Team02 PPFS Hydroponic Global
Team02 PPFS Hydroponic Global
Team02 PPFS Hydroponic Global
Study
Brian DeKock
Brenton Eelkema
Jacqueline Kirkman
Nathan Meyer
Brandon Vonk
December 6, 2010
Calvin College; Grand Rapids, MI
Engineering 339: Senior Design Engineering Capstone
Executive Summary
Food production, distribution and consumption have become a growing concern due to population
growth in developing countries and the movement of populations into more urban settings. One way
to mitigate the increase in costs for food production and decrease the amount of energy expended on
food production is to grow food locally. Local foods provide a more sustainable means for
consumption of produce without requiring consumers to decrease the amount of fresh produce
purchased. Sustainability is increased because the distance produce is shipped before reaching
market is reduced, thus resulting in the use of smaller quantities of fossil fuels. The HydroTower
design was developed as a means to decrease the cost of food production, decrease the number of
miles necessary for producing shipments and increase the number of people with access to fresh
produce. HydroTower will accomplish such a reduction in shipping distances and cost of food
production by bringing the ability for consumers to grow their own produce in optimized growing
conditions. There will no longer be a need to have a garden plot or ideal weather for produce to
grow. HydroTower will allow consumers to grow their own food without the need for a green
thumb, plots of land or precious time to grow food. While
HydroTower provides numerous solutions, the overarching objective is succinctly stated as: feed
people, more efficiently, through hydroponics.
Initial project designs and analysis show that HydroTower is a feasible project that combines
interdisciplinary designs including biological, chemical, electrical and mechanical principles. This
design feasibility has been confirmed through hydroponic experiments along with engineering
calculations and analysis in LED Light System designs and structural designs. In addition, the
HydroTower is a viable project both economically and technically. Economically the HydroTower
will produce the highest quality food at a cost lower than that of comparable food items. Technically
the HydroTower will provide an innovative nutrient control system that combines both mechanical
and electrical engineering knowledge. Furthermore, market research has shown that HydroTower has
economic competitors who do not provide what the HydroTower will offer. A competitive price for
the HydroTower of less than $200 will ensure that the HydroTower is a strong contender in the
household hydroponic market.
Table of Contents
Table of Acronyms.................................................................................iv
List of Tables........................................................................................v
List of Figures......................................................................................vi
1. Introduction.....................................................................................1
1.1. Project.......................................................................................1
1.2. Team.........................................................................................2
2. Design Specifications............................................................................3
2.1. Requirements...............................................................................3
2.1.1. Functional Requirements..............................................................3
2.1.2. Performance Requirements............................................................5
2.1.3. Interface Requirements..................................................................6
2.1.4. Environmental Requirements.........................................................6
2.1.5. Underwriters Laboratories Requirements............................................7
2.1.6. User Requirements.....................................................................8
2.1.7. Manufacturing Requirements.........................................................8
2.1.8. Delivery Requirements.................................................................9
3. Hydroponics.................................................................................10
3.1. Hydroponic Basics........................................................................10
3.2. Types of hydroponic systems...........................................................11
3.2.1. Flood and drain (Ebb and Flow).....................................................12
3.2.2. Continuous drip......................................................................12
3.2.3. Float...................................................................................13
3.2.4. Aeroponics............................................................................14
1
CPU
EC
Table of Acronyms
Central Processing Unit
Electro Conductivity
4
HydroTower
LCD
LED
MS
Microsoft
PCB
PPFS
SWOT
UI
User Interface
WBS
List of Tables
Table
1:
List
of
Engineering
339/340
Professors
and
Concentrations......................................................1
Table
2:
October
hydroponic
experiments
with
soybeans
and
radishes................................................16
Table
3:
October
hydroponic
Experiment
#2.......................................................................................17
Table
4:
Different
options
for
touch-screen
devices.............................................................................23
Table
5:
Maximum
loads
on
the
power
supply....................................................................................31
Table
6:
Hoagland's
Solution
.............................................................................................................35
Table
7:
Electrodes
and
interferences
................................................................................................36
Table
8:
Psychrometric
calculations
variable
list .................................................................................40
Table
9:
Summary
of
wick
humidifier
design
for
fan
usage .................................................................41
Table
10:
Full
assembly
of
second
HydroTower
prototype...................................................................45 Table 11: Census Bureau
2008 population..........................................................................................47
Table
12:
Prototype
Costs
.................................................................................................................57 Table
13:
Variable
and
fixed
costs
estimations
for
HydroTower
...........................................................58 Table 14: Tech-Lead positions for the
HydroTower Team ....................................................................60
List of Figures
Gardening
Solutions
Figure
1.2:
HydroTower:
(Engr
339/340
Team
2) ..................................................2
Figure 2: Diagram of hydroponics .....................................................................................................10
Figure 3: Benefits of Hydroponics .....................................................................................................11
Figure
4:
Diagram
of
flood
and
drain
(Ebb
and
flow)
system ...............................................................12
Figure 5: Top Fed Continuous Drip System ........................................................................................13
Figure 6: Float method of hydroponics ...............................................................................................14
Figure 7: Aeroponic method of hydroponics .......................................................................................14
Figure 8: Hydroponic grwoth over 3 weeks with 2 soybean plants and 4 radish
plants ...........................17
Figure 9: Hydroponic growth over 2 weeks with 3 soybean plants and 3
radishes..................................18
Figure 10: Soybean plants at week 2 ..................................................................................................19
Figure 11: Radish plants at week 2.....................................................................................................19
Figure
12:
soybean
plant
with
signs
of
iron
deficiency ........................................................................19
Figure
13:
Radish
plant
with
signs
of
iron
deficiency ..........................................................................20
Figure 14: Initial Setup .....................................................................................................................25
Figure 15: Water Supervisor Program ................................................................................................26
Figure 16: Main UI ...........................................................................................................................26
Figure
17:
Calculation
for
target
amount
of
LEDs ...............................................................................27
Figure
18:
Simulink
Air
Temperature
Control
System .........................................................................28
Figure
19:
Schematic
of
control
system
for
nutrient
control .................................................................29
Figure 20: Plant light frequency response ...........................................................................................30
Figure
21:
First
HydroTower
prototype
design
(circular) .....................................................................33
Figure
22:
Second
HydroTower
prototype
(rectangular) ......................................................................34
Figure
23:
Survey
results
on
likely
aspects
for
purchasing
HydroTower ...............................................49
Figure
24:
Survey
results
on
customers
growing
their
own
food...........................................................49
Figure 25: RotoGro 240 Rotating Garden ...........................................................................................53
Figure 26: Desktop Hydroponic system ..............................................................................................54
Figure 27AeroGarden Pro 200 ...........................................................................................................54
Figure 28: Biosphere Home Farming .................................................................................................55
Figure 29: Kitchen Nano Garden .......................................................................................................56
Figure 31: WBS Spring Semester.......................................................................................................62
7
1. Introduction
The introduction provides a brief overview of the project and team. The project fulfills
requirements of the 2010-2011 Calvin College Engineering Senior Design class and
specifically, the project selected has been titled HydroTower: Gardening Solutions.
The Calvin College engineering capstone is designed to provide a real world experience
to engineering students in their final year of undergraduate education. Students within senior
design choose both their own teams and projects under the direction of five engineering
professors, one in each of the four concentrations (Electrical/Computer, Chemical,
Civil/Environmental and
Mechanical). Table 1.1 shows the senior design professors and their corresponding
concentrations. Engineering 339 in the fall and then the subsequent Engineering 340 in the
spring combine project implementation with class lecture and discussion to prepare students
to enter the workforce following graduation.
