STATEMENT OF CORRESPONDING APPLICATIONS

This application is based on the provisional specification filed in relation to New Zealand Patent Application No. 735270, the entire contents of which are incorporated herein by reference.

TECHNICAL FIELD

Embodiments of the present disclosure relate to an apparatus for processing meat - more particularly the processing of a rib portion of a carcass.

BACKGROUND ART

I n order to create saleable product, animal carcasses are disassembled into portions according to the intended market. Traditionally, this disassembly is achieved by skilled labourers performing various processes with handheld blades to produce the desired cuts of meat. Automation of these processes is generally desired for a variety of reasons, including increased productivity, decreased reliance on skilled labour, product consistency and appearance, improved occupational health and safety conditions, and reduction of product handling for hygiene purposes.

Numerous machines have been developed to automate various operations associated with the processing of animal carcasses. However, there remain certain operations and product specifications which either cannot be performed at all using machines to date, or at least are not as efficient or accurate as would be preferred.

For example, current practise with regard to deboning a rib portion is to remove the meat, at least in part, by hand-held knife, with the inherent disadvantages of; poor, variable yield, knife scores in the product, OS&H issues and diffculty in attracting skilled labour. It is an object of the present invention to address the foregoing problems or at least to provide the public with a useful choice.

Further aspects and advantages of the present invention will become apparent from the ensuing description which is given by way of example only. SUMMARY

Reference will be made throughout the specification to the slaughtered animal being a beef animal. However, this should not be considered limiting as the present invention may be applied to the processing of meat from essentially any vertebrate animal.

Generally, reference to a rib portion should be understood to include the part of the carcass between the thirteenth rib, and the fourth or fifth rib (depending on the specification). This portion may be referred to as the "rib set" in the art of meat processing. It should be appreciated that this is not intended to be limiting, as other rib portions may be produced depending on desired specifications and processed using the apparatus of the present disclosure. Further, the present disclosure is primarily directed to the processing of rib portions which have been split down the median plane or centreline, however it should be appreciated that this is not intended to preclude the application of the principles herein described to the same part of the carcass maintained as a saddle. In such applications it is envisaged that the blade systems described herein could be reoriented to accommodate an orientation of a saddle in which the feather bones are approximately vertical.

In the context of processing beef rib portions, it is envisaged that the present disclosure may have particular application to deriving one or more of the following product specification(s) from the rib portion: Spencer Roll, and Cube Roll.

Generally, reference to a processing axis throughout the specification should be understood to mean an axis long which a rib portion is guided for processing. Throughout the specification reference may be made to various elements being biased or orientated relative to a processing axis. It should be appreciated that this is not intended to be limited to a precise delimitation of a line between two points. Rather, reference to a processing may be understood to encompass a plane intersecting the axis referred to above, where the various elements are orientated relative to the plane. Deviation from a vertical or horizontal orientation may be permitted - both in terms of alignment or shape of an element. Reference to such should be understood as providing context to the description of the invention, rather than necessitating a strict adherence unless expressly stated.

Reference to a median plane should be understood to mean that which divides a carcass, or portion thereof such as a rib set, into left and right sides. Aspects of an apparatus may be described with reference to the median plane where the rib set is intended to be positioned such that the median plane is substantially aligned with the featherbones of the rib set.

Resilient deformation should be understood to mean a property of an object wherein the object is capable of fairly well assuming its shape within a short time following deformation. According to an exemplary embodiment there may be provided a rib processing assembly, including: a rib blade having a leading cutting edge, wherein the rib blade is resiliently deformable to curve sideways.

According to an exemplary embodiment there may be provided a rib processing apparatus. The rib processing apparatus may include a rib processing assembly. The rib processing assembly may include a rib blade having a leading cutting edge, wherein the rib blade is resiliently deformable to curve sideways. The rib processing apparatus may further include a guide defining a processing axis, configured to receive a rib portion of a carcass to be moved relative to the rib processing assembly along the processing axis.

In an exemplary embodiment the rib blade may have a first end and a second end, wherein the leading cutting edge extends along an edge between the first and second ends. In an exemplary embodiment, the rib blade may be secured in position at a first end proximate to the processing axis, curved sideways to achieve a desired curvature, and secured at the second end distal from the processing axis.

