WO2021159182A1

WO2021159182A1 - A system and method for producing fodder

Info

Publication number: WO2021159182A1
Application number: PCT/AU2021/050120
Authority: WO
Inventors: Michael Crowe
Original assignee: Michael Crowe
Priority date: 2020-02-13
Filing date: 2021-02-12
Publication date: 2021-08-19

Abstract

The present invention relates to the devices, methods and systems for producing fodder. The invention provides an apparatus for processing trays of fodder comprised of germinated seed. The apparatus includes a harvesting zone in which fodder is separated from a tray, a seed depositing zone in which fresh seed is deposited onto the tray, and a conveyer for translating the tray between the harvesting zone and the seed depositing zone. The invention is adapted for use in the production of fodder from germinated seed for use in meat production or for the production of milk or other by-products of animal husbandry.

Description

A SYSTEM AND METHOD FOR PRODUCING FODDER TECHNICAL FIELD

[001] The present invention relates to the devices, methods and systems for producing fodder. The invention relates in particular to the production of fodder from germinated seed for use in meat production or for the production of milk or other by-products of animal husbandry.

BACKGROUND

[002] Beef and lamb are typically either pasture-fed or grain fed or both. Some beef and lamb is pasture fed and then may be grain fed in the last few days depending on climatic conditions and product specifications. Grass fed meat comes from animals that have only grazed on grass. They feed on a range of different types of grasses, depending on climate and region. Likewise, dairy animals such as cows, goats and sheep are usually pasture fed and this may be supplemented or replaced with fodder.

[003] The productivity and capacity of pasture depends on a variety of factors. Productivity is affected by the composition of the pasture as this affects palatability and productivity. Leafiness and protein content of leaves are key determiners of a plant's palatability and productivity and vary between pasture species. Nitrogen/protein content changes throughout the year and varies between the plant stem and leaf.

[004] Pasture growth is also a key determinant of productivity and capacity and is determined by a combination of rainfall intensity, ground cover, soil type and condition, evaporation, slope and tree cover. Better quality soil leads to better quality pasture. Soil health has a direct impact on protein levels in pasture. Low soil phosphorus and nitrogen are the most common nutrient restrictions on pasture growth. Other soil-related factors are the level of organic matter available (providing plant nutrients and helping to bind soil for better water infiltration) and the level of pasture cover. If pasture cover is low then water runs off and there is greater risk of erosion. It is vital to manage pasture so that the top layer of soil (1-3cm) is preserved.

[005] The management of pastures to maximise productivity and capacity and in turn to maximise meat, milk or other animal production is a complex task. Rainfall, which is uncontrollable, is a key factor in meat and milk production. Livestock farmers have used systems to produce fodder to supplement pasture feeding by sprouting or germinating seed. The fodder that is produced is palatable and nutritious. Fodder can be produced year-round regardless of climate. Sprouting techniques are able to produce fodder more water efficiently than pasture grown grass feed. Sprouting systems also occupy a smaller footprint than pastures which can enable greater intensity and more efficient land use.

[006] Existing fodder systems consist of a frame comprising shelves supporting trays made of metal or plastic. A layer of seeds is spread over the trays and they are irrigated at predetermined intervals. The seeds will usually sprout within 24 hours and in 5 to 8 days have produced a 6 to 8-inch-high grass mat. After the mat is removed from the tray, it can go into a feed mixer or otherwise be fed to livestock.

[007] A difficulty with these systems is achieving sufficient fodder production economically and cost effectively. Systems involving the production of fodder on trays requires the movement of large trays which themselves are heavy and when supporting a mat of germinated seed are heavier still. The trays must be moved so that they can be removed from their racks, to be covered with seed or harvested and replaced to their racks. If the trays are to be moved manually the trays must not be too large otherwise they will be too heavy, particularly when the seed has sprouted and is ready for harvest. Small trays combined with the need to move the trays manually results in a system that is not scalable and is therefore inefficient and non-economic. Also, manual systems tend to result in uneven distribution of seed on the tray [008] The manipulation of trays of fodder is often difficult because of the heavy combined weight of the trays and the fodder growing on the trays and is often generally inconvenient, labour intensive and results in an uneven growth of fodder.

[009] Automated units have been constructed in which trays are mechanically moved along a conveyor system whereby trays sown with seeds are picked up and trays of fodder are then harvested from the other end of the production unit. The capital outlay required for such a system is often prohibitive and as a result automated systems have not generally found acceptance in the production of fodder for livestock.

[0010] The systems described above all have inherent problems or constraints that make the production of fodder for use as a feed for livestock uneconomic or impractical.

[0011] The present invention enables the intensive production of fodder that overcomes or alleviates at least some of the above described problems. Other objects and advantages of the invention will become apparent from the following description

[0012] Any discussion of background art throughout the specification should in no way be considered as an admission that any of the documents or other material referred to was published, known or forms part of the common general knowledge.

SUMMARY OF THE INVENTION

[0013] Accordingly, in one aspect, the invention provides an apparatus for processing trays of fodder comprised of germinated seed, the apparatus including: a harvesting zone in which fodder is separated from a tray, a seed depositing zone in which fresh seed is deposited onto the tray, and a conveyer for translating the tray between the harvesting zone and the seed depositing zone. [0014] Embodiments of the invention are advantageous because the tray is translated from the harvesting zone to the seed spreading zone and fresh seed is deposited thereon as the tray translates along a substantially linear and horizontal path. The tray moves along a straight path and the elevation of the tray does not substantially change as it moves from the harvesting zone to the seed spreading zone.

[0015] Embodiments of the invention obviate the need to lift or lower the tray or to move the tray in a transverse direction relative to the direction of translation between the harvesting zone and the seed spreading zone. Minimal manipulation of the tray in as few directions as possible is preferable to minimise the possibility for uncontrolled movement of the tray and potential downtime of an automated or semi-automated seed harvesting and seed spreading apparatus.

