Calibrating the operation of a cutter used in a portioning system to cut workpieces into portions, wherein the work- piece is carried along a driven conveyance device past a scanner and then to a cutting apparatus. The calibration method employs a correction algorithm to correct for vari- ables or limitations in the condition of one or more com- ponents of the portioning system and/or variations or limi- tations in the operation or operational capabilities of the portioning system. The correction algorithm may also factor in the physical condition, configuration, or composition of the workpieces being portioned, as well as whether the workpieces move on the conveyance device prior to and/or during the portioning operation.
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21. Calibrating a cutter system for cutting variable-sized workpieces into portions of one or more physical parameters by first cutting a variable-sized sample workpiece into portions as the representative variable-sized sample workpiece is carried along a driven conveyance device prior to the operation of the cutter system on a production basis, wherein the representative variable-sized sample workpiece is scanned while traveling on the conveyance device at a constant speed with the scanner at a location along the conveyance device, and then the representative variable-sized sample workpiece is cut into portions by a cutter positioned downstream from the scanning device while traveling on the conveyance device, a calibration method comprising, prior to the operation of the cutter system on a production basis, adjusting the time delay period occurring between the scanning of the representative variable-sized sample workpiece and the subsequent operation of a cutter without altering the speed of the conveyance device to accommodate variations in the physical condition of the cutter system components and limitations in the operation or operational capabilities of the cutter system, whereby the adjusted time delay is used during the subsequent production cutting of the workpieces, including with changes occurring to the belt speed for throughput purposes.
23. A method of calibrating a rotary cutter system for cutting variable-sized workpieces into portions of desired physical parameters by first cutting a representative variable-sized sample workpiece into portions as the representative variable-sized sample workpiece is carried along a driven conveyance device prior to operating the rotary cutter system on a production basis to cut workpieces, the rotary cutter system comprising a scanner for scanning the repreentative variable-sized sample workpiece being conveyed on the conveyance device and a rotary cutter positioned downstream from the scanner to cut the representative variable-sized sample workpieces while being carried by the conveyance device into portions, the scanner being in position along the conveyance device, the method comprising, prior to the operating of the rotary cutter system on a production basis, calibrating the rotary cutter system by:
adjusting the time delay period occurring between the scanning of the representative variable-sized sample workpiece and the subsequent operation of the rotary cutter without adjusting the speed of the conveyance device; and
using a weight adjustment algorithm employing one or more variables to accommodate the physical condition, configuration, and/or composition of the representative variable-sized sample workpiece, whereby the adjusted time delay period is used during the subsequent cutting of the workpieces by the rotary cutter system on a production basis, including with changes occurring to the belt speed for throughput purposes.
7. Calibrating a cutting system for cutting workpieces into portions as the workpiece is carried along a driven conveyance device, the calibration occurring prior to the production operation of the cutting system, comprising:
prior to operating the cutting system to cut workpieces on a production basis:
(a) determining the position of a representative non-production sample workpiece on a driven conveyance device;
(b) physically characterizing the representative non-production sample workpiece;
(c) based on the results of physically characterizing the representative non-production sample workpiece, operating a cutter to cut the representative non-production sample workpiece into portions which are carried along on the driven conveyance device; and
(d) calibrating the cutting system to adjust the time span required for the non-production sample workpiece to travel on the conveyance device between the determined position of the representative non-production sample workpieces on the conveyance device and the operation of the cutter without altering the speed of the conveyance device based on one or more of:
(i) variables or limitations in the condition of one or more components of the cutting system and/or in the operation or operational capabilities of the cutting system;
(ii) the physical condition and/or physical configuration and/or physical composition of the representative non-production sample workpiece;
(iii) the movement of the representative non-production sample workpiece relative to the conveyance device prior to and/or during the operation of the cutter; and
(iv) (e) maintaining the calibration of the cutting system during the production cutting of the workpieces.
