GB1578524A

GB1578524A - Transporting and sorting poultry carcasses

Info

Publication number: GB1578524A
Application number: GB3220679A
Authority: GB
Original assignee: AUTO SYSTEMS Ltd
Current assignee: AUTO SYSTEMS Ltd
Priority date: 1977-03-01
Filing date: 1977-03-01
Publication date: 1980-11-05

Description

(54) TRANSPORTING AND SORTING POULTRY CARCASSES.

(71) We, AUTO SYSTEMS LIMITED of Crosland Hall, Netherton, Huddersfield, West Yorkshire, a British Company, do hereby declare the invention, for which we pray that a patent may be granted to us, and the method by which it is to be performed, to be particularly described in and by the following statement: The invention relates to the transporting and sorting of poultry carcasses.

The invention provides a system for transporting and sorting pultry carcasses comprising an overhead conveyor system, a control unit, a grading station, means for feeding information into the control unit regarding the grade of carcasses as they pass the grading station, a weighing station, means for feeding into the control unit information regarding the weight of carcasses as they pass the weighing station, and a plurality of drop-off mechanisms spaced apart along the overhead conveyor system, the control unit being operable to remove each carcass from the conveyor using a selected drop-off mechanism, in dependence upon the weight and/or grade of the carcass.

The control unit preferably comprises at least one memory to store the signals received from the feed means.

The memory may comprise a shift register having provision to receive a grading signal from each of the feed means and store the signals in the section in the order in which they are received by the section, and the grading apparatus includes a shift sensor which senses the passage of carcasses past the grading station and indexes the shift register to a new position after the passage of each group of carcasses, so that a group of grading signals in the first section of the register is transferred to the next section of the register and the first section of the register is ready to receive a new group of grading signals associated with the next group of carcasses.

There may be a grading console having at least two sets of signal initiating means, one set for each carcass of a group present at the grading station, the apparatus also including means to associate each of said sets with one particular carcass of the said group.

To assist the operator there may be provided indicating means to indicate to the operator which of a group of carcasses at the grading station is associated with which feed means. For example the feed means may be numbered and there may be means to display associated numbers on or adjacent to the carcasses at the grading station. Alternatively the feed means may be identified by colour, there being means to assoicate each colour with one of the carcasses at the grading station.

The control unit may have a plurality of shift registers for receiving information regarding the weight of the carcasses, the shift register which receives information about one particular carcass being dependent on the grading information stored relating to the particular carcass.

At least one shift register may be arranged in combination with two potentiometers for use in controlling the range of weight information which can be stored in that shift register.

The control unit may have a plurality of replaceable modular components.

By way of example, specific embodiments of the invention will now be described, with reference to the accompanying drawings, in which: Figure 1 is a view of one embodiment of the apparatus according to the invention; Figure 2 is an alternative form of grading console; Figure 3 is a schematic diagram indicating an alternative arrangement for the apparatus; Figure 4 illustrates in more detail some part of the control unit shown in Figure 3; Figures 5 and 6 illustrate some further parts which may be added to the control unit.

Referring first to Figure 1. there is shown a rail 10 carrying a succession of chicken carcass-carrying shackles 11; each shackle runs on rollers 12 and the shackles are interconnected by a driving chain 13. The spacing between successive shackles is six inches. At a weighing station 100 a weigh cell 14 feeds to a control unit 15 a weight signal each time a shackle passes through the weighing station. The control unit associates each signal with the appropriate shackle and utilises the signal in subsequent control of the shackle.

For example all carcasses lying in a particular weight range may be dropped off their shackles into a particular recovery bin. The operation of the weigh cell is as described in Application No. 30952/73 (Serial No. 1488345) and will not therefore be described in detail.

The weigh cell 14 makes an almost instantaneous assessment of the shackle weight and hence it is immaterial that the carcasses are so close together. The weigh cell is able to pass each signal to the control unit well before the next carcass reaches the weigh station. Each signal is fed into a shift register in the control unit and as the next carcass enters the weighing station it actuates a proximity sensor 17 which indexes the shift register one position ready to receive the next weight signal. The proximity sensor 17 also allows the weigh cell to pass the next weight signal to the shift register when the following carcass is at the optimum position in relation to the weigh cell.The sensor opens a gating device in the control unit when a shackle passcs the sensor and the sensor is positioned so that when a shackle is at the sensor the following shackle is at the optimum weighing position.

