阅读说明：本技术 用于处理屠体部分的方法和系统 (Method and system for processing carcass parts ) 是由 U·C·尼尔森 于 2019-06-19 设计创作，主要内容包括：公开了一种用于处理屠体部分的方法。该方法包括：在控制单元处确定切割的屠体部分的目标重量；使用检测单元检测屠体部分,以确定所述屠体部分的质量分布,并且将所述质量分布提供给控制单元；使用控制单元基于目标重量和质量分布计算屠体部分的切割计划；使用机械夹具以便夹持屠体部分并且将所述屠体部分布置成执行所述切割计划；以及根据切割计划使用切割单元切割屠体部分,以便根据目标重量生产切割的屠体部分。同时公开了一种用于处理屠体部分的对应的系统。(A method for processing carcass parts is disclosed. The method comprises the following steps: determining a target weight of the cut carcass part at the control unit; detecting the carcass part using a detection unit to determine a mass distribution of the carcass part and providing the mass distribution to a control unit; calculating a cutting plan for the carcass part based on the target weight and the mass distribution using the control unit; using a mechanical clamp for clamping a carcass part and arranging the carcass part to perform the cutting plan; and cutting the carcass part using the cutting unit according to the cutting plan so as to produce the cut carcass part according to the target weight. A corresponding system for processing carcass parts is also disclosed.)

1. A method for processing a carcass part, the method comprising:

determining a target weight of the cut carcass part at the control unit;

detecting the carcass part using a detection unit to determine a mass distribution of the carcass part and providing the mass distribution to a control unit;

calculating a cutting plan for the carcass part based on the target weight and the mass distribution using the control unit;

using a mechanical clamp for clamping a carcass part and arranging the carcass part to perform the cutting plan; and

the carcass parts are cut using a cutting unit according to a cutting plan in order to produce cut carcass parts according to a target weight.

2. Method according to claim 1, wherein the method comprises forming a carcass part of a batch, and wherein the target weight is determined based on a target batch weight and a weight of a current unfinished batch.

3. Method according to claim 2, wherein the target weight is determined based on a target number of carcass parts in the batch and a number of carcass parts in the current incomplete batch.

4. Method according to claim 2 or 3, wherein the target weight is determined based on the weight of the carcass part and/or based on the weight of one or more carcass parts located upstream of the carcass part.

5. Method according to any of claims 2 to 4, further comprising determining at the control unit a new target weight for subsequently cut carcass parts, the new target weight being determined at least based on the target batch weight and the updated weight of the current incomplete batch, and optionally based on the target number of carcass parts in the batch and the updated number of carcass parts in the current incomplete batch, and further optionally also based on the weight of a subsequent carcass part and/or the weight of one or more carcass parts located upstream of the subsequent carcass part.

6. The method of any preceding claim, wherein the target weight is determined based on one or more of a target minimum scrap weight, a target maximum scrap weight, and a target scrap weight.

7. Method according to any of the preceding claims, wherein the target weight is determined based on a minimum and/or maximum cut carcass part weight.

8. Method according to any of the preceding claims, wherein the detection unit comprises a weighing unit and detecting the carcass part comprises weighing the carcass part by the weighing unit.

9. Method according to any of the preceding claims, wherein the detection unit comprises an imaging unit and detecting the carcass part comprises imaging the carcass part by the imaging unit in order to determine the volume distribution of the carcass part.

10. Method according to any of the preceding claims, wherein the detection unit comprises a scanning unit and detecting the carcass part comprises scanning the carcass part by the scanning unit, wherein the scanning unit is preferably an ultrasound unit or an X-ray unit.

11. Method according to any of the preceding claims, further comprising detecting a carcass part in order to identify a predetermined anatomical region of the carcass part and calculating a cutting plan based on the mass distribution and the predetermined anatomical region.

12. The method of claim 11, wherein calculating a cutting plan comprises identifying cut lines within a predetermined anatomical region that produce cut carcass parts meeting a target weight.

13. Method according to any of the preceding claims, further comprising detecting the carcass part in order to identify a main axis of the carcass part, and wherein calculating the cutting plan comprises calculating a cutting line relative to the main axis.

14. The method of claim 13, wherein calculating the cut line relative to the main axis comprises calculating a cut line that defines a substantially acute angle relative to the main axis.

15. The method of claim 13, wherein calculating a cut line relative to the main axis comprises calculating a cut line that generally defines a plane parallel to the main axis.

16. Method according to any of the preceding claims, further comprising detecting the carcass part in order to identify the presence and location of a foreign object within the carcass part, and wherein the cutting plan is further calculated based on the location of the foreign object and optionally the target weight is determined based on the presence of the foreign object.

17. Method according to any of the preceding claims, wherein arranging the carcass part to perform a cutting plan comprises moving the carcass part relative to a cutting unit.

18. Method according to any of the preceding claims, further comprising transporting the carcass part to a mechanical clamp using a transport unit.

19. Method according to claim 18, wherein clamping the carcass part comprises lifting the carcass part off the transport unit.

20. Method according to claim 18 or 19, wherein arranging the carcass parts to perform a cutting plan comprises moving the carcass parts on the transport unit and wherein the transport unit is subsequently used to transport the carcass parts to the cutting unit.