[0016] Preferably, the harvesting zone includes a mechanism for tilting the tray to cause the fodder to move relative to the tray.

[0017] Preferably, the mechanism for tilting the tray includes a tilting tray support that has a horizontal position wherein in the horizontal position a portion of the tray is supported by the tilting tray support and another portion of the tray is supported by the conveyer.

[0018] Preferably, the tilting tray support includes a plurality of rollers for permitting translation of the tray thereon.

[0019] Preferably, operation of the conveyer removes the tray from the tilting tray support of the harvesting zone.

[0020] Preferably, the conveyer translates the tray on a linear and horizontal path between the harvesting zone and the seed depositing zone and as the fresh seed is deposited onto the tray. [0021] Preferably, the seed depositing zone includes a seed hopper configured to release seed as the tray translates beneath the hopper.

[0022] Preferably, the seed hopper is configured to release seed at a predetermined rate relative to the speed of translation of the tray to control the distribution of seed deposited on the tray.

[0023] Preferably, the harvesting zone includes a second conveyer for receiving the fodder from the tray and depositing the fodder into a receptacle.

[0024] Preferably, the conveyer translates the tray to a holding zone after the fresh seed is deposited onto the tray.

[0025] Preferably, the translation of the tray between the harvesting zone, the loading zone and the holding zone is along a linear path.

[0026] Preferably, the apparatus includes a lifting device for placing a tray of fodder onto the harvesting zone.

[0027] Preferably, the lifting device is adapted to remove the tray of fodder from a rack.

[0028] Preferably, the lifting device is adapted to translate in a direction parallel to the direction of translation of the tray on the conveyer.

[0029] Preferably, the lifting device translates on a linear track.

[0030] Preferably, the lifting device includes a four-axis arm including a pair of forks adapted to support and lift the tray from below.

[0031] Preferably, the lifting device is adapted to remove a tray of fresh seed from the holding zone.

[0032] In another aspect, the invention provides a system for producing fodder comprised of germinated seed, the system including: a rack supporting trays of fresh seed deposited thereon; an enclosure for receiving the racks and in which the seed is exposed to light and water for germinating the seed; and the apparatus for processing trays of fodder of any one of the preceding claims for separating fodder comprised of germinated seed from the trays.

[0033] Preferably, the rack includes a frame comprising a series of tray receptacles that are each adapted to receive a tray thereon.

[0034] Preferably, the rack includes a network of water spray heads connectable to a water supply for spraying water onto the seed on the trays.

[0035] Preferably, the enclosure includes a series of light sources mounted to the walls for exposing the seed on the trays to light.

[0036] Preferably, the system includes a mobile powered moving apparatus for moving the racks between the enclosure and to a position adjacent to the apparatus for processing trays of fodder.

[0037] Preferably, the system further includes a lifting device including a mechanical arm mounted on an elongated track, wherein the mechanical arm is adapted to lift a tray off the rack and lower the tray onto the harvesting zone.

[0038] Preferably, the mechanical arm is adapted to translate along the track between a location aligned with the harvesting zone for lowering a tray thereon and a location aligned with the holding zone for lifting a tray with fresh seed deposited thereon.

[0039] Preferably, the mechanical arm is adapted to translate along the track to locations aligned with each of a plurality of the racks.

[0040] In yet another aspect, the invention provides a method for processing trays of fodder comprised of germinated seed, the method including: providing a tray of germinated seed on a support; separating the germinated seed from the tray, translating the tray from the support on a conveyer; and depositing fresh seed onto the tray as it translates.

[0041] Preferably, the method includes tilting the support and the tray thereon to cause the fodder to move relative to the tray.

[0042] Preferably, the method includes drawing the tray off the support by operation of the conveyer when the support and the tray thereon are in a horizontal position.

[0043] Preferably, the method includes translating the tray to a holding zone after the fresh seed is deposited onto the tray.

[0044] Preferably, the method includes lifting the tray of fresh seed from the holding zone and depositing the tray of fresh seed on a rack in an enclosure.

[0045] Preferably, the method includes exposing the tray of fresh seed to light and water to cause germination of the seed.

BRIEF DESCRIPTION OF THE FIGURES

[0046] The present invention will now be described in more detail with reference to preferred embodiments illustrated in the accompanying figures, wherein:

[0047] Figure 1 illustrates a diagrammatic representation of a system for producing fodder comprised of germinated seed in accordance with an embodiment of the invention.

[0048] Figure 2 illustrates a diagrammatic representation of an apparatus for processing trays of fodder comprised of germinated seed including a harvesting zone, a seed spreading zone, a holding zone and a conveyer, wherein a tray covered in fodder for harvesting is positioned in the harvesting zone.

[0049] Figure 3 illustrates the apparatus of Figure 2 wherein a support surface and the tray supported thereon are tilted to allow fodder to slide off the tray and onto another conveyer that is inclined and which in turn draws the fodder off the tray and deposits the fodder into a receptacle in the form of a trailer.

[0050] Figure 4 illustrates the apparatus of Figure 2 wherein the support surface has been returned to its level position and wherein the tray has been translated off the support surface of the harvesting zone and through a cleaning station and towards the seed spreading zone.

[0051] Figure 5 illustrates the apparatus of Figure 2 wherein a tray is being covered with fresh seed in the seed spreading zone, comprised of a hopper containing a store of fresh seed and a slot opening discharging fresh seed onto the tray and where another tray is located in the harvesting zone and yet another tray covered in fresh seed is located in the holding zone.

[0052] Figure 6 illustrates a diagrammatic representation of part of the system of Figure 1 including the apparatus of Figure 2 for processing trays of fodder and a lifting device comprised of a mechanical arm comprising mounted on an elongated track and supporting a tray covered in fodder about to be lowered onto the harvesting zone.

[0053] Figure 7 illustrates the features of Figure 6 wherein the tray covered in fodder has been lowered onto the harvesting zone by the lifting device.

