WO2023075844A1

WO2023075844A1 - Poultry beak processing system and method

Info

Publication number: WO2023075844A1
Application number: PCT/US2022/026474
Authority: WO
Inventors: Scott C. Johnson; Nathan A. BLUM
Original assignee: Nova-Tech Engineering, Llc
Priority date: 2021-10-29
Filing date: 2022-04-27
Publication date: 2023-05-04
Also published as: CN217657693U; CN116058305A

Abstract

Systems and methods for processing the beaks of poultry to control beak size and growth using non-contact energy are described herein. The poultry beak processing systems and methods include one or more masks that are separate from the cradles used to deliver birds to the beak processing system. As a result, replacement of a single mask in the poultry beak processing systems described herein provides adjustments to the masking for each and every cradle within the beak processing system. The masks may be selected such that they are better tailored to fit the beaks of the birds being processed such that more precise control over the amounts or portions of the beaks exposed to energy can be achieved. Beak shape and/or size can vary based on, e.g., flock age, size, species, strain, sex, etc.

Description

POULTRY BEAK PROCESSING SYSTEM AND METHOD

RELATED APPLICATION

This application claims the benefit under 35 U.S.C. § 119 of U.S. Provisional Application Serial No. 63/273,438, filed 29 October 2021, and titled POULTRY BEAK PROCESSING SYSTEM AND METHOD, which is incorporated herein by reference in its entirety.

FIELD

Poultry beak processing systems and methods are described herein.

BACKGROUND

Young birds may use their beaks for pecking other birds. In addition, adult poultry may use their beaks on other adult and juvenile poultry. Such beak use can harm poultry. Accordingly, the beaks of birds may be processed to reduce the danger posed by the beaks when used on other birds.

Beak processing was significantly improved using non-contact energy as described in U.S. Patent Nos. 5,651,731; 7,232,450; and 7,363,881 (all to Gorans et al.). The apparatus and methods described in those documents provide a more humane method for processing beaks because the method is bloodless, induces little or no shock, and minimizes damage to the bird.

SUMMARY

Systems and methods for processing the beaks of poultry to control beak size and growth using non-contact energy are described herein.

Poultry beak shape and/or size (where the term “beak” is used generically to include beaks of birds such as chickens, turkeys, etc. as well as bills of birds such as ducks, geese, etc.) can vary significantly based on the species, gender, and age of birds. In addition to variations in beak shape and/or size between species, the inventors have also determined that variations in shape and/or size of beaks can be found between different breeds, varieties, strains, breeding flocks, etc.

Known beak processing systems using non-contact energy to process poultry beaks such as those disclosed in, e.g., U.S. Patent Nos. 5,651,731 and 7,232,450 rely on masking to control the portions of the beaks exposed to the non-contact energy to protect the birds and to provide desired outcomes. The masking in these systems is provided on the head positioning portion on each cradle used to deliver birds to the processing location within a beak processing system. As a result, adjustment of the processing system to accommodate differences in beak size and/or shape requires replacement of at least a portion of the head positioning portion of each and every cradle used to deliver birds to the processing location in the beak processing system. Many embodiments of these systems include 20, 30, or even more cradles which makes adjustments to masking a relatively time-consuming process that requires replacement of the entire set of cradles or removal and replacement of a portion of each cradle in the processing system.

The poultry beak processing systems and methods described herein include one or more masks that are separate from the cradles used to deliver birds to the beak processing system. As a result, replacement of a single mask in the poultry beak processing systems described herein provides adjustments to the masking for each and every cradle within the beak processing system. The ability to easily and quickly adjust the masking provides users with the improved opportunity for more precise control over the delivery of energy to the beaks being processed which, in turn, leads to better outcomes for the birds and improvements in productivity for producers. In one or more embodiments, the masks may be selected such that they are better tailored to fit the beaks of the birds being processed such that more precise control over the amounts or portions of the beaks exposed to energy can be achieved. As discussed herein, beak shape and/or size can vary based on, e.g., flock age, size, species, strain, gender, etc.

One potential advantage of improved masking is that higher energy delivery rates and/or energy density may be used in processing. Increased energy delivery rate and/or energy density can improve repeatability of the beak processing. In a first aspect, one or more embodiments of a poultry beak processing system for processing the beak of a bird as described herein includes: a positioning device configured to retain a head of a bird in a head cavity, wherein the head cavity comprises a beak aperture on a processing side of the positioning device, and wherein the positioning device is in a processing location; a non-contact energy source emitting energy; a plurality of masks, wherein each mask of the plurality of masks comprises a mask cavity extending through a mask body between a first opening on a first side facing the processing side of the positioning device and a second opening on a second side facing away from the processing side of the positioning device, wherein the second opening of the mask cavity of the mask in the operating position is smaller than the beak aperture of the positioning device, and wherein the second opening of a first mask of the plurality of masks comprises a different shape and/or size than the second opening of a second mask of the plurality of masks; a mask support, wherein the plurality of masks are attached to the mask support, wherein the mask support comprises an operating position and a storage position. When each mask of the plurality of masks is in the operating position: the first opening on the first side of the mask in the operating position is aligned with the beak aperture such that a beak of a bird head located in the head cavity extends through the beak aperture into the mask cavity of the mask in the operating position, and an exposed portion of a beak of a bird head located in the head cavity extending into the mask cavity of the mask in the operating position extends out of the mask cavity through the second opening such that energy emitted by the non-contact energy source is incident on the second side of the mask in the operating position and the exposed portion of the beak. The system optionally includes a mask actuator operably connected to the mask support, wherein the mask actuator is configured to move the mask support between a home position and a masking position, wherein the first opening on the first side of the mask in the operating position is closer to the processing side of the positioning device when the mask support is in the masking position than when the mask support is in the home position; and, optionally, a controller operably connected to the energy source and the mask actuator, the controller configured to: operate the mask actuator to move the mask support from the home position to the masking position, and operate the energy source to emit energy for a selected period of time after operating the mask actuator to move the mask support from the home position to the masking position.

