Abstract:
An egg carrier including a gripper mechanism wherein the egg carrier operative to grip and release and egg at a predetermined orientation. Accordingly, the egg carrier includes a mechanism whereby the gripper mechanism can be rotated whereby an egg can be released at an angle greater or less than 90°. The gripper mechanism capable of gripping an egg in one orientation and then pivoting or changing the orientation of the egg such that the egg is released at a predetermined angle.

Description:
FIELD OF THE INVENTION 
       [0001]    The present disclosure relates generally to an apparatus and method of egg transfer within an egg handling machine, and in particular to an improved apparatus and method for transferring eggs within the egg handling machine in which eggs may be loaded, handled, and subsequently packaged. 
       BACKGROUND 
       [0002]    Various types of machines are available for handling and packaging eggs, with each step of the process occurring within a particular station. Each station accomplishes a particular task including but not limited to washing, drying, weighing, sorting and packing of the eggs. Often, each station may accomplish a plurality of tasks. The varied number of stations encountered requires transportation of the egg through multiple stations to final packaging, and frequently at high rates of speed. The stations may be modular, so that the machine can be reconfigured to satisfy a particular processing need. 
         [0003]    Depending on the space configurations of the manufacturing environment, the stations may be arranged in a straight line, or may have an angular relationship, such as “L” shaped, or “U” shaped or the like. During transportation of the eggs through each of the stations by a conveying mechanism, the eggs may travel in a random manner, or in an organized manner, such as in lanes. The eggs may have a predetermined orientation with respect to a major axis of the egg, i.e. smaller more pointed end first, or larger more rounded end first. An example of a conveying mechanism is an in-feed roller conveyor. Another example of a conveying mechanism is an overhead carriage assembly and egg gripper or holder. The holder may grip the egg with a predetermined orientation, such as horizontally or vertically. Further, in handling eggs, the ability to handle a high volume of eggs in a brief time is an important capability. 
         [0004]    While existing egg handling machines work well, improving specific features associated with transport of the eggs will enhance overall line speed. For example, the eggs may be initially fed into the machine without the same orientation, and at some point in the process the orientation of the egg will need to be sensed and the eggs uniformly arranged. Further, during transport of the eggs between stations, the type of conveyor may change, such as from an overhead gripper to a series of rotating brushes, cup, basket or the like. For example, the rotating brushes may facilitate the transfer of the egg into another type of conveying mechanism. In a high-speed environment, such changes may slow down the overall process. 
         [0005]    In another example of an existing feature of an egg handling machine, the cups used to transport the eggs have a clamshell shape and pivot about a pivot axis located above the centerline of the egg. While the present cups work, the overall line speed is reduced due to the opening and closing of the cups while receiving and removing the egg. 
         [0006]    In yet another example, of an existing feature of an egg handling machine, the eggs are either oriented tip up or tip down, and are released at a 90 degree angle from an overhead conveyer onto another conveying mechanism. While the presently used release angle works, the line speed of the machine may not be optimized due to the trajectory of the egg. 
         [0007]    Thus, there is a need for an improved apparatus and method for efficiently and rapidly conveying eggs through multiple processing stations and facilitating the rapid transition of the eggs through the multiple processing stations, within an egg handling machine. 
       SUMMARY OF THE DISCLOSURE 
       [0008]    Accordingly, the present disclosure relates to an improved egg orientation mechanism for orienting eggs within a machine for handling eggs. The egg orientation mechanism includes a plurality of eggs positioned randomly on a first egg conveying mechanism. A lifter mechanism may be located adjacent the first egg conveying mechanism, wherein the lifter mechanism raises a portion of each egg away from the first egg conveying mechanism to off balance the egg. The egg orientation mechanism may also includes a sidewall adjacent the first egg conveying mechanism, and an end of the off balance egg contacts the sidewall to rotate the egg and to orient the egg with the larger end of the egg leading as the egg is released from the first egg conveying mechanism into a second egg conveying mechanism positioned below the first egg conveying mechanism. 
