Automated Poultry Leg Deboning System
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Solution Overview
Problem
Current automated deboning processes for poultry legs are costly and complex, making them inaccessible to smaller meat processing industries, and require manual preparation steps that are time-consuming and inefficient.
Innovation Solution
A method and system for automatically removing meat from poultry extremities by holding the first bone at a free end, mechanically separating the meat, severing the second bone at the joint, and collecting the meat, which can be adapted using existing equipment with minimal modifications, allowing for a two-step process that includes optional pre-cutting and skin removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automated deboning processes are implemented, then productivity and efficiency are improved, but device complexity and cost increase significantly
Solution Approach 1:
The deboning process is divided into distinct sequential stages: initial positioning, first meat separation, bone severing, and second meat removal. Each stage uses dedicated simple equipment rather than one complex machine, reducing overall system complexity while maintaining automation and productivity.
Solution Approach 2:
The invention uses simple, inexpensive mechanical components such as basic cutters, scrapers, and conveyors that can be easily replaced or adjusted. Rather than investing in complex expensive automated systems, the process uses multiple simple devices that perform specific functions sequentially.
2Ease of manufacture
If existing equipment is used with minimal modifications, then cost is reduced, but manufacturing precision and process reliability may be compromised
Solution Approach 1:
The process begins with preliminary steps including positioning the bone, making initial cuts to expose the joint, and preparing the meat-bone interface. These preliminary actions using simple equipment create optimal conditions for subsequent precise meat separation, ensuring both cost-effectiveness and deboning precision.
Solution Approach 2:
The invention introduces intermediate processing steps and auxiliary equipment such as positioning fixtures, guide rails, and intermediate conveyors that bridge the gap between simple existing equipment and the required precision. These intermediaries enable accurate meat separation without requiring complex modified equipment.
3Device complexity
If manual preparation steps are required, then equipment complexity is reduced, but loss of time and productivity decrease
Solution Approach 1:
The invention combines multiple operations into integrated equipment units. For example, the cutter and scraper functions are combined in a single automated station, and the bone severing and meat separation are performed in continuous sequence without manual intervention, eliminating preparation time while keeping individual equipment units simple.
Solution Approach 2:
The process is designed to be self-sufficient with automated positioning, cutting, and scraping mechanisms that require minimal manual setup or intervention. The equipment automatically performs all necessary operations including initial cuts, meat separation, bone severing, and collection, eliminating time-consuming manual preparation steps.
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 approach simplifies the deboning process, reduces equipment requirements, and makes it cost-effective for smaller industries, enabling efficient and reliable meat removal from poultry extremities with reduced manual intervention and inedible remnants.
Implementation Method 1
mechanically separating the meat from the first bone and moving the meat lengthwise of the first bone in a direction toward the joint
Data Source
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AI summary
A method of automatically removing meat from an animal or poultry extremity that includes first and second bones articulated by a joint and surrounded by the meat. The method includes a step (3), which provides the animal or poultry extremity, and a step (11) of holding the first bone at a free end thereof remote from the joint. Further the method includes a step (19) of separating the meat from the first bone while moving the meat lengthwise of the first bone in a direction toward the joint, and moving the meat, preferably just short of the joint. The method is continued by the steps (25, 27) of severing the second bone from the first bone adjacent the joint, and collecting the severed second bone with all the meat attached thereto. In a continuation of the method the steps (29, 21) are performed of holding the thus collected second bone at a distal end thereof remote from an end that was attached to the first bone and separating, as well as removing the meat from the second bone longitudinally thereof in a direction toward the end that was attached to the first bone. The continuation of the method is concluded with collecting the meat (37). Also provided is a system (1) that includes means for performing the steps of the method.