Abstract:
Portioning system ( 10 ) includes a conveyor ( 12 ) for conveying work products ( 14 ) past a scanner ( 16 ). A data processor ( 22 ) receives the scanning data and generates a thickness and/or volume distribution of the work product. The processor is programmed to determine in advance how the work product may be portioned into a plurality of desired end products, and more specifically how one or more of the end products may be cut and then subsequently sliced without having to re-scan the cut portion. The processor controls a cutting device ( 18 ) for portioning the work product under the cutting strategy determined by the processor, and also controls a slicing device ( 20 ) for subsequently slicing one or more of the cut portions to achieve a desired thickness per the determined cutting strategy.

Description:
CROSS-REFERENCE TO RELATED APPLICATION  
       [0001]     This application is based on and claims the benefit of U.S. Provisional Application No. 60/640,282, filed Dec. 30, 2004. 
     
    
     TECHNICAL FIELD  
       [0002]     The present invention relates to processing work products, and more specifically to estimating and optimizing the yield from portioning work products, such as food products.  
       BACKGROUND  
       [0003]     Work products, including food products, are cut or otherwise portioned into smaller portions by processes in accordance with customer needs. Also, excess fat, bone and other foreign or undesirable materials are routinely trimmed from the food products. Much of the portioning/trimming of work products, in particular food products, is now carried out with the use of automated portioning machines. These machines use various scanning techniques to ascertain the size and shape of the work product as it is being advanced on a moving conveyor. This information is analyzed with the aid of a computer to determine how to portion the work product into the desired sizes, weights or other criteria being used. For example, if work product portions of a specific weight are desired, the information from the scanner may be employed to control the operation of a crosscutting device to cut the work product into the desired portion sizes. If the work product changes in width or thickness along its length, the location of the crosscut made in the work product to achieve a desired end portion weight may be controlled.  
         [0004]     Work products may be thicker than desired for the portions to be cut from the work product. To achieve satisfactory thicknesses, a horizontal slicer may be used. Generally, the slicing operation occurs prior to the cutting process which, as noted above, is carried out by automated portioning machines. With the slicing done ahead of the portioner, the entire workpiece is sliced. If the workpiece is not of uniform thickness, at least some of the material trimmed from the workpiece may be relatively thin and, as such, of low economic value.  
       SUMMARY  
       [0005]     This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This summary is not intended to identify key features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.  
         [0006]     A portioning apparatus includes a conveyor for conveying work products to be portioned, and a scanner for scanning the work product as the work product is being transported by the conveyor. A data processor receives the data from the scanner and determines the thickness profile of the work product. The processor is programmed to predetermine how the work product may be portioned into a plurality of desired end portions or products where one or more of the portions cut from the work product may be subsequently sliced by a slicer to achieve a desired physical parameter for the end product without having to re-scan the cut portion to be sliced.  
         [0007]     The system may also include a cutter for cutting the work product into select portions. The system may also include a slicer to slice selected cut portions into desired thickness to achieve the desired physical configuration of the end product&#39;s portion from the work product.  
         [0008]     The foregoing system may be used to perform various portioning methods, including a method consisting of the steps of scanning a work product and then using such scanning information to determine the three-dimensional configuration of the work product. A determination is made as to how the work product may be portioned based on desired end products achieved from the scanned work product, bearing in mind that the cut portions may be sliced into specific thicknesses subsequent to the cutting operation. The method also includes cutting the work product into two-dimensional shapes based on the cutting strategy determined, then slicing specific two-dimensional shapes to achieve a desired thickness of the portioned end product.  
         [0009]     The method may also include slicing selected cut portions into fixed thicknesses.  
         [0010]     The method also contemplates slicing the cut two-dimensional shapes into different thicknesses specific to the desired three-dimensional configuration of the end product portion. 
     
    
     DESCRIPTION OF THE DRAWINGS  
       [0011]     The foregoing aspects and many of the attendant advantages of this invention will become more readily appreciated as the same become better understood by reference to the following detailed description, when taken in conjunction with the accompanying drawings, wherein:  
         [0012]      FIGS. 1, 2 , and  3 , in combination comprise a schematic view of a disclosed embodiment.  
         [0013]      FIG. 4  is a flow diagram of a disclosed embodiment. 