         [0009]    The present disclosure also relates to a clamshell egg holder for transporting eggs in a machine for handling eggs having a front wall with an upper end and a lower end, wherein the front wall has a predetermined height. The clamshell holder also has a rear wall with an upper end and a lower end, wherein the rear wall has a predetermined height. An egg receiving space is formed between the front wall and the rear wall, and either one of the front wall or rear wall is pivotal about a pivot point that is located below a centerline of the egg receiving space to increase the egg receiving space when catching the egg and decreasing the egg receiving space when holding the egg. 
         [0010]    The present disclosure further relates to a method of releasing an egg from an egg carrying mechanism in a machine for handling eggs, the method includes the steps of holding an egg using an egg holder, wherein the egg has a first predetermined orientation of 90 degrees with respect to a frame supporting the egg carrier mechanism. The method further includes the step of rotating the egg carrying mechanism so that the egg has a second predetermined orientation with respect to the frame, and releasing the egg at an angle that is either greater than 90 degrees or less than 90 degrees with respect to the frame. 
         [0011]    Advantageously, an apparatus and method of egg handling is disclosed for transporting eggs within a high-speed machine. An advantage of the present disclosure is that the eggs are oriented quickly by taking advantage of the natural characteristics of the eggs without requiring additional inspection for proper orientation. Another advantage is that all the eggs are rotated so that the narrower or tip end is up and the larger, more rounded end downward in a rapid paced mechanical process, thus assuring proper orientation. Still another advantage of the present disclosure is that by orienting the eggs so that the larger end impacts the conveying mechanism first, the egg will not skid or rotate upon landing. A further advantage of the present disclosure is that a clamshell egg holder is provided having a pivot point that is below the centerline of the egg receiving portion of the egg holder to facilitate higher speed transfers to occur more safely to the egg carrier. Still a further advantage of the present disclosure is that a direct carrier-to-carrier transfer may be made, thus eliminating an intermediate transfer mechanism, such as a cup to brush transfer. Yet a further advantage of the present disclosure is that the eggs may be released from an overhead conveying mechanism into a flatbed conveying mechanism or receiver at a predetermined angle other than 90 degrees to optimize trajectory of egg. Yet still a further advantage of the present disclosure is in the ability to maximize line speeds of the egg handling machine. 
         [0012]    Other features and advantages of the present disclosure will become readily appreciated based upon the following description when considered in conjunction with the accompanying drawings. 
     
    
     
       DESCRIPTION OF THE DRAWINGS 
         [0013]      FIG. 1  is a perspective view of an egg handling machine according to the present disclosure. 
           [0014]      FIG. 2  is a perspective view of an egg orientation mechanism for use with the egg handling machine of  FIG. 1 . 
           [0015]      FIG. 3   a  is another perspective view of the egg orientation mechanism for use with the egg handling machine of  FIG. 1 . 
           [0016]      FIG. 3   b  is a detailed view of the egg orientation mechanism of  FIG. 3   a.    
           [0017]      FIG. 4  is a perspective view of an egg carrier for use in the egg handling machine of  FIG. 1 . 
           [0018]      FIG. 5  is an enlarged rear view of the egg carrier of  FIG. 4 . 
           [0019]      FIG. 6  is an enlarged side view of the egg carrier of  FIG. 4 . 
           [0020]      FIG. 7  is a perspective view of a clam-shell egg holder for use with the egg handling machine of  FIG. 1 . 
           [0021]      FIG. 8  is a perspective view illustrating motion of the egg into the clam-shell carrier. 
           [0022]      FIG. 9  is a flowchart of a method of releasing eggs into an egg holder for use with the egg handling machine of  FIG. 1 . 
       
    
    
     DESCRIPTION 
       [0023]      FIG. 1  illustrates an egg handling machine  10  used to handle eggs. The egg handling machine  10  may include various stations  11 , and within each station  11  one or more actions may be performed. Examples of stations  11  may include an input or loading station, an accumulator, a washing station, a leak detection station, a dirt detection station, a grading station, a crack detection station, a blood detection station, or an output packaging station, to be described. Other examples relating to processing stations include a breaking and separation station, pasteurization station, drying station, deshelling station, or the like. Further types of stations  11  are contemplated depending on the particular need for the eggs  28 . Advantageously, the individual stations are modular, and the use of a station or order of the stations  11  can be varied depending on the particular need. The egg handling machine  10  depicted in  FIG. 1  is by way of example and not of limitation, and could utilize more, less or different stations. 