Table 1: List of Engineering 339/340 Professors and Concentrations
Ned Nielsen
Mechanical
J. Aubrey Sykes
Chemical
Steve VanderLeest
Electrical/Computer
Wayne Wentzheimer
Chemical
David Wunder
Civil/Environmental
1.1. Project
In 2008, for the first time in history, more than half of the global population lived in
cities. Furthermore, projections for urban growth and development by research completed by
Dickson Despommier (author of The Vertical Farm: Feeding the World in the 21 st Century)
concluded that by the year 2050, nearly 80% of the earth's population will reside in urban
centers. 1 Such a situation presents a unique opportunity to feed populations in cities which
subsequently living long distances from agricultural areas. Furthermore, the idea of
hydroponic vertical farming allows those persons without access to outdoor garden areas to
produce their own food. The specific product HydroTower was developed from Disckson
1 Despommier, Dickson. "The Problem." The Vertical Farm. Ed. Dr. Dickson
Despommier Ph. D. Environmental Health Science of Columbia University, n.d.
Web. http://www.verticalfarm.com/
1
Despommiers commercial vertical farming ideas, but adapted for residential hydroponic
growing use. Overall, HydroTower will reduce the amount of fossil fuels used in food
production, decrease the distance produce is shipped to reach market and eliminate the use of
pesticides and herbicides.
1.2. Team
The HydroTower Team is comprised of a mixture between electrical and
mechanical engineering concentrations and is also an interdisciplinary project combining
electrical, mechanical, chemical and biological knowledge and design. The learning
experience for the individual team members is benefitted by such diversity.
Figure 1.2: HydroTower: Gardening Solutions (Engr 339/340 Team 2). Back Row (Left to Right): Jacqueline Kirkman
(ME), Brandon Vonk (EE). Front Row (Left to Right): Brian DeKock (ME), Nathan Meyer (EE), Brenton Eelkema (EE)
Electrical concentration members include Brenton Eelkema, Nathan Meyer and Brandon
Vonk while the mechanical concentration members include Brian DeKock and Jacqueline
Kirkman. Brenton Eelkema will graduate with a BSE Electrical Engineering concentration
and is from Irvine, California. Nathan Meyer grew up in Elmhurst, Illinois and is studying
Electrical and Computer Engineering and is getting a minor in Physicsand he currently has an
internship with DornerWorks in Grand Rapids. Brandon Vonk is originally from Hamilton,
Ontario, Canada, is an Electrical Engineering Major with a Physics Minor at Calvin College.
Brandon has also had an internship with Johnson Controls Inc. Brian DeKock grew up in Salt
2
Lake City, Utah and is pursuing a BS in Mechanical Engineering. Brian currently has an
internship with Temper in Rockford and is also seeking a full time position after graduation.
Jacqueline Kirkman will graduate in May 2011 with a BSE Mechanical Engineering
concentration and a minor in
International Relations. Jacqueline has interned at Westinghouse Electric Co in Pittsburgh,
PA.
2. Design Specifications
2.1. Requirements
The following design requirements are assumed to be System-Level Design. 2 These
requirements have an established concept development but are not fully implemented as a
detailed design. Therefore, these requirements have not been finalized and may or may not be
represented in the final prototype. However the following design requirements do represent
the current design direction and specification for HydroTower. Requirements headings are not
ranked in order of importance, however sub headings are ranked by the currently foreseen
importance to overall success and design of the product. The HydroTower will function
according the requirements stated below:
j.
Power Consumption: The HydroTower will not consume power greater than what is
available in a conventional 120 VAC outlet. Power on and shutoff switch will be easily
accessible and labeled near the user interface. Attachment Plugs and Receptacles along
with
Fuses will be in accordance with UL standards. 3
k. Light Emitting Diodes: LEDs will be shielded by the outer shell of the HydroTower in
order to prevent retina damage from bright LEDs to users outside of the HydroTower.
Warning label will be placed on the inside of the HydroTower.4
l.
Strength: HydroTower will be able to endure the climbing and pulling of a small child or
animal no more than 3 feet tall and 30 lbs. HydroTower structural design will first and
foremost focus on the supports holding together the base unit and additional stackable
units. Secondly, HydroTower structural design will focus on building a strong
containment reservoir to ensure water does not escape HydroTower. In addition, the outer
shell of HydroTower will be able to endure a moderate amount of force exerted by
accidents and normal wear such as running into HydroTower while walking or usage past
the specified design life.
N.p.,
n.d.
Web.
05
Dec.
2010.
<http://www.ul.com/global/eng/pages/offerings/industries/lighting/lightingindustryse
rvices/articles/>.
5
r.
Water Resistance: Water resistance will be an utmost issue when dealing with almost all
major components of HydroTower. Water resistance will be assumed using the water
criteria set out in the earlier section titled, Water Reservoir and Usage. Water overflow
will be considered and overflow channels will exist on each level to ensure that water
does not exit HydroTower during standard operation.
2.1.4.
Environmental Requirements
Visual: HydroTower will have a uniform outer shell made of plastic that will
be a neutral color. An effort will be made to contain the LED light from
HydroTower to prevent the light from being a large distraction in the room
ii. Sound: HydroTower will not produce any sustained noise that is greater than
60 dB.
iii. Smell: HydroTower will not contaminate its immediate location with any
smell from inside the unit. Further research will determine if an air purifier
is needed during the operation of HydroTower.
iv. Humidity: The humidity of HydroTower will be optimized to a relative
humidity of 50%. Measurement and control of humidity will be taken care
of by the control system.
7
b. Outside Environment: The outside environment will be defined as any part of the
environment that that HydroTower interacts with both directly and indirectly.
i.
ii. Water and Nutrient Disposal: Water disposal will be based on the method
of hydroponics chosen in the second semester. Leftover water at the end of a
growing cycle will have little nutrients and will be discarded. Waste water
will be limited to, at most, half of water reservoir capacity.
3. Hydroponics
This section details the basics of hydroponics such as various growing methods, and various
advantages and disadvantages to each growing method mentioned. Some of the advantages
and disadvantages are in regards to growth times, ease of use, portability, maintenance, and
complexity.
Web.
05
Dec.
2010.
<http://www.tutorvista.com/content/biology/biologyiv/plant-nutrition/deficiencysymptoms-elements.php>.
10
There are many advantages of having a soilless medium to grow plants. Since no
soil is needed and the replacement medium does not grip the roots like soil does, the
plants can be transported from one place to another. This will allow for easier access for
conducting disease inspection and treatment, as well as allow for repositioning during
growth for greater plant density, light access, and other minor adjustments. Another
advantage of using a hydroponic system is that the efficiency of plant growth. Nutrients
can be delivered to the plant roots as is described in the next section. Lou Albright, a
Professor at Cornell University has been able to achieve harvests of head lettuce within
35 days after seeding and produces 58 heads per square foot, per year (approximately
400 tons per acre per year) 7. This is compared to average yields of head lettuce being
ready for harvesting in 70 to 80 days after seeding 8 and producing 17 tons per acre 9
per year. While these numbers are quite significant, one must remember that hydroponic
systems allow for year-round production, and are not generally exposed to harsh outdoor
N.p.,
n.d.
Web.
05
Dec.
2010.
<http://www.bee.cornell.edu/cals/bee/people/profile-albright.cfm>.
8 Sanders, Douglas C. "Lettuce Production." North Carolina Cooperative Extension:
Home. N.p., n.d. Web. 05 Dec. 2010. <http://www.ces.ncsu.edu/depts/hort/hil/hil11.html>.
9 Jackson, Louise, Keith Mayberry, Frank Laemmlen, Steve Koike, Kurt Schulbach,
and William Chaney. Iceberg Lettuce Production in California. Vegetable Research
and
Information.
University
of
California,
n.d.
Web.
<http://ucanr.org/freepubs/docs/7215.pdf>.
11
environments. Figure 310 shows the benefits of hydroponics in the area of reducing the
number or resources used in growing plants. In a conventional soil system, water
reaching plant roots is dependent upon the soil type, which at times can lead to waste of
water. However, water is controlled in HydroTower thus reducing the amount of water
both used.
A brief summary of the benefits of using hydroponics is the growing time is decreased
by over fifty percent, the amount of nutrients and land used is decreased by over 75 percent,
and the total water used is decreased by almost ninety percent.
11 "Dual Flow Hydroponic System Ebb and Flow NFT." Hydroponics Supplies
Darlington
County
Durham.