[0054] Figure 8 illustrates a diagrammatic representation of a rack of the system of Figure 1 , wherein the rack includes a frame comprised of a series of tray receptacles with trays supported thereon.

[0055] Figure 9 illustrates a side view of the rack of Figure 8 with the trays supported thereon.

[0056] Figure 10 illustrates an end view of the rack of Figure 8 with the trays supported thereon. [0057] Figure 11 illustrates a diagrammatic representation of the rack of Figure 8 wherein the trays have been removed to reveal a network of sprayer heads mounted thereto.

[0058] Figure 12 illustrates a side section view of the rack of Figure 8.

[0059] Figure 13 illustrates a cross section view of the rack of Figure 8.

[0060] Figure 14 illustrates a diagrammatic view of the inside of an enclosure of the system of Figure 1 containing one of the racks therewithin.

[0061] The invention will now be described in further detail with reference to the embodiments illustrated in the Figures.

DETAILED DESCRIPTION

[0062] The present invention broadly relates to apparatus and methods for producing fodder comprised of sprouted or germinated seed and to apparatus and methods for processing trays of fodder comprised of germinated seed.

[0063] Specifically, with reference to Figures 1 to 7, an embodiment of the invention is illustrated comprising an apparatus 10 for processing trays of fodder comprised of germinated seed. The apparatus 10 includes a harvesting zone 20 in which fodder 2 is separated from a tray 5. The apparatus 10 also includes a seed spreading zone 40 in which fresh seed 1 is spread onto an upper surface 6 of the tray 5. The seed spreading zone 40 could alternatively be described as a “seeding zone”.

[0064] The apparatus 10 further includes a translation means, which in the embodiment illustrated in Figures 1 to 7 includes a conveyer 80, for translating the tray 5 between the harvesting zone 20 and the seed spreading zone 40 wherein the fresh seed is spread onto the tray as the tray 5 is being translated. Another embodiment of the translation means for translating the tray 5 between the harvesting zone 20 and the seed spreading zone 40 includes a magnetic levitation and drive arrangement, which includes an electromagnetic apparatus embedded in a base for suspending the tray 5 and for driving movement of the tray 5 between the harvesting zone 20 and the seed spreading zone 40. Yet another embodiment of the translation means includes an arrangement of rollers such as unidirectional or multidirectional wheels or rollers mounted on a base for supporting the tray 5 thereon and for driving movement of the tray 5 between the harvesting zone 20 and the seed spreading zone 40.

Harvesting Zone

[0065] Referring to Figure 2, the harvesting zone 20 is comprised of a frame 74 including support members 71 upstanding from a floor and supporting a horizontal member 73. The harvesting zone 20 has an upwards facing support surface 72. The support surface 72 is adapted to receive and support the tray 5, including fodder 2 on the upper surface 6 of the tray 5 that is ready for harvest. Referring to Figure 4, the support surface 72 includes a plurality of rollers 75 mounted transversely to contact with the bottom surface of the tray 5 and thereby support the tray 5. The rollers 75 are arranged in two groups and are separated by a transverse slot 71a that is open to one side.

[0066] The support surface 72, including the plurality of rollers 75 mounted transversely thereto, has a longitudinal length dimension that is approximately two-thirds the longitudinal length of the tray 5. Thus, when the tray 5 is placed on the support surface 72, approximately one-third of the length of the tray 5 overhangs the opposite end 72b of the support surface 72, and the rollers 75 mounted thereto.

[0067] Referring to Figure 3, the harvesting zone 20 includes a mechanism for tilting the support surface 72 and with the tray 5 supported thereon. Any mechanism for causing the support surface 72 to tilt may be employed. In the illustrated embodiment, the tilting mechanism consists of the support surface 72 being pivotally connected at one end 72a to the horizontal member 73 or the upstanding support members 71 of the frame 74. An actuator 73a, which in the embodiment illustrated in Figure 3 is a linear actuator such as a hydraulic actuator but which could instead be a rotary actuator coupled to the pivotal connection 72a, causes the support surface 72 to pivot about the pivotal connection 72a and thereby lift the opposite end 72b of the support member 72 as illustrated in Figure 3. In this way, the support surface 72, including the rollers 75 and the tray 5 supported thereon tilt. As the tray 5 tilts, the fodder 2 on the tray 5 begins to slide off the tray 5. Thus, the fodder 2 is separated from the tray 5 in the manner described above. A receptacle 100 may be positioned adjacent to the pivotally connected end 72a of the support member 72 to receive the fodder 2 as the fodder 2 slides off the tray 5.

[0068] The tilting support surface 72 includes a pair of laterally opposite side members 76. The side members 76 taper inwardly so that the distance between the side members 76 across that transverse width of the support surface 72 is slightly less than the width of the tray 5. The side members 76 engage side edges of the tray 5 as the support surface 72 tilts to limit movement of the tray 5 relative to the support surface 72. As the support surface 72 tilts, the tray 5 slides slightly down the inclined support surface 72 and into engagement with the side members 76 which limit any further movement of the tray 5 down the inclined support surface 72.

Conveyer System

[0069] In the embodiment of Figures 1 to 7, the translation means includes a conveyer 80. The conveyer 80 includes a conveyer belt assembly 87 for translating the tray 5 between the harvesting zone 20 and the seed spreading zone 40. In embodiments described herein, the translation means may include more than one conveyer or conveyer belt assembly.

[0070] Referring to Figure 4, the conveyer belt assembly 87 includes a loop of a carrying medium, namely a belt 88 and multiple pulleys 89. The pulleys 89 are mounted on a frame 86. The frame 86 comprises support members 81 upstanding from a floor and supporting a horizontal member 83. The pulleys 89 are mounted to the horizontal member 83 at locations that are spaced apart from each other. The belt 88 is positioned around the pulleys 89 and is adapted to rotate around the pulleys 89. At least one of the pulleys 89 is a drive pulley that is coupled to a drive motor that is operable to selectively drive the movement of the belt 88. A portion of the belt 88 that is upwards facing functions as a support surface 82 of the conveyer 80.