In one or more embodiments of a poultry beak processing system according to a first aspect as described herein, the second opening of the first mask comprises a shape that is the same as the second opening of the second mask.

In one or more embodiments of a poultry beak processing system according to a first aspect as described herein, the second opening of the first mask and the second opening of the second mask are the same size.

In one or more embodiments of a poultry beak processing system according to a first aspect as described herein, the second opening of the first mask comprises a shape and size that are the same as the second opening of the second mask.

In one or more embodiments of a poultry beak processing system according to a first aspect as described herein, the mask support comprises a platform configured to move each mask of the plurality of masks into the operating position from the storage position. In one or more embodiments, the platform comprises a rotating platform configured to rotate each mask of the plurality of masks into the operating position from the storage position.

In one or more embodiments of a poultry beak processing system according to a first aspect as described herein, the controller is configured to operate the mask actuator to move the mask support from the masking position to the home position after the selected period of time.

In one or more embodiments of a poultry beak processing system according to a first aspect as described herein, the mask support and the plurality of masks are attached to a housing containing the non-contact energy source, and wherein the mask actuator moves the housing when moving the mask support between the home position and the masking position.

In one or more embodiments of a poultry beak processing system according to a first aspect as described herein, the energy source is configured such that energy emitted by the energy source is incident on the second side of the mask in the operating position. In one or more embodiments, the energy source is configured such that energy emitted by the energy source is incident on the second side of the mask in the operating position when the mask support is in the home position and when the mask support is in the masking position.

In one or more embodiments of a poultry beak processing system according to a first aspect as described herein, only one mask of the plurality of masks is in the operating position at any given time.

In one or more embodiments of a poultry beak processing system according to a first aspect as described herein, the positioning device comprises a first positioning device of a plurality of positioning devices, and wherein the mask in the operating position is configured to be used with each positioning device of the plurality of positioning devices after each positioning device of the plurality of positioning devices is moved into the processing location.

In a second aspect, one or more embodiments of a method of processing the beak of a bird restrained in a processing location includes: moving a positioning device to a processing location, wherein a head of a bird is retained in a head cavity of the positioning device, and wherein a first portion of the beak of the bird extends through a beak aperture on a processing side of the positioning device; moving a mask from a home position to a masking position, wherein the mask comprises a mask cavity extending through a mask body between a first opening on a first side facing the processing side of the positioning device and a second opening on a second side facing away from the processing side of the positioning device, wherein moving the mask from the home position to the masking position moves the beak into the mask cavity such that a masked portion of the first portion of the beak of the bird is located within the mask cavity and an exposed portion of the first portion of the beak extends out of the second opening of the mask cavity when the mask is in the masking position; and delivering non-contact energy to the exposed portion of the beak of the bird after moving the mask from the home position to the masking position. In one or more embodiments of a method according to the second aspect as described herein, moving the mask from the home position to the masking position comprises rotating the mask about a mask axis.

In one or more embodiments of a method according to the second aspect as described herein, the non-contact energy delivered to the exposed portion of the beak is incident on the second side of the mask when the mask is in the home position and when the mask is in the masking position.

In one or more embodiments of a method according to the second aspect as described herein, delivering non-contact energy to the exposed portion of the beak comprises delivering the non-contact energy for a selected time period after moving the mask from the home position to the masking position.

In one or more embodiments of a method according to the second aspect as described herein, the method comprises moving the mask from the masking position to the home position after the selected time period.

In one or more embodiments of a method according to the second aspect as described herein, the second opening of the mask cavity is smaller than the beak aperture of the positioning device.

In one or more embodiments of a method according to the second aspect as described herein, the mask is in an operating position on the mask support, wherein the mask comprises a first mask of a plurality of masks, wherein each mask of the plurality of masks comprises a mask cavity extending through a mask body between a first opening on a first side facing the processing side of the positioning device and a second opening on a second side facing away from the processing side of the positioning device when each mask of the plurality of masks is in the operating position on the mask support, and wherein the method comprises: removing the first mask from the operating position; and placing a second mask of the plurality of masks in the operating position on the mask support, wherein the second opening of the first mask comprises a different shape and/or size than a second opening of the second mask of the plurality of masks. In one or more embodiments of a method according to the second aspect as described herein in which the mask is in an operating position on a mask support, the method comprises moving the first mask to a first storage position on the mask support after removing the first mask from the operating position.

In one or more embodiments of a method according to the second aspect as described herein in which the mask is in an operating position on a mask support, placing the second mask in the operating position on the mask support comprises moving the second mask out of a second storage position on the mask support.

In one or more embodiments of a method according to the second aspect as described herein in which the mask is in an operating position on a mask support, removing the first mask from the operating position and placing the second mask in the operating position comprises rotating the mask support about a support axis, and wherein, optionally, the support axis is in a fixed position relative to the delivery axis.

In one or more embodiments of a method according to the second aspect as described herein, the positioning device comprises a first positioning device of a plurality of positioning devices, and wherein the method comprises moving a second positioning device of the plurality of positioning devices to the processing location after delivering non-contact energy to the exposed portion of the beak of the bird in the first positioning device, wherein a head of a second bird is retained in a head cavity of the second positioning device, and wherein a first portion of the beak of the second bird extends through the beak aperture on a processing side of the second positioning device.