N.p.,
n.d.
Web.
05
Dec.
2010.
<http://www.secretgardenhydroponics.co.uk/product/Dual_flow_01-015-005>.
12 "Pros and Cons of Ebb and Flow Hydroponics | Easy Hydroponics." Hydroponics
|
Easy
Hydroponics.
N.p.,
n.d.
Web.
05
Dec.
2010.
<http://www.easyhydroponics.net/pros-and-cons-of-ebb-and-flowhydroponics.html>.
13
An advantage of using the continuous drip method is that the nutrient solution does
not need to be aerated because the roots are constantly covered with a thin film that allows
for air to penetrate and reach the roots. However, a disadvantage of this system is that the
drip nozzle needs to deliver one drop at a time, it is quite possible for the nozzle itself to
become clogged. The need to manually unclog a nozzle could have a negative impact on
the low maintenance of the HydroTower.
3.2.3. Float
The float method of a hydroponic system is one where the nutrients are simply being
circulated in some type of reservoir. On top of the reservoir is a flotation device that holds
the plants. There are holes in the flotation device that allow the roots to grow into the water.
The circulation of the water is typically performed by submerged pump in the corner of the
apparatus.
13 "Build Your Own Hydroponics System | BGHydro." Hydroponics | Hydroponic
Supplies.
N.p.,
n.d.
Web.
05
Dec.
2010.
<http://www.bghydro.com/bgh/static/articles/0806_byos.asp>.
14
An advantage of using the float method is that it is one of the simplest systems to
implement because the nutrients do not need injection into the water. Instead, a slow
circulation and aeration of the water is provided by the pumps.
Some disadvantages of using this system are that the roots of the plants will not have
full access to the open air. As a result, the nutrient solution will need to be aerated to
provide proper oxygenation to the roots of the plants. Furthermore, this system is not as fast
as some of the other alternatives as a result of the aeration problems.
3.2.4. Aeroponics
The aeroponic method is where the plants are held suspended by some apparatus
while the nutrient solution is sprayed onto the roots. Some further variations of aeroponics
include spraying constantly, spraying for a few minutes per hour, etc.
An advantage of using an aeroponic system is that the roots receive more oxygen
than the other methods due to the naturally aerated nutrient spray, and the roots exposed
roots. As a result, this method yields some of the fastest growing plants in hydroponic
systems.
A disadvantage of this system is that the roots of the plant need to be exposed to the
open air which means that a base medium can not obstruct airflow to the roots. Growing
mediums capable of providing sufficient airflow to the plant roots will not allow sufficient
grip for the roots in order to support the plant. As a result, separate mechanisms are needed
to either suspend the plant, or provide enough support to keep the plants from falling over.
16
Hydroponics Growing Systems Explained One by One." Hydroponics Gardening - Start a Small Garden Indoors- Helpful
Guide. N.p., n.d. Web. 05 Dec. 2010. <http://www.jasons-indoor-guide-to-organic-andhydroponicsgardening.com/hydroponics-growing-systems.html>.
growth speed and availability in the biology department. These seeds were first placed in a
plastic bag between a moist paper towels for five days in order for germination to occur. The
germinated seeds were then transplanted to plastic cups with a water nutrient system that is
further described in the Nutrient section of this report. Soybean seedlings were placed in
two cups and radish seedlings were placed in four cups for a total of six cups. Cups 1 and 2
used two times the normal concentration Hoaglands Solution. Cups 3 and 4 used 50%
concentration
Hoaglands solution. Cups 5 and 6 used the normal 100% solution Hoaglands Solution is
the standard liquid nutrient used to feed plants in a hydroponic system. This solution
consists of 12 elements dissolved into water to supply all of the plants needs and is again
discussed in the Nutrients section of this report.15 The table below tracks the growth over
three weeks.
Table 2: October hydroponic experiments with soybeans and radishes
#
1
2
3
4
5
6
The graph below represents the hydroponic growth over three weeks. Five out of the
six plants show a quality rate of growth.
17
Figure 8: Hydroponic grwoth over 3 weeks with 2 soybean plants and 4 radish plants
In three weeks, only plant one showed no growth. The two soybean plants, numbers
four and six, showed the highest growth rates. The radishes showed a lower but still
comparable
numbers between plants. The above results would indicate that 50% Hoaglands solution is the
best choice to grow plants. However these results may be deceiving due to the fact that these
experiments were not carried out over the full life cycle of the plants. Results will need to be
confirmed during Engr 340 to show that 50% Hoaglands solution is in fact detrimental to the
overall growth of the plants. In the second week, three more soybean plants and three more
radish plants were started. Each of these plants were placed in 100% concentration Hoaglands
solution.
The results are displayed in the table below.
Table 3: October hydroponic Experiment #2
Type/Hoagland%
Week 2 (g)
Week 3 (g)
Soybean/100%
4.2
6.8
Soybean/100%
4.64
7.4
Soybean/100%
4.89
6.8
Radish/100%
4.32
5.7
18
Radish/100%
3.55
4.83
Radish/100%
4.26
5.93
Figure 9: Hydroponic growth over 2 weeks with 3 soybean plants and 3 radishes
The above graph shows that the weight of some of the soybeans nearly doubled.
The radishes showed a slightly low speed of growth. These results confirm that plants can
be grown in Hoaglands solution and thus Hoaglands solution will be used in
HydroTower. However, there were some signs of fatigued growth on many of the plants.
The pictures below show the soybean and radish plants, respectively. The next two pictures
following the week 2 growth pictures show the beginnings of iron deficiency. This is
indicated by the curled leaves and slightly brown color.
19
20
separate reservoir for growing plants will be beneficial for implementing the control system.
Having a separate reservoir inside HydroTower allows for filtering of foreign materials out
of the system (eg: plant leaves or root debris). Speed of growth using this system meets the
requirements the Team set. Lastly, with the flood and drain system, little resources are
wasted due to a water recycle system.
3.4.2. Transparency, Stewardship and Trust
The requirements of HydroTower are influenced by the selected design norms of
transparency, stewardship and trust. The HydroTower team wants to be open and genuine
with customers such that customers both understand how HydroTower functions and secondly
understand the benefits of HydroTower and hydroponics (see Hydroponic Basics section).
The
Team also wants to be good stewards of Gods creation by eliminating many of the fossil
fuels and costs used in transportation and other current food processes, which are also
directly linked to the transparency aspect of having users understand the benefits of
hydroponics. Lastly, HydroTower will produce food for people, making trust a design norm
since customers must not feel as though HydroTower is neither unsafe nor unhealthy.
22
23
Device/
Screen
Resolution Support
Size
When comparing these alternatives, it is hard to see a clear choice that is superior to
the rest. The TouchShield Slide would prove to be a more reliable option but is also the
most expensive, costing almost three times more than the competition. The TouchShield
Slide device, however, does provide the clearest documentation, providing sample code, and
support to make development easier. The BL-TFT240320PLUS is also a possible option
because the the BLTFT240320PLUS has the same 3.2-inch screen as the TouchShield Slide but has a lower
price.
16
"2.8 TFT Color LCD,touch Screen Shield V1.2 for Arduino 168/328 - 35.00 : Nuelectronics.com, Arduino Freeduino
Projects." Nuelectronics.com. N.p., n.d. Web. 05 Dec. 2010. <http://www.nuelectronics.com/estore/index.php?main_
page=product_info&cPath=1&products_id=19>.
17
"BL-TFT240320PLUS V2." Circuit Ides Design. N.p., n.d. Web. 05 Dec. 2010. <http://www.circuitidea.com/devboard/BLTFT240320PLUS-V2.html>.
18
"Liquidware : TouchShield Slide." Liquidware : Open Source Electronics. N.p., n.d. Web. 05 Dec. 2010.
<http://www.liquidware.com/shop/show/TSL/TouchShield Slide>.
15 Arduino - 3.2 Inch TFT Touch Screen with Arduino Interface V2." ThaiEasyElec.net. N.p., n.d. Web. 05 Dec. 2010.
<http://www.thaieasyelec.net/index.php/Arduino/3-2-inch-TFT-Touch-Screen-with-Arduino-Interface-V2/p_68.html>.
