Modular instantaneous high-voltage electric shock daze automatic production line for small crayfish

Abstract

This invention discloses a modular, instantaneous high-voltage electric stunning automatic production line for crayfish, aiming to overcome the shortcomings of existing water bath electric shock technology and achieve integrated operation of crayfish cleaning and instantaneous electric stunning. The production line includes a crayfish cleaning mechanism, a plastic tunnel, several electrodes, a lift, and a high-voltage pulse generator. The plastic tunnel is fixed in the front-middle section of the crayfish cleaning mechanism's inner cavity. Several electrodes are equidistantly fixed to the inner sidewall of the plastic tunnel. The lift is located at the feeding port on the front side of the crayfish cleaning mechanism. The high-voltage pulse generator is located on the sidewall of the crayfish cleaning mechanism and is compatible with the electrodes. The crayfish cleaning mechanism includes a water tank support, a water tank, an inclined chain conveyor, a circulating water pump, a water supply pipe, a mesh plate, and rotating rollers. These components work together to achieve automatic feeding, cleaning, instantaneous electric stunning, and transfer of live crayfish. The high-voltage pulse generator contains a capacitor-stored pulse power supply, which, together with the electrodes, forms an instantaneous high-voltage electric field, reducing damage to the crayfish. The production line adopts a modular design, facilitating inspection and maintenance, adapting to large-scale processing, and balancing animal welfare and product quality.

Description

Technical Field

[0001] This invention relates to the field of crayfish production line technology, specifically to a modular automatic production line for instantaneous high-voltage electric stunning of crayfish. Background Technology

[0002] Crayfish, scientifically known as *Procambarus clarkii*, is an important freshwater farmed shrimp species in my country, beloved by consumers for its delicious meat and rich nutritional value. In recent years, with the continued boom in the crayfish market, the crayfish processing industry has experienced rapid development, and market demand for high-quality crayfish products is constantly increasing.

[0003] In existing technologies, the traditional crayfish processing technology is relatively simple, mainly including the following steps: First, the live crayfish are cleaned to remove impurities such as mud, dirt, and algae from the surface of the crayfish; then, they are directly blanched (also known as scalding or pre-cooking) to denature the crayfish protein through high temperature, thereby reducing the initial bacterial colony, fixing the color, and making it easier for subsequent processing; finally, deep processing such as shelling, seasoning, and packaging is carried out according to product requirements.

[0004] However, this traditional processing method causes a severe stress response when live shrimp are subjected to sudden high temperatures directly from the cleaning stage to the blanching stage. This manifests as violent struggling, a surge in the secretion of stress hormones (such as cortisol and adrenaline), and a dramatic change in metabolic rate. These stress responses negatively impact the taste and quality of the shrimp meat in several ways, primarily in the following aspects:

[0005] First, the shrimp meat becomes tough. Specifically, stress can cause muscle fiber contraction and degeneration, and excessive protein denaturation can cause the shrimp meat to lose its elasticity, resulting in a tough and dry texture that affects its edibility.

[0006] Second, the loss of umami substances. Specifically, stress response accelerates the decomposition and metabolism of umami substances such as flavor amino acids and nucleotides in shrimp, leading to a reduction in the umami flavor of shrimp meat.

[0007] Third, product yield decreases. Specifically, stress causes shrimp to lose water, resulting in shrinkage and deformation of the shrimp meat, leading to increased weight loss and impacting the company's economic benefits.

[0008] Meanwhile, due to the animal welfare policy requirements of countries in Europe and the United States (such as Norway, New Zealand, Australia, as well as Germany and Italy), products that are processed without meeting animal welfare policy requirements will be subject to export restrictions, affecting the export trade of crayfish.

[0009] To address these issues, the industry has attempted several methods to reduce the stress response of crayfish, such as cooling them with ice water before scalding or using anesthetics. However, these methods all have their limitations. Cooling with ice water is cumbersome, inefficient, and results in uneven cooling; using anesthetics may pose food safety risks and does not align with consumers' pursuit of natural and healthy food.

[0010] Furthermore, traditional constant-current electroshock techniques for stunning shrimp also have some shortcomings. Constant-current electroshock equipment is typically bulky, consumes a lot of power, and its current parameters are difficult to control precisely, easily causing localized over-electric damage or even death in shrimp, resulting in a high defect rate. At the same time, the processing efficiency of constant-current electroshock equipment is relatively low, making it difficult to meet the needs of large-scale industrial production.

