Abstract:
Broccoli heads are placed individually, with the stem down or laying horizontal, in a receiving cup in a loading position. A gripping mechanism engages the stem portion to secure the head in place. A positioning and cutting assembly adjusts the position of the receiving cup to a cutting position with the head down and stem up and rotates the receiving cup. The assembly includes a cutting mechanism having a blade that engages the rotating head to cut the florets. The blade cuts off the florets which fall to a first location where they are collected in a first collecting bin or by a first collection conveyor. The assembly next adjusts the receiving cup to a releasing position, whereupon the clamping mechanism disengages to release the stem, which falls to a second location where it is collected on a second collecting conveyor or in a second collecting bin. The assembly then returns the receiving cup to the loading position.

Description:
CROSS-REFERENCES TO RELATED APPLICATIONS 
     N/A 
     BACKGROUND 
     The present invention relates generally to methods and devices for floreting broccoli, and more particularly to systems and methods for automatically dissecting broccoli heads into florets and stems. 
     Various methods and machines that are directed to a broccoli floreting processes and apparatus are well known in the art. Cutting broccoli heads by hand with an ordinary cutting device is an easily available and flexible method to floret broccoli heads. However, these manual processes are disadvantageous because they are time consuming processes that require high amounts of manpower. Different mechanical procedures speed up the processing time through the use of automated and semi-automated machines. These machines cut the broccoli in ways which causes instability and, therefore yields less efficient cutting results. It is desirable to achieve a more consistent floret length from the floreting process. Previous automated and semi-automated broccoli floreting machines yield broccoli heads of varying floret length. Consequently, such dimensional variance results in vast amounts of scrap because the changes in broccoli head dimensions does not allow for consistent cutting locations between the broccoli head elements and the automated machine cutting implements. 
     Another approach known in the art uses two cutting blades that cut the broccoli from both sides to attempt to address these shortcomings. However, the constant clashing of the blades in their contact point entails apace abrasion and inaccurate cuts. Also, the constant clashing of the blades leads to higher maintenance costs of replacement parts and greater machine downtime. 
     Another well known process is a core removal device that features two blades folding up. The blades are affixed on a sliding support that moves perpendicular to a conveyor means layer and is equipped with an adjustable regulator that allows vertical tuning as well as offset modulation. However, this approach does not allow the dimensional consistency to eliminate scrap and further exhibits many of the machine downtime drawbacks previously discussed. 
     Another similar process is a device that features pivotably mounted blades for cutting movement in which the cutting edges follow an accurate path to achieve a complete removal of the stem. These blades are also connected together and are formed with cutting edges which open and close in the manner of a beak. The cutter elements are mounted on a carrier plate which is pivotable between the cutting and core discharge positions about a pivot axis to one side of and parallel with a conveyor means. It misses however any further means for fixture. 
     A broccoli head trimming apparatus variably and shakily holding the heads by an inflatable elastomeric collar that transports the broccoli on a conveyor means was also developed for bulk processing of broccoli heads. When the broccoli head approaches the trimming station the machine&#39;s conveyor means is slowed down and enables a guillotine blade to cut of the florets. This movement and the collection of the cut-off florets falling down by gravity on a lower level, increases the machines loss ratio of such processes. 
     Another previously developed process features a clamping portion that can be opened and closed and transports vegetable around the plane of the loop. When the clamping portion is in its closed position and the stalks are affixed in its holding portion, a rotary saw cuts off the stalks. However, this approach does not provide for a proper and complete removal of the cores according to the peculiar form of stems and florets, thus resulting in high amounts of scrap as well. 
     Several further approaches have been developed to slice broccoli heads into spears. A device using this approach divides the heads into multiple segments by a segmenting knife and, then, separates the florets by use of a spinning, semispherical cutter. To sever the florets, such a cutter sweeps through approximately ninety degrees. Alternatively, the broccoli can be transported while laying on its side. A clamping jaw grasps the stems end of a broccoli, straightens them up and a slicing means that is mounted in a vertically aligned relation for joint rotational movement separates the florets. The slicing means provides a plurality of straight knife blades angularly related to each other for providing a plurality of longitudinal slices, severing the broccoli head in spears. The drawback to these methods is that they are instable and don&#39;t provide for accurate cuts, again leading to high amounts of scrap and ultimately higher processing costs. 
     Therefore it is desirable to provide a faster and more efficient methods of floreting broccoli. 
