Abstract:
An apparatus for cutting poultry carcasses as they are continuously conveyed by a shackle conveyor having a plurality of shackles. The inventive apparatus comprises a gap provided between two rails. The rails are positioned such that the exterior of the carcass adjacent the spine will contact and slide along the back rail while the front rail will pivot the front half of the carcass backward with respect to the back half, thereby placing the skin connecting the two halves in a peeling position with respect to the front half. The apparatus further comprises a blade positioned for cutting a segment of skin while the carcass is in this stretched position such that at least most of the segment of skin remains attached to the back half.

Description:
FIELD OF THE INVENTION 
     The present invention relates to apparatuses for dividing poultry carcasses to produce front half and back half products. 
     BACKGROUND OF THE INVENTION 
     When processing chicken and other poultry, a two-step procedure is typically used to divide and cut the poultry carcass laterally into a front half product and a back half product. The front half will typically comprise the breasts, keel, wings, and a portion of the back. The back half, or saddle, typically comprises the legs, thighs, and the remainder of the back. In the first (primary) step of the halving procedure, most of the skin around the eviscerated pack is cut and the backbone is at least partially broken, or cut, such that the front half is left hanging from the back half by substantially only a segment of skin tissue (possibly including some meat) extending between the front and back sections of the backbone. In the next (secondary) step, this segment is cut so that the front half is completely separated from the back half of the carcass. 
     A typical primary halving apparatus is described in U.S. Pat. No. 4,593,435. Eviscerated poultry carcasses are conducted, in inverted position, through the apparatus of U.S. Pat. No. 4,593,435 by means of both a shackle conveyor and a screw-type conveyor. Within the apparatus, each carcass is first delivered to an inclined, rotating cog wheel having an array of teeth formed around the circumference thereof. The cog wheel also has a slot provided therein for receiving a stationary severing blade. The teeth of the cog wheel engage the front skin covering the evisceration vents of the poultry carcasses and hold the carcasses in tensioned position such that the stationary blade engages each carcass at the base of the keel and cuts the connecting tissue webs disposed between the breast and thigh portions of the carcass. Following the cutting operation, each carcass is delivered to an inclined, counter-rotating conical auger which engages the enlarged opening formed by the cutting operation and effects a downward bending movement of the front half about a longitudinal guide rod. This bending operation breaks the carcass backbone into two separate pieces such that the front half of the carcass hangs loosely from the back half by means of only a segment of back skin tissue (possibly including some meat) which remains attached to both the forward and rearward backbone sections. 
     Heretofore, the front and back sections of a “halved” poultry carcass of the type provided by the apparatus and method of U.S. Pat. No. 4,593,435 have been separated from each other by simply cutting the segment of skin which extends between the separated backbone sections. Some typical secondary halving devices utilize a rotating circular blade into which the birds are guided. The rotating blade makes a square cut such that none of the connecting skin or meat is left hanging from the back half (i.e., the saddle) of the carcass. Other typical secondary halvers utilize stationary blades which also provide a square cut on the saddle. 
     Following separation, the front half and back half carcass sections can be processed, as desired, in separate sectioning operations to produce wings, breasts, thighs, and the like. The back half sections are also commonly sold in one piece without further removal and sectioning. 
     Unfortunately, when poultry carcasses are halved and separated in the manner described above, the segment of back skin in question remains attached to the front half product and is typically not recovered in a desirable manner. Commonly, after the front half of the poultry carcass is subjected to further sectioning operations, the skin and meat attached to the center of the forward backbone section will simply be rendered along with other by-products of the sectioning process. 
     In addition to undesirably removing all of the connecting skin and meat from the saddle, the secondary halving devices heretofore used in the art typically contact and create forces on the a rib cage of the carcass sufficient to cause some of the ribs to be broken. Such rib breakage detrimentally affects the efficiency of subsequent deboning operations by significantly reducing the amount of rib meat which can be removed as a part of the breast filet. 
     SUMMARY OF THE INVENTION 
     The present invention provides a secondary halving apparatus which satisfies the needs and alleviates the problems discussed above. The inventive apparatus provides increased leg quarter yield by leaving a flap of skin and meat attached to the back half of the carcass. Additionally, the inventive system applies pressure to the spine of the carcass, rather than the to ribs, so that rib breakage is greatly reduced. Moreover, the inventive apparatus is simpler and less costly than other devices, requires less maintenance, is more reliable, and is significantly easier to clean and sanitize. 
