relative to a transporter module. The lifting mechanism includes a pair of laterally extending, vertically movable sub-rails 291 , 292 upon which are rotatably mounted flanged wheels 293 together with a rotary drive pair having stepper motors 284 and friction drive wheels 285 for engaging ends of a rectangular tray 40. The degree of lift is sufficient for a loaded tray to clear the longitudinally disposed flanged guide wheels 262, 264 and be initially carried solely by the laterally disposed wheels 292, 294 for lateral movement by frictional drive rollers 285, for receiving a tray from a cooperating outward VRC 350.

Vertical reciprocating conveyor (VRC) - inward /outward

Turning initially to Fig. 5A, the inward VRC mechanism 300 includes an upstanding frame 302 that is mounted for longitudinal movement on upper and lower guides 304, 306 which are fast with the entry sides 402 of the climate cells 400.1 , 400.2, 400.3. A motor 301 located near the foot of the frame 302 effects movement of the frame along the guides 304, 306. The mobile frame 302 includes a pair of pillars 308, 309 that carry between them, a vertically movable lifting carriage 310. The lifting carriage 310 is arranged for reception, from the lift mechanism 240 of any one of the inward transporter modules 200.1 , 200.2, 200.3, of a tray for insertion into a climate cell 400 at a selected level. The lifting carriage 310 is moved vertically by a drive motor 307 mounted on an upper cross beam 303 provided between the pillars 308, 309. The VRC motors operate under the control of a local sub-controller 381 (discussed further below in relation to Fig. 10) mounted in an inward VRC control cabinet 380, which travels together with the upstanding frame 302 in this embodiment. Further details of the tray lifting carriage 310 can be seen in Fig. 5B and Figs 6C-6D, the lifting carriage having a pair of lateral end plates 31 1 , 312 and longitudinal supports 317, 318 therebetween. Upon each end plate there is rotationally mounted a series of flanged guide wheels 313, 314 together with lateral drive motors 315 and frictional drive rollers 316 coupled thereto. The lifting carriage also includes a central support structure 320 having a support platform 321 mounted between a pair of lateral support members 322 that span the longitudinal supports 317, 318.

Further provided on the inward lifting carriage 310 is a ratcheting pusher mechanism, having fingers 323 that protrude upwardly through apertures provided adjacent to corners of the support platform 321 . The pusher fingers 323 are operated to periodically retract and extend, such as by a rotary eccentric drive (not shown), and are arranged to engage with mouths of longitudinal recesses provided in an undersurface of the trays 40. It should be noted that apart from the absence of the (additional) ratcheting pusher mechanism 323 of the carriage 310 discussed in relation to Fig. 5B, the configuration of the outward VRC 350 and related lifting carriage 360 is substantially as described above (save for changes to the reference numerals).

Support structure and horticultural enclosures

Turning to the drawings in Figs 6A and 6B, there is shown an enclosure, in the form of a climate cell 400, for a multi-level tray support structure 20 visible in the sectional view (Fig. 6B). The enclosure includes an entry side 402 and an exit side 404, which is visible in Fig. 6A, with outer walls 406 and roof 407 being formed from insulating panels such as foamed plastics cores sandwiched between outer metallic skins, such as aluminium. The internal tray support structure 20 includes a supporting cross-bar 22 at each level which define a number of horizontal bays 410 having respective bay doors 408. Each bay of the support structure can accommodate a laterally extending horizontal array of single growth trays or benches 40. The bay doors 408 are pivotally mounted at a top longitudinal edge and opened independently by a drive (not shown) to allow passage of inward or outward tray movements. The view in Fig. 6C shows a portion of the entry side 402 of a climate cell 400 including the internal multi-level tray support rack 20 with cross bars 22 and associated bays 410, the bay doors here having been removed for clarity.

The climate cell further includes an operator access door 412 and an outlet 414 for an exhaust fan. A dehumidifier assembly 416 and associated heat pump 417 is provided for conditioning the air fed into the climate cell via supply duct 418. A control cabinet 420 which includes an electrical switch board and local sub-controller 421 , which is linked to a central industrial computer (not shown, see discussion of Fig. 10 below). Internally of the cell, access ladders 422 are provided for inspection of the tray and associated lighting and irrigation systems (not shown) which may be dosed from reagent supply 426 - see also broken away panel 406' in Fig. 6A. An internal plenum 424 directs air supplied by duct 418 across the trays 40 when disposed in respective bays. Harvester

A harvester module 500 for harvesting mature crops grown on a series of trays 40 exiting a climate cell 400 is shown in Figs 7A-7C. The harvester 500 includes a pair of rails 502, 504 supported by posts 506 and held in spaced relation by cross-members 508. The rails 502, 504 each carry respective flanged guide wheels 512, 514 for movably supporting a tray 40. The rails are longitudinally aligned with corresponding rails 252, 254 provided on an adjacent transporter module 250.1 (see Fig. 2A). The harvester module rails are also equipped with a tray detection arrangement including a detector transceiver 524 and associated reflector 526, coupled to a local sub-controller 521 in control and communications cabinet 520. A harvesting device 510 is located above the pair of rails, having a mouth 51 1 and associated transverse travelling cutting head (not shown) for separating crop foliage from supporting stalks. A first conveyor 513, having an endless belt (driven by motor 515) with a forward edge coincident with the mouth 51 1 of the harvester device, carries the cut foliage upwardly from the travelling tray 40. The harvest is then deposited on a transverse conveyor 516 having a further motor 517 driven belt which carries the foliage to a processing and packing area 550 (see Figure 2A).

