Device and method for performing a cut in a poultry leg on a poultry leg conveying device moving in a system for deboning poultry legs in an automated poultry processing line

Abstract

The present invention relates to a device for performing a cut in a poultry leg on a poultry leg conveying device moving in a system for deboning poultry legs in a poultry processing line, the device comprising a first cylindrical cam (21) fixed in the device for performing a cut, the first cam (21) comprising recessed tracks (12, 15, 16, 17) along its circumference, the tracks (12, 15, 16, 17) defining distinct paths; a second cam (51) fixed in the device for performing a cut; a carousel (5) arranged to rotate around the centre of the cams (21, 51), the carousel (5) comprising, on its circumference, pairs of spaced vertical rods (6), each pair of rods (6) being arranged to slidably receive a cutting module, wherein the cutting module comprises: a first movable block (14) engaged in the track (12) of the cam (21) and a support block (26) coupled to the first movable block (14); a second movable block (23) engaged in the track (15) of the cam (21); a third movable block (24) engaged in the track (16) of the cam (21); a fourth movable block (7) engaged in the track (17) of the cam (21); each pair of rods (6) being further arranged to receive a leg support device by means of a fixed block (53), the leg support device being actuated by the second cam (51); and a cutting blade (25) fixed to the support block (26).

Description

DEVICE AND METHOD FOR PERFORMING A CUT ON A POULTRY LEG IN A POULTRY LEG CONVEYOR DEVICE THAT CIRCULATES IN A POULTRY LEG DEBONING SYSTEM IN AN AUTOMATED POULTRY PROCESSING LINE FIELD OF THE INVENTION

[0001] The present invention relates to a device and a method for performing a "C" cut on poultry legs circulating in a poultry leg deboning system in a food production line. More specifically, the present invention relates to an automated device and method for performing a "C" cut on poultry legs. FUNDAMENTALS OF THE INVENTION

[0002] Due to the constant pursuit of greater efficiency and safety in meat processing in the poultry industry, various devices for making cuts in poultry legs for deboning are known in the state of the art.

[0003] Patent BR112017016154-0B1 discloses a device for producing a longitudinal incision in an animal extremity part with a first bone and a second bone articulated by a joint. The device includes a guide element, a cutting unit associated with the guide element to translate the longitudinal movement. The cutting unit includes a cutting blade mounted for movement between a first position and a second position in a foreground. The device further includes a primary drive mechanism to move the cutting unit longitudinally from the elongated linear guide element. The device also includes a secondary drive mechanism to move the cutting blade between the first position to receive an animal extremity part transported by the conveyor in the cutting unit and the second position to perform the preparatory longitudinal incision of the animal extremity part.The cutting blade has an adjustable cutting direction in a second plane perpendicular to the first plane.

[0004] The BR112017016154-0B1 device features a rotating carousel comprising upper and lower discs and pairs of parallel vertical shafts responsible for sliding a cutting unit. The rotating carousel rotates in coordination with a suspended conveyor responsible for carrying the animal parts. Centered on the carousel is a stationary drum including guide tracks around its perimeter, where the guide tracks are responsible for inducing up and down movements of the cutting unit, as well as activating elements of the cutting unit, such as a positioning roller, a cutting knife (blade), among others.

[0005] US patent document 20240180176A1 discloses a slit-forming device for chicken thigh meat that includes: an ankle support piece configured to hold a bone-in chicken thigh meat ankle cut from a femur of a chicken carcass; a blade unit having a slit-forming blade; an insertion drive piece configured to drive the blade unit so that a blade tip of the slit-forming blade is inserted into the chicken thigh meat along an opposite side relative to a patella on a tibia between the chicken thigh meat held in the ankle support piece; and a leg meat pressing piece configured to elastically press a surface of the chicken thigh meat on one side of the patella.

