Optical Egg Picker Malfunction Detection

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Solution Overview

Problem

Conventional egg handling devices fail to reliably detect and remove non-live eggs from egg flats, leading to contamination risks and inefficiencies in vaccination processes, especially in flu vaccine production, due to issues like vacuum line plugging and adhesive foreign matter.

Innovation Solution

The method involves using a light source and detector or camera to measure the time a light path is blocked as an egg picker moves above and across the egg carrier, generating signals to indicate whether an egg has been successfully removed, and tracking the number of failed removals to identify malfunctioning pickers, thereby ensuring accurate egg removal and maintaining equipment functionality.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional vacuum-based egg picker is used to remove eggs from carrier, then egg removal function is provided, but vacuum lines become plugged and reliability deteriorates

Engineering Contradiction:

Improveegg picker reliabilityVSAvoidvacuum line plugging

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The patent replaces the vacuum-based mechanical egg picking system with an optical detection system that uses light sources and sensors to detect egg presence and picker malfunction without physical contact, eliminating vacuum line plugging issues while maintaining egg removal functionality

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces optical sensors and light sources as intermediary detection elements between the egg picker and the eggs, allowing indirect monitoring of egg removal status without the vacuum system directly contacting the eggs, thus preventing plugging while maintaining reliability

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If automatic egg removal system is implemented, then productivity increases, but detection of malfunctioning pickers becomes more difficult

Engineering Contradiction:

Improveegg removal efficiencyVSAvoidpicker malfunction detection

Core Design Contradiction:

ProductivityVSDifficulty of detecting and measuring

Solution Approach 1:

The patent implements an optical feedback system where sensors detect whether eggs have been successfully removed from the carrier and provide real-time information about picker performance, enabling automatic identification of malfunctioning pickers while maintaining high productivity

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The egg picker system performs self-diagnosis through the optical detection system that automatically monitors its own operation and identifies malfunctions without external intervention, maintaining productivity while enabling easy malfunction detection

Inventive Principle:

Principle #25Self-service

3Loss of time

If non-live eggs are not promptly removed from carrier, then handling time is reduced, but contamination risk increases

Engineering Contradiction:

Improveegg handling timeVSAvoidcontamination risk

Core Design Contradiction:

Loss of timeVSObject-affected harmful factors

Solution Approach 1:

The patent uses optical sensors to detect and identify non-live eggs before they are removed from the carrier, allowing the system to prepare for their removal and ensure prompt elimination, thus minimizing contamination risk while optimizing handling time

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent replaces manual inspection and handling with an automated optical detection system that quickly identifies non-live eggs and coordinates their removal, reducing both handling time and contamination risk through rapid automated processing

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

This solution enables quick identification and removal of non-live eggs, reduces contamination risks, and maintains the reliability of egg handling systems by detecting malfunctioning egg pickers, improving hatch rates and vaccine production efficiency.

Implementation Method 1

measuring a length of time that the light path is blocked when the egg picker is moved from the first location to the second location and back towards the first location

Methodology Applied

Scientific EffectLight blockage: Absorption (EM radiation)

Data Source

PatentUS8339587B2Method for detecting a malfunctioning egg picker

Publication Date: 2012.12.25 ZOETIS SERVICES LLC

AI summary

Methods and apparatus are provided that automatically determine whether or not eggs designated for removal from an egg carrier have been removed by an egg removal apparatus. Light is emitted along a path above and across an egg carrier as an egg picker moves to pick up an egg. The length of time that the light path is blocked when the egg picker is moved is measured and used to determine whether or not the egg has been removed from the carrier. Another apparatus and method is provided for detecting a malfunctioning egg picker. A detection device detects a number of eggs in the egg carrier. A control device monitors the egg picker and the detection device. The control device calculates the number of eggs in the egg carrier for determining when the number of eggs varies a predetermined amount from an egg count number for the egg carrier.