Source: INTERNATIONAL ELECTRONIC MACHINES CORPORATION submitted to
COMPLETE AUTONOMOUS VENTILATION ENVIRONMENT SYSTEM (CAVES) FOR SMALL AND MID-SIZE FARMS
Sponsoring Institution
National Institute of Food and Agriculture
Project Status
ACTIVE
Funding Source
Reporting Frequency
Annual
Accession No.
1028938
Grant No.
2022-33610-37901
Cumulative Award Amt.
$599,790.00
Proposal No.
2022-04423
Multistate No.
(N/A)
Project Start Date
Sep 15, 2022
Project End Date
Sep 14, 2025
Grant Year
2022
Program Code
[8.12]- Small and Mid-Size Farms
Recipient Organization
INTERNATIONAL ELECTRONIC MACHINES CORPORATION
850 RIVER ST
TROY,NY 121801239
Performing Department
(N/A)
Non Technical Summary
Active ventilation is energy intensive, demanding over twenty percent of a typical farm's electrical needs. Ventilation practices vary depending on the size of the building, specific livestock animals, layout of the building, temperature, humidity, and more. Automated systems on larger farms have shown significant energy savings, but installation and maintenance of new systems is a significant cost to smaller farms.This demonstrates a need for affordable, intelligent, adaptable, retrofittable ventilation systems than can be tailored to the needs of small to mid-size farms.In Phase I, International Electronic Machines Corp (IEM) demonstrated that the Complete Autonomous Ventilation Environment System (CAVES) for Small Farms was a feasible and practical solution to these challenges. CAVES is an intelligent, customizable, scalable, adaptable control and ventilation system that monitors key parameters of barn environment - temperature, humidity, vapors/gases including ammonia, hydrogen sulfide, CO, and CO2, -- and combines them with knowledge of barn size, configuration, and number and type of livestock to reliably ensure proper ventilation at minimal power usage by actively controlling ventilation fans. CAVES can be retrofitted to existing ventilation fans. Phase I work demonstrated that CAVES could reduce power demand by more than 80 percent over standard ventilation operations, offering a very quick ROI even on a small farm.In Phase II, IEM will first develop a sensor to verify the energy use and environmental conditions in small barns, and using this data create a Phase II prototype of CAVES to demonstrate that CAVES is commercially viable as well as physically practical.
Animal Health Component
50%
Research Effort Categories
Basic
(N/A)
Applied
50%
Developmental
50%
Classification

