SORTING CONVEYOR

Field of the Invention

The present invention relates to a method for removing a broiler from an overhead sorting conveyor in a controlled manner and an apparatus capable of removing a broiler from an overhead shackle conveyer.

Background of the Invention

In a slaughterhouse for broilers, the broilers are hanging from their legs on a shackle mounted on an overhead conveyor. The broilers are transported through the slaughter house by various overhead conveyors (one for each department), and the broilers are weighed on a transfer/rehanging module. After transferring the birds to the overhead sorting conveyor, the quality of each individual broiler is determined by the use of cameras.

Dependent on the quality, weight and production orders, the broilers are destined for either cut-up or whole bird packing. The whole birds are likewise divided according to weight and quality. The overhead sorting conveyor and related drop stations is controlled by a master sys tem collecting data of the different broilers such as quality, weight, and position on the overhead sorting conveyor.

An overhead sorting conveyor may have a speed up to 250 birds/min. All the above- mentioned characteristics must be measured without slowing down the overhead sort ing conveyor.

Likewise, the broilers must be removed without slowing down the overhead sorting conveyor. This is presently done using a pusher, which is activated by the master con- trol system having a broiler position registered per broiler. The broiler position is based on the registered measured data and the speed of the overhead sorting conveyor, and thus the broiler position is not sufficiently exact. A wide collection chute is placed under each drop station on the overhead sorting conveyor for collection of the broilers before bagging and packing. The broiler will tumble randomly due to the way they are pushed-off the shackle and the drop dis tance, to the chute. A feeding operator will pick up the broiler from the collection chute and feed it one by one into the packaging machine. In the current set-up, one operator is able to feed 10-12 broilers/min to the packaging machine. A typical over head sorting conveyor would have around 20 drops and packing stations in order to deal with all the bird calibration sizes. Thus, there is a need for a faster way of pack aging broilers, and furthermore there is a need for packaging without manual interven- tion.

Object of the Invention

It is an object of the invention to provide a method and apparatus for enable transfer ring broilers from a shackle mounted on a overhead sorting conveyor in motion, to a static catching device, in a controlled manner, and at the same time to increase the packaging capacity.

Description of the Invention

An object of the invention is achieved by a method for removing a broiler from an overhead sorting conveyor in a controlled manner enabling feeding to a packaging machine. The method comprises acts of:

- providing a pusher, and a gripper facing the pusher;

- receiving a broiler position from a master system;

- pushing the broiler using the pusher as a function of the broiler position towards the gripper;

- gripping the broiler as a function of the broiler position using the gripper; and

- releasing the broiler from the gripper.

The pusher and the gripper are positioned on opposite sides of the overhead sorting conveyor. The act of pushing will thus cause the broiler to move towards the gripper which can then grip the broiler. The skilled person would know how to calibrate the pusher and gripper such that the gripper grips with a delay relative to the push from the pusher in order to catch the broiler. The broiler will hang from a shackle by the legs, and the pusher may be adapted for pushing the broiler legs for releasing the broiler from the shackle. The gripper may be adapted for griping the broiler legs as described later in the description. The broiler is released from the gripper when the kinetic energy has been removed from the broiler, this may be done by releasing after a delay. However, the movement of the broiler could also be measured using one or more sensors.

The system secures that the broiler keeps the same orientation from shackle to gripper, unlike the prior art where the orientation after release is random. Thereby the broilers are re-moved from the overhead sorting conveyor in a controlled manner as the broil ers will always face the same direction, and this enables a faster feeding of the pack aging machine. Even if the feeding to a packaging machine is still performed manual ly. It is estimated that the packing speed can be increased to 15-18 broilers/min.

The broiler will be moving at a high speed, and thus the gripper may be positioned slightly downstream relative to the pusher to compensate from the momentum of the broiler in the direction of the overhead sorting conveyor. In an aspect of the invention, the method may further comprise an act of

- providing a sensor upstream to the pusher;

- detecting a broiler having the broiler position on the overhead sorting conveyor by a sensor; and

- adjusting the broiler position as a function of sensor data.