In a third aspect, one or more embodiments of a poultry beak processing system for processing the beak of a bird as described herein includes: a positioning device configured to retain a head of a bird in a head cavity, wherein the head cavity comprises a beak aperture on a processing side of the positioning device, and wherein the positioning device is in a processing location; a non-contact energy source emitting energy; a mask comprising a mask cavity extending through a mask body between a first opening on a first side facing the processing side of the positioning device and a second opening on a second side facing away from the processing side of the positioning device; a mask actuator operably connected to the mask support, wherein the mask actuator is configured to move the mask between a home position and a masking position, wherein the first opening on the first side of the mask is closer to the processing side of the positioning device when the mask is in the masking position than when the mask is in the home position, and wherein the first opening on the first side of the mask is aligned with the beak aperture when the mask is in the masking position such that a beak of a bird head located in the head cavity extends through the beak aperture into the mask cavity of the mask in the operating position and an exposed portion of a beak of a bird head located in the head cavity extending into the mask cavity of the mask extends out of the mask cavity through the second opening such that energy emitted by the non-contact energy source is incident on the second side of the mask and the exposed portion of the beak; and a controller operably connected to the energy source and the mask actuator, the controller configured to: operate the mask actuator to move the mask from the home position to the masking position, and operate the energy source to emit energy for a selected period of time after operating the mask actuator to move the mask from the home position to the masking position.

In one or more embodiments of a poultry beak processing system according to the third aspect as described herein, the controller is configured to operate the mask actuator to move the mask support from the masking position to the home position after the selected period of time.

In one or more embodiments of a poultry beak processing system according to the third aspect as described herein, the mask is attached to a housing containing the noncontact energy source, and wherein the mask actuator moves the housing when moving the mask between the home position and the masking position.

In one or more embodiments of a poultry beak processing system according to the third aspect as described herein, the energy source is configured such that energy emitted by the energy source is incident on the second side of the mask. In one or more embodiments, the energy source is configured such that energy emitted by the energy source is incident on the second side of the mask when the mask is in the home position and when the mask is in the masking position. In one or more embodiments of a poultry beak processing system according to the third aspect as described herein, the positioning device comprises a first positioning device of a plurality of positioning devices, and wherein the mask in the operating position is configured to be used with each positioning device of the plurality of positioning devices after each positioning device of the plurality of positioning devices is moved into the processing location.

In a fourth aspect, one or more embodiments of a method of adjusting the masking of non-contact energy in the processing of bird beaks includes: selectively replacing a first mask in an operating position on a poultry beak processing system with a second mask selected from a plurality of masks, wherein each mask of the plurality of masks comprises a mask cavity extending through a mask body between a first opening on a first side and a second opening on a second side, wherein the second opening of the mask cavity is smaller than the first opening, and wherein the second opening of a first mask of the plurality of masks comprises a different shape and/or size than the second opening of a second mask; and delivering non-contact energy to the second side of the second mask and an exposed portion of a beak of a bird extending out of the second opening of the second mask.

In one or more embodiments of methods according to the fourth aspect as described herein, the method comprises delivering non-contact energy to a plurality of birds using the second mask.

In one or more embodiments of methods according to the fourth aspect as described herein, replacing the first mask with the second mask comprises moving the second mask from a storage position to the operating position.

In one or more embodiments of methods according to the fourth aspect as described herein, replacing the first mask with the second mask comprises moving the first mask from the operating position to a storage position.

In one or more embodiments of methods according to the fourth aspect as described herein, the first mask and the second mask are attached to a mask support, and wherein replacing the first mask with the second mask comprises rotating the mask support about a support axis. As used herein with respect to the restraint of live birds, the term "atraumatic restraint" (and variations thereof) means restraint that does not require puncturing the skin of the bird to restrain the bird.

As used herein, the term “aligned with” as used in connection with various components, axes, directions of travel, etc. includes both parallel and generally parallel arrangements. For example, two axes may be described as “aligned with” when the axes are both perfectly parallel with each other or nearly parallel, e.g., the axes may form an angle with each other that is greater than 0° but 10° or less.

Numeric values used herein include normal variations in measurements as expected by persons skilled in the art and should be understood to have the same meaning as “approximately” and to cover a typical margin of error, such as ±5 % of the stated value.

Terms such as “a,” “an,” and “the” are not intended to refer to only a singular entity but include the general class of which a specific example may be used for illustration.

The terms “a,” “an,” and “the” are used interchangeably with the term “at least one.” The phrases “at least one of’ and “comprises at least one of’ followed by a list refers to any one of the items in the list and any combination of two or more items in the list.

As used here, the term “or” is generally employed in its usual sense including “and/or” unless the content clearly dictates otherwise. The term “and/or” means one or all of the listed elements or a combination of any two or more of the listed elements.

The words “preferred” and “preferably” refer to embodiments that may afford certain benefits, under certain circumstances. However, other embodiments may also be preferred, under the same or other circumstances. Furthermore, the recitation of one or more preferred embodiments does not imply that other embodiments are not useful and is not intended to exclude other embodiments from the scope of the disclosure, including the claims. BRIEF DESCRIPTION OF THE DRAWING

The views of the drawing depict various features of only some illustrative embodiments of the present invention, with like reference numerals indicating like features in the figures.

FIG. l is a perspective view of one illustrative embodiment of a poultry beak processing system as described herein.

FIG. 2 is a perspective view of the system of FIG. 2 with the shield removed.

FIG. 3 is a left side view of the poultry beak processing system of FIG. 1.

FIG. 4 is an enlarged front view of a portion of the system of FIG. 3 with the head clamp removed.

FIG. 5 is an enlarged bottom perspective view of the poultry beak processing system of FIG. 3.

FIG. 6 is an enlarged view of the masks and mask support depicted in FIG. 4.

FIG. 7 is a front perspective view of one illustrative embodiment of a mask used in the poultry beak processing systems described herein.

FIG. 8 is a rear perspective view of the mask of FIG. 7.