Knowledge Area (KA)Subject of Investigation (SOI)Field of Science (FOS)Percent
40272102020100%
Goals / Objectives
It has been long known that demand-controlled ventilation (DCV) is an effective means of reducing power usage in many commercial and government settings. This applies to farm buildings, and livestock barns in particular, and indeed large livestock housing facilities are generally supplied with automated ventilation systems which account for not just external and internal temperature, humidity, and waste gas production, but also number and type of livestock. The latter is often unappreciated by the layman, who may not realize that the "comfort zone" of temperature for cows (40-65 degrees F) is very significantly different from that for pigs (65-90 degrees F) or chickens (50-68 degrees F) in roughly the same humidity conditions (RCI, 2020). These temperatures also vary with age of the animal.On small farms, this is not currently automated; a typical ventilation strategy is based on the farmer's perceptions. If they think it's too hot, or the barn smells too strongly, the fans are switched on. They are generally left on until the farmer gets around to turning them off, and in summer may be left on most or all of a day. This was verified during IEM's Phase I work, with all of the farming employees interviewed agreeing that this was roughly the usual strategy.This ad hoc approach is unlikely to reach the optimum of ventilating only as and when needed. There is the potential for extremely large power savings by two mechanisms:Automatically engaging ventilation only as needed, based on actual, objective measurements of temperature, humidity, air speed during ventilation, waste gas concentrations, and type of livestock, andControlling ventilation speeds directly rather than having a simple on/off operationIf feasible, the latter becomes very important, because energy usage of a ventilation fan varies drastically - to the third power - with the speed of the fan (University of Georgia, 2017). Many fans are designed as single-speed devices - they are either fully on, or off. Adding speed controls allows the fan to still move considerable amounts of air at vastly reduced energy cost.It is noticeably less expensive to run a fan at three-quarters speed for an entire day than to run it at full speed for half the day, and reducing the speed to half cuts energy usage, and thus cost, when compared to running for the same time at full speed. It is possible to easily retrofit existing fans with variable speed controls (varying the voltage or the frequency, depending on fan design), thereby reducing the cost of the proposed system to the small farmer.However, duty-cycling - through intelligent control of ventilation -- is the other key approach. This relies on two factors: being able to measure vital parameters in the environment, and having appropriate knowledge of the comfort and health requirements of the livestock. The latter must be properly programmed into the system so that, for example, it is understood that livestock that have undergone heat stress may require more than six hours of continuing ventilation to allow them to fully dissipate that heat load and recover (Dewell, 2010).CAVES draws on years of IEM experience in sensor and control design as well as intelligent AI systems for the evaluation of sensor data and application of that data to take useful actions; this has ranged from our Personal Air Safety System (PASS) for miners to our Integrated Sensor Air Quality Control System (ISAQCS) smart demand-controlled ventilation project with the New York State Energy Research and Development Authority (NYSERDA), Stabilizer Level Accurate Measurement System (SLAMS) for NAVSEA, wheel and brake metrology systems for our WISE® suite of railroad measurement and maintenance products, and others.The significant reduction in energy consumption may also make a renewable energy (solar) approach for barn ventilation feasible. IEM's Phase I results indicated that the expected energy reductions from CAVES would reduce the space and cost needed for a solar-powered ventilation system by a factor of five..Overall, the benefits of CAVES are simple and straightforward:Reduce ventilation energy costs by between forty and eighty percent (translating to a total energy savings of between 8-16% based on an average of 20% of a farm's energy used for ventilation); this produces a ROI of between 6 months and 2 years based on calculated cost of CAVES.Reduce overall emissions through reduction of energy usageMaintain livestock comfort throughout the yearReduce or eliminate discomfort and health impacts of irritant gases on both livestock and farm workersImprove animal quality and output of farm products through maintenance of livestock comfort and health
Project Methods
Overall, the objective of the Phase II work will be to develop a complete Phase II prototype of CAVES that is shown to meet the practical goals - reduction of energy usage to a significant degree in a realistic barn setting while maintaining healthy and comfortable conditions for animals and workers - and which will provide a foundation for a commercial, affordable version of CAVES. Specific goals include:Develop and finalize performance specifications and practical requirements for CAVESObtain real-world data on the conditions seen in small-farm barns and the actual (as opposed to claimed) ventilation usage and performanceEvaluate and select sensors for the Phase II systemDesign Phase II sensor, fan control, and gateway systemsCreate Phase II software for data collection, analysis, fan control, and interface/data display and updatingVerify performance of Phase II CAVESEvaluate market demands, access approaches, licensing/certifications, and other issues which will have to be addressed for a fully commercialized productProve through this work that CAVES is a fully practical and affordable solution for this challenge

Progress 09/15/22 to 09/14/23

Outputs
Target Audience:During this period, IEM maintained communication with several local farms, including Brookbound Farm, Cunningham Lake View Farm, Willow Marsh Farm, and Smith's Orchard Farm, at various points in and around the Capital District of New York. IEM will be increasing our contact with these farms, and other local animal caretaking associations, for testing purposes in the second half of this project.. Changes/Problems: Nothing Reported What opportunities for training and professional development has the project provided? Nothing Reported How have the results been disseminated to communities of interest?IEM was visited during this period by Timothy Connor from the USDA, during mid-June of 2023. This included an overview of the work done to that point, with an assembled first prototype of the Survey Node. Mr. Connor had several useful suggestions to apply to the project going forward, as well as possible applications for IEM technology in other areas such as food safety. This aids in the dissemination of IEM's progress to USDA, which is naturally one community of interest. What do you plan to do during the next reporting period to accomplish the goals?With the new Survey Nodes completed, IEM will perform the planned survey of ventilation effectiveness in actual livestock areas, barns, etc., to determine the best use-cases for CAVES in real-worled locations. This will include more outreach to local farms and such (and possibly large animal shelters/zoos/nature preserves with indoor animal housing), Cooperative Extensions, and so on. IEM also intends to contact theARS (Agricultural Research Service), possibly through the Technology Transfer office, to see if a test/demonstration location is available for final demonstration of CAVES. Once the Survey Nodes have acquired sufficient data in different locations, IEM will be in a position to analyze the data and construct appropriate operational profiles for the CAVES system, including number and location of sensing nodes, the likely operational load expected with CAVES and thus the expected savings of energy for the relevant institutions, and also a determination of which sensors are most vital for these functions. Reducing the number of sensors would be economically wise, if the same basic results can be obtained. Based on these results and operational plan, IEM will be able to design the final Sensor Nodes (which may or may not all incorporate fan control capability, depending on manufacturing practicalities), Gateway System, and the software to support a practical, simple user interface demonstrating the operation of CAVES. These systems will be tested in one or more local barns and, if feasible, at a USDA-connected facility for demonstration.

