Pork neck bone cutting assembly and method and meat processing system

Abstract

A method for at least partially severing a neck bone portion having a spinal column, featherbones and a rib structure from a partial carcass is provided. The method comprises cutting the carcass with a first cutting tool adapted to cut the partial carcass along a first cutting path around and along the spinal column to a predetermined cutting length, according to a first cutting sequence and cutting the carcass with a second cutting tool adapted to cut the partial carcass along a second cutting path around the rib structure and around the spinal column, according to a second cutting sequence. The first and second cutting sequences are performed in a single continuous or semi-continuous operation. There is also provided a cutting assembly and a meat processing system.

Description

[0001] PORK NECK BONE CUTTING ASSEMBLY AND METHOD AND MEAT PROCESSING SYSTEM TECHNICAL FIELD

[0002]

[0001] The present disclosure relates to devices, systems and methods for neck bone lifting operations, and more particularly relates to a method to automatically remove neck bones from the shoulder of animal carcasses.

[0003] BACKGROUND ART

[0004]

[0002] The manual removal of the neck bone is a common deboning operation performed in slaughterhouses and slaughter plants. Today’s slaughtering plants, such as those processing pigs, are operating cutting and deboning lines at a pace sometimes as high as 1 ,450 heads per hour, or more. The manual removal of the neck bone on a production line is a strenuous activity linked to a high occurrence rate of professional injuries. It often requires workers with superior aptitudes and butchering skills. Even then, several weeks of training are required to fully train a worker, as the worker often ends up needing to be rotated with one or more other assignments to prevent injuries. In the modern context of labor shortage, this is of great concern for the plant operators. Some plants even report that the neck bone removal operation is the bottleneck of their cut floor. This situation leads many slaughterhouses to accept a compromise on cut yield to relieve the pressure on the understaffed operation and allow production to run at an expected pace.

[0005]

[0003] The great challenge of lifting neck bones stems from the complexity of the neck bone shape. The atlas vertebra, the featherbones, the curvature of the spine, the transition from the spine to the ribs, are all irregularities which the worker must contend with using their cutting tool. The resulting irregular cutting path can result in a heightened risk of shoulder injuries, among others.

[0004] In view of the above, there is a need to overcome or at least reduce some of the known drawbacks and / or deficiencies associated with conventional methods and / or devices.

[0006] SUMMARY

[0007]

[0005] According to an aspect of the present disclosure, a method for at least partially severing a neck bone portion from a carcass having a spinal column and a rib structure is provided. The method includes cutting the carcass with a first cutting tool adapted to cut the carcass along a first cutting path around and along the spinal column to a predetermined cutting length, according to a first cutting sequence; and cutting the carcass with a second cutting tool adapted to cut the carcass along a second cutting path around the rib structure and around the spinal column, according to a second cutting sequence, wherein the first and second cutting sequences are performed in succession.

[0008]

[0006] According to a possible embodiment, at least one of the first cutting sequence and the second cutting sequence is adapted to be performed manually or automatically.

[0009]

[0007] According to a possible embodiment, the first and second cutting tools are operatively connectable to a support frame rotatably connectable to a manipulator system .

[0010]

[0008] According to a possible embodiment, the manipulator system comprises a robotic arm, and wherein the support frame is rotatably connected at a distal end of the robotic arm for enabling movement of the first and second cutting tools in a 3D environment.

[0011]

[0009] According to a possible embodiment, the method further comprises, after cutting the carcass with one of the first cutting tool and the second cutting tool, changing the one of the first cutting tool and the second cutting tool on the support frame with the other one of the first cutting tool and the second cutting tool.

[0010] According to a possible embodiment, the first and second cutting tools are operatively connected to first and second support frames, respectively, and the first and second support frames are rotatably connected to first and second manipulator systems, respectively.

[0012]

[0011] According to a possible embodiment, the first cutting tool comprises an annular blade defining a closed perimeter and adapted to cut circumferentially around the spinal column and along the predetermined cutting length in a single operation.

[0013]

[0012] According to a possible embodiment, the second cutting tool is one of a waterjet, a cutting blade, a laser, an ultrasonic knife, an ultrasonic saw, a reciprocating knife and a reciprocating saw.

[0014]

[0013] According to a possible embodiment, at least one of the first cutting path and the second cutting path is defined according to at least one of a yield optimization assessment, a neck bone morphology, cutting tool capacities and cut quality requirements.

[0015]

[0014] According to a possible embodiment, the yield optimization assessment includes market value of different meat pieces associated with the neck bone portion.

[0016]

[0015] According to a possible embodiment, the first cutting path is at least partially defined by a curvature of the spinal column.

[0017]

[0016] According to a possible embodiment, the first cutting sequence comprises, following cutting along the spinal column to the predetermined cutting length, having the first cutting tool reverse along the spinal column to exit the carcass proximate an entry point of the first cutting tool.

[0018]

[0017] According to a possible embodiment, the first cutting sequence comprises having the first cutting tool penetrate and exit the carcass at substantially a same location on the carcass.

[0018] According to a possible embodiment, the first and second cutting tools are independently movable with respect to each other.

[0019]

[0019] According to a possible embodiment, the first and second cutting tools are independently operational from each other.

[0020]

[0020] According to a possible embodiment, the second cutting path is adapted to connect with the first cutting path in at least one location.

[0021]

[0021] According to a possible embodiment, the second cutting path includes cutting underneath featherbones.

[0022]

[0022] According to a possible embodiment, the carcass corresponds to a half carcass, or a shoulder cut of a pig.

[0023]

[0023] According to a possible embodiment, combined cuts of the first cutting tool and the second cutting tool fully detach the neck bone portion from the carcass.

[0024]

[0024] According to a possible embodiment, the method further comprises, prior to cutting the carcass : gathering data regarding the carcass using a measuring system; and creating and sending cutting instructions based on gathered data by the measuring system to the first and second cutting tools, the cutting instructions comprising the first and second cutting paths.

[0025]

[0025] According to a possible embodiment, the measuring system is configured to gather data between the first and second cutting sequences in order to create and send updated cutting instructions following a completion of a first one of the first and second cutting sequences.

[0026]

[0026] According to a possible embodiment, the measuring system includes a vision system provided with at least one of a camera, a 2D scanner, a 3D scanner, an X-ray scanning machine and a CT scanning machine.

[0027] According to a possible embodiment, the measuring system is configured to gather data of a plurality of carcasses such that the first and second cutting paths are created and customized for each carcass, individually.

[0027]

[0028] According to a possible embodiment, the second cutting sequence is performed before the first cutting sequence.

[0028]

[0029] According to a possible embodiment, the first cutting sequence is performed before the second cutting sequence.

[0029]

[0030] According to a possible embodiment, the first cutting sequence is performed simultaneously with the second cutting sequence.

[0030]

[0031] According to a possible embodiment, the method further comprises conveying the carcass along a processing line using a conveying assembly, the first and second cutting tools being positioned along the processing line.

[0031]

[0032] According to a possible embodiment, the method further comprises stabilizing the carcass using a companion chain extending along the processing line.

[0032]

[0033] According to a possible embodiment, the method further comprises indexing the carcass using an indexing apparatus at least at a starting point of the processing line.

[0033]

[0034] According to a possible embodiment, the indexing apparatus comprises a plate provided with fixed markers configured to enable adjusting a position of the carcass relative to the fixed markers.

[0034]

[0035] According to a possible embodiment, each carcass is adjusted in a fixed starting position using the fixed markers of the indexing apparatus.

[0035]

[0036] According to a possible embodiment, the plate is adapted to stabilize the carcass conveyed along the processing line.

[0037] According to another aspect of the present disclosure, a cutting assembly for at least partially severing a neck bone portion from a carcass is provided. The neck bone portion of the carcass has a spinal column and a rib structure. The cutting assembly includes a first cutting tool adapted to cut the carcass along a first cutting path and according to a first cutting sequence including: penetrating the carcass proximate a cranial end of the spinal column; and cutting along the spinal column to a predetermined cutting length. The cutting assembly also includes a second cutting tool adapted to cut the carcass along a second cutting path and according to a second cutting sequence including: cutting around the rib structure; and cutting around the spinal column; wherein the first and second cutting sequences are performed in succession or simultaneously.

[0036]

[0038] According to a possible embodiment, the second cutting sequence includes penetrating the carcass proximate a distal end of the rib structure and exiting the carcass after cutting around the spinal column.

[0037]

[0039] According to a possible embodiment, the second cutting sequence includes penetrating the carcass proximate the spinal column and exiting the carcass proximate a distal end of the rib structure after cutting around the rib structure.

[0038]

[0040] According to a possible embodiment, the step of cutting around the spinal column includes cutting around the featherbones.

[0039]

[0041] According to a possible embodiment, the step of cutting around the spinal column includes at least partially cutting the featherbones.

[0040]

[0042] According to a possible embodiment, the cutting assembly further comprises a manipulator system having a robotic arm, and wherein the first and second cutting tools are operatively connectable to the manipulator system.