21. Method according to any of claims 1 to 19, comprising cutting the carcass part while it is clamped by a mechanical clamp.

22. Method according to any of the preceding claims, wherein the mechanical clamp comprises a weighing unit and the method further comprises weighing the cut carcass part with the mechanical clamp after performing the cutting plan.

23. Method according to any of the preceding claims, wherein the cutting unit is configured to cut along a predetermined cutting direction, and wherein clamping the carcass part comprises arranging the carcass part relative to the predetermined cutting direction such that the cutting unit can cut the carcass part according to a cutting plan.

24. Method according to any of the preceding claims, comprising clamping the carcass part at the picking position using a mechanical clamp, and the method further comprises storing the cut carcass part in a storage position separate from the picking position using a mechanical clamp.

25. Method according to claim 24, wherein the method comprises forming a batch of carcass parts and wherein the storage location is a package for the batch of carcass parts.

26. The method according to any of the preceding claims, wherein the cutting unit comprises a cutting knife, wherein the knife is preferably configured to cut within a single cutting plane.

27. Method according to any of the preceding claims, comprising determining a plurality of target weights, each target weight being associated with a respective order to be fulfilled, and the method further comprises selecting one of the plurality of target weights that best corresponds to the detected carcass part, wherein the cutting plan is calculated based on the selected target weight and the mass distribution of the detected carcass part.

28. Method according to claim 27, wherein the one target weight that best corresponds to the detected carcass part is selected from a plurality of target weights based on one or more of the following information: estimated rim charge weight, presence and/or location of a foreign object, weight of one or more carcass parts located upstream of the carcass part, predicted updated batch weight of one or more orders to be fulfilled, predicted updated number of carcass parts in a batch of one or more orders to be fulfilled, and total number of each order.

29. A system for processing carcass parts, the system comprising:

a control unit adapted to determine a target weight of a cut carcass part and to calculate a cutting plan for the carcass part based on the target weight and a mass distribution of the carcass part;

a detection unit adapted to detect carcass parts to determine a mass distribution of the carcass parts and to provide the mass distribution to a control unit;

a mechanical clamp adapted to clamp a carcass part and to arrange the carcass part to perform a cutting plan; and

a cutting unit adapted to cut the carcass part according to a cutting plan in order to produce a cut carcass part according to a target weight of the cut carcass part.

30. System for processing carcass parts according to claim 29, adapted to perform the method according to any one of claims 1 to 28.

31. A computer-readable medium comprising computer-executable instructions that, when executed by a computer, cause the computer to perform the steps of:

determining a target weight of the cut carcass part;

calculating a cutting plan for the carcass part based on the target weight and the received mass distribution of the carcass part;

instructing a mechanical clamp to clamp a carcass part and to arrange the carcass part to perform a cutting plan;

the cutting unit is instructed to cut the carcass part according to the cutting plan in order to produce the cut carcass part according to the target weight.

32. The computer-readable medium of claim 31, wherein the instructions cause a computer to perform the method of any of claims 1-28.

Technical Field

The present invention is directed to a method of processing carcass parts, in particular chicken breasts, and a system for processing said carcass parts.

Background

To better fulfill specific order requirements, carcass parts (such as chicken breasts) are often processed by cutting or clipping. In particular, cutting and trimming is usually performed such that the cut carcass part meets the weight requirements. For example, one particular requirement in the art is that the cut carcass part has a weight corresponding to a single meal. Processing may also include cutting carcass parts to remove foreign bodies (such as fat and bone pieces). In other particular cases, the carcass part may be cut to a size suitable for fulfilling a part of an order for the carcass part of a batch, for example a batch of chicken breasts weighing 750 grams.

In order to reduce labor costs, improve the accuracy of the parts that can be cut, reduce waste of product due to scrap, minimize giveaway due to product oversize, and improve processing speed, many automated systems for processing carcass parts have been developed. Typically, the most efficient method of cutting a carcass part to the required weight will involve making unique cuts to that carcass part, and a common method of accommodating these unique cutting plans is to provide complex robotic arms for cutting along any desired cut line. One example of a known system for cutting carcass parts can be found in WO 2015/198062 a 1. In this system, complex robotic cutting arms with water jets are used to cut the carcass parts in order to remove foreign bodies. However, such robotic arms are very expensive, thus preventing these more efficient methods for processing carcass parts from being widely adopted. It is therefore an object of the present invention to provide an improved method for processing carcass parts which does not comprise expensive and complex robotic cutting arms, while maintaining the benefits associated with a customized cutting plan for individual carcass parts.

Disclosure of Invention

According to a first aspect of the invention, there is provided a method of processing a carcass part comprising: determining a target weight of the cut carcass part at the control unit; detecting the carcass part using a detection unit to determine a mass distribution of the carcass part and providing the mass distribution to a control unit; calculating a cutting plan for the carcass part based on the target weight and the mass distribution using the control unit; using a mechanical clamp for clamping a carcass part and arranging the carcass part to perform the cutting plan; and cutting the carcass part using the cutting unit according to the cutting plan so as to produce the cut carcass part according to the target weight. It has been realized that the handling of carcass parts can be made more cost-effective by clamping the carcass part with a mechanical clamp and arranging the carcass part relative to the cutting unit to perform the cutting plan. The use of such a mechanical clamp to arrange the carcass part before cutting allows more complex cutting plans to be performed by a relatively simple cutting unit.