[0006] Patent PI1103165-4B1 presents a method and a device for splitting a chicken leg, which is suspended by the ankle joints from a conveyor that forms part of a series of conveyors that are mobile in a processing line. The leg comprises a thigh and a drumstick that are connected to each other by the knee joint, and a positioning step is applied to position the leg in the proper position for cutting. Subsequently, in an incision step, a knife is attached to the leg. This incision step is followed by a splitting step in which the knife is moved through the leg to provide a split in the longitudinal direction, so as to allow the subsequent deboning step of the leg.The device for deboning a chicken leg, as described in Patent PI1103165-4B1, comprises a pressing element responsible for pressing the chicken leg, near the knee joint, against an opposing surface, and a second pressing element for pressing the chicken leg laterally, thus arranging the chicken leg in a substantially straight orientation.

[0007] Patent BR112012010258-3 BI discloses an automated device for deboning a bone-in leg from a livestock carcass, comprising a clamping unit suspending the bone-in leg and including a servomotor, a threaded shaft connected to a servomotor output shaft, and a threaded lifting and lowering block mounted on the threaded shaft. A lifting and lowering roller mounted on a lifting and lowering shaft moves along a travel path to lower and transfer the bone-in leg to a subsequent workstation. By bringing an oscillating roller mounted on the lifting and lowering shaft into contact with the meat plate, the lifting and lowering shaft is rotated by an adjustable angle so that the bone-in leg faces rounded cutting blades. Thus, the path of the rounded cutting blades can be approximately straight, thereby simplifying and reducing the cost of the travel mechanism.

[0008] Although devices and methods exist for performing cuts on a poultry leg in a poultry leg conveyor device that circulates in a poultry leg deboning system on an automated poultry processing line, as known from the prior art, said devices are not capable of guaranteeing precise and consistent cuts.

[0009] The device and method presented herein seek to solve the challenge of increasing productivity by automating the process of deboning poultry legs, allowing for faster and more efficient operation. The increased productivity offered by the device and method of the present invention is advantageous because it is achieved through standardization of deboning, greater precision and quality of cut, greater food safety offered by the processed products, reduction of human error, and greater safety for operators. SUMMARY OF THE INVENTION

[0010] Considering the aspects and problems presented in the current state of the art, and with the purpose of overcoming them, a new and unprecedented device was developed for cutting a poultry leg in a poultry leg conveyor device that circulates in a poultry leg deboning system in an automated poultry processing line. A corresponding method was also developed.

[0011] The device that is the subject of the present invention is for cutting a poultry leg in a poultry leg conveyor device that circulates in a poultry leg deboning system in an automated poultry processing line, wherein the poultry leg comprises a thigh and a drumstick. The device of the present invention comprises a first cylindrical meat piece fixed to the cutting device, the first meat piece comprising recessed tracks along its circumference, the tracks being vertically spaced and defining distinct paths; a second meat piece fixed to the cutting device;A carousel configured to rotate around the center of the meats, the carousel comprising, in its circumference, pairs of spaced vertical rods, each pair of rods being configured to receive, in a sliding manner, a cutting module, wherein the cutting module comprises: a first movable block engaged in the track of the first meat and a support block coupled to the first movable block; a second movable block engaged in the track of the first meat; a third movable block engaged in the track of the first meat; a fourth movable block engaged in the track of the first meat; each pair of rods being further configured to receive a leg support device via a fixed block, the leg support device being actuated by the second meat; a cutting blade fixed to the support block.

[0012] A second object of the present invention relates to a method for performing a cut on a poultry leg in a poultry leg conveyor device that circulates in a poultry leg deboning system in an automated poultry processing line, which is performed by the device of the present invention, wherein the method has the steps of: receiving a poultry leg hanging on a hook in the poultry leg conveyor device, the poultry leg conveyor device moving at a constant speed; synchronizing a rotational movement of a carousel of the cutting device with the movement of the poultry leg conveyor device; activating the leg support through the movement of the carousel in relation to the meat, the leg support maintaining the poultry leg stable in a vertical position;Support the bird's leg with a bar in a position opposite to the center of the carousel when activating the moving block through the movement of the carousel in relation to the meat; make an incision in the bird's leg with the cutting blade when activating the moving block through the movement of the carousel in relation to the meat; move the cutting blade vertically downwards, making a cut along the thigh of the bird's leg, when activating the moving blocks through the movement of the carousel in relation to the meat; bend the bird's leg at its joint with the bar when activating the moving block through the movement of the carousel in relation to the meat; when the cutting blade is in the region of the bird's leg joint, retract the bar when activating the moving block again. DESCRIPTION OF THE FIGURES

[0013] The device and method according to the present invention are further explained by means of the accompanying drawings, in which: Figure 1 shows a complete configuration of the device that is the subject of the present invention.