The master system has a broiler position associated with each broiler, however, de pending on the precision of the broiler position, the method may need additional data related to the broiler position. However, in case of a minor speed variation on the overhead sorting conveyor and the distance to the drop station, the precision of the actual shackle position can vary from the broiler position according to the master sys tem, and the method may need more precise date regarding the actual broiler position in order to remove the broiler in a controlled manner. The sensor upstream relative to the pusher enables detecting the broiler with the associated broiler position with a greater precision. Thus, the master system data in combination with the sensor up stream provides an adjusted shackle position with a greater precision.

The sensor used may be a photocell or laser sensor or alternative a high-speed camera. The increased precision of the broiler position on the overhead shackle conveyor low ers the risk of the pusher missing the broiler, and/or the gripper not gripping the bird.

The sensor may even be a piezoelectric sensor, however, a non-contact sensor is pre ferred.

In an aspect of the invention, the method may further comprise an act of

- feeding the broiler into a packaging machine.

The act of feeding may be performed by releasing the broiler into a narrow chute lead ing to a buffer in front of a packaging machine. The narrow chute is designed to pre vent rotation of the broiler.

Thereby, the packing speed can be increased to around 30 broilers/min, without any manual labor, and thereby decreasing the risk of contamination and lowering the pro duction costs.

The narrow chute may be an U-shaped narrow chute.

The method can in theory supply 50-100 broilers per minute to a packaging machine if the packaging machine has the required capacity. In an embodiment the pusher and the gripper supply broilers in a controlled manner to two or more packagingmachines. Thereby the total volume of the system can be reduced.

An object of the invention is achieved by an apparatus having a pusher and a gripper and means adapted to execute the acts of the method previously described.

An object of the invention is achieved by an apparatus for removing a broiler from an overhead sorting conveyor. The apparatus comprises:

- a pusher for pushing broilers of a shackle; - a gripper facing the pusher and being positioned on an opposite side of an overhead sorting conveyor during use; and

- a controller adapted for receiving a broiler position of a broiler from a master system and adapted for activating the pusher and gripper based on the broiler position.

The controller ensures the pusher pushes the broiler at the correct time based on the broiler position, and that the gripper grips the broiler at a time delayed relative to the pusher. The gripper will grip the broiler and hold the grip for a time period such that the kinetic energy is removed from the broiler. Thereby, the broiler is moved from the overhead sorting conveyor moving at a speed of 250 broilers/min to a stationary posi tion at the gripper. The release from the gripper will be in a controlled manner such that broiler always have the same orientation, and this enable faster feeding to a pack aging machine even when the feeding is done by manual labor.

The 250 broilers/min is equivalent to a broiler passing a point on the overhead sorting conveyor every 240 ms or about 4 broiler through a point each second.

The apparatus can remove broilers at random without receiving information from the master system, as the pusher and the gripper can push and grip without the master system. However, in modem day slaughterhouses there are always a high degree of sorting and thus a random packaging of broiler will in effect never happen.

In an embodiment, the pusher may be a well-known pusher for pushing the broiler of a shackle. Many of the known pushers comprise a push head arranged for pushing the ankles of the broiler. The pusher may be powered by pneumatics or servo motor or hydraulics.

The broilers hang from shackles with an orientation which is substantially parallel with gravitation vector. Tests have however shown that the known pushers pushing the ankles of the broiler causes the broiler to have a more horizontal orientation as the pushing on the ankles causes the broiler to rotate while moving towards the gripper.

The rotation can be counter acted by the pusher comprising a substantially T-shaped push head, where the push head have a downwardly extending flange for engaging the main body, typically the breast part, of the broiler. Thereby, the broiler is pushed at the ankles and at the main body, and this counter-acts the rotation of the broiler, and as a consequence, the broiler is pushed off the shackle while having an orientation which is substantially parallel with gravitation vector.

In an embodiment the pusher may comprise a curved pusher body having pusher guide allowing the pusher to move in a more reliable matter along said pusher guide. The pusher may be controlled by pneumatics or a motor which will cause the curved pusher body in a direction defined by the pusher guide. The pusher may comprise a main pusher head connected to the curved pusher body. The main pusher head is adapted to push broiler legs such that the broiler is pushed off a shackle.

