Rib Primal Cut Portioning Using 3D Bone Mapping
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Solution Overview
Problem
Existing methods for portioning and trimming rib primal cuts, such as St. Louis style ribs, face challenges in accurately cutting around embedded bones and cartilage, leading to difficulty in achieving uniform meat portions and increased risk of miss-cuts.
Innovation Solution
A system and method that utilizes scanning technology to generate data on the physical characteristics of rib primal cuts, including bone locations and sizes, to model and simulate optimal cutting paths, enabling precise portioning and trimming into desired sub primal cuts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If hand cutting or powered band saw is used to trim rib primal cuts, then the cutting process is simple and equipment is basic, but the cutting accuracy is poor and miss-cuts increase due to embedded bones and cartilage being invisible
Solution Approach 1:
The system performs preliminary scanning of the rib primal cut to generate a 3D model and identify bone locations before cutting begins. This advance preparation allows the cutting path to be planned around embedded bones and cartilage, preventing miss-cuts without requiring complex real-time adjustments during the cutting process
Solution Approach 2:
A 3D computational model serves as an intermediary between the invisible embedded bones and the cutting tool. The model translates internal bone structures into visible spatial information, enabling accurate cutting path planning without direct visual contact with the bones during cutting
2Productivity
If manual trimming is performed to achieve uniform meat portions, then equipment simplicity is maintained, but productivity decreases and yield is reduced due to difficulty in making accurate curved cuts
Solution Approach 1:
The system replaces manual mechanical cutting with an automated waterjet cutting system guided by 3D modeling. The waterjet follows computationally determined paths that account for bone locations and desired portion uniformity, achieving both high productivity and cutting precision without manual intervention
Solution Approach 2:
The cutting system dynamically adjusts the cutting path based on the 3D model of individual rib primal cuts. Each cut is customized according to the specific bone structure detected, allowing uniform portions to be achieved across varying meat geometries while maintaining high automated productivity
3Manufacturing precision
If scanning technology is implemented to detect bone locations, then cutting accuracy improves, but equipment complexity and initial investment increase
Solution Approach 1:
Instead of using complex physical scanning equipment, the system creates a computational 3D copy or model of the rib primal cut's internal structure. This virtual model captures bone locations and geometries, enabling accurate cutting planning without requiring expensive or complex physical scanning hardware
Solution Approach 2:
The system replaces complex mechanical scanning equipment with computational modeling techniques. The 3D model is generated through image processing and computational geometry rather than physical measurement, reducing equipment complexity while maintaining detection accuracy
4Loss of substance
If automated portioning is used to reduce miss-cuts, then yield and quality improve, but the complexity of determining optimal cutting paths increases
Solution Approach 1:
The system performs preliminary computational analysis to determine optimal cutting paths before actual cutting begins. By pre-calculating paths that maximize meat yield and avoid bones based on the 3D model, the system reduces complexity during execution while achieving high yield and quality results
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
Enables accurate and safe portioning of rib primal cuts with reduced miss-cuts, improving yield and quality of higher value meat products by adhering to desired physical characteristics and production requirements.
Implementation Method 1
The workpiece is scanned while being conveyed to generate data regarding the physical characteristics of the workpiece. Data generated by the scanning of the workpiece is used to determine the physical characteristics of the workpiece, including the location, shape and size of the bones embedded in the workpiece.
Data Source
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Figure 4
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.