[0014] Figure 2 shows in detail the movable blocks of an exemplary cutting module of the device that is the subject of the present invention.

[0015] Figure 3 shows in detail the fixed block of an exemplary cutting module of the device that is the subject of the present invention.

[0016] Figure 4 presents a first approximate view of the device that is the subject of the present invention.

[0017] Figure 5 shows a second close-up view of the device that is the subject of the present invention.

[0018] Figure 6 presents a third, close-up view of the device that is the subject of the present invention.

[0019] Figure 7 presents a fourth close-up view of the device that is the subject of the present invention.

[0020] Figure 8 presents a fifth, approximate view of the device that is the subject of the present invention.

[0021] Figure 9 illustrates how the "C" cut is made in the bird's leg using the device that is the subject of the present invention. DETAILED DESCRIPTION

[0022] This section presents in detail the solution proposed by the present invention, with reference to the figures described in the previous section.

[0023] According to Figure 1, it is possible to observe the device for cutting a poultry leg in a poultry leg conveyor device that circulates in a poultry leg deboning system in an automated poultry processing line, the subject of the present invention. The device of the present invention comprises a carousel 5 configured to rotate around a central axis, a first fixed and centered meat 21 with the carousel 5, and a second meat (shown in Figure 4), that is, while the first cylindrical meat 21 and the second meat are stationary, the carousel 5 rotates around the same central axis. Along its circumference, the carousel 5 accommodates multiple cutting modules.

[0024] In a preferred configuration, carousel 5 accommodates 16 (sixteen) cutting modules.

[0025] Figure 2 shows elements of an exemplary cutting module that comprise the device that is the subject of the present invention. Specifically, the cutting module comprises movable blocks 7, 14, 23, 24. A lever 35, attached to movable block 14 and movable block 23, is configured to transfer motion from movable block 23 to a transverse movable block 26, to which a cutting blade 25 is attached. A rod 19 connected to movable block 24 transfers the motion from movable block 24 to actuate a bar 22 that rotates around a cylinder 38 which is fitted onto a shaft 28. A rod 20 connected to movable block 7 transfers its motion to the bar 18 which rotates around a shaft 30.

[0026] Figure 3 shows a fixed block 53 that forms part of a leg support device and is configured to not move. A bearing 52 is responsible for actuating an articulated assembly that is attached to the fixed block 53 by a hinge pin 54. The moving assembly also comprises an upper spring 55 attached by a spring support 57 to the fixed block 53, and a lower spring 56. The upper and lower springs 55, 56 serve to absorb small displacements of the bird leg during the cutting process. When the articulated assembly is actuated, a leg support 50 is activated to maintain the bird leg in a perfectly vertical position throughout the process.

[0027] Next, with reference to figures 4 to 9, the operation of the device that is the subject of the present invention will be described. To facilitate understanding of the device of the present invention, figures 4 to 9 illustrate only one cutting module. However, the device should be considered as containing multiple cutting modules in sequence along the circumference of the carousel 5.

[0028] Figure 4 presents a first approximate view of the device of the present invention. It can be observed that the cutting module is coupled to the carousel 5 by means of two parallel vertical rods 6 fixed to the carousel 5. As mentioned in relation to Figure 2, the cutting module comprises the movable blocks 7, 14, 23, 24, which are configured to slide up or down on the rods 6. The movable blocks 7, 14, 23, 24 are also individually engaged in recessed tracks 12, 15, 16, 17 present on the surface of the cam 21. Thus, the relative vertical position of the movable blocks 7, 14, 23, 24 depends on the path defined by the tracks 12, 15, 16, 17. The leg support device will be activated by the contact of the bearing 52 with the cam 51.