Upstream of the weighing station is a grading station 16 where an operator visually assesses the carcasses and grades them as sub-standard or satisfactory. We have found that it is difficult for the operator to make a decision about a carcass and transmit an appropriate signal in the time which it takes a carcass to travel six inches and thus the grading station cannot operate efficiently if it is similarly arranged to the weighing station.

Instead, the grading station is of sufficient length to accommodate four carcasses at once. and the operator has a grading console 18 which has four pairs of buttons, each pair numbered 1 to 4. Below the chain 13. and extending for the length of the grading station, is a display unit 19 which has four panels 20 each comprising an electronic display capable of displaying any number from I to 4. Each display has a counter associated therewith. the counters being coupled to a proximity sensor 21 and being out of phase with each other in such a way that when a first group of four shackles is at the grading station the display unit shows the numbers 1 to 4 in sequence below the associated shackles. In the position shown in Figure 1, the first shackle of a group has just left the grading station and the first shackle of a new group of four has just entered.The counters have indexed accordingly and the first shackle of the new group has been allocated the number 1. Thus as each shackle enters the grading station it is allocated a number from 1 to 4 and as the shackle moves through the grading station the allocated number appears to follow it across the display panel. Thus the operator is able to associate one particular number from 1 to 4 with any given shackle which is at the grading station at any one time.

A further shift register in the control unit 15 is associated with the grading operation and has four separate inputs, one linked to each pair of buttons on the grading console 18. For any one position of the shift register it can receive four separate grading signals, one at each input, in any order, and will store these signals in an order which depends on the pair of buttons to which the input is linked. The signal from the buttons marked 1 will be stored first, and so on up to the number 4. For every fourth pulse from the proximity sensor 21, the shift register shifts to a new position ready to receive a further set of four signals.

All the operator need do is examine each carcass as it enters the grading station, allocate a grade to the carcass. note the number displayed under the carcass, and then press the appropriate button of the pair having the same number as the carcass. Although he must grade four carcasses over a distance of two feet. this has been found to be easier than grading one carcass over a distance of six inches.

Downstream of the weighing station are three drop-off mechanisms 23, 24 and 25, each associated with a respective receiving bin 26. 27 and 28. On receipt of an appropriate signal from the control unit 15, each drop-off unit is operable to release the particular shackle which is at the drop-off mechanism when the signal is received, so that any carcass carried by the shackle falls into the bin below.

In this particular example the control unit is programmed to drop all sub-standard carcasses into bin 26 and to sort satisfactory carcasses into two weight ranges, one to be deposited in bin 27 and one to be deposited in bin 28. The control unit is arranged to monitor the signals appearing at a particular point in the shift register associated with the grading signals. the point being as many steps apart from the first section of the shift register as there are shackles between the dropoff mechanism 23 and the grading station.

Thus the information appearing at the monitored point relates to the shackle which is at that moment at the drop-off mechanism 23.

If the information indicates a sub-standard carcass, the control unit causes the drop-off mechanism to release the carcass. If the information indicates a satisfactory carcass, no signal is passed to the drop-off mechanism.

The control unit similarly monitors other points in the shift register associated with the weighing station, and carcasses are dropped into bin 27 and bin 28 according to their weight.

The information supplied to the control unit 15 may be utilised in a variety of other ways. For example there may be drop-off points where a particular weight range is required, and a certain grade or grades of carcass are acceptable, while another grade or grades are not. In such a case an arrangement as shown in Figure 3 may be used, in which the control unit 15 comprises a control and inhibition unit 30, a grading shift register 31, and a plurality of weight shift registers 32,33, 34. Each of the registers 32,33, 34 is associated with one particular drop-off mechanism 23, 24, 25.The number of sections in the grading shift register 31 is related to the number of shackles lying between the grading station and the weighing station such that the grading information stored in the last section of the shift register 31 relates to the shackle which is being weighed by the weigh cell 14. The control and inhibition unit 30 draws a grading information signal from the last section of the shift register 31 half a pitch ahead of the weight signal received from the weigh cell 14. The weight signal is fed to all three weight shift registers 32, 33, 34 but the unit 30 inhibits from accepting the weight signal any weight shift register which is associated with a drop-off mechanism which does not require that grade of bird.If more than one of the shift registers 32, 33, 34 is associated with a drop-off mechanism which does require the grade of bird indicated, then one of the shift registers will inhibit the other or others, and the weight signal will only be stored by that one shift register. The shift register with priority may simply be the first one in the line, or may be given priority by an additional device such as those described later.

