Abstract:
A picker apparatus for defeathering or plucking of poultry and other avian in a food processing facility includes a universal mount picker assembly including a belt drive system for driving a plurality of rotatable picker members with a drive motor disposed centrally in relation to the picker members, and a quick release positioning adjustment for the operating components of a picker apparatus.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS  
       [0001]     This application claims priority based on Provisional Application Ser. No. 60/539,294, filed Jan. 26, 2004. 
     
    
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH AND DEVELOPMENT  
       [0002]     None.  
       FIELD OF THE INVENTION  
       [0003]     The present invention relates generally to a picker apparatus for defeathering or plucking of poultry and other avian in a food processing facility. More particularly, one aspect of the present invention is concerned with an improved belt drive system for driving a plurality of rotatable devices, and another aspect of the present invention is concerned with a quick release positioning adjustment for the operating components of a picker apparatus.  
       BACKGROUND OF THE INVENTION  
       [0004]     In typical poultry/avian processing facilities, birds are shackled to an overhead conveyor that sequentially passes the carcasses from equipment that stuns, kills, and scalds the birds, to plucking equipment that removes the feathers, and then to other equipment for evisceration and further processing. Generally, picker machines use rubber fingers mounted on rows or banks of contra-rotating discs or drums to rub the feathers off of the birds. Often opposing banks of discs and/or multiple banks of discs having a variety of orientations are utilized to make contact with, and thus pluck feathers from, all sides of the carcass.  
         [0005]     In many picker machines in which opposing banks of discs are employed, the disc banks are mounted to a frame with a carrier that allows for horizontal adjustment of the opposing banks with respect to each other. Such horizontal adjustment is necessary to allow the opposing banks to be moved apart from each other for routine cleaning and maintenance. The horizontal adjustment of the picker banks is usually controlled by a crank screw that is connected to each of the bank carriers. Adjustment with the crank screw is slow, as hand cranks are usually utilized due to the corrosive nature of food processing facilities, which greatly reduces the life of electric motors. More importantly, each time the carriers are adjusted from an operating position to a cleaning position, it is difficult to readjust the carriers back to the exact same operating position.  
         [0006]     The drive mechanism for existing picker machines includes a drive motor located at one end of the bank of picker discs. Each picker disc is connected to a drive pulley, and a flat belt is connected to the drive motor and intertwined with drive pulleys such that alternating discs are rotated by the drive belt in opposite directions. Such is accomplished by winding the belt around the top of one pulley, around the bottom of the next pulley, around the top of the next, and so forth. Motor inefficiency and wear are extremely high for such drive systems because the motor, being located at either end of the bank of pickers, must pull all pulleys from a single point. Similarly, the forces exerted on the pulley located furthest away from the drive motor in a disc bank are extremely high. In addition, substantial belt tension is required to prevent the belt from slipping on the pulleys, making replacement of the belt and/or the motor difficult and increasing the wear on all components in the system. Another disadvantage resulting from the location of the motor at either end of the banks of picker discs is that such requires two variations for each picker bank, one having the motor at one end, and another having the motor at the opposite end, depending upon the installation location of the picker banks. For example, a particular installation might require that all motors be located toward the front of the picker machine. Thus picker banks located on the left side of the machine (with the picker discs facing inward) would require the motor to be located to the right side of the bank, and the bank on the right side of the machine would require that the motor be located on the left side of the bank.  
         [0007]     Accordingly, it is desirable to provide a method and apparatus that permits fast, easy adjustment of picker banks while at the same time maintaining a desired operating position for the picker banks, and a drive system for a picker machine that has higher efficiency, decreased wear, and which is universal for various installation locations.  
       SUMMARY OF THE INVENTION  
       [0008]     There is, therefore, provided in the practice of the invention an apparatus and method for defeathering or plucking of poultry in a food processing facility, including an apparatus that permits fast, easy adjustment of picker banks while at the same time maintaining a desired operating position for the picker banks, and further including a drive system for a picker machine that has higher efficiency, decreased wear and which is universal for various installation locations.  
         [0009]     The objects of the invention are accomplished through the use of a picker machine that includes a frame having a cross member for mounting horizontally adjustable carriers. The carriers are slidably mounted to the frame cross member. Picker banks are attached to the carriers for horizontal adjustment with the carriers. The carriers each include a releasable connection to a carrier stop. The carrier stops are threadingly engaged with a crank screw in the same manner in which the carriers of the prior art are engaged with the crank screw.  