FIG. 9 is a side view of the mask of FIGS. 7-8.

FIG. 10 is a rear view of the mask of FIGS. 7-9.

FIG. 10A is a cross-sectional view of the mask of FIGS. 7-10 taken along line 10A- lOA in FIG. 10.

FIG. 11 is a perspective view of one illustrative embodiment of a poultry cradle including a head positioning device that can be used in connection with the poultry beak processing systems described herein.

FIG. 12 is an enlarged front view of the head positioning device on the poultry cradle depicted in FIG. 11.

FIG. 13 is an enlarged rear view of the head positioning device on the poultry cradle depicted in FIG. 11.

FIG. 14 is an enlarged side view of the head positioning device on the poultry cradle depicted in FIG. 11. FIG. 15 is a side view of one illustrative embodiment of a head positioning device with the head of a bird retained in a head cavity of the head positioning device.

FIG. 16 is a side view of the head positioning device of FIG. 15 with one illustrative embodiment of a mask located against the processing side of the head positioning device of FIG. 15.

FIG. 17 is a side view and FIG. 18 is a bottom perspective view of the poultry beak processing system of FIGS. 1-3 with frame components and the shield removed to expose the mask actuator and associated components used to move a mask support and associated masks between a home position and a masking position as described herein.

FIG. 19 depicts the illustrative embodiment of a poultry cradle including a head positioning device as depicted in FIGS. 11-14 in a processing location relative to an energy source and a mask in the home position of one illustrative embodiment of a poultry beak processing system as described herein.

FIG. 20 depicts the components of FIG. 19 after movement of the mask to the masking position.

FIG. 21 is a schematic diagram of components in one illustrative embodiment of a poultry beak processing system as described herein.

While the above-identified figures (which may or may not be drawn to scale) set forth embodiments of the invention, other embodiments are also contemplated, as noted in the discussion. In all cases, this disclosure presents the invention by way of representation and not limitation. It should be understood that numerous other modifications and embodiments can be devised by those skilled in the art, which fall within the scope of this invention.

DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

Before any illustrative embodiments are described in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the figures of the drawing. The invention is capable of other embodiments and of being practiced or of being carried out in various ways.

One illustrative embodiment of a poultry beak processing system as described herein is depicted in FIGS. 1-3, where FIG. 1 is a perspective view of the illustrative embodiment of the poultry beak processing system 10, FIG. 2 is a perspective view of the system 10 with the shield 13 removed, and FIG. 3 is a left side view of the system as depicted in FIG. 2 (i.e., with the shield 13 removed).

The poultry beak processing system 10 includes a non-contact energy source 20 configured to emit energy used to process poultry beaks as described herein. The energy source 20 is located within a housing 22 that includes an aperture 24 through which energy emitted by the energy source 20 is delivered to the beak of a bird as described herein. Shield 13 may be provided to limit the distribution of any stray energy emitted from energy source 20 during use of the beak processing system 10.

The non-contact energy source preferably emits electromagnetic energy useful for processing beaks of birds. One nonlimiting example of a suitable bulb that may be used in the non-contact energy sources of the poultry beak processing systems described herein is a bulb emitting electromagnetic energy in, e.g., the infrared spectrum from 700 nanometers to 1 millimeter, although a variety of energy emitting bulbs may be used.

As used herein, “electromagnetic energy” includes energy with wavelengths/frequencies suitable for delivering sufficient energy by radiation to the beak of a bird to effect thermal beak processing as discussed herein.

In addition to the energy source 20, the depicted illustrative embodiment of beak processing system 10 includes masks 30 used to mask the beaks of poultry located in a processing location relative to the beak processing system 10. The depicted illustrative embodiment of the processing system 10 further includes an optional bird head clamp 14 mounted on arm 15. The bird head clamp 14 is used to urge the head of a bird retained in the processing location in front of mask 32. In the depicted illustrative embodiment, the processing location may be defined as the volume or location located between the masks 30 and the bird head clamp 14 as depicted in, e.g., FIGS. 2, 3, and5. In the illustrative embodiment of beak processing system 10, the energy source 20 and the mask assembly (including mask support 40 and masks 30) are mounted on a mask carriage 50. In one or more embodiments, the mask carriage 50 attached to fixed frame 12 and configured for rotation (relative to the fixed frame 12) about a mask axis 31 between a home position and a masking position as described herein.

The mask assembly including masks 30 and mask support 40 are depicted in an enlarged view in FIG. 4. The depicted embodiment of the mask assembly includes a pair of masks 32 and 32’, both of which are mounted on mask support 40. With reference to, for example, FIGS. 3-6, mask 32 is located in an operating position of the beak processing system 10 such that the mask 32 is positioned directly in front of the aperture 24 of energy source 20 (see, for example, FIG. 5) such that energy emitted by the energy source 20 through aperture 24 is directed at the mask 32 in the operating position.

Mask 32’ is located in a storage position relative to mask 32 which is in the operating position. In the storage position, the mask 32’ is available for use in the beak processing system 10 as described herein but is not active in masking the beaks of any birds when in the stores position.

The depicted illustrative embodiment of mask support 40 is configured for use with up to three masks although only two masks 30 are depicted in the illustrative embodiment of FIGS. 1-4. In particular, mask support 40 defines a set of positions 42,44, and 46 arrayed radially on the support 40.

The depicted illustrative embodiment of mask support 40 is configured for rotation about a support axis 41 to move masks within any one of the positions 42, 44, and 46 (when a mask is present in position 46) to the operating position located directly in front of aperture 24 of energy source 20. Although mask support 40 includes positions for up to three masks, alternative embodiments include positions for only two masks or four or more masks. Although mask support 40 is configured for rotation to move masks 30 into and out of the operating and storage positions, alternative embodiments of mask supports that may be used in poultry beak processing systems as described herein may move masks in translation and/or a combination of translation and rotation as needed to properly locate a mask in the operating position as described herein.