A pair of drives 530, including frictional drive rollers 532 coupled to drive motors on respective rails 502, 504 in order to provide more positive drive in view of resistance encountered as a mature crop approaches and is engaged by the cutting head of harvesting device 510. The harvester module further includes an upright 518 upon which is mounted a monitor, such as a video camera 522. Shown in Fig 7D is a view of the outward or exit transport path 50 looking towards the mouth 51 1 of the harvesting device 510, wherein a tray 40 (which here happens to be empty for clarity) is travelling from the last of the outward transporters 250.3 and onto the harvester module 500.

Turntable modules

Figure 7E shows an outward-to-return turntable 650 (see also Fig. 2A), with the harvester module 500 to the right-hand side and the growth media recovery module 700 to the left-hand side. The turntable 650 employs the common transporter paired elongate rail structure 652, 654 with cross- members 658 having respective sets of flanged guide wheels 662, 664 and rotational drives 680 (on both rails as per the harvester 500) with motors coupled to frictional drive rollers 682. However, the pair of rails and cross-members instead together form a turntable sub-assembly 659 that is rotationally mounted via a vertical pivot (not shown) with respect to a fixed L-shaped sub-frame 660, which sub-frame is in turn supported by posts 656. The sub-frame 660 of the embodiment is coupled to rails 504, 502 of the harvester by drop-down brackets 666, and includes further fixed rail sections 667, 668 that are equipped with stops 690 to arrest over-rotation of the rotating sub-assembly. The rotating sub-assembly 659 is rotated on the pivot by an actuator (not shown) under control of the harvester sub-controller 521 .

Turning to Fig. 7F, there is illustrated a return-to-inward turn-table 600 which is coupled between the return path 60 and inward path 30 of the benches 40. The construction of turn-table 600 is similar to that of turn-table 650, save for that the subassembly 610 is T shaped. The T shape allows for a tray 40 - here shown exiting a growth media filling module 800 - to travel either toward the harvester 100 or be reversed by drive 630 along the inward path 30 into the stacker module 900 for temporary storage in a rack 910; as also apparent from Fig. 2A. An actuator M for rotating turn-table sub-assembly 609 is here controlled by the seeder sub-controller 121 .

Media recovery and Bench washer

Figures 8A-8E show a combined growth media recovery 700 and bench washer module 750. Turning first to Figs 8A and 8D-8E, the growth media recovery module includes a frame 701 offset and adjacent to the return path 60, and located between the turntable 650 and the bench wash module 750. The recovery module frame includes longitudinally disposed members 702, 704 supported on posts 706 and spaced by cross-members 708. The cross-members 708 here extend across and above any tray passing thereunder and support suction inlet heads 712 of a cyclonic separator 710, also mounted on frame 701 . The suction inlet heads are coupled by ducting 714 to an overhead inlet of the separator. The cyclonic separator 710 includes an impeller housing 716, the impeller therein being powered by a drive motor 720.

The frame 710 also includes an upright 718 upon which is mounted a monitor in the form of video camera 722. Signals from the camera and tray presence sensors (not shown) are linked to a combined media recovery-wash sub-controller 771 in cabinet 770 by cable run 773 (see Figure 8B). The frame further supports an angled rotary screen or trommel 730 which is fed by the lower outlet 719 of the cyclonic separator. The trommel, whose cylindrical screen 732 is driven by motor 738, includes an aperture size selected to pass growth media particles or "pebbles" for collection in sump 707. Matter not passing through the screen 732 exits a lower end of the trommel via chute 734 for collection in a receptacle, such as wheeled bucket 736. It is to be noted that trays 40 traversing the growth media recovery module 700 in return path 60 are supported by the flanged wheels of the adjacent turntable 650 and the bench wash module 750, as seen in Fig. 8A. This arrangement is facilitated by the overhanging inlet heads and offset frame 701 of the recovery module, wherein a step-down bracket 666 of turntable 650 is fixed to an outer cross-member 758 of the tray washing module 750. Turning now to Figures 8B and 8C, the bench washer module includes a fixed outer frame 751 , with outer longitudinal members 752, 754 spaced apart by outer cross-members 758. The outer frame is mounted on posts 756 and rotatably supporting an inner sub-frame 760 which carries trays 40. The inner sub-frame includes longitudinal rails 763, 765 carrying two series of flanged guide wheels 762, 764 together with multiple drives 780, each including a motor and friction drive roller 782 coupled thereto. The longitudinal rails 763, 765 are held in spaced relation by cross- members 768 and arranged for alignment with rails and guide wheels of cooperating modules, for example rails 652, 654 of adjacent turn-table 650.