         [0010]     In operation, the carriers are connected to the carrier stops and the crank screw is rotated to provide fine-tuning adjust of the carriers. In a preferred embodiment, the crank screw will have reverse threads on each side of the screw (i.e. one side left-handed threads, the other right-handed), such that one carrier stop is engaged with each side and rotation of the screw will result in the two stops either moving together or apart depending upon the direction of rotation. Once the desired adjustment is achieved for the operating position, no further rotation of the crank screw is required. When necessary to adjust the carriers apart for cleaning or maintenance, the connection between the carriers and the carrier stops is released and the carriers are slid apart from each other. When cleaning or maintenance is completed, the carriers are slid back together and reconnected to the carrier stops. In this fashion, the carriers can be quickly and easily returned to their original operating position.  
         [0011]     The drive system of the invention includes a drive motor centrally located within the bank of picker discs. The motor is connected to the pulleys of the picker discs with a ribbed drive belt. In a preferred embodiment each picker bank has two drive motors which are located in the middle of a plurality of disks. A spring loaded tensioner is provided in a preferred embodiment to permit easy removal and replacement of the drive belt.  
         [0012]     In operation the ribbed belt allows the drive motor to both pull and also push the pulleys of the picker discs. This results in decreased wear on the motor versus the prior art systems in which the motor is only pulling the pulleys. In addition, the use of the ribbed belt reduces the amount of belt tension necessary for the machine. Thus, easy removal and replacement of the belts with the spring loaded tensioner is possible. The location of the motor within the bank of pickers, versus at one end of the bank, reduces the forces on pulleys located away from the motor. Furthermore, the central location of the motor allows a single bank design to be universal regardless of the bank&#39;s installation orientation (i.e. right or left side of the machine).  
         [0013]     The foregoing and other objects are intended to be illustrative of the invention and are not meant in a limiting sense. Many possible embodiments of the invention may be made and will be readily evident upon a study of the following specification and accompanying drawings comprising a part thereof. Various features and subcombinations of invention may be employed without reference to other features and subcombinations. Other objects and advantages of this invention will become apparent from the following description taken in connection with the accompanying drawings, wherein is set forth by way of illustration and example, an embodiment of this invention. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0014]     Further features of the present invention will become apparent to those skilled in the art to which the present invention relates from reading the following description with reference to the accompanying drawings, in which:  
         [0015]      FIG. 1  is a left side perspective view of the picker machine of the invention with the carriers connected to the carrier stops and the picker banks in an operational position;  
         [0016]      FIG. 2  is a perspective view of the first end frame of the machine shown in  FIG. 1 , showing the frame end assembly and the carrier assemblies;  
         [0017]      FIG. 2A  is an enlarged fragmentary view of first end frame shown in  FIG. 2 , showing the carrier support assemblies, the carrier stops and the lateral position adjuster;  
         [0018]      FIG. 3  is an exploded perspective view of the first end frame shown in  FIG. 2 ;  
         [0019]      FIG. 4A  shows an enlarged fragmentary view of the right carrier support assembly and latch plate of the carrier assembly shown in  FIG. 2 ;  
         [0020]      FIG. 4B  shows an exploded enlarged fragmentary view of the right carrier support assembly and latch plate of the carrier assembly shown in  FIG. 3 ;  
         [0021]      FIG. 4C  shows an exploded enlarged fragmentary view of the lateral position adjuster shown in  FIG. 3 ;  
         [0022]      FIG. 5A  is a front elevational view of the picker bank support bracket of the carrier assembly shown in  FIG. 3 ;  
         [0023]      FIG. 5B  shows an exploded perspective front elevational view of the picker bank support bracket of the carrier assembly shown in  FIG. 3 ;  
         [0024]      FIG. 6  is a front elevational view of the first end frame of the machine shown in  FIG. 1 , with the carrier assemblies in an operational position;  
         [0025]      FIG. 7  is a front elevational view of the first end frame of the machine shown in  FIG. 1 , with the carrier stop latches in a released position;  
         [0026]      FIG. 8  is a front elevational view of the first end frame of the machine shown in  FIG. 1 , with the left carrier assembly in operational position and the right carrier assembly in a non-operational position;  
         [0027]      FIG. 9  is a front elevational view of the first end frame of the machine shown in  FIG. 1 , with both carrier assemblies in a non-operational position;  
         [0028]      FIG. 10A  is a top perspective view of a picker bank assembly of the machine shown in  FIG. 1 ;  
         [0029]      FIG. 10B  is a view of the inner face of the picker bank assembly shown in  FIG. 10A , with the picker disks removed;  
         [0030]      FIG. 10C  is an end view of the picker bank assembly shown in  FIG. 10A ;  
         [0031]      FIG. 11  is a front view of a picker bank assembly of the machine shown in  FIG. 1 , with motors installed and cover removed to show details of the drive belt arrangement.  