1. A method for calibrating a cutting system for cutting variable-sized food workpieces into portions of selected physical parameters prior to operating the cutting system on a production basis, the cutting system having a conveyance device for conveying variable-sized sample food workpieces past a scanner used to physically characterize the variable-sized sample food workpieces and then to a cutting device to cut the variable-sized sample food workpieces into portions, the method calibrating the time span between when the variable-sized sample food workpieces are scanned by the scanner and the cutting of the variable-sized sample food workpieces with the cutting device, the method comprising:
prior to the operation of the cutting system to cut variable-sized food workpieces on a production basis:
a. scanning variable-sized sample food workpieces at a scanner while being transported on a conveyance device to produce data related to the physical condition and/or physical configuration and/or the physical composition of the variable-sized sample food workpieces;
b. thereafter using the data from the scanner to physically characterize the scanned variable-sized sample food workpieces as well as the portions to be cut from the variable-sized sample food workpieces based on one or more selected physical parameters;
c. thereafter portioning the representative variable-sized sample food workpieces using the cutting device in accordance with the one or more selected physical parameters while being transported on the conveyance device;
d. physically measuring the cut portions for compliance with the one or more selected physical parameters;
e. determining the variance between the one or more selected physical parameters of the cut portions as determined by the scanner and as physically measured;
f. adjusting the calibration of the cutting device by adjusting the time span between the scanning of the representative variable-sized sample food workpieces and operation of the cutting device without altering the speed of the conveyance device, based on the variance of the one or more selected physical parameters of the cut portions as determined by the scanner and as physically measured; and
g. thereafter during the operation of the cutting system to cut variable-sized food workpieces on a production basis maintaining the adjusted calibration of the cutting systemduring the subsequent cutting of the food workpieces on a production basis.
2. The method according to
3. The method according to
4. The method according to
5. The method according to
6. The method according to
the density of the variable-sized sample workpiece, the length of the variable-sized sample food workpiece, and the distance along the variable-sized sample food workpiece at which a cut of the variable-sized sample food workpiece is being made;
the density of the variable-sized sample food workpiece based on the height of the portion being cut by the cutting device;
the volume of the variable-sized sample food workpiece, the length of the variable-sized sample food workpiece, and the distance along the variable-sized sample food workpiece at which a cut of the variable-sized sample food workpiece is being made;
the volume of the variable-sized sample food workpiece based on the height of the portion being cut by the cutting device;
the delay between the scanning of the variable-sized sample food workpiece and the operation of the cutting device, the delay is based on the overall length of the variable-sized sample food workpiece and the distance along the variable-sized sample food workpiece at which a cut of the variable-sized sample food workpiece is being made.
8. Calibrating a cutting system according to
(i) variations in the speed of the conveyance device;
(ii) variations in the speed at which the conveyance device is driven;
(iii) whether the conveyance device is of continuous construction or composed of a plurality of sections or segments; and
(iv) inaccuracies in determining, or limitation in being able to determine, the position of the representative non-production sample workpiece on the conveyance device.
9. Calibrating a cutting system according to
(i) the type of representative non-production sample workpiece;
(ii) if a representative non-production sample workpiece is a food product, the type of food product;
(iii) if the representative non-production sample workpiece is meat, the type of meat;
(iv) the length of the representative non-production sample workpiece;
(v) the thickness of the representative non-production sample workpiece;
(vi) the condition of the perimeter of the representative non-production sample workpiece;
(vii) the condition of the leading edge of the representative non-production sample workpiece;
(viii) variations in the thickness of the representative non-production sample workpiece;
(ix) variations in the height of the top surface of the representative non-production sample workpiece;
(x) the temperature of the representative non-production sample workpiece;
(xi) the density of the representative non-production sample workpiece;
(xii) if the representative sample non-production workpiece is meat, the extent of marbling of the meat; and
(xiii) if the representative non-production sample workpiece is meat, the extent of fat within the meat;
(xiv) the position of the skin of the non-production sample workpiece relative to the top of the non-production sample workpiece; and
(xv) the condition of an edge of the non-production sample workpiece.
