Rack Drive Floor Expulsion System for Laying Nests
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Solution Overview
Problem
Existing laying nest expulsion systems, such as gear rack and torsion systems, face challenges including high operational costs due to heavy-duty requirements, inefficient space usage, and incomplete removal of hens, particularly dead birds, which affects desoiling and sanitation.
Innovation Solution
A rack drive expulsion system with a gear wheel and arcuate gear rack integrated into the floor of the laying nest, allowing the floor to pivot and act as the expulsion plate, reducing the number of moving parts and optimizing space usage, enabling efficient hen removal and improved sanitation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a gear rack system is used to expel hens, then hens can be removed from the laying nest, but the system requires heavy-duty drive components and high operational power
Solution Approach 1:
Instead of lifting the floor upward to expel hens (conventional gear rack system), this invention inverts the approach by rotating the floor horizontally around a vertical axis. The floor rotates from a horizontal position to a vertical position, using gravity to facilitate hen expulsion rather than direct mechanical lifting force.
Solution Approach 2:
The invention replaces the conventional vertical lifting mechanical system with a horizontal rotation system. A single gear wheel engages with the floor's gear rack to initiate rotation, and the floor's own weight and gravitational force complete the expulsion action, reducing the need for heavy-duty drive components.
2Productivity
If the gear rack extends below the box to enable expulsion, then hens can be effectively removed, but the ability to stack multiple boxes is reduced
Solution Approach 1:
The gear rack is inverted and integrated onto the underside of the floor rather than extending below the box. This allows the expulsion mechanism to be contained within the box volume, enabling vertical stacking of multiple boxes while maintaining effective hen removal capability.
Solution Approach 2:
The gear rack is nested within the floor structure itself, with the gear rack teeth formed on the underside of the floor panel. This nested configuration eliminates the need for external protruding components, maximizing space efficiency for stacking.
3Device complexity
If a torsion expulsion system is used, then hens can be removed with simpler mechanics, but the expulsion plate may block the egg discharge opening
Solution Approach 1:
The floor is segmented into distinct functional zones: an egg discharge opening area and an expulsion area. The expulsion plate is positioned and sized to rotate only over the hen-containing area, leaving the egg discharge opening clear and unobstructed during the expulsion cycle.
Solution Approach 2:
The expulsion plate is designed with dynamic positioning that changes during operation. It rotates from a retracted position (allowing egg discharge) to an extended expulsion position (removing hens), then returns to the retracted position, dynamically avoiding blockage of the egg opening.
4Reliability
If heavy-duty drive components are used to lift full weight of hens plus bottoms, then reliable expulsion is achieved, but manufacturing cost and device complexity increase
Solution Approach 1:
The system inverts the force application approach: instead of applying upward force to lift hens against gravity, the floor rotates horizontally and uses gravity to facilitate downward and outward hen movement. This reduces the mechanical force requirements and simplifies the drive system.
Solution Approach 2:
The floor's own weight and the gravitational force acting on the hens are utilized to accomplish the expulsion action. The single gear wheel provides only the initial rotational impulse, after which gravity performs the main work of moving the floor and expelling hens, reducing the need for complex heavy-duty drive components.
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 achieves efficient hen removal with fewer moving parts, reduced operational power consumption, and enhanced desoiling capabilities, maximizing nesting space and ensuring consistent removal of hens and detritus.
Implementation Method 1
a gear wheel having a plurality of teeth, the gear wheel being fixedly connected with the first shaft; a gear rack having a plurality of teeth that correspond to the teeth of the gear wheel
Data Source
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AI summary
This invention relates to laying nest having a rack drive expulsion system. As disclosed herein, the invention preferably comprises a laying nest for hens comprising a box and a rack drive floor expulsion system. The floor pivotably moves between first and second positions by virtue of a gear rack that is fixedly connected to and disposed within the box, and a gear wheel that is rotatably connected to the floor. Accordingly, the expulsion system provides for the selected removal of hens from the laying nests as desired.