[0041]

[0043] According to a possible embodiment, the first and second cutting tools are rotatably connected at a distal end of the robotic arm for enabling movement of the first and second cutting tools in a 3D environment.

[0044] According to a possible embodiment, the manipulator system comprises first and second manipulator systems, and wherein the first and second cutting tools are rotatably connected to the first and second manipulator systems, respectively.

[0042]

[0045] According to a possible embodiment, at least one of the first and second cutting tools is independently movable with respect to the other one of the cutting tools.

[0043]

[0046] According to a possible embodiment, the first cutting tool comprises an annular blade defining a closed perimeter and adapted to cut circumferentially around the spinal column and along the predetermined cutting length in a single operation.

[0044]

[0047] According to a possible embodiment, the second cutting tool is one of a waterjet, a cutting blade, a laser, an ultrasonic knife, an ultrasonic saw and a reciprocating knife.

[0045]

[0048] According to a possible embodiment, the second cutting tool is shaped and sized to enable the second cutting path to connect with the first cutting path in at least one location.

[0046]

[0049] According to a possible embodiment, the first and second cutting tools are independently movable with respect to each other.

[0047]

[0050] According to a possible embodiment, the first and second cutting tools are independently operational from each other.

[0048]

[0051] According to a possible embodiment, at least one of the first cutting path and the second cutting path is defined according to at least one of a yield optimization assessment, a neck bone morphology, cutting tool capacities and cut quality requirements.

[0049]

[0052] According to a possible embodiment, the first cutting tool is adapted to follow a curvature of the spinal column.

[0053] According to a possible embodiment, the carcass corresponds to a half carcass, or a shoulder cut of a pig.

[0050]

[0054] According to a possible embodiment, the carcass includes one or more legs.

[0051]

[0055] According to a possible embodiment, the carcass is devoid of legs.

[0052]

[0056] According to a possible embodiment, the first cutting tool and the second cutting tool are configured to cooperate to fully detach the neck bone portion from the carcass.

[0053]

[0057] According to a possible embodiment, the second cutting sequence is performed before the first cutting sequence.

[0054]

[0058] According to a possible embodiment, the first cutting sequence is performed before the second cutting sequence.

[0055]

[0059] According to another aspect, a meat processing system for processing carcasses and sever a neck bone portion therefrom is provided. The meat processing system includes a conveying assembly adapted to convey the carcasses along a predetermined path; and a cutting assembly provided about the predetermined path of the conveying assembly, the cutting assembly being defined as above.

[0056]

[0060] According to a possible embodiment, the conveying assembly further comprises a transport rail and a cradle pivotally connected to the transport rail, and wherein the cradle is adapted to hold the carcasses in a static position.

[0057]

[0061] According to a possible embodiment, the conveying assembly is arranged in a carousel configuration such that the predetermined path forms a closed or semi-closed path.

[0058]

[0062] According to a possible embodiment, the meat processing system further comprises a measuring system operable to index the carcasses being conveyed along the predetermined path prior to being processed by the cutting assembly.

[0063] According to a possible embodiment, the measuring system is configured to gather data of each carcass individually such that the first and second cutting paths are created and customized for each carcass, individually.

[0059]

[0064] According to a possible embodiment, the meat processing system further comprises a processor operable to create and send cutting instructions to the first and second cutting tools based on the data gathered by the measuring system.

[0060]

[0065] According to a possible embodiment, the measuring system includes a vision system provided with at least one of a camera, a 2D scanner, a 3D scanner, an X-ray scanning machine and a CT scanning machine.

[0061]

[0066] According to another aspect, a meat processing system for processing carcasses and sever a neck bone portion therefrom is provided. The meat processing system includes a measuring system adapted to collect data regarding the carcasses; a processor configured to receive and analyze the data in order to generate cutting instructions; and a cutting assembly adapted to receive the cutting instructions, comprising: a first cutting tool, adapted to cut the carcass based on the cutting instructions by cutting along the spinal column to a predetermined cutting length; and a second cutting tool, adapted to cut the carcass based on the cutting instructions by cutting around the rib structure towards the spinal column and around the spinal column.

[0062]

[0067] According to a possible embodiment, the measuring system is configured to collect data regarding each carcass, individually, and wherein the processor is configured to generate customized cutting instructions for each carcass, individually.

[0063]

[0068] According to another aspect, a meat processing system for processing carcasses and removing a portion therefrom is provided. The meat processing system includes a measuring system adapted to collect data regarding the carcasses; a processor configured to receive and analyze the data in order to: create a digital cut along the carcass to enable removal of the portion; and generate cutting instructions including decomposing the digital cut in at least a first cutting sequence and a second cutting sequence. The meat processing system also includes a cutting assembly adapted to receive the cutting instructions and comprising a first cutting tool, adapted to cut the carcass based on the first cutting sequence; and a second cutting tool, adapted to cut the carcass based on the second cutting sequence.

[0064] BRIEF DESCRIPTION OF DRAWINGS

[0065]

[0069] Figure 1 is a perspective view of a meat processing system, in accordance with an embodiment, showing cutting tools provided along a processing line.

[0066]

[0070] Figure 2 is a perspective view of the meat processing system, in accordance with an embodiment, showing meat pieces transported along the processing line.

[0067]

[0071] Figure 3 is a perspective view of a manipulator system provided with a first cutting tool, in accordance with an embodiment.

[0068]

[0072] Figure 4 is a perspective view of a manipulator system provided with a second cutting tool, in accordance with an embodiment.

[0069]

[0073] Figure 5 is a front view of a piece of meat, viewed from the medial plane, showing a cutting path of the first cutting tool, in accordance with an embodiment.

[0070]

[0074] Figure 6 is a front view of the piece of meat shown in Figure 5, showing a cutting path of the second cutting tool, in accordance with an embodiment.

[0071]

[0075] Figure 7 is a perspective view of a conveying assembly, in accordance with an embodiment, showing cradles holding respective meat pieces.

[0072]

[0076] Figure 8 is a perspective view of a conveying assembly according to an alternate embodiment, showing a flighted conveyor having flights of predetermined configurations.

[0073]

[0077] Figure 9 is a perspective view of a manipulator system according to an alternate embodiment, showing a pair of first cutting tools mounted to a common robotic arm.

[0078] Figure 10 is a perspective view of a manipulator system according to an alternate embodiment, showing a first cutting tool and a second cutting tool mounted to a common robotic arm.

[0074]

[0079] Figure 11 is a perspective view of a manipulator system according to an alternate embodiment, showing a robotic arm provided with a tool changer enabling selective connection of one of a plurality of cutting tools.

[0075]

[0080] Figure 12 is a perspective view of a meat piece processed following a precut operation, showing the ribs folded back on a middle section prior to initiating a cutting sequence for deboning the meat piece, according to an embodiment.

[0076]

[0081] Figure 13 is a front view of the piece of meat shown in Figure 6, showing a cutting path of the precut operation shown in Figure 12, in accordance with an embodiment.

[0077] DETAILED DESCRIPTION

[0078]

[0082] As will be explained below in relation to various implementations, the present disclosure describes apparatuses, systems and methods for automating various operations in a meat processing plant, such as cutting, lifting and / or separating a section of a meat piece.

[0079]

[0083] In some embodiments, the present disclosure describes a cutting assembly operable to process an animal carcass, such as a pork carcass or a pork shoulder. The cutting assembly includes a pair of cutting tools operable to cut into the pork carcass in order to at least partially sever a pork neck bone and enable removal (i.e. , lifting) thereof. This type of operation can be referred to as “deboning” or “neck bone lifting” operations. Each cutting tool can be mounted on respective manipulator systems operable to manipulate the cutting tools in a 3D environment surrounding the pork carcass. The first cutting tool is adapted to perform a first cut around a spinal column of the carcass. The second cutting tool is adapted to perform a second cut around the ribs and the spinal column, joining the first cut. The two cuts cooperate to sever the neck bone from the carcass to enable removal / extraction.

[0080]

[0084] In some embodiments, the two cuts partially sever the neck bone, and an additional action is performed to completely remove the neck bone from the carcass. For instance, an additional cut can be performed by an automated cutting tool or manually by an operator to complete the removal of the neck bone from the carcass. Alternatively, a mechanical force (e.g., a pulling force) can be applied to the partially severed neck bone to complete the separation process.

[0081]

[0085] In some embodiments, the present disclosure describes a meat processing system in the meat processing plant that includes a conveying assembly, a measuring system, a processing assembly and the cutting assembly. The conveying assembly can include a loading station, where the pork carcasses, or parts thereof, are loaded on a conveyor. Each carcass travels along the conveyor to be processed by different systems of the meat processing system to produce various byproducts. The measuring system is operable to scan the carcasses mounted on the conveyor to gather and send data to the processing assembly. The data is then analyzed by the processing assembly which can be adapted to generate cutting instructions for various processing machines mounted along the conveyor, such as the pair of cutting tools of the cutting assembly.