     The present invention provides an apparatus for cutting poultry carcasses as they are continuously conveyed by a shackle conveyor having a plurality of shackles. The poultry carcasses conveyed to the inventive apparatus have been previously processed such that each of the poultry carcasses includes a back half comprising two legs retained in the shackles and a front half which has been partially cut away from the back half. The back half further comprises a back portion of a spine of the poultry carcass and the front half comprises a front portion of the spine. The front half hangs from the back half by at least a segment of skin extending between the back and front portions of the spine. The inventive apparatus comprises a back rail and a front rail. The front rail is positioned adjacent to the back rail such that a gap is provided between the rails. The gap is positioned such that the poultry carcasses will travel into the gap as they are conveyed by the shackle conveyor. The back rail and the front rail are positioned with respect to each other and with respect to the shackle conveyor such that, as each poultry carcass travels into the gap, the exterior thereof adjacent the spine will contact and slide along the back rail while the front rail will operate to pivot the front half of the carcass backward with respect to the back half to thus place the segment of skin in a peeling position with respect to the front portion of the spine. The apparatus further comprises cutting means positioned for cutting the segment of skin from the front portion of the spine while the segment of skin is in the peeling position such that the front half is separated from the back half and at least most of the segment of skin remains attached to the back half. 
     Further objects, features, and advantages of the present invention will be apparent to those skilled in the art upon examining the accompanying drawings and upon reading the following description of the preferred embodiments. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 provides an elevational back view of an embodiment  2  of the inventive secondary halving apparatus. 
     FIG. 2 provides an elevational front view of inventive apparatus  2 . 
     FIG. 3 provides a top view of front and back rail structures  8  and  10  employed in inventive apparatus  2  as seen from perspective  3 — 3  shown in FIG.  1 . 
     FIGS. 4-7 provide sequential inlet end views of a poultry carcass  26  being received, positioned, and cut in inventive apparatus  2 . 
     FIG. 8 provides an elevational outside view of back rail structure  10 . 
     FIG. 9 provides a plan view of back rail structure  10  as seen from perspective  9 — 9  shown in FIG.  8 . 
     FIG. 10 provides an elevational inlet end view of back rail structure  10  as seen from perspective  10 — 10  shown in FIG.  8 . 
     FIG. 11 provides an elevational inside view of front rail structure  8 . 
     FIG. 12 provides a plan view of front rail structure  8  as seen from perspective  12 — 12  shown in FIG.  11 . 
     FIG. 13 provides an elevational inlet end view of front rail structure  8  as seen from perspective  13 — 13  shown in FIG.  11 . 
     FIG. 14 provides an exploded perspective view of front and back rail structures  8  and  10 . 
     FIG. 15 provides an assembled perspective view of front and back rail structures  8  and  10 . 
     FIG. 16 provides another assembled perspective view of front and back rail structures  8  and  10 . 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     An embodiment  2  of the inventive secondary halving apparatus is depicted in FIGS. 1-15, Inventive apparatus  2  comprises: a frame  4  positionable on a shackle conveyor  6 ; a front rail structure  8  suspended within frame  4 ; a back rail structure  10  suspended within frame  4 ; a blade assembly  12  removably secured on back rail  10 ; a gap  14  formed between rails  8  and  10 ; a pair of outwardly curved rods  16  and  18  provided on the initial ends of rails  8  and  10 ; a product bin  20  provided on the bottom of frame  4  for receiving cut product; and a product deflector wall  22  extending upwardly from the trailing end of bin  20  to prevent product from dropping outside of the bin. 
     Shackle conveyor  6  comprises a plurality of shackles  24  which continuously deliver poultry carcasses  26  through inventive apparatus  2 . The legs  28  of carcasses  26  are retained in shackles  24  such that carcasses  26  hang upside down. Each eviscerated poultry carcass  26  has already been delivered through a primary halving device (not shown) such that the carcass comprises a front half  30  which hangs from the back half (saddle)  32  by at least a segment of skin  34  which extends between the backbone portions of the two halves. As mentioned above, the front half  30  of the carcass typically includes the wings, breasts, keel, and the forward section of the back. The back half typically includes the thighs, legs, and the remaining rearward portion of the back. 
     Poultry carcasses  26  can generally be any type of eviscerated fowl. Examples of preferred types of fowl include chickens, turkeys, ducks, geese, and guineas. Poultry carcasses  26  are preferably eviscerated chicken carcasses. 
     Front rail structure  8  preferably comprises: an elongate bar, rod, or similar structure  36  having curved rod  16  extending from the initial end thereof; a first attachment bolt  38  or similar attachment structure extending laterally from the mid-portion of the outer edge  40  of bar  36 ; a spacer  42  extending upwardly from the rearward end of outer edge  40 ; and a second attachment bolt  44  or similar structure extending laterally outward from the upper end of spacer  42 . 
     The back rail assembly  10  is close to a mirror image of front rail structure  8  in that back rail structure  10  comprises: an elongate bar, rod, or similar structure  46  having outwardly curved rod  18  secured to the initial end thereof; a first attachment bolt  48  extending laterally outward from the mid-portion of elongate bar  46 ; and a second attachment bolt  50  extending laterally outward from a vertical spacer  52  secured at the rearward end of the outer edge  54  of bar  46 . However, in contrast to the spacer  42  of front rail structure  8 , the spacer  52  of back rail structure  10  extends downward rather than upward. Additionally, back rail structure  10  includes blade assembly  12  provided nearer the rearward end of the upper surface  56  of elongate bar  46  and preferably also includes an elongate, small diameter, rounded rod  58  or similar rounded structure secured or formed along the inner edge  60  of the upper surface  56  of bar  46 . Rod  58  extends to blade assembly  12  and preferably has an outwardly curved forward end  62 . 
