Lettuce Core Removal via Sectional Optical Detection
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Solution Overview
Problem
Current methods for removing the core of varying-shaped lettuces and salads result in significant yield losses and product non-conformities due to inaccuracies in positioning the cutting blades, leading to discarded good leaves and core pieces in the packaged product.
Innovation Solution
A process and installation that orient the lettuce head with its underside facing upwards, cutting it into sections perpendicular to the core axis, allowing precise detection and removal of core pieces using optical or optoelectronic equipment and a circular knife adapted to each section, ensuring accurate core identification and removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If circular knives are placed in the path of lettuce leaves to cut all around the stalk, then the peeling process can be automated for standard-shaped lettuces, but significant yield losses occur when processing lettuces with varying core shapes and sizes
Solution Approach 1:
The lettuce head is divided into multiple sections by cutting planes perpendicular to the core axis. Each section is processed individually through the trimming device, allowing precise adaptation to the actual core position and shape in each section, thereby avoiding unnecessary removal of good leaves while maintaining automation.
Solution Approach 2:
The patent replaces purely mechanical circular knife cutting with a system that uses optical or optoelectronic detection equipment to identify core position and shape, then uses this information to control the trimming process. This substitution of detection and control mechanisms enables precise adaptation to varying core characteristics while maintaining automated operation.
2Ease of operation
If circular knives are positioned to cut close to the stalk, then complete unhooking of leaves is achieved, but inaccuracies occur when core shape is unknown, leading to peeling defects
Solution Approach 1:
The lettuce head is first cut into sections before the trimming operation. This preliminary segmentation allows the actual core position and shape to be revealed in each section, enabling subsequent precise trimming adjustments to be made based on actual observations rather than assuming a standard core configuration.
Solution Approach 2:
The patent implements a feedback mechanism where optical or optoelectronic detection equipment observes the core position and shape in each section, and this information is used to control the trimming device. This closed-loop feedback enables the system to adapt to varying core characteristics and maintain high peeling precision.
3Reliability
If pieces of core are not properly discarded, then they may end up in packaged products causing non-conformities, but more aggressive trimming increases yield losses
Solution Approach 1:
The trimming device is configured to remove core material only from specific locations where the detection equipment identifies actual core presence. Each section is trimmed locally according to its specific core characteristics rather than applying uniform aggressive trimming throughout, thereby maintaining product quality while minimizing yield loss.
Data Source
Figure 1A~2
Figure 3
Figure 4A~4C
AI summary
The method involves determining an axis (Z-Z) of a core of a vegetable i.e. adult salad head (1). The vegetable is cut into a set of sections along a set of cutting planes (P1, P2) that is arranged approximately perpendicularly to the axis. A position of the core in the set of sections is determined. The core is cut along the axis. A cut section is recovered, and a cycle of detection of the presence of core is repeated. The position of the core is determined for other sections, and the core is cut in the corresponding section in the event of presence of the core. An independent claim is also included for an installation for removing the core from the vegetable such as head of an adult salad.