Arduino - HomePage. N.p., n.d. Web. 05 Dec. 2010. <http://arduino.cc/en/>.
20
24
25
Welcome
Set Date
/Time
Check Nutrient
And Water Levels
Prompt to
Address
Reservoir
Levels
Low Levels
Levels OK
No
Prompt to Start
Plant Cycle
Enter Sleep
mode
Yes
Begin Growth
Cycle
Program
Flood Level X
Wait while
Roots Soak
Increment X
Drain Level X
Check Nutrient
Concentrations
OK
No
Low Nutrients
Calculate and
Inject Make
-up
Nutrients
All Levels
Watered
?
Yes
End
26
The User Interface on the touch screen will need to give several options and controls
over the HydroTower system. The high level view of this menu is shown in Figure 16. From
here the user can control the lighting and pumping schedule of the HydroTower. Also, the
user can let the system know that they have added or removed plants from the system.
Another menu provides the user a way to read and address maintenance alerts.
StatusScreen
Scheduling Editor
Add Plants
Maintenance Alert
Manager
27
The microcontroller will illuminate the LEDs based on a summer daylight schedule,
allowing for a shortening day, since this is a trigger to some fruiting plants to bear fruit
because a shortening day indicates fall and the onset of the end of the growing season. The
lighting system will also allow for the LEDs to be shut-off when there is ample light being
supplied externally.
4.1.4.3.
Temperature Control
The next control system will be responsible for maintaining the temperature of the
water and air in the system. The microcontroller will take in voltage information from
thermocouples installed in HydroTower, and turn on and off separate heaters accordingly to
regulate the temperature required. The system will likewise enable exhaust fans installed in
the HydroTower to bring in cool air from the outside environment if the inside temperature
rises above the allowable range specified in Temperature of the Mechanical section. The
Simulink model below shows the preliminary air temperature control system.
28
The air temperature control system will include a thermostat that will monitor the air
temperature inside the HydroTower. The maximum temperature allowed in the system is
80F. Above this temperature the heater will shut off allowing for cooling from the exhaust
fans. The minimum temperature allowed is 70F. Below this value the heaters will turn on.
Influences on this system include the conductive and convective heat transfers from outside
the HydroTower via the walls and the fans, but more analysis will be performed during Engr
340.
The water temperature control system will be nearly the same as the air temperature
control system. However, in this case, there will be no influence from exhaust fans. The
desired water temperature will be the same as the air temperature (70F). This system will
include a separate thermostat. To control the temperature of the water, a water heater will
be employed which will turn on at the minimum temperature and turn off at the maximum
temperature via thermostat control. The dissipative conduction and convection will provide
the cooling of the water, and the water heater will provide heat.
The temperature control system is currently being expanded to provide a qualitative
cost analysis of running the heaters in the system. With this analysis, the microcontroller will
be able to minimize costs of the system whilst changing the thermostat maximum and
minimum values to be used in Engr 340.
4.1.4.4.
Nutrient Injection
differently depending on which delivery method is decided upon once a final design direction
is reached in January of 2011.
If HydroTower employs the spray/drip system, Hoaglands solution will be premixed
and no replenishment solution will be necessary. If HydroTower uses a flood and drain
system, which has water being recycled, then nutrients will need to be injected into the water
to keep the nutrients at an optimal level. This injection system will consist of six nutrient
reservoirs that each have a valve to control the release of nutrient concentrates. To measure
out precise amounts of concentrate, each valve will have an accompanying control system.
Figure 19 shows the general form of this controls system.
The Arduino microcontroller will decide when and how much concentrate to add
based on one of two methods. The open-loop method includes a schedule that is
determined based on how many plants are in the system and a predetermined rate of
consumption for each nutrient.
The closed-loop method involves determining what the concentration of nutrients is in the
recycled water and compensating to replenish absorbed nutrients. The closed-loop method is
more accurate and represents an ideal solution for HydroTower, however currently there is
no proven method to determine the necessary concentrations in real time, and such issues are
discussed in the Nutrient System portion of the Mechanical Systems section. The first
method has the benefit of being simpler to implement, however it cannot respond to
unpredictable situations. Currently the team is pursuing both methods to determine which
one is feasible for the final design direction of HydroTower, which is also discussed in the
Nutrient System portion of the Mechanical Systems section.
30
The LEDs needed were donated by SoundOff Signal Inc. The acquired LEDs will
need heat sinks to be designed to run them at 1W such that heat can be dissipated away from
the LEDs for proper operation. The best option for these LEDs is to run them at 1W with an
ambient temperature of 80F, and maximum junction temperature of 257F. This means that
using copper, heat sinks in the shape of a square (notches cut for leads as in datasheets 18, 19)
17 "PHOTOSYNTHESIS." Estrella Mountain Community College. N.p., n.d. Web.
05
Dec.
2010.
<http://www2.estrellamountain.edu/faculty/farabee/biobk/BioBookPS.html>.
18 "LR W5SM." OSRAM Opto Semiconductors - Product Catalog. N.p., n.d. Web.
05
Dec.
2010.
<http://catalog.osramos.com/catalogue/catalogue.do?
favOid=000000000003f86200020023&act=showBookmark>.
19 "LD W5SN." OSRAM Opto Semiconductors - Product Catalog. N.p., n.d. Web. 05 Dec. 2010.
<http://catalog.osramos.com/catalogue/catalogue.do?favOid=000000030002a14801f30023&act=showBookmark>.
31
will require a side length of up to 4 centimeters for red and 6 centimeters for blue. Full
analysis of the selected red and blue LEDs are contained in Appendix C and D.
Component
Voltage
Current
Watts
Base (x1)
Pump
Arduino
24V
5V
3A
0.5A
72W
2.5W
Valves
25V
.5A
12.5W
Heater
25V
3A
75W
12V
12V
2A
0.25A
Max Power
24W
3W
243W
The power system will supply power not only for the base unit and the first growing
unit, but also for a second growing level. The largest power draw in each of the growing units
will be the LED lighting. Each unit will need sturdy electrical connections to ensure stable
operation and stand up to repeated assembly and disassembly.
5. Mechanical Systems
5.1. Requirements
HydroTower mechanical components range from the structure of the housing unit to
the pumping, piping and heating of HydroTower. The specific requirements from the
32
mechanical systems are based upon heating/heat transfer and the structure/frame for
HydroTower.
The plants within HydroTower must be in a temperature range no lower than 40F
and no higher than 85F wherein the optimum temperature is 70F.20 Furthermore, the
mechanical system must maintain the interior of HydroTower at a relative humidity no lower
than 30% and no higher than 70% wherein the optimum relative humidity is 50%. 21 Another
aspect of the heating/ventilation of HydroTower is in regards to the housing of the electrical
components and controls. The current HydroTower prototype design has the electrical
housing contained within the base unit.
5.2. Size
Based upon the objectives and goals for HydroTower, the unit size was developed to
fit within a residential dwelling. Thus, some design specifications were made such that
HydroTower accommodates a range of users from third world countries in villages to
apartment dwellers in the United States or classrooms in schools. Specifically, HydroTower is
designed with a 2.5 foot diameter and is no more than 6 foot tall. The current prototype of the
HydroTower is fabricated from wood provided by Calvin College. Figures 21 and 22 depict
the main designs for
HydroTower. While the first built prototype is circular and has a 2.5 foot diameter, the Team
has decided to change the HydroTower structure design to a rectangular module with a short
end length of 32 inches. Figure 22 depicts the next HydroTower structure design. A
rectangular structure was chosen for several reasons. First, while circular shapes are assumed
to be more aesthetically pleasing, a rectangular shape is more functional when placed in a
room. The HydroTower Team rationalized that most likely, the placement of a HydroTower
unit would be in a corner of a room, thus making rectangular a more feasible option.
