Singulation and separation system

Abstract

A singulation and separation system for singulating and separating a batch of product, comprising: a singulation pan comprising an array of channels extending from an input end to an output end; a matrix of flow regulators for regulating the flow of product through the channels, each flow regulator comprising a rotating hub and a plurality of flexible prongs radiating from the rotating hub for contacting a product moving through an associated channel; and a series of flow distributors at the output end of the singulation pan, each flow distributor associated with a channel and comprising a rotating hub and a plurality of angled blades radiating from the rotating hub.

Description

[0001] SINGULATION AND SEPARATION SYSTEM

[0002] RELATED APPLICATIONS

[0003] The present application claims priority to US Provisional Application No. 63 / 618,974, filed January 9, 2024 and entitled "Singulation and Separation System", the contents of which are incorporated herein by reference.

[0004] BACKGROUND OF THE INVENTION

[0005] The invention relates generally to shrimp processing, in particular the singulating and separating of shrimp before subsequent processing, such as deheading, grading, cleaning, cooking, peeling freezing, cooking or another process.

[0006] Deheading, grading, sorting or other processing systems may require shrimp to be singulated and separated prior to processing. Product is usually provided in bulk, then separated for processing. Because shrimps, especially peeled shrimps, are wet and somewhat sticky, they tend to adhere to each other. Touching or piggy-backed shrimps can cause problems for subsequent processes. Other products may also require separation and singulation prior to a process.

[0007] SUMMARY OF THE INVENTION

[0008] One version of an apparatus embodying features of the invention for separation and singulating a batch of a product comprises a singulation pan having a plurality of channels and including an array of flow regulators for regulating the flow of product through each channel. Each flow regulator comprises a rotatable hub and a plurality of flexible prongs for contacting and controlling the flow of the product. At an output end, a flow distributor controls the disposition of the product onto a conveyor. Rotating spacing rollers further separate and position the product before passing the product to a processing area for processing.

[0009] According to one aspect, an apparatus for singulating shrimp comprises a first channel for receiving shrimp and moving shrimp from a first end to a second end and a first rotating flow regulator in the channel. The first rotating flow regulator comprises a rotating hub and a plurality of flexible prongs radiating from the rotating hub.

[0010] According to another aspect, a singulation and separation system for singulating and separating a batch of product comprises a singulation pan comprising an array of channels extending from an input end to an output end, a matrix of flow regulators for regulating the flow of product through the channels and a series of flow distributors at the output end of the singulation pan. Each flow regulator comprises a rotating hub and a plurality of flexible prongs radiating from the rotating hub for contacting a product moving through an associated channel. Each flow distributor is associated with a channel and comprises a rotating hub and a plurality of angled blades radiating from the rotating hub.

[0011] BRIEF DESCRIPTION OF THE DRAWINGS

[0012] FIG. 1 is an isometric view of a shrimp processing system including a singulation and separation section according to an embodiment of the invention;

[0013] FIG. 2 is an isometric view of a singulation pan of the system of FIG. 1;

[0014] FIG. 3 is a side view of the singulation pan of FIG. 2;

[0015] FIG. 4 is an overhead view of the singulation pan of FIG. 3;

[0016] FIG. 5 is a side view of a first flow regulator in a first set of flow regulators in the singulation pan of FIG. 2;

[0017] FIG. 6 is a side view of a second flow regulator in a second set of flow regulators in the singulation pan of FIG. 2;

[0018] FIG. 7A is an isometric view of a flow distributor of the singulation pan of FIG. 2;

[0019] FIG. 7B is a side view of the flow distributor of FIG. 7A;

[0020] FIG. 8 is a side view of an end of a channel in the singulation pan during singulation of a batch of shrimp flowing through the channel;

[0021] FIG. 9A is a side view of a spacing section of the singulation and separation section of FIG. 1 including separation rollers;

[0022] FIG. 9B is an isometric view of the spacing section of FIG. 9A.

[0023] DETAILED DESCRIPTION

[0024] The invention will be described below relative to certain illustrative embodiments, though the invention is not limited to the illustrative embodiments. For example, the separation and singulation system is not limited to shrimp, but can be used to separate and singulate any suitable product prior to further processing.