         [0024]    In the illustrated example of an egg handling machine, the eggs  28  may be initially placed into the egg handling machine  10  at a loading station  20  with a random orientation of the egg, i.e. orientation of major axis  42  of egg (to be described). The loading station  20  may include an accumulator  22  to orient the eggs  28  into a predetermined number of rows, such as  18 . Various types of accumulators  22  may be utilized, such as dividers or walls, or rollers, or brushes or the like. Eggs  28  travel via a conveying mechanism  18  (to be described) to the next processing station, which in this example is a washing station  19 , and the eggs are washed. The eggs may then be transported to the next station, which in this example is a detection station  21 , such as a leak or crack detection station. For example, in a leak detection station the eggs are examined for the presence of a leak using a leak detection mechanism as is understood in the art. If a leak in the egg is detected, it may be discarded. The eggs  28  may be then moved through a drying station  23 , and dried. The eggs  28  may then be moved to another detection station, such as a dirt detection station  25 , and a presence of dirt on the egg is detected using a dirt detection mechanism as is understood in the art. The eggs  28  may also be moved through a grading station  27 , in which each egg may be examined (such as by weighing or the like) and assigned a particular grade. Finally, the eggs may be moved through an output station  29  and prepared for removal from the machine  10 . An example of an output station  29  is a packaging station, which may facilitate the final packing of the egg into cartons. It should be appreciated that several operations may be combined to occur within one station. 
         [0025]    While each station  11  performs different functions, each station  11  has similar features. That is, each station  11  of the egg handling machine  10  of this example generally includes a frame  12 . Depending on the type of station and function occurring within, the frame  12  may generally planar table top  14  and supports or legs  16  that support the table top  14 , although other frame configurations are contemplated. A conveying mechanism generally shown at  18  is supported by the frame  12 , and moves the eggs through and between the previously described stations  11 . Various types of conveying mechanisms  18  are contemplated, such as an endless conveyor or feeder assembly having associated egg carrier mechanisms  34  i.e. brushes, rotatable rollers, grippers, carriers or the like for moving or holding the eggs. The type of conveying mechanism  18  is non-limiting and may be selectively determined according to the task occurring at a particular station. In an example as shown in  FIGS. 2 and 3 , a first conveying mechanism  18   a  includes rollers  26 , each roller extends parallel to and spaced apart from another roller. Rotation of the rollers  26  is via respective pinions which mesh with racks located alongside rollers. Racks and pinions may serve to automatically rotate the rollers  26  as the eggs  28  move along an endless path, such as by a chain and drive element. A second conveying mechanism  18   b  receives the eggs from the first conveying mechanism in a manner to be described. The conveying mechanism  18  includes other features that are not shown but understood, such as motors, servos, belts, or the like to facilitate the operation of the conveying mechanism  18 . 
         [0026]    Referring back to  FIGS. 2-3   b , an egg orientation mechanism  24  used to orient all of the eggs  28  in a predetermined manner is illustrated. In this example, the egg orientation mechanism  24  is positioned at the end of the loading station  19 , although it can be positioned within any station whereby a predetermined orientation of the egg is desirable, i.e. grading or output or the like. By way of reference, the egg  28  has a major axis  42  extending longitudinally through the egg from a tip or narrower end of the egg as shown at  28   a  to a larger, more rounded end of the egg as shown at  28   b.    
         [0027]    The egg orientation mechanism  24  may include a rotatable sprocket wheel  30  that is secured to the final set of rollers  26   a  of the first conveying mechanism  18   a  of this example to facilitate rotation of the conveying mechanism. The egg orientation mechanism  24  may also include a lifter mechanism  36  that raises the egg. For example, the lifter mechanism  36  may be a pivotal member positioned on the rollers  26  so that it is located beneath the egg  28 . In this example, the lifter mechanism  36  is located on the final set of rollers  26   a  before the egg falls off. The lifter mechanism  36  of this example includes a body portion  36   a  and a plurality of fingers  36   b  projecting from the body portion  36   a.  The body portion  36   a  is generally circular, and includes a central aperture for mounting the lifter mechanism  36  to the roller, and the finger  36   b  is rectangular. Other configurations are contemplated. As the egg  28  moves along the rollers  26 , the lifter mechanism  36  is rotating about the roller  26 , such that the finger  36   a  contacts the egg  28  and lifts the end of the egg  28  off the roller  26  as the traveling egg crosses the lifter mechanism. Since the tip  28   a  of the egg is by nature driven sideways or outwardly as the egg  28  travels along the rollers  26 , the lifting motion of the egg  28  initially throws the egg  28  off balance. 
