11th IFAC Workshop on Intelligent Manufacturing Systems ThFT2.

4
The International Federation of Automatic Control
May 22-24, 2013. São Paulo, Brazil

Towards Sustainability of Protected Agriculture:

Automatic Control and Structural Technologies Integration of an
Intelligent Greenhouse
Paul Cepeda. Pedro Ponce. Arturo Molina. Esther Lugo

Tecnológico de Monterrey Campus Ciudad de México

(e-mails: paul.cepeda.rode@gmail.com, pedro.ponce@itesm.mx,
armolina@itesm.mx, estherlg7705@yahoo.com.mx).

Abstract: Nowadays, protected agriculture has continually lagged because of the scarce and slow
technological advances and unskilled labor. The implementation of intelligent greenhouses to improve
the quality and quantity of crops allows a precise regulation of the environmental conditions inside the
greenhouse considering the lifecycle of the crop within the control rules. The main objective of the
present is to describe the stages of analysis, design and implementation of an intelligent greenhouse
developed in the Tecnológico de Monterrey Campus Ciudad de México. The focus of this is based on the
sustainable development approach considering a robust design that integrates reliable, simple, efficient,
ecologic and low cost materials and systems with the aim of achieving the automation and control of the
microenvironment. The reason of using artificial intelligence techniques over conventional methods,
resides in the fact that the greenhouse model is highly nonlinear at many operating points.
Keywords: Technological advances, intelligent greenhouses, precise regulation, environmental
conditions, sustainable development, low cost, automation, control, artificial intelligence, nonlinear.

1. INTRODUCTION
The greenhouse effect, proposed by Jean Baptiste Joseph
Fourier in 1824, comes from the old gardening glass
buildings, its meaning is linked to the overheating of the
planets surfaces due to atmospheres, Balas [2008]. Therefore,
in agreement with the greenhouse effect, a building designed
for the protection of growing plants (protected agriculture)
out of season against excessive cold or heat was called
greenhouse or glasshouse.
The greenhouse structure protects the crops from the rain and
wind allowing solar radiation passes through the walls
making possible the heat exchange with the exterior
environment.
By the middle of 19th century, all the techniques needed for
Fig. 1. Typical Diagram of an Automated Greenhouse
successful greenhouse gardening were developed; the
greenhouse went from being a mere refuge from a hostile Greenhouses provided with the appropriate equipment the
climate into a controlled environment, adapted to the needs of environmental conditions can be further improved by means
particular plants, Greenhouses [2011]. of climate and irrigation control, Javadikia et al. [2009].
These improvements have become in recent years a mean to
By the late 1970s, it was possible to build a small greenhouse achieve controlled production obtaining higher quality and
with automatic controls for less than one third the cost of a economic benefits, Trabelsi et al. [2007].
small car. Today a variety of greenhouses are available, many
of them built with glass or plastic enclosed framed structure Greenhouse technologies with controllable environments will
in modular form to permit easy expansion. Automated trigger the following achievements:
greenhouses, as shown in Fig. 1, are commonly used for the
production of fruits, vegetables, flowers and any other plants x To ensure production quality ± commercial objectives
that require special environmental conditions, Tiwari [2003]. by setting quality standards.
x To achieve highest productivity.
The control of climatic environment and irrigation systems in
x To control calendars of production ± manage the
greenhouses has received considerable attention in these last
years. The main purpose of a greenhouse is to improve the beginning and completion of production.
environmental conditions in which plants are grown. x To save energy ± low cost of operation.