[0071] The conveyer belt assembly 87 is adjacent to the free end 72b of the supporting surface 72 of the harvesting zone 70. The upwards facing support surface 82 of the conveyer belt assembly 87 is level with the rollers 75 comprising the upwards facing support surface 72 of the harvesting zone 70. Another transverse slot 71 b is defined by a gap between the free end 72b of the support surface 72 (i.e. , the rollers 75) of the harvesting zone 20 and the support surface 82 (i.e. the belt 88) of the conveyer belt assembly 87. The transverse slots 71a, 71b are open to one side and are adapted to allow a lifting device to lower the tray 5 onto the support surface 72 of the harvesting zone 70 in a manner described in further detail below.

[0072] As illustrated in Figure 2, when the tray 5 is on the support surface 72 of the harvesting zone 20, approximately one-third of the tray 5 overhanging the free end 72b is supported on the support surface 82 of the conveyer belt assembly 87. As illustrated in Figure 4, after the fodder 2 is separated from the tray 5 in the manner described above, the conveyer belt assembly 87 is activated to cause the support surface 82 of the belt 88 to move in a direction away from the harvesting zone 20 and towards the seed spreading zone 40. Because approximately one-third of the tray 5 is supported on the conveyer belt 88, as the conveyer belt 88 moves it draws the tray 5 from the harvesting zone 20. The rollers 75 provide little resistance and allow the tray 5 to be drawn therefrom. By using rollers 75 to support the tray 5 the tangential force resulting from friction between the tray 5 and the moving conveyer belt 88 is adequate to move the tray 5 out of harvesting zone 20.

Tray Cleaning Station and Seed Spreading Zone

[0073] As illustrated in Figures 4 and 5, the conveyer 80 is adapted to translate the tray 5 from the harvesting zone 20 to the seed spreading zone 40 where fresh seed 1 is deposited onto the tray 5. A tray cleaning station 30 is located between the harvesting zone 20 and the seed spreading zone 40. The tray cleaning station 30 is comprised of a brush 90 that is located above the support surface 82 of the conveyer 80. As the tray 5 is translated by the conveyer 80 from the harvesting zone 20 and towards the seed spreading zone 40 the brush 90 contacts with the upper surface 6 of the tray 5 to thereby remove any debris or residue. The brush 90 may be stationary or it may be configured to move relative to the support surface 82 of the conveyer 80. In place of the brush 90, another scouring or cleaning device may be used such as an elongated and flexible scraping member or a pressurised water spray.

[0074] Referring to Figures 1 to 5, the seed spreading zone 40 includes a hopper 44 positioned above the support surface 82 of the conveyer 80 and located downstream of the harvesting zone 20 and the tray cleaning station 30. The hopper 44 comprises a container or bin 45 defining an internal cavity 46 for receiving a quantity of fresh seed. As illustrated in Figure 1, a silo 42 containing a large store of the fresh seed 1 is located near the hopper 44 and an auger 43 is adapted to feed the seed 1 to the hopper 44 as needed. The bin 45 tapers at the bottom to form an elongated narrow slot opening 47 that is oriented transverse to the direction of translation of the tray 5 on the conveyer 80. The slot opening 47 includes a closure (not shown) that is coupled to an actuator (not shown) that is operable to close and to open the slot opening 47. The actuator is controlled to open the closure when the tray 5 is directly below the slot opening 47 to discharge fresh seed 1 from the hopper 44 onto the upper surface 6 of the tray 5. The size of the slot opening 47, which can be determined by controlling the amount that the closure opens relative to the slot opening 47, is configured to ensure that the fresh seed 1 is released at a predetermined rate relative to the speed of translation of the tray 5 to control the distribution of the fresh seed 1 deposited on the tray 5.

[0075] For example, the seed 1 is released at a rate that is determined as a function of the speed at which the tray 5 is translated by the conveyer 80 to achieve a desired depth of the fresh seed 1 deposited on the upper surface 6 of the tray 5. Desirably, the depth of the seed 1 on the tray 5 will depend on the type of seed being used, however, a depth of about 1 to 2 centimetres is desirable for barley. Any cereal grain may be used including but not limited to oats, barley, wheat and triticale. Also, varieties of corn, beans, lupins and peas may be germinated using the system. All seeds must be spread at a desirable depth on the tray not to exceed the ability of water to penetrate the bed of seed, enabling the lower levels of grain on the tray to germinate. The depth of seed placement on the tray 5 will, in most cases, be around 20mm but this depth can vary with seed size and shape.

[0076] In an embodiment, the apparatus includes a measuring device to measure the depth of the seed 1 on the tray 5 after slot opening 47. In embodiments, the measuring device is a mechanical distance measuring device or a laser distance measuring device and is mounted above the support surface 82 of the conveyer 80 in the seed spreading zone 40. The measuring device is adapted to measure the depth of the seed 1 on the tray 5 after slot opening 47. Data indicative of the measured depth of the seed 1 can be fed into a controller to adjust the amount that the closure opens relative to the slot opening 47 or the speed of translation of the tray 5, or both, to control the distribution and depth of the fresh seed 1 deposited on the tray 5. The controller is able to control the distribution and depth of the fresh seed 1 deposited on the tray 5 in real time to ensure accurate and controlled distribution of seed.

Holding Zone

[0077] As illustrated in Figure 5, the conveyer 80 is adapted to continue translating the tray 5 until the tray 5 has passed completely underneath the slot opening 47 of the hopper 44. Thus, substantially the entire upper surface 6 of the tray 5 is covered in fresh seed 1 to the desired depth. The conveyer 80 continues to translate the tray 5 to a holding zone 110 as illustrated in Figure 1. The holding zone 110 is located immediately adjacent to the downstream end of the conveyer 80.