[0082]

[0086] As will be described further below, the removal of the neck bone is simplified as the complexity of the process is reduced using the different systems of the meat processing system. In other words, the meat processing system as described herein allows for establishing a pace deboning line, where each step of the process is broken down and simplified to facilitate completion. In other words, any given task can be divided up in multiple simpler tasks. It is thus correspondingly simpler to train operators and / or to automate machines to perform each task. The pace deboning line can improve efficiency of the plant / slaughterhouse and increase yield. Simpler tasks for operators can also reduce risks of injuries typically associated with complex tasks and / or repetitive tasks.

[0087] With reference to Figures 1 and 2, a meat processing system 10 is shown. In this embodiment, the meat processing system 10 includes a cutting assembly 20, a conveying assembly 22, a measuring system 26 and a processing assembly 28. As will be described further below, carcasses 30, or at least parts thereof, are transported via the conveying assembly 22 and processed (e.g., cut, divided, separated, etc.) by the cutting assembly 20. The measuring system 26 is adapted to gather and transmit data relative to the carcasses 30 to the processing assembly 28, which is configured to analyze the data. The analyzed data can be used to assist the operations of various machines, such as those of the cutting assembly 20.

[0083]

[0088] In some embodiments, the cutting assembly 20 is operable to cut and / or sever pieces of meat from a carcass 30 or from a part of the carcass. In the present disclosure, the cutting assembly 20 is described as being configured to lift (e.g., cut and sever) the neck bone portion 32 of a pork carcass 30. However, it should be noted that the devices, systems and methods described herein can be implemented and used in different plants for processing different meat pieces or different products entirely (e.g., in other industries).

[0084]

[0089] It should also be noted that, as used herein, the expression “carcass” can refer to a complete pork carcass or a partial pork carcass (e.g., a half carcass), such as a shoulder cut. Alternatively, in relation to a given meat processing plant, the carcass can refer to any other animal carcass. A person skilled in the art would readily understand that, depending on the type of carcass (e.g., full carcass vs half carcass) and / or of animal (e.g., beef, lamb, veal, pork, mutton, etc.) being processed, additional steps might be useful or required to facilitate subsequent processing operations. For instance, for a half carcass, it should be understood that the head of the animal is previously removed from the carcass. Similarly, portions of the spine and / or ribs can be pre-cut to facilitate neck bone removal operations. For example, backfinning operations, which are performed on the slaughter line (e.g., prior to chilling the carcasses), aim to loosen meat from the featherbones. Backfinning can be done on loins as well as shoulders, in which case backfinning operations would correspond to the aforementioned pre-cut, thereby simplifying the neckbone removal.

[0085]

[0090] In this embodiment, the cutting assembly 20 includes at least one cutting tool 33. The cutting tool 33 is adapted to at least partially sever a meat piece from the carcass 30. The cutting tool 33 can include any one or combination of water jets, circular saws, reciprocating saws, cutting blades, ultrasonic knives, ultrasonic saws, lasers, band saws, hole saws, circular trimming knives, scissors, etc. The cutting tool may be powered hydraulically, pneumatically, electrically or any combination thereof. In the present embodiment, the cutting assembly 20 includes a first cutting tool 34 and a second cutting tool 36 operable to perform one or more cuts on the carcasses 30 being conveyed along a conveyor 23. In some embodiments, the first cutting tool 34 is operable to perform a first cut, and the second cutting tool 36 is operable to perform a second cut. The first and second cuts can cooperate to at least partially sever the neck bone portion 32 from the pork carcass. It is thus noted that the cutting assembly 20 decomposes the neck bone lifting procedure in at least two cuts, allowing for the complexity of each cut to be lowered. Each cut can be performed with a different cutting tool to improve cut speed, yield or both.

[0086]

[0091] As seen in Figures 1 and 2, each cutting tool 33 can be provided adjacent to the conveyor 23 to enable cutting the carcasses 30 in succession. In other words, the cutting tools 33 can be configured to repeat a given number of steps, based on instructions, on each carcass. In some embodiments, the first cutting tool 34 and the second cutting tool 36 are adapted to cut every single carcass 30 disposed on the conveyor 23. Alternatively, a plurality of first cutting tools 34 and a plurality of second cutting tools 36 can be provided along the processing line to enable cutting a plurality of carcasses simultaneously. The first and second cutting tools can include various different cutting instruments. For example, in order to adapt to size variations from one carcass to another, a given cutting tool can be equipped with cutting instruments of different sizes (e.g., a plurality of circular trimming knives with respective diameters). It should also be noted that each cutting tool can be equipped with different cutting instruments capable of doing the same cut. In some embodiments, the cutting tools can be configured to pick and choose the instrument best suited to perform the desired cut, for instance, based on data gathered by the measuring system 26.

[0087]

[0092] With reference to Figures 1 to 4, in some embodiments, each cutting tool 33 is mounted on respective manipulator system 40 adjacent to the conveyor 23. It is appreciated that the expression “adjacent”, in this context, can include any suitable location, including but not limited to, laterally adjacent the conveyor on the factory floor, partially or completely below the conveyor, partially or completely above the conveyor (e.g., an overhead robot manipulator) or any suitable combination thereof. Particularly, the first cutting tool 34 can be operatively coupled to a first manipulator system 40a at a first position along the conveyor 23, and the second cutting tool 36 can be operatively coupled to a second manipulator system 40b at a second position along the conveyor 23. As seen in Figure 1, the first and second manipulator systems 40a, 40b can be adjacent one another on a common side of the conveyor. However, it is appreciated that other configurations are possible. For instance, in some embodiments, the manipulator systems are further apart and / or provided on opposite sides of the conveyor. Alternatively, the second manipulator system 40b can be located upstream of the first manipulator system 40a to allow the second cutting sequence to be performed prior to the first cutting sequence. In yet another possible embodiment, the first manipulator system 40a and the second manipulator system 40b can be positioned in a way that the two manipulator systems can work at the same time on the same carcass 30 in a synchronized matter, among other possibilities.

[0088]

[0093] During operation of the meat processing system 10, the carcasses 30 are conveyed along the conveyor 23. Once a carcass 30 moves proximate to the first cutting tool 34, the first manipulator system 40a is operated, automatically or manually, to move the first cutting tool 34 to enable engagement with the carcass 30 (e.g., to cut the carcass). Then, once proximate to the second cutting tool 36, the second manipulator system 40b is operated, automatically or manually, to move the second cutting tool 36 to enable cutting the carcass 30 further. In some embodiments, the conveyor 23 can be adapted to change speeds once the carcass 30 moves proximate to one of the cutting tools. For instance, the conveyor 23 can slow down to allow enough time for the cutting tool 33 to perform the required operations before speeding back up to move the carcass further along the processing line. Alternatively, the conveyor 23 can be completely halted (i.e., become immobile) as the cutting tools 33 operate on the carcasses 30. In yet another embodiment, the conveyor can correspond to and / or operate as a step conveyor. It should be understood that, as used herein, a step conveyor is a type of conveyor that moves products (e.g., carcasses) in a series of fixed, predetermined stops and starts, instead of a continuous flow. These predetermined stops can allow for precise and timed operations. These systems are also known as indexable conveyors or indexable step conveyors.

[0089]

[0094] Referring more specifically to Figures 3 and 4, each cutting tool can be operatively connected to a distal end 41 of respective manipulator systems which are configured for displacing the cutting tools to cut the carcasses in desired locations and / or according to predetermined instructions. In some embodiments, the cutting tools 33 can be mounted on a support frame 38 mounted to the distal end 41 of the corresponding manipulator system 40 (i.e., to the end effector of the robotic arm). The manipulator system 40 can include a robotic manipulator or robotic arm 42 adapted to displace the support frame 38, and thus the cutting tool 33, closer to and around the carcass 30 to enable cutting operations. In other words, the robotic arm 42 is configured to displace the cutting tool 33 in a 3D environment surrounding the carcass 30. However, it is appreciated that other manipulator systems can be used, such as a bridge extending over the conveyor similar to known x-y cutting tables, for example.

[0090]

[0095] In some embodiments, the support frame 38 can be rotatably coupled to the distal end of the robotic arm 42 to enable adjustments of an orientation of the cutting tools 33 with respect to the carcass 30. It should be noted that, by having the first and second cutting tools 34, 36 mounted to respective robotic arms 42, the first and the second cutting tools 34, 36 can be independently moved with respect to each other, and can further be independently operated from one another. In some embodiments, the first and second cutting tools can be provided on respective sides of the conveyor, or at any other suitable location, to adapt to a specific plant floor layout, for example.

[0091]

[0096] In an alternate embodiment, shown in Figures 9 and 10, the first and the second cutting tools 34, 36 can each be coupled to a single manipulator system 40 (e.g., to a single robotic arm). The single manipulator system can be provided with two support frames 38 such that each cutting tool 33 is mounted onto respective support frames, or a single support frame shaped and sized to enable connection of both cutting tools thereon, for instance, to enable sequential first and second operations with the first and second tools, respectively. In another embodiment, as shown in Figures 8, 10 and 11, the manipulator system 40 can include a tool changer 75, operable to enable changing the cutting tool coupled to the manipulator system. As such, the robotic arm 42 can be operated using a plurality of different tools connectable and interchangeable using the tool changer 75.