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In advanced greenhouse automation systems, the regulation
of indoor environment is focus on creating an appropriate
microclimate for the intensification of plant growth and
reduction of the final cost, Kolokotsa et al. [2010]. The most
relevant variables considered and controlled in a hydroponic
automated greenhouse are: temperature, relative humidity,
light intensity, CO2 concentration and, electrical conductivity
and pH of the nutrient solution in the irrigation system.
The main problem that should be taken into account for the
greenhouse control is the complex interactions between the
inside and outside parameters. Conventional control systems
are not suitable for this type of applications because a
greenhouse model shows non-linear behavior on many
points, Fourati and Chtourou [2007]. It is not possible to
achieve an accurate mathematical model reason why artificial
intelligence techniques DUH DSSOLHG 7KHVH WHFKQLTXHV GRQ¶W
need a mathematical model, Oduk and Allahverdi [2011].
One of the most significant difficulties faced by designers of
greenhouses is the construction of a structure that allows the
correct regulation of the environmental conditions. The
structure, automation systems and control should be closely
linked; if the structure or automation systems are not properly
installed, the control strategy could be the best but it will
perform as the worst and vice versa.
The intelligent greenhouse of Tecnológico de Monterrey
Campus Ciudad de Mexico is a project framed within the
sustainability, understanding that in its design and
functionality it responds to social, economic and ecological
aspects, the key pillars of sustainable development.
2. GREENHOUSES:
GENERAL OVERVIEW
2.1 Greenhouse Basic Elements
A greenhouse is basically composed by the following basic
elements, University of Maryland [2013], AMCI [2008]:
Frame or structure: The principal consideration in selecting
the frame is its load-bearing requirement. Each manufacturer
will specify the appropriate bow spacing depending on the
strength of the tubing.
Cladding: It is expected that the covering material allows
heat storage to provide maximum energy savings by means of
reducing heat loss.
End walls: Provide more protection against wind and air
infiltration, and better insulation.
Cooling and ventilation systems: Greenhouses need vent
systems as passive ventilation for air exchange and in order
to equalize temperatures within the greenhouse. In case of
poor airflows active ventilation is needed, such as exhaust
fans, to perform the same functions.
2.2 Greenhouse Structure Types
The structure type selection is based on factors such as soil
type, topography, winds, bio-climatological requirements of
the crop, the climatic characteristics of the area, labor and
cost. Based on the above mentioned considerations, different
types of structures have been developed such as parral or
classic, post and rafter, asymmetrical, chapel, double chapel
and tunnel or semicircular, Pacheco [2006].
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2.3 Greenhouse Materials
The greenhouses design takes place in such a way that can be
YHULILHG WKDW LW GRHVQ¶W H[FHHG WKH ORDG OLPLWV DW DQ\ WLPH
This is determined according to the type of greenhouse and
the materials used. For an intelligent greenhouse containing
high value equipment and crops, they should not be designed
for a lifecycle less than 10 years. To avoid structure damages,
it should be considered the stress limits, which are associated
with a structure collapse endangering human life, Muñoz et
al. [2013]. The ultimate limit states, which may require
consideration, are: breakage, shakiness, fatigue, excessive
tensions and deformations. The most commonly used
materials for the structure, cladding and floor, FAO [2002],
Service [2012], are:
Structure Materials: Galvanized Steel, maple Wood, low
carbon steel (AISI 1010), Aluminum Alloy (Aluminum
6061), high-strength low-alloy steel (HSLA 340).
Cladding Materials: Low density polyethylene (PE), glass,
polyvinyl Chloride (PVC).
Floor Materials: The materials of greenhouses floor goes
from bare ground to concrete, but the cost and pollution they
produced had led to look for others such as eco-materials.
2.4 Greenhouse Locations
Any greenhouse should be located in places with the
adequate sunlight, adequate soil drainage, easy access for
people and materials, access to utilities, and a pleasing blend
with the landscape. Other location considerations include
ensuring that location is even and that the soil drains well.
Low areas with poor air drainage should be avoided,
especially those surrounded by woods or buildings; cold and
humid air can remain and increase heating costs.
2.5 Greenhouse Structural Loads
The loads affecting the greenhouse structures critically are
permanent loads such as wind, snow, permanent or temporary
facilities, crop loads and concentrated vertical loads. The
biggest enemy of a greenhouse is the wind. Wind loads
increase the tensile and shear stresses on covering films and
degrade them by abrasion and friction. In particular cases,
sandstorms can be especially destructive, Grafiadellis [1999].
The way the film is installed (e.g., with wire supports or
clipping) can also cause mechanical stress leading to the
rupture of film, Briassoulis et al. [2004].
2.6 Eco-materials
Some of the materials used for building a greenhouse could
not be environment friendly due to their long period of
degradation. Eco-materials appear to handle this situation;
these are the materials which give less environmental impact
with high recyclability and efficient utilization of material.