[0011] In addition, existing cleaning equipment and electrocution treatment equipment are usually operated independently, requiring additional conveying equipment and manual operation, which not only increases equipment investment and floor space, but also reduces production efficiency and increases labor intensity.

[0012] Therefore, there is an urgent need to develop a new crayfish processing technology and equipment to effectively solve the stress response problem in traditional processes, while achieving efficient and automated production operations. Summary of the Invention

[0013] The purpose of this invention is to provide a modular, instantaneous high-voltage electric stunning automated production line for crayfish, addressing the shortcomings mentioned in the background technology. Specifically, it solves the problems of existing water bath frequency electric shock technology, which suffers from severe meat damage, uneven stunning, uncontrollable parameters, and an inability to balance animal welfare and product quality, as well as a lack of adaptability to large-scale automated crayfish processing production lines. To overcome these shortcomings, this technical solution adopts a modular design, integrating crayfish cleaning and instantaneous high-voltage electric stunning into a single operation. The specific details are as follows:

[0014] The system includes a crayfish cleaning mechanism, a plastic tunnel fixed in the front middle section of the inner cavity of the crayfish cleaning mechanism, and several electrodes fixed at equal intervals on the inner sidewall of the plastic tunnel. A hoist is installed at the front feeding port of the crayfish cleaning mechanism, and a high-voltage pulse generator adapted to the electrodes is installed on the left sidewall of the crayfish cleaning mechanism. The plastic tunnel serves as the core electric shock area to guide the crayfish through in an orderly manner. The several electrodes form an electric field that works with the high-voltage pulse generator to achieve instantaneous high-voltage electric stun. The hoist enables automatic feeding of live crayfish and improves the level of automation in the operation.

[0015] The crayfish cleaning mechanism includes a water tank support, a water tank fixed inside the support, and an inclined chain conveyor fixed to the rear of the water tank. A circulating water pump is fixed to the bottom of the rear of the support. Several water supply pipes are installed at the bottom of the inner cavity of the water tank. A mesh plate is laid in the middle layer of the inner cavity of the water tank. An array of rotating rollers is rotatably arranged in the inner cavity of the water tank. The support supports the water tank, which serves as the space for cleaning and electrocution. The inclined chain conveyor transports the processed crayfish. The circulating water pump and water supply pipes work together to create a flowing water flow to improve the cleaning effect. The mesh plate carries the crayfish and filters impurities. The rotating rollers drive the crayfish to move in an orderly manner to achieve thorough cleaning.

[0016] Preferred solution: The high-voltage pulse generator is internally equipped with a capacitor-type pulse power supply that provides pulse current to the electrodes; this power supply replaces the traditional power frequency power supply, generates high-frequency high-voltage pulse current that penetrates the crayfish's nervous system to achieve instantaneous coma, reduces muscle spasms and damage to the crayfish shell and muscles, and the pulse parameters can be adjusted according to the crayfish's size and physiological state to solve the problem of uncontrollable parameters.

[0017] Preferred solution: The top of the right side wall of the water tank is provided with multiple overflow ports, and each overflow port is equipped with a filter screen; the overflow ports discharge excess water to prevent overflow, and the filter screen filters impurities, reduces environmental impact and reduces the risk of clogging.

[0018] A preferred solution is that multiple drain ports are installed at equal intervals at the bottom of the water tank; the drain ports regularly discharge impurities and wastewater to ensure the cleanliness of the water in the tank and improve the cleaning quality.

[0019] Preferred solution: The pumping end of the circulating water pump is connected to the tap water pipe, and the port of the water supply pipe that extends to the outside of the water tank is interconnected and connected to the drain end of the circulating water pump; this structure realizes the circulation and replenishment of tap water and uniform spraying, ensuring sufficient water supply and reducing water quality deterioration.

[0020] Preferred solution: The elevator is used to transport live shrimp into the tank, and the inclined chain conveyor is used to transport the washed and stunned crayfish from the tank to the next process; the two work together to achieve fully automated transfer of crayfish throughout the process, connecting processing links and improving work efficiency.