The rotational support of the sub-frame 760 includes spigot members 766 provided centrally and extending outwardly from the cross-members 768 and supported by adjacent bracing members 767. The spigots 766 are journaled in bearings (not shown) provided in the adjacent outer cross- members 758 of the fixed frame 751 , whereby the sub-frame can rotate about its longitudinal axis for the purpose of inverting a tray 40. In order to retain trays 40 in place, as shown in Fig. 8A and with particular reference to Fig. 8F, each of the longitudinal rails 763, 765 carry a series of outwardly extending retaining arms 784 carrying casters 786 at distal ends thereof, which retaining arms are located adjacent each guide wheel series 762, 764. The trays 40 include a base with upstanding side walls (refer Fig. 7D), and the normally upper-most surface of the side walls is engaged by the casters 786 when the tray is upright and its base supported by the underlying flanged wheels 762, 764. Effectively the side wall of a tray is sandwich between casters and wheels whereby, upon inversion by the rotating sub-frame 760, the tray is retained in place upon the sub-frame 760. The tray is supported by the casters 786 when inverted, thereby continuing to allow longitudinal movement.

Rotational movement of the sub-frame 751 is effected by a drive including a motor 769 and transmission (not shown) coupling the motor to a spigot 766 of the sub-frame. In the present embodiment, a second outer frame 751 ' and second rotating sub-frame 760' are provided in a siamesed arrangement with the above-described "first" outer frame and sub-frame. In the drawings, similar reference numeral are employed by similar second components, that are identified by use of a "prime" marking of said reference numerals. This is evident in the further detail shown in Figure 8F. A central wash bay 790 is provided between the siamesed frames, through which the inverted trays 40 pass for cleaning and disinfecting, including by application of washing fluids 792 and disinfecting fluids 794 pumped from respective containers by pumps 796. Upon completion of the washing and disinfecting steps, trays are returned to an upright position for on-forwarding to the adjacent media loading assembly 800; see Fig. 8A (described further below). Turning briefly to Figure 8C, there is shown a proximity sensor 778, limit switch 779 associated and trigger arm 777, utilised for detecting the orientation of a sub-frame 760 relative to outer frame 751 . Signals from these sensors are fed to a sub-controller 771 located in the communications and control cabinet 770, for effecting control of drive motor 769. Growth medium loading

Returning to Figs 8A and 8E, the growth medium loader 800 of the embodiment includes a conveyor 810 which extends from a lower end 812 within sump 707 below the trommel 730 of the medium recovery module 700, having an endless belt 81 1 disposed adjacent to the tray washing module 750. The medium loader further includes a dispenser 830 with hopper 832 provided on an upstanding frame 831 sharing a common post 561 ' with the wash module 750. The upstanding frame 831 also supports an upper end 814 of the conveyor, whereby the recovered growth media may be deposited directly into the hopper receptacle 832 for dispensing as required. Fresh growth media can also be loaded manually to the receptacle by way of make-up. Return-to-inward turntable

Figure 7F depicts the return -to- inward path turntable module 600, including a portion of a growth tray 40 emerging from the growth medium loading assembly 800. The turntable module 600 includes a pair of elongate rails 602, 604 spaced by cross-members 608 having respective sets of flanged guide wheels 612, 614 and rotational drives 630 coupled to friction drive rollers 632, together forming a rotating sub-assembly 609. The rotating sub-assembly 609 is shown in Fig. 7F aligned with the return path 60 and in receipt of a front portion of tray 40, is pivotally mounted to a T-shaped fixed sub-frame 610.

The frame for supporting sub-assembly 609 includes horizontally disposed fixed rail sections 617, 619 resting on posts 606. Free ends of the rail sections are coupled to elongate rails of adjoining modules (e.g. rail 904 of tray stacker 900) by drop-down brackets 616. The T-shaped structure allows bi-directional movement of trays 40 along the path 30, i.e. parallel with fixed frame rail section 619, as desired.

It is to be appreciated, including upon review of Fig. 2A, that trays or benches 40 may, after revolving the sub-assembly 609 into alignment with entry path 30 alignment, proceed from the turntable 600 either forward along the entry path to the seeder module 100 or, alternatively, be reversed by the drives 630 on turntable assembly 609, into the bench stacker module 900, for temporary storage as required. Bench/tray stacker

Figures 9A and 9B show the bench stacker module 900 which includes a vertical storage frame 910. In common with other of the modules transited by trays 40, the bench stacker includes a pair of elongate rails 902, 904 mounted on posts 906 and held in spaced relation by cross- members 908. The posts 906 are secured to a support surface, such as a concrete slab, by a mounting bracket 907. Each of the elongate rails 902, 904 rotatably supports a respective series of flanged guide wheels 912, 914 enabling longitudinal movement of trays therealong.