Secondly, in regards to manufacturing of HydroTower, square and rectangular components
are made faster and more easily. The dimension of 32 inches for the short end was based on
20 Raven, Peter H., Ray F. Evert, and Susan E. Eichhorn. Biology of Plants. 6th ed.
New York: W.H. Freeman and Worth Company, 1999.728-730. Print.
21 Raven, Peter H., Ray F. Evert, and Susan E. Eichhorn. Biology of Plants. 6th ed.
New York: W.H. Freeman and Worth Company, 1999.728-730. Print.
33
standard widths of doors in houses. Team HydroTower assumed that a HydroTower unit
would be situated in a living room
or den area in a house and/or in a corner of an apartment or other building. Standard widths
for door frames are 34 inches, but Team HydroTower took into account extra clearances. 22
22 DoItYourself. What is the Standard Door Fram Width? Nov 30, 2010. <http://www.doityourself.com/stry/what-is-the-standarddoor-frame-width>
34
a method would first add the needed nutrients to the water supply and would secondly
adequately mix the water supply and nutrients before pumping to the plants. For the initial
design, the direct injection of the nutrients would be performed by low-pressure valves.
However, as indicated later in this section, since the nutrient system is still in preliminary
designs specific valves and calculations regarding proper mixing will be performed once a
final design direction has been selected. Real time measurements of the water would
determine the amount of nutrient makeup necessary before the water would re-enter
HydroTower for plant feed, thus implementing a recycle stream for HydroTower. The water
measurements would occur in the base unit water reservoir to ensure a clear reading occurs
representative of the entire water system.
Hoagland's Solution
Majors:
2M KNO3
Stock
Solution
mL Stock
Solution/1
L
202g/L
2.5
236g/0.5L
2.5
15g/L
1.5
2M MgSO4 x 7H2O
493g/L
1M NH4NO3
80g/L
2M Ca(NO3)2 x 4H2O
Minors:
1L
H3BO3
2.86g/L
MnCl2 x 4H2O
1.81g/L
ZnSO4 x 7H2O
0.22g/L
CuSO4
H3MoO4 x H2O or
0.051g/L
0.09g/L
Na2MoO4 x 2H2O
0.12g/L
136g/L
0.5
Recycle streams would require water analysis based on both pH and electroconductivity (EC)using electrodes measuring the amount of nutrients in the stream. However,
electrodes capable of measuring individual ions from within a solution do not exist thus
leading to possible design changes in the direction of the HydroTower project. As indicated
36
previously, the initial theoretical design had the objective of measuring and making up the
absorbed nutrient in realtime. However, the initial theoretical design also intended to use EC
electrodes to measure each individual ion, which is not possible to do for two reasons. No
electrodes exist capable of measuring the ions wherein the ions are in solution with other ion
nutrients. Table 725 contains the electrodes capable of measuring ions, but also shows the
problem in that ions have interferences
in the Hoaglands Solution. For an example of interference, in Hoaglands Solution one of the
ion nutrients to measure is NO3, but one of the interferences for NO3 is ClO4. Cl2 is one of the
miconutrients, and when ClO4 dissociates in solution, Cl2 is left, thus inhibiting the NO3
electrode. The mentioning of dissociation of ions in solution is what leads toseveral
alternative solutions or directions for HydroTower and measuring the nutrients in real-time.
Currently, two alternative designs are occurring t along a parallel time basis. One design
alternative will become the new HydroTower design direction by January 2011.
Table 7: Electrodes and interferences
Mode Ion
l
ISE2 Ammonium
0B
NH4 +
ISE2 Bromide
1B
BrISE2 Cadmium
2B
Cd2+
ISE2 Calcium
3B
Ca2+
Sensor
state
0.4 - 79900
Interferences
pH
0 - 50
K+
Electroly
te
4 - 10 NaCl
0 - 50
2 - 14 KNO3
of Cl-and NH3
solid 10-7 - 10-1 0.01 - 11200 0 - 50
state
polymer
5.10-6 100
0.2 - 40000
0 - 50
1.8 - 35500
0 - 50
ISE2 Chloride
4B
Cl-
state
ISE2 Copper
5B
Cu2+
0 - 50
state
ISE2 Cyanide
6B
CN-
0 - 50
state
ISE2 Fluoride
7B
F-
0.02 - sat.
0 - 50
OH-
state
0.1 - 10800
0 - 50
3 - 10 KCl
1 - 12 KNO3
KNO3
KCl
2.5 - (NH4)2S
11
O4
37
state
ISE3 Lead
0B
Pb2+
state
0.006 127000
0 - 50
0 - 14 KNO3
S2O3 -2 , NH3
solid 10-6 - 10-1 0.2 - 20700
0 - 50
KNO3
ISE3 Nitrate
1B
NO3 -
polymer
7.10-6 100
0.5 - 62000
0 - 50
2.5 - (NH4)2S
11
O4
ISE3 Perchlorate
2B
ClO4 -
polymer
7.10-6 100
0.7 - 99500
0 - 50
2.5 - (NH4)2S
11
O4
ISE3 Potassium
3B
K+
polymer
10-6 - 100
0.04 - 39000 0 - 50
Cs+, NH4 +
2 - 12 NaCl
Hg+, Hg2+
2 - 12 KNO3
ISE3 Silver/Sulphi
solid 10-7 - 100 0.01 4B
de
state
107900
Ag+/S20.003 32000
ISE3 Sodium
glass
10-6 - sat. 0.02 - sat.
5B
Na+
0 - 50
0 - 50
ISE3 Surfactant
6B
X+/X-
0 - 50
similar types of
surfactants
2 - 12 KCl
5 - 10 KCl
polymer
ISE3
Water polymer
7B
hardness
Ca2+/Mg2+
ISE5 Ammonia
0B
NH3
0.4 - 4000 0 - 50
(Ca2+)
0.01 - 17000 0 - 50
volatile amines
11 13
NH4Cl
ISE5
Carbon
gas 10-4 - 10-2 4.4 - 440
1B
dioxide
sensing
CO2/CO3 2-
0 - 50
4.8 - NaHCO3
5.2
ISE5
Nitrogen
gas
5.10-6 - 0.2 - 220
2B
oxides
sensing 5.10-3
NOx
0 - 50
1.1 - NaNO2
1.7
The first alternative to the flood and drain system with the direct injection of nutrients is an
aeroponic/spray hydroponic technique. Such a system would change the design of
HydroTower in that the spray nozzles would direct the flow of water to plant roots and
Hoaglands solution would be added directly into the water spray. One objective of the spray
technique would be to minimize the amount of waste water from such a process of spraying
the plants throughout the day. Despite a change in design for HydroTower, the Team is
maintaining the initial goals of providing sustainable methods for growing produce and other
plants. The need to eradicate waste water left over from watering/feeding the plants is
environmentally unsound in two ways. First, the waste water would contain the nutrients,
which should not be introduced directly into a water treatment system (eg: should not be
poured down a residential drain). It is not environmentally appropriate to implement a design
38
which would require users to dispose of the chemical waste through residential
water/drainage systems. While the nutrients are found naturally in soil and nature,
introducing higher concentrations and having the only method of disposal as residential
drains does not align with the goals or objectives of HydroTower as being a sustainable
design. Secondly, wasting water is not efficient for the overall delegation of water as a
resource and is thus not a feasible option for the HydroTower design project.
The second alternative for the flood and drain system with the electrode analysis
would be to research solutions for analyzing individual ions in the water nutrient system. The
premise behind the second design alternative is based upon knowledge that when compounds
are in solution, ions dissociate and are thus individual elements. For example, NH 3 is a
compound in
Hoaglands Solution, but in theory, the second alternative would use an electrode which
measures for N elements. Electrodes for N, Mg, Ca, K and possibly Fe would be used in
research to measure the conductivity of the water solution and analyze for specific algorithms
to add the makeup nutrients. Professor Doug VanderGriend will also be assisting team
HydroTower in researching possible ways to isolate the dissociated elements in solution
using electrodes much like the initial design intended. Furthermore, Professor VanderGriend
would assist in analyzing the data collected from the electrodes to see if any empirical
relations may relate the element ions to the amount of nutrient in the water solution. Said
research will begin at the very end of first semester and will continue into January 2011.