         [0028]    The egg orientation mechanism  24  also includes a sidewall  32  positioned adjacent the rollers  26 . In this example the sidewall  32  is a rigid material that is fixedly attached and adjacent to the last roller  26   a,  although other configurations are contemplated. The sidewall  18  is located so that the egg can contact the sidewall  18  either as it is lifted up or when falling off the last roller  26   a  to create a “drag” effect. Further, the last roller  26   a  may be rotated in a direction that is opposite of the earlier rollers  26  to further induce the rotation of the egg. Thus, the egg tip  28   a  will make contact with the stationary sidewall  32  before falling off the rollers  26 . The contact between the egg tip  28   a  and sidewall  32  induces a natural rotation of the egg, i.e. backspin, about its natural axis of about 90 degrees. Since the egg is naturally eccentric, the backspin turns the egg  28  so that the larger, more rounded or bottom end  28   b  of the egg leads as the egg falls off the rollers  26  onto an egg carrier mechanism  34  associated with the second conveying mechanism  18   b.  The contact with the wall accelerates the motion of the egg  28 . For example, the bottom end  28   b  falls first vertically off the rollers, as shown at  48 . The major axis  42  of the egg  28  is perpendicular to the forward motion of the first conveying mechanism  18   a  as the egg leaves the first conveying mechanism  18   a,  and the egg  28  now has a predetermined orientation as it falls into the egg carrier mechanism  34  associated with the second conveying mechanism  18   b  so that the bottom of the egg initially contacts the second conveying mechanism  18   b.  In this example, the egg carrier mechanism is a gripper  35  having fingers. All eggs  28  will be mechanically turned to have the same orientation, such as 90 degrees with the tip end up. Since the egg orientation is now known, the egg carrier mechanism  34  or gripper  35  of this example can be manipulated as necessary, i.e. as shown at  50 . Advantageously, the eggs are all oriented without the need for any type of sensing mechanism. As a result, the eggs can move at a high rate of speed, such as 6 eggs per second. 
         [0029]    It is contemplated that the egg orientation mechanism  24  may include either or both of the lifter mechanism  26  and the sidewall  32 , depending on the needs of the egg handling machine  10 . 
         [0030]    Thus, in operation of the egg orientation mechanism  24  of this example, the eggs  28  have been initially accumulated, such as at an egg accumulation station  11 . The eggs  28  may be funneled into defined rows, and move in a forwardly direction using the first conveying mechanism  18   a,  such as via rollers  26 . At this point, the eggs  28  do not have a predetermined orientation with respect to each other. However, if the eggs are moving along rollers  26 , the tip end  28   a  of the egg  28  tends to migrate outwardly, i.e. towards the frame  12 . As the egg  28  moves along the rollers  26 , eggs  28  move across the lifter mechanism  36  and the egg  28  is lifted slightly by actuation of the lifter mechanism  36 . The elevation of the egg causes the egg  28  to contact the sidewall  32 , which creates a drag on the egg resulting in the egg  28  becoming unbalanced and rotating about its major axis up to 90 degrees. The major axis of the egg is now perpendicular to the earlier, forward motion of the egg, and each egg  28  has the same orientation. In this example, the larger, rounded egg end  28   b  is now leading. The egg is released into an egg carrier mechanism  34  associated with the second conveying mechanism  18   b,  which may be positioned to catch the egg  28  below the first conveying mechanism  18   a.  For example, the egg may be released onto a second egg carrier mechanism  34 , such as grippers, brushes, rollers, a carrier, receiver or the like associated with the second egg conveying mechanism  18   b . The egg  28  may now be carried to the next station using the second conveying mechanism  18   b . Advantageously, the eggs  28  now have a predetermined orientation. 