[0021] A preferred embodiment: Multiple bearings adapted to rotate at both ends of the rotating rollers are embedded on both sides of the water tank; a sprocket is installed on the right end of each rotating roller; and a transmission chain is set between the sprockets; the bearings support the rotation of the rotating rollers and reduce friction; the sprockets and the transmission chain cooperate to achieve synchronous rotation of the rotating rollers and ensure consistent conveying.

[0022] A preferred embodiment: A motor is fixed to the front right side of the water tank, and the output shaft of the motor is connected to the right end of the foremost rotating roller. A housing is fixed to the right side wall of the water tank to cover the motor, transmission chain and sprocket. The motor provides power to the rotating roller, and the housing protects the relevant components and reduces failure and safety risks.

[0023] Preferred solution: A control cabinet is installed on the side wall of the water tank; the control cabinet integrates a PLC control unit and a human-machine interface to realize the linkage of the whole line, can automatically switch the power supply status according to whether the shrimp are present, display relevant parameters in real time, and is equipped with a safety interlock device to ensure the safety of operation.

[0024] The technical effects and advantages provided by the present invention in the above technical solution are as follows:

[0025] In this technical solution, a lifting machine automatically feeds live shrimp, and an inclined chain conveyor connects to the next processing step to transfer the processed crayfish. The two work together to replace manual operation, improving work efficiency and adapting to large-scale processing scenarios. A circulating water pump delivers tap water to the water supply pipe, forming a uniform water flow. This, combined with rotating rollers moving the crayfish and a mesh screen for filtration, ensures thorough cleaning of the crayfish. An overflow outlet discharges excess water, and a wastewater discharge port removes impurities, guaranteeing both cleaning effectiveness and water quality. A high-voltage pulse generator provides pulsed current, which, together with several electrodes, forms a uniform instantaneous high-voltage electric field, instantly stunning the crayfish, reducing muscle spasms, shell breakage, and muscle fiber damage, improving product quality, and considering animal welfare. This effectively addresses the shortcomings of existing water bath electroshock technology. Attached Figure Description

[0026] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments recorded in this invention. For those skilled in the art, other drawings can be obtained based on these drawings.

[0027] Figure 1 Schematic diagram of a crayfish cleaning and stunning production line;

[0028] Figure 2 This is a schematic diagram of an electric shock tunnel;

[0029] Figure 3 This is an exploded view of the cleaning mechanism;

[0030] Figure 4 This is a partial schematic diagram of the cleaning mechanism.

[0031] Appendix Figure 1 - Appendix Figure 4 Explanation of the markings in the text:

[0032] 1. Lobster cleaning mechanism; 1-1. Water tank; 1-2. Water tank support; 1-3. Overflow outlet; 1-4. Mesh plate; 1-5. Water supply pipe; 1-6. Rotary roller; 1-7. Inclined chain conveyor; 1-8. Circulating water pump; 1-9. Outer shell; 1-10. Drive chain; 1-11. Electric motor; 2. High-voltage pulse generator; 3. Plastic tunnel; 4. Elevator; 5. Electrode. Detailed Implementation

[0033] To provide a clearer explanation and illustration of the technical solutions and implementation methods of the present invention, several preferred specific embodiments for implementing the technical solutions of the present invention are described below. The following description is merely exemplary and not intended to limit the scope, application, or use of this disclosure. It should be understood that in all these drawings, the same or similar reference numerals indicate the same or similar parts and features. The various drawings only schematically illustrate the concept and principle of the embodiments of the present disclosure and do not necessarily show the specific dimensions and proportions of the various embodiments of the present disclosure. The technical solutions of the present invention will be clearly and completely described below in conjunction with the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention.