However, a time limit on the research and design of electrodes capable of analyzing the water
solution after which the first design alternative will be implemented fully.
A final design direction will be selected by the middle of January 2011.Currently,
the Team has been split into two sub-groups, one group looking into the first alternative of
the spray system and the second sub-group focusing on research for the electrodes. Until the
final design direction is selected, the team will remain working on the two alternative design
options. Should one design become very apparent as the best alternative, that design will
become the new final design direction. Delegation of time and efforts has been a 50-50 split
between both design alternatives, but as the project continues, one design alternative will
become the main focus in which case delegation of time and effort will become 90-10 (90%
of the time being on the final design direction and 10% being towards ensuring the correct
design direction was chosen).
39
5.4. Psychrometrics
Mechanical design of HydroTower for optimal plant growth includes humidity and
temperature control of the water and nutrient system. The environmental conditions for plants
are optimal when relative humidity is about 50% and temperature is 70F.26
5.4.1. Humidification
From a biological standpoint, if humidity is too high, and condensation forms on plant
leaves, the plants become susceptible to fungus and disease. 27 Thus, the mechanical design
of HydroTower includes compensation for air flow and ventilation to regulate the humidity
within the HydroTower growing structure. Furthermore, if the relative humidity is too low,
plants will close their stomatas, which are how plants intake CO 2 and release O2. Should
the humidity become too low, a humidifier will turn on via the control system for
psychrometrics and will subsequently add moisture to the air within HydroTower.
Initially, the mechanical designs were going to measure humidity with a hygrometer and
then have the regulation of air flow controlled by fans and a venting system with mechanical
flaps capable of different degrees of opening/closing. However further analysis of
alternative design options showed that a more complex and expensive humidity control
system was not necessary to meet the design requirements. For example, below is a list of
the alternative designs for the humidifiers/dehumidifiers, four humidifying systems
researched and then analyzed included the following.
1) Steam humidifiers which boil water to release steam into the air
2) Impeller humidifiers which move water through a diffuser to make very fine
water droplets in the air
3) Ultrasonic humidifiers which vibrate at an ultrasonic frequency to create water
droplets which are absorbed into the air.
4) Wick/evaporative humidifier which draws water out of a reservoir and allows
water to evaporate as air passes over the wick via a fan-powered ventilation
system Qualitative and quantitative analysis of the cost and implementation of
each of the four humidifying/dehumidifying systems was completed to move
26 Raven, Peter H., Ray F. Evert, and Susan E. Eichhorn. Biology of Plants. 6th ed.
New York: W.H. Freeman and Worth Company, 1999.728-730. Print.
27 Raven, Peter H., Ray F. Evert, and Susan E. Eichhorn. Biology of Plants. 6th ed.
New York: W.H. Freeman and Worth Company, 1999.728-730. Print.
40
to provide 12cfm of air flow (cited in bibliography page DC Fan Data Sheet and NMB-Mat
DC Axial Fan). Equation 6.4.1 shows the main equation used to calculate the needed air
flow rate while full calculations are contained in Appendix E. The result of the calculation
showed that one fan capable of 12cfm would be enough to maintain the proper humidity
within HydroTower since the calculated air flow rate was 5.1 cfm based on the previously
mentioned conditions.
Equation 6.4.1
The following table shows the variables and variable names.
Table 8: Psychrometric calculations variable list
Variable
Variable Name
Units
Cfm
Gal/min
Providing HydroTower remains with the flood and drain system along with the current
prototype model as the final design direction, HydroTower will implement a wick
humidifier due to the low cost and simplicity of implementing the design both in
prototyping and in manufacturing. The wick humidification system will work well for
ensuring that the air within HydroTower remains at about 50% relative humidity because as
the air becomes more humid, the water requires more energy to evaporate and the same
principle applies for dry air (easier to evaporate water when air is less humid). Thus, the
wick humidification system works by natural evaporation of water from the wick. Specific
design of the wick humidifier will occur during spring semester once the final design
direction is known. However, one specific issue with wick humidification to be addressed
during the design phase is that wick humidification will be to ensure that condensation does
not occur within the HydroTower. Thus, as previously mentioned, the two fans will be
42
installed on each growing level on either side of HydroTower. The wick humidifier will
have a control system based on readings from a hygrometer. For the control system, if the
humidity is too high the fan furthest to the water input flow (hence, the fan without the wick
in front of it) will turn on. Should the humidity remain high, both fans will turn on. The failsafe method to ensure humidity can be lowered within HydroTower will be looked into
further during the spring semester. The table below shows a more visual summary of how
the fans will turn on and off via the control system and hygrometer readings.
Table 9: Summary of wick humidifier design for fan usage
System Reading
Off
On
On
Off
ranges On
On
Extreme
high or low
Fail-safe method
for humidity out of
range
To be determined in To be determined in
spring semester
spring semester
5.4.2. Temperature
Control of the temperatures of both water and air are necessary to optimize plant
growth, however, hierarchically, the water temperature is more important. Such a decision is
based on the rate of heat dissipation from the water and the rationalization that the air
temperatures will be relative to the ambient air in a room of a residential area. The optimum
growing temperature for most plants is 70F.30 Using the waste heat from the electrical
components has been discussed as a method to control the heat of the water. However, since
the Team is still working towards finalizing a design direction, specific mechanical design
and analysis for the temperature control system have been placed on hold until a final design
direction is chosen.
30 Raven, Peter H., Ray F. Evert, and Susan E. Eichhorn. Biology of Plants. 6th ed.
New York: W.H. Freeman and Worth Company, 1999.728-730. Print.
43
6. Frame Structure
The responsibility of the frame and structure design of HydroTower is one portion of the
mechanical responsibilities of Team HydroTower and specifically falls to Brian DeKock and
Jacqueline Kirkman. The frame and structure design must fit within the objectives of a
modularized unit which is light weight and easily transported when emptied from plants and
water. The frame structure must also be sturdy enough to be operable under safe conditions.
Specific quantities and objectives on the safety regulations for HydroTower have not yet been
quantified but will be addressed once a final design direction has been chosen. Furthermore,
specific requirements on the weight and transportability of HydroTower are estimated thus far
in the design process. This section addresses the specifications of the frame of HydroTower
including the size, safety, mobility, manufacturability and appearance of HydroTower.
31 DoItYourself. What is the Standard Door Fram Width? Nov 30, 2010. <http://www.doityourself.com/stry/what-is-the-standarddoor-frame-width>
44
(overall square meters comparable to an outdoor garden The current height of HydroTower
includes a base unit
1 foot high with each modular growing level 2 feet high. Thus, the maximum height of
HydroTower would be 5 foot.
The modular and stackable design provides the user with adaptability and portability
such that a user may choose how many plants are grown and the overall configuration of
HydroTower. For example, a user may purchase the base unit and one growing level, one
base unit and two growing levels. Many possibilities for base unit and growing levels exist,
but the constraints are that at least one base unit and one growing level are necessary for
function while the maximum is two growing levels supported on one base unit.
6.3 Mobility
The HydroTower must be mobile enough to be moved by one average-sized adult
person regardless of gender. Mobility of HydroTower is very important to the overall
success of the project. HydroTower will be purchased as a fully assembled base unit with
one growing level. Additional growing levels may be purchased individually. However, all
modular components must be easily moved from the store to the users residence and must
be easily set-up by the user. Initial market research has confirmed HydroTower will need to
produce food for a family but will need to fit in a corner of a room. The final design of
45
HydroTower will determine the overall mobility of the product instead of the mobility
determining the design since the Team has chosen overall function as a higher priority than
mobility. However, mobility is still a factor in design decisions and will be used more during
second semester and final design selections.