The eco-materials can be classified into four main categories:
nonlinear source materials, materials for ecology and
environmental protection, materials for society and human
health, materials for energy. Some examples for eco-
materials are showed in Table 1, Nowosielski [2007].
367
 Table 1. Examples of Eco-materials Applications 4. INTELLIGENT GREENHOUSE:
PRODUCT DESIGN
Categories Examples
Eco-cement, coal ash concrete, The mechanical, electrical, electronic and control systems of
Recycled the intelligent greenhouse contemplate the physical structure,
marine block.
Wood based materials, ventilation, humidification, and hydroponic system. The
Renewable biodegradable plastic made of a sensors, actuators and a controller form the control loop for
vegetable base. regulating the variables which seeks to provide the adequate
Wear resistant metals and alloys, microclimate within the greenhouse. The material, the
Material for structure and the automation systems are selected, designed
pre-paint steels, corrosion resistant
efficiency and described below; the control is explained later.
steel and alloy
Biodegradable plastics, functionally 4.1 Materials Selection
Material for easy
graded material, colorbetos which
disposal or recycle
replaces asbestos. The selected material for the structure is galvanized steel.
Hazardous free Chromium-free steel, heavy metals This material is widely used in the construction of
materials free polyesters. greenhouses because of its mechanical properties of high
Materials for resistance to stress and ensures structural integrity for natural
Vibration damping steel sheet, disasters as high winds.
reducing human
sound proof panels.
health impacts The cladding chosen is treated plastic (polyethylene) with
Ultra-light steel, high magnetic UV II stabilizer 720 calibers because of its low cost,
Materials for
induction steel sheets, highly versatility, malleability, substantial mechanical properties and
energy efficiency
endothermic steel. it is a lightweight material, thus no heavy loads are generated
Selective transparent glass, highly on the greenhouse structure.
Materials for
durable sealing sheets for solar
green energy The hydroponic and water fogging system is mostly
batteries.
composed by PVC (polyvinyl chloride). Finally, the
Some combination of these eco-materials may serve for the greenhouse floor is pure concrete in order to provide stability
greenhouse structure, cladding and floor in future to the structure and not allow the growth of harmful plants
developments. inside the greenhouse.
3. INTELLIGENT GREENHOUSE: 4.2 Structural and Automation Systems Design
PRODUCT SPECIFICATIONS
In the development of greenhouses is essential to make a The physical structure designed is based on a modular
specifications list where the points of what designers expect architecture that allows easy assembly/disassembly and
at the end are exposed. The most relevant are described below: scalability with the aim of achieving a quick installation and
increase the surface if necessary.
Functionality: Maintain the optimal conditions for crops, The design of the structure has two side vents and a zenith
ability to operate in different places, rational use of energy, assisting air exchange and a passive temperature regulation; it
easy mounting and dismantling of the structure. is also considered two exhaust fans that will be started in case
Dimensions: Optimum height for proper ventilation, wide that the passive system could not respond to control needs.
and long enough for a proper distribution of crops, correct The intelligent greenhouse also features a shading system
curvature of the top (roof) to prevent condensation and with the intention of protecting the crop against solar
subsequent drip on crops causing the damages, enough radiation regulating the light intensity.
amount of space for production.
To adjust the relative humidity a water fogging system was
Automation: Correct instrumentation for the greenhouse selected. This system, besides increasing the humidity, also
operation; temperature, relative humidity, light intensity, helps regulating the temperature together with the ventilation
electrical conductivity and pH control. system; thermodynamically, increasing relative humidity the
Materials: Use of high resistance and noncorrosive materials, temperature decreases and vice versa.
implementation of low cost materials, shading mesh with UV The irrigation is based on a hydroponic technique called NFT
protection. (Nutrient Film Technique) which consists in recirculating a
Lifecycle and maintenance: Easy access to the components nutrient solution through the pipes feeding the crop. Attached
for maintenance, periodic equipment review to avoid failures, to the hydroponic system there is a nutrient supply system.
XVHU¶V PDQXDO GHYHORSPHQW This consists of three tanks that store the necessary solutions
for every stage of crop growth. The number of tanks varies
Cost: Cost reduction without affecting the greenhouse according to the requirements of nutrition stages of crop.
efficiency, use high-tech looking for an optimal relationship
between cost and benefit. The complete assembly of the intelligent greenhouse
including the above explained structure and automation
To meet the specifications, the design of the intelligent systems is shown in Fig. 2 in CAD (Computer Aided
greenhouse is composed by the integration of different Design). The shading and ventilation systems, humidification
technologies which are: modular structure, hydroponic and irrigation and, nutrient supply are driven by electric gear-
irrigation system, automation systems, and control strategies. motors, pumps and control valves, respectively.