Thus weight information about any one carcass is stored in only one shift register, and is stepped through the register by subsequent pulses from the sensor 17.

Each register 32, 33, 34 is set to receive only signals lying within a particular weight range so even if a register is associated with the grade indicated and is not inhibited, it will not accept a signal lying outside its own selected weight range.

Each register 32, 33, 34 has a number of sections related to the number of shackles lying between the weigh cell 14 and the associated drop-off mechanism so that the signal relating to a particular carcass will reach the final section of the shift register at the same time as the carcass reaches the drop-off mechanism. The signal appearing in the final section causes actuation of the mechanism and the carcass falls into a bin assoicated with the particular grade and weight of that carcass.

The parts of the control unit comprise modular units which can be plugged together to provide various grading and weighing systems. Figure 4 illustrates three modules 32a, 33a, and 34a together with an associated legend panel 35, These units are intended to plug into a control and inhibition unit side by side. Module 32a has two potentiometer dials 36 and 37 which are used to set the lower and upper limits of a weight range respectively. If dial 36 were set to 2 pounds for example, and dial 37 were set to 5 pounds, then the shift register forming part of the module would accept a weight signal initiated by a carcass weighing between 2 and 5 pounds, provided that the register is not inhibited by the grading information or by one of the other modules described below.

The module 32a has an on/off switch 38 and a second switch 39 to couple the module to the associated drop-off mechanism. There are lights 40 and 41 to indicate respectively whether the weights set on dials 36 and 37 have been exceeded and lights 42 and 43 to indicate respectively whether the register has accepted a weight signal or been inhibited.

There is also a light 44 to indicate that a carcass associated with that module has reached the associated drop-off mechanism and a light 45 which comes on momentarily each time the associated drop-off unit operates.

The module 34a is identical to module 32a and may for example be set to receive signals in a weight range 6 to 8 pounds. The module 33a is also identical except that it has no dials 36 and 37 and no lights 40 and 41. This module will accept any weight signals lying between the two ranges covered by modules 32a and 34a, i.e. lying in the range 5 to 6 pounds.

Since the size of the shift register in each module is fixed, each module is only suitable to operate a drop-off mechanism arranged a predetermined number of shackles away from the weigh cell but the positions of the drop-off mechanisms can be adjusted as desired, the associated modules being unplugged from the control unit and replaced by other similar modules having appropriately sized shift registers.

Figure 5 shows a modular counter which may be coupled to one of the modules 32a to 34a to count the number of carcasses dropped off in the weight range associated by that module. The counter may be arranged to inhibit the further operation of the module after a preselected number of carcasses have been dropped off. The desired number is set at 46 using a knurled wheel 47 and when the carcasses counted (indicated at 48) reaches the desired number, an inhibit signal is generated. A visual and/or audible warning may be initiated by the counter when the desired total is reached so that an operator may remove the full bin, replace it with an empty one and then reset the counter so that the associated module is no longer inhibited, by pressing a reset button 49.

Figure 6 shows a shift register module 50, with an associated drop-off 53, coupled to a device for limiting the rate at which carcasses are dropped off by that module. The limiting device comprises a pulse generator 51 and a counter 52. If a drop off rate of say ten carcasses per minute is required, the generator 51 is set to feed ten pulses per minute to the counter 52. Each pulse causes the counter to increase its count by one. The module 50 is coupled to the counter so that every time the module accepts a weight signal it causes the counter to decrease its count by one.

Whenever the counter indicates a total of zero, an inhibit signal is passed to the module 50, preventing it from acccpting further signals until the counter incrcases its count to a positive value.

The invention is not restricted to the details of the foregoing example. For instance it may be desired to grade carcasses into more than two grades, for example "Trim" carcasses (e.g. carcasses which have been trimmed to remove a burn mark left by an electric stunning operation), "Wing missing" carcasses, "Parts missing" carcasses, and "Grade A" carcasses. With such an arrangement a grading console as shown in Figure 2 may be used, there being four buttons associated with each of the numbers 1 to 4, one button for each grade. If necessary, two or more operators may be used, each dealing with two of the grades or two of each group of four carcasses.

