Rib Primal Cut Portioning Using X-Ray Bone Detection
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Solution Overview
Problem
The challenge in meat processing lies in accurately portioning and trimming rib primal cuts of quadruped animals, particularly the St. Louis style rib rack, due to the embedded bones and cartilage, which are not visible, making it difficult to make precise cuts and achieve uniform meat portions without risking personnel safety or incurring miss-cuts, while also aiming to maximize yield and quality.
Innovation Solution
A system and method that involves scanning the meat workpiece to generate data on the location, size, and shape of embedded bones, using this data to determine the optimal cutting strategy, and controlling a cutter to make precise cuts based on desired physical characteristics of the final pieces, including the use of X-ray scanning and optical scanning to ensure accurate portioning and trimming.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual or powered band saw cutting is used to portion rib primal cuts, then the process is simple and equipment is easy to operate, but the cutting precision is poor and miss-cuts occur frequently due to invisible embedded bones and cartilage
Solution Approach 1:
The system performs preliminary scanning of the rib primal cut using X-ray and optical sensors to detect the location, shape, and size of embedded bones and cartilage before cutting. This advance detection allows the control system to plan cutting paths that avoid these structures, ensuring precise cuts without accidentally cutting through bones or cartilage, thereby eliminating miss-cuts before the cutting operation begins.
Solution Approach 2:
The patent introduces an intermediary detection system consisting of X-ray scanners and optical sensors that act as mediators between the cutting tool and the rib primal cut. These sensors detect the invisible embedded bones and cartilage and transmit this information to the control system, which then adjusts the cutting path accordingly. This intermediary detection layer enables precise cutting without direct visual contact with the hidden internal structures.
2Reliability
If hand cutting or powered band saw is used, then equipment complexity is low, but personnel safety is compromised due to difficulty in making accurate cuts and potential contact with hidden bones and cartilage
Solution Approach 1:
The rib primal cut performs self-service by detecting its own internal bone and cartilage structure through X-ray and optical scanning. The embedded bones and cartilage are automatically detected and their locations are mapped by the scanning system, eliminating the need for operator intervention to visually locate these structures. This self-detection capability ensures safety by preventing the cutter from contacting hidden hard structures that could cause accidents.
Solution Approach 2:
The patent replaces the mechanical cutting system with an automated controlled cutting system guided by non-contact sensing. Instead of relying on manual operation or simple powered saws that require direct contact and visual guidance, the system uses X-ray and optical sensors to detect internal structures and a control system to automatically guide the cutter, substituting mechanical manual operation with automated sensor-guided control to improve safety.
3Productivity
If traditional cutting methods are used, then equipment is simple, but productivity is reduced due to frequent miss-cuts and need for rework
Solution Approach 1:
The system implements feedback by continuously scanning the rib primal cut and using the detected bone and cartilage location data to adjust the cutting path in real-time. The control system receives feedback from the sensors about the actual internal structure and modifies the cutting trajectory accordingly, ensuring that cuts are made optimally to avoid bones and cartilage. This closed-loop feedback control eliminates miss-cuts and rework, significantly improving portioning efficiency.
Solution Approach 2:
The scanning and detection of bone and cartilage locations is performed as a preliminary action before the cutting operation begins. This advance detection allows the system to plan the optimal cutting path that maximizes meat yield and avoids hidden structures, preventing miss-cuts before they occur and eliminating the need for rework, thereby improving overall productivity.
4Manufacturing precision
If cuts are made without visual guidance of embedded bones, then the process is fast, but manufacturing precision deteriorates leading to non-uniform meat portions
Solution Approach 1:
The system performs preliminary scanning and creates a digital model of the rib primal cut's internal bone and cartilage structure before cutting begins. This advance detection and modeling allow the control system to plan the precise cutting path that ensures uniform meat portions, avoiding the need for slow visual inspection during cutting while maintaining high precision.
Solution Approach 2:
The patent creates a digital copy or model of the rib primal cut's internal structure through X-ray and optical scanning. This digital model replicates the location and shape of embedded bones and cartilage, allowing the control system to plan cutting paths based on this virtual representation. The digital copy enables precise cutting without requiring physical visual inspection, maintaining speed while achieving uniform portions.
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 enables accurate and safe portioning of rib primal cuts, minimizing miss-cuts and maximizing the yield of high-quality rib meat products by ensuring precise cuts based on the physical characteristics of the bones and cartilage, thus improving the efficiency and safety of the meat processing process.
Implementation Method 1
The workpiece is scanned while being conveyed to generate data regarding the physical characteristics of the workpiece... including the location, shape and size of the bones embedded in the workpiece
Implementation Method 2
using the data to determine the physical characteristics of the workpiece, including the location, shape and size of the bones embedded in the workpiece
Data Source
AI summary
An animal ribcage primal cut having a bone array located therein is portioned into one or more sub primal cuts, each having at least one bone located therein. The primal cut is scanned at scanning station 14 while being conveyed on a conveyor 12 to determine the physical characteristics of the primal cut. A processor 18 determines how to portion the primal cut into desired sub primal cuts in accordance with desired physical characteristics of the sub primal cut and production requirements for the sub primal cuts. A controller controls a cutter to divide the primal cut into one or more sub primal cuts according to the determination previously made on how to portion the primal cut into desired sub primal cuts.