46
47
6.5 Aesthetics
Part of designing in engineering is to make a product that not only serves its purpose,
but also is pleasing to the eye. Marketing for HydroTower is for in-home and residential
usage, thus, the HydroTower will be placed in the house or apartment and will need to
coordinate with interior dcor. Some brainstorming has concluded HydroTower could be
manufactured in several colors or could have some patterns on the exterior such that users
could select the design which best fits their style and dcor. Aesthetics will be a strong
selling point for HydroTower as a product. Successfully blending function and aesthetics
will be a key component in selling the HydroTower. While function of HydroTower is
hierarchically a higher priority than aesthetics, if
HydroTower does not meet the aesthetic appeal to potential customers the overall success of
HydroTower as a product will be lessened.
48
7. Business Analysis
7.1. Market Research
7.1.1. Customer
HydroTower involves minimizing space and maximizing efficiency to grow plants in
a non-commercial environment. The market for this type of product would be anyone who
does not have gardening space to grow vegetables and plants. More specifically, HydroTower
is being targeted at women who have a family at home and need fresh produce for their
children. The table below shows the 2006-2008 statistics from the United States Census
Bureau.
Table 11: Census Bureau 2008 population32
Between the ages of 25 and 39 there are over 30 million women living in the United
States. If only 1% of the population of women in the United States buy at HydroTower within
the first two years over 60,000 units could be sold each year.
Growth in this market could increase as larger questions are raised about the safety of
consumers in commercial food production. Additional growth could be driven by the growing
number of people moving into cities and living in apartments and high rise condominium
towers. HydroTower presents the perfect solution for the consumer who is looking to eat fresh
produce whose quality can be ensured all while reducing the carbon footprint of large scale
food production.
32
http://factfinder.census.gov/servlet/STTable?_bm=y&-geo_id=01000US&
qr_name=ACS_2008_3YR_G00_S0101&ds_name=ACS_2008_3YR_G00_
49
33
Brentlinger,
PRODUCTION
D.J.
2007.
IN
THE
NEW TRENDS
U.S.
Acta
IN
Hort.
HYDROPONIC
(ISHS)
CROP
742:3133.
http://www.actahort.org/books/742/742_3.htm
50
9. Please list what vegetables you would want to grow most in a hydroponic
system?
10. Which of the following would make you more likely to purchase and use a
hydroponic system?
The HydroTower team is currently not ready to fully analyze the results of the online
survey. Before next semester we hope to at least double the amount of responses to the
survey. In addition we hope to increase the variety of people who take our survey from
college students to older adults and our target market, women with families. The following
figure shows two slides from the final semester presentation detailing our results. Results
will be summarized in the second half of our project during Engr 340.
51
34 35
Alarge portion of the individual hydroponic gardening industry is based off of the internet
according to both Mud Lake Farms and Horizon Hydroponics. Many individuals have
posted their own builds and recommendations on many websites that cannot be found
commercially.
Nov.
2010.
http://www.popularmechanics.com/technology/engineering/gonzo/4273680
37
Brentlinger,
PRODUCTION
D.J.
2007.
IN
THE
NEW TRENDS
U.S.
Acta
IN
Hort.
HYDROPONIC
(ISHS)
CROP
742:3133.
<http://www.actahort.org/books/742/742_3.htm>
54
55
Opportunities: Many small and startup companies in the industry. This competition
will keep the HydroTower team thinking and working towards the best possible solution.
Threats: Large corporation industrial designs
The second established competitor is the Desktop Hydroponic System. The Desktop
Hydroponic System is a compact planter that grows small herbs on desk using sunlight or the
artificial light from an office. This product has a strong visual appeal and a low cost of $40.
The weaknesses of the Desktop Hydroponic System are that it has no additional light source
and is not big enough to feed a family. Growing options are limited.
39
38 "RotoGro 240 Rotating Garden." HHydro.com. N.p., n.d. Web. 5 Dec. 2010.
<http://www.hhydro.com/RotoGro-240-RotatingGarden.html>.
39 "ThinkGeek :: Power Plant Herb Garden." ThinkGeek. N.p., n.d. Web. 05 Dec. 2010.
<http://www.thinkgeek.com/homeoffice/kitchen/b7d7/?cpg=cj&ref=&CJURL>.
56
The AeroGarden Pro 200 Indoor Tabletop Vegetable Garden is a fully automated
system that is capable of growing multiple types of herbs and vegetables. For $200 the
indoor garden provides everything that is needed to start growing. The weaknesses of this
product are that it lacks growing spaces and still does not have a strong visual appeal. 40
40 "The Indoor Tabletop Vegetable Garden." Hammacher Schlemmer. N.p., n.d. Web. 05 Dec. 2010.
<http://www.hammacher.com/publish/75426.asp#?cm_mmc=CJ-_-2617611-_-3682082-_-Save up to 70% on Electronics>.
57
41 "Biosphere Home Farming by Philips." Yanko Design. N.p., n.d. Web. 05 Dec. 2010.
<http://www.yankodesign.com/2009/03/17/the-ultimate-recycle-bin-nourishes-as-well/>.
42 "Kitchen Nano Garden." Fast Co. Design. N.p., n.d. Web. 5 Dec. 2010.
<www.fastcodesign.com/idea-2010/kitchen-nanogarden>.
58
59
8. Business Financials
HydroTower has been identified as a potential marketing and business opportunity. The
business financials section contains estimates on costs and revenue possible for HydroTower.
Professor Medema of the Business Department at Calvin assisted the HydroTower Team in
beginning an analysis on HydroTower. However, due to the issues faced in selecting a final
design direction, much of the financial analysis will occur during Engr. 340.
The current outlook for HydroTower is to sell modularized levels, the first of which would
be the base unit. Subsequent stackable units could be purchased and attached to the base unit.
HydroTower will also sell refills of the nutrient concentration bottles.
Material for
Purchase
# of
Units
Cost
per Total Cost
Unit ($)
($)
Description
Nails
12
Perlite
3.79
3.79
Seeds
60
Nutrients (in L of
solution)
3.79
starting a new business for this product would be feasible. The cost analysis was based on
concepts learned in
Business 357. The BizPlan financial template was used to analyze a three year product
forecast. Based on information from the continuous online survey, there is a predicted
market that is estimated to have sales revenue of $100,000 in the first year. The number of
units sold is based on assuming a small percent of the market will purchase it each year,
gradually increasing as it gains recognition. The fixed cost in the first year is higher than the
second and third years because of repair, replacement and initial purchasing costs. The
depreciation expense fluctuates because the initial purchasing cost and interest is compiled
throughout the next two years. The equipment purchase for the second year and the third are
much lower but still exist because the growth of the company. Interest rates are based on a
pessimistic view of the economy.
analysis is solely a prediction and only used as a way to assess the start up of a potential
business.
More cash flow analysis will be done in the second semester when more
information can be obtained. In conclusion, based on the assumed number of units sold, the
business will break even around the end of year two and turn a large profit at the end of year
three.
Table 13: Variable and fixed costs estimations for HydroTower
Fixed Costs
Rent on Facility
Renting Equipment for Manufacturing
Taxes
Salaries (manager, 4 employees at
40,000/employee)
Amount
100,000
200,000
50,000
290000
20000
15
75000
50
100
30
25
10
10
250000
500000
150000
125000
50000
50000
61
Microprocessor
Housing/Build materials
Total
Breakeven Point ($)
30
20
150000
100000
1450000
2,110,000
422
62
9. Management
9.1. Project
Since the Team is comprised of two mechanical and three electrical engineering
students, work was delegated to each member according to the strengths each member
provides the Team. Table 9.1.1 shows the work delegated to each Team member. While
multiple members of the Team work together, one member is designated as a Tech-Lead and
is thus responsible for the overall organization of their specific task area.
Table 14: Tech-Lead positions for the HydroTower Team
Task
Tech
Lead
Business
Big Idea Project
Nathan
Elevator Pitch
Brandon
Engineering Business
Plan
Jacqueli
ne
PPFS
Project Requirements
Brenton
Research
Brian
Feasibility
Jacqueli
ne
Design
PCB
Brandon
Power System
Brandon
User Interface
Nathan
Brenton
Brenton
Nathan
Structure Design
Brian
Air Flow
Jacqueli
ne
Water Piping
Brian
Heating/Cooling
Brian
Chemical Distribution
Jacqueli
ne
63
Jacqueline Kirkman was delegated the air flow system and the chemical
distribution system. Jacqueline has the most experience of the group members
in chemical systems and was thus the logical choice. Psychrometrics and air
ventilation were also assigned to Jacquelines responsibilities. Jacqueline has
further acquired the position of Project Manager due to her organizational and
detail-oriented management skills, thus other tasks are delegated to
Jacqueline which fall under team management but are not specifically listed
here.