     BRIEF SUMMARY 
     Systems, apparatus and methods for floreting broccoli heads are provided. In certain embodiments, systems, methods and apparatus include a receiving cup coupled with a positioning and cutting assembly. Broccoli heads are placed individually, with the stem down or horizontal, in a receiving cup in a loading position. A gripping mechanism engages the stem portion to secure the head in place. The assembly adjusts the position of the receiving cup to a cutting position with the head down and stem up and rotates the receiving cup. A cutting mechanism includes a blade that engages the rotating head to cut the florets. The blade cuts off the florets which fall to a first location where they are collected in a first collecting bin or by a first collection conveyor. The assembly next adjusts the receiving cup to a releasing position, whereupon the clamping mechanism disengages to release the stem, which falls to a second location where it is collected on a second collecting conveyor or in a second collecting bin. The assembly then returns the receiving cup to the loading position. 
     Embodiments and aspects of the present invention are also applicable to cutting cauliflower heads. 
     In certain other embodiments, systems, methods and apparatus include a receiving cup coupled with a positioning and cutting assembly. Broccoli heads are placed individually, stem down, in a receiving cup in a loading position. A clamping mechanism engages the stem portion to secure the head in place. The assembly adjusts the position of the receiving cup to a cutting position with the head down and stem up and rotates the receiving cup. A cutting mechanism includes a blade that engages the rotating head to cut the florets. The blade cuts off the florets which fall to a first location where they are collected in a first collecting bin or by a first collection conveyor. The assembly next adjusts the receiving cup to a releasing position, whereupon the clamping mechanism disengages to release the stem, which falls to a second location where it is collected on a second collecting conveyor or in a second collecting bin. The assembly then returns the receiving cup to the loading position. 
     One embodiment of the present invention is the industrial fixed mounted application of the device wherein the apparatus is mounted in a fixed location and the broccoli heads are transported to the facility and processed in a production line. The apparatus is permanently affixed to a base or the floor of a production area. 
     Another embodiment of the invention is a mobile agricultural application where the apparatus can be installed on different types of tractors or other agricultural implements. An immediate handling and machining in the field is possible. Further, apparatus tolerances are developed to allow for some movement of the mobile platform base and/or a slow movement of the process throughout the field, much like the speed found in a combine or other farm implement machinery. 
     According to yet another aspect, an apparatus for processing a broccoli head is provided. The apparatus typically includes a support structure, and a head cutting and positioning assembly coupled with the support structure. The assembly typically includes a receiving cup for receiving a stem portion of a broccoli head when in a loading position, a gripping mechanism coupled to the receiving cup and configured to engage the stem portion of the broccoli head in the receiving cup to secure the broccoli head thereto, and an adjustment mechanism coupled to the receiving cup and configured to adjust positions of the receiving cup between the loading position, a cutting position and a releasing position. The assembly also typically includes a rotation mechanism configured to rotate the receiving cup, and a cutting mechanism including a blade configured to engage and cut a rotating broccoli head when in the cutting position. During typically operation, the rotation mechanism rotates the receiving cup at least when in the cutting position, the cutting mechanism cuts an unprocessed broccoli head held in the rotating receiving cup to form a broccoli floret portion and a broccoli stem portion, wherein the floret portion falls or drops to a first location, whereafter the adjustment mechanism adjusts the receiving cup to the releasing position, and whereafter the clamping mechanism releases the stem portion and the stem portion falls or drops to a second location different than the first location. 
     According to yet another aspect, a method for processing broccoli heads is provided. The method typically includes receiving a broccoli head in a receiving cup in a loading position, automatically gripping a stem portion of the broccoli head in the receiving cup so as to secure the broccoli head thereto, and automatically adjusting a position of the receiving cup to a cutting position. The method also typically includes automatically rotating the receiving cup at a rotation rate, such that the broccoli head rotates about an axis of the clamped stem portion, and automatically cutting the rotating broccoli head with a cutting blade when in the cutting position thereby creating a broccoli floret portion and a broccoli stem portion, wherein the broccoli floret portion falls to a first location and wherein the broccoli stem portion is held in the receiving cup. The method also typically includes automatically adjusting the position of the receiving cup to a releasing position, and automatically ungripping (or deactivating the gripping mechanism) the broccoli stem portion so that the broccoli stem portion is released and falls to a second location different than the first location. 