In one or more alternative embodiments mask support 40 may be configured to accept only a single mask held in the operating position with the mask being removed from the mask support and replaced with a different mask as desired. In embodiments in which mask support 40 is configured to receive only a single mask, it should be understood that the housing 22 of the energy source 20 may effectively function as the mask support. In other words, a separate article may not be required in systems where only a single mask is attached to the system in the operating position at any given time.

With reference to FIGS. 6- 10 A, one illustrative embodiment of masks that may be used in the poultry beak processing systems described herein may be described in more detail (noting that the depicted masks 32 and 32’ are configured for use with ducks). With reference to mask 32, the mask 32 includes a mask cavity 35 extending through a mask body between a first opening 34 located on a first side 33 of the mask 32 and extending to a second opening 36 located on a second side 37. The second opening 36 on the second side 37 of the mask 32 is smaller than the first opening 34 and, as will be described herein, also smaller than a beak aperture of a positioning device used to properly position a beak of a bird in a mask found in the operating position of the beak processing systems as described herein.

Mask 32’ as seen in FIG. 6 also includes a mask cavity 35’ extending between a first opening 34’ and a second opening 36’ on the second side of the mask 32’. Among the differences between masks 32 and 32’ is the size of the second openings 36 and 36’, noting that the second opening 36’ of mask 32’ is smaller than the second opening 36 of mask 32. In one or more alternative embodiments, the shapes of the second openings may also differ in any pair of masks used in connection with a beak processing system as described herein.

Differences between the size and/or shape of the second openings on masks used in the poultry beak processing systems described herein provide the user with the ability to tailor or adjust the portion of a beak exposed to energy emitted from aperture 24 of energy source 20 as described herein. For example, using mask 32 with its larger second opening 36 when processing a bird from a species or flock with a smaller beak may result in an excessive amount of the smaller beak being exposed to energy emitted through aperture 24 of energy source 20. Alternatively, using mask 32’ with its smaller second opening 36 when processing a bird from a species or flock with a larger beak may result in an insufficient amount of the larger beak being exposed to energy emitted through aperture 24 of energy source 20.

The masks 30 depicted in connection with the beak processing system 10 are configured for use with a positioning device configured to retain a head of a bird in a head cavity, with the head cavity having a beak aperture on a processing side of the positioning device such that a portion of the beak of a bird having its head retained in the head cavity is available for processing using non-contact energy as described herein.

Figures 11-14 depict one illustrative embodiment of a poultry cradle CIO that may be used to position birds in a processing location of the poultry beak processing systems described herein. Various features of one or more embodiments of the poultry cradle CIO may be further described in the U.S. Provisional Application titled POULTRY CRADLES AND METHODS OF RESTRAINING POULTRY filed on even date herewith in the name of Applicant Nova-Tech Engineering, LLC (Attorney Docket No. 0294.000062US60) and/or in the U.S. Provisional Application titled POULTRY CRADLE UNLOADING SYSTEMS AND METHODS filed on even date herewith in the name of Applicant Nova-Tech Engineering, LLC (Attorney Docket No. 0294.000073US60).

The depicted poultry cradle CIO includes a torso support C40, a shank/leg control apparatus C50 located at one end of the torso support C40, and a positioning device C70 located at the opposite end of the torso support C40. The various components may be operably attached in a manner that provides for atraumatic restraint of a bird positioned in the poultry cradle CIO.

The torso support C40 is preferably shaped to generally follow the anatomical shape of the torso of a bird located in the poultry cradle CIO such that the torso of the bird is generally evenly supported. As a result, the shape of the torso support C40 may be different depending on the breed, age, gender, etc. of the birds that are to be restrained in the poultry cradle CIO.

The optional shank/leg control apparatus C50 is provided and positioned to restrain the shanks/legs of a bird having its torso supported by the torso support C40.

The poultry cradles CIO also include a positioning device C70 positioned to support and retain the head of a bird located in the poultry cradle CIO. The positioning device C70 includes a first side facing the head of a bird retained in the poultry cradle CIO and a processing side C76 on the opposite side of the positioning device C70. The positioning device C70 also includes a head cavity C72 extending through the positioning device C70 to a beak aperture C73 on the processing side C76 of the positioning device C70. The head cavity C72 extends through the positioning device C70 such that a portion of the beak of a bird with its head retained in the head cavity C72 extends through the beak aperture C73 and is exposed proximate the processing side C76 of the positioning device C70.

The depicted illustrative embodiment of positioning device C70 includes head clamps C74 movable between an open configuration and a closed configuration. In the open configuration, each head clamp C74 is positioned such that the head of a bird can be positioned in the head cavity C72 as described herein. In the closed configuration, the head clamps 74 function to retain the head of the bird in the head cavity C72 such that at least a portion of the beak extends out of the head cavity C72 through beak aperture C73 on the processing side C76 of the positioning device C70. The head clamps C74 may rotate about head clamp axes C71 when moving between their open and closed configurations.

FIG. 15 is a side view of one illustrative embodiment of a head positioning device C70 with the head 60 of a bird retained in a head cavity of the head positioning device C70. When the head 60 of the bird is retained in the head cavity of the head positioning device C70, a first portion 64 of the beak 62 extends through the beak aperture in the head positioning device C70 such that the first portion 64 of the beak 62 is exposed on the processing side C76 of the head positioning device C70. FIG. 16 is a side view of the head positioning device C70 of FIG. 15 with the illustrative embodiment of mask 32 located against the processing side C76 of the head positioning device C70. One positioned as depicted in FIG. 16, the mask 32 can be described as being in a masking position proximate the processing side C76 of the positioning device C70.