HydroTower was selected in the final four applicants. The Big Idea Contest
was a competition hosted by the Enterprise Center at Calvin; HydroTower
made it to the final four but did not win the grand prize of $200. Nathan has
been assigned to maintain the team website and update it as content becomes
available.
64
Brandon Vonk has the responsibility of designing the power systems and
printed circuit boards (PCBs) along with the lighting system for HydroTower.
Brandon has the most experience with PCBs and thoroughly enjoys working
with power systems, making him the best choice. Brandon has also been
delegated the responsibility of maintaining an updated team budget.
65
9.3. Budget
Brandon Vonk is responsible for maintaining an updated budget for the team.
Maintaining the budget requires updating both the working budget and the projections for
the budget in MS Excel. Completing the necessary order forms when necessary is also
contained within the responsibilities for maintaining the proper budget. Current expenses
and more cost details are contained in Section 8.
9.4. Website
Nathan Meyer is responsible for both updating and maintaining the team website.
Nathan is the most familiar with programming and the DreamWeaver software and was thus
the most logical choice for the overall upkeep of the website.
to the onset of the meetings. Furthermore, meeting agendas are distributed before each
meeting such that all team members can review the agenda and have input on meeting
topics. All meeting topics are prioritized to ensure items of higher importance are discussed
and issues of highest importance can be addressed in the most efficient manner.
Weekly status updates for both the team members and the overall team are sent out
every week to the Teams advisor, Professor VanderLeest. Each team member records the
amount of hours they work individually, and team hours are designated for when all team
members are present for a meeting or for team work. Team status reports are submitted on
Sunday evenings to Professor VanderLeest after each individual member reports their time,
their accomplishments for the week of submittal and their tasks for the next week.
Jacqueline Kirkman organizes the final team weekly status update.
9.6. Resources
Listed below are the key resources contributing to the success of Team 2.
Professor David Dornbos, taught the Team how to mix Hoaglands solution
and gave access to the Biology departments plant laboratory and gave Team
02 seeds to begin experimenting hydroponic growth. Has been a continuous
resource for knowledge about plant growth and optimization.
Professor Uko Zylstra, connected the Team with Mud Lake Farms (Kris and
Steve Haitsma).
Steve & Kris Van Haitsma, owners of Mud Lake Farm, provided the Team
with information about hydroponic growth and gave the Team a tour of Mud
Lake Farm hydroponic floating system.
10.3.
N.p.,
n.d.
Web.
05
Dec.
2010.
<http://www.asme.org/Communities/Innovates/Programs/Innovation_Showcase_ISh
ow.cfm>.
44 "IEEE Engineering in Medicine and Biology Society Undergraduate Student Design Competition." IEEE. N.p., n.d. Web.
05 Dec. 2010. <http://www.ieee.org/membership_services/membership/students/awards/eng_medicine_undergrad_ design.html>.
68
The IEEE Presidents Change the World Competition recognizes and rewards
students who identify a real-world problem and apply engineering, science, computing,
and leadership skills to solve it. The contest offers students the perfect opportunity to
have their ingenuity and enthusiasm for engineering and technology recognized by
prestigious IEEE members
around the globe. 45
11. Conclusions
Overall, Engr. 339/340 and the PPFS concluded that HydroTower: Gardening Solutions as
both a project and product are feasible based upon proven technologies, analysis and testing of
current prototype designs. We have achieved many milestones throughout the course of this
semester such as building a prototype, selecting and obtaining LEDs, upload of the team website,
basic analysis of air flow design, and selection of frame structure as a of a rectangular modular
unit.
Although some aspects of the final design have yet to be fully addressed, they will be
attended to next semester. This includes nutrient system, rectangular prototype, final design
components, and the finalized business plan. The team as identified a few concerns which one
being the cost of the HydroTower in a new and competitive market, another is the integration of
computer/electrical and mechanical systems, but realizing these risks will prove to help the
design process and help in the decision making process. The project is on schedule and the
HydroTower team is confident that is can complete the final design on time and according to
design specifications.
For the second part of our project the HydroTower team plans to accelerate the development
of our design. We are confident that we will be able to move forward at a greater pace due to the
development of our team and the creation of a framework that will enable us to move on from
our mistakes and repeat our successes. The HydroTower team will continue to work through
January in order to hopefully finalize design requirements and ensure that financial and planning
projections are met.
We will continue our work in the second semester in order to insure that requirements
and deadlines are met promptly. We will no longer have the option to make major design
45 "Presidents' Change the World Competition." IEEE. N.p., n.d. Web. 05 Dec. 2010.
<http://www.ieee.org/membership_
services/membership/students/competitions/change_the_world/index.html>.
69
changes that could fundamentally effect how our product works. Again, fundamental
decisions will need to be made on the nutrient system in order to ensure a viable product.
The HydroTower team hopes that these decisions will help to create a high quality Senior
Design project and overall excellent project.
Appendix A: Work Breakdown Structure/ Milestones
70
71
73
74
75
76
Appendix C:
(Cont)
Lighting System Design Calculations (Red
LEDs)
77
Appendix C:
(Cont)
78
Appendix C:
(Cont)
Lighting System Design Calculations (Red LEDs)
79
Appendix C:
(Cont)
80
Appendix C:
(Cont)
Lighting System Design Calculations (Red
LEDs)
81
Appendix C:
(Cont)
82
83
84
85
86
87
88
Assumptions:
Compressed liquid water
Enclosed space
Heat loss only from water to air (enclosed) by natural
convection
<Could add heat loss from sides>
2.0 Inputs
Pressur
e:
P
P_sat_T_ambie
nt
14.696 psia
0.17795 psia
94
<assumed>
<calculated from
T_ambient>
stPSAT
Temperature:
Water
In
70 F
21.11 C
<assumed>
<calculated>
Water
Out
65 F
<assumed>
Ambien
t
50 F
<assumed>
10 C
<calculated>
3 inches <assumed>
0.25 feet
<calculated>
89
ss
OD
ID
2.5 feet
<measured>
2.25 feet
<calculated>
1 feet
<measured>
Height
Volume of Water in Base
Unit:
V_gal
V_m^3 0.015051 m3
09
<calculated>
V_L
<calculated>
15.05109 L
33
0.5 %
Properties
<Assumed
Compressed Liquid>
Thermal
Conductivity
Heat Transfer
Coef
Surface Area:
Water
A_s
Density
Characteristic
Length
L_c
kinematic
viscosity
Prandtl Number
Pr
gravity
Volume
Expansion Co
Thermal
Difusivity
0.34889 Btu/hr-ft-F
51
<calculat
ed>
stCDL
<calculat
ed>
stVCL
k*Nu/
L_c
3.9760 ft^2
78
62.308 ft^3/lb
56
m
2.25
ft
0.0006 lbm/ft-s
81
0.1214
45
32.2
<assume
d>
<calculat
ed>
stVISL
ft/s2
0.01428 1/F
6
0.00560
7
<assume
d>
<calculat
ed>
90
Specific Heat
Cp
0.9986 Btu/lbm-F
62
<calculat
ed>
stCPL
m_dot_
a
12
cfm
Flow Rate of
Water
m_dot_
w
2.31E- lbm/s
03
Specific Volume of inlet
water
0.0160 ft^3/lb
49
m
91
92
Enthalpy of
Water
h_w_1
38.091 Btu/lbm
55
h_w_2
33.097 Btu/lbm
23
Enthalpy of Air
h_a_1
h_a_2
omega_
1
omega_
2
0.07647 lbm/ft3
5.062 cfm
93
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