The pusher may comprise one, two or more body pusher heads for pushing the body off the broiler. The curved pusher body is curved to ensure that the main pusher head pushes the broiler legs first or at least at the same time as the body pusher heads. This enables the broiler to be pushed from the shackle without changing the orientation of the broiler by also pushing the body of the broiler.

The pusher may be made of stainless steel or be made of composite material. The composite material has a lower weight enabling faster movement of the pusher.

In an aspect of the invention, the apparatus may further comprise a sensor positioned upstream relative to the pusher for detecting the broiler with the broiler position, and the sensor is in communication with the controller, which is adapted for adjusting the broiler position based on sensor data.

The sensor decreases the uncertainty of the broiler position, and thus the pusher and gripper can be controlled such that stray pushes are prevented. A stray push is under stood as a push which completely misses, this is a rare event for known pushes, or where the push is slightly too soon or slightly too late causing the broiler to make un wanted movement causing the gripper to miss the grip, or causes the gripper to only catch a single leg. Thus, the sensor increases the reliability of the apparatus and thus also the package speed. The sensor may be a photo sensor or a laser sensor or camera such as a high-speed camera.

The sensor may be a piezo-electric sensor although it is preferred that the sensor is a non-touch sensor.

In an aspect of the invention, the gripper may comprise:

- two leg guides for guiding the broiler legs, at least one of the leg guides comprises

- a first and a second arm extending from a pivotal end towards a distal end, wherein the first and/or the second arm are pivotal between an open position and a catch posi tion, wherein the arms form a channel for guiding the broiler legs towards the pivotal end.

The purpose of the leg guides is to grip a right and a left leg broiler leg, respectfully.

The distal end of the first and second arms in the open position are far apart to allow the broiler legs to move in between and the first and second arms form the channel in the catch position wherein the distal ends are closer relative to the open position.

The channel is adapted for preventing the broiler leg ankle to move through the chan nel while allowing the broiler leg to move along the channel towards the pivotal end.

In an embodiment, both the leg grippers may comprise a first and a second arm ex tending from a pivotal end towards a distal end, wherein the first and/or the second arm are pivotal between an open position and a catch position, wherein the arms form a channel for guiding the broiler legs towards the pivotal end.

The first and second arms may have, when being in the catch position, a mutual dis tance being smaller than the width of the channel to prevent blow-back of the broiler.

The first and second arm may have convex surfaces facing the opposite arm, the con vex surfaces reduces friction and decreases the risk of damaging the broiler legs such as cutting the skin near the ankles. The leg guides may be controlled by the use of pneumatics or servo motor.

The leg guides may be controlled by the use of hydraulics.

Each of the arms of both leg guides may have a gear at the pivotal end interconnected with the other gears of the other arms such that the arms move synchronously, which makes the gripper easier to control.

Each guide may have a member extending from one of the gears in a direction sub stantially opposite to the arms, wherein each member is interconnected by a linear actuator controlling the movement of each arm. Thereby, the activation of the linear actuator will cause the arms of the leg guides to pivot in a simple but controlled man ner.

In an aspect of the invention, the channel may have a channel width, which channel width decreases towards the pivotal end. Thereby the same gripper will be able to grip broilers of different sizes.

In an aspect of the invention, the gripper is angled upwardly relative to a horizontal plane.

In an aspect of the invention, the apparatus may comprise a receiving trough being positioned below the gripper for stopping the broiler.

The receiving trough may be a plane surface stopping the broiler.

The receiving trough may be a plane surface having side guide for stopping the broil er.

The receiving trough may be made of a metal such as steel.

In an embodiment, the apparatus may further comprise a chute for guiding a broiler released from the gripper towards and optionally into a packaging machine. In an embodiment, the apparatus may further compress a chute for guiding broilers from the gripper towards and optionally buffer system in front of a packagingmachine.

An object of the invention is achieved by use of sensor upstream to a pusher for ad- justing a broiler position. Thereby, the pusher can be controlled with a higher level of precision.

