Robotic Carcass Cutting with 3D Imaging and Adaptive Control
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Solution Overview
Problem
Current automated carcass cutting systems are limited in their ability to perform all major processing cuts and lack integration of product and information flows, leading to inefficiencies and bottlenecks in large-scale commercial operations, and they often require manual intervention due to variations in animal carcasses.
Innovation Solution
An integrated automated meat processing system utilizing X-ray and optical imaging to create three-dimensional models of carcasses, combined with robotic arms and precise cutting mechanisms, allowing for end-to-end processing without the need for manual handling and enabling scalable and flexible operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automated carcass cutting systems are implemented, then butchering time and butcher injury are reduced, but the systems are expensive and capable of performing only a limited number of processing operations
Solution Approach 1:
The robotic arm system is designed to perform multiple different cutting operations and processing tasks on various carcass types through programmable control and interchangeable end effectors, allowing a single automated system to replace multiple specialized manual butchering operations
2Productivity
If automated carcass cutting systems are implemented, then butchering time is reduced, but the systems require transfer between manual and automated processes
Solution Approach 1:
The system integrates X-ray imaging, optical imaging, 3D modeling, and robotic cutting operations into a single unified automated workflow, eliminating the need for separate manual and automated process stages by combining all functions within one continuous automated system
Solution Approach 2:
X-ray and optical imaging systems capture and process carcass data before the cutting operation begins, creating 3D models that guide the robotic arm in advance, allowing the system to plan and execute cuts without intermediate manual intervention
3Productivity
If automated carcass cutting systems are implemented, then butchering time is reduced, but the systems are not adapted to take into account variations between different animal carcasses
Solution Approach 1:
X-ray and optical imaging systems continuously scan and capture images of each carcass, providing real-time feedback data that is processed into 3D models, allowing the control system to automatically adjust cutting parameters and paths based on the specific anatomical variations of each individual carcass
Solution Approach 2:
The system dynamically modifies cutting parameters such as blade position, angle, depth, and speed based on 3D model data derived from imaging, enabling automatic adaptation to different carcass sizes, shapes, and anatomical features without manual reprogramming
4Manufacturing precision
If manual butchering methods are used, then skill and judgement can produce high standard butchered meat product, but the methods are time consuming and require considerable training
Solution Approach 1:
The system replaces the manual mechanical skill of butchers with an automated robotic arm controlled by computer algorithms that process imaging data, transferring the decision-making function from human judgement to automated image analysis and control software
5Ease of operation
If manual butchering methods are used, then flexibility in working hours is maintained, but human contact with the carcass increases the risk of bacterial contamination
Solution Approach 1:
The robotic arm system replaces human hands in direct contact with carcasses throughout the entire processing operation, eliminating the source of bacterial contamination while maintaining operational flexibility through programmable control
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 high accuracy and efficiency in carcass cutting, optimizing equipment utilization, reducing labor costs, and enhancing product yield and value by minimizing manual handling and allowing for flexible operating schedules.
Implementation Method 1
X-ray and vision systems have been employed
Data Source
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AI summary
Methods of automated meat processing including an end to end processing method in which carcasses are cut into major portions at a first robotic processing station and into minor portions at robotic processing sub-stations. In one processing method carcass portions are acquired by a robotic arm, imaged and then cuts performed without transfer. In another a first series of processing steps are performed by rotating carcass portions through a plurality of processing stations and a second series of processing steps are performed as carcass portions are advanced along a linear conveyor. In another processing method a plurality of clamps are employed to stabalise a saddle section during a flap cut. In another processing method split pins are used to position a saddle section for a vertebrae cut. In another method a spinal cord is removed by applying a pressurised fluid stream against one end of the spinal cord and applying suction at the other end of the spinal cord.