         [0031]    Referring to  FIGS. 4-6 , an egg carrier mechanism  34  which is a gripper egg carrier mechanism  35  is illustrated. The gripper egg carrier mechanism  35  may be used to catch the egg  28  after the egg has been oriented using the egg orientation mechanism  24 . Further, the gripper egg carrier mechanism  35  may be used with the improved method of releasing an egg, to be described. The gripper egg carrier mechanism  35  may be utilized within any of the stations  11 . By way of example, the gripper egg carrier  35  is shown after the eggs have been oriented using the egg orientation mechanism  24 . In an example, the gripper egg carrier mechanism  35  includes a plurality of individual egg holders  38  that catch the egg and impedes further momentum of the egg. A plurality of egg holders  38  are in spaced relation to each other. The number of egg holders  38  corresponds to the number of rows of eggs. For example, the gripper egg carrier mechanism  35  includes a cross member  44  and a pair of egg grippers  40  are mounted to the cross member corresponding to the number of rows of eggs. Each egg gripper  40  include a pair of opposed gripper fingers  46  that are pivotally secured to the cross member  44  at an upper end of the gripper finger  46 . The gripper fingers  46  can engage an egg in various orientations, such as horizontal or vertical. In this example, the egg tip  28   a  is pointed downwardly so that the rounded egg end  28   b  is held in a more positive manner, although other positions are contemplated. 
         [0032]    The cross member  44  may be pivotally attached to a drive member  52  such as a chain drive  52  via a connecting member or cam  54 . The pivotal attachment of the cross member  44  may provide for the pivotal movement of the egg holder  38  in a manner to be described to vary the release angle of the egg. By way of example, coupled at the end of each cam member is an extension bar which is spaced from the end cam member by an integral spacer. A bar may be provided with an upper T-shaped portion which is engageable with the latch pins of a comb assembly and solenoid actuated plunger to cause rotational movement of the cross member  44  in a manner to be described. 
         [0033]    The egg may be carried through each of the various stations using the egg holder  38  or grippers  40  of this example. Advantageously, the eggs  28  have a predetermined orientation, which in this example is with the egg tip  28   a  pointed downwardly so that the rounded egg end  28   b  is held by the gripper fingers  46  in a more positive manner. Other orientations are contemplated, and the gripper egg carrier mechanism  35  may be manipulated accordingly. 
         [0034]    Referring to  FIGS. 7-8 , another example of an egg carrier mechanism  34  which has an improved clam-shell type egg holder is illustrated. The clamshell receiver  60  receives and supports the egg  28  while transporting the egg through the predetermined station and may be utilized within any of the stations  11 . By way of example, the clamshell receiver  60  is shown carrying the eggs into the packaging station. The clamshell receiver  60  is secured to a cross-member  44 , and such attachment may be stationary or pivotal in a manner to be described. The clamshell receiver  60  includes a front wall  56  and a rear wall  58 . The front wall  56  may be shorter than the rear wall  58  by a predetermined amount so as to receive the egg  28 . An egg-receiving portion  62  is formed in the space between the front wall  56  and rear wall  58 . Each of the front wall  56  and rear wall  58  have a predetermined shape, to better accommodate the egg  28 . In this example, the front wall  56  and rear wall  58  each have a “V” shape, although other linear, curved or curvilinear shapes are contemplated to create a “soft” target for the egg to distribute impact forces of the egg contacting the rear wall  58 . The walls  56 ,  58  may be formed of one member, or multiple members. It is contemplated that each of the front wall and rear wall may be flexible strips. Further the walls  56 ,  58  may be formed from a suitable material having some elasticity, i.e. a plastic, such as Delran, or polyurethane or the like. The material is selectively determined to preclude fracture of the egg. The clamshell receiver  60  can receive the egg  28  in any orientation. In an example, the egg  28  is received in a vertical orientation with the tip  28   a  facing downwardly in a manner to be described, i.e. the major axis of the egg is perpendicular to the direction of travel of the conveying mechanism. 