Although the method is directed to the treatment of carcass parts, it is also conceivable to apply the method to other types of food parts, such as fish parts and meat parts.

The target weight may be a single value, such as 160 grams, or may be a range, such as 150 grams to 160 grams. In some simple cases, the target weight of each cut carcass part may be a single value fixed for each carcass part. However, in most cases, there are many factors that will affect the determination of the target weight, as will be described below. However, it should be noted that the determination of the target weight may be made at any stage prior to calculating the cutting plan, and indeed in some embodiments, the detection data (e.g., mass distribution) may be one of the factors used to determine the target weight. Similarly, the mechanical clamp may have received the carcass part before the target weight is determined.

It should also be noted at this stage that the mechanical clamping and cutting unit will normally be controlled by the control unit to perform the above-mentioned tasks.

A common carcass part order type is a carcass part in batches, where each batch has a target weight. For example, it is common to purchase batches of packaged chicken breasts having a set weight. In order to efficiently accommodate batch weight requirements, preferably the method comprises forming the carcass parts of the batch and determining the target weight based on the target batch weight and the weight of the current unfinished batch. Typically the target lot weight will be the weight associated with a particular order. For example, the order may be 1000 batches of chicken breast, each batch weighing 750 grams, in which case the target batch may weigh 750 grams. Likewise, any tolerance for batch weight may be accommodated by a target batch weight, which is a weight range (e.g., 740 grams to 760 grams). The weight of the current unfinished lot may be the weight of the lot currently being prepared. If no portion has been assigned to a batch, the weight of the current unfinished batch may be 0 grams, or may be some non-zero value less than the target batch weight. For example, if the current unfinished weight of a lot is 590 grams, and the target lot weight is 750 grams, the target weight for finishing the lot may be determined to be 160 grams. In this case, the method comprises calculating the target weight as the weight required to complete the batch before detecting the carcass part and calculating the cutting plan required to achieve said target weight.

Some orders may require a certain number of carcass parts in a batch of carcass parts. For example, one order may be 1000 batches, each batch having 4 chicken breast portions weighing 750 grams total. Thus, preferably the target weight is determined based on the target number of carcass parts in the batch and the number of carcass parts in the current incomplete batch. It should be noted here that the target number of carcass parts may equally well be in the range, for example three to five carcass parts. By including a target number of carcass parts in the determination of the target weight, it may be prevented that unfinished batches of carcass parts cannot be produced which cannot be completed by an incoming carcass part.

Preferably, the target weight is determined based on the weight of the carcass part and/or based on the weight of one or more carcass parts located upstream of the carcass part. Including the weight of the incoming carcass part in the determination of the target weight may for example prevent the use of very large carcass parts to produce small cut carcass parts, which may result in the production of large quantities of low value trim carcasses. Including the weight of the upstream carcass part in the determination also allows the system to be sensitive to weight variations of the incoming carcass part and to use the incoming carcass part more efficiently. For example, the method may take into account that the upstream carcass part is relatively small, thus increasing the target weight of the carcass part in question, so that the incoming smaller carcass part can be accommodated into a specific batch.

The above focuses on the determination of a single target weight for a single carcass part. However, it will be appreciated that the method will be repeated for each subsequently received carcass part. For example, the method may comprise determining a target weight for a subsequently cut carcass part, determining the new target weight based at least on the target batch weight and the updated weight for the current incomplete batch, and optionally determining the new target weight based on the target number of carcass parts in the batch and the updated number of carcass parts in the current incomplete batch, and further optionally determining the new target weight based on the weight of a subsequent carcass part and/or the weight of one or more carcass parts located upstream of the subsequent carcass part. For example, the updated weight of the current incomplete batch may be determined by adding the previous target weight to the previous weight of the current incomplete batch. Alternatively, the incomplete batch may be weighed to update the weight of the current incomplete batch. In yet another alternative, each cut carcass part may be weighed after cutting and before being included in the batch to confirm the exact weight of the carcass part and to maintain the running total weight of the batch.

In some embodiments, the target weight is determined based on one of a target minimum scrap weight, a target maximum scrap weight, and a target scrap weight. The trim is a part of the carcass part, usually the smaller part of the divided carcass part, which is used for by-products such as chicken nuggets or processed foods. The value of the trim is usually lower than the other parts of the cut carcass part that are formed as part of the cutting plan. Therefore, it is generally desirable to ensure that the scrap does not exceed the target maximum weight. On the other hand, in some cases, scrap material below a certain weight will have more limited use, which further reduces its value or requires complete scrap removal. Thus, some embodiments include a target minimum rim charge weight to obtain rim charges that can be used for preferred rim charge products, although the target minimum rim charge weight may be ignored in situations where the rim charge cannot be used (e.g., when bone chips are present in the rim charge). In some particular cases, it may be desirable to obtain an edge trim having a particular weight, and this may be a factor in determining the target weight. For example, the rim charge can be used as chicken nuggets which are of higher value if they can be sold together in bulk and each nugget has a similar weight. By taking into account the value of the trim when determining the target weight, the total value extracted from the carcass part can be maximized, thereby improving cost-effectiveness.