With the mask in the masking position proximate the processing side C76 of the positioning device C70, the first portion 64 of the beak 62 of the bird 60 is located within and extends out of a mask cavity 35 in the mask 32. As a result, a masked portion of the first portion 64 of the beak 62 of the bird 60 is located within the mask cavity 35 and an exposed portion 66 of the first portion 64 of the beak 62 extends out of the second opening of the mask cavity in mask 32 when the mask is in the masking position as depicted in FIG. 16. Non-contact energy emitted by, e.g., energy source 20 through its aperture 24, and directed at the second side 37 of the mask 32 is prevented (i.e., masked) from reaching the masked portion of the first portion 64 of the beak 62 of the bird 60 located within the mask cavity 35. That energy is, however, capable of reaching the exposed portion 66 of the first portion 64 of the beak 62 for processing of the beak tissue in that exposed portion 66.

One or more embodiments of the poultry beak processing systems described herein may include a mask actuator operably connected to the mask support (and the masks attached to thereto), with the mask actuator being configured to move the mask support and masks from a home position to a masking position.

In connection with the illustrative embodiment of poultry beak processing system 10, FIGS. 17-18 depict one illustrative embodiment of a mask actuator and associated components used to move the mask support 40 (and masks 30) between a home position and a masking position. It should be understood that in FIGS. 1-3 as well as FIGS. 17-18 the mask support 40 and associated masks are in the masking position.

The mask actuator is, in the depicted embodiment, obscured from view within a shuttle 52 configured to move along rails 53 that extend between a pair of rail supports 54. Mask actuator is, in the depicted embodiment, in the form of a pneumatic cylinder damped to control the rate at which the shuttle 52 moves along rails 53 between the rail supports 54. In the depicted embodiment rail supports 54 are fixedly attached to a frame member 16 which is, in turn, attached to frame members 12 as seen in, for example, FIGS. 1-3.

Movement of shuttle 52 along rails 53 between rail supports 54 is transferred to mask carriage 50 through fork 56 that mates with crossbar 57 extending between the members of mask carriage 50 (see, e.g., FIG. 18). That movement of the shuttle 52 along rails 53 causes mask carriage 50 to rotate about mask axis 31. Rotation of the mask carriage 50 about mask axis 31 moves the mask support between its home position and its masking position as described herein. Although the depicted illustrative embodiment of beak processing system 10 uses rotational motion to move the mask support and associated masks between their home and masking positions, one or more alternative embodiments of beak processing systems as described herein may involve movement of the mask support and associated masks in translational motion or any other combination of rotation and translation suitable for any given system.

Although the depicted embodiment of mask actuator may take the form of a pneumatic cylinder, examples of other potentially useful actuators include, but are not limited to, a piston/cylinder operated hydraulically, using a solenoid, etc., a motor with or without a gear assembly (e.g., a rack and pinion, etc.), magnetic/electromagnetic linear actuators, rotary actuators (e.g., pneumatic actuators, magnetic/electromagnetic actuators, etc.), etc.

Although FIGS. 1-3 and 17-18 depict the mask support and associated masks in the masking position, FIGS. 19-20 are provided to illustrate movement of the mask support and associated masks from the home position to the masking position in one or more embodiments of poultry beak processing systems as described herein.

In particular, FIG. 19 depicts the mask support 40 along with mask 32 in the home position relative to the positioning device C70 of cradle CIO located in a processing location relative to the poultry beak processing system 10 overall. As discussed herein, in the depicted illustrative embodiment the mask support 40 with mask 32 located thereon is attached to housing 22 of energy source 20. Housing 22 of energy source 20 is, in turn, attached to mask carriage 50 which rotates about mask axis 31 as described herein. As depicted in FIG. 19, the first side 33 of mask 32 is spaced apart from the processing side C76 of the positioning device C70.

Figure 20 depicts the mask support 40 along with mask 32 after rotation of the mask carriage 50 about mask axis 31 as described herein. That movement of the mask support and associated mask from the home position of FIG. 19 to the masking position of FIG. 20 positions the mask closer to the processing side C76 of the positioning device C70 than when the mask support 40 and associated mask 32 are in the home position as seen in FIG. 19.

Movement of the mask 32 from the home position as seen in FIG. 19 to the masking position as seen in FIG. 20 moves a beak of a bird extending out of the processing side C76 of the positioning device C70 into the mask cavity of the mask 32 such that a masked portion of the first portion of the beak of the bird is located within the mask cavity of mask 32 and an exposed portion of the first portion of the beak extends out of the mask cavity as described herein in connection with, e.g., FIGS. 15-16. The first opening on the first side 33 of the mask 32 in the operating position on mask support 40 is closer to the processing side C76 of the positioning device C70 when the mask support 40 (and associated mask 32) is in the masking position as depicted in FIG. 20 than when the mask support 40 (and associated mask 32) is in the home position as depicted in FIG. 19.

FIG. 21 is a schematic diagram of components that may be found in one illustrative embodiment of a poultry beak processing system as described herein. The depicted system includes a controller 100 operably connected to a non-contact energy source 120 and a mask actuator 152.

The mask actuator 152 is operably connected to a mask/mask support 130/140 of the poultry beak processing systems described herein. As described herein, the mask actuator 152 is used to move the masks/mask supports between their home and masking positions as described herein and the controller 100 is operably connected to the mask actuator 152 to operate the mask actuator 152 to move the masks/mask supports between their home and masking positions. The controller 100 may, in one or more embodiments, be configured to operate the energy source 122 emit energy for a selected period of time after, for example, operating the mask actuator 152 to move a mask/mask support 130/140 from a home position to a masking position. In one or more embodiments, the controller 100 may also be configured to operate the mask actuator 152 to move the masks/mask supports 130/140 from their masking positions to their home positions after emitting energy for the selected period of time.