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Fig. 2. Intelligent Greenhouse ± CAD a. Assembly b. Structure c.
Vent System d. Exhaust Fan e. Shading Mesh System f. Water
Fogging System g. Hydroponics and Nutrient Supply System
5. INTELLIGENT GREENHOUSE CONTROL
The Tecnológico de Monterrey Campus Ciudad de México
developed a climate control module for greenhouses called
Green Tech Control and Supervisor (patent). This controller
has the task of managing and monitoring the weather
conditions inside the greenhouse, temperature and relative
humidity, making decisions autonomously (without an
operator) of what to do considering the optimal conditions
programmed. These decisions are obtained from monitoring
the internal and external sensors.
The control system provides a high degree of autonomy to
the greenhouse; it is only required that the user, operator or
farmer make occasional visits to check the levels of water
and nutrients in the storage tanks. The Green Tech Control
and Supervisor has four modes of operation which are
flexible and adaptable to the requirements of the end user, a
manual control (user) and three automated. The autonomous
decisions are taken based on three types of intelligent
controllers: time control, decision tree and fuzzy logic. Once
the control decides the action to follow the actuators are
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activated by a power control module. This stage allows the
energy conduction through the single phase or three phase
lines as the case of the actuators.
The Green Tech Control and Supervisor is being developed
in stages, a first one, as already mentioned, only take into
account the weather conditions regulating variables such as
temperature and relative humidity; a second phase of
development of the Green Tech Control and Supervisor will
include an external module for handling irrigation systems, in
this case hydroponic.
The automatic control techniques were developed based on
the knowledge of skilled operators in greenhouses, reason
why it was not necessary to set the greenhouse model.
Linked to the intelligent control strategies that control the
climatic conditions within the greenhouse, the Green Tech
Control and Supervisor also ensures minimum energy
consumption and protects the entire greenhouse structure
against abrupt climate changes, specifically against rain and
wind. No matter what automatic control is selected or
running the controller is constantly checking for extreme
conditions which may affect the structure, these are:
x If the wind speed is equal or above the limit of strong
wind, for protection to the physical structure, the
controller will close all the vents.
x If the wind speed is strong, the controller checks the
wind direction in order to close only the affected
vents. This allows cooling of the greenhouse through
the non-exposed vents.
x Any finding of rain, the vents will close preventing
structural damages due to water accumulations or
floods inside the greenhouse.
Manual Control
This mode is used to control all the actuators movement
manually; this means that using the keyboard the user can
turn on/off the systems without any parameters or prior
programming.
Time Control
This control selection is in the automatic menu where the
controller will maintain or regulate the temperature reference
that you assign. The time control name comes from the fact
that the controller waits for a change in the temperature
ranges to make a decision of action.
There are three important set points for this control mode: a
desired temperature with a certain allowed band, a high
critical temperature and low critical temperature. If the
temperature is in desired range, the actuators remain off; if
the temperature is out of the band without exceeding the high
or low critical values, the actuators are started to meet the
needs; if the temperature exceeded the critic levels, the
actuators are activated as the case and also the alarm.
Decision Trees Control
Its operation is based on following a series of decisions
preprogrammed based on the set points assigned by the user.
This control strategy combines the readings received from the
sensors and depending on the references consigned the
controller makes a decision from a decision network that
could trigger the actuators simultaneously.
369
Fuzzy Logic Control Due to the mechanical features, durability, economy and
versatility of materials presented above, it was chosen
In this scheme, a PD (Proportional - Derivative) Takagi ± galvanized steel for the structure, polyethylene for the
Sugeno fuzzy control is implemented. This controller keeps cladding and PVC for hydroponics and the fog system.
the temperature inside the greenhouse at a programmed
reference by an intelligent activation of the actuators. The On the other hand, there is the Green Tech Control and
degree of activation depends on how far is the current to the Supervisor which is in charge of giving protection to the
desired temperature. This controller avoids sudden changes greenhouse structure and automation systems against extreme
with proportional openings. For example if the actual weather conditions such as strong winds, torrential rains, and
temperature barely exceeds the desired point, the vents will high temperatures, among others, without leaving aside its
rise slightly proportionally or when the temperature is main task, regulation of the micro-climate within the
excessive, the opening is total. greenhouse ensuring high production and crop quality.
The added value of the Green Tech Control and Supervisor is
6. RESULTS that it gathers different control techniques in order to satisfy
Greenhouses structures must meet the following conditions: the market needs, at this time four different modes. A special
lightweight and strong, economic material, easy to care, feature it offers is the possibility to be reprogrammed which
expandable, adaptable and modifiable to cover materials. In brings versatility to include new controllers. Table 4 brings a
this order, Table 2 and Table 3 present a brief comparison comparison between different control techniques which can
between greenhouse structure types and materials, respectively. be found in literature or in the market, including the current
methods. The comparison takes into account their complexity
Table 2. Greenhouse Structure Types Comparison and the need of a mathematical model to be designed.
Types Table 4. Controllers Type Comparison
1 2 3 4 5 6 7
Mathematical
Price Low Med. Med. Low Med. High High Controller Complexity
Model
Volume Low Med. High High High High Low Bang-bang No Low
Construct. Diff. Med. Med. Easy Med. Easy Diff. PID Yes Low
Ventilation Poor Good Exc. Good Exc. Good Exc. Auto-Tuning PID Yes Medium
Durability Low Med. Med. High High High High Time Control No Low
Zenith No Yes Yes Yes Yes Yes Yes Robust H2 Yes High
Model Predictive Yes High
Table 3. Greenhouse Structure Materials Comparison Decision Trees No Low
Structure Fuzzy Logic No Medium
Mechanical properties of high resistance to Neural Networks No High
GV
stresses. Ensures structural integrity against
Steel The three modes of automatic control of the Green Tech
climate and natural disasters as high speed winds.
Control and Supervisor GRQ¶W QHHG WR EH GHYHORSHG WKURXJK D
Low cost and versatility. Steel and wood structures mathematical model and its complexity goes from low to
Wood possess concrete foundation to ensure structural medium which demonstrate their simplicity. The proposed
integrity against natural disasters. methods can handle system nonlinearities. Finally, the
Mechanical properties very similar to those of following pictures demonstrate the completion of the project.
AISI
galvanized steel. It is cheaper and it has less
1010
environmental impact than galvanized steel.
ALU It is very light. Not used to build structures due to
M its poor resistance to stresses. It is advisable to use
6061 near places where food is produced.
It has mechanical properties that favor the
HSLA greenhouse structural integrity. It is used in some
340 tubes, bases and joints. Not suggested for use in
agricultural production areas. Low durability.
Cladding
Low cost. Resistant to extreme weather conditions,
PE molding ability and lightweight. Not readily
degradable so its use must be measured.
+LJK FRVW ,W LVQ¶W DV PDOOHDEOH DQG DGMXVWDEOH DV
Glass PE. It is heavier so the structure would be subject
to greater stresses. It is fragile.
The most economical and used choice. Widely
used due to its versatility, malleability and
PVC mechanical properties. It is lightweight so it
GRHVQ¶W JHQHUDWH ODUJH VWUHVVHV LQ WKH VWUXFWXUH 1RW
Fig. 3. Greenhouse and Automation Systems
environmentally friendly, slow to degrade.