[0078] Referring to Figures 1 to 5, the holding zone 110 includes a frame 116 comprising upstanding support members 111 supporting a horizontal member 113. The horizontal member 113 has an upwards facing support surface 112. The conveyer 80 is configured to translate the tray 5 onto the support surface 112. The support surface 112 is adapted to receive and support the tray 5 with the fresh seed 1 spread onto the upper surface 6 of the tray 5. The support surface 112 of the holding zone 110 includes a pair of transverse slots 119 that are open to one side to allow a lifting device to lift the tray 5 off the support surface 112 in a manner described in further detail below. The holding zone 110 may be configured to include a conveyer or drive wheels or rollers, such as multidirectional rollers, or some other mechanism for translating the tray 5 to assist in ensuring that the tray 5 passes completely from the conveyer 80 to the holding zone 110. Alternatively, the holding zone 110 may include idling rollers to passively allow the conveyer 80 to translate the tray 5 onto the support surface 112 of the holding zone 110.

[0079] In embodiments of the apparatus 10 the tray 5 moves from the harvesting zone 20 to the seed spreading zone 40 where the fresh seed 1 is deposited onto the tray 5 as it translates along a substantially linear and horizontal path. Accordingly, the tray 5 preferably moves along a straight and level path as it moves from the harvesting zone 20 to the seed spreading zone 40 and subsequently to the holding zone 110.

[0080] Translating the tray 5 along a linear and level path from the harvesting zone 20, at which the fodder 2 is separated from the tray 5, to the seed spreading zone 40, at which the fresh seed is spread onto the tray 5, requires no lifting or lowering of the tray 5 or movement of the tray 5 in a direction transverse to the direction of translation of the tray 5.

[0081] The direction of movement of the tray 5 from the harvesting zone 20 to the seed spreading zone 40 a horizontal axis (e.g. X axis), then an advantage of embodiments of the invention is that the movement of the tray 5 from the harvesting zone 20 to the seed spreading zone 40 and seeding of the tray 5 does not require lifting or lowering of the tray 5 in a vertical axis (e.g., Y axis) or lateral or transverse movement (e.g. Z axis). Minimal manipulation of the tray 5 in as few directions as possible is preferable to minimise the possibility for uncontrolled movement of the tray 5 or movement outside of a defined tolerance of the apparatus.

[0082] It is desirable in an automated or semi-automated system for separating fodder from a tray and for seeding the tray, such as the apparatus 10 described and illustrated herein, that manipulation of the tray 5, particularly in multiple axes (e.g., X, Y and Z axes) is minimised. If the tray 5 being manipulated moves uncontrollably or to a position outside of a defined tolerance then the system may need to shut down so that an operator can manually reposition the tray 5 to a position within the defined tolerance. Minimising faults or downtime to reposition the tray 5 improves the efficient operation of the system. Also, because of the weight of the tray 5, particularly with seed or fodder on the tray, it is desirable to minimise the need for manual repositioning of the tray 5.

Further Conveyer

[0083] As illustrated in Figures 1 to 5 and, in particular in Figures 6 and 7, a further conveyer 120 is provided adjacent to the pivotally connected end 72a of the support member 72 to receive and to draw the fodder 2 from the tray 5 and to deposit the fodder into the receptacle 100. In the embodiment of the apparatus 10 illustrated in the Figures, the further conveyer 120 is preferably inclined so as to translate the fodder 2 from the harvesting zone 20 and to deposit the fodder 2 into the receptacle 100, which in the illustrated embodiment is a trailer 105. The trailer 100 can be hitched to a tractor or other vehicle to transport the fodder 2 to another location or for feeding livestock.

[0084] As described above, when the tilting support surface 72 is tilted with the tray 5 thereon the pair of laterally opposite side members 76 engage the side edges of the tray 5 to prevent the tray 5 from sliding down the inclined support surface 72. A plate member 77 extends laterally across the support surface 72 at the pivotally connected end 72a thereof. Part of the plate member 77 is located underneath an edge of the tray 5 and spans a gap between the support surface 72 and the further conveyer 120. The plate member 77 provides for an uninterrupted surface over which the fodder 2 can slide easily off the tray 5 and onto the further conveyer 120. Lifting Device

[0085] Referring to Figures 1 , 6 and 7, there is shown a lifting device 200 preferably comprised of a mechanical arm 210 comprising a four-axis robot mounted on an elongated track 230. The arm 210 is comprised of a set of members, called elongated links 212, 214, 216, connected by pivotal joints 211, 213, 215. A proximal elongated link 212 is mounted via a swivel coupling 219 to a base 220. An intermediate elongated link 214 is coupled to the proximal link 212 by a first pivotal joint 211. A distal link 216 is coupled to the intermediate link 214 by a second pivotal joint 213. A pair of spaced apart forks 225 are coupled to the distal link 216 by a third pivotal joint 215.

[0086] In embodiments, the mechanical arm may comprise a six-axis or seven axis robot mounted on the elongated track. Six-axis robots, or articulated robots, allow for articulated and interpolated movement to any point within the working envelope. Axis 1 - Rotates robot at the base of the robot, Axis 2 - Forward / back extension of robot's lower arm, Axis 3 - Raises / lowers robot's upper arm, Axis 4 - Rotates robot's upper arm (wrist roll), Axis 5 - Raises / lowers wrist of robot's arm, and Axis 6 - Rotates wrist of the robot's arm. In embodiments involving the use of a seven-axis robot, yet another axis of movement allows the robot additional flexibility to arrive at an end effector position with several joint configurations. It is used to avoid singularities and to be able to avoid certain objects by placing the arm in different orientations than a six-axis robot could accomplish.

[0087] The track 230 is located adjacent to the apparatus 10 comprised of the harvesting zone 20, the seed spreading zone 40, the translation means (e.g., the conveyer 80) and the holding zone 110. The mechanical arm 210 is adapted to translate along the track 230 between positions adjacent to the harvesting zone 20 and the holding zone 110. The base 220 which supports the arm 210 may be configured to include wheels and a drive motor to translate the lifting device 200 along the track 230.

