Fluid Jet Sorting System for High-Speed Meat Product Separation
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Solution Overview
Problem
Current sorting systems for small meat products, such as chicken nuggets, face challenges in achieving high-speed and accurate sorting due to the need for precise separation and handling of small, lightweight pieces, which existing mechanical and electro-mechanical systems cannot efficiently manage, leading to increased giveaway and reduced productivity.
Innovation Solution
A sorting system utilizing a conveyor with embedded nozzles that discharge fluid transversely to blow off workpieces into specific chutes based on characteristics determined by a scanner, allowing for precise and efficient sorting of small pieces by weight and size, with the ability to configure for different products and settings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional mechanical roller graders or weigh scale graders are used for sorting small meat pieces, then sorting can be performed, but the sorting speed is too slow to handle thousands of pieces per hour
Solution Approach 1:
The patent replaces traditional mechanical roller graders and weigh scale graders with a vision-based sorting system using cameras and image processing algorithms. This substitution enables high-speed sorting of small meat pieces by analyzing visual characteristics rather than relying on slow mechanical weighing processes, achieving the capability to handle thousands of pieces per hour while maintaining sorting precision through advanced image analysis
Solution Approach 2:
The patent uses optical copying through camera imaging to create digital representations of meat pieces for analysis. Instead of physically weighing each piece with slow mechanical scales, the system captures optical copies and processes them through image recognition algorithms, enabling rapid identification and sorting based on visual characteristics that correlate with weight and quality
2Measurement precision
If weigh belt graders are used for sandwich sized chicken portions, then accurate weight-based sorting is achieved, but the system cannot efficiently sort very small pieces like chicken nuggets at high speeds
Solution Approach 1:
The patent replaces the mechanical weigh belt grader system with a vision-based sorting system that uses cameras and image processing to identify and sort small meat pieces. This substitution removes the physical constraints of mechanical weighing mechanisms, allowing the system to process very small pieces like chicken nuggets at high speeds while maintaining accurate sorting based on visual characteristics that correlate with weight
3Ease of operation
If the sorting system uses traditional mechanical separation methods, then sorting can be performed, but small lightweight pieces cannot be efficiently separated and handled
Solution Approach 1:
The patent replaces traditional mechanical separation methods with a vision-guided system that uses cameras and image processing to identify small lightweight pieces. The system then uses controlled air jets or other non-contact actuation methods to separate and direct pieces into appropriate bins, achieving both high handling efficiency for small pieces and precise separation accuracy based on visual analysis of piece characteristics
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system enables accurate and high-speed sorting of small meat products, reducing giveaway and increasing productivity by allowing for precise separation and handling of small pieces, achieving sub-gram accuracy and handling thousands of pieces per hour with minimal equipment and labor.
Implementation Method 1
one or more blow off bars (BB) positioned over the top surface of the conveyor system, wherein the blow off bars include one or more nozzles that discharge a fluid across the conveyor to blow off workpieces
Data Source
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AI summary
A method and system for sorting workpieces, such as chicken nuggets. The sorting system includes a conveyor system that advances in a forward direction and one or more blow off bars positioned over the conveyor system. The blow off bars extend along the forward advancing direction. The blow off bars include one or more valved nozzles connected to a pressurized source of a fluid, and the nozzles are positioned to discharge the fluid across the conveyor system.