The sensor may be around 5-100 cm upstream from the pusher, or 5-20 cm or 10 cm however other distances can be used.

A computer program product comprising instructions to cause the apparatus to exe cute the steps of the method.

A computer-readable medium having stored thereon the computer program.

Description of the Drawing

Embodiments of the invention will be described in the figures, whereon:

Fig. 1 illustrates a schematic of an apparatus;

Fig. 2 illustrates a schematic of another apparatus;

Fig. 3 illustrates a side view of a test apparatus;

Fig. 4 illustrates a shackle, a pusher and a gripper;

Fig. 5 illustrates a gripper gripping a broiler;

Fig. 6 illustrates a top view of the gripper gripping a broiler;

Fig. 7 illustrates an embodiment of an actuation of a gripper;

Fig. 8 illustrates an arm for a leg guide to form part of a gripper;

Fig. 9 illustrates another embodiment of a pusher; and

Fig. 10 illustrates a method for removing a broiler from an overhead sorting convey or in a controlled manner.

Detailed Description of the Invention

Fig. 1 illustrates a schematic of an apparatus 10. The apparatus 10 is positioned at an overhead sorting conveyor 90 conveying broilers 100 hanging from shackles 92 on the overhead sorting conveyor 90. The figure only shows a single broiler 100 moving past the apparatus 10 to show the principle.

A master system 300 will keep track of each broiler 100 and will have a broilers posi tion 102 associated with each broiler 100. The broiler position 102 received from the master system 300 has an uncertainty, this is illustrated by the circle around the broiler 100 being larger than the broiler 100. The apparatus 10 is for removing the broiler 100 from the overhead sorting conveyor 90.

The apparatus 10 comprises a pusher 20 for pushing broilers 100 of a shackle 92 (not shown) in this figure.

The apparatus 10 comprises a gripper 40 facing the pusher 20 and being positioned on an opposite side of the overhead sorting conveyor 90 during use. The gripper is adapted for gripping the pushed broilers 100. The gripper 40 will release the broiler 100 when the broiler 100 is at rest i.e. without kinetic energy.

The apparatus 10 comprises a controller 80 adapted for receiving the broiler position 102 of the broiler 100 from the master system 300 and adapted for activating the pusher 20 and gripper 40 based on the broiler position 102.

Tests have shown that if the controller 80 only bases the broiler position 102 from the master system 300 then there will be broilers 100 which will not be gripped by the gripper 40 or the gripper will only grip a single leg.

The reliability of the apparatus can be significantly improved by the apparatus (10) further comprises a sensor 70 positioned upstream relative to the pusher 20 for detect ing the broiler 100 with the broiler position 102. The sensor 70 is in communication with the controller 80, which is adapted for adjusting the broiler position 102 based on sensor data. In the figure the adjusted broiler position 102 is shown by a circle sub stantially being equal to the broiler.

The sensor 70 may be a photo sensor or a laser sensor or camera such as a high-speed camera.

Thereby, a broiler 100 hanging in a shackle 92 from an overhead sorting conveyor 90 can be removed in a controlled manner to a stationary apparatus 10, which grips the broiler 100 and releases the broiler 100.

Fig. 2 illustrates a schema of another apparatus 10.

The apparatus 10 is positioned at an overhead sorting conveyor 90 conveying broilers 100 hanging from shackles 92 on the overhead sorting conveyor 90. The figure only shows a single broiler 100 moving past the apparatus 10 to show the principle.

A master system 300 will keep track of each broiler 100 and will have a broilers posi tion 102 associated with each broiler 100. The broiler position 102 received from the master system 300 has an uncertainty, this is illustrated by the circle around the broiler 90 being larger than the broiler 90. The apparatus 10 is for removing the broiler 100 from the overhead sorting conveyor 90.

The apparatus 10 comprises a pusher 20 for pushing broilers 100 of a shackle 92 (not shown) in this figure.