The controller 100 may be provided in any suitable form and may, for example, include memory and a controller. The controller may, for example, be in the form of one or more microprocessors, Field-Programmable Gate Arrays (FPGA), Digital Signal Processors (DSP), microcontrollers, Application Specific Integrated Circuit (ASIC) state machines, etc. The controllers may include one or more of any suitable input devices configured to allow a user to operate the poultry beak processing systems described herein (e.g., keyboards, touchscreens, mice, trackballs, etc.), as well as display devices configured to convey information to a user (e.g., monitors (which may or may not be touchscreens), indicator lights, etc.). Although not depicted separately, the controller 100 may incorporate a pneumatic and/or hydraulic control system in those systems in which one or more of the actuators use pneumatic and/or hydraulic components (such as, for example, the embodiment of the poultry beak processing system described herein).

All references, applications, and publications cited herein are expressly incorporated herein by reference in their entirety into this disclosure, except to the extent they may directly contradict this disclosure. Although specific illustrative embodiments have been described herein, it will be appreciated by those of ordinary skill in the art that a variety of alternate and/or equivalent implementations can be substituted for the specific embodiments shown and described without departing from the scope of the present disclosure. It should be understood that this disclosure is not intended to be unduly limited by the illustrative embodiments and examples set forth herein and that such examples and embodiments are presented by way of example only with the scope of the disclosure intended to be limited only by the claims.

Claims

CLAIMS WHAT IS CLAIMED IS:

1. A poultry beak processing system for processing the beak of a bird, the system comprising: a positioning device configured to retain a head of a bird in a head cavity, wherein the head cavity comprises a beak aperture on a processing side of the positioning device, and wherein the positioning device is in a processing location; a non-contact energy source emitting energy; a mask comprising a mask cavity extending through a mask body between a first opening on a first side facing the processing side of the positioning device and a second opening on a second side facing away from the processing side of the positioning device; a mask actuator operably connected to the mask support, wherein the mask actuator is configured to move the mask between a home position and a masking position, wherein the first opening on the first side of the mask is closer to the processing side of the positioning device when the mask is in the masking position than when the mask is in the home position, and wherein the first opening on the first side of the mask is aligned with the beak aperture when the mask is in the masking position such that a beak of a bird head located in the head cavity extends through the beak aperture into the mask cavity of the mask in the operating position and an exposed portion of a beak of a bird head located in the head cavity extending into the mask cavity of the mask extends out of the mask cavity through the second opening such that energy emitted by the non-contact energy source is incident on the second side of the mask and the exposed portion of the beak; and a controller operably connected to the energy source and the mask actuator, the controller configured to: operate the mask actuator to move the mask from the home position to the masking position, and

22 operate the energy source to emit energy for a selected period of time after operating the mask actuator to move the mask from the home position to the masking position.

2. A system according to claim 1, wherein the controller is configured to operate the mask actuator to move the mask support from the masking position to the home position after the selected period of time.

3. A system according to any one of the preceding claims, wherein the mask is attached to a housing containing the non-contact energy source, and wherein the mask actuator moves the housing when moving the mask between the home position and the masking position.

4. A system according to any one of the preceding claims, wherein the energy source is configured such that energy emitted by the energy source is incident on the second side of the mask.

5. A system according to claim 4, wherein the energy source is configured such that energy emitted by the energy source is incident on the second side of the mask when the mask is in the home position and when the mask is in the masking position.

6. A system according to any one of the preceding claims, wherein the positioning device comprises a first positioning device of a plurality of positioning devices, and wherein the mask in the operating position is configured to be used with each positioning device of the plurality of positioning devices after each positioning device of the plurality of positioning devices is moved into the processing location.

7. A poultry beak processing system for processing the beak of a bird, the system comprising: a positioning device configured to retain a head of a bird in a head cavity, wherein the head cavity comprises a beak aperture on a processing side of the positioning device, and wherein the positioning device is in a processing location; a non-contact energy source emitting energy; a plurality of masks, wherein each mask of the plurality of masks comprises a mask cavity extending through a mask body between a first opening on a first side facing the processing side of the positioning device and a second opening on a second side facing away from the processing side of the positioning device, wherein the second opening of the mask cavity of the mask in the operating position is smaller than the beak aperture of the positioning device, and wherein the second opening of a first mask of the plurality of masks comprises a different shape and/or size than the second opening of a second mask of the plurality of masks; a mask support, wherein the plurality of masks are attached to the mask support, wherein the mask support comprises an operating position and a storage position, and wherein, when each mask of the plurality of masks is in the operating position: the first opening on the first side of the mask in the operating position is aligned with the beak aperture such that a beak of a bird head located in the head cavity extends through the beak aperture into the mask cavity of the mask in the operating position, and an exposed portion of a beak of a bird head located in the head cavity extending into the mask cavity of the mask in the operating position extends out of the mask cavity through the second opening such that energy emitted by the non-contact energy source is incident on the second side of the mask in the operating position and the exposed portion of the beak; optionally, a mask actuator operably connected to the mask support, wherein the mask actuator is configured to move the mask support between a home position and a masking position, wherein the first opening on the first side of the mask in the operating position is closer to the processing side of the positioning device when the mask support is in the masking position than when the mask support is in the home position; and optionally, a controller operably connected to the energy source and the mask actuator, the controller configured to: operate the mask actuator to move the mask support from the home position to the masking position, and operate the energy source to emit energy for a selected period of time after operating the mask actuator to move the mask support from the home position to the masking position.

8. A system according to claim 7, wherein the second opening of the first mask comprises a shape that is the same as the second opening of the second mask.

9. A system according to claim 7, wherein the second opening of the first mask and the second opening of the second mask are the same size.