A drive including a digital stepper motor 930 coupled to a fictional drive roller 932 is provided to propel trays 40 along the rails in either direction on inward path 30. A tray presence sensor 924 and cooperating reflector 926 are provided to detect the arrival (and departure) of a tray, wherein sensor signals are fed to a sub-controller 921 within control cabinet 920. The vertical storage frame or rack 910 includes four(4) columns 916 fixed at their lower ends to either of the elongate rails 902, 904 and at their upper ends by cross-members 918 and longitudinal braces 919 intermediate the cross-members. The columns 916 each further include an inwardly facing vertical slot 915 from which protrude lifting fingers 942 of a vertical drive 940, such as an enclosed endless chain supported by sprockets (not shown) mounted at opposed ends of the columns. Each lifting drive chain is driven by a common transmission including a motor 944, differential gear set 945 and drive shafts 946 coupled thereto by each of the lower sprockets. In use, a tray 40 arriving on the elongate rails 902, 904 stops when its presence at a distal end is detected. The lifting motor 944 is then operated whereby the lowermost set of protruding fingers 942 engage with an under-surface of the tray, preferably at recesses provided in the under- surface to mitigate against slippage during take-up of load. Motor 944 continues to operate until the tray is lifted clear of the rails 902, 904 and sufficient clearance is provided for a succeeding tray to enter the stacker module 900. From the storage rack 910, benches or trays 40 may be removed (or re-inserted) as required, for example by a lift truck for the purpose of repair, maintenance or during initial loading of an empty climate cell 400.

Control scheme

Figure 10 shows a schematic block diagram of the communications and control system 1000 for operational modules of the present embodiment. The control system employs a distributed input/output arrangement, with each module's sub-controller node running its own local control sequence, overseen by a central supervisory controller in the form of an industrial, rack-mounted computer 1001 utilizing system control and data acquisition (SCADA) software. The computer 1001 further includes user interface equipment including a keyboard and pointing device 1002, such as a mouse, track ball or electronic pen and a display device 1004, such as an LED display screen, each coupled to a central processor 1006 and communications interface 1008. The keyboard, pointing device and display device may be embodied as a laptop computer having a touch screen and interfaced to the computer 1001 .

During intensive harvesting, growth medium recovery and seeding operations, for example may typically consume around 3-6 hours in a one week period (depending on the particular crop), the vertical farming system is manned and operations monitored through a SCADA human user interface mimic display supported by video cameras mounted at critical locations (as described above) in the system.

A communications link 1010, suitably employing a twisted wire pair and implementing the "Modbus" protocol, couples local sub-controllers together in a ring emanating from the communications interface 1008 of the industrial computer 1001 , and traversing the following sub- controllers:

• seeder 121 >

• inward transporters 221 .n >

• inward VRC 331 (also coupled individually to each inward transporter sub-controller) >, outward VRC 381 (also coupled individually to each outward transporter sub-controller)

<, =

outward transporters 271 .n <

harvester 521 <; and

composite media recovery/bench wash/media load 721 <>

Legend: > inward path (30) modules

< outward path (50) modules

<> return path (60) assemblies/module

= "push" path (70) growth cells

Note also that the sub-controllers for each of the inward VRC 331 and outward VRC 381 interconnected by communications link in the push path (70) in order to complete the "ring".

In the embodiment, the seeder sub-controller 121 controls an actuator M that effects rotation of return-to-inward turntable 600; whilst the harvester sub-controller 521 controls another actuator M that similarly effects rotation of the outward-to-return turntable 650. The VRC sub-controllers 331 , 381 directly operate actuators 408i, 408o for the doors 408 on respective entry/exit sides of the climate cells, since the VRC is appraised of the desired level of the climate cell 400 for bench transfer. This avoids the need for any communications with the climate sub-controllers 421 , allowing their focus to be control of a desired growing environment within respective chambers. Noting that where multiple climate chambers are provided, different crops may be cultivated independently as desired, suitably having over-lapping maturity dates.

The operation of the distributed control system, particularly the hand-off of bench transport control between modules which is triggered by tray/bench presence sensor arrangements, may be understood with reference to the method discussed below in relation to the flow chart of Figure 1 1 .

Operating method

In Figures 1 1 A- 1 1 C there is shown a flow chart depicting the main steps of an operating method 1 100 of a preferred embodiment of the invention, as coordinated by conjoint operation of the central processor 1006 and distributed sub-controllers discussed in relation to Fig. 10. Turning first to Fig. 1 1 A, the operating method is capable of commencing from two different starting points, depending on the status of the growth trays benches. The vertical farming machinery 10 can start operations in either a "cold start" or empty state at initial step 1 102 (typically employed during commissioning or after a major over-haul or deep maintenance), or with at least one of the climate cells 400 loaded with a crop ready to harvest, from step 1 120.

We will first discuss operations commencing from step 1 120 for a fully loaded machine, as this is the most common operating mode during the cyclic re-use of growth trays or benches 40 for cultivating crops. In step 1 122, the bench stacker module 900 operates and sends a tray 40 preloaded with growth media or "pebbles" to the seeder 100. In step 1 124, seeds are set in the growth media and receive a dose of nutrient. Reference may be had to the present inventor's copending international patent application No. PCT/AU2018/050626 for examples of suitable growth media. As depicted in Fig. 1 1 B, upon leaving the seeder, the newly seeded bench 40 is passed to the line of inward transporter modules 200 in step 1 126. Assuming that the first climate cell 400.1 is here to be reloaded, as instructed by the central processor 1006, control would pass to inward VRC module 300 in step 1 132 and linked outward VRC module in step 1 134.