If desired, the display unit 19 may be dispensed with, the shackles being painted different colours, e.g. red, black, green and blue for each group of four shackles, and the grading console 18 being marked red, black, green and bluc accordingly, instead of 1, 2, 3 and 4.

In some processes, the weight of the carcasses may be altcred after some preliminary processing. For example, after certain weights and grades of carcass have been dropped off, the remaining carcasses may have giblets inserted into them. and it may then be necessary to drop these carcasses off at other points, according to weight and grade. In such a case a further weighing station, similar to that shown in Figure 1 may be provided at a point dowstream of the giblet insertion point. The control unit may be programmed to retain the information from the grading station, but to cancel the original information regarding weight and replace it with the information from the second weighing station, the original grading information and new weight information being utilised to control subsequent processing and handling.

It is advantageous that the control unit is of modular construction, with plug-in panels, each carrying the necessary logic circuitry associated with one particular operation, for example one particular drop-off point.

Our co-pending application No. 3883/76 (Serial No. 1578523 relates to other aspects of the system shown in the accompanying drawings.

WHAT WE CLAIM IS: 1. A system for transporting and sorting poultry carcasses comprising an overhead conveyor system, a control unit, a grading station, means for feeding information into the control unit regarding the grade of carcasses as they pass the grading station, a weighing station, means for feeding into the control unit information regarding the weight of carcasses as they pass the weighing station, and a plurality of drop-off mechanisms spaced apart along the overhead conveyor system, the control unit being operable to remove each carcass from the conveyor using a selected drop-off mechanism in dependenace upon the weight and/or grade of the carcass.

2. A system as claimed in Claim 1, the grading station having grading apparatus for use in associating one of a plurality of grades with each of the carcasses travelling in succession past the grading station, the grading station being of sufficient length to accommodate a group of at least two carcasses at any one time, and the grading apparatus comprising a plurality of means for feeding a grading signal to the control unit, the number of feed means being equal to the number of articles which can be accommodated at the grading station.

3. A system as claimed in Claim 2, in which the control unit comprises at least one memory to store the signals received from the feed means.

4. A system as claimed in Claim 3, in which the memory comprises a shift register having a plurality of sections, each section of the register having provision to receive a grading signal from each of the feed means and store the signals in the section in the order in which they are received by the section, and the grading apparatus includes a shift sensor which senses the passage of carcasses past the grading station and indexes the shift register to a new position after the passage of each group of carcasses, so that a group of grading signals in the first section of the register is transferred to the next section

**WARNING** end of DESC field may overlap start of CLMS **.

Claims

**WARNING** start of CLMS field may overlap end of DESC **. inhibit the further operation of the module after a preselected number of carcasses have been dropped off. The desired number is set at 46 using a knurled wheel 47 and when the carcasses counted (indicated at 48) reaches the desired number, an inhibit signal is generated. A visual and/or audible warning may be initiated by the counter when the desired total is reached so that an operator may remove the full bin, replace it with an empty one and then reset the counter so that the associated module is no longer inhibited, by pressing a reset button 49. Figure 6 shows a shift register module 50, with an associated drop-off 53, coupled to a device for limiting the rate at which carcasses are dropped off by that module. The limiting device comprises a pulse generator 51 and a counter 52. If a drop off rate of say ten carcasses per minute is required, the generator 51 is set to feed ten pulses per minute to the counter 52. Each pulse causes the counter to increase its count by one. The module 50 is coupled to the counter so that every time the module accepts a weight signal it causes the counter to decrease its count by one. Whenever the counter indicates a total of zero, an inhibit signal is passed to the module 50, preventing it from acccpting further signals until the counter incrcases its count to a positive value. The invention is not restricted to the details of the foregoing example. For instance it may be desired to grade carcasses into more than two grades, for example "Trim" carcasses (e.g. carcasses which have been trimmed to remove a burn mark left by an electric stunning operation), "Wing missing" carcasses, "Parts missing" carcasses, and "Grade A" carcasses. With such an arrangement a grading console as shown in Figure 2 may be used, there being four buttons associated with each of the numbers 1 to 4, one button for each grade. If necessary, two or more operators may be used, each dealing with two of the grades or two of each group of four carcasses. If desired, the display unit 19 may be dispensed with, the shackles being painted different colours, e.g. red, black, green and blue for each group of four shackles, and the grading console 18 being marked red, black, green and bluc accordingly, instead of 1, 2, 3 and 4. In some processes, the weight of the carcasses may be altcred after some preliminary processing. For example, after certain weights and grades of carcass have been dropped off, the remaining carcasses may have giblets inserted into them. and it may then be necessary to drop these carcasses off at other points, according to weight and grade. In such a case a further weighing station, similar to that shown in Figure 1 may be provided at a point dowstream of the giblet insertion point. The control unit may be programmed to retain the information from the grading station, but to cancel the original information regarding weight and replace it with the information from the second weighing station, the original grading information and new weight information being utilised to control subsequent processing and handling. It is advantageous that the control unit is of modular construction, with plug-in panels, each carrying the necessary logic circuitry associated with one particular operation, for example one particular drop-off point. Our co-pending application No. 3883/76 (Serial No. 1578523 relates to other aspects of the system shown in the accompanying drawings. WHAT WE CLAIM IS:

1. A system for transporting and sorting poultry carcasses comprising an overhead conveyor system, a control unit, a grading station, means for feeding information into the control unit regarding the grade of carcasses as they pass the grading station, a weighing station, means for feeding into the control unit information regarding the weight of carcasses as they pass the weighing station, and a plurality of drop-off mechanisms spaced apart along the overhead conveyor system, the control unit being operable to remove each carcass from the conveyor using a selected drop-off mechanism in dependenace upon the weight and/or grade of the carcass.

of the register and the first section of the register is ready to receive a new group of grading signals associated with the next group of carcasses.

5. A system as claimed in any one of the preceding claims, in which the grading apparatus includes a grading console having at least two sets of signal initiating means, one set for each carcass of a group present at the grading station, the apparatus also including means to associate each of said sets with one particular carcass of the said group.

6. A system as claimed in any one of the preceding claims, having indicating means to indicate to the operator which of a group of carcasses at the grading station is associated with which feed means.

7. A system as claimed in Claim 6, in which the feed means are numbered and there are means to display associated numbers on or adjacent to the carcasses at the grading station.

8. A system as claimed in Claim 6, in which the feed means are identified by colour, there being means to associate each colour with one of the carcasses at the grading station.

9. A system as claimed in any one of the preceding claims, in which the control unit has a plurality of shift registers for receiving information regarding the weight of the carcasses, the shift register which receives information about one particular carcass being dependent on the grading information stored relating to that particular carcass.

10. A system as claimed in Claim 9, in which at least one shift register is arranged in combination with two potentiometers for use in controlling the range of weight information which can be stored in that shift register.

11. A system as claimed in any one of the preceding claims, in which the control unit has a plurality of replaceable modular components.

12. A system as claimed in Claim 11, in which a first of said modular components comprises means for receiving information regarding the weight of a carcass lying within a first preselected weight range, said first modular component having means for preselecting the upper and lower limits of said first weight range.

13. A system as claimed in Claim 12, further comprising a second modular component comprising means for receiving information regarding the weight of a carcass lying within a second preselected weight range, the component having means for preselecting the upper and lower limits of said second weight range.

14. A system as claimed in Claim 13, further comprising a third modular component comprising means for receiving information regarding the weight of a carcass lying within a third weight range, the upper limit of the third weight range being defined by the lower limit of the first weight range and the lower limit of the third weight range being defined by the upper limit of the second weight range.

15. A system as claimed in Claim 12, including means to temporarily and selectively inhibit said means for receiving information regarding the weight of a carcass lying within said first preselected weight range, so that a weight information signal generated by a particular carcass is not passed to said means for receiving information.

16. A system as claimed in Claim 15, in which a further of said modular components comprises a counter connected to said first modular component, and means to preselect a number of the counter, the counter being arranged to inhibit the first modular component from receiving any further weight signals once it has received a number of weight signals equal to the number preselected on the counter.

17. A system as claimed in Claim 15, in which a further of said modular components comprises a pulse generator in combination with a counter, the pulse generator being arranged to clock the counter in one direction and said first modular component being arranged to clock the counter in the opposite direction each time the modular component receives a weight signal, the counter being arranged to inhibit said first modular component from receiving weight signals so long as the count on the counter is at a zero datum level.

18. A system as claimed in Claim 13 or Claim 14, in which said first modular component comprises a first shift register, and said second modular component comprises a second shift register having a different number of sections than said first shift register.

19. A system for transporting and sorting poultry carcasses constructed and arranged substantially as herein described, with reference to the accompanying drawings.