[0092]

[0097] Referring more specifically to Figure 8, the tool changer 75 can enable a first operation (e.g., a first cut) to be done with a first tool , followed by a change of the first tool to a second tool, and then the completion of a second operation (e.g., a second cut) with the second tool. In other words, each manipulator system 40 can be configured to have a single cutting tool 33 connected thereto, which can be disconnected and replaced via operation of the tool changer 75. In another embodiment, shown in Figure 10, the manipulator system 40 can include two or more cutting tools 33. For instance, and as illustrated the manipulator system 40 can include the first cutting tool 34 and the second cutting tool 36 (e.g., connected to the same robotic arm 42 end effector). In this embodiment, the first cutting tool 34 is connected to the robotic arm 42 via the tool changer 75, while the second cutting tool 36 is operatively coupled to the robotic 42, but without the tool changer 75. As such, the first cutting tool is interchangeable with other tools, such as different first cutting tools 34 (e.g., of different shapes, sizes, wear condition, etc.) or a different tool altogether. It should be noted that, while only the first cutting tool is illustrated with the tool changer 75, the second cutting tool can alternatively, or additionally, be similarly provided with a corresponding tool changer 75.

[0093]

[0098] In some embodiments, and as shown in Figure 9, the manipulator system 40 can be provided with two or more cutting tools 33 of a common type but of respective sizes and / or shapes. This configuration enables dynamic adjustments of the cutting tool to accommodate for parts (e.g., meat pieces, carcasses, etc.) of different sizes and / or shapes. It is also noted that the two or more cutting tools can be identical, enabling one or more of the tools to act as a redundancy to the other(s). In yet another embodiment, illustrated in Figure 11, a third and / or fourth manipulator system 40 can be provided (e.g., with or without the tool changer 75) in order to offer redundancy for the first and / or second cutting tools. As such, should the first and / or second manipulator system stop operating, the third and / or fourth manipulator system could take over to complete the corresponding task. It is appreciated that a single manipulator system (e.g., the third manipulator system) provided with a tool changer 75 can provide redundancy for both the first and second cutting tools. Alternatively, a pair of manipulator systems (e.g., the third and fourth manipulator systems) devoid of the tool changer 75 can provide redundancy for respective ones of the first and second cutting tools.

[0094]

[0099] The single manipulator system can be useful for creating a compact processing system 10, thereby reducing the operational footprint of the various machines along the processing line. Compact systems can be useful and better adapted for slower and / or lower capacity / output factories, which typically have smaller or space-restricted floor plans, slower line speeds and / or smaller daily production. In some embodiments, the first and second cutting tools can be removably connected to the support frame to enable interchanging the tools when needed, either manually or automatically. It is also noted that using a single manipulator system can assist in reducing installation and maintenance costs, among other advantages.

[0100] In some embodiments, the robotic arm 42 of each manipulator system 40 can include a base 43 and a plurality of robotic arm sections 45 operatively connected to one another. The base 43 and each arm section 45 can be operable to rotate about respective pivot axes to enable the displacement of the cutting tools 33 in the 3D environment. In other words, the different components of the manipulator system 40 allows for the cutting tools 33 to have six (6) degrees of freedom and be moved and rotated in different directions simultaneously to enable fluent or smooth movements in three dimensions. However, different configurations can allow for different degrees of freedom and corresponding possible movements.

[0095]

[0101] As seen in Figure 3, the first cutting tool 34 is mounted on a first support frame 38a connected to a first manipulator system 40a. The first manipulator system 40a can include a first robotic arm 42a. In this embodiment, the first cutting tool 34 includes an annular blade 35 defining a closed perimeter 37. The annular blade 35 can be operatively coupled to a motor 39 configured to engage the annular blade 35 in motion to perform cuts in the carcasses. As will be described further below, the first cutting tool 34 (e.g., the annular blade 35) is configured to cut the carcasses along a first cutting path 58 and according to a first cutting sequence.

[0096]

[0102] Referring now to Figure 4, the second cutting tool 36 is mounted on a second support frame 38b connected to a second manipulator system 40b. The second manipulator system 40b can include a second robotic arm 42b. In this embodiment, the second cutting tool 36 includes a reciprocating knife 60. The reciprocating knife 60 can be operatively coupled to a motor 61 configured to engage the reciprocating knife 60 in motion (e.g., a rapid back and forth motion) to cut the carcasses. In some embodiments, the reciprocating knife 60 can operate at frequencies in the infrasonic, audible and / or ultrasonic ranges. Similar to the first cutting tool, the second cutting tool 36 (e.g., the reciprocating knife 60) is configured to cut the carcasses along a second cutting path 62 and according to a second cutting sequence.

[0103] Turning now to Figure 5, in this embodiment, the carcass 30 is a partial pork carcass which includes the neck bone portion 32. More specifically, the carcass 30 corresponds to a shoulder cut having at least a partial spinal column 44. Other cuts and / or parts of the carcass can be used, such as a complete half carcass having a complete or a partial spinal column 44. The shoulder cut typically includes a rib structure 50 having a plurality of ribs 52 extending from the spinal column 44. The brisket 54 (or parts thereof) can also be present at the distal end of the ribs 52. As seen in Figure 5, the spinal column 44 has a longitudinal curvature 56 and can also include thoracic vertebrae 48 provided with featherbones 46, and lumbar vertebrae similarly provided with featherbones.

[0097]

[0104] In some embodiments, as seen in Figures 5 to 7 and 9 to 11, the carcass 30 can include a leg 59, or a portion thereof, which can remain attached as the processing of the shoulder is initiated. In some embodiments, the deboning process can include partially or completely severing the leg 59 from the shoulder. Alternatively, the leg 59 can be cut and / or removed prior to initiating the deboning process (e.g., prior to operating the first cutting tool). For instance, Figure 8 illustrates an embodiment where the carcasses 30 (e.g., the shoulders) are conveyed without the leg 59.

[0098]

[0105] In this embodiment, the first cutting tool 34 is adapted to cut the carcass 30 along a first cutting path 58 and according to a first cutting sequence. The first cutting tool 34 starts the first cutting sequence at a cranial extremity 55 of the spinal column 44. In other words, the annular blade 35 initiates the first cut by entering the shoulder all around the spinal column on the fore side of the shoulder. The first cutting path 58 follows the longitudinal curvature 56 of the spinal column 44 up to a predetermined cutting length. The annular blade 35 follows the first cutting path 58 and cuts circumferentially around the spinal column 44, creating a circular cut defined by the closed perimeter 37 of the annular blade 35. The spinal column 44 therefore runs through the annular blade 35 during the first cutting sequence. As the annular blade 35 progresses along the first cutting path 58, the cut section of the spinal column is lifted from the carcass 30 and extends through the closed perimeter 37 of the annular blade 35.

[0099]

[0106] In this embodiment, once the first cutting tool 34 has reached the predetermined cutting length, the first cutting sequence includes reversing the first cutting tool 34 to exit the carcass 30. More specifically, the annular blade 35 moves along the first cutting path 58 in the opposite direction in order to exit the carcass 30 at the same location as it has entered (e.g., on the fore side of the shoulder). It is appreciated that the exit path of the first cutting tool 34 can be similar to the entry path, although not exactly the same. In another embodiment, the first cutting sequence can include having the first cutting tool 34 exit the carcass 30 at any other suitable location.

[0100]

[0107] In some embodiments, the predetermined cutting length can be defined by at least one of a neck bone morphology (which can be specific to each species), annular blade capacities (e.g., capacity to cut, available power, blade resistance, etc.) and cut quality requirements, among others. It should thus be understood that the predetermined cutting length does not correspond to a singular fixed length for every carcass, but rather corresponds to a cutting length determined (e.g., measured, calculated, programmed, etc.) for each carcass. As will be described further below, the meat processing system can include a vision system (e.g., cameras, lasers, etc.) and a processing system (e.g., a processor / processing unit) configured to assess each carcass. The vision and processing system can thus be adapted determine and establish the predetermined cutting length for each carcass. However, it is appreciated that a singular predetermined cutting length (e.g., a fixed length / cutting distance) can be established for a plurality of carcasses, for example, assembled in batches.

[0101]

[0108] In some embodiments, the annular blade 35 can be shaped and adapted to cut the featherbones 46 as the annular blade follows the first cutting path 58. For instance, the diameter of the annular blade 35 can be sufficient to allow the spinal column 44 and the featherbones to fit within the closed perimeter 37 of the annular blade 35. However, it is appreciated that other configurations are possible and can be implemented, such as annular blades having a diameter adapted to allow the spinal column 44 to run through, but not the featherbones. As such, the featherbones 46 can be cut during the first cut. In some embodiments, the first cutting tool can alternatively include a J-shaped knife, a U-shaped knife, a V-shaped knife, a straight knife, or any other knife or saw adapted for cutting the carcass 30 in the desired manner (e.g., according to the first cutting sequence).