[0025] A shrimp processing system embodying features of the invention is shown in FIG. 1. A shrimp singulation and separation portion of the overall system is shown in FIGS. 2—4. The illustrative shrimp processing system 10 includes a bulk feed tank 12 for holding a batch of shrimp or other product to be processed. A flighted, inclined conveyor belt 20 pulls shrimp out of the bulk feed tank 12. The shrimp fall off the outfeed end of the flighted, inclined conveyor belt 20 into a singulation pan 30, which divides the shrimp into several lanes and spreads that shrimp out before depositing the shrimp on a processing conveyor 24. A pair of spacing rollers 70, 72 above the processing conveyor 24 further space and position the shrimp on the processing conveyor 24 before passing the separated shrimp to a processing station 80, shown as a de-heading station, though the invention is not so limited.

[0026] As shown in FIGS. 2—4, a singulation pan 30, which may be formed of sheet metal or another suitable material, forms a plurality of channels 31 into which the shrimp are divided. The illustrative channels 31 are parallel, but the invention is not so limited. A motor 28 vibrates the singulation pan 30 to urge the shrimp from an input end 32 to an output end 33. In an embodiment, the singulation pan 30 is positioned on a decline to facilitate movement of the shrimp towards the output end 33. Discharge chutes 68 at the output end 33 deposit shrimp that has been singulated in the channels 31 onto the processing conveyor 24. In one embodiment, each channel 31 comprises a flat bottom wall and vertical side walls, or angled side walls so that the channel 31 narrows toward the bottom, but the channels can have any suitable configuration for separating and moving a product.

[0027] Each channel 31 includes one or more flow regulators for regulating the flow of the shrimp through the channel. In an illustrative embodiment, the system includes a matrix of flow regulators across the length and width of the singulation pan 30. Mounting walls 35 are attached to a frame 37 mounting the singulation pan 30 for mounting and positioning the flow regulators.

[0028] A first set 40 of flow regulators is disposed at a first longitudinal location and includes a series of synchronized flow regulators 41, each associated with a channel 31. As shown in FIG. 5, each flow regulator 41 comprises a base 42 mounted on a rotatable shaft 44, shown as a drum motor. The illustrative base 42 is cylindrical or disc-shaped, but the invention is not so limited. A plurality of flexible prongs 43 are distributed about the periphery of the base 42 and radiate from the base 42. The flexible prongs 43 contact and separate the product moving through the channel 31. The flexible prongs 43 have a length selected so that the tips of the prongs sweep the floor 32 of the associated channel 31 as the base rotates with the shaft, i.e., the length of the prongs is slightly larger than the distance between the bottom of the base and the bottom of the channel 31. The flexible prongs 43 are separated at their tips by a distance approximately equal to the length of a shrimp or other product to be singulated. In an illustrative embodiment, a flow regulator includes nine flexible prongs extending from and distributed about the periphery of the base, but the size, shape, number and configuration of the flexible prongs can vary depending on the type of product processed, the speed of the product on the singulation pan and other factors. The illustrative flexible prongs 43 have a circular cross-section, but the invention is not so limited.

[0029] The illustrative flow regulators 41 are centered over each channel 31, but can alternatively be offset to one side of the associated channel 31.

[0030] In an embodiment, the flow regulators 41 rotate at a speed slightly faster than the speed at which the shrimp move through the channels 31. However, in another embodiment, the flow regulators can be slower than or rotate at the same speed as the shrimp flow. A flow regulator 41 thus separates adjacent shrimp in the channel by sweeping a first shrimp forward with a flexible prong as it moves over the channel bottom and holding a second shrimp back with a trailing flexible prong.

[0031] Downstream of the first set 40 of flow regulators, a second set 50 of flow regulators may provide additional product separation, each associated with a channel. A third set 56 of flow regulators spans the channels 31 downstream of the second set 50. A fourth set 58 of flow regulators spans the channels 31 downstream of the third set. At the output end 33, a set 60 of flow distributors controls the discharge of shrimp onto the conveyor belt 24.