10. Calibrating a cutting system according to
(i) the speed at which the representative non-production sample workpiece is carried along by the driven conveyance device is not uniform;
(ii) the conveyance device vibrates the representative non-production sample workpiece as the representative non-production sample workpiece is being carried along by the conveyance device;
(iii) the speed at which the cutter cuts the representative non-production sample workpiece;
(iv) the sharpness of the cutter;
(v) whether the representative non-production sample workpiece transfers from one section of a conveyance device to another;
(vi) the angle of cut of the cutter into the representative non-production sample workpiece; and
(vii) the number of portions cut from the representative non-production sample workpiece.
11. Calibrating a cutting system according to
12. Calibrating a cutting system according to
13. Calibrating a cutting system according to
14. Calibrating a cutting system according to
15. Calibrating a cutting system according to
16. Calibrating a cutting system according to
17. Calibrating a cutting system according to
cutting representative non-production sample workpieces into a series of portions,
weighing the portions in the order in which the portions were cut; and
based on the variations in the weights of the portions cut, adjusting the timing of the operation of the cutter.
18. Calibrating a cutting system according to
19. Calibrating a cutting system according to
a delay correction for each workpiece to correct a delay between the physical characterization of the representative non-production workpiece and the subsequent operation of the cutter;
a correction of the volume of the representative non-production sample workpiece for each portion cut from the representative non-production sample workpiece;
a correction of the density of the representative non-production sample workpiece for each portion cut from the representative non-production sample workpiece; and
a correction for the height for the representative non-production sample workpiece for each cross-sectional cut made in the representative non-production sample workpiece.
20. Calibrating a cutting system according to
22. Calibrating a cutter system according to
(i) variations in the speed of the conveyance device;
(ii) variations in the speed at which the conveyance device is driven;
(iii) whether the conveyance device is composed of a unitary conveyance length or composed of a plurality of conveyance length sections; and
(iv) inaccuracies in determining the position of the workpiece on the conveyance device via the scanner.
24. The calibration method according to
(i) the type of representative variable-sized sample workpiece;
(ii) if the representative variable-sized sample workpiece is a food product, the type of food product;
(iii) if the representative variable-sized sample workpiece is meat, the type of meat;
(iv) the length of the representative variable-sized sample workpiece;
(v) the width of the representative variable-sized sample workpiece
(vi) the thickness of the representative variable-sized sample workpiece;
(vii) the condition of the perimeter of the representative variable-sized sample workpiece;
(viii) the condition of the leading edge of the representative variable-sized sample workpiece;
(ix) variations in the thickness of the representative variable-sized sample workpiece;
(x) variations in the height of the top surface of the representative variable-sized sample workpiece;
(xi) the temperature of the representative variable-sized sample workpiece;
(xii) the density of the representative variable-sized sample workpiece;
(xiii) if the representative variable-sized sample workpiece is meat, the extent of marbling of the meat; and
(xiv) if the representative variable-sized sample workpiece is meat, the extent of fat within the meat;
(xv) the position of the skin of the variable-sized sample workpiece relative to the top of the variable-sized sample workpiece; and
(vi) the condition of an edge of the variable-sized sample workpiece.
25. The method of
26. Calibrating a cutting system according to
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Delay 0=the nominal “scan-to-cut” delay as measured by a tape measure, ruler, or other physical technique.
A=equation constant
B=equation constant
x=the distance down the workpiece where the cut is being made
L=the overall length of the workpiece.
Alternatively, with respect to the computer, the weight correction algorithm can be expressed as a correction of the density or volume of the workpiece for each cross-section cut from the workpiece. One example of a density correction algorithm could be the following:
Density=Density O×(A+B)×(×/L)), wherein:
Density O=actual measured density of the workpiece
A=equation constant
B=equation constant
x=a distance down the workpiece at which the cut is being made
L=the overall length of the workpiece
Rather than correcting for density, the correction algorithm can be expressed in terms of a volume correction. As such, the equation above would be the same except Density O would be replaced by Volume O, which would be the actual measured density of the workpiece.
Thirdly, the weight correction algorithm could be expressed in the computer as a height correction algorithm, correcting for the height of each cross-section cut from the workpiece.