In an exemplary embodiment in which the rib portion is split, the rib blade may be secured to extend upwardly from the first end before curving sideways. It is envisaged that in an exemplary configuration in which a saddle rib portion is to be processed, a first rib blade may extend sideways from the processing axis in a first direction before curving downwardly, and a second rib blade may extend sideways from the processing axis in a second direction away from the first direction before curving downwardly.

In an exemplary embodiment, the curvature of the rib blade may be controlled by applying a force to the second end of the rib blade. For example, the second end of the rib blade may be connected to an actuator - whether directly or via an intermediary linking member such as a length of chain or a solid linkage - and the actuator controlled to change the curvature of the rib blade.

In an exemplary embodiment, the curvature of the rib blade may be controlled by adjustment of a first force to a first position at the second end of the rib blade, and a second force to a second position at the second end of the rib blade, wherein the first position is closer to the leading cutting edge of the blade, and the second force is applied in a direction non-parallel to the direction in which the first force is applied.

In an exemplary embodiment in which the rib portion is split, and the rib blade extends upwardly from the first end before curving sideways, the direction in which the first force is applied may be generally perpendicular to the processing axis. In an exemplary embodiment, the direction in which the second force is applied may be generally parallel to the processing axis. In controlling these forces, the curvature of the rib blade along both its length and width may be adjusted. It should be appreciated that reference to the directions being perpendicular and parallel to the processing axis is intended to indicate the relative orientation rather than requiring strict adherence to specific angles.

For example, by increasing tension in the direction of the processing axis, it is envisaged that the angle of incidence of the leading edge of the rib blade, relative to the bones, may be increase. By increasing the tension in the direction perpendicular to the processing axis, it is envisaged that the leading edge of the rib blade may be forced harder against the bone.

In an exemplary embodiment, a constant tension or pressure level applied to the second end of the rib blade may be maintained during passage of the rib portion. It is envisaged that this may allow for the rib blade to follow the shape of the ribs as they expand in size along the rib portion. In an exemplary embodiment, the curvature of the rib blade, or pressure applied, may be adjusted during passage of the rib portion.

It is envisaged that the rib blade may be shaped such that the rib blade flares outwardly from the leading edge - i.e. the leading edge of the rib blade is closer to the bone of the rib product than a rear edge of the rib blade - to ensure that the leading edge contacts the bone and assist with lifting the meat away from the bone as the rib product passes.

In an exemplary embodiment the rib blade may be made from a sheet material of sufficient hardness to retain an edge but flexible enough to achieve a desired curvature while allowing for movement to follow the interface between the ribs and muscle attached thereto. For example, the rib blade may be made of a sheet metal such as spring stainless steel having a thickness of about 1 mm to about 2 mm thick. It should be appreciated that this is not intended to be limiting to all embodiments of the present disclosure - for example the rib blade may be made of a plastics material or a composite metal/plastic structure.

In an exemplary embodiment the leading edge of the rib blade may be sharpened. For completeness, it is envisaged that in embodiments when the rib blade is made of sufficiently thin material, sharpening of the edge may not be required.

In an exemplary embodiment, the rib processing assembly may include a dorsal blade oriented relative to the rib blade to pass along the dorsal processes of the rib portion. In an exemplary embodiment in which the rib portion is split, and the rib blade extends upwardly from the first end before curving sideways, the dorsal blade may extend sideways away from the processing axis in an opposite direction to the rib blade. In an exemplary embodiment, the apparatus may include a dorsal process support member laterally offset from the processing axis, configured to lift the dorsal processes of the rib portion to the dorsal blade. In an exemplary embodiment, the vertical distance between the dorsal process support member and the dorsal blade may be controllable - for example by an actuator configured to lift and/or lower the dorsal process support member to force the dorsal processes against the dorsal blade. In an exemplary embodiment, the dorsal process support member may be biased upwardly towards the dorsal blade as the rib portion passes through the rib processing assembly - for example by maintaining a constant pressure.