10. A system according to claim 7, wherein the second opening of the first mask comprises a shape and size that are the same as the second opening of the second mask.

11. A system according to any one of claims 7 to 10, wherein the mask support comprises a platform configured to move each mask of the plurality of masks into the operating position from the storage position.

12. A system according to claim 11, wherein the platform comprises a rotating platform configured to rotate each mask of the plurality of masks into the operating position from the storage position.

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13. A system according to any one of claims 7 to 12, wherein the controller is configured to operate the mask actuator to move the mask support from the masking position to the home position after the selected period of time.

14. A system according to any one of claims 7 to 13, wherein the mask support and the plurality of masks are attached to a housing containing the non-contact energy source, and wherein the mask actuator moves the housing when moving the mask support between the home position and the masking position.

15. A system according to any one of claims 7 to 14, wherein the energy source is configured such that energy emitted by the energy source is incident on the second side of the mask in the operating position.

16. A system according to claim 15, wherein the energy source is configured such that energy emitted by the energy source is incident on the second side of the mask in the operating position when the mask support is in the home position and when the mask support is in the masking position.

17. A system according to any one of claims 7 to 16, wherein only one mask of the plurality of masks is in the operating position at any given time.

18. A system according to any one of claims 7 to 17, wherein the positioning device comprises a first positioning device of a plurality of positioning devices, and wherein the mask in the operating position is configured to be used with each positioning device of the plurality of positioning devices after each positioning device of the plurality of positioning devices is moved into the processing location.

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19. A method of processing the beak of a bird restrained in a processing location, the method comprising: moving a positioning device to a processing location, wherein a head of a bird is retained in a head cavity of the positioning device, and wherein a first portion of the beak of the bird extends through a beak aperture on a processing side of the positioning device; moving a mask from a home position to a masking position, wherein the mask comprises a mask cavity extending through a mask body between a first opening on a first side facing the processing side of the positioning device and a second opening on a second side facing away from the processing side of the positioning device, wherein moving the mask from the home position to the masking position moves the beak into the mask cavity such that a masked portion of the first portion of the beak of the bird is located within the mask cavity and an exposed portion of the first portion of the beak extends out of the second opening of the mask cavity when the mask is in the masking position; and delivering non-contact energy to the exposed portion of the beak of the bird after moving the mask from the home position to the masking position.

20. A method according to claim 19, wherein moving the mask from the home position to the masking position comprises rotating the mask about a mask axis.

21. A method according to any one of claims 19 to 20, wherein the non-contact energy delivered to the exposed portion of the beak is incident on the second side of the mask when the mask is in the home position and when the mask is in the masking position.

22. A method according to any one of claims 19 to 21, wherein delivering non-contact energy to the exposed portion of the beak comprises delivering the non-contact energy for a selected time period after moving the mask from the home position to the masking position.

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23. A method according to claim 22, wherein the method comprises moving the mask from the masking position to the home position after the selected time period.

24. A method according to any one of claims 19 to 23, wherein the second opening of the mask cavity is smaller than the beak aperture of the positioning device.

25. A method according to any one of claims 19 to 24, wherein the mask is in an operating position on the mask support, wherein the mask comprises a first mask of a plurality of masks, wherein each mask of the plurality of masks comprises a mask cavity extending through a mask body between a first opening on a first side facing the processing side of the positioning device and a second opening on a second side facing away from the processing side of the positioning device when each mask of the plurality of masks is in the operating position on the mask support, and wherein the method comprises: removing the first mask from the operating position; and placing a second mask of the plurality of masks in the operating position on the mask support, wherein the second opening of the first mask comprises a different shape and/or size than a second opening of the second mask of the plurality of masks.

26. A method according to claim 25, wherein the method comprises moving the first mask to a first storage position on the mask support after removing the first mask from the operating position.

27. A method according to any one of claims 25 to 26, wherein placing the second mask in the operating position on the mask support comprises moving the second mask out of a second storage position on the mask support.

28. A method according to any one of claims 25 to 27, wherein removing the first mask from the operating position and placing the second mask in the operating position

28 comprises rotating the mask support about a support axis, and wherein, optionally, the support axis is in a fixed position relative to the delivery axis.

29. A method according to any one of claims 19 to 29, wherein the positioning device comprises a first positioning device of a plurality of positioning devices, and wherein the method comprises moving a second positioning device of the plurality of positioning devices to the processing location after delivering non-contact energy to the exposed portion of the beak of the bird in the first positioning device, wherein a head of a second bird is retained in a head cavity of the second positioning device, and wherein a first portion of the beak of the second bird extends through the beak aperture on a processing side of the second positioning device.

30. A method of adjusting the masking of non-contact energy in the processing of bird beaks, the method comprising: selectively replacing a first mask in an operating position on a poultry beak processing system with a second mask selected from a plurality of masks, wherein each mask of the plurality of masks comprises a mask cavity extending through a mask body between a first opening on a first side and a second opening on a second side, wherein the second opening of the mask cavity is smaller than the first opening, and wherein the second opening of a first mask of the plurality of masks comprises a different shape and/or size than the second opening of a second mask; and delivering non-contact energy to the second side of the second mask and an exposed portion of a beak of a bird extending out of the second opening of the second mask.

31. A method according to claim 30, wherein the method comprises delivering noncontact energy to a plurality of birds using the second mask.

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32. A method according to any one of claims 30 to 31, wherein replacing the first mask with the second mask comprises moving the second mask from a storage position to the operating position.

33. A method according to any one of claims 30 to 32, wherein replacing the first mask with the second mask comprises moving the first mask from the operating position to a storage position.

34. A method according to any one of claims 30 to 33, wherein the first mask and the second mask are attached to a mask support, and wherein replacing the first mask with the second mask comprises rotating the mask support about a support axis.

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