Although the control unit may simply prioritize different types of orders, for example, orders for cut carcass parts over orders for chicken nuggets made from the trim, in some embodiments the control unit is also provided with value data which may include values associated with cut carcass parts and trim of different sizes. Subsequently, the target weight may also be determined based on the value data. For example, a batch of orders for cut carcass parts may have a value of 4 pounds per kilogram of carcass, while a chicken order using trim may have a value of 2 pounds per kilogram, and a processed food order using trim may have a value of 1 pound per kilogram of carcass. The determination of the target weight may take these values into account in order to extract the maximum value from the entering carcass part.

There are various ways to detect carcass parts. In some embodiments, the detection unit comprises a weighing unit and detecting the carcass part comprises weighing the carcass part by the weighing unit. In a very simple embodiment, the weight determined by the weighing unit can be used in combination with a typical model of the breast part of a chicken to estimate the mass distribution of the carcass part. However, in most cases, the weight will be used in conjunction with an imaging device, as will be discussed below.

The method may comprise a detection unit comprising an imaging unit and detecting the carcass part comprises imaging the carcass part by the imaging unit for determining the volume distribution of the carcass part. In some simplified cases, this volume distribution may be used in combination with the average mass density of the type of carcass part being processed to establish the mass distribution. Preferably, however, such an embodiment will be combined with a weighing cell as described above.

In particular, the combination of a weighing unit and an imaging unit as described above will allow a more accurate mass distribution to be established, thereby improving the accuracy of the cutting plan.

In a further preferred embodiment, the detection unit comprises a scanning unit, such as an ultrasound unit or an X-ray unit, and detecting the carcass part comprises scanning the carcass part by the scanning unit. That is, a scanning unit is preferably provided which is capable of directly measuring the mass distribution of the carcass part. For example, as described above, an X-ray unit may be used to generate a mass profile representative of the carcass part. Such a scanning unit will generally further improve the accuracy of the mass distribution, thus allowing a more accurate cutting plan to be calculated. For example, such a scanning unit will typically accommodate mass density variations throughout the whole carcass part, which may then be taken into account in the cutting plan.

As is apparent from the above, the detection unit may comprise a plurality of separate units collecting respective sets of detection data, and indeed the weighing, imaging and scanning units may be used in combination with each other. The detection unit may also comprise other means for collecting other types of detection data, such as a camera for detecting blood spots.

For carcass parts, such as in particular chicken breasts, it is often preferred that the cutting plan is customized according to the anatomy of the particular type of carcass part. For example, for a chicken breast, it is preferable to form a rim charge at the thicker end of the breast and near the inward facing surface of the breast so that the external appearance is maintained. Thus, preferably, detecting the carcass part comprises identifying a predetermined anatomical region of the carcass part and calculating the cutting plan based on the mass distribution and the predetermined anatomical region. For example, calculating a cutting plan may include identifying cut lines within a predetermined anatomical region that can produce cut carcass parts meeting a target weight. In this case, using a chicken breast as an example, the predetermined anatomical region may be a region located at the thicker end of the chicken breast and near the inward facing side of the chicken breast. It should be appreciated here that a cut line refers to a two-dimensional region defined through the carcass part which divides the carcass part into two parts. The region may be planar or may have a more complex shape.

Another means of ensuring that the cutting plan maintains the external appearance, in particular in a chicken breast, comprises detecting the carcass part in order to identify the main axis of the carcass part, wherein calculating the cutting plan comprises calculating a cutting line relative to the main axis. For example, the cutting plan may require that the cutting line has a predetermined angular extent relative to the main axis. In particular, calculating the cut line relative to the main axis includes calculating a cut line that generally defines an acute angle relative to the main axis.

In an alternative embodiment, calculating the cut line relative to the main axis comprises calculating a cut line that generally defines a plane parallel to the main axis. This can be used, for example, to cut a constant thickness from the inward facing surface of a chicken breast. This represents a method of reducing the weight of carcass parts while achieving a high value trim product. This cutting arrangement may, for example, maintain the outward appearance of the breast of a chicken and obtain an edge trim that may, for example, be used for edge trim products such as steak.

In some preferred embodiments, the method further comprises detecting the carcass part in order to identify the presence and location of a foreign object (such as a bone fragment) within the carcass part, and further calculating the cutting plan based on the location of the foreign object. That is, the cutting plan may be required to contain foreign bodies in the trim in order to ensure that the cut carcass part is free of foreign bodies. Further, the target weight may be determined based on the presence of foreign matter. For example, the control unit may aim to minimize the size of the scrap, so that the scrap with foreign bodies is rejected as scrap, while minimizing the lost value. Conversely, if substantial scrap is produced, further processing of the scrap is required to remove the foreign matter and save the usable portion of the scrap, or reject the larger scrap and lose the added value of the usable carcass scrap, both of which are less cost effective.