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Fig. 4. Green Tech Control and Supervisor
7. CONCLUSIONS
Protected agriculture has become very important in
agricultural industry, both local and national governments
have increased the idea to build greenhouses to increase the
production of fruits, vegetables, legumes and flowers. The
private sector is the one that has captured the massive
construction of greenhouses in areas strategically productive
and also being the driving force behind its technification and
modernization. Today a greenhouse has at least lateral or
zenith ventilation with manual override.
A product design methodology was followed from
specifications until the construction of the functional
prototype of an intelligent greenhouse. The selection of the
greenhouse materials was based on the so-called
conventional. These present strong mechanical properties but
cost and pollution have led to seek others such as eco-
materials. An important thing to keep in mind is the strictly
connection between the structure, automation systems and
control; if the structure or automation systems are not
properly fitted the controlOHU ZRQ¶W have its best performance.
Having a climate control module, Green Tech Control and
Supervisor, regulating temperature and humidity with four
different control modes, ensures a high quality crop; if also
controls the irrigation, production maximizes profits in terms
of time and economic retribution. The control modes allow a
smooth weather regulation without leaving aside the entire
greenhouse protection against extreme weather conditions,
increasing the materials durability.
Finally, the level of technology will determine how excellent
or poor the production will be; according to the climatic
conditions of the greenhouse, suitable for crop growth, a
better harvest and growth in less time will be achieved.
The future work will be focus on creating a framework of
some of the ecological materials presented in this paper to
show which of them, due to their mechanical properties, may
be candidates for future greenhouse structures. On the other
hand, improve the Green Tech Control and Supervisor with
other control techniques merging artificial intelligence such
as fuzzy logic, neural networks and genetic algorithms, with
nonlinear control methods like sliding mode; and, finally,
develop an irrigation and nutrient supply control as an
external module of the Green Tech Control and Supervisor.
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