         [0032]      FIG. 12  is a partially exploded view of the picker bank assembly of  FIG. 11 , showing details of the motor mount, drive belt, belt tensioner and pulley assemblies.  
         [0033]      FIG. 13  shows enlarged and exploded enlarged views of the belt tensioner shown in  FIG. 12 . 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0034]     The invention will now be described with reference to the drawing figures, in which like reference numerals refer to like parts throughout. For purposes of clarity in illustrating the characteristics of the present invention, proportional relationships of the elements have not been maintained in the Figures. Instead, the sizes of certain small components have been exaggerated for illustration.  
         [0035]     The picker apparatus of the invention, as shown in  FIG. 1 , includes a frame  100  which supports multiple carrier assemblies  200 . The carrier assemblies in turn hold the picker bank assemblies  300 . The frame holds the carriers and picker banks in line with a conveyor (not shown), so that avian carcasses are passed between the picker bank assemblies  300  to be defeathered. The carrier assemblies  200  allow the picker bank assemblies  300  to be moved between their operational position and their inoperative and spread apart maintenance position.  
         [0036]     The frame  100  has a plurality of side members  101  and  102 , cross members  103 , and corner members  104 , with sufficient strength and stiffness to support the operational components of the apparatus. The frame members  101 ,  102 ,  103 , and  104  may be joined together with any type of suitable fasteners or in any other manner known to those skilled in the art. While the drawing figures show frame members  101 ,  102 , and  103  in horizontal arrangement, and corner members  104  in vertical arrangement, the invention contemplates frame members in other arrangements; for example, frame members  101  and  102  defining an “X” in joining two corner members  104 , and/or corner members arranged at an angle where the lower ends of pairs of corner members  104  are farther apart than the respective upper ends, and/or the cross members  103  defining an angle, the vertex of which may be either above or below the horizontal. The apparatus further includes a plurality of carrier assemblies  200  slidably mounted on the cross members  103 , and a plurality of picker bank assemblies  300  supported by the carrier assemblies  200 , the details of which are further described below.  
         [0037]     An embodiment of the invention includes at least four corner frame members  104  arranged in a rectangular pattern, wherein pairs of corner frame members  104  that define each side of the length of the apparatus are connected by at least two side frame members  101 , and at least two side frame members  102 , and further including at least one cross member  103  attached to the top of each pair of corner frame members  104  defining the ends of the apparatus. The apparatus further includes a conveyor rail  105  attached to the underside center point of each of the cross members  103  and running the length of the apparatus for conveying avian carcasses through the apparatus for defeathering. The apparatus further includes at least four carrier assemblies  200  slidably mounted in opposing pairs on the cross members  103 , and at least two picker bank assemblies  300  on each side of the apparatus ( FIG. 1 ), the picker bank assemblies  300  being supported at each end by the carrier assemblies  200 , the details of which are described below. In the embodiment shown in  FIG. 1 , four picker bank assemblies  300  are mounted in pairs, one in upper position and one in lower position, on each side of the apparatus.  
         [0038]     The carrier assemblies  200  of the invention, as shown in  FIG. 2 ,  FIG. 2A , and  FIG. 3 , include vertical columns  201 ; carrier support assemblies  202  for slidably engaging the cross member  103 ; releasable adjustable carrier stops  203  and a lateral position adjustment assembly  204  for adjustment of the operating position of the carrier stops  203 ; a moveable latch plate  205  for engaging the carrier stops  203  to fix the carrier assemblies  200  in operating position; manual release handles  206  for releasing latch plates  205  from engagement with carrier stops  203 ; and picker bank support brackets  207  for mounting the picker bank assemblies  300 .  