[0102]

[0109] Turning now to Figure 6, in this embodiment, the second cutting tool 36 is adapted to cut the carcass 30 along a second cutting path 62 and according to a second cutting sequence. The reciprocating knife 60 starts the second cutting sequence at the distal extremity of the ribs 52 (e.g., spaced from the spinal column 44). In other words, the reciprocating knife 60 enters the shoulder under the ribs 52, “foot side" (e.g., alongside the edge of the brisket bone 54, if present, or alongside the tip of the ribs).

[0103]

[0110] The reciprocating knife 60 cuts the carcass 30 following a natural curvature of the ribs 52 up to the spinal column 44. The reciprocating knife 60 then cuts around the spinal column 44 to exit the carcass 30 on the opposite side, proximate a bottom end of the carcass 30, as shown in Figure 6. The second cutting path 62 can have the reciprocating knife 60 cut around the featherbones 46 as it cuts around the spinal column 44 (e.g., if the featherbones are still present following the first cut). In addition, when the lumbar vertebrae are present, the second cutting tool can also be adapted to cut around the corresponding featherbones when cutting around the spinal column 44. Alternatively, the reciprocating knife 60 can be adapted to cut through the featherbones 46. It is appreciated that, in some embodiments, the second cutting tool can alternatively include a non-oscillating knife (e.g., the robot can instead oscillate back and forth), a waterjet, a cutting blade, a laser, an ultrasonic knife, an ultrasonic saw or any other knife or saw adapted for cutting the carcass 30 in the desired manner (e.g., according to the second cutting sequence).

[0104]

[0111] In some embodiments, the second cutting path 62 can be defined the other way around (e.g., the second cutting sequence can be reversed). The second cutting tool 36 can enter the carcass 30 at the spinal column 44, then cut around the spinal column 44 and around the featherbones 46, and can finally follow the natural curvature of the ribs 52 to exit proximate the distal extremity of the ribs 52.

[0105]

[0112] At this point, following the first and the second cuts, the neck bone portion 32 is partially or totally disconnected from the carcass 30. It is thereby noted that the second cutting path 62 connects with the first cutting path 58 in at least one location to enable the first cut and the second cut to cooperate for lifting the neck bone portion 32. If the neck bone portion 32 is partially severed, an additional cut may be required and can be done automatically (e.g., by an automated cutting tool) or manually, thus completing the neck bone removal from the shoulder. Alternatively, a partially removed neck bone portion can also be disconnected and removed by pulling on it, thereby tearing the remaining tissue connecting the neck bone portion to the rest of the carcass. It should also be noted that the order of the cuts can be reversed. More particularly, in some embodiments, the second cut (as described above) can be done first, while the first cut (as described above) can be done second. The resulting combined cut would be similar, if not identical, to the combined cut described above.

[0106]

[0113] Referring back to Figures 1 and 2, in this embodiment, the conveying assembly 22 includes a conveyor 23 adapted to convey (e.g., transport) the carcasses 30 along the processing line. In some embodiments, the conveyor 23 can include a transport rail 64 defining a carousel operable to create a closed or semi-closed path. The carcasses 30 are mounted on the transport rail 64 of the conveyor 23 at a loading station 24. The transport rail 64 can include cradles 66 configured to have the carcasses 30 mounted thereon in a predetermined and / or desired position, for example, to allow the cutting assembly 20 to operate on the carcasses 30.

[0107]

[0114] In some embodiments, and with reference to Figure 7, the cradles 66 can have a cradle body 68 defining a pocket 70 having a profile similar to a general shape of the carcass 30 (or partial carcass). As seen in Figure 7, in this embodiment, the partial carcass corresponds to the shoulder cut 31 (or simply “shoulder”)- As such, the shoulder 31 can be mounted on the cradle 66 to have a main portion thereof rest within the pocket 70 of the cradle body 68. In this embodiment, the cradles 66 also include a stabilizer 72 configured to maintain the shoulder 31 in the predetermined position within the pocket 70 as the shoulder 31 is transported along the processing line, and as the cutting assembly 20 cuts into the shoulder 31. In this embodiment, the stabilizer 72 includes a gripper 74 operable to grasp and hold a part of the shoulder cut by an appendage (e.g., by the foot) or around a junction of the appendage and a main portion of the cut of meat to maintain the shoulder 31 in place during cutting operations. In the illustrated embodiment, the main portion of the cut of meat corresponds to a section surrounding the ribs and the spinal column. By grasping the shoulder 31 proximate the foot, it is noted that the gripper 74 is spaced from the first and second cutting paths, thereby preventing the gripper 74 from interrupting the first and / or second cutting sequences.

[0108]

[0115] It should be noted that that the illustrated embodiments are exemplary only and that other configurations are possible. For instance, the cradles can be shaped and sized to hold and retain respective carcasses therein without requiring the gripper. As such, the carcasses can be deposited and picked up from the cradles without the intermediary step of operating the gripper, for example. In some embodiments, the carcasses can be transported in different orientations, as illustrated in Figures 9 to 11, where the carcass is rotated by about 90 degrees relative to the configuration shown in Figures 5 to 7. This configuration can simplify the cutting path of one or both cutting tools, thereby facilitating the overall process.

[0109]

[0116] In other embodiments, the transport rail 64 can include other means of transporting the carcasses (or other items), such as hanger chains configured to have individual carcasses hanging from chains, hooks and / or gambrels. Alternatively, or additionally, the conveyor 23 can correspond to a simple and / or flat conveyor (e.g., standard conveyor belt), for example.

[0110]

[0117] In some embodiments, and with reference to Figure 10, the conveying unit assembly can include a companion chain 85 configured to stabilize the conveyed products (e.g., carcasses and / or parts thereof). The companion chain 85 can include a stabilizing surface 86 configured to engage the transported products to stabilize (e.g., prevent or at least partially reduce movement thereof). The stabilizing surface 86 can be static or adapted to move with the transported products. For example, the companion chain 85 can include a secondary conveyor belt 88 configured to urge the products along the processing line together with the conveyor 23. Other stabilizing systems can be used in addition or as an alternative to the ones described herein. For example, US publication No. 2025 / 0049052A1 discloses carcass stabilizing systems, means and devices and is incorporated herein in its entirety by reference.

[0111]

[0118] In some embodiments, the cradle 66 can be pivotably connected to the transport rail 64 to enable adjusting an angle of the cradle 66 (and thus of the shoulder cut held therein) relative to the transport rail 64 and / or the cutting assembly 20. As will be described further below, the angle at which the shoulder 31 is held can be modified, for example, passively, manually, automatically, dynamically and / or actively. The cradle 66 can be conveyed along the transport rail 64 in a vertical position, in a horizontal position or at any other suitable angle in between. Therefore, it is noted that each piece of meat on the transport rail 64 can be transported in respective orientations. In this embodiment, adjustable angle of the cradles allows for the shoulders 31 which are not actively being processed (e.g., acted upon by a tool) to be moved away and at least partially separated from the shoulders 31 which are being processed. This can prevent interference issues with the shoulders 31 adjacent (e.g., upstream and / or downstream) to the shoulders 31 being processed, while also providing more space for the tools (e.g., the manipulator system 40) to move around the shoulders 31.

[0112]

[0119] Alternatively, in some embodiments, the conveying assembly 22 can include a conventional conveyor belt, a conveyor with chains to hang the carcasses 30, an indexing / step conveyor with cradles or mounting fixtures, a rotating apparatus with cradles, a flighted conveyor (e.g., flighted belt conveyors, chain-and-flight conveyors, screw conveyors, etc.), a robotic manipulator configured to present each carcass, individually, to each processing robot, or any other suitable conveying mechanism and / or combination thereof.

[0113]

[0120] As seen in Figure 8, the conveyor 23 corresponds to a flighted conveyor 80 having spaced apart flights 82. The flights 82 can be shaped and sized to facilitate transporting the carcasses 30 along the processing line. In this embodiment, the carcasses 30 are upheld and carried by the flights 82 (e.g., positioned on top of the flights). As illustrated, the flights 82 can be serrated and include teeth 84 to prevent, or at least reduce, movement of the carcasses being transported. As illustrated, the flights 82 can have a predetermined configuration (e.g., shape, position, etc.), such as having one end defined as a generally triangular shape adapted to keep one side of the carcasses raised relative to the other. This configuration can assist in positioning the carcasses in a desired position and / or orientation to facilitate operation of the cutting tool 33, among others. The flighted conveyor 80 can correspond to an “infinite” cradle and / or conveyor configured to define a loop in order to generally continuously provide a moving surface with a distribution of flights 82.