Typically, the use of a mechanical clamp for arranging the carcass part in such a way that the cutting plan is performed will comprise moving the carcass part relative to the cutting unit. For example, the mechanical gripper may transport the carcass part to the cutting unit and place it in a desired position or orient it as required so that the cutting unit can perform a cutting plan.

In some embodiments, the method further comprises transporting the carcass part to a mechanical gripper using a transport unit, and preferably further comprises lifting the carcass part off the transport unit using a mechanical gripper. Lifting the carcass part, especially during cutting, may prevent the cutting unit from damaging the transport unit. Alternatively, arranging the carcass parts to perform a cutting plan may comprise moving or reorienting the carcass parts on the transport unit and subsequently transporting the carcass parts to the cutting unit using the transport unit. In these embodiments, the mechanical clamp may place the carcass part such that when it reaches the cutting unit it is in a position allowing a cutting plan to be performed.

Preferably, the method comprises cutting the carcass part while the carcass part is clamped by the mechanical clamp. This may increase the accuracy of performing the cutting plan, as the mechanical clamp dampens the movement of the carcass part during cutting.

In many embodiments, in order to minimize costs associated with the cutting unit, the cutting unit is configured to cut along a predetermined cutting direction, and arranging the carcass part comprises arranging the carcass part relative to the predetermined cutting direction such that the cutting unit is capable of cutting the carcass part according to a cutting plan.

Preferably, the mechanical gripper is also used as part of the sorting and conveying of the cut carcass parts. For example, preferably the method comprises clamping the carcass part at the picking position using a mechanical clamp and storing the cut carcass part at a storage position separate from the picking position. In particular, in case the method comprises forming a carcass part of a batch, preferably the storage position is a package for the carcass part of the batch. That is, the mechanical clamp may serve the additional function of arranging the cut carcass parts in batches in the respective packages. This may further reduce the cost of a system implementing the method, as no separate robot arm is required for sorting and packaging the batches of carcass parts. For example, the mechanical gripper may pick up the carcass part and hold the carcass part during execution of the cutting plan. Thus, the trim can be separated from the cut carcass part held in the mechanical clamp. The mechanical gripper may then transfer the cut carcass parts directly into the package for the batch of carcass parts.

In some embodiments, the mechanical clamp comprises a weighing unit and the method further comprises weighing the cut carcass part with the mechanical clamp after performing the cutting plan. This embodiment allows a mechanical fixture to confirm that the cutting plan is performed with acceptable accuracy. This embodiment is particularly preferred when combined with the above batch formation using mechanical clamps, as it allows the control unit to infer the weight of the batch in progress with high accuracy.

The method may be implemented in the most cost-effective manner when the cutting unit is a low-cost cutting unit, and preferably the cutting unit comprises a cutting knife, and further preferably the knife is configured to cut within a single cutting plane. Also here, a mechanical clamp is used in combination with a relatively simple cutting unit, which mechanical clamp is responsible for moving and orienting the carcass part and enables the cutting unit to perform the cutting plan.

Although the above-described aspects of the invention are designed to arrange the carcass parts with mechanical clamps so that no complex cutting devices are required, it will also be appreciated that the various preferred features discussed above introduce their own advantages so that it may be desirable to carry out the method without the alternative of mechanical clamps. For example, the comparison method may include calculating a cutting plan and executing the cutting plan without mechanical fixture intervention. Nevertheless, a mechanical clamp may be used after performing the cutting plan, e.g. for arranging the cut carcass parts in batches, as described above.

The above has been described in relation to a system where the target weight is determined for a single order, i.e. the system processes a single order of cut carcass parts at a time. However, typically the system will have multiple orders intended to be fulfilled simultaneously. This may be multiple orders of the same type, or multiple orders of different types, or a mixture of both. For example, there may be a batch of two chicken breasts weighing 300 grams, and there may be two batches being made, one of which is an in-progress order weighing 160 grams, and one of which is an in-progress order weighing 155 grams. Alternatively, or in addition, the system may have two types of orders, for example, an order for a batch of two chicken breasts weighing 300 grams, and an order for a single chicken breast weighing 150 grams. In situations like this, it is desirable to ensure that the carcass part is assigned to the order that can extract the highest value. Preferably, therefore, the method comprises determining a plurality of target weights, each target weight being associated with a respective order to be fulfilled, and further comprising selecting one of the plurality of target weights that best corresponds to the detected carcass part, wherein the cutting plan is calculated based on the selected target weight and the mass distribution of the detected carcass part. Here, the system effectively simulates the assignment and handling of carcass parts from each order by determining a respective target weight. The system may estimate the total value to be obtained by processing the carcass part from each order and may select the highest value order as the order to be fulfilled. Alternatively, the system may simply select the order with the lowest gift, i.e. the expected weight of the cut carcass part minimally exceeds the weight required by the corresponding order.

