U.S. patent application number 10/649362 was filed with the patent office on 2004-07-22 for material handling system and method for products manually processed.
This patent application is currently assigned to P & G Developments Pty Ltd.. Invention is credited to Jacobsen, Glenn, Matkovich, Mario.
Application Number | 20040139692 10/649362 |
Document ID | / |
Family ID | 3827418 |
Filed Date | 2004-07-22 |
United States Patent
Application |
20040139692 |
Kind Code |
A1 |
Jacobsen, Glenn ; et
al. |
July 22, 2004 |
Material handling system and method for products manually
processed
Abstract
The present invention provides a material handling system and
method for a product to be manually processed by an operator (O) at
a work-station (10). The material handling system (100) includes:
batch delivery means (20) for automatically delivering batches of
the product to the work-station (10) on an "as required" or "on
demand" basis for manual processing by the operator; and packing
container delivery means (60) for automatically delivering
individual packing containers (61) to the work-station on an "as
required" or "on demand" basis for filling with the product after
manual processing by the operator. Each batch of product is
typically supplied in a batch container (21) and the system may
further include batch container dispatch means (40) for
automatically dispatching the batch containers (21) from the
work-station (10) on an "as required" or "on demand" basis after
the operator has finished manually processing the product it
contained. The system also typically includes packing container
dispatch means (80) for automatically dispatching product-filled
packing containers (61) from the work-station on an "as required"
or "on demand" basis.
Inventors: |
Jacobsen, Glenn; (West
Footscray, AU) ; Matkovich, Mario; (Williamstown,
AU) |
Correspondence
Address: |
HAHN LOESER & PARKS, LLP
TWIN OAKS ESTATE
1225 W. MARKET STREET
AKRON
OH
44313
US
|
Assignee: |
P & G Developments Pty
Ltd.
|
Family ID: |
3827418 |
Appl. No.: |
10/649362 |
Filed: |
August 26, 2003 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
10649362 |
Aug 26, 2003 |
|
|
|
PCT/AU02/00213 |
Feb 27, 2002 |
|
|
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Current U.S.
Class: |
53/55 ; 53/250;
53/391 |
Current CPC
Class: |
B65B 57/12 20130101;
B65B 67/02 20130101; A22C 17/0093 20130101 |
Class at
Publication: |
053/055 ;
053/250; 053/391 |
International
Class: |
B65B 067/00; B65B
057/00 |
Foreign Application Data
Date |
Code |
Application Number |
Feb 27, 2001 |
AU |
PR3403 |
Claims
1. A material handling system for a product to be manually
processed by an operator at a work-station, including: batch
delivery means for automatically delivering batches of the product
to the work-station on an "as required" or "on demand" basis for
manual processing by the operator; and packing container delivery
means for automatically delivering individual packing containers to
the work-station on an "as required" or "on demand" basis for
filling with the product after manual processing by the
operator.
2. A material handling system according to claim 1, wherein the
batch delivery means includes means for sensing or identifying when
a batch of product is required at the work-station.
3. A material handling system according to claim 2, wherein each
batch of product is provided in a batch container, and the batch
delivery means includes a shuttle device for transporting one of
the batch containers from a product supply station to the
work-station when the work-station is identified as requiring the
product batch.
4. A material handling system according to claim 3, wherein the
batch delivery means includes a mechanism for transferring the
batch container from the shuttle device to an access position for
the operator at the work-station.
5. A material handling system according to claim 4, wherein the
batch delivery means includes a batch container buffer for
accommodating a batch container of product adjacent the
work-station.
6. A material handling system according to claim 1, wherein the
packing container delivery means includes means for sensing or
identifying when a packing container is required at the
work-station, and means for conveying individual packing containers
to the work-station when the work-station is identified as
requiring one or more of the packing containers.
7. A material handling system according to claim 6, wherein the
packing container delivery means includes guide means for directing
delivery of the packing containers to a filling position at each of
the operator work-stations.
8. A material handling system according to claim 7, wherein the
guide means is in the form of a chute that extends from a packing
container conveyor to the work-station.