[0114]

[0121] Referring back to Figures 1 and 2, in this embodiment, the measuring system 26 can be adapted to index and track the position of the carcasses 30 within the meat processing system 10 and along the processing line. In some embodiments, the measuring system 26 can include one or more vision devices, such as cameras, adapted to visually detect, identify and / or track the position of the carcasses. However, it is appreciated that other means are possible and can be implemented for detecting and monitoring the position of items along a processing line. For example, an encoder provided along the conveyor can be implemented to detect, identify and / or track the location of the different carcasses 30. In some embodiments, vision systems or devices can be provided in various locations around the plant (e.g., the kill floor, the cut floor, etc.) to gather data regarding the carcasses at different steps of the process. It is appreciated that indexing the carcasses can be done on the kill floor such that the indexing data can be sent to other parts / locations of the plant. This approach can assist in tracking each item (e.g., each carcass) transported along a processing line, for instance, including tracking its location, along with identifying each processing operation that that particular item has undergone since being indexed.

[0115]

[0122] In this embodiment, the measuring system 26 can be configured to scan the neck bone portion 32 to gather various data such as overall dimensions, physical characteristics (e.g., presence of fat or other tissue types), dimension of a physical feature, prevalence of a tissue type in the meat, presence of a feature (or lack thereof), cut surface aspect, cut surface characteristics, presence of sawdust, characteristics of the sawdust, presence of damage on meat, presence of damage on specific meat structure, surface aspect, subsurface aspect, presence of debris on the meat (e.g., meat flap, small pieces of meat or fat, etc.), presence of foreign material, etc. For example, the measuring system 26 can include a vision system including at least one of a camera, a 2D scanner, a 3D scanner, an X-ray scanning machine, a CT scanning machine, laser line(s), laser scatter information, etc.

[0116]

[0123] It should therefore be understood that the measuring system 26 can gather data specific to each piece of meat. In this embodiment, the measuring system 26 can transmit the gathered data to the processing assembly 28 for analysis. More specifically, and for example, the processing assembly 28 can receive and analyze the data gathered by the measuring system 26 to create cutting instructions for transmission to the cutting assembly 20. The cutting instructions can include various information such as which cutting tool to use on any given carcass 30. In some embodiments, the processing assembly 28 can be configured to create the first cutting path and the second cutting path for each carcass 30, individually, and send the information to the first and second cutting tools. For instance, the predetermined cutting length of the first cutting path can be defined for each carcass, although other configurations are possible, such as defining the predetermined cutting length for a batch of carcasses, for example.

[0117]

[0124] In some embodiments, the measuring system 26 can be configured to scan the neck bone portion 32 before and after the first cut in order to further improve the accuracy of the second cut. Particularly, the measuring system 26 can include an intermediary vision system configured to gather data of the neck bone portion which has just undergone the first cut. The new position of meat piece intermediary vision system can transmit the gathered data to the processing assembly 28 for analysis. The analyzed data can be used to assist the operations of subsequent steps, including the second cut to be completed., among others. In some embodiments, the measuring system 26 can include a plurality of intermediary vision systems, each configured to gather data at respective points along the processing line and / or after each operation (e.g., cut, rotation, placement, etc.). The measuring system can also include a final vision system configured to gather data relative to the final product. The final product data can be used as feedback and / or reference points for subsequent pieces / carcasses, for example. It should be noted that the processing assembly 28 can be integrated into the measuring system 26 (e.g., onboarded with the vision system / camera) or be independent.

[0118]

[0125] It is further noted that the measuring system 26 can be adapted to characterize the spinal column 44 (e.g., shape, size, curvature, etc.). The processing assembly 28 can therefore create cutting instructions relative to the specific characteristics of the spinal column 44 of each carcass 30. In some embodiments, the measuring system 26 and the processing assembly 28 can be adapted to optimize cut yields of different meat pieces obtainable from a common carcass based on various factors.

[0119]

[0126] For instance, depending on the current market pricing, the processing assembly 28 can vary the specifications of different meat pieces. If the neck bone portion 32 is currently worth more (e.g., based on weight), the processing assembly 28 can leave more meat on a section of the neck bone portion 32 located at a junction between the picnic and the shoulder butt (e.g., more meat on the shoulder butt and less on the picnic shoulder). Therefore, the value of the neck bone portion 32 can be increased while sacrificing a portion of the picnic shoulder (that would have a lower value relative to the shoulder butt). In other circumstances, such as with different market pricing, the processing assembly 28 can adjust the different cuts to maximize the value of the final meat pieces. It should be noted that the processing assembly 28 can use or consider other factors prior to varying the specifications of the meat pieces. Among others, the produced by-products can have their specifications (e.g., shape and size, including thickness and ratios between meat, fat, cartilage, etc.) adjusted based on goal weights, goal sizes, desired cut quality, etc.

[0120]

[0127] In some embodiments, the meat processing system 10 can include an indexing apparatus (now shown) configured to assist the measuring system 26 (e.g., the vision system) to index the carcass prior to, during and / or after processing. It should be understood that the action of “indexing” the carcass can include gathering and / or transmitting information regarding the carcass, such as a carcass identification number, a carcass type, overall dimensions, overall shape and / or shapes of specific parts, weight, etc. It is appreciated that the features identified by the measuring system (e.g., overall dimensions, physical characteristics (e.g., presence of fat or other tissue types), dimension of a physical feature, prevalence of a tissue type in the meat, presence of a feature (or lack thereof), cut surface aspect, cut surface characteristics, presence of sawdust, characteristics of the sawdust, presence of damage on meat, presence of damage on specific meat structure, surface aspect, subsurface aspect, presence of debris on the meat (e.g., meat flap, small pieces of meat or fat, etc.), presence of foreign material, etc.) and related data can be included in the indexing process.

[0121]

[0128] The indexing apparatus can include a plate positioned at a predefined location along the processing line, such as at a start thereof. The plate can include markers detectable by the measuring system, together with the carcass, to initially index the carcass prior to processing (e.g., before the first and second cuts). The markers can include a grid pattern and / or points on the plate, among other possibilities. The indexing apparatus can thus provide a fixed reference point usable to define a correspondingly fixed and / or constant starting point for the processing system for each carcass to be processed. It should be noted that, by providing a fixed starting point, differences between the starting positions of each carcass can be reduced or eliminated, thereby providing a more consistent process and more consistent by-products (e.g., final meat products).

[0122]

[0129] In some embodiments, the indexing apparatus can include a plurality of plates provided at respective locations along the processing line. As such, the configuration of the piece of meat can be adjusted, if necessary, at many points along the processing line. For instance, the piece of meat can be initially adjusted at the starting point, re-adjusted (if needed) after the first cut, and so on. The plate can also be adapted to assist in stabilizing the piece of meat during the cutting process. In some embodiments, the plate of the indexing apparatus can correspond to the stabilizing surface of the companion chain, although other configurations are possible.

[0123]

[0130] It will be appreciated from the foregoing disclosure that there is provided a meat processing system including a loading station 24, where the shoulders (or various other meat pieces) are set on the conveyor system which is operable to move the shoulders through the different systems of the meat processing system and to carry away the different byproducts created along the way. The meat processing system also includes a measuring system for scanning the shoulders and a processing system that analyzes the scans from the measuring system to produce customized cutting instructions. Finally, the articulated robots of the cutting assembly perform cuts with specialized tools, based on the instructions created by and transmitted from the processing system.

[0124]

[0131] It is noted that the meat processing system decomposes the neck bone lifting procedure in two sequenced cuts, thus lowering the complexity of each cut. Each cut is performed with a different cutting tool, which allows the plant to meet the application requirements in cut speed and yield. It should be noted that typical shoulder deboning lines will include neckbone lifters (typically done manually) and neckbone trimmers. In some embodiments, the shoulder deboning line can require including more neckbone trimmers than neckbone lifters to ensure clean cuts and quality of the produced meat pieces, among others. However, it should be noted that, by having many trimmers, the production line may end up with large quantities of trimmings while losing out on potential shoulder meat (e.g., on the butt and picnic). The processing system described herein can assist in creating lean cuts (or close to the bone) for lifting the neckbone, which will reduce the number of trimmers required.

[0125]

[0132] The present disclosure may be embodied in other specific forms without departing from the subject matter of the claims. The described example embodiments are to be considered in all respects as being only illustrative and not restrictive. For example, while the embodiments described herein include a pair of articulated robots provided with respective cutting tools, the procedure can be accomplished using a single robot configured to follow a single cutting sequence. Inversely, the meat processing system can include more than two robots, for example, to further decompose the procedure in additional cuts (e.g., decomposing the second cutting sequence itself into two or more operations) and / or to accommodate for increased production capacity. It should also be noted that the meat processing system as described herein can be adapted to remove neck bones from the shoulders of any other animal species.

[0126]

[0133] In some embodiments, a cleaning or sanitizing station can be added as part of the meat processing system 10. The sanitizing station can be configured to enable cleaning and / or sanitizing the cutting tools 33. The sanitizing station can be located within the range of motion of the manipulator systems 40 to allow the manipulator systems to move the cutting tools 33 to the sanitizing station. The cutting tools 33 can be cleaned and sanitized after each cut, at regular intervals and / or at any suitable intervals. The cutting tools can therefore be cleaned and / or sanitized dynamically (e.g., during operation) without requiring halting or slowing down production. The manipulator systems can each share a common sanitizing station, or a plurality of sanitizing stations can be provided and associated with respective manipulator systems.