An example of an algorithm in this regard is the following:
Density=Density O×((A+B)×H), wherein:
Density O=the actual measured density of the workpiece.
A=equation constant
B=equation constant
H=the height of the portion (preferably at the middle of the portion) being cut.
Rather than expressing the above equation in terms of density, the equation can be expressed in terms of volume. In that regard, the Density O would be replaced by Volume O, which is the actual measured density of the workpiece.
Regardless of how the weight correction algorithm is expressed in the computer with respect to system 10, the actual nature of the correction will always be to correct the delay (per piece) between scanning and cutting because each of the portions, and thus weights of the portions, is controlled solely by when the blade passes through the workpiece.
The foregoing equations are not to be exclusive. In this regard, other specifications or measures could be used in the correction algorithms that may be more appropriate for the type of workpiece being portioned, including the type of meat being portioned, for example, steaks versus chicken nuggets versus salmon fillets. Also, additional or different set of measures or factors could be utilized, for example, a set composed of height of the workpiece, distance down the length of the workpiece, the length of the workpiece, as well as the width of the workpiece. Of course, with more factors, likely more equation constants will be required, which may be troublesome in that many regression analysis techniques do not function well in situations with a large number of equation constants and a small number of data points.
As a further matter, although numerous correction parameters or variables have been discussed above and a significant number of such parameters or variables can be employed in a weight correction algorithm, in a production situation, not all of the potential parameters or variables need be employed. As noted above, it is possible to only rely on one or two variables, such as the length of the workpiece and the distance down the workpiece at which a cut is being made. If a sufficient number of test pieces are used in the calibration mode, relying on the length of the workpiece and the distance down the workpiece in the weight correction algorithm can result in accurate portions being cut from the workpiece.
The weight correction algorithms can be executed in various ways in the production mode of system 10 within the portioner program being utilized, depending upon the structure of the portioner program, its data of storage arrangement, as well as perhaps personal preference of the programmer. In this regard, one execution method would be to make corrections to the scanned height, length, width, volume, or weight or density or other physical parameter of a given light stripe progressing down the product length as the product is being scanned.
Accordingly, the collected data with respect to the workpiece simply gets stored as a corrected value. Another execution method of the weight correction algorithm would be to store the objective raw scanned data in a matrix and then construct a second correction matrix that is modified in accordance with the weight correction algorithm.
A third methodology would be to make corrections to the specifications of the workpiece per the weight correction algorithm while the objective raw data from the scanning is being summed thereby to determine the position of the cuts to be made in the workpiece.
A fourth potential methodology would be to create a “delay matrix” as a lookup table. The lookup table is applied to the uncorrected positions of the cut using the raw scanning data. As a consequence, the position of the cuts is then corrected. Of course, other methodologies could be utilized to execute the weight correction algorithm in a production mode in system 10.
While illustrative embodiments have been illustrated and described, it will be appreciated that various changes can be made therein without departing from the spirit and scope of the invention.
Although this specification describes determining the position of a workpiece 14 on conveyor 12 through the use of scanner 16 in conjunction with encoder 50, it will be appreciated that other techniques can be utilized for determining the position of a workpiece on the conveyor. One alternative approach would be to utilize an electronic or optical beam which is “cut” by the workpiece as the workpiece moves on the conveyor. Also, rather than using an encoder 50 associated with drive roller 44, other types of encoders, including optical encoders, can be utilized.
In addition, the foregoing specification illustrates and describes a cutting knife or blade 22 of a cutting device 24, powered by a servo motor 26. The present disclosure can be utilized with other types of cutting devices, including, without limitation, circular saws, radial saws, reciprocating saws, hacksaws, Stryker® saws, oscillating saws, waterjet cutters, laser cutters, or other cutters capable of making the required cuts through the workpiece.
Further, the foregoing description includes examples of specific algorithms that may be utilized in conjunction with the present disclosure. However, as noted above, the present disclosure is not limited to the specific algorithms set forth above. Other algorithms that perform the required function described and/or claimed in the present application may be utilized.
Blaine, George R., Hocker, Jon A., Stockard, Richard D.
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