Poultry Processing Conveyor Batching and Distribution
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Solution Overview
Problem
Existing animal processing facilities face challenges in efficiently and accurately distributing harvested poultry parts due to complex and crowded conveyor systems, making it difficult to access and clean these systems effectively.
Innovation Solution
A poultry processing system that utilizes hoppers to batch poultry parts and a data processing system to control the movement of these parts onto a transportation conveyor based on weight or count thresholds, ensuring accurate and efficient distribution and packaging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If conveyors are positioned closely together to save space, then the processing facility footprint is reduced, but the conveyors become difficult to access and clean
Solution Approach 1:
The conveyor system is divided into separate, modular sections that can be independently accessed and maintained. Each conveyor segment is designed as a discrete unit with access points, allowing cleaning operations on one section without disrupting others, thus maintaining compact overall layout while improving individual component accessibility.
Solution Approach 2:
The conveyor arrangement utilizes three-dimensional spatial configuration rather than purely two-dimensional close positioning. Conveyors are arranged at different elevations and angles, creating vertical and diagonal separation that reduces horizontal footprint while maintaining adequate access corridors for cleaning operations.
2Adaptability or versatility
If multiple conveyors are used to transport harvested tissues, then distribution capability is improved, but the system complexity and difficulty of maintenance increase
Solution Approach 1:
The conveyor system employs standardized, multi-functional modules that can serve multiple distribution routes and product types. Each conveyor unit is designed with universal mounting interfaces and interchangeable components, allowing the same hardware configuration to handle different tissue types and delivery destinations, thereby reducing overall system complexity despite increased distribution capability.
Solution Approach 2:
The system incorporates easily replaceable conveyor sections that can be quickly removed, cleaned, or replaced without affecting the entire system. Worn or contaminated segments are discarded and replaced with fresh modules, maintaining high distribution capability while simplifying maintenance through modular replacement rather than complex overhauls.
3Speed
If conventional conveyor systems are used without batching, then continuous flow is maintained, but packaging accuracy and speed are reduced
Solution Approach 1:
The system implements periodic batching cycles where conveyors accumulate a predetermined quantity or weight of harvested tissues into discrete batches before releasing them to packaging. This rhythmic accumulation and release pattern optimizes packaging line throughput while ensuring consistent batch sizes that improve packaging accuracy and enable faster processing cycles.
Solution Approach 2:
Weight sensors and counters on the conveyors provide real-time feedback on batch composition, allowing the system to automatically adjust accumulation rates and timing. This closed-loop control ensures that batches are released to packaging at optimal moments with precise target weights, simultaneously maximizing packaging speed and maintaining high accuracy through continuous monitoring and adjustment.
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 increases the speed and accuracy of animal processing by systematically depositing poultry parts onto the conveyor, improving the efficiency of the packaging process and facilitating better cleaning and maintenance of the conveyor systems.
Implementation Method 1
The first input device includes a weight sensor configured to detect the weight of the poultry parts within the first hopper
Data Source
AI summary
A poultry part harvesting, sorting, and packaging apparatus and system utilizes an arrangement of hoppers to batch poultry parts removed by cut-up machines and deposits the batches onto a transportation conveyor. Each batch is contained within a separate zone on the conveyor, and the system tracks the location of batches and open spaces on the conveyor to deliver the batches to user defined locations.