Impacts
What was accomplished under these goals? In this period, IEM moved forward on a number of the goals of the CAVES Phase II project. As detaled further below, IEM: Surveyed multiple sensor types and vendors Tested samples of all sensors of interest Selected Phase II sensors for all analytes Incorporated sensors, communications, power, and data processing elements to an initial Survey Node design Verified performance of these designs Finalized the designs for the Survey Node Produced a ruggedized, deployable version of the Survey Node for testing Initial work focused upon the sensors for the project. For Phase II, it was necessary to select sensors that would be usable in field testing and demonstrations, thus in addition to basic sensitivity to the target analytes, the sensors had to be rugged enough for use in real-world conditions, as well as reasonably affordable, compact, and preferably of the same form factor to allow substitution of other sensors for other applications envisioned for CAVES. IEM examined sensors from six different candidate vendors, rating them on these and other qualities (for example, warm-up/activation time, power consumption, integration electronics required, additional functionality such as included temperature or humidity sensors, and so on). One sensor (CO2) had to be selected separately from the others, as there are very limited modes of sensing that are accurate for CO2. The remainder were all acquired from a single vendor who also offered numerous other sensors that will be relevant to some of the other applications (community air quality monitoring) contemplated for the system. All four of these sensors have a generally cylindrical profile, making them easy to incorporate into a line of circular sockets for easy mounting or replacement. These sensors also come with their signal conditioning board included and are factory calibrated, removing two other challenging elements of sensor use; factory calibration, especially, is useful as it removes the need for IEM to construct or lease a sealed calibration environment controllable to one percent or better precision. The original plan to use the current of an existing fan to provide a signal of when the fan was on or off encountered some challenges. This would be simple if the system were to be a "pass-through" design for a plugged-in fan, but that design will not happen until the final Fan Control nodes are created. CAVES required another means to sense when the fan corresponding to a Survey Node was active; after considering several methods, IEM selected a sensitive differential pressure sensor that would respond to a sudden increase in air motion at a selected location (selected via a simple extended tube). Testing showed that this worked quite reliably when the tube was placed near the intake side of the fan. IEM also examined the power system needed both for the Survey Node and the more general CAVES nodes in the future. For the Survey Node, the units need to be independent and self contained, able to function for as long as feasible without maintenance or intervention. This allows IEM to simply place the Survey Node at the chosen location in the target barn and leave it there until the time has come to recover it. One challenge faced by the current sensors is that they are fairly power-hungry and require notable warm-up times. This may have to be addressed for the final design, but for the Survey Node the solution is simply to have extra batteries. The current design incorporates four lithium polymer batteries with a total charge of 10 A-H which will run the Survey Node for considerable time. IEM then designed an initial version of the Survey Node; this included the selected sensors (and temperature and humidity, which were included in the other sensors' designs), increased computational power in a new microcontroller board, a field display, onboard storage, and data communications (both USB and LoRA based). These designs proved acceptable in performance, with a few minor issues. IEM addressed these issues and produced a revised version of the Survey Node designs, the primary changes being to ruggedize the system prior to full demonstration. Accordingly, thisfinal, rugged version of the Survey Node is in the process of being assembled; this design incorporates all the functionality of the prototype assembled earlier in this period, but also adds a weather-sealed protective case, secured tiedowns for all cabling, vibration/impact resistant socketing of all key compoents, and provisions for even more power storage if needed.

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