         [0039]     The lateral position adjustment assembly of the invention, as shown in  FIG. 2 ,  FIG. 2A ,  FIG. 3  and  FIG. 4C , includes two threaded carrier stops  203  slidably engaging the cross member  103  and threadingly engaged with an adjustment screw  208  attached to the upper side of the cross member, the adjustment screw  208  having reverse threaded sections for adjustment of the carrier stops  203  in opposing directions, thus by rotating the adjustment screw  208  the carrier stops  203  are moved closer together, and by rotating the adjustment screw  208  in the opposite direction the carrier stops  203  are moved apart in order to set the operating position appropriate to the size of avian to be defeathered. The carrier stops  203  further include a latch stud  210  capable of quick release engagement with the carrier support assemblies  202 . The latch stud  210  further includes a groove for receiving the latch plate  205 .  
         [0040]     In an embodiment of the invention as shown in  FIG. 3  and  FIG. 4C  the carrier stops  203  include guide members  212  extending downward from the carrier stops  203  and engaging the vertical faces of the cross member  103  for maintaining stable engagement along the length of the cross member. The adjustment screw  208  is rotatably connected to an angled gear housing  214 , the gear housing including a quick release fitting  216  connected to a gear shaft opposite the adjustment screw connection, the quick release fitting  216  engaging a removable crank handle (not shown) for rotating the adjustment screw  208  for adjustment of the operating position of the carrier stops  203 .  
         [0041]     In another embodiment of the invention the adjustment screw  208  further includes an enlarged diameter end flange  218  opposite the gear housing  214 , and engaging the adjacent carrier stop  203  to limit carrier stop travel preventing disengagement of the carrier stop  203  from the adjustment screw  208 .  
         [0042]     In an embodiment of the invention the carrier support assemblies  202  include, as shown in  FIG. 4B , a front carrier support plate  220  and a rear carrier support plate  221  attached to either face of vertical column  201 ; at least two connecting axles (not shown) and rollers  222  for slidably engaging the cross member  103 . In another embodiment, to avoid bouncing of the carrier assemblies  200 , each carrier support assembly  202  includes at least two connecting axles and rollers  222  for engaging the top surface of the cross member  103 , and at least two connecting axles and rollers  222  for engaging the lower surface of the cross member  103 , the rollers  222  having larger diameter outer flanges for stable engagement with the vertical faces of cross member  103 .  
         [0043]     In an embodiment of the invention the latch plate  205  is movably attached to the front carrier support plate  220 , the latch plate  205  including a notch  224  at one end, the latch plate moving adjacent the notched end in a manner that allows the latch plate  205  to engage the carrier stop latch studs  210  in operating position and be disengaged from the carrier stops  203  for movement of the carrier assemblies  200  apart. The latch plate  205  is perforated at the other end for engagement  226  with manual release handle  206  for moving latch plate  205  up and down to effect engagement with, or disengagement from the carrier stop latch studs  210 . Thereby, the operating position of the carrier stops  203  can be set using the lateral position adjustment assembly  204 , after which the carrier assemblies  200  can be quickly and easily latched into operating position or released using release handle  206  and moved apart for routine maintenance of the apparatus as shown in  FIG. 6 ,  FIG. 7 ,  FIG. 8 , and  FIG. 9 .  
         [0044]     The notched latch plate  205  is perforated  226  at the end opposite notch  224  for engagement with the manual release handle  206 , the latch plate  205  containing an additional oblong or curved slot  228  near notch  224  to allow pivot, and a further perforation  230  between slot  228  and release handle perforation  226 , for attachment to connection  232  and pivot connection  234  on the front carrier support plate  220  in a manner to allow latch plate  205  to move up and down within a confined distance in response to movement of the manual release handle  206 .  
         [0045]     In an embodiment of the invention, at least one picker bank support bracket  207  is attached to vertical column  201  near the mid-point and extending below the mid point of the length of vertical column  201 , wherein, as shown in  FIG. 5A  and  FIG. 5B , the picker bank support bracket  207  includes a support plate  236  having slots  238  for slidably mounting eyelets  240  on adjustable support assemblies  242  engaging adjustment screws  246 . The adjustment screws  246  are connected to the support plate  236  through mounts  248  in a manner that allows rotation of adjustment screws  246 . The eyelets  240  and support assemblies  242  are capable of securely engaging the picker bank assemblies  300  ( FIG. 1 ) in a manner that allows the alignment of the operating face of the picker bank assemblies  300  ( FIG. 1 ) to be adjusted at a forward or reverse angle from vertical for optimum contact with the avian carcass being defeathered.  