Racks [0088] As illustrated in Figure 1 , on a side of the track 230 opposite to the apparatus 10 there are a set of racks 300. One of the racks 300 is illustrated in detail in Figures 8 to 14 and includes a frame 310 comprised of a set of central upright members 312 and sets of outboard upright members 314, 316 on opposite sides of the central upright members 312. The frame 310 further includes horizontal base members 304 that are fixed at opposite ends to the outboard upright members 314, 316. The horizontal base members 304 extend between the outboard upright members 314, 316 and support a pair of forklift tunnels 301, 302. The forklift tunnels 301, 302 extend longitudinally from a lateral side of the frame 310 towards the opposite lateral side of the frame. The forklift tunnels 301 , 302 may be open at both lateral sides of the frame 310 to receive the forks of a forklift for lifting and repositioning the rack 300.

[0089] A series of tray receptacles 320 are provided that extend outwardly from both sides of the central upright members 312 and to the outboard upright members 314, 316. Each tray receptacle 320 is comprised of a pair of lateral support members 322, 324, preferably comprised of elongated angle members, that are parallel and spaced apart from each other. Each lateral support member 322, 324 is fixed to one of the central upright members 312 and is fixed to one of the outboard upright members 314, 316. From an outboard end towards an inboard end, the lateral support members 322, 324 are slightly inclined from between 0 degrees and 5 degrees and preferably about 2 degrees or about 3 degrees or about 4 degrees or about 5 degrees or any increment therebetween. A longitudinal support member 326 also comprised of an elongated angle member extends between and is fixed to the inboard ends of each of the angle members 322, 324. A set of intermediate support members 303, that in the illustrated embodiments are comprised of elongated angle members, extend outwardly from the longitudinal support member 326 and are parallel with and located between the lateral support members 322, 324. The intermediate support members 303 provide additional support for the tray 5 located thereon.

[0090] As illustrated in Figure 8, one of the trays 5 is adapted to be supported on the pair of lateral support members 322, 324 and the longitudinal support member 326. The outboard end of the lateral support members 322, 324 include a flange or an upturned surface to abut with a front edge of the tray 5 supported thereon to prevent the tray 5 from sliding off. Each rack 300 includes a plurality of the tray receptacles 320 located one above another and vertically spaced apart.

[0091] As illustrated in Figure 1 , the mechanical arm 210 is adapted to move on the elongated track 230 to a position aligned with one of the racks 300. The arm 210 is adapted to locate the forks 225 beneath one of the trays 5 covered with fodder 2 ready for harvesting and to lift the tray 5 off the rack 300. In the embodiment illustrated in Figure 1, the arm 210 rotates about the swivel coupling 219 with the tray 5 supported on the forks 225 and locates the tray 5 in alignment with the harvesting zone 20. The arm 210 proceeds to lower the tray 5 onto the support surface 72. The transverse slots 71a, 71b receive the forks 225 and the tray 5 is supported, in part on the rollers 75 and in part on the support surface 82 of the conveyer 80 in the manner described above. In another embodiment, the arm 210 can be configured to locate the tray 5 on another supporting surface, such as a transportation rack for transporting the tray 5 from a location between the location of the racks 300 and the harvesting zone 20.

[0092] After the mechanical arm 210 deposits the tray 5 in the harvesting zone 20 the fodder 2 is harvested in the manner described above. The tray 5 is subsequently translated from the harvesting zone 20, through the tray cleaning station 30 and the seed spreading zone 40 to the holding zone 110. During this time, the mechanical arm 210 is adapted to pick up another one of the trays 5 from the rack 300. After the first tray 5 has moved out of the harvesting zone 20 the mechanical arm 210 lowers the second one of the trays 5 onto the support surface 72 of the harvesting zone 20. The fodder 2 on the second tray 5 is harvested as described above. The second tray 5 is subsequently translated from the harvesting zone 20, through the tray cleaning station 30 and the seed spreading zone 40 to the holding zone 110.

[0093] During the time the second tray 5 is harvested, the mechanical arm 210 translates along the track 230 from the harvesting zone 20 to a position aligned with the holding zone 110. The mechanical arm 210 locates the forks 225 beneath the first one of the trays 5 covered with fresh seed 1 supported on the upwards facing support surface 112 of the holding zone 110. The pair of transverse slots 119 that are open to one side to allow the forks 225 to lift the tray 5 from beneath and off the support surface 112. With the tray 5 supported on the forks 225, the arm 210 rotates about the swivel coupling 219 and translates along the track 230 to a location aligned with the rack 300 upon which the tray 5 was originally supported. The arm 210 proceeds to replace the tray 5 on its tray receptacle 320.

[0094] After the mechanical arm 210 deposits the tray 5 on its tray receptacle 320, the mechanical arm 210 picks up another one of the trays 5 covered in fodder 2 from the rack 300. The mechanical arm 210 deposits the tray 5 in the harvesting zone 210 in the manner described above. The cycle is again repeated until all of the trays 5 covered in fodder 2 are harvested and covered with fresh seed 1 and replaced on the racks 300.

Growing Enclosures

[0095] As illustrated in Figures 1 and 14, a series of enclosures 400 are provided to receive the racks 300 with the trays 5 covered with fresh seed 1. Each enclosure 400 is comprised of upstanding walls 410 and a roof 420 defining an internal chamber 430. A wall 410 at one end includes an opening 412 containing a door 415 to access the chamber 430.