     
    
     DETAILED DESCRIPTION  
       [0014]      FIGS. 1-3  schematically illustrate a portioning system  10  suitable for implementing an embodiment of the present invention. Of course, multiple conveyors can be used in conjunction with the present invention. The portioning system  10  includes conveyor  12  for carrying a work product  14  to be portioned. The system  10  also includes a scanning system  16  for scanning the work product  14  and a cutter  18  for cutting the work product into one or more pieces of desired sizes or other physical parameters. A slicer  20  is schematically illustrated in  FIG. 3  as located downstream from the cutter  18 . The conveyor  12 , the scanning system  16 , the cutter  18 , and slicer  20  are coupled to, and controlled by, processor  22 . As illustrated, the processor includes a user interface  24  (keyboard, mouse, etc.) and an output device  26  (monitor, printer, etc.).  
         [0015]     Generally, the scanning system  16  scans the work product  14  to produce scanning information representative of the work product, and forwards the scanning information to the processor  22 . The processor  22  analyzes the scanning data to develop a thickness profile of the scanned work product. The processor also develops an area and/or volume distribution of the scanned work product. The processor  22  then can model the work product to determine how the work product might be portioned into end product sets composed of one or more end products of specific physical criteria, including, for example, weight, shape, thickness, length, or width. In this regard, the processor takes into consideration that the thickness of the work product may be altered after the work product has been portioned by the cutter  18 . In addition, the processor factors in any defects found in the work product during the scanning process. With all these criteria and factors in mind, the processor determines how the work product may be portioned into one or more end product sets. The processor  22  then controls the cutter  18 , as well as the slicer  20 , to portion the work product according to the selected end product set.  
         [0016]     Describing the foregoing systems in more detail, the conveyor  12  carries the work product  14  beneath a scanning system  16 . The scanning system  16  may be of a variety of different types, including a video camera  30  to view a work product  14  illuminated by one or more light sources  32 . Light from the light source is extended across the moving conveyor belt  48  to define a sharp shadow or light stripe line, with the area forwardly of the transverse beam being dark. When no work product  14  is being carried by the infeed conveyor  12 , the shadow line/light stripe forms a straight line across the conveyor belt. However, when a work product  14  passes across the shadow line/light stripe, the upper, irregular surface of the work product produces an irregular shadow line/light stripe as viewed by a video camera  32  directed diagonally and downwardly on the work product and the shadow line/light stripe. The video camera detects the displacement of the shadow line/light stripe from the position it would occupy if no work product were present on the conveyor belt. This displacement represents the thickness of the work product along the shadow line/light stripe. The length of the work product is determined by the distance of the belt travel that shadow line/light stripes are created by the work product. In this regard, an encoder  34  is integrated into the infeed conveyor  12 , with the encoder generating pulses at fixed distance intervals corresponding to the forward movement of the conveyor.  
         [0017]     In lieu of a video camera, the scanning station may instead utilize an x-ray apparatus for determining the physical characteristics of the work product, including its shape, mass, and weight. X-rays may be passed through the object in the direction of an x-ray detector (not shown). Such x-rays are attenuated by the work product in proportion to the mass thereof. Scanner system  16  includes a generator  30  to irradiate the work product  14  to be scanned with X-ray radiation and a receiver  32  to receive the attenuated radiation. The receiver portion  32  can be integral with the generator  30 .  
         [0018]     Attenuation of the X-rays can occur by passing through the work product or by reflection from the work product. When radiation passes through the work product, a certain amount of radiation is absorbed by the work product through which it passes, therefore there will be a relationship in the amount between the radiation sent to the work product and the radiation received after it has passed through the work product. The cause of absorption is believed to reside in the chemical bonds within the molecules of the work product. Radiation once attenuated can be collected and converted into a useable form. Photodiodes, for example, may be used to convert an amount of radiation in the visible range into a voltage or current signal. For X-rays, a scintillating material may be used to generate visible light capable of detection by a photodiode. This method is described in U.S. Pat. No. 5,585,603 to Vogeley, Jr., which is herein incorporated by reference.  
         [0019]     The foregoing scanning systems are known in the art and, thus, are not novel per se. However, the use of these scanning systems in conjunction with the other aspects of the described embodiments are believed to be new.  
         [0020]     The data and information measured/gathered by the scanning device(s) is transmitted to the processor  22 , which records the location of the work product  14  on the conveyor  12 , as well as the length, width and thickness of the work product about the entire area of the work product. With this information, the processor can develop an area profile as well as a volume profile of the work product. Knowing the density of the work product, the processor can also determine the weight of the work product or segments thereof.  