     According to yet another aspect, an apparatus for processing broccoli heads is provided. The apparatus typically includes a support structure, and a head cutting and positioning assembly coupled with the support structure. The assembly typically includes a plurality of receiving cups, each for receiving a stem portion of a broccoli head when in a loading position, a gripping mechanism coupled with each receiving cup and configured to engage the stem portion of the broccoli head in the receiving cup to secure the broccoli head thereto, and an adjustment mechanism coupled to each receiving cup and configured to adjust positions of the receiving cup between the loading position, a cutting position and a releasing position. The assembly also typically includes a rotation mechanism for each receiving cup that is configured to rotate the receiving cup, and a cutting mechanism for each receiving cup that includes a blade configured to engage and cut a rotating broccoli head when in the cutting position. During operation, for each receiving cup, the rotation mechanism rotates the receiving cup at least when in the cutting position, the cutting mechanism cuts an unprocessed broccoli head held in the rotating receiving cup to form a broccoli floret portion and a broccoli stem portion, wherein the floret portion falls or drops to a first location, whereafter the adjustment mechanism adjusts the receiving cup to the releasing position, and whereafter the clamping mechanism releases the stem portion and the stem portion falls or drops to a second location different than the first location. 
     Reference to the remaining portions of the specification, including the drawings and claims, will realize other features and advantages of the present invention. Further features and advantages of the present invention, as well as the structure and operation of various embodiments of the present invention, are described in detail below with respect to the accompanying drawings. In the drawings, like reference numbers indicate identical or functionally similar elements. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  illustrates an apparatus for processing broccoli florets according to one embodiment. 
         FIG. 2  illustrates a method of floreting broccoli using an apparatus of  FIG. 1  according to one embodiment. 
         FIG. 3  illustrates an embodiment incorporating a sensor that measures the position of the top of a head held in a receiving cup. 
         FIG. 4  illustrates an embodiment incorporating a sensor that measures the width or diameter of a head held in a receiving cup; and  FIG. 5  illustrates an example of a support structure coupled with a tractor trailer and including a plurality of receiving cups. 
     
    
    
     DETAILED DESCRIPTION 
     Specific examples of components and arrangements are described below to simplify the present disclosure. These are, of course, merely examples and are not intended to be limiting. In addition, the present disclosure may repeat reference numerals and/or letters in the various examples. This repetition is for the purpose of simplicity and clarity and does not in itself dictate a relationship between the various embodiments and/or configurations discussed. 
     The embodiments herein introduce improved methods and apparatus for use in floreting broccoli heads. Broccoli heads are individually placed in cups wherein the stems penetrate a hole in the cup. In one embodiment, the head is placed and securely held in the cup which is then repositioned to a cutting position and rotated while a blade engages the rotating head to produce florets which drop to a first location. After cutting, the cup is repositioned to a release position where the stem is released to a second location. 
       FIG. 1  illustrates an apparatus including a positioning and cutting assembly  100  for processing broccoli florets according to one embodiment.  FIG. 1   a  illustrates assembly  100  with a receiving cup  110  in a first, loading and securing position;  FIG. 1   b  illustrates assembly  100  in a second, cutting position, and  FIG. 1   c  illustrates the assembly  100  in a third, releasing position. The cutting and positioning assembly  100  includes a receiving cup or chuck  110  for receiving a broccoli head  105 , stem first, and a gripping mechanism for securing the head to the receiving cup. In one embodiment, the gripping mechanism  115  includes a bladder  120  within the receiving cup, the bladder being in fluid communication with a pump mechanism ( 340 ,  FIG. 3 ). Upon activation, the pump mechanism fills the bladder with air or other gas such that a stem inserted into the receiving cup is engaged by the pressure/frictional force of the filled bladder. A rotation mechanism ( 330 ,  FIG. 3 ) to rotate the receiving cup, and a cutting mechanism, including a blade for engaging the head when in the cutting position, are also provided for cutting a held broccoli head as will be described in more detail below. The assembly  100  also includes various pneumatic elements and mechanical connectors configured to adjust the position of the receiving cup, and hence a held broccoli head, to the different positions. Adjustment includes rotation of the cup  110  around an adjustment axis. As shown in  FIG. 1   a , for example, when in the loading position, a worker is able to load a broccoli head, stem first, into a receiving cup  110 . When in the cutting position as shown in  FIG. 1   b , florets cut by the cutting mechanism fall or drop to a first location, e.g., collection bin or conveyor  106   1 . When in the releasing or dumping position as shown in  FIG. 1   c , a released stem portion falls or drops to a second location, e.g., collection bin or conveyor  106   2 , different than the first location. Operation of assembly  100  will be described in connection with a process embodiment shown in  FIG. 2 .  FIG. 5  shows an example of a support structure  10  coupled with a tractor trailor  20  and including a plurality of receiving cups  110  as described in more detail herein. 