         [0035]    In the example of a clam-shell egg carrier, a lower edge of each of the front wall  56  and the rear wall  58  are pivotally connected to the cross member  44  at a first pivot point  64  that is located below a center line of the egg receiving portion  62 . In a further example, the first pivot point  64  is located at the lowermost edge of the front wall  56  and rear wall  58 . Pivotal movement of each of the front wall  56  and rear wall  58  is controlled by the respective pivot mechanism (not shown) associated with either the front wall  56  or rear wall  58 . It is contemplated that either the front wall  56  or rear wall  58  may pivot independently or both walls may pivot concurrently about the first pivot point. For example, the front wall  56  may pivot outwardly or away from the rear wall to receive the egg. In another example, each of the front wall  56  and rear wall  58  may pivot outwardly or away from each other. The walls move together to grip, cradle or otherwise hold the egg  28 . Similarly, one or both of the walls  56 ,  58  may pivot outwardly to release the egg  28 , such as into another egg carrier  34  associated with a conveying mechanism  18  in another station. For example, the egg may be released into another clamshell receiver  60 . 
         [0036]    In another example, either one or both of the front wall  56  and rear wall  58  may have a second pivot point as shown at  66  that is located above the centerline of the egg receiving portion  62 . The second pivot point  66  would facilitate release of the egg by pivotal movement of the upper portion of the front wall  56  or rear wall  58  in an outwardly direction. 
         [0037]    In operation, the front and/or rear wall pivot about a first pivot point  64  located below a centerline of the egg receiving portion  62  of the clamshell receiver. As the egg  28  is released into the clamshell receiver  60 , the egg first hits the rear wall  58 , and then slides downwardly along the rear wall  58  into the egg-receiving portion  62  of the clamshell receiver. Advantageously, the line speed of the conveying mechanism  18  may be increased since the eggs are caught in a more positive manner. 
         [0038]    Referring to  FIG. 9 , a method of releasing an egg into the egg carrier mechanism  34  is illustrated. The methodology begins at  100  with the step of providing an egg  28  having a predetermined orientation in an egg carrier mechanism  34 . In this example, the egg carrier mechanism  34  is a gripper egg carrier mechanism  35 . The egg is held by the gripper fingers  46  with a horizontal orientation in this example, although other orientations are contemplated. The methodology advances to block  102  and includes the step of pivoting the egg carrier mechanism  35  or egg holder  38 , i.e. grippers  40  of this example, a predetermined amount. As shown in  FIGS. 4-6 , the egg holder cross member  44  is pivoted forwardly or rearwardly to a predetermined angle, such as 45 degrees, so that the angle of the major axis  42  of the egg with respect to the direction of motion changes. As a result of pivoting the egg carrier mechanism  34 , the egg  28  is released at a predetermined release angle with respect to the table top  14  that is less than or greater than 90 degrees, but not 90 degrees. The method advances to block  104  and includes the step of releasing the egg. The trajectory of the egg is skewed due to the angular release of the egg  28  as shown in  FIG. 8  at  68 . The egg  28  may be released into another egg carrier mechanism  34  and associated egg holder  38  in a controlled manner, such as into a clam shell receiver, cup or brush or the like. Advantageously, the skewed release trajectory allows for more efficient transfer of the egg between different egg holders. In this example the egg is released with the egg tip pointed downwardly, although other orientations are contemplated. 
         [0039]    In an example, the egg holders  38  or grippers  40  of this example, are arranged to have a 4-inch spacing between gripper fingers  46 , so as to release eggs at a high rate of speed into another egg holder  38  i.e. clamshell receivers  60 , having a 3-inch spacing. Multiple rows of the clamshell receivers  60  may be positioned in multiple configurations so as to sequentially catch the eggs. If the eggs are released into a clamshell receiver  60 , the egg first hits the rear wall, and then slides downwardly into the egg-receiving portion  62  of the clamshell receiver. Advantageously, the line speed of the conveying mechanism may be increased since the eggs are caught in a more positive manner. 
         [0040]    The present disclosure has been described in an illustrative manner. It is to be understood that the terminology which has been used is intended to be in the nature of words of description rather than of limitation. Many modifications and variations of the present example are possible in light of the above teachings. Therefore, within the scope of the appended claims, the present disclosure may be practices other than as specifically described.