[0029] In a preferred configuration, the movable blocks 7, 14, 23, 24 are engaged in the recessed tracks 12, 15, 16, 17 by means of bearings 8, 9, 10, 11.

[0030] According to the present invention, the movable block 14 moves up and down guided by the rods 6, being actuated by the bearing 8 which is engaged in the track 12 of the cam 21. The movable block 23 moves up and down guided by the rods 6, being actuated by the bearing 9 which is engaged in the track 15 of the cam 21. The movable block 24 moves up and down guided by the rods 6, being actuated by the bearing 10 which is engaged in the track 16 of the cam 21. The movable block 7 moves up and down guided by the rods 6, being actuated by the bearing 11 which is engaged in the track 17 of the cam 21.

[0031] According to the upward or downward path of track 15, the movable block 23 moves. When block 23 rises, it pushes lever 35, which in turn moves the transverse movable block 26 horizontally outwards, towards a hook 1 on which a bird's leg is positioned where the cut will be made. As explained, a cutting blade 25 is fixed to the transverse movable block 26 via a cutting blade support 27. Therefore, this movement is responsible for the incision of the cutting blade 25 in the bird's leg.

[0032] Similarly, the upward or downward path of track 17 dictates the movement performed by the moving block 7. The movement of the moving block 7 is transferred by the rod 20 to the bar 18, which is responsible for supporting the bird's leg from the outside in, keeping the bird's leg, after the incision of the cutting blade 25, close to the cutting module.

[0033] Figure 5 shows the device of the present invention in the first stage of the cutting process. The bird leg (not shown), as explained, must be on hook 1. The bird leg support 50 is actuated by the bearing 52 which runs on the carcass 51, keeping the bird leg in a perfectly vertical position. The movable block 7 is the first to move, following the path of the track 17. As block 7 rises, the rod 20 is pushed, actuating the bar 18. The bar 18 rotates around the axis 30. With the completion of the ascent of track 17, the bar 18 aligns itself and approaches hook 1.

[0034] Figure 6 shows the device at a second stage of the cutting process. As the carousel 5 continues to rotate, track 15 raises the movable block 23. This movement activates lever 35, which pushes the transverse movable block 26 towards hook 1. Figure 7 illustrates the movable block 23 at its ideal point, taking the transverse movable block 26 to its maximum travel. This causes the cutting blade 25 to make an incision in the bird's leg hanging on hook 1.

[0035] Figure 8 shows the continuation of the cutting process performed by the device of the present invention. Following the rotation of the carousel 5, the tracks 12, 15, 16, 17 begin to descend together and parallel, thus causing the blocks 7, 14, 23, 24 to move accordingly, following the defined paths. Thus, the cutting blade 25 begins its descent along a thigh bone of the bird's leg to a joint of the bird's leg between the thigh and the drumstick.

[0036] When track 16 changes its path to an upward direction, the movable block 24 pushes the rod 19, causing the bar 22 to rotate around the axis 28 and rise, folding the thigh so that the cutting blade 25 continues the "C" cut close to the bone. This movement occurs to raise the thigh when the cutting blade 25 is in the region of the bird's leg joint. This causes the cutting blade 25 to continue cutting close to the thigh bone and perform the "C" cut. The thigh remains raised until track 16 descends again, lowering the movable block 24, causing the bar 22 to descend and the thigh to return to its original position. At this moment, tracks 12, 15, 16, 17 of meat 21 have moved blocks 7, 14, 23, 24 vertically away from hook 1, and cutting blade 25 has already made the cut to the end.

[0037] According to the present invention, the cutting blade 25 is fixed, so there is no need to tilt or rotate it to make the desired "C" cut. The cutting blade 25 is moved, firstly, horizontally forward to penetrate the meat of the poultry leg and, secondly, vertically downward to cut the meat.