Other factors may influence the target weight selected for the carcass part. Preferably, the one target weight that best corresponds to the detected carcass part is selected from a plurality of target weights based on one or more of the following information: estimated rim charge weight, presence and/or location of a foreign object, weight of one or more carcass parts located upstream of the carcass part, predicted updated batch weight (i.e. compared to target batch weight) of one or more orders to be fulfilled, and predicted updated number of carcass parts in a batch of one or more orders to be fulfilled (i.e. compared to target number of parts in a completed batch). Other factors that may influence the decision include the total number of orders of each type to be fulfilled, and the time since the last carcass part was assigned to each order type. For example, if there are 1000 batches of an order for two chicken breasts weighing 300 grams and 100 orders for a single chicken breast weighing 150 grams, the system may tend to select a batch of two chicken breasts because there are more such orders to fulfill. Alternatively, if for example the last 5 servings, the carcass part is assigned to an order of a single chicken breast weighing 150 grams, the system may start to tend to start weighing batches of two chicken breasts to account for this deviation.

According to a second aspect of the present invention, there is provided a system comprising: a control unit adapted to determine a target weight of a cut carcass part and to calculate a cutting plan for the carcass part based on the target weight and a mass distribution of the carcass part; a detection unit adapted to detect carcass parts to determine a mass distribution of the carcass parts and to provide the mass distribution to a control unit; a mechanical clamp adapted to clamp a carcass part and to arrange the carcass part to perform a cutting plan; and a cutting unit adapted to cut the carcass part according to a cutting plan in order to produce a cut carcass part according to a target weight of the cut carcass part.

It will be appreciated that all of the preferred features of the first aspect of the invention described above apply equally to the second aspect of the invention.

According to a third aspect of the present invention there is provided a computer-readable medium comprising computer-executable instructions which, when executed by a computer, cause the computer to perform the steps of: determining a target weight of the cut carcass part; calculating a cutting plan for the carcass part based on the target weight and the received mass distribution of the carcass part; instructing a mechanical clamp to clamp a carcass part and to arrange the carcass part to perform a cutting plan; the cutting unit is instructed to cut the carcass part according to the cutting plan in order to produce the cut carcass part according to the target weight. Also, this aspect of the invention corresponds to the following instructions: the instructions are to be executed by a control unit in order to implement the method of the first aspect of the invention. Any of the preferred features discussed above apply equally to this aspect of the invention.

Drawings

The invention will now be described with reference to the accompanying drawings, in which:

fig. 1 schematically shows a system for processing carcasses according to an embodiment of the invention;

FIGS. 2A and 2B illustrate a mechanical clamp suitable for use in the system of FIG. 1;

figures 3A to 3C show a cutting unit suitable for use in the system of figure 1;

FIG. 4 is a flow chart illustrating a method implemented by the system of FIG. 1;

fig. 5A and 5B schematically show a system for processing carcasses at two different stages in the processing according to an embodiment of the invention; and

fig. 6 shows a cutting unit suitable for use in the system of fig. 5A and 5B.

Detailed Description

A first embodiment of the present invention will now be described with reference to fig. 1 to 4.

Figure 1 schematically shows a system for implementing the method of the invention. The system 1 comprises a series of conveyors 20, which conveyors 20 convey uncut carcass parts 10 (in this case chicken breasts) through a detection unit 100, a mechanical clamp 200 and a cutting unit 300 of the carcass handling system, which will be described in more detail below.

The conveyor is connected (not shown) to a control system 50, which control system 50 operates all elements of the system. As shown in fig. 4, the first step in performing the method is to enter order data into the control unit 50 in step S100. In the simplest case, the order data may simply comprise a fixed target weight for the cut carcass part; more commonly, however, the order data includes multiple elements. For example, the order data may include orders for different types of end products, such as a single chicken breast order, batches of chicken breasts having a specified weight and a specified quantity, and a trim order. The order data associated with an individual chicken breast may include a target weight range, for example, a minimum cut carcass part weight and/or a maximum cut carcass part weight, and a target minimum trim weight and/or a target maximum trim weight. The batch order may include a target weight for each batch and/or the number or range of cut carcass parts to be included in each batch. One example of a batch order may be a 700 gram piece of breast meat where the individual portions weigh no more than 200 grams or no less than 150 grams. The order data may also include data regarding orders to be fulfilled using the rim charge. For example, high value scrap products, such as chicken nuggets, may require a target minimum scrap weight or target weight. While an oversized trim can be cut to meet the target trim weight, this additional processing will reduce the cost effectiveness of the trim and reduce the overall value extracted from the carcass part, so the maximum trim weight can also be included. The order data may also include data for low value rim charge orders, such as processed food orders that use rim charges that are not suitable for higher value orders.

The carcass part 10 entering the carcass processing system 1 is first conveyed by the conveyor 20 to the detection unit 100. The detection unit in this embodiment comprises an X-ray unit and may additionally comprise a weighing unit and/or a camera or other imaging unit. The elements of the detection unit 100 collect detection data in step S200, which data in this case comprise at least the mass distribution generated by the X-ray unit, which is able to directly map the quality of the chicken breast. The detection data may also include details of the foreign object, such as bone fragments or blood spots, providing data on the presence, location, size and shape of the foreign object. The detection data may also include the weight measured by means more accurate than the X-ray unit, as well as data about the registration position of the carcass part 10 on the conveyor 20.

