# Automation Systems Automating vertical farm operations for efficiency and consistency. ## Automation Levels ### Manual Operation ``` Human → Observe → Decide → Act → Monitor Pros: Low cost, flexible Cons: Labor intensive, inconsistent, human error Best for: Small hobbyist operations ``` ### Semi-Automated ``` Sensors → Alert → Human Decision → Automated Action Pros: Reduced labor, consistent execution Cons: Still requires monitoring, delayed response Best for: Small-medium commercial operations ``` ### Fully Automated ``` Sensors → Controller → Algorithm → Action → Verify Pros: 24/7 operation, optimal control, data-driven Cons: High upfront cost, requires expertise Best for: Commercial production facilities ``` ## Control System Architecture ``` ┌─────────────────────────────────────────────────────────────────┐ │ AUTOMATION ARCHITECTURE │ ├─────────────────────────────────────────────────────────────────┤ │ │ │ LAYER 4: BUSINESS INTELLIGENCE │ │ ┌──────────────────────────────────────────────────────────┐ │ │ │ Analytics │ Forecasting │ Optimization │ Reporting │ │ │ └──────────────────────────────────────────────────────────┘ │ │ │ │ │ LAYER 3: SUPERVISORY CONTROL │ │ ┌──────────────────────────────────────────────────────────┐ │ │ │ Recipe Management │ Scheduling │ Alarm Management │ │ │ └──────────────────────────────────────────────────────────┘ │ │ │ │ │ LAYER 2: ZONE CONTROLLERS │ │ ┌────────────┐ ┌────────────┐ ┌────────────┐ ┌────────────┐ │ │ │ Zone A │ │ Zone B │ │ Zone C │ │ Zone D │ │ │ │ Controller │ │ Controller │ │ Controller │ │ Controller │ │ │ └────────────┘ └────────────┘ └────────────┘ └────────────┘ │ │ │ │ │ LAYER 1: FIELD DEVICES │ │ ┌──────────────────────────────────────────────────────────┐ │ │ │ Sensors │ Actuators │ Valves │ Pumps │ Lights │ HVAC │ │ │ └──────────────────────────────────────────────────────────┘ │ │ │ └─────────────────────────────────────────────────────────────────┘ ``` ## Automated Systems ### Lighting Automation ```typescript interface LightingAutomation { // Photoperiod control schedule: { onTime: string; // "06:00" offTime: string; // "22:00" rampUp: number; // minutes to full brightness rampDown: number; // minutes to off }; // Intensity control intensity: { mode: 'fixed' | 'dli_target' | 'adaptive'; targetDLI?: number; maxPPFD: number; }; // Spectrum control (tunable LEDs) spectrum: { vegetative: { blue: 30, red: 60, farRed: 10 }; flowering: { blue: 20, red: 70, farRed: 10 }; auto_switch_day?: number; // Day to switch }; } ``` ### Irrigation Automation ```typescript interface IrrigationAutomation { // Timing-based schedule: { intervalsPerDay: number; duration: number; // seconds times: string[]; // ["06:00", "12:00", "18:00"] }; // Sensor-based triggers triggers: { minMoisturePercent?: number; // Start irrigation below this maxMoisturePercent?: number; // Stop irrigation above this ecThreshold?: number; // Flush if EC too high }; // Flow control flowRate: number; // L/min maxDuration: number; // Safety limit } ``` ### Nutrient Dosing Automation ```typescript interface DosingAutomation { targetEC: number; targetPH: number; // PID control parameters ec_pid: { kp: 0.5, ki: 0.1, kd: 0.05 }; ph_pid: { kp: 0.3, ki: 0.05, kd: 0.02 }; // Dosing limits maxDoseML: number; // Per adjustment minDoseInterval: number; // Seconds between doses mixTime: number; // Seconds to wait after dosing // Stock solution mappings ecUp: string[]; // ["nutrient_a", "nutrient_b"] ecDown: string[]; // ["fresh_water"] phUp: string; // "ph_up" phDown: string; // "ph_down" } ``` ### Climate Automation ```typescript interface ClimateAutomation { // Temperature control cooling: { stage1_offset: 1; // First stage at target + 1°C stage2_offset: 2; stage3_offset: 3; }; heating: { stage1_offset: -1; stage2_offset: -2; }; // Humidity control humidify_below: number; dehumidify_above: number; // CO2 control co2: { inject_below: number; stop_above: number; only_when_lights_on: boolean; }; // Ventilation ventilation: { outdoor_temp_min: number; // Don't vent if too cold outdoor_temp_max: number; // Don't vent if too hot humidity_threshold: number; }; } ``` ## Recipe-Driven Automation ### How Recipes Control Automation ``` Recipe Definition │ ▼ ┌─────────────────┐ │ Current Day │ ─────────→ Stage Lookup │ of Crop Batch │ └─────────────────┘ │ ▼ ┌─────────────────┐ │ Stage Settings │ │ - Temperature │ │ - Humidity │ │ - Light PPFD │ │ - Light hours │ │ - EC target │ │ - pH target │ │ - CO2 level │ └────────┬────────┘ │ ┌────────────┴────────────┐ ▼ ▼ ┌──────────────┐ ┌──────────────┐ │ Update Zone │ │ Update Zone │ │ Setpoints │ │ Light Schedule│ └──────────────┘ └──────────────┘ │ │ ▼ ▼ Controllers adjust Light timers to new targets updated ``` ### Stage Transition Automation ```typescript function updateBatchStage(batch: CropBatch): void { const recipe = getRecipe(batch.recipeId); const currentDay = calculateDay(batch.plantingDate); // Find current stage const stage = recipe.stages.find(s => currentDay >= s.daysStart && currentDay <= s.daysEnd ); if (stage && stage.name !