[0032] As shown in FIG. 6, a flow regulator 51 in the second set 50 comprises a series of disc-shaped bases 52 mounted on an axle 54, each base corresponding to a channel 31. Flexible prongs 53 are distributed about the periphery of the base and radiate from the base. The flexible prongs 53 have a length selected so that the tips of the prongs sweep the floor 32 of the associated channel 32 as the base 52 rotates with the axle 54, i.e., the length of the prongs is slightly larger than the distance between the bottom of the base and the bottom of the channel 31. The illustrative second set 50 is different from the first set 40 in that it is not powered, but synchronized with the first set 40. In another embodiment, each set of flow regulators can be independently powered. The flow regulators in the third set 56 and forth set 58 can be identical to those in the second set 50, or can have another configuration.

[0033] The flow regulators in the second, third and— or fourth sets 50, 56, 58 can be synchronized to the first set of flow regulators 40 through timing belts or other suitable power transmission means, or the flow regulators can be separately powered.

[0034] Referring back to FIGS. 2—4, a third set 56 of flow regulators provide additional product separation downstream of the second set 50 of flow regulators 51. The third set 56 can be identical to and synchronized with the second set 50. The illustrative third set 56 comprises a plurality of flexible prongs radiating from a base mounted on a rotating axle.

[0035] A fourth set 58 of flow regulators provide additional product separation downstream of the third set 56 of flow regulators. The fourth set 58 can be identical to and synchronized with the second and third sets 50, 56. The illustrative fourth set 58 comprises a plurality of flexible prongs radiating from a base mounted on a rotating axle.

[0036] At the output end 33, the singulation pan 30 includes a series of flow distributors 60 for distributing product onto the conveyor belt 24. As shown in FIGS. 7A and 7B, each flow distributor 61 is associated with a channel 31 and includes a disc-shaped hub 62 mounted on a rotating axle 64, which may be synchronized with or otherwise tied to the first, second, third and— or fourth sets of flow regulators 40, 50, 56, 58 or independently powered. Angled blades 63 radiate from the hub 62. Each blade 63 comprises a planar paddle angled at about 45 degrees relative to the direction of travel of the product. The illustrative blades 63 are stiffer than the flexible prongs 43, 53 of the flow regulators. Each flow distributor 60 comprises four angled blades 63, but can alternatively comprise any suitable number of blades.

[0037] As it rotates, a first angled blade 63 pushes a lead shrimp in the channel 31 into an output chute 68 at the output end 33 of the singulation pan. If another shrimp is close to the lead shrimp, a second angled blade 63 controls the lagging shrimp to space it from the lead shrimp before pushing the lagging shrimp into the output chute 68, spaced from the lead shrimp. Each output chute 68 deposits shrimp onto the processing conveyor 24 for further positioning and singulation before processing. The processing conveyor 24 preferably moves faster than the flow distributors 60 to further separate shrimp deposited therefrom.

[0038] FIG. 8 is a side view of a downstream portion of a channel 31 during separation of a batch of shrimp. A first rotating prong 53a from a flow regulator in the fourth set of flow regulators 58 controls the forward movement of a first shrimp 90a, while a second rotating prong 53b also contacts and pushes the first shrimp 90a. The second rotating prong 53b also controls the forward movement of a second shrimp 90b to space it from the first shrimp 90a.

[0039] At the output end, a leading angled blade 63b of a flow distributor 61 pushes a lead shrimp 90c onto an output chute 68, while retaining subsequent shrimp 90d, 90e, before a lagging angled blade 63b rotates into position to push shrimp 90d onto the output chute 68, while retaining shrimp 90e until another angled blade 63c rotates into position to contact the shrimp 90d and push it onto the output chute 68.

[0040] Referring to FIGS. 9A and 9B, the illustrative spacing rollers 70, 72 provide further singulation and separation of the shrimp on the processing conveyor 24 and may position the shrimp in an optimal position for processing. As show, each spacing roller 70, 72 spans the width of the processing conveyor. As the product passes below each spacing roller 70, 72, the spacing rollers provide further separation and spacing of the product on the conveyor belt 24.