[0096] As illustrated in Figures 8 to 14, each one of the racks 300 is provided with a network of sprayer heads 350 mounted just below the level of each tray receptacle 320 except for the lowermost tray receptacle 320. The sprayer heads 350 are connected to a system of water conduits 355 supported by the frame 310 of the rack 300 which are connectable to a water supply. The intermediate support members 303 of the frame 310 support the water conduits 355 and the sprayer heads 350. In the illustrated embodiments, there are four intermediate support members 303 that each support a part of the water conduit 355 and a respective sprayer head 350. Instead of all of the intermediate support members 303 supporting a sprayer head 350, one, two or three of the intermediate support members 303 may support a sprayer head 350.

[0097] Each enclosure 400 includes a water outlet (not shown) adapted to be coupled to the system of water conduits 355 mounted to the frame 310 of the rack 300. The enclosure 400 also includes a series of water sprayer heads 450 mounted to the roof 420 and aligned with (i.e. positioned above) the racks 300.

[0098] When the water supply for the enclosure 400 is turned on, the roof mounted sprayer heads 450 are adapted to spray a fine mist of water onto the uppermost trays 5 on the racks 300. Also, the network of sprayer heads 350 mounted to the frame 310 of the rack 300 are adapted to spray a fine mist of water onto the tray 5 beneath. The water supply for the enclosure 400 is controlled to supply a predetermined amount of water for a predetermined amount of time and at predetermined intervals onto the trays 5 covered with fresh seed 1. A series of light sources 440 are mounted to the walls 410 to provide light to assist in stimulating the seed to germinate and grow. Over 5 to 8 days, the fresh seed 1 germinates and sprouts to form the fodder 2 comprised of a 6 to 8-inch-high grass mat.

[0099] As illustrated in Figure 1, the racks 300 are moved into and out of the enclosure 400 by a mobile powered lift device such as a forklift 390 which may be automated or manually operated. The forklift tunnels 301 , 302 receive the forks of the forklift 390 for lifting and moving each of the racks 300. When the fodder 2 supported on trays 5 in an enclosure 400 is ready for harvest the forklift 390 is adapted to enter the enclosure 400, lift the rack 300 from an end thereof and to move the rack 300 to a position located adjacent to the elongated track 230 upon which the mechanical arm 210 is mounted.

[00100] In another embodiment, not illustrated in the drawings, a mobile robot may be employed to move the racks 300 in and out of the enclosure 400 and to their respective positions adjacent to the elongated track 230. The mobile robot may be configured to be guided by a track laid in the ground or may be preprogramed to follow a course with the assistance of GPS technology or image capture or other sensors.

[00101] In another embodiment, not illustrated in the drawings, the racks 300 remain stationary within the enclosure 400 and the elongated track 230 is configured to translate the lifting device 200 between the racks 300 and the harvesting zone 20. The base 220 is configured to translate the lifting device 200, as well as any trays 5 picked from the racks 300 by the lifting device 200, along the track 230 from the location of the racks 300 to the harvesting zone 20 and vice versa. In an embodiment, the racks 300 are located in an enclosure 400 and the track 230 is configured to translate the lifting device 200 to a location adjacent to each of the racks 300 within the enclosure 400 and the harvesting zone 20. In an embodiment, the racks 300 are configured to enable the lifting device 200 to access the trays 5 supported thereon from one side of the rack 300.

[00102] In the embodiment illustrated in Figure 1 , there are three racks 300 that must each be positioned at a predetermined location and orientation adjacent to the track 230. The lifting device 200 is preprogramed to remove and replace the various trays 5 from the racks 300 so that precise positioning of the racks 300 relative to the track 230 and the lifting device 200 thereon is critical to operation of the system.

[00103] In embodiments, the lifting device 200 includes a means for locating the racks 300 and trays 5 in three-dimensional space. For example, the lifting device 200 may include a camera, a laser based imaging device or a radar based system for establishing the relative position of the lifting device 200 and racks 300 and/or the trays 5 supported thereon.

[00104] After the fodder 2 on the trays 5 has been harvested and fresh seed 1 placed thereon, the lifting device 200 is adapted to relocate the trays 5 onto the racks 300. In some embodiments, the forklift 390 is adapted to lift each one of the racks 300 and to move the racks 300 into an empty one of the enclosures 400. There are 6 or 7 enclosures 400 each containing 2, 3, 4 or more of the racks 300. In this manner, the trays 5 within each enclosure 400 may be harvested on a 6 or 7 day cycle. In other embodiments, the lifting device 200 is configured to locate the trays 5 onto another supporting surface, such as a transportation rack for transporting the loaded trays 5 from the apparatus 10 to the racks 300 located within the enclosure 400.

Control System

[00105] In embodiments, a processing device is adapted to control the apparatus 10 and the system comprising the apparatus as described above. A control processor is adapted to control the operation of the lifting device 200 including movement of the mechanical arm 210 on the track 230 as described above. Sensors are provided to transmit data to the control processor to indicate if the racks 300 are in the correct position relative to the track 230 before the lifting device 200 will commence lifting of any of the trays 5 from one of the racks 300. The sensors will also provide an indication to the control processor if any of the racks 300 have moved. If movement of the racks 300 beyond a tolerance is detected then the control processor can shut down the system until the position of the rack 300 is corrected.

[00106] Sensors are also positioned on the lifting device 200 to provide an indication to the control processor if any of the trays 5 are not in a correct location on a rack 300 or within a given tolerance to thereby shut down the system until the position of the tray 5 on the rack 300 can be corrected. Sensors may also be provided to determine if the position of the tray 5 is within parameters on the forks 225 of the mechanical arm 210 or if the tray 5 requires repositioning thereon.

[00107] Sensors are also positioned in the harvesting zone 20 to detect if a tray 5 is located in the harvesting zone and is correctly positioned on the tilting support surface 72 or within tolerance. The sensors are adapted to provide an indication to the control processor if a tray 5 in the harvesting zone 20 has moved to a location outside a given tolerance and can shut down the system until the position of the tray 5 can be corrected. The operation of the harvesting zone 20 is also controlled by the control processor. In particular, the actuator 73a for tilting the support surface 72 along with the tray 5 supported thereon is controlled by the control processor.