The apparatus 10 comprises a gripper 40 facing the pusher 20 and being positioned on an opposite side of the overhead sorting conveyor 90 during use. The gripper is adapted for gripping the pushed broilers 100. The gripper 40 will release the broiler 100 when the broiler 100 is at rest i.e. without kinetic energy.

The apparatus 10 comprises a controller 80 adapted for receiving the broiler position 102 of the broiler 100 from the master system 300 and adapted for activating the pusher 20 and gripper 40 based on the broiler position 102. Tests have shown that if the controller 80 only bases the broiler position 102 from the master system 300 then there will be broilers 100 which will not be gripped by the gripper 40 or the gripper will only grip a single leg.

The reliability of the apparatus can be significantly improved by the apparatus (10) further comprises a sensor 70 positioned upstream relative to the pusher 20 for detect ing the broiler 100 with the broiler position 102. The sensor 70 is in communication with the controller 80, which is adapted for adjusting the broiler position 102 based on sensor data. In the figure the adjusted broiler position 102 is shown by a circle sub stantially being equal to the broiler.

The sensor 70 may be a photo sensor or a laser sensor or camera such as a high-speed camera.

Thereby, a broiler 100 hanging in a shackle 92 from an overhead sorting conveyor 90 can be removed in a controlled manner to a stationary apparatus 10.

The apparatus 10 further comprises a narrow chute 210 below the gripper 40 and when the broiler 100 is released from the gripper 40, and then the broiler 100 will slide down the narrow chute 210. The narrow chute 210 is narrow to prevent rotation of the broiler 100 towards a packaging machine 100. The broiler 100 may be feed au tomatic to the packaging machine 200 or the broiler 100 may be feed manually to the package machine 200.

Fig. 3illustrates side view of a test apparatus 10. The test apparatus 10 comprises a pusher 20 for pushing broilers 100 of a shackle 92.

The test apparatus 10 comprises a gripper 40 facing the pusher 20 and being posi tioned on an opposite side of an overhead sorting conveyor 90 (not shown).

The test apparatus 10 comprises a controller 80 adapted for receiving a broiler posi tion 102 of a broiler 100 from a master system 300 (not shown) and adapted for acti vating the pusher 20 and gripper 40 based on the broiler position 102. The apparatus 10 further comprises a sensor 70 (not shown) positioned upstream rela tive to the pusher 20 for detecting the broiler 100 with the broiler position 102), and the sensor 70 is in communication with the controller 80, which is adapted for adjust ing the broiler position 102 based on sensor data.

The apparatus 10 further comprises a narrow chute 210 having a buffer 85 in the form of a pneumatic spade which can prevent a broiler 100 from sliding further down. The narrow chute 210 may have several buffers 85 such that the several broilers can be positioned along the narrow chute 210 awaiting packaging at a packaging machine 200 (not shown).

Fig. 4illustrates a shackle 92, a pusher 20 and a gripper 40.

The shackle 92 will hang from an overhead sorting conveyor 90. The shackle 92 is a well-known conventional shackle 92.

The pusher 20 comprises an overall T-shaped design. The pusher 20 comprises main pusher head 22 adapted for pushing the legs of a broiler 100 as the broiler 100 hangs from the shackle 92 in the legs. The pusher 20 comprises a downwardly extending flange 24 and a body pusher head 26 connected to the downwardly extending flange 24.

The purpose of the downwardly extending flange 24 and the body pusher head 26 is to move the broiler 100 from the shackle 92 without changing the orientation of the broiler 100 by also pushing the body of the broiler 100.

The pusher 20 may also be designed as shown in figure 9.

The gripper 40 comprises two leg guides 50A, 50B for guiding the broiler legs 104 and gripping the broiler legs 104. This is shown in greater detail in figure 5.

Fig. 5illustrates a gripper 40 gripping a broiler 100 by the broiler legs 1041, 104II.

The gripper 40 comprises two leg guides 50A, 50B for guiding the broiler legs 104. Each leg guide 50A, 50B comprises a first and a second arm 52A, 52B, 52C, 52D ex tending from a pivotal end 42 towards a distal end 44. The first and the second arm 52A, 52B, 52C, 52D are pivotal between an open position 54 and a catch position 56, wherein the arms 52A, 52B, 52C, 52D form a channel 58A, 58B for guiding the re spective broiler legs 1041, 104II towards the pivotal end 42.