In an exemplary embodiment, the rib processing assembly may include a blade connector securing the rib blade relative to the dorsal blade. In an exemplary embodiment, the blade connector may include a transition blade portion at an end proximate to the leading edge of the rib blade. The transition blade portion may act as a wedge, starting from a front edge against the leading edge of the rib blade, and angling outwardly.

In an exemplary embodiment, the apparatus may include a bone guide, having an actuator configured to selectively apply pressure to the rib portion to press towards the rib blade. In an exemplary embodiment, the bone guide actuator may be controlled to press the rib portion towards the rib blade, on the rib portion actuating a trigger mechanism. In an exemplary embodiment, the trigger mechanism may be positioned behind a leading point of contact of the rib processing assembly along the processing axis, such that the one or more blades of the rib processing assembly are engaged with the rib portion when pressure is applied by the bone guide.

In an exemplary embodiment the trigger mechanism may also be used to trigger control of one or more of the actuators controlling at least one of: the rib blade, and the dorsal process support member.

In an exemplary embodiment the trigger mechanism may include more than one trigger point. For example, the trigger mechanism may be staged to trip a first sensor, such as a roller lever actuated valve, prior to tripping a second sensor. In an exemplary embodiment, the trigger mechanism may include a second trigger set behind a first trigger along the processing axis (for example, such that the bone guide is actuated on the first trigger, and once a predetermined distance has passed the characteristics of the rib blade are adjusted on the second trigger).

In an exemplary embodiment, the apparatus may include a product actuating device configured to control relative movement of the rib portion to the rib processing assembly. The product actuating device may, for example, be a pusher configured to move the rib portion along the guide. In an exemplary embodiment, the pusher may include a wand configured to extend along the rib portion against the vertebrae below the ribs. It is envisaged the wand may assist in maintaining the position of the rib portion as it is moved relative to the rib processing assembly. I n an exemplary embodiment the pusher may include a bone pushing surface, and a muscle pushing surface offset from the bone pushing surface. In operation, the bone pushing surface may pass on one side of the rib blade, while the muscle pushing surface passes on the other side of the rib blade.

Operation of the apparatus and various assembles may be controlled by pneumatic or hydraulic logic, manually operated switches, or at least one processor. The processor may include one or more application specific integrated circuits (ASICs), digital signal processors (DSPs), digital signal processing devices (DSPDs), programmable logic devices or controllers (PLDs, PLCs), field programmable gate arrays (FPGAs), computers, lap tops, controllers, micro-controllers, microprocessors, electronic devices, other electronic units (whether analogue of digital) designed to perform the functions described herein, or a combination thereof.

BRIEF DESCRIPTION OF THE DRAWINGS

Further aspects of the present invention will become apparent from the ensuing description which is given by way of example only and with reference to the accompanying drawings in which: FIG. 1A is a perspective view of an exemplary bone structure of a rib set to be processed in accordance with an aspect of the present disclosure;

FIG. IB is an end view of the exemplary rib set;

FIG. 2A is a first perspective view of an exemplary rib processing apparatus;

FIG. 2B is a second perspective view of an exemplary rib processing apparatus;

FIG. 3A is a perspective view of a processing portion of an exemplary rib processing apparatus;

FIG. 3B is a second perspective view of the processing portion of an exemplary rib processing apparatus;

FIG. 3C is a top view of the processing portion of an exemplary rib processing apparatus;

FIG. 3D is an end view of the processing portion of an exemplary rib processing apparatus; FIG. 3E is a side view of the processing portion of an exemplary rib processing apparatus;

FIG. 4A is a front view of an exemplary rib processing assembly;

FIG. 4B is a perspective view of the rib processing assembly;

FIG. 4C is a side view of the exemplary rib processing assembly;

FIG. 4D is an enlarged perspective view of a portion of the exemplary rib processing assembly; FIG. 4E is a perspective view of a portion of the exemplary rib processing assembly; FIG, 5A is a perspective view of the exemplary rib processing apparatus in operation; and

FIG. 5B is a side view of the exemplary rib processing apparatus in operation.