[0041] The first spacing roller 70 comprises a rotating base 73 and an array of bristles 74 radiating from the base 73. Each bristle 74 has a substantially frustoconical shape, but the invention is not so limited. The bristles 74 may be formed of rubber or another suitably flexible material. As shown in FIG. 9A, the tips of the bristles 74 are spaced from the conveyor belt 24. The space between the tips of the bristles 74 and the conveyor top surface is slightly smaller than the thickness of a shrimp 90 or other product being singulated. The illustrative spacing roller 70 rotates at a pace that is slower than the processing conveyor 24, but the invention is not so limited.

[0042] The second spacing roller 72 also comprises a rotating base 75 and an array of frustoconical-shaped bristles 76 radiating from the base 75. The illustrative bristles 76 are shorter than the bristles 73 and extend to the conveyor belt 24 to provide further separation of shrimp or other product on the processing conveyor. After singulation using the singulation pan 30 and spacing rollers 70, 72, the product can be processed at a processing station 80, which can include a visioning section and a deheading section, but the invention is not so limited.

[0043] Although the separation and singulation system has been described in detail with reference to a few versions, other versions are possible. The scope of the claims is not meant to be limited to the details of the exemplary versions.

Claims

WHAT IS CLAIMED IS:

1. An apparatus for singulating shrimp comprising: a first channel for receiving shrimp and moving shrimp from a first end to a second end; and a first rotating flow regulator in the channel, comprising a rotating hub and a plurality of flexible prongs radiating from the rotating hub.

2. The apparatus of claim 1, wherein each prong extends to a bottom wall of the first channel as the rotating hub rotates through a revolution.

3. The apparatus of claim 1, wherein the first channel vibrates to move shrimp from the first end to the second end.

4. The apparatus of claim 1, wherein the first channel angles downwards from the first end to the second end.

5. The apparatus of claim 1, further comprising a second rotating flow regulator downstream of the first rotating flow regulator.

6. The apparatus of claim 5, wherein the second rotating flow regulator is synchronized with the first rotating flow regulator.

7. The apparatus of claim 1, further comprising a rotating flow distributor at the second end of the first channel, the rotating flow distributor comprising a rotating hub and a plurality of angled blades radiating from the rotating hub.

8. The apparatus of claim 7, wherein the rotating flow distributor pushes a singulated shrimp into a discharge chute extending from the second end of the first channel.

9. The apparatus of claim 1, wherein the first channel discharges singulated shrimp onto a processing conveyor at the second end.

10. The apparatus of claim 9, wherein the processing conveyor includes a first spacing roller above the processing conveyor comprising a rotating hub and an array of bristles radiating from the hub for contacting shrimp on the processing conveyor.

11. The apparatus of claim 10, wherein the bristles have a frustoconical shape.

12. The apparatus of claim 10, wherein the ends of the bristles are spaced from the processing conveyor.

13. The apparatus of claim 10, further comprising a second spacing roller downstream of the first spacing roller, the second spacing roller comprising a rotating hub and an array of bristles that contact the processing conveyor.

14. A singulation and separation system for singulating and separating a batch of product, comprising: a singulation pan comprising an array of channels extending from an input end to an output end; a matrix of flow regulators for regulating the flow of product through the channels, each flow regulator comprising a rotating hub and a plurality of flexible prongs radiating from the rotating hub for contacting a product moving through an associated channel; and a series of flow distributors at the output end of the singulation pan, each flow distributor associated with a channel and comprising a rotating hub and a plurality of angled blades radiating from the rotating hub.

15. The singulation and separation system of claim 14, further comprising a plurality of discharge chutes extending from the output end of the singulation pan, wherein each flow distributor pushes a singulated product into a discharge chute16. The singulation and separation system of claim 14, further comprising a motor for vibrating the singulation pan.

17. The singulation and separation system of claim 14, wherein each channel comprises a flat bottom and vertical side walls.

18. The singulation and separation system of claim 14, wherein each prong has a length that is slightly larger than the distance between the rotating hub and the bottom of the associated channel.

19. The singulation and separation system of claim 14, wherein the flexible prongs are separated at their tips by a distance approximately equal to a length of a product being singulated.

20. The singulation and separation system of claim 14, wherein the flow regulators rotate at a speed that is faster than the speed at which the product moves through the channel.

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