Each channel 58 A, 58B has a channel width 59 A, 59B, which channel width 59 A, 59B decreases towards the pivotal end 42. This enables that the same gripper 40 can grip broiler legs 104 of different sizes, and furthermore the decreasing channel width 59A, 59B also acts to stop the broilers gradually.

The gripper 40 is angled upwardly relative to a horizontal plane as makes the gripping of the broiler legs more reliable.

The apparatus 10 comprises a receiving trough 75 which is positioned below the grip per 40 for stopping the broiler 100. The trough 75 decreases the time for the broiler 100 to be at rest i.e. without kinetic energy. Thus, the broiler 100 can be released more quickly, and the gripper 40 is then ready for gripping the next broiler 100. Thus, the trough 75 increases throughput.

Fig. 6 illustrates a top view of the gripper 40 shown in figure 5 gripping a broiler 100 at the broiler legs 104.

Fig. 7 illustrates an embodiment of an actuation of a gripper 40. This gripper 40 is the gripper 40 shown in fig. 5-6.

Each arm 52A-D is at the pivotal end 42 connected to a gear 53A-53D. Gear 53A is connected by a thread connected to gear 53B, which is connected by a thread connect ed to gear 53C, which is connected by a thread connected to gear 53D. Thus, each gear 53A-D will move in unity and thus each arm 52A-52D will move in unity.

Gear 53A and gear 53D comprise a member 51 A, 5 ID extending in a direction sub stantially opposite to the arms 52A, 52D. The members 51 A, 5 ID are connected to an actuator such as a pneumatic actuator which can cause the members 51 A, 5 ID and thus gears 53A-53D and arms 52A-D to displace between an open position 54 and a catch position 54.

Fig. 8illustrates an arm 52 for a leg guide 50 to form part of a gripper 40.

The arm 52 comprises a pivotal end 42 with a gear 53 and a distal end 44. The arm 52 has a rounded side extending between the pivotal end 42 and the distal end 44, which will face and frictionally connect with a broiler leg 104. The side is rounded to avoid cutting the broiler leg 104 when gripping the broiler leg 104.

Fig. 9illustrates embodiment of a pusher 20.

The pusher 20 comprises a curved pusher body 28 having pusher guide 29 allowing the pusher to move in a more reliable matter. The pusher is controlled by pneumatics or a motor which will cause the curved pusher body in a direction defined by the pusher guide 29.

The pusher 20 comprises a main pusher head 22 connected to the curved pusher body 28. The main pusher head 22 is adapted to push broiler legs 104.

The pusher 20 comprises two body pusher heads 261, 2611 for pushing the body of the broiler 100. The curved pusher body 28 is curved to ensure that the main pusher head 22 pushes the broiler legs 104 first or at least at the same time as the body pusher head 261, 2611. This enables the broiler 100 to be pushed from the shackle 92 without changing the orientation of the broiler 100 by also pushing the body of the broiler 100.

Fig. 10 illustrates a method 1000 of for removing a broiler from an overhead sorting conveyor 92 in a controlled manner.

The method 1000 comprises acts of - providing 1100 a pusher 20, and a gripper 40 facing the pusher 20;

- receiving 1200 a broiler position 102 from a master system 300;

- pushing 1300 the broiler 100 using the pusher 20 as a function of the broiler position 102 towards the gripper 40; - gripping 1400 the broiler 100 as a function of the broiler position 102 using the grip per 40; and

- releasing 1500 the broiler 100 from the gripper 40. The method 1000 may further comprise acts of

- providing 1000 a sensor 70 upstream to the pusher 20;

- detecting 1210 a broiler 100 having the broiler position 102 on the overhead sorting conveyor 90 by a sensor 70; and

- adjusting 1220 the broiler position 102 as a function of sensor data.

The method 1000 may further comprise an act of feeding 1600 the broiler 100 into a packaging machine 200.