DETAILED DESCRIPTION FIG. 1A and FIG. IB illustrates the bone structure of an exemplary rib set 100 to be processed in accordance with an exemplary embodiment of the present disclosure. The rib set 100 includes the thoriac vertebrae (generally designated as vertebrae 102) between the sixth rib 104 and the twelfth rib 106. The rib set 100 illustrated has been split along the dorsal spinal processes, or featherbones (generally designated as featherbones 108). In the exemplary embodiments illustrated, the target meat for removal from the rib set 100 is the Cube Roll or Spencer Roll.

FIG. 2A illustrates a rib processing apparatus 200, including a processing portion 202, and a cabinet 204 housing components discussed below with reference to FIG. 2B. The processing portion 202 has a processing axis (indicated by dashed line 206) along which a rib portion (for example rib set 100), is moved to be processed. A rib processing assembly 208 is positioned on the processing axis 206 for separating the meat from the bone of the rib set 100. The assembly 208 includes a resiliently deformable rib blade 210 (illustrated in an un-tensioned state in FIG. 2A) extending upwardly from a first end secured proximate the processing axis 206 and curving sideways away from the processing axis 206. The rib blade 210 is made of, for example, spring stainless steel having a thickness of about 1 mm. The assembly 208 further includes a dorsal blade 212 extending away from the rib blade 210 in an orientation substantially perpendicular to the rib blade 210 at its first end. A blade connection member 214 connects the rib blade 210 to the dorsal blade 212, as will be described in further detail below.

The rib processing apparatus 200 includes a first rib blade tensioning actuator 216, connected to a second end of the rib blade 210 distal from the first end at a point proximate to the leading edge of the rib blade 210. The first rib blade tensioning actuator 216 is configured to extend and retract in a direction substantially perpendicular to the processing axis 206. The rib processing apparatus 200 includes a second rib blade tensioning actuator 218, connected to a second end of the rib blade 210 distal from the first end at a point proximate to the trailing edge of the rib blade 210. The second rib blade tensioning actuator 218 is configured to extend and retract in a direction substantially parallel to the processing axis 206. The first and second rib blade tensioning actuators 216, 218 are secured to brackets mounted on an upper mounting beam 220.

While not illustrated, it should be appreciated that the rib blade tensioning actuators 216, 218 may be connected directly to the rib blade 210, or via an intermediary linkage (for example a length of chain or a solid link). Further, in the exemplary embodiment illustrated each of the rib blade tensioning actuators 216, 218 are connected to their respective brackets by a pivoting joint.

The rib processing apparatus 200 includes a pusher 222 configured to drive the rib set 100 along the processing axis 206. The pusher 222 includes a bone pushing surface 224, and a meat pushing surface 226 - spaced apart to allow passage of the rib blade 210 therebetween. The pusher 222 also includes a wand 228 configured to extend along the rib set 100 against the vertebrae 102 below the ribs 104, 106.

A dorsal process support member in the form of dorsal plate 230 is positioned on the same side of the processing axis 206 as the dorsal blade 212. The dorsal plate 230 is pivotally connected to the processing portion 202 at an end distal from the dorsal blade 212. The free end of the dorsal plate 230 is positioned beneath the dorsal blade 212. A dorsal plate actuator 232 is positioned beneath the dorsal plate 230 and is controllable to apply pressure to the dorsal plate 230 to raise and lower the dorsal plate 230.

A bone guide 234 is positioned on the distal side of the processing axis 206 to the dorsal blade 212, controllable to apply pressure to a passing rib set 100 as will be discussed in greater detail further below.

Referring to FIG. 2B, the cabinet 204 (hidden in FIG. 2B) houses a hydraulic power pack including an electric motor 236 and hydraulic tank 238 (containing a hydraulic pump). A hydraulic pusher cylinder 240, powered by the hydraulic power pack, actuates the pusher 222. A trigger device 242 is also housed in the cabinet 204, including roller lever actuated valves for signalling a trigger condition as will be described further below.

