Carcass Part Processing System with Rotating Saw and Positioning
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Solution Overview
Problem
The existing methods for removing a hock/shank from a pork shoulder result in inconsistent cuts and yield loss, with bone dust contamination, which affects the quality and value of the meat.
Innovation Solution
A system utilizing a rotating saw blade and positioning pair structures that allow for precise planar cuts at a predetermined position, synchronized with 360° cuts through the skin and muscle structures, minimizing bone dust and ensuring clean cuts by adjusting the angular position of the carcass parts and using a combination of overhead and positioning conveyor systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual hock/shank removal is performed on a horizontal conveyor, then the process is simple to operate, but the cuts are inconsistent and yield is lost
Solution Approach 1:
The patent replaces manual mechanical cutting with an automated rotating saw blade system. The saw module includes a rotating saw blade that performs precise planar cuts through the carcass parts, eliminating the inconsistency of manual cutting while maintaining operational simplicity through automation.
Solution Approach 2:
The patent implements preliminary positioning of carcass parts using positioning pair structures before the cutting operation. The carcass parts are positioned and stabilized in a predetermined orientation on the conveyor, ensuring that subsequent cuts are made at consistent, predetermined locations, thereby improving cut consistency.
2Loss of substance
If manual cutting is used, then the equipment is simple, but bone dust contaminates the meat and yield is reduced
Solution Approach 1:
The patent replaces manual cutting tools with a rotating saw blade system that produces cleaner cuts with minimal bone dust generation. The controlled mechanical cutting action of the rotating saw blade separates bone from meat more efficiently, reducing bone dust contamination and improving yield.
Solution Approach 2:
The positioning pair structures are configured to pre-position carcass parts in optimal orientations before cutting. This preliminary positioning ensures that cuts are made at precise locations and angles, maximizing meat yield by minimizing unnecessary bone inclusion and reducing bone dust generation.
3Manufacturing precision
If carcass parts are hung vertically and stabilized, then cut consistency improves, but the positioning system becomes more complex
Solution Approach 1:
The patent uses positioning pair structures that are pre-configured to automatically position and stabilize carcass parts in predetermined orientations as they move along the conveyor. This preliminary positioning action ensures consistent vertical hanging and stabilization without requiring complex active control systems.
Solution Approach 2:
The positioning pair structures are designed to self-position carcass parts through their geometric configuration and interaction with the conveyor system. The structures work passively to align and stabilize parts using the conveyor's motion and gravity, eliminating the need for complex active positioning mechanisms.
4Loss of substance
If a rotating saw blade is used for planar cuts, then yield increases and bone dust is reduced, but the system complexity increases
Solution Approach 1:
The patent introduces a rotating saw blade system that replaces less efficient cutting methods. The rotating saw blade delivers superior cut quality with minimal bone dust and maximum yield, and it is integrated into the existing conveyor system, balancing improved performance with manageable system complexity.
Solution Approach 2:
The positioning pair structures prepare carcass parts by pre-positioning them in optimal orientations before they reach the rotating saw blade. This preliminary preparation ensures that the saw blade operates at maximum efficiency, achieving high yield and clean cuts while simplifying the overall control requirements of the sawing system.
Data Source
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Figure 3a~3b
AI summary
A system for processing carcass parts includes an overhead conveyor and a saw module comprising supporting means for interacting with a lower end portion of each incoming carcass part, the supporting means adjusting an angular position of the carcass parts as a result of the carcass parts resting at least partly on the supporting means while being conveyed by the overhead conveyor. A positioning conveyor having a plurality of spaced-apart positioning pair structures arranged below the overhead conveyor and adjacent to the supporting means receives the carcass parts from the supporting means. Each carcass part is guided into a predetermined position within the positioning pair structures and cut at a predetermined position, e.g. defined by a 360° cut through skin and muscle structures of each of the carcass parts.