[0127]

[0134] S imilarly, in some embodiments, a sharpening station can be added as part of the meat processing system 10. The sharpening station can be configured to enable sharpening the cutting tools 33. The sharpening station can be located within the range of motion of the manipulator systems 40 to allow the manipulator systems to move the cutting tools to the sharpening station. The cutting tools 33 can be sharpened after each cut, at regular intervals and / or at any suitable intervals. The cutting tools can therefore be sharpened dynamically (e.g., during operation) without requiring halting or slowing down production. The manipulator systems can each share a common sharpening station, or a plurality of sharpening stations can be provided and associated with respective manipulator systems.

[0128]

[0135] In some embodiments, the featherbones can be “precut” in order to further simplify the neckbone lifting operations. This precutting step can be done on the kill floor (aka “backfinning” operations) adapted to loosen the featherbones from the loin meat as well as from the shoulder meat. Precutting of the featherbones could be done manually before the neckbone lifting for all shoulders (e.g., when no backfinning operations are implemented) or for remaining shoulders (e.g., if backfinning operations are implemented). Similarly, in some embodiments, the ribs of the neckbone can be precut (e.g., using a circular saw). As such, the second cutting sequence would not have to include a cutting path under the ribs because the ribs would be gone, resulting in a smaller / shorter cutting path. An example of precut ribs is shown in Figures 12 and 13. Alternatively, although the ribs are precut, the second cutting sequence can perform the entire cut, following the same cutting path as though the ribs are present. It is appreciated that the cutting path is therefore not adjusted or changed between pieces, which can simplify and facilitate the overall operations.

[0129]

[0136] In other words, in some embodiments, the precutting operations can create a precut but still have the ribs remain on the shoulder for the neckbone removal process. As such, processing of the shoulder can still include a first cut of the spinal column done with the first cutting tool, and a second cut done with the second cutting tool. However, in this embodiment, the second cutting tool can follow a partial second cutting sequence, where the cutting tool cuts into the shoulder until the precut. Alternatively, the second tool could continue the cut (i.e. , complete the second cutting sequence) to debone the remaining portion of the ribs and brisket. In yet another embodiment, a third cutting tool can be used to debone the remaining part following the partial second cutting sequence, for example.

[0130]

[0137] In another embodiment, the precutting operations can create a precut which enables lifting the ribs on the center section of the carcass (see Figures 12 and 13) when the shoulder is processed. In this embodiment, the shoulder can thus be deboned with the first and second cuts, using the first and second cutting tools, respectively. The second cut can similarly correspond to a partial cut to cut until the precut. In some embodiments, the brisket can still be attached to the lifted ribs during precutting operations, or left on the shoulder. If the brisket remains on the shoulder, the brisket can be deboned according to the first and second cutting sequences, even if the ribs are gone.

[0131]

[0138] In some embodiments, the cutting assembly can be provided with one or more sensors configured to monitor the operations of the various cutting tools. For example, a force sensor can be coupled to one or both of the cutting tools in order to monitor the force / pressure applied to and / or by the cutting tool during the corresponding cutting sequence. It is noted that, if a cutting tool cuts a carcass proximate or towards a bone, the force required to continue cutting the carcass will gradually increase. The force sensor can therefore provide indications of force variations, enabling dynamic adjustments of the cutting path to avoid cutting the bone, for example. In other words, force sensors can enable adjusting a cutting tool’s planned or predetermined cutting path during the cutting operation.

[0132]

[0139] The described example implementations are to be considered in all respects as being only illustrative and not restrictive. In the present disclosure, an embodiment is an example or implementation of the described devices, systems and methods. The various appearances of “one embodiment,” “an embodiment” or “some embodiments” do not necessarily all refer to the same embodiments. Although various features may be described in the context of a single embodiment, the features may also be provided separately or in any suitable combination. Conversely, although the described devices, systems and methods may be described herein in the context of separate embodiments for clarity, it may also be embodied in a single embodiment. Reference in the specification to “some embodiments”, “an embodiment”, “one embodiment”, or “other embodiments”, means that a particular feature, structure, or characteristic described in connection with the embodiments is included in at least some embodiments, but not necessarily in all embodiments.

[0133]

[0140] As used herein, the terms “coupled”, “coupling”, “attached”, “connected” or variants thereof as used herein can have several different meanings depending on the context in which these terms are used. For example, the terms coupled, coupling, connected or attached can have a mechanical connotation. For example, as used herein, the terms coupled, coupling or attached can indicate that two elements or devices are directly connected to one another or connected to one another through one or more intermediate elements or devices via a mechanical element depending on the particular context.

[0134]

[0141] Similarly, positional descriptions such as “top”, “bottom”, “above”, “under”, “below”, “left”, “right”, “front”, “rear”, “parallel”, “perpendicular”, “transverse”, “inner”, “outer”, “internal”, “external”, and the like should, unless otherwise indicated, be taken in the context of the figures and should not be considered limiting.

[0135]

[0142] In the above description, the same numerical references refer to similar elements. Furthermore, for the sake of simplicity and clarity, namely so as to not unduly burden the figures with several references numbers, not all figures contain references to all the components and features, and references to some components and features may be found in only one figure, and components and features of the present disclosure which are illustrated in other figures can be easily inferred therefrom. The implementations geometrical configurations, materials mentioned and / or dimensions shown in the figures are optional, and are given for exemplifications purposes only.

[0136]

[0143] In addition, although the optional configurations as illustrated in the accompanying drawings comprises various components and although the optional configurations of the described devices and systems as shown may consist of certain geometrical configurations as explained and illustrated herein, not all of these components and geometries are essential and thus should not be taken in their restrictive sense, i.e. should not be taken as to limit the scope of the present disclosure. It is to be understood that other suitable components and cooperations thereinbetween, as well as other suitable geometrical configurations may be used for the implementation and use of the described devices and systems, and corresponding parts, as briefly explained and as can be easily inferred herefrom, without departing from the scope of the disclosure.

Claims

CLAIMS1. A method for at least partially severing a neck bone portion from a carcass having a spinal column and a rib structure, the method comprising: cutting the carcass with a first cutting tool adapted to cut the carcass along a first cutting path around and along the spinal column to a predetermined cutting length, according to a first cutting sequence; andcutting the carcass with a second cutting tool adapted to cut the carcass along a second cutting path around the rib structure and around the spinal column, according to a second cutting sequence, wherein the first and second cutting sequences are performed in succession.

2. The method according to claim 1 , wherein at least one of the first cutting sequence and the second cutting sequence is adapted to be performed manually or automatically.

3. The method according to claim 1 or 2, wherein the first and second cutting tools are operatively connectable to a support frame rotatably connectable to a manipulator system.

4. The method according to claims 3, wherein the manipulator system comprises a robotic arm, and wherein the support frame is rotatably connected at a distal end of the robotic arm for enabling movement of the first and second cutting tools in a 3D environment.

5. The method according to claim 4, further comprising, after cutting the carcass with one of the first cutting tool and the second cutting tool, changing the one of the first cutting tool and the second cutting tool on the support frame with the other one of the first cutting tool and the second cutting tool.

6. The method according to any one of claims 1 to 5, wherein the first and second cutting tools are operatively connected to first and second support frames, respectively, and the first and second support frames are rotatably connected to first and second manipulator systems, respectively.

7. The method according to any one of claims 1 to 6, wherein the first cutting tool comprises an annular blade defining a closed perimeter and adapted to cut circumferentially around the spinal column and along the predetermined cutting length in a single operation.

8. The method according to any one of claims 1 to 7, wherein the second cutting tool is one of a waterjet, a cutting blade, a laser, an ultrasonic knife, an ultrasonic saw, a reciprocating knife and a reciprocating saw.

9. The method according to any one of claims 1 to 8, wherein at least one of the first cutting path and the second cutting path is defined according to at least one of a yield optimization assessment, a neck bone morphology, cutting tool capacities and cut quality requirements.

10. The method according to claim 9, wherein the yield optimization assessment includes market value of different meat pieces associated with the neck bone portion.

11. The method according to any one of claims 1 to 10, wherein the first cutting path is at least partially defined by a curvature of the spinal column.

12. The method according to any one of claims 1 to 11 , wherein the first cutting sequence comprises, following cutting along the spinal column to the predetermined cutting length, having the first cutting tool reverse along the spinal column to exit the carcass proximate an entry point of the first cutting tool.

13. The method according to any one of claims 1 to 12, wherein the first cutting sequence comprises having the first cutting tool penetrate and exit the carcass at substantially a same location on the carcass.

14. The method according to any one of claims 1 to 13, wherein the first and second cutting tools are independently movable with respect to each other.

15. The method according to any one of claims 1 to 14, wherein the first and second cutting tools are independently operational from each other.