[0034] This embodiment is a modular, instantaneous high-voltage electric stunning automatic production line for crayfish. The overall structure adopts a modular assembly, facilitating later inspection, maintenance, and individual module replacement. It is suitable for large-scale crayfish processing and solves technical problems existing in current water bath electric stunning technology, such as meat damage, uneven stunning, and uncontrollable parameters. It also integrates crayfish cleaning and instantaneous high-voltage electric stunning, balancing animal welfare and product quality. The production line includes a crayfish cleaning mechanism 1, with a plastic tunnel 3 fixed to the front-middle section of its inner cavity. The plastic tunnel 3 serves as the core electric stunning area, guiding crayfish through in an orderly manner, reducing crayfish stacking, thereby improving stunning uniformity and reducing crayfish damage rate. Several electrodes 5 are fixed at equal intervals to the inner sidewall of the plastic tunnel 3, evenly distributed to form a uniform electric field, ensuring that all crayfish passing through the plastic tunnel 3 receive a stable electric shock, improving stunning consistency. The elevator 4 is located at the feeding port on the front side of the crayfish cleaning mechanism 1. It is used for automatic feeding of live crayfish, replacing manual feeding, which can improve work efficiency and ensure uniform feeding. The high-voltage pulse generator 2 is located on the left side wall of the crayfish cleaning mechanism 1 and is adapted to several electrodes 5. It is used to provide a stable pulse current to the electrodes 5 to achieve instantaneous high-voltage electric stun operation for crayfish.

[0035] The crayfish cleaning mechanism 1, as the core support and cleaning module of the production line, comprises a water tank support 1-2, a water tank 1-1, an inclined chain conveyor 1-7, a circulating water pump 1-8, a water supply pipe 1-5, a mesh plate 1-4, and a rotating roller 1-6. The water tank 1-1 is fixed inside the water tank support 1-2, which provides stable support for the water tank 1-1, ensuring the stability of the entire cleaning mechanism during operation. The inclined chain conveyor 1-7 is fixed to the rear of the water tank 1-1, transporting the crayfish that have undergone cleaning and electric stunning to the next processing step, achieving automatic transfer of crayfish, connecting various processing stages, and improving the automation level of the production line. The circulating water pump 1-8 is fixed to the bottom rear of the water tank support 1-2, with its pump end connected to a tap water pipe, continuously drawing tap water to replenish the water tank 1-1, ensuring sufficient water volume to meet the water requirements for cleaning and electric stunning operations. Water supply pipes 1-5 are installed at the bottom of the inner cavity of water tank 1-1, and their ports extend to the outside of water tank 1-1, connecting to the drain end of circulating water pump 1-8. Tap water drawn by circulating water pump 1-8 is transported to water tank 1-1 via water supply pipes 1-5. The water supply pipes 1-5 are evenly distributed at the bottom of water tank 1-1, ensuring uniform water spray and improving the cleaning effect for crayfish. Simultaneously, they create a flowing water flow, reducing water quality deterioration within water tank 1-1. A mesh plate 1-4 is laid in the middle layer of the inner cavity of water tank 1-1 to support the crayfish, creating a gap between the crayfish and the water supply pipes 1-5 at the bottom of water tank 1-1. This does not obstruct water flow and prevents inadequate cleaning caused by direct contact between the crayfish and the water supply pipes 1-5. It also filters impurities generated during the crayfish cleaning process, reducing the risk of blockage at the water supply pipes 1-5 and the drain port. The rotating roller array 1-6 is rotatably set inside the water tank 1-1. When the rotating roller 1-6 rotates, it can drive the crayfish in the water tank 1-1 to move slowly, so that the crayfish can fully contact the water flow to improve the cleaning effect. At the same time, it pushes the crayfish to move towards the plastic tunnel 3, so as to realize the orderly transportation of crayfish and reduce the accumulation of crayfish in the water tank 1-1.

[0036] The high-voltage pulse generator 2 is equipped with a capacitor-stored pulse power supply. This capacitor-stored pulse power supply replaces the traditional power frequency power supply and can generate high-frequency high-voltage pulse current. This pulse current forms an instantaneous high-voltage electric field through several electrodes 5. The electric field can penetrate the crayfish's nervous system, causing the crayfish to become momentarily stunned. Compared with traditional power frequency AC, this structure can reduce the phenomenon of severe muscle spasms in crayfish and reduce the probability of muscle fiber damage. At the same time, the capacitor-stored pulse power supply can adjust the pulse-related parameters according to the size of the crayfish and the physiological state of different seasons to adapt to different operating needs and solve the technical problem of uncontrollable parameters of existing equipment. Multiple overflow ports 1-3 are opened on the top of the right side wall of the water tank 1-1. Each overflow port 1-3 is equipped with a filter screen. The overflow ports 1-3 are used to drain excess water in the water tank 1-1 to prevent the water level in the water tank 1-1 from overflowing due to excessive height. The filter screen is used to filter impurities in the water flow, which can reduce the impact of impurities discharged through the overflow ports 1-3 on the environment and reduce the probability of blockage of the overflow ports 1-3. Multiple drain ports are installed at equal intervals at the bottom of the water tank 1-1 to drain the sediment and wastewater inside the water tank 1-1. Regularly opening the drain ports can clean the impurities inside the water tank 1-1, ensuring the cleanliness of the water inside the water tank 1-1 and helping to improve the cleaning quality of the crayfish.