[0038] Figure 9 illustrates more clearly the "C" cut made by the device of the present invention. As explained, the cut must be made flush with the thigh and drumstick bone. To do this, an incision is made with the cutting blade 25 at point 33 of the bird's leg, descending to point 32, where the bird's leg is articulated and where the drumstick is inclined by the bar 22 so that the cutting blade 25 remains flush with the bone, continuing to point 34. The "C" cut, also known as the thigh score, is necessary to facilitate the deboning of the meat that remains over the thigh, drumstick, and joint bone.

[0039] According to a second object of the present invention, a method is presented for performing a cut on a poultry leg in a poultry leg conveyor device that circulates in a poultry leg deboning system in an automated poultry processing line using the device of the present invention.

[0040] The method that is the subject of the present invention comprises the following steps: receiving a bird leg hanging from a hook 1 on the bird leg conveyor device, the bird leg conveyor device moving at a constant speed; synchronize a rotational movement of a carousel 5 of the cutting device with the movement of the bird leg transport device; Activate the leg support 50 by moving the carousel 5 in relation to the meat 51, the leg support 50 keeping the bird's leg stable in a vertical position; support the bird's leg with a bar 18 by a position opposite to the center of the carousel 5 when activating the movable block 7 through the movement of the carousel 5 in relation to the meat 21; Using the cutting blade 25, make an incision in the bird's leg by activating the movable block 23 through the movement of the carousel 5 in relation to the meat 21; move the cutting blade 25 vertically downwards, making a cut along the thigh of the bird leg, by activating the moving blocks 7, 14, 23, 24 through the movement of the carousel 5 in relation to the cam 21; bend, using bar 22, the bird's leg at its joint by activating the movable block 24 through the movement of the carousel 5 in relation to the meat 21 when the cutting blade 25 is in the region of the bird's leg joint; and, retract bar 22 when activating movable block 24 again.

[0041] As described, the device and method of the present invention advantageously offer: - Cutting precision: the cutting blade is configured to start cutting the meat close to the thigh bone, following a precise "C" shaped path through the joint to the end of the thigh bone, ensuring consistent and uniform cuts; Automation: The device integrates an automated system for moving the blocks that support the equipment parts, reducing the need for manual intervention and increasing efficiency. - Positioning system: the device includes a positioning mechanism that firmly holds the bird's leg during the cutting process, minimizing errors and ensuring the correct final result; - Waste reduction: the device was designed to minimize meat loss during cutting, maximizing yield; - Adaptation to different sizes: the device was designed to adapt to different sizes of bird legs, ensuring consistency and quality; - Modular design: the device was designed in a modular way, allowing for easy maintenance and replacement of components, as well as enabling future technology upgrades; - Reduced risk of contamination: minimizing manual handling contributes to a safer environment in terms of food hygiene; - Ease of integration: the device can be easily integrated into existing automated production lines, increasing the versatility of the deboning process; and, - Possibility of adjustments: adjustments in cutting depth, adapting to different sizes and shapes of poultry legs.

[0042] The advantages described above obtained through the device and method of the present invention are achieved primarily by: - Bird leg orientation: the bird leg is positioned with the side where the cut should be made facing inwards towards the device; - Linear displacement of the cutting blade: the cutting blade moves linearly towards the bird's leg; - Cutting blade stability: the cutting blade maintains the same position and angle during the cutting process, from the beginning of the thigh bone until it passes the end of the hamstring bone; - Support rod: the support rod for the bird's leg moves externally to the bird's leg, from the outside in, maintaining a constant cutting depth throughout the process; - Thigh bend: when the cutting blade reaches the bird's leg joint, a second rod bends the thigh against the cutting blade, ensuring that the cut is made flush with the thigh bone; and, - Synchronized movement of the blocks: the four movable blocks, controlled by the recessed tracks on the carcass, perform synchronized vertical movements to position the parts of the device and execute all the movements necessary for cutting.

[0043] The device and method described herein, which are the subject of this patent, may have their basic constituent elements constructed using different technologies, as well as different accessory configurations according to the characteristics, types of installations, and needs of the users; logically, alterations may be made to the device and method without loss of the innovation presented herein.