16. The method according to any one of claims 1 to 15, wherein the second cutting path is adapted to connect with the first cutting path in at least one location.

17. The method according to any one of claims 1 to 16, wherein the second cutting path includes cutting underneath featherbones.

18. The method according to any one of claims 1 to 17, wherein the carcass corresponds to a half carcass, or a shoulder cut of a pig.

19. The method according to any one of claims 1 to 18, wherein combined cuts of the first cutting tool and the second cutting tool fully detach the neck bone portion from the carcass.

20. The method according to any one of claims 1 to 19, further comprising, prior to cutting the carcass:gathering data regarding the carcass using a measuring system; andcreating and sending cutting instructions based on gathered data by the measuring system to the first and second cutting tools, the cutting instructions comprising the first and second cutting paths.

21. The method according to claim 20, wherein the measuring system is configured to gather data between the first and second cutting sequencesin order to create and send updated cutting instructions following a completion of a first one of the first and second cutting sequences.

22. The method according to claim 20 or 21 , wherein the measuring system includes a vision system provided with at least one of a camera, a 2D scanner, a 3D scanner, an X-ray scanning machine and a CT scanning machine.

23. The method according to claim 22, wherein the measuring system is configured to gather data of a plurality of carcasses such that the first and second cutting paths are created and customized for each carcass, individually.

24. The method according to any one of claims 1 to 23, wherein the second cutting sequence is performed before the first cutting sequence.

25. The method according to any one of claims 1 to 23, wherein the first cutting sequence is performed before the second cutting sequence.

26. The method according to any one of claims 1 to 23, wherein the first cutting sequence is performed simultaneously with the second cutting sequence.

27. The method according to any one of claims 1 to 26, further comprising conveying the carcass along a processing line using a conveying assembly, the first and second cutting tools being positioned along the processing line.

28. The method according to claim 27, further comprising stabilizing the carcass using a companion chain extending along the processing line.

29. The method according to claim 27 or 28, further comprising indexing the carcass using an indexing apparatus at least at a starting point of the processing line.

30. The method according to claim 29, wherein the indexing apparatus comprises a plate provided with fixed markers configured to enable adjusting a position of the carcass relative to the fixed markers.

31. The method according to claim 30, wherein each carcass is adjusted in a fixed starting position using the fixed markers of the indexing apparatus.

32. The method according to claim 30 or 31 , wherein the plate is adapted to stabilize the carcass conveyed along the processing line.

33. A cutting assembly for at least partially severing a neck bone portion from a carcass, the neck bone portion of the carcass having a spinal column and a rib structure, the cutting assembly comprising:a first cutting tool adapted to cut the carcass along a first cutting path and according to a first cutting sequence including:penetrating the carcass proximate a cranial end of the spinal column; andcutting along the spinal column to a predetermined cutting length; anda second cutting tool adapted to cut the carcass along a second cutting path and according to a second cutting sequence including:cutting around the rib structure; andcutting around the spinal column;wherein the first and second cutting sequences are performed in succession or simultaneously.

34. The cutting assembly according to claim 33, wherein the second cutting sequence includes penetrating the carcass proximate a distal end of the rib structure and exiting the carcass after cutting around the spinal column.

35. The cutting assembly according to claim 33, wherein the second cutting sequence includes penetrating the carcass proximate the spinal column and exiting the carcass proximate a distal end of the rib structure after cutting around the rib structure.

36. The cutting assembly according to any one of claims 33 to 35, wherein the step of cutting around the spinal column includes cutting around the featherbones.

37. The cutting assembly according to any one of claims 33 to 35, wherein the step of cutting around the spinal column includes at least partially cutting the featherbones.

38. The cutting assembly according to any one of claims 33 to 37, further comprising a manipulator system having a robotic arm, and wherein the first and second cutting tools are operatively connectable to the manipulator system .

39. The cutting assembly according to claim 38, wherein the first and second cutting tools are rotatably connected at a distal end of the robotic arm for enabling movement of the first and second cutting tools in a 3D environment.

40. The cutting assembly according to claim 38 or 39, wherein the manipulator system comprises first and second manipulator systems, and wherein the first and second cutting tools are rotatably connected to the first and second manipulator systems, respectively.

41. The cutting assembly according to any one of claims 33 to 40, wherein at least one of the first and second cutting tools is independently movable with respect to the other one of the cutting tools.

42. The cutting assembly according to any one of claims 33 to 41 , wherein the first cutting tool comprises an annular blade defining a closed perimeter andadapted to cut circumferentially around the spinal column and along the predetermined cutting length in a single operation.

43. The cutting assembly according to any one of claims 33 to 42, wherein the second cutting tool is one of a waterjet, a cutting blade, a laser, an ultrasonic knife, an ultrasonic saw and a reciprocating knife.

44. The cutting assembly according to any one of claims 33 to 43, wherein the second cutting tool is shaped and sized to enable the second cutting path to connect with the first cutting path in at least one location.

45. The cutting assembly according to any one of claims 33 to 44, wherein the first and second cutting tools are independently movable with respect to each other.

46. The cutting assembly according to any one of claims 33 to 45, wherein the first and second cutting tools are independently operational from each other.

47. The cutting assembly according to any one of claims 33 to 46, wherein at least one of the first cutting path and the second cutting path is defined according to at least one of a yield optimization assessment, a neck bone morphology, cutting tool capacities and cut quality requirements.

48. The cutting assembly according to any one of claims 33 to 47, wherein the first cutting tool is adapted to follow a curvature of the spinal column.

49. The cutting assembly according to any one of claims 33 to 48, wherein the carcass corresponds to a half carcass, or a shoulder cut of a pig.

50. The cutting assembly according to any one of claims 33 to 49, wherein the carcass includes one or more legs.

51. The cutting assembly according to any one of claims 33 to 49, wherein the carcass is devoid of legs.

52. The cutting assembly according to any one of claims 33 to 51 , wherein the first cutting tool and the second cutting tool are configured to cooperate to fully detach the neck bone portion from the carcass.

53. The cutting assembly according to any one of claims 33 to 52, wherein the second cutting sequence is performed before the first cutting sequence.

54. The cutting assembly according to any one of claims 33 to 53, wherein the first cutting sequence is performed before the second cutting sequence.

55. A meat processing system for processing carcasses and sever a neck bone portion therefrom, the meat processing system comprising:a conveying assembly adapted to convey the carcasses along a predetermined path; anda cutting assembly provided about the predetermined path of the conveying assembly, the cutting assembly being defined in any one of the preceding claims.

56. The meat processing system of claim 55, wherein the conveying assembly further comprises a transport rail and a cradle pivotally connected to the transport rail, and wherein the cradle is adapted to hold the carcasses in a static position.

57. The meat processing system of claim 55 or 56, wherein the conveying assembly is arranged in a carousel configuration such that the predetermined path forms a closed or semi-closed path.

58. The meat processing system of any one of claims 55 to 57, further comprising a measuring system operable to index the carcasses being conveyed along the predetermined path prior to being processed by the cutting assembly.

59. The meat processing system of claim 58, wherein the measuring system is configured to gather data of each carcass individually such that the first andsecond cutting paths are created and customized for each carcass, individually.

60. The meat processing system of claim 58 or 59, further comprising a processor operable to create and send cutting instructions to the first and second cutting tools based on the data gathered by the measuring system.

61. The meat processing system of any one of claims 58 to 60, wherein the measuring system includes a vision system provided with at least one of a camera, a 2D scanner, a 3D scanner, an X-ray scanning machine and a CT scanning machine.

62. A meat processing system for processing carcasses and sever a neck bone portion therefrom, the meat processing system comprising :a measuring system adapted to collect data regarding the carcasses; a processor configured to receive and analyze the data in order to generate cutting instructions; anda cutting assembly adapted to receive the cutting instructions, comprising:a first cutting tool, adapted to cut the carcass based on the cutting instructions by cutting along the spinal column to a predetermined cutting length; anda second cutting tool, adapted to cut the carcass based on the cutting instructions by cutting around the rib structure towards the spinal column and around the spinal column.

63. The meat processing system of claim 62, further comprising the features of any one of the preceding claims.

64. The meat processing system of claim 62 or 63, wherein the measuring system is configured to collect data regarding each carcass, individually, and wherein the processor is configured to generate customized cutting instructions for each carcass, individually.

65. A meat processing system for processing carcasses and removing a portion therefrom, the meat processing system comprising :a measuring system adapted to collect data regarding the carcasses; a processor configured to receive and analyze the data in order to:create a digital cut along the carcass to enable removal of the portion; andgenerate cutting instructions including decomposing the digital cut in at least a first cutting sequence and a second cutting sequence; and a cutting assembly adapted to receive the cutting instructions and comprising:a first cutting tool, adapted to cut the carcass based on the first cutting sequence; anda second cutting tool, adapted to cut the carcass based on the second cutting sequence.

66. The meat processing system of claim 65, further comprising the features of any one of the preceding claims.

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