The outward VRC 350 normally operates in synchronism with the inward VRC 350 in step 1 134, noting the inter-process "ready" semaphore crossing to step 1 132. For example, doors 408 for accessing a selected level of the multi-level tray support structure 20 are opened on both sides 402, 404 of the climate cell 400. in readiness for tray movements. The operating method 1 100 of the embodiment relies upon the inward VRC 300 pushing the seeded tray into the climate cell, resulting in a tray 40' holding mature crop growth emerging from the exit side of the climate cell 400.1 traversing push path 70. This tray movement operation is reflected in steps 136, 138 wherein the seeded tray 40 enters on one side and the crop carrying tray 40' emerges on the other side. Manual intervention is provided for in step 1 137, allowing for manual push of a tray or bench 40. In step 1 138, the outward VRC 350.1 will laterally transfer the cropped tray 40' after movement of the carriage platform 360 to transporter level.

Referring to Fig. 1 1 C, control will then pass (along path "c"), to the outward transporter 250.1 in step 1 144 which propels tray 40' toward the harvester 500. By way of further explanation, a tray 40' instead emerging from the third climate cell 400.3 would be passed sequentially along path 50 by transporters 250.3 250.2 and 250.1 and onward to harvester 500. In step 1 146 the harvester 500 is operated to harvest foliage from the crop grown in tray 40'. Upon completion or harvest, the tray 40' is forward to the media recovery apparatus 700 via the outward-to-return turntable 650, under control of the harvester sub-controller 521 . In step 1 148, the cyclone vacuum 710 is operated to remove loose matter from the tray 40', which matter is passed to the trommel 730 in order to screen the pebble-like growth media from remaining debris. The media pebbles are then washed in sump 707 in readiness for re-cycling to the media loading apparatus 800. Manual intervention is possible in step 1 149, for example to halt rotation of the trommel screen 732.

Returning to Figure 1 1 A (via return path "b"), control then passes to the bench washer module 750 in step 1 106 after passing through the media recovery apparatus 700. The bench or tray 40' is rolled over by inner sub-frame 760, passed over a central pressure washer to siamesed rotating sub-frame 760' (see Fig. 8F) and then rolled upright gain. The upright washed/disinfected tray 40 is then forwarded to the media loading apparatus 800 in step 1 108. Again, there is an opportunity for manual intervention in step 1 107, including to allow loading of addition pebble media into hopper 832 of the growth media dispenser 830. At decision point 1 1 10, where the climate cell 400 to be harvested is flagged (for example by coordinating central processor 1006) as full, here in the sense of each level being filled with newly seeded trays, any remaining surplus benches 40 are forwarded via return -to- inward turntable 600 to the bench stacker module 900 in step 1 1 14. If the climate cell is not full at decision point 1 1 10, control passes back to seeder in step 1 124.

It should be appreciated, that whilst we have focused on the progress of but one initially seeded bench 40 inward to climate cell 400.1 at a desired level and the consequent progress of a cropped bench 40' (pushed) outward from the same climate cell at the same level; each of the above described steps are operating sequentially for a plurality of benches in sequence both inward to and outward from any (preferably one) of the climate cells, at a rate influenced by the operating speed of each locally controlled individual module or tray handling apparatus. Put another way, as soon as a tray or bench is processed by an individual module and departs, a new tray/bench can commence processing at the module which signals its neighboring sub-controller accordingly. This is largely facilitated by the distributed, modular control scheme, which is merely overseen by the central industrial computer 1001 - including for monitoring and fault reporting.

By way of example, at any one time in the vertical farming apparatus 10, a first bench 40.1 can be ready at the stacker 900, a second bench 40.2 undergoing seeding at the seeder module 100; a third 40.3 being passed along path 30 by the inward transporter line 200; a fourth bench 40.4 being elevated by the inward VRC 300.2 to a desired climate cell level; a fifth 40.5 being lowered by the outward VRC 350.2 to the outward transporter 250.2; a sixth 40'.6 being passed along path 50 by the outward transporter line; a seventh 40'.7 undergoing harvesting at module 500; together with an eighth tray 40'.8 and possibly ninth 40.9 undergoing recovery and washing/reloading operations at module 700, 750, 800.

The industrial computer also operates to individually control the growing environment with each of the enclosed climate cells 400, and in the present embodiment dedicated control lines 1040 are provided to each cell sub-controllers 421 .1 , 421 .2 and 421 .3.

Turning to the alternative, and less used starting point for the method of the embodiment, we return to the cold start with empty machine, commencing at step 1 102 in Fig. 1 1 A. In step 1 103, an empty bench is typically hand loaded onto a transporter in the outward path 50, conveniently at bench transporter 250.1 , at a point before passing through (inoperative) harvesting and pebble recovery modules. This enables washing and disinfecting of benches at the operative washer module 750 in step 1 106, before the clean bench passes to pebble load module 800. The remaining process steps proceed as discussed in steps 1 107, 1 108 et seq., above. The present embodiments of the invention address the requirement for convenient, and preferably automated, handing of plant growth trays including externally of a controlled environmental enclosure in vertical agriculture, for purposes that may incorporate at least partial automated mechanization of transport of trays or benches through one or more of seeding, harvesting a mature crop and subsequent emptying, cleaning and preparing the growth trays for re-use. The embodiment provides an automated farming system for controlled growth of crops, including ten(10) sub-systems, including for growth tray or bench handling, integrated with one another to provide a scalable, commercially relevant farming solution requiring minimal labour input and basic skill levels. The sub-systems have been largely modularized to maximize scalability of the system for different end-user requirements. As discussed above, particularly in relation to Figures 1 1 A-1 1 C, each sub-controller has a programmed set of actions executed with the aid of sensors giving feedback to ensure completion of tasks prior to hand-off to the next sub-controller in the processing sequence or path.