         [0021]     The scanning information can also be used to ascertain whether there are any defects in the work product. Such defects might include tears, holes, fat, bone, or cartilage. For example, if an x-ray apparatus is utilized, and if a hole or tear exists, the x-rays will be attenuated to a lesser extent than if the work product was structurally intact. Also, for work products composed of raw meat, the density of fat, bones, and cartilage is different from the density of the meat. This density variation results in a difference in the attenuation of the x-rays passing through the work product. For example, the density of bone is greater than the density of meat. Thus, the x-rays passing through the bone will be attenuated to a greater extent than the x-rays passing through the meat. As a consequence, by the scanning process, the existence as well as the position and size of the defects in the work product may be ascertained. Examples of the foregoing scanning devices are disclosed in U.S. Pat. No. 6,563,904, incorporated by reference herein.  
         [0022]     Preferably the computer  22 , having a central processing unit  40  (hereinafter CPU) and a memory  42 , will be used in the method according to the present invention. Data consisting of desired end product shapes are stored in the computer memory  22 . The memory can store additional maps that can readily be selected by a user via a user interface  24 , for example, when changing product lines. For instance, the user may be processing chicken breasts for a particular customer who may have a particular desired shape; when the order of the customer is filled, the user may switch the mode of the computer to a different product to meet the specifications of a different customer. This switch may be automated and triggered by a counter that keeps track of the number of work product portions that have been processed, or the switch may be carried out manually to allow the user time to retool any apparatus or recalibrate. In other alternate embodiments, a library of maps for a whole production plan can be stored in the memory of a computer.  
         [0023]     As shown in  FIG. 2 , the computer  22  can be in communication with a network system  46  which allows the computer  22  to talk to and share information with other computers. Computer  22  can also drive other periphery hardware besides the scanner system  16 . For instance, computer  22  can direct the operation of the conveyor  12 , cutting device  18 , and slicer  20 . Finally, computer  22  can receive information from various sensors  48  to guide or direct a multitude of systems.  
         [0024]     Various types of cutting devices  18  may be utilized to cut the work product  14  into smaller end portions. Examples of cutting devices include high-speed water jets, lasers, rotary saws, hacksaws, guillotines, and band saws. Such cutting devices are articles of commerce. Cutting devices of the foregoing nature are described in U.S. Pat. No. 5,931,178, to Pfarr, which is incorporated herein by reference. Band saws and blades are described in U.S. Pat. No. 5,937,080, to Vogeley, Jr., et al., which is herein also incorporated by reference. The processor  22  can control the cutting path of the cutting devices  18  to automatically segment the work product into a set of smaller end product portions.  
         [0025]     As shown in  FIG. 3 , slicer  20  is located downstream from the cutter  18 . Various types of slicers may be utilized to slice the work product into one or more desired thicknesses. For example, the slicer may be in the form of a high-speed water jet, a laser, a rotary saw, a hacksaw, or band saw. Also, the slicer may be adjustable so that a desired thickness of each individual work product is obtained. Such adjustment may be under the control of the processor  22 .  
         [0026]     The slicer  20  is used to alter the thickness of the work product. The work product, or portions of the work product, may be substantially thicker than desired for end products portioned from the work product. For example, if sandwich portions are to be cut from chicken breasts, part or the entire chicken breast may be substantially thicker than the desired sandwich portion. As a consequence, it is necessary to slice the chicken breast to obtain thickness that is within acceptable limits.  
         [0027]     With the slicer located downstream of the cutter  18 , the slicer can be selectively utilized on selected portions of the work product after the operation of the cutter  18 . For example, the cutter  18  may be used to cut a specific portion  50  from the work product, and thereafter, that specific portion may be sliced to achieve a desired thickness as well as a desired product shape or area. The remainder of the work product that is not sliced can remain in its original thickness, which may be thicker than the sliced portion, thus available for other uses requiring thicker portions. If the entire work product is sliced before cutting, then the remainder of the work piece, exclusive of specific portion  50 , may be too thin for most uses, thus reducing the overall economic value of the work piece. This may be avoided by being able to slice selected portions of the work piece, such as portion  50 , after cutting.  
         [0028]     The work product  14  may be cut and sliced in different orders. For example, referring to  FIG. 2 , a portion  50  of the workpiece  14  may first be cut by cutter  18 , and then such portion  50 , shown in  FIG. 3 , may be sliced to a desired thickness. In doing so, the entire width of the workpiece  14  corresponding to the portion  50  also will be sliced to the desired thickness. When the portion  50  is being cut by cutter  18 , the remaining portion  15  may also be cut into desired end pieces, for example, strip pieces  52  as well as cube pieces  54 . As will be appreciated, because of the slicing of the portion  50 , the cube pieces located alongside portion  50  will be reduced in thickness to the thickness of the portion  50 , see  FIG. 3 .  