In step S300, the detection unit 100 transfers the detection data to the control unit 50. Subsequently, in step S400, the control unit may use the detection data and the order data to determine a target weight for the carcass part. For example, the order data may include an order for 700 grams of four chicken breasts, where the individual portions weigh no more than 200 grams or no less than 150 grams, and may also include an order for chicken nuggets, each weighing between 15 and 20 grams. If the carcass part 10 is determined to have a weight of 212 grams, the control system may identify a target weight of 195 grams with 17 grams of trim so that both elements of the cut carcass part may be used to fulfill a high value order.

After determining the target weight, the control unit determines a cutting plan using the target weight and the mass distribution in step S500. In this embodiment, the cutting unit cuts along a plane at a fixed angle to the conveyor, as will be described in more detail below. However, the mechanical clamp can arrange the carcass part before cutting, so the control unit can evaluate the number of different positions along the cutting plane for cutting the carcass part, which the carcass part may be arranged at. The control unit identifies a location to cut that meets a target weight criterion.

The carcass part 10 is conveyed to a mechanical clamp 200, which mechanical clamp 200 is shown in more detail in fig. 2A and 2B. The mechanical clamp 200 includes a main support column 202 and two pistons 203 disposed on opposite sides of the column 202. At the lower end of the column 202 is arranged a pair of clamping jaws comprising opposing jaw elements 201a, 201b, which jaw elements 201a, 201b define an elongated V-shaped channel therebetween in the closed position. Each jaw element 201a, 201b is hinged at its upper end, near the support column, such that the lower end of the jaw is movable to open and close the V-shaped channel. The clamp is connected to a transport unit (not shown) at the upper end of the column 202. The transport unit is able to rotate the entire clamp 200 around the central axis of the column, giving the mechanical clamp a 360 ° rotation. The transport unit is also capable of raising and lowering the mechanical gripper and of effecting a translational movement of the gripper. Thus, the control system 50 can arrange the clamp such that the length of the V-shaped tunnel is aligned with the main axis of the carcass part 10. Subsequently, the clamp can be lowered into position and the jaws 201a, 201b closed to clamp and collect the carcass part. Subsequently, the clamp can be moved and rotated further to change the position and orientation of the carcass part relative to the conveyor surface, thereby achieving step S600 of fig. 4.

The conveyor 20 then conveys the arranged carcass parts 10 to the cutting unit 300 shown in fig. 3A to 3C. The cutting unit 300 includes a support frame 301. The rotary cutting unit is held above the conveyor 20 by a support frame 301. The rotary cutting unit comprises a motor 302 and a rotary cutter 303. The motor maintains the shear cutter 303 at a fixed 45 angle relative to the transverse dimension of the conveyor. The conveyor 20 comprises a slot 21 extending in the length direction of the conveyor, into which slot 21 a shear cutter 303 extends. The slot thus prevents the knife from damaging the conveyor, while allowing the knife to cut completely through the carcass part. Fig. 3C shows the carcass part 10 in the process of being cut by the cutting unit 300 in step S700. The carcass parts have been arranged so that when the conveyor 20 moves the chicken breast 10 past the stationary cutting knife, the knife cuts into the thicker end of the chicken breast at an angle of 45 °. Cut at an angle of 45 ° into the thicker end of the chicken breast so that the interior facing side of the chicken breast is more contained in the rim charge than the exterior facing side of the chicken breast. This cutting arrangement ensures that the cut chicken breast appears substantially intact when the outward facing surface of the breast is examined.

Once cut, the order data is updated to reflect that a cut carcass part has been produced and the cut carcass part 11 and trim 12 are passed downstream for further processing (e.g. packaging). When a subsequent carcass part is detected, the method is repeated starting from step S200. Although fig. 4 shows that the detection of a new carcass part only takes place after step S800, in practice the method will operate continuously and the new carcass part will normally be detected while the first carcass part is processed.

A second embodiment will now be described with reference to fig. 4 to 6.

Figure 5A schematically illustrates another system for implementing the method of the present invention. The system 1 comprises a series of conveyors 20, the conveyors 20 conveying uncut carcass parts 10 (again chicken breasts) past the detection unit 100 and the integrated clamping and cutting unit 250 of the carcass processing system, as will be described in more detail below. The final conveyor 20 is shown holding a tray 15 in which the batches of carcass parts are to be formed in the tray 15 by the carcass handling system.

The system also comprises a control unit 50 into which order data is entered in step S100. In this embodiment, the system 1 forms a cut carcass part of a batch, so the order data for example comprises the following orders: two pieces of cut chicken breast having a total weight of 300 grams, and wherein each piece of meat weighs no less than 125 grams and no more than 175 grams. As described above, the order data also includes data regarding the scrap products to be fulfilled.

The carcass part 10 entering the carcass processing system 1 is first conveyed to the detection unit 100 by the conveyor 20. The detection unit comprises an X-ray unit, a weighing unit and a camera. In step S200, the elements of the detection unit 100 collect detection data, which in this case comprise the mass distribution generated by the X-ray unit, the weight from the weighing unit and the image data from the camera.