         [0046]     The picker bank assemblies  300  of the apparatus, as shown in  FIG. 10A ,  FIG. 10B ,  FIG. 10C ,  FIG. 11 ,  FIG. 12 , and  FIG. 13 , include a housing  301  and frame  302  for supporting the picker disk drive system, including at least one drive motor  305 , at least one drive belt  307 , at least one drive pulley  309 , a plurality of picker disks  303  and picker disk pulleys  311 , at least one drive belt tensioner  313  for engaging drive belt  307  with varying degree of force for adjusting slack in the drive belt, a plurality of mounting studs  317  attached to the frame end plate  319  for engaging the picker bank support brackets  207 , and at least one return pulley  315  to return the drive belt  307  to engagement with tensioner  313 .  
         [0047]     In one embodiment the picker bank drive system of the apparatus includes at least one drive motor  305  centrally located along the picker bank frame  302  within a set of picker discs  303  disposed in lateral alignment within the housing, the drive motor  305  and drive pulley  309  being engaged with the picker disk pulleys  311  with a double-ribbed drive belt  307 , the drive system further including at least one spring loaded drive belt tensioner  313 . The configuration of the mounting studs  317  is identical on each end of the picker bank assemblies  300  of the invention, thus the picker bank assemblies  300  of the invention are capable of installation on either side of the apparatus, in either the upper or lower position.  
         [0048]     In another embodiment, as shown in  FIG. 10B  and  FIG. 11 , each picker bank assembly  300  has at least two drive motors  305  and drive pulleys  309 , each of which are located along the picker bank frame  302  in a position central to a set of picker discs  303  disposed in lateral alignment within the housing, at least two drive belts  307 , each engaging separate drive motors  305 , drive pulleys  309  and sets of picker disk pulleys  311 , at least two spring loaded drive belt tensioners  313 , and at least two return pulleys  315  comprising a common idler assembly mounted at an angle to maintain uniform spacing of the picker disk pulleys  311  at the end of each set of picker discs  303  relative to the spacing of the picker disk pulleys  311  within each set of picker discs  303 .  
         [0049]     In an embodiment of the invention as shown in  FIG. 13 , the spring loaded drive belt tensioners  313  include a compression spring guide  327  threaded on at least one end and penetrating the frame end plate  319 . The compression spring guide  327  may be interference fit to the end plate  319 , or loose fit to the end plate  319  and retained by any suitable fastener on the outside face of end plate  319 . The spring loaded drive belt tensioners  313  further include a pulley  321  for engaging drive belt  307 , a pivot block  323 , pivot shaft  324 , mounting bracket  325  attached to frame  302 , compression spring retainer  328 , and limit collar  329  to limit compression of the compression spring  331 . The compression spring retainer  328 , limit collar  329 , and compression spring  331  slide onto compression spring guide  327  and are retained in place with washer  333  and nut  334 .  
         [0050]     In operation, the apparatus of  FIG. 1  is assembled with a plurality of picker fingers (not shown) installed on each picker disk  303 , picker bank assemblies  300  are mounted to support brackets  207  on carrier assemblies  200 . Carrier stops  203  are adjusted to optimum position by rotation of adjustment screw  208 , and the carrier assemblies  200  are then latched in operational position with latch plates  205  engaged with latch studs  210  of carrier stops  203 . The drive motors  305  are started causing picker disks  303  to rotate, avian carcasses are placed in shackles for conveying along the conveyor rail  105 , and are then conveyed through the apparatus for defeathering.  
         [0051]     After defeathering of the avian carcasses is complete, the drive motors  305  are stopped, and the operator quickly and easily releases each carrier support assembly  202  by pulling release handle  206  to the raise latch plate  205  to disengage from the latch stud  210 , as shown in  FIG. 7 , and then slides the carrier assembly  200  away from the center of the apparatus, as shown in  FIG. 8 . In this manner each carrier support assembly  202  can be released and the carrier assemblies  200  with picker bank assemblies  300  can be fully moved away from the center of the apparatus, as shown in  FIG. 9  for easy cleaning and maintenance, following which the carrier assemblies  200  can be quickly returned and latched in operational position.  
         [0052]     While preferred embodiments and particular applications of this invention have been shown and described, it is apparent to those skilled in the art that many other modifications and applications of this invention are possible without departing from the inventive concepts herein. It is, therefore, to be understood that, within the scope of the appended claims, this invention may be practiced otherwise than as specifically described, and the invention is not to be restricted except in the spirit of the appended claims. Though some of the features of the invention may be claimed in dependency, each feature has merit if used independently.