Claims

CLAIMS 1. Device for performing a cut on a poultry leg in a poultry leg conveyor device that circulates in a poultry leg deboning system in an automated poultry processing line, wherein the poultry leg comprises a thigh and a drumstick; the device being characterized by the fact that it comprises: a first cylindrical meat (21) fixed in the cutting device, the first meat (21) comprising tracks (12, 15, 16, 17) in low relief along its circumference, the tracks (12, 15, 16, 17) being spaced vertically and defining distinct paths; a second meat (51) fixed to the device for performing cutting; a carousel (5) configured to rotate around the center of the meats (21, 51), the carousel (5) comprising, on its circumference, pairs of spaced vertical rods (6), each pair of rods (6) being configured to receive, in a sliding manner, a cutting module, wherein the cutting module comprises: a first movable block (14) engaged in the track (12) of the cam (21) and a support block (26) coupled to the first movable block (14); a second mobile block (23) engaged on the track (15) of the car (21); a third mobile block (24) engaged on the track (16) of the car (21); and, a fourth mobile block (7) engaged on the track (17) of the car (21); each pair of rods (6) being further configured to receive a support device by means of a fixed block (53), the support device being actuated by the second rod (51); and a cutting blade (25) fixed to the support block (26).

2. Device according to claim 1, characterized in that the bird leg is arranged on a hook (1) of the bird leg deboning system.

3. Device according to claim 1 or 2, characterized in that the movable blocks (7, 14, 23, 24) are individually engaged in the tracks (12, 15, 16, 17) by means of bearings (8, 9, 10, 11).

4. Device according to any one of claims 1 to 3, characterized in that the leg support (50) is mounted on a movable structure comprising a bearing (52), an upper spring (55), a lower spring (56) and a pivot pin (54).

5. Device according to any one of claims 1 to 4, characterized in that at least two horizontal shafts extending in a radial direction outward from the first movable block (14) are configured to receive the support block (26) in a sliding manner.

6. Device according to any one of claims 1 to 5, characterized in that the second movable block (23) is connected to a lever (35) connected to the support block (26) and to the first movable block (14).

7. Device according to any one of claims 1 to 6, characterized in that the third movable block (24) is connected to a rod (19) attached to a bar (22) configured to rotate around an axis (28).

8. Device according to any one of claims 1 to 7, characterized in that the fourth movable block (7) is connected to a rod (20) attached to a bar (18).

9. Method for performing a cut on a poultry leg in a poultry leg conveyor device that circulates in a poultry leg deboning system in an automated poultry processing line using a device as defined in claim 1, characterized in that it comprises: receiving a bird leg hanging from a hook (1) on the bird leg conveyor device, the bird leg conveyor device moving at a constant speed; synchronize a rotational movement of a carousel (5) of the cutting device with the movement of the bird leg transport device; activate the leg support (50) by moving the carousel (5) in relation to the meat (51), the leg support (50) keeping the bird's leg stable in a vertical position; support the bird's leg with a bar (18) by a position opposite to the center of the carousel (5) when activating the moving block (7) through the movement of the carousel (5) in relation to the meat (21); make an incision in the bird's leg using the cutting blade (25) by activating the movable block (23) through the movement of the carousel (5) in relation to the meat (21); move the cutting blade (25) vertically downwards, making a cut along the thigh of the bird leg, by activating the moving blocks (7, 14, 23, 24) through the movement of the carousel (5) in relation to the meat (21); bend, with the bar (22), the bird leg at its joint by activating the movable block (24) through the movement of the carousel (5) in relation to the meat (21) when the cutting blade (25) is in the region of the bird leg joint; retract the bar (22) when activating the movable block (24) again.

10. Method according to claim 9, characterized in that the steps of bending the bird leg and retracting the bar (22) occur while the cutting blade (25) is still moving vertically downwards.

11. Method according to claim 9 or 10, characterized in that the movable blocks (7, 14, 23, 24) are engaged in low-relief tracks (12, 15, 16, 17) on the surface of the cam (21) by means of bearings (8, 9, 10, 11), and in which the actuation of the movable blocks occurs by altering the direction of paths defined by the tracks (12, 15, 16, 17).

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