In step S300, the detection unit 100 transfers the detection data to the control unit 50. Subsequently, in step S400, the control unit may use the detection data and the order data to determine a target weight for the carcass part. In this case the detection data comprise data indicating that the bone piece 13 is contained in the current carcass part 10 and an indication that the carcass part weight is 184 grams. In step S400, the control unit recognizes the presence of a bone block. Since any trim including the bone piece 13 is either scrap or requires further processing to recover usable carcasses, the control unit is configured to minimize the size of the trim to reduce the amount of wasted carcasses. Thus, the control unit 50 determines a target weight of 170-175 grams, leaving 9-14 grams of trim, in order to maximize the amount of carcasses used to fulfill the order.

After determining the target weight, the control unit 50 determines a cutting plan using the target weight, the mass distribution, and the position of the foreign matter in step S500. In this embodiment, the cutting unit also cuts at a fixed angle along a plane, so the control unit 50 identifies the location where the cut is to be made, i.e. meeting the target weight criterion and including the bone pieces 13 in the rim-charge portion 12, based on the mass distribution.

The carcass part 10 is then conveyed to an integrated clamping and cutting unit 250, said clamping and cutting unit 250 being shown in more detail in fig. 6. The integrated clamping and cutting unit 250 includes a main support column 252 and two pistons 253 disposed on opposite sides of the column 252. At the lower end of the post 252 is disposed a pair of clamping jaws comprising opposed jaw members 251a, 251b, which in the closed position define an elongate V-shaped channel between the jaw members 251a, 251b, the elongate V-shaped channel having a chamfered edge at the front end of the channel and at the bottom edge of the jaw members 251a, 251b, as will be described below. Each jaw element 251a, 251b is hinged at its upper end, near the support post, such that the lower end of the jaw is movable to open and close the V-shaped channel. The clamp is connected to a transport unit (not shown) at the upper end of the column 252. The transport unit is able to rotate the entire clamping and cutting unit 250 around the central axis of the post 252, giving the mechanical clamp a 360 ° rotation. The transport unit is also capable of raising and lowering the mechanical clamp. Finally, the transport unit is able to move the mechanical gripper along the track between a pick-up position (shown in fig. 5A) and a dispensing position (shown in fig. 5B). The picking position is the position where the carcass part to be cut is collected. The dispensing position will be described in more detail below.

The clamping and cutting unit 250 further comprises a cutting unit 350. The cutting unit includes a support member 351 extending from the support column 252 to an actuator 352. The actuator acts on a cutting knife 353, the cutting knife 353 being arranged at a 45 ° angle to the long axis of the V-shaped channel defined by the jaws 251a, 251 b. In the extended position, the cutting blade 353 extends along the edges of the jaws 251a, 251b at the chamfered edges. The actuator 352 operates the cutting blade 353 in a guillotine-like motion, raising and lowering the blade along the beveled edge. The movement of the knife 353 causes the leading end of any carcass part held in the jaws 251a, 251b to receive a cut at a 45 ° angle, thereby creating a rim of the carcass part.

First, the carcass part is clamped and arranged using the clamping and cutting unit 250 described above in step S600, lifted off the conveyor, after which the guillotine-like movement of the cutting knife 353 effects step S700 by cutting the carcass part according to the cutting plan. The scrap containing the bone pieces 13 falls down to the conveyor 20 below. If the clamping and cutting unit 250 comprises a coupling of the jaw elements 251a, 251b capable of measuring the weight, the clamp can then determine the exact weight of the cut carcass part and provide this information to the control unit.

As shown in fig. 5B, the clamping and cutting unit 250 is then moved by the transport unit to a separate conveyor 20 on which the tray 15 is disposed. In fig. 5B, the tray 15 is shown downstream of the conveyor where the carcass parts enter the system; however, this is for clarity only. Typically, the trays 15 will be arranged on parallel conveyor lines, allowing the trimmings to travel along the downstream conveyor for further processing. The holding and cutting unit 250 deposits the cut carcass parts 11 in the tray 15 and updates the order data to reflect that the batch being processed has a cut carcass part 11 weighing 170-175 grams. This weight, which is used to update the order data, may be more accurate if weighed after cutting.

Subsequently, the method returns to step S200 for a subsequent carcass part. Now the control unit will use the detection data and determine a target weight for the subsequently cut carcass part based on updated order data reflecting the required cut carcass part weight of 125-130 grams.

In another version of the embodiment of fig. 5A and 5B, a buffer may be included between the detection unit 100 and the holding unit 250, which allows the control unit to collect detection data on multiple incoming carcass parts. For example, if such a system is in an operating state as described above (i.e. with a batch of two chicken breasts having a total weight of 300 grams and in which each meat piece weighs no less than 125 grams and no more than 175 grams of order), the control unit may make use of this buffer to better fulfill the order. For example, the control unit may distinguish between a first carcass part weighing 184 grams and a second carcass part weighing 200 grams. On this basis the control unit may determine that the first carcass part should be cut to, for example, 140 grams to reduce the size of the trim that needs to be formed on the second carcass part weighing 200 grams and to ensure that both trimmings can be used for high value trim products without significant further processing.