Referring to FIG. 3A to FIG. 3C, the bone guide 234 includes a bone guide shoe 244 extending alongside the rib blade 210, a bone guide actuator 246, and bone guide linkages 248a and 248b. On activation of the trigger device 242, the bone guide actuator 246 drives the bone guide shoe 244 towards the rib blade 210. The height of the pusher wand 228 is such that it passes over the bone guide shoe 244. In FIG. 3D, it may be seen that the processing portion 202 includes a pusher guide beam 250, with a pusher guide 252 positioned on the pusher guide beam 250 and connected to the pusher 222.

FIG. 3E shows the processing portion 202 from the side, with a trigger lever 256 and trigger rod 258 exposed. The trigger lever 256 is positioned behind the leading edge of the assembly 208 along the processing axis 206. On being pushed by the rib set 100, and more particularly featherbones 108, the trigger lever 256 pivots, driving the trigger rod 258 forward to move a cam relative to the roller lever actuated valves of the trigger device 242. The positioning of the roller lever actuated valves allows for a staged triggering if desired. Referring to FIG. 4A to 4C, the rib blade 210 has a first end 400 to be secured proximate to the processing axis 206, and a second end 402 distal from the first end 400. The rib blade 210 has a leading edge 404 between the first end 400 and the second end 402, facing the pusher 222. The leading edge 404 may be sharpened, although it is envisaged that the 1 mm thickness of the sheet steel from which the rib blade 210 is manufactured may be sufficient for separating the meat from the bone of the rib set 100. The leading edge 404 sweeps backwards from the first end 400 to the second end 402 along the processing axis 206. The rib blade 210 also includes a trailing edge 406 between the first end 400 and the second end 402, facing away from the pusher 222.

The second end 402 of the rib blade 210 includes a first rib blade tensioning actuator connection point 408 proximate to the leading edge 404, and a second rib blade tensioning actuator connection point 410 behind the first connection point 408 relative to the leading edge 404.

The dorsal blade 212 includes a bevelled leading edge 412 for insertion between the feather bones 108 of the rib set 100 and the meat thereon. The blade connector 214 include a transition blade portion 414 at an end proximate to the leading edge 406 of the rib blade 210. The transition blade portion 400 is in the form of a wedge, starting from a front edge against the leading edge 406 of the rib blade 210, and angling outwardly along the dorsal blade 212.

In FIG. 4D, it may be seen that the blade connector 214 includes alternating side apertures 416 and T- slots 418. FIG. 4E shows cheese head fasteners 420 extending from the rib blade 210 towards the dorsal blade 212. A locking tab 422 includes a locking pin 424at a first end, inserted down through the blade connector (not shown in FIG. 4E) to be positioned between the head of the cheese head fastener 420 and the rib blade 210, thereby preventing extraction of the fastener 420. The locking tab 422 is secured by an inverted cheese head fastener 426 received within the T-slot 418. A plurality of such locking tabs 108 may be used to secure the rib blade 210 relative to the dorsal blade 212.

Referring to FIG. 5A and FIG. 5B, in use the rib set 100 is positioned in front of the pusher 222 and actuated to bring the rib set 100 to the assembly 208 such that the transition blade portion 400 is inserted into the channel between the sixth rib 104 and the feather bones 108. The feather bones 108 are located between the dorsal blade 212 and the dorsal plate 230, with the dorsal plate 230 initially maintained at a fixed height below the dorsal blade 212.

As the rib set 100 is pushed forward, the featherbones 108 actuate the trigger lever 256. This triggers actuation of the bone guide 234 to bear the bone guide shoe 244 against the side of the vertebrae 102, below the wand 228. Further, the dorsal plate 230 is lifted to apply a constant pressure to the feature bones 108, such that the bevelled leading edge 412 of the dorsal blade 212 is forced onto the bone as the rib set 100 passes through the rib processing assembly 108. The curvature of the rib blade 210 may initially approximate that of the sixth rib 104. The tension applied by the first rib blade tensioning actuator 216 and second rib blade tensioning actuator 218 to the rib blade 210 may be maintained (rather than maintaining a fixed position of the actuators) such that the curvature of the rib blade 210 expands to accommodate the increasing size of the ribs through to the twelfth rib 106 as the rib set 100 passes through the rib processing assembly 108. It is envisaged that the flexure of the rib blade 210 allows it to ride over deviations along the surface of the bone to reduce the likelihood of the blade jamming in the bone, and/or improve yield of the meat recovered.