== batch.currentStage) { // Stage has changed! batch.currentStage = stage.name; // Update zone setpoints updateZoneTargets(batch.zoneId, stage); // Trigger any stage actions executeStageActions(batch, stage, currentDay); // Log transition logEvent('stage_transition', batch.id, stage.name); } } ``` ## Robotics Integration ### Seeding Automation ``` ┌─────────────────────────────────────────────────────────────┐ │ SEEDING AUTOMATION │ ├─────────────────────────────────────────────────────────────┤ │ │ │ 1. Tray Loading │ │ Robot arm places empty trays on conveyor │ │ │ │ 2. Media Filling │ │ Automated hopper fills trays with growing media │ │ │ │ 3. Seed Placement │ │ Precision seeder places seeds at correct spacing │ │ Vision system verifies placement │ │ │ │ 4. Cover/Press │ │ Automated press firms seeds into media │ │ Vermiculite cover applied │ │ │ │ 5. Labeling │ │ QR code applied linking to blockchain record │ │ │ │ 6. Transport │ │ Automated cart moves to germination zone │ │ │ └─────────────────────────────────────────────────────────────┘ ``` ### Transplanting Automation ```typescript interface TransplantRobot { type: 'robotic_arm' | 'gantry' | 'mobile'; capabilities: { seedlingsPerHour: number; success_rate: number; // 95%+ plant_spacing_accuracy: number; // ±2mm }; integration: { vision_system: boolean; // For plant detection force_feedback: boolean; // Gentle handling api_endpoint: string; // LocalGreenChain integration }; } ``` ### Harvesting Automation | Crop Type | Automation Method | Speed | Accuracy | |-----------|-------------------|-------|----------| | Microgreens | Blade cut | Fast | High | | Lettuce | Root cut + vacuum | Medium | High | | Basil | Selective picking | Slow | Medium | | Tomatoes | Vision + gripper | Slow | High | ## Scheduling System ### Batch Scheduling ```typescript interface BatchScheduler { // Calculate optimal start dates calculatePlantingDate( recipe: GrowingRecipe, targetHarvestDate: Date, zoneAvailability: ZoneCalendar ): Date; // Optimize zone utilization optimizeZoneAssignment( batches: CropBatch[], zones: GrowingZone[] ): Assignment[]; // Handle conflicts resolveConflicts( pending: CropBatch[], capacity: number ): Resolution; } ``` ### Maintenance Scheduling ```typescript const maintenanceSchedule = { daily: [ { task: 'sensor_check', duration: 15 }, { task: 'visual_inspection', duration: 30 } ], weekly: [ { task: 'calibrate_ph', duration: 30 }, { task: 'calibrate_ec', duration: 30 }, { task: 'filter_check', duration: 15 } ], monthly: [ { task: 'deep_clean', duration: 240 }, { task: 'sensor_calibration', duration: 60 }, { task: 'equipment_service', duration: 120 } ] }; ``` ## Data-Driven Optimization ### Machine Learning Integration ``` Historical Data │ ├── Environmental readings ├── Crop performance ├── Energy usage └── Yield data │ ▼ ┌─────────────────────┐ │ ML Models │ │ │ │ - Yield prediction │ │ - Recipe optimization│ │ - Anomaly detection │ │ - Energy optimization│ └─────────────────────┘ │ ▼ ┌─────────────────────┐ │ Recommendations │ │ │ │ - Adjust setpoints │ │ - Modify recipes │ │ - Predict issues │ └─────────────────────┘ ``` ### Optimization Targets | Metric | Optimization Method | |--------|---------------------| | Yield | Adjust PPFD, DLI, nutrients | | Quality | Fine-tune environment | | Energy | Shift operations off-peak | | Water | Optimize irrigation timing | | Labor | Batch scheduling | ## API Integration ### LocalGreenChain Integration ```typescript // Automation system reports to LocalGreenChain async function reportEnvironment( batchId: string, readings: EnvironmentReading ): Promise { await fetch('/api/vertical-farm/batch/{batchId}/environment', { method: 'PUT', body: JSON.stringify(readings) }); } // Automation receives commands from LocalGreenChain async function fetchSetpoints(zoneId: string): Promise { const response = await fetch(`/api/vertical-farm/zone/${zoneId}/setpoints`); return response.json(); } ``` ## Best Practices ### Reliability 1. **Redundancy** - Backup sensors, dual pumps 2. **Fail-safes** - Default to safe state on failure 3. **Monitoring** - 24/7 alerting 4. **Testing** - Regular system tests 5. **Documentation** - Keep procedures updated ### Security 1. **Access control** - Role-based permissions 2. **Audit logging** - Track all changes 3. **Network security** - Segmented OT network 4. **Updates** - Regular firmware patches 5. **Backups** - Configuration backups