[0037] Multiple bearings are embedded on both sides of the water tank 1-1. These bearings are adapted to the two ends of the rotating rollers 1-6 to support the rotation of the rollers 1-6, reduce friction during rotation, ensure smooth rotation, and extend the service life of the rollers 1-6. A sprocket is installed on the right end of each roller 1-6, and a transmission chain 1-10 is installed between the sprockets. The transmission chain 1-10 enables synchronous rotation of multiple rollers 1-6, ensuring consistent movement of the crayfish. The motor 1-11 is fixed to the front right side of the water tank 1-1, and its output shaft is connected to the right end of the foremost roller 1-6, providing power for its rotation. When the motor 1-11 runs, it drives the foremost roller 1-6 to rotate. Through the cooperation of the sprocket and the transmission chain 1-10, it drives the remaining rollers 1-6 to rotate synchronously, achieving automated rotation of the rollers 1-6. The outer casing 1-9 is fixed to the right side wall of the water tank 1-1, covering the motor 1-11, transmission chain 1-10, and sprockets. This protects these components, reducing malfunctions caused by water and impurities contacting them, and lowering the safety risks associated with personnel contacting rotating parts during operation. The control cabinet, installed on the side wall of the water tank 1-1, integrates a PLC control unit and a human-machine interface (HMI). It enables integrated control of the entire production line, with a "power on when shrimp are present, power off when shrimp are absent" logic control function. The HMI displays parameters such as voltage, current, and frequency in real time and supports parameter storage and retrieval. Furthermore, the control cabinet is equipped with a safety interlock device, and a safety limit switch at the inspection door ensures immediate power cut-off and discharge upon door opening. It also features an emergency stop button and an insulation monitoring system to enhance production line safety and reduce the risk of high-voltage electric shock.

[0038] This production line, through the coordinated operation of its components, can automatically feed, uniformly clean, instantaneously stun, and automatically transfer crayfish. Its modular design facilitates later inspection and maintenance. The core capacitor-based pulse power supply, used in conjunction with several electrodes, overcomes the shortcomings of existing water bath electroshock technology, reducing crayfish claw breakage, preserving the integrity of crayfish limbs, and improving product appearance. Simultaneously, the instantaneous high-voltage stun minimizes crayfish suffering and stress, enhancing product palatability and meeting animal welfare requirements. It is suitable for large-scale crayfish processing in China.

[0039] The workflow of this technical solution is as follows: After the production line is started, the motor 1-11 runs and drives the frontmost rotating roller 1-6 to rotate. Through the cooperation of the sprocket and the transmission chain 1-10, all rotating rollers 1-6 rotate synchronously. At the same time, the circulating water pump 1-8 starts, drawing tap water and delivering it to the water tank 1-1 through the water supply pipe 1-5. The water is sprayed into the water tank 1-1, and excess water is discharged through the overflow port 1-3. The filter screen filters impurities in the water flow. The elevator 4 automatically transports live shrimp onto the mesh plate 1-4 in the water tank 1-1. The rotating roller 1-6 drives the live shrimp to move slowly, and the flowing water washes the live shrimp. The impurities generated during washing fall below the mesh plate 1-4 and can be discharged periodically through the drain port. Live shrimp are pushed into plastic tunnel 3 by rollers 1-6. At this time, high-voltage pulse generator 2 is activated, and its internal capacitor-stored pulse power supply provides pulse current to several electrodes 5. The electrodes 5 form an instantaneous high-voltage electric field, and the live shrimp are momentarily stunned by electric shock as they pass through plastic tunnel 3. After cleaning and stunning, the crayfish continue to move to the rear of water tank 1-1 and are transported to the next process by inclined chain conveyor 1-7. The control cabinet realizes the linkage of the entire line through PLC control unit, automatically switching between power supply and power failure based on whether the shrimp are present. The human-machine interface displays relevant parameters in real time. Safety interlock devices are used to ensure operational safety. During maintenance, opening the maintenance door triggers a safety limit switch to cut off power and discharge. The emergency stop button can stop the entire line operation in an emergency.