The pusher 222 continues to push the rib set 100 though, with the bone pushing surface 224 and the meat pushing surface 226 passing to either side of the rib blade 210 until the meat is separated from the bone to achieve the desired specification. The actuators associated with the rib blade 210, pusher 222, and dorsal plate 230 may then be reset in preparation for processing of the next rib set 100.

The invention(s) may also be said broadly to consist in the parts, elements and features referred to or indicated in the specification of the application, individually or collectively, in any or all combinations of two or more of said parts, elements or features. Where in the foregoing description reference has been made to integers or components having known equivalents thereof, those integers are herein incorporated as if individually set forth.

It should be noted that various changes and modifications to the presently preferred embodiments described herein will be apparent to those skilled in the art. Such changes and modifications may be made without departing from the spirit and scope of the disclosure and without diminishing its attendant advantages. It is therefore intended that such changes and modifications be included within the present disclosure.

The steps of a method, process, or algorithm described in connection with the present disclosure may be embodied directly in hardware, in a software module executed by one or more processors, or in a combination of the two. The various steps or acts in a method or process may be performed in the order shown, or may be performed in another order. Additionally, one or more process or method steps may be omitted or one or more process or method steps may be added to the methods and processes. An additional step, block, or action may be added in the beginning, end, or intervening existing elements of the methods and processes.

Reference throughout this specification to "one embodiment" or "an embodiment" (or the like) means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the disclosure. Thus, appearances of the phrases "in one embodiment" or "in an embodiment" or the like in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the described features, structures, or characteristics may be combined in any suitable manner in at least one embodiment. In the foregoing description, numerous specific details are provided to give a thorough understanding of the exemplary embodiments. One skilled in the relevant art may well recognize, however, that embodiments of the disclosure can be practiced without at least one of the specific details thereof, or can be practiced with other methods, components, materials, et cetera. In other instances, well-known structures, materials, or operations are not shown or described in detail to avoid obscuring aspects of the invention.

The illustrated embodiments of the disclosure will be best understood by reference to the figures. The foregoing description is intended only by way of example and simply illustrates certain selected exemplary embodiments of the disclosure. It should be noted that the flowchart and block diagrams in the figures illustrate the architecture, functionality, and operation of possible implementations of systems, apparatuses, methods and computer program products according to various embodiments of the disclosure. In this regard, each block in the flowchart or block diagrams may represent a module, segment, or portion of code, which comprises at least one executable instruction for implementing the specified logical function(s). It should also be noted that, in some alternative implementations, the functions noted in the block may occur out of the order noted in the figures. For example, two blocks shown in succession may, in fact, be executed substantially concurrently, or the blocks may sometimes be executed in the reverse order, depending upon the functionality involved. It will also be noted that each block of the block diagrams and/or flowchart illustration, and combinations of blocks in the block diagrams and/or flowchart illustration, can be implemented by special purpose hardware-based systems that perform the specified functions or acts, or combinations of special purpose hardware and computer instructions.

Throughout this specification, the word "comprise" or "include", or variations thereof such as "comprises", "includes", "comprising" or "including" will be understood to imply the inclusion of a stated element, integer or step, or group of elements integers or steps, but not the exclusion of any other element, integer or step, or group of elements, integers or steps, that is to say, in the sense of "including, but not limited to".

It will be understood by those with skill in the art that if a specific number of an introduced claim element is intended, such intent will be explicitly recited in the claim, and in the absence of such recitation no such limitation is present. For non-limiting example, as an aid to understanding, the following appended claims contain usage of the introductory phrases "at least one" and "one or more" to introduce claim elements. However, the use of such phrases should not be construed to imply that the introduction of a claim element by the indefinite articles "a" or "an" limits any particular claim containing such introduced claim element to disclosures containing only one such element, even when the same claim includes the introductory phrases "one or more" or "at least one" and indefinite articles such as "a" or "an"; the same holds true for the use in the claims of definite articles.