In compliance with the statute, the invention has been described in language more or less specific to structural or methodical features.

The term "comprises" and its variations, such as "comprising" and "comprised of" is used throughout in an inclusive sense and not to the exclusion of any additional features. It is to be understood that the invention is not limited to specific features shown or described since the means herein described comprises preferred forms of putting the invention into effect. The invention is, therefore, claimed in any of its forms or modifications within the proper scope of the appended claims appropriately interpreted by those skilled in the art.

Throughout the specification and claims (if present), unless the context requires otherwise, the term "substantially" or "about" will be understood to not be limited to the value for the range qualified by the terms.

Throughout the description and claims of this specification, the singular encompasses the plural unless the context otherwise requires. In particular, where the indefinite article is used, the specification is to be understood as contemplating plurality as well as singularity, unless the context requires otherwise.

Features, integers, characteristics, compounds, chemical moieties or groups described in conjunction with a particular aspect, embodiment or example of the invention are to be understood to be applicable to any other aspect, embodiment or example described herein unless incompatible therewith.

Any embodiment of the invention is meant to be illustrative only and is not meant to be limiting to the invention. Therefore, it should be appreciated that various other changes and modifications can be made to any embodiment described without departing from the spirit and scope of the invention. LIST OF REFERENCE NUMERALS