         [0029]     Other cutting and slicing procedures may be utilized. For example, portion  50  may first be cut from the work piece  14  by cutter  18 . At the same time, the additional portions  52  and  54  also may be cut. Thereafter, the end product piece  50  to be subsequently sliced, may be separated from the remainder of the work piece, for example, by being picked up and moved to another location on the conveyor  12 , which location is known to the portioning system  10 . With this known location, the slicer  20  can subsequently slice the cut portion  50  to a desired thickness. The remaining cut portions  52  and  54  can continue on the conveyor, to be subsequently offloaded and placed at a desired location. The portion  50 , after being sliced by slicer  20 , may also be offloaded at a desired location.  
         [0030]     Rather than moving the cut portion  50  to a new location, the cut portion may remain at its location on the conveyor  12 , and the remainder of the workpiece  14 , including the cut portions  52  and  54 , may be removed from the conveyor with the pickup device, or moved to another location on the conveyor with a pickup device. In this situation, only the portion  50  will be sliced by slicer  20 , and the remainder of the portion  15 , including the portions  52  and  54 , can remain in original thickness. This generates less trim and more useable end product than if the entire work piece  14  were sliced by slicer  20  or even if the entire width of the workpiece corresponding to end piece  50  were sliced by the slicer  20 . As a consequence, the yield from the workpiece  14  is improved.  
         [0031]     Various pickup devices can be used in conjunction with the present invention. Such pickup devices may be operated by suction, by clamping action, by one or more forks that stab the work product, etc. An example of such pickup device is disclosed in U.S. Pat. No. 6,826,989, incorporated herein by reference. Arms or gates, not shown, may be used in conjunction with such pickup devices to move or remove the work product residual of cut portion  50  so that only the cut portion is sliced by slicer  20 .  
         [0032]     The system  10 , described above, may be utilized to pre-determine how work product  14  may be portioned by a combination of initially cutting the work product and then optionally slicing one or more of the cut work product portions. The end portions may be of the same or of differing sizes depending on how the work product may be most efficiently portioned, as well as depending on customer needs.  FIG. 4  schematically illustrates one method of using system  10  to portion work product  14  in the foregoing manner.  
         [0033]     The method starts at  100  and includes the step  102  of scanning the work piece to be portioned. Thereafter, at step  103 , the scanning information is used to generate volume distribution of the work piece. Next, at step  104 , the processor is used to model the work piece to determine how the work piece might be portioned into end product sets composed of one or more end products of specific physical criteria, for example, weight, shape, thickness, length, or width. Information on such criteria and desired end product sets is available to the processor from database  106 . The processor also considers how the portions cut from the work product may be sliced to a required thickness after cutting. The processor uses all this information to determine how to optimally cut the work piece, as well as to determine which of the cut work pieces are to be sliced after cutting. At decision step  110 , if the processor has determined that a particular cut portion of the work piece will not be sliced, then cutting occurs at  112 A, and then the present method for that particular cut portion has been completed. However, if the processor has determined that the cut portion is to be subsequently sliced, cutting occurs at step  112 B and then subsequently slicing occurs at step  114  to complete the method.  
         [0034]     Of course, other methods may be utilized in conjunction with portioning system  10 . For example, as noted above, after being cut, portions to be sliced may be separated from the remainder of the cut portions and then sliced separately from the remaining cut portions.  
         [0035]     As a further alternative, the cut portions to be subsequently sliced may be left in place, and the remainder of the cut portions and trim may be removed or otherwise separated from such work piece. In this manner, only the designated cut portions are sliced.  
         [0036]     While the preferred embodiment of the invention has been illustrated and described, it will be appreciated that various changes can be made therein without departing from the spirit and scope of the invention.  
         [0037]     For example, although the foregoing description discussed scanning by use of a video camera  30  and light source  32 , as well as by use of x-rays, other three-dimensional scanning techniques may be utilized. For example, such additional techniques may be by ultrasound or moire fringe methods. In addition, electromagnetic imaging techniques may be employed. Thus, the present invention is not limited to use of video or x-ray methods, but encompasses other three-dimensional scanning technologies.