     Front rail  8  and back rail  10  can be adjustably suspended within frame  4  using four T-bolts or similar structures  64 . Provided at the lower ends of T-bolts  64  are lateral pipe or tubing segments  66  which are received on the attachment bolts  38 ,  44 ,  48 , and  50  of rail structures  8  and  10 . Lateral segments  66  are adjustably held in fixed position on bolts  38 ,  44 ,  48 , and  50  by nuts  68 . The upper ends of T-bolts  64  are preferably adjustably retained in support members  55  of frame  4  using nuts or other threaded attachments  57  which will allow vertical adjustment of the T-bolts  64  and rail structures  8  and  10 . 
     The cutting blade assembly  12  employed in inventive apparatus  2  preferably comprises: a retaining plate  70  having beveled inner and forward edges  72  and  74 ; an attachment bolt  76  secured to and extending upwardly from back rail  10 ; a pair of guide pins  78  extending upwardly from the upper surface  56  of back rail  10 ; a corresponding pair of apertures  80  formed in retaining plate  70  for receiving guide pins  78  to thereby align and hold retaining plate  70  such that the inner edge  72  thereof does not extend beyond the inner edge  60  of back rail  10 ; and a replaceable blade  82  which is removably clamped between retaining plate  70  on the upper surface  56  of back rail  10 . 
     For reasons discussed hereinbelow, T-bolts  64  and vertical spaces  42  and  52  are preferably employed to adjustably suspend front rail structure  8  and back rail structure  10  within housing  4  such that (a) each of rails  8  and  10  is inclined downwardly in the direction of travel  84  of poultry carcasses  26  but (b) front rail  8  is inclined at a greater angle than back rail  10  whereby the distal end  86  of front rail  8  is positioned below the distal end  88  of back rail  10  and the outwardly curved rod  16  provided at the initial end of front rail  8  is positioned above the outwardly curved rod  18  provided on the initial end of back rail  10 . Additionally, the distal ends  86  and  88  of rails  8  and  10  are preferably closer, in horizontal orientation, than the initial ends thereof such that the lateral gap  14  formed between the rails converges horizontally (i.e., becomes narrower horizontally) toward blade  82  as illustrated in FIG.  3 . If necessary to achieve a desired degree of rotation of the front halves  30  of the carcasses as discussed hereinbelow, the degree of horizontal convergence can even be adjusted to the point that the rails  8  and  10  actually cross in the vicinity of the blade  82 . 
     FIGS. 4-7 provide four sequential views, as seen from the inlet end  85  of inventive apparatus  2 , of a carcass  26  as it is conveyed through apparatus  2  toward blade assembly  12 . Front rail structure  8  and back rail structure  10  are preferably positioned and respectively inclined within housing  4  such that (a) the outwardly curved rods  16  and  18  provided at the initial ends of the front and back rails  8  and  9  receive the poultry carcasses  26  being conveyed by shackle conveyor  6  and guide the carcasses  26  into gap  14 , (b) the outside of the spinal portion  87  of carcass  26  contacts and slides along the inner edge  60  of back rail  10 ; (c) the breast side of the hanging front half  30  of carcass  26  contacts the inner edge  45  of front rail  8  so that, due to the greater angle of inclination of front rail  8  and the convergence of gap  14 , front rail  8  pulls front half  30  downward and pivots front half  30  backward with respect to back half  32  such that the segment of skin  34  attaching front half  30  to back half  32  is placed in a peeling position with respect to front half  30  (i.e., a position wherein front half  30  is pulled or turned with respect to skin segment  34  in the direction  75  shown in FIG.  7 ), and (d) when thus positioned, carcass  26  is conveyed through blade assembly  12  so that blade  82  cuts the skin segment  34  closely across the backbone portion of the pivoted front half  30  of carcass  26 . As a result, almost all of the skin segment  34  is removed from front half  30  and is desirably retained as a part of back half  32 . 
     When the front halves  30  of carcasses  26  are separated from back halves  32 , front halves  30  simply drop into product bin  20 . The back halves  32 , on the other hand, are still retained in shackles  24  and are carried by shackle conveyor  26  to other downstream stations. 
     Thus, the present invention is well adapted to carry out the objects and attain the ends and advantages mentioned above as well as those inherent therein. While presently preferred embodiments have been described for purposes of this disclosure, numerous changes and modifications will be apparent to those skilled in the art. Such changes and modifications are encompassed within the spirit of this invention as defined by the appended claims.