       FIG. 2  illustrates a method  200  of processing a broccoli head to produce floret portions and a stem portion using an assembly  100  of  FIG. 1  according to one embodiment. Harvested broccoli is first cut into unprocessed head elements  105  and then placed in the receiving cups  110  by a field worker; hence, in step  210 , a broccoli head is received in receiving cup  110  when receiving cup  110  is in the loading position as shown in  FIG. 1   a . The loading position may be configured such that the stem portion points downward (e.g., at an angle between 0 degrees (horizontal) and vertical (90 degrees)) or lays horizontal. In step  220 , the broccoli head is secured in the receiving cup. The gripping mechanism engages either automatically or in response to a user activated control signal. For example, after inserting the stem in the receiving cup, a user may press a button which activates the gripping mechanism to engage the stem and secure the broccoli head in the receiving cup. In certain aspects, the gripping mechanism includes a bladder  120  within the receiving cup portion. A pump mechanism, when activated, pumps air into the bladder to thereby inflate the bladder and engage the stem by pressure/frictional force. 
     In step  230 , the receiving cup is repositioned to a cutting position as shown in  FIG. 1   b . In certain aspects, step  230  is performed automatically after the broccoli head has been secured in step  220 . It should be understood that step  230  may be initiated automatically or in response to a separate user control signal. In step  240 , rotation of receiving cup  110  is initiated. For example, the rotation mechanism rotates or spins receiving cup  110  at a rate of up to about 180 rpm or more. Rotation may be initiated before or after receiving cup  110  is repositioned to the cutting position. In step  250 , the cutting mechanism is engaged. In one embodiment, a blade is inserted into the rotating head to sever florets from the stem portion. In one embodiment, the position and orientation of the cutting blade with respect to the rotating broccoli head is determined based on one or more broccoli head sensors (not shown in  FIG. 1 ) as will be discussed in more detail below. Upon being cut, broccoli florets fall or drop to a first location below the assembly. In one embodiment, a collection bin is positioned at the first location. In another embodiment, a portion of a collection conveyor is located at the first location, whereby florets dropped onto the conveyor at the first location are transported to another location by the conveyor. 
     In step  260 , the receiving cup is repositioned to a release position as shown in  FIG. 1   c . In certain aspects, step  260  is performed automatically after cutting has completed, e.g., after the cutting blade has been inserted and retracted from the rotating broccoli head. It should be understood that step  260  may be initiated automatically or in response to a separate user control signal. In step  270 , the stem portion is released from receiving cup  110 ; the gripping mechanism disengages the stem to allow the stem to fall by way of gravity. For example, in embodiments using a pump and bladder mechanism, air is released or allowed to escape from the bladder thereby removing the pressure/frictional force acting by the bladder on the stem. Upon being released, the broccoli stem falls or drops to a second location below the assembly. In one embodiment, a collection bin is positioned at the second location. In another embodiment, a portion of a second collection conveyor is located at the second location, whereby stems dropped onto the second conveyor at the second location are transported to another location by the conveyor. In step  280 , the receiving cup is adjusted back to the receiving or loading position to allow for another broccoli head to be received and processed. 
     Sensors 
     In certain embodiments, one or more sensors are used to determine size characteristics of a head held in a receiving cup. This information is used to adjust the position and/or orientation of a cutting blade and thereby optimize the floret sizes cut from a broccoli head. 