[0040] The foregoing has only described certain exemplary embodiments of the present invention by way of illustration. Undoubtedly, those skilled in the art can modify the described embodiments in various ways without departing from the spirit and scope of the present invention. Therefore, the foregoing drawings and descriptions are illustrative in nature and should not be construed as limiting the scope of protection of the claims of the present invention.

Claims

1. A modular, instant, high-voltage electric shock-induced daze of crayfish automatic production line, characterized in that: The device includes a lobster cleaning mechanism (1), a plastic tunnel (3) fixed in the front middle section of the inner cavity of the lobster cleaning mechanism (1), and several electrodes (5) fixed at equal intervals on the inner side wall of the plastic tunnel (3). The lobster cleaning mechanism (1) is equipped with a lifting machine (4) at the front feeding port, and a high-voltage pulse generator (2) adapted to the electrodes (5) is provided on the left side wall of the lobster cleaning mechanism (1). The lobster cleaning mechanism (1) includes a water tank support (1-2), a water tank (1-1) fixed inside the water tank support (1-2), and an inclined chain conveyor (1-7) fixed to the rear side of the water tank (1-1). A circulating water pump (1-8) is fixed at the bottom of the rear side of the water tank support (1-2). Several water supply pipes (1-5) are installed at the bottom of the inner cavity of the water tank (1-1). A mesh plate (1-4) is laid in the middle layer of the inner cavity of the water tank (1-1). An array of rotating rollers (1-6) is rotatably arranged in the inner cavity of the water tank (1-1).

2. The modular, instant, high-voltage stunning, automatic production line for small crayfish according to claim 1, characterized in that: The high-voltage pulse generator (2) is internally equipped with a capacitor-type pulse power supply that provides pulse current to the electrode (5).

3. The modular, instant, high-voltage stunning, and automatic production line for small crayfish according to claim 1, characterized in that: The top of the right side wall of the water tank (1-1) has multiple overflow ports (1-3), and each overflow port (1-3) is equipped with a filter screen.

4. The modular, instant, high-voltage stunning, and automatic production line for small crayfish according to claim 1, characterized in that: The bottom of the water tank (1-1) is equipped with multiple sewage discharge ports at equal intervals.

5. The modular, instant, high-voltage, electrically induced stunning and chilling D. aztecus production line of claim 1, wherein: The pumping end of the circulating water pump (1-8) is connected to the tap water pipe, and the water supply pipe (1-5) extends through the port outside the water tank (1-1) and is connected to the drain end of the circulating water pump (1-8).

6. The modular, instant, high-voltage stunning, and automatic production line for small crayfish according to claim 1, characterized in that: The elevator (4) is used to transport live shrimp into the interior of the water tank (1-1), and the inclined chain conveyor (1-7) is used to transport the lobsters that have been cleaned and stunned inside the water tank (1-1) to the next process.

7. The modular, instant, high-voltage electric stunning, and automatic production line for small crayfish according to claim 1, characterized in that: The water tank (1-1) has multiple bearings on both the left and right sides that are adapted to rotate at both ends of the rotating roller (1-6). The right end of the rotating roller (1-6) is equipped with a sprocket, and a transmission chain (1-10) is provided between the sprockets.

8. The modular, instant, high-voltage electric stunning, and automatic production line for small crayfish according to claim 1, characterized in that: An electric motor (1-11) is fixed to the front right side of the water tank (1-1). The output shaft of the electric motor (1-11) is connected to the right end of the frontmost rotating roller (1-6). A housing (1-9) is fixed on the right side wall of the water tank (1-1) to cover the electric motor (1-11), the transmission chain (1-10), and the sprocket.

9. The modular, instant, high-voltage electric stunning, and automatic production line for small crayfish according to claim 1, characterized in that: A control cabinet is installed on the side wall of the water tank (1-1).

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