10 horticultural installation 226 second detector transceiver

20 multi-level farming structure 228 second reflector

22 cross bars 230 first longitudinal drive motor

30 entry path 231 second longitudinal drive motor

40 trays or benches 232 first friction drive roller

50 exit path 233 second friction drive roller

60 return path 234 lifter lateral drives

70 push path 235 lifter friction rollers

240 lift mechanism

100 seeder station 241 lateral sub-rail

102 elongate rail 242 lateral sub-rail

104 elongate rail 243 flanged guide wheels

106 support posts 244 flanged guide wheels

107 surface fixing brackets

108 cross-members 250 outward transporter module

1 10 seed hopper 252 elongate rail

1 1 1 hopper drive motor 254 elongate rail

1 12 flanged guide wheel 256 support posts

1 14 flanged guide wheel 258 cross-members

1 16 dispensing tubes 262 guide wheels

1 18 upright 264 guide wheels

120 seeder control cabinet

121 seeder sub-controller 270 transporter control cabinet

122 video camera 271 out transport sub-controller

123 video camera interface 272 first detector transceiver

124 detector transceiver 273 third detector transceiver

126 reflector 274 first reflector

128 nutrient supply 275 third reflector

130 drive - stepper motor 276 second detector transceiver

132 friction drive roller 278 second reflector

280 first longitudinal drive motor

200 inward transporter module 281 second longitudinal drive motor

202 elongate rail 282 first friction drive roller

204 elongate rail 283 second friction drive roller

206 support posts 284 lifter lateral drive motors

208 cross-members 285 lifter friction rollers

212 guide wheels 290 lift mechanism

214 guide wheels 291 lateral sub-rail

292 lateral sub-rail

220 transporter control cabinet 293 flanged wheels

221 .n in transport sub-controller 294 flanged wheels

222 first detector transceiver

223 third detector transceiver

224 first reflector inward VRC

225 third reflector frame drive motor 302 upstanding frame 400. n climate cell

303 upper cross-beam 402 inward or entry side

304 upper guide 404 outward or exit side

306 lower guide 406 cell walls

307 carriage drive motor 407 cell roof

308 first pillar 408 bay doors

309 second pillar 408i inward door actuator

310 tray lifting carriage 408o outward door actuator

31 1 first end plate 410 bay levels

312 second end plate 412 operator access door

313 flanged wheels 414 exhaust fan outlet

314 flanged wheels 416 dehumidifier

315 lateral drive motors 417 heat pump

316 friction drive rollers 418 air supply duct

317 longitudinal support 420 cell control cabinet

318 longitudinal support 421 . n cell sub-controller

320 central support structure 422 access ladder

321 support platform 424 internal plenum

322 lateral support members 426 liquid reagent supply

323 lateral pusher fingers

330 inward VRC control cabinet 500 harvester module

331 inward VRC sub-controller 502 support rail

504 support rail

350 outward VRC 506 .posts

351 frame drive motor 508 cross-members

352 upstanding frame 510 harvesting device

353 upper cross-beam 51 1 mouth

354 upper guide 512 flanged wheels

356 lower guide 513 first conveyor

357 carriage drive motor 514 flanged wheels

358 first pillar 515 conveyor drive motor

359 second pillar 516 second conveyor

360 tray lifting carriage 517 second conveyor drive

361 first end plate 518 upright

362 second end plate 520 comms and control cabinet

363 flanged wheels 521 harvester sub-controller

364 flanged wheels 522 video camera

365 lateral drive motors 524 detector transceiver

366 friction drive rollers 526 reflector

367 longitudinal support 530 tray drive/motors

368 longitudinal support 532 frictional drive rollers

370 central support structure

371 support platform 550 packing area

372 lateral support members

380 outward VRC control cabinet 600 return-to-outward turntable

381 outward VRC sub-controller 602 elongate rail

604 elongate rail 606 support posts 752 outer longitudinal member

608 cross-members 754 outer longitudinal member

609 rotating sub-assembly 756 support posts

610 fixed sub-frame 758 outer cross-members 612 flanged wheels 760 rotating inner sub-frame 614 flanged wheels 762 flanged guide wheels

616 drop-down bracket 763 inner longitudinal rail

617 fixed rail section 764 flanged guide wheels

618 fixed rail section 765 inner longitudinal rail 640 rotation stops 766 spigot members

767 bracing beams

650 inward-to-return turntable 768 inner cross-members

652 elongate rail 770 comms and control cabinet

654 elongate rail 771 return path sub-controller

656 support posts 772 video camera

658 cross-members 773 comms cable run

659 rotating sub-assembly 774 detector transceiver

660 fixed sub-frame 776 reflector

662 flanged wheels 777 proximity trigger arm 664 flanged wheels 778 proximity sensor

666 drop-down bracket 780 drive motor

667 fixed rail section 782 friction drive roller

668 fixed rail section 784 outward support arm 690 rotation stops 786 tray support caster

790 central wash bay

700 media recovery module 792 washing fluid container

701 offset frame 794 disinfecting fluid container

702 longitudinal frame member 796 fluid pump

704 longitudinal frame member

706 support posts 800 medium loading

707 sump 810 conveyor

708 cross-members 81 1 endless belt

710 cyclonic separator 812 conveyor lower end 712 suction heads 814 conveyor upper end 714 inlet duct 830 media dispenser

716 impeller housing 831 upstanding frame

718 upright 832 dispenser receptacle 720 cyclone drive motor

722 video camera

730 rotary screen/trommel 900 tray/bench stacker

732 cylindrical screen 902 elongate rail

734 outlet chute 904 elongate rail

736 wheeled bucket 906 support posts

738 trommel drive 907 surface fixing brackets

908 cross-members

750 trav or bench wash module 910 stacker support frame

751 fixed outer frame 912 flanged guide wheels 914 flanged guide wheels 945 differential gear set

915 vertical slots 946 drive shafts

916 storage frame columns

918 storage frame cross-members 1000 communications and control

919 storage frame braces system

920 comms and control cabinet 1001 industrial control computer

921 stacker sub-controller 1002 input device/s

924 detector transceiver 1004 display device

926 reflector 1006 central processor

930 drive motor 1008 communications interface

932 friction drive roller 1010 communications link ring

940 vertical drive 1040 climate cell control lines

942 lifting fingers

944 vertical drive motor

Claims

1 . An apparatus for sequential carriage of growth trays around and through a mechanised, multi-level farming structure having an entry side and an exit side for said growth trays of a crop, the carriage apparatus including:

an inward transporter disposed along the entry side of the farming structure for transporting at least one tray containing growth media from a seeding station;

an upstanding elevator for elevating said at least one tray to a selected level of the farming structure and inserting said tray into the entry side of said farming structure; an automatic controller for coordinating movement of the trays into the entry side and/or out of the exit side of said farming structure;

an upstanding receiver for receiving and lowering said at least one tray containing a mature crop from the exit side of the farming structure;

an outward transporter disposed along the exit side of the farming structure for transporting said at least one tray to a harvesting station;

a growth media remover for removing growth media from each tray; and a tray washer for emptying and washing empty trays.

2. The tray carriage apparatus according to claim 1 , wherein the inward transporter includes guide wheels for movably supporting a tray and a drive for propelling the trays.

3. The tray carriage apparatus according to claim 2, wherein the guide wheels are rotatably mounted in two parallel sets on respective longitudinal rails.

4. The tray carriage apparatus according to either claim 2 or claim 3, wherein the drive includes a drive motor coupled to a friction drive roller arranged for engagement with a tray.

5. The tray carriage apparatus according to any one of claims 1 to 4, wherein the inward transporter includes a plurality of modules arranged in longitudinal alignment with one another.

6. The tray carriage apparatus according to any one of claims 1 to 5, wherein the inward transporter further includes at least one presence sensor for detecting a location of said at least one tray, the presence sensor suitably comprises a signal transceiver and reflector pair at each detection location.

7. The tray carriage apparatus according to any one of claims 1 to 6 wherein the upstanding elevator includes an elevator carriage for said trays that is horizontally alignable with the inward transporter or at least a module thereof, and is selectively vertically alignable with any level of the multi-level farming structure.