       FIG. 3  illustrates an embodiment incorporating a sensor that measures the position of the top of a head held in a receiving cup. In certain aspects, an optical sensor is used, for example a break-beam photo sensor or other optical sensor. In certain aspects, a mechanical sensor is used, such as a bar coupled with a biasing mechanism which provides feedback based on the angle at which the bar contacts the head. As shown in  FIG. 3 , a sensor  310  detects the position of the top of a head held in receiving cup  110 . A cutting mechanism includes a cutting blade  320 ; the position and orientation of the blade is adjusted based on the sensor feedback from sensor  310 . For example, for a large head size as shown in  FIG. 3   a , the blade is positioned as shown (the blade engages the rotating head by activation of the cutting mechanism which may include linearly sliding the blade  320  into the rotating head and/or sliding the blade into the head in an arced path). Similarly, for a small head the cutting mechanism is positioned as shown in  FIG. 3   b , and for a medium head, the cutting mechanism is positioned as shown in  FIG. 3   c . It should be appreciated that multiple activations of the cutting mechanism may occur. For example, for a large head, as determined by the sensor  310  ( FIG. 3   a ), the cutting mechanism activates to engage the blade with the head as shown in  FIG. 3   a  producing a first set of florets, then the sensor is adjusted and detects a smaller head portion (e.g.,  FIG. 3   b  or  3   c ) thereby activating the blade at a lower position to cut additional florets. 
     In certain aspects, the cutting mechanism is mechanically coupled with the sensor  310 , e.g., as the sensor moves downward or upwards, so too does the cutting mechanism and blade. The orientation of the blade may also adjust as the cutting mechanism raises or lowers. In certain aspects, the cutting mechanism is electrically coupled with the sensor, e.g., as the sensor moves downward or upwards, a control signal is provided to the cutting mechanism to adjust the cutting mechanism and blade accordingly. An integrated processor or intelligence module (not shown) such as an ASIC may be used to process signals from the sensor  310  and generate signals for controlling the cutting mechanism and other components. 
       FIG. 4  illustrates an embodiment incorporating a sensor that measures the width or diameter of a head held in a receiving cup. In certain aspects, an optical sensor is used, for example a break-beam photo sensor or other optical sensor. In certain aspects, a mechanical sensor is used, such as a bar coupled with a biasing mechanism which provides feedback based on the angle at which the bar contacts the head. As shown in  FIG. 4 , a sensor  410  detects the position of the widest part a head held in receiving cup  110 . The position and orientation of the cutting blade is adjusted based on the sensor feedback from sensor  410 . For example, for a large diameter head size as shown in  FIG. 4   a , the blade may be positioned or oriented than for medium diameter head ( FIG. 4   b ) or a small diameter head ( FIG. 4   c ). In certain aspects, the cutting mechanism is mechanically coupled with the sensor  410 , e.g., as the sensor moves inwards or outwards, so too does the cutting mechanism and blade. The orientation of the blade may also adjust as the cutting mechanism adjusts. In certain aspects, the cutting mechanism is electrically coupled with the sensor  410 , e.g., as the sensor moves inwards or outwards, a control signal is provided to the cutting mechanism to adjust the cutting mechanism and blade accordingly. The integrated processor or intelligence module may be used to process signals from the sensor  410  and generate signals for controlling the cutting mechanism and other components. In one embodiment, both the head length sensor  310  and the head width sensor  410  are simultaneously active, providing feedback information for adjusting the cutting mechanism accordingly to produce florets having controlled size characteristics. For example, in certain aspects, the cutting assembly is controlled to produce florets having a substantially constant (e.g., within about 10% to 20% consistency in length and width) floret size. 
     In certain embodiments, blade  320  is swept pneumatically towards the spin axis of the receiving cup and head, and the blade is oriented so as to cut substantially parallel to the spin axis, e.g., as shown in  FIG. 3   a . In other embodiments, the blade orientation is configured with an angle to the spin axis. In certain aspects, the blade assembly starts to move in a linear fashion until the “end of head” position is detected. At that point, when the sensor has seen the end of head, the blade sweeps along a circular or rotary path. Upon completing this “sweep” of the blade, the blade end of travel is detected, and linear motion is resumed. This second linear move is to gain mechanical clearance to avoid any collisions as the gripping device is moved to the “releasing” position, and then returned to the “loading” position. 
     U.S. patent application Ser. No. 12/033,791 is hereby incorporated by reference for all purposes. 
     Although the invention is illustrated and described herein as embodied in one or more specific examples, it is nevertheless not intended to be limited to the details shown, since various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims. For example, embodiments and aspects of the present invention are useful for cutting cauliflower heads or other vegetables. For cauliflower heads, in certain embodiments, one or more blades that create a “V” cut to remove the core from the florets may be desirable. Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the scope of the invention, as set forth in the following claims.