[00108] Sensors can be positioned in the holding zone 110 to detect if a tray 5 is correctly positioned on the support surface 112 or within tolerance. The sensors are adapted to provide an indication to the control processor if a tray 5 in the holding zone 20 has moved to a location outside of a given tolerance to thereby shut down the system until the position of the tray 5 can be corrected.

[00109] The control processor also controls operation of the actuator for the closure for the slot opening 47 of the hopper 44 to control the speed of opening, the size of the opening and when to open and close. The control processor also controls the speed of the conveyer 80 to ensure that the translation of the tray 5 relative to the rate at which seed 1 is deposited provides a desired seed depth on the tray 5.

[00110] The reference herein to a control processor may be a reference to a single processor or a plurality of processors or processing systems. The processor and the sensors and various components controlled by the processor may communicate via a wired connection or wirelessly.

[00111] Although the invention has been described with reference to specific examples, it will be appreciated by those skilled in the art that the invention may be embodied in many other forms, in keeping with the broad principles and the spirit of the disclosure described herein.

Claims

Claims:

1. An apparatus for processing trays of fodder comprised of germinated seed, the apparatus including: a harvesting zone in which fodder is separated from a tray, a seed depositing zone in which fresh seed is deposited onto the tray, and a conveyer for translating the tray between the harvesting zone and the seed depositing zone.

2. The apparatus of claim 1, wherein the harvesting zone includes a mechanism for tilting the tray to cause the fodder to move relative to the tray.

3. The apparatus of claim 2, wherein the mechanism for tilting the tray includes a tilting tray support that has a horizontal position, wherein in the horizontal position a portion of the tray is supported by the tilting tray support and another portion of the tray is supported by the conveyer.

4. The apparatus of claim 3, wherein the tilting tray support includes a plurality of rollers for permitting translation of the tray thereon.

5. The apparatus of claim 3 or claim 4, wherein operation of the conveyer removes the tray from the tilting tray support of the harvesting zone.

6. The apparatus of any one of the preceding claims, wherein the conveyer translates the tray on a linear and horizontal path between the harvesting zone and the seed depositing zone and as the fresh seed is deposited onto the tray.

7. The apparatus of any one of the preceding claims, wherein the seed depositing zone includes a seed hopper configured to release seed as the tray translates beneath the hopper.

8. The apparatus of claim 7, wherein the seed hopper is configured to release seed at a predetermined rate relative to the speed of translation of the tray to control the distribution of seed deposited on the tray.

9. The apparatus of any one of the preceding claims, wherein the harvesting zone includes a second conveyer for receiving the fodder from the tray and depositing the fodder into a receptacle.

10. The apparatus of any one of the preceding claims, wherein the conveyer translates the tray to a holding zone after the fresh seed is deposited onto the tray.

11. The apparatus of claim 10, wherein translation of the tray between the harvesting zone, the loading zone and the holding zone is along a linear path.

12. The apparatus of any one of the preceding claims, further including a lifting device for placing a tray of fodder onto the harvesting zone.

13. The apparatus of claim 12, wherein the lifting device is adapted to remove the tray of fodder from a rack.

14. The apparatus of claim 12 or claim 13, wherein the lifting device is adapted to translate in a direction parallel to the direction of translation of the tray on the conveyer.

15. The apparatus of claim 14, wherein the lifting device translates on a linear track.

16. The apparatus of any one of claims 12 to 15, wherein the lifting device includes a four-axis arm including a pair of forks adapted to support and lift the tray from below.

17. The apparatus of any one of claims 12 to 16 when dependent on claim 10, wherein the lifting device is adapted to remove a tray of fresh seed from the holding zone.

18. A system for producing fodder comprised of germinated seed, the system including: a rack supporting trays of fresh seed deposited thereon; an enclosure for receiving the racks and in which the seed is exposed to light and water for germinating the seed; and the apparatus for processing trays of fodder of any one of the preceding claims for separating fodder comprised of germinated seed from the trays.

19. The system of claim 18, wherein the rack includes a frame comprising a series of tray receptacles that are each adapted to receive a tray thereon.

20. The system of claim 19, wherein the rack includes a network of water spray heads connectable to a water supply for spraying water onto the seed on the trays.

21. The system of any one of claims 18 to 20, wherein the enclosure includes a series of light sources mounted to the walls for exposing the seed on the trays to light.

22. The system of any one of claims 18 to 21, further including a mobile powered moving apparatus for moving the trays between the enclosure and to a position adjacent to the apparatus for processing trays of fodder.

23. The system of any one of claims 18 to 22, further including a lifting device including a mechanical arm mounted on an elongated track, wherein the mechanical arm is adapted to lift a tray off the rack and lower the tray onto the harvesting zone.

24. The system of claim 23 when dependent on claim 10 or claim 11 , wherein the mechanical arm is adapted to translate along the track between a location aligned with the harvesting zone for lowering a tray thereon and a location aligned with the holding zone for lifting a tray with fresh seed deposited thereon.

25. The system of claim 23 or claim 24, wherein the mechanical arm is adapted to translate along the track to locations aligned with each of a plurality of the racks.

26. A method for processing trays of fodder comprised of germinated seed, the method including: providing a tray of germinated seed on a support; separating the germinated seed from the tray, translating the tray from the support on a conveyer; and depositing fresh seed onto the tray as it translates.

27. The method of claim 26, including tilting the support and the tray thereon to cause the fodder to move relative to the tray.

28. The method of claim 27, including drawing the tray off the support by operation of the conveyer when the support and the tray thereon are in a horizontal position.

29. The method of claim 26, including translating the tray to a holding zone after the fresh seed is deposited onto the tray.

30. The method of claim 29, including lifting the tray of fresh seed from the holding zone and depositing the tray of fresh seed on a rack in an enclosure.

31. The method of any one of claims 26 to 30, including exposing the tray of fresh seed to light and water to cause germination of the seed.