8. The tray carriage apparatus according to claim 7, wherein the elevator carriage further includes a pusher mechanism for pushing said at least one tray into a selected level of the multi-level structure, suitably laterally with respect to the carriage.

9. The tray carriage apparatus according to either claim 7 or claim 8, wherein the upstanding elevator services a plurality of rows of tray supports in the multi-level structure; and the elevator carriage is also movable along the structure, preferably for indexed alignment with individual transporter modules.

10. The tray carriage apparatus according to any one of claims 1 to 9, wherein the upstanding receiver includes a receiver carriage for said at least one tray that is horizontally alignable with the outward transporter or at least a module thereof, and is selectively vertically alignable with any level of the multi-level farming structure.

1 1 . The tray carriage apparatus according to claim 10, wherein the upstanding receiver services a plurality of rows of trays in a multi-level structure, the receiver carriages are movable along the structure, preferably for indexed alignment with individual transporter modules.

12. The tray carriage apparatus according to either claim 10 or claim 1 1 , wherein movement of carriages in the upstanding elevator and upstanding receiver is effected by provision of a longitudinally movable frame including columns supporting the carriages for vertical movement.

13. The tray carriage apparatus according to claim 12, wherein the longitudinally movable frame includes a drive coupled to a carriage for selectively raising and lowering of the trays thereon.

14. The tray carriage apparatus according to any one of claims 1 to 13 wherein the automatic controller further includes a plurality of local sub-controllers co-located with each of the transporters, elevator, receiver, growth media remover and tray washer in a modular arrangement, each sub-controller coupled to a central control processor via a communications link.

15. The tray carriage apparatus according to claim 14 wherein handover of control between local sub-controllers is triggered by tray or bench presence sensors associated with respective modules of the carriage apparatus.

16. The tray carriage apparatus according to any one of claims 1 to 15, wherein the multi-level farming structure is contained within one or more enclosures whereby a growing environment for the crop is controllable.

17. The tray carriage apparatus according to claim 16, wherein the automatic controller is further configured to independently control the growing environment within each enclosure of the farming structure and/or nutrient supply to the crop until maturity.

18. The tray carriage apparatus according to any one of claims 1 to 15, where each level of the multi-level farming structure provides for support of a row of trays in side- by-side relation, the row extending laterally from the entry side to the exit side of the structure.

19. The tray carriage apparatus according to any one of claims 1 to 15, wherein the outward transporter includes guide wheels for movably supporting a tray and a drive for propelling the trays.

20. The tray carriage apparatus according to claim 19 wherein the guide wheels are rotatably mounted in two parallel sets on respective longitudinal rails disposed along the exit side of the structure.

21 . The tray carriage apparatus according to either claim 19 or claim 20, wherein the drive includes a drive motor coupled to a friction drive roller arranged for engagement with a tray.

22. The tray carriage apparatus according to any one of claims 1 to 21 , wherein the outward transporter comprises a plurality of modules arranged in longitudinal alignment with one another.

23. The tray carriage apparatus according to any one of claims 1 to 22, wherein the outward transporter further includes at least one presence sensor for detecting the location of a tray, the presence sensor suitably comprises a signal transceiver and reflector pair.

24. The tray carriage apparatus according to any one of claims 1 to 23, wherein the growth media remover includes a vacuum apparatus and a screen for separating growth media pebbles from debris.

25. The tray carriage apparatus according to claim 24, wherein the vacuum apparatus includes a cyclone separator and the screen comprises a trommel.

26. The tray carriage apparatus according to any one of claims 1 to 25 wherein the tray washer includes a tray inversion apparatus for inverting said at least one tray prior to liquid pressure washing.

27. The tray carriage apparatus according to any one of claims 1 to 26 further including a seeding station prior to the inward transporter, the seeding station having a seed hopper and pneumatic seed dispenser.

28. The tray carriage apparatus according to any one of claim 1 to 27 further including at least one turn-table module for rotating said at least one tray between either the inward transporter or the outward transporter and an auxiliary module path disposed at an angle to said transporters.

29. The tray carriage apparatus according to claim 28 wherein the auxiliary module path includes one or more of the growth media remover, the tray washer, a growth media loading conveyor and a tray stacker for storage of said one or more trays.

30. A method for sequential carriage of growth trays around and through a multilevel farming structure having an entry side and an exit side for said trays, the method including the mechanised steps of:

transporting from a seeding station and along the entry side of the farming structure at least one tray containing growth media for growth of a crop;

elevating said at least one tray to a selected level of the farming structure and inserting said tray into the structure;

automatically controlling movement of the trays into the entry side and/or out of the exit side of the multi-level structure;

receiving and lowering said at least one tray containing the mature crop from the exit side of the farming structure;

transporting said at least one tray along the exit side of the farming structure to a harvesting station; and

removing growth media from the tray and washing the tray.

31 . The tray carriage method according to claim 30 further including the antecedent step of distributing seed for the crop into said at least one tray containing the growth media.

32. The tray carriage method according to either claim 30 or 31 including the step of harvesting the mature crop prior to growth media removal.

33. The tray carriage method according to any one of claims 30 to 32 further including automatically controlling a growing environment within an enclosure containing the farming structure and/or nutrient supply to the crop until maturity.