9. A material handling system according to claim 8, wherein the
packing container delivery means includes a packing container
buffer for accommodating a plurality of packing containers adjacent
the work-station.
10. A material handling system according to claim 9, wherein the
packing container buffer is provided in the guide chute.
11. A material handling system according to claim 1, wherein the
work-station is designed to ergonomically accommodate a human
operator and includes a work space in which the product may be
manually processed by the operator, the batch delivery means being
adapted to deliver the batches of the product to an access position
at the work-station within easy reach of the operator, and the
packing container delivery means being adapted to deliver the
individual packing containers to a filling position at the
work-station within easy reach of the operator.
12. A material handling system according to claim 11, wherein the
work space takes the form of bench space immediately in front of
the operator, and wherein the access position to which the batch
containers of product are delivered is adjacent to and in front of
the work space within easy reach of the operator, and the filling
position to which the packing containers are delivered is adjacent
and to one side of the work space where the operator can fill it
with the product after that product has been manually
processed.
13. A material handling system according to claim 1, further
including packing container dispatch means for automatically
dispatching product-filled packing containers from the work-station
on an "as required" or "on demand" basis.
14. A material handling system according to claim 13, wherein the
packing container dispatch means includes a mechanism to remove the
product-filled packing container from the filling position at the
work-station, and an actuator device for use by the operator to
actuate the removal mechanism when that filled packing container is
ready for dispatch.
15. A material handling system according to claim 14, wherein the
removal mechanism of the packing container dispatch means is
adapted to discharge the product-filled packing container to a
conveyor for carrying that container to a final packaging
station.
16. A material handling system according to claim 1, further
including batch container dispatch means for automatically
dispatching the batch containers from each work-station on an "as
required" or "on demand" basis.
17. A material handling system according to claim 16, wherein the
batch container dispatch means includes a mechanism to remove the
batch container from the access position at the work-station, and
an actuator device for use by the operator to actuate the removal
mechanism when that batch container is ready for dispatch.
18. A material handling system according to claim 17, wherein the
mechanism to remove the emptied batch container from the access
position is adapted to transfer that container to a conveyor, which
is able to carry it to a batch container return station.
19. A material handling system according to claim 1, further
including a computer controller for controlling the various
automatic operations of the system.
20. A material handling system according to claim 1, wherein the
work-station is any one of a plurality of separate work-stations
belonging to the material handling system.
21. A material handling system according to claim 1, wherein the
material handling system is in the form of a processing line having
a plurality of separate operator work-stations, said processing
line having most of the system conveying and transporting
operations occurring along a substantially common, primary line of
direction.
22. A material handling system according to claim 21, wherein the
operator work-stations are spaced apart along the processing line
with the work-stations located on both sides of that line.
23. A material handling method for a product to be processed
manually by an operator at a work-station, the method including the
steps of: automatically delivering discrete batches of the product
to the work-station on an "as required" or "on demand" basis for
manual processing by the operator; and automatically delivering
individual packing containers to the work-station on an "as
required" or "on demand" basis for filling with the product
processed by the operator.
24. A material handling method according to claim 23, further
including the step of: automatically dispatching each
product-filled packing container from the work-station on an "as
required" or "on demand" basis.
25. A material handling method according to claim 23, wherein each
batch of product is supplied in a batch container and the method
further includes the step of: automatically dispatching the batch
container from the work-station on an "as required" or "on demand"
basis.
26. A material handling system for a product to be manually
processed by an operator at a work-station, including: packing
container delivery means for automatically delivering individual
packing containers to the work-station on an "as required" or "on
demand" basis for filling with the product after manual processing
by the operator; packing container dispatch means for automatically
dispatching product-filled packing containers from the work-station
on an "as required" or "on demand" basis.
27. A material handling system according to claim 26, further
including batch delivery means for automatically delivering batch
containers of the product to the work-station on an "as required"
or "on demand" basis for manual processing by the operator.
28. A material handling system according to claim 27, further
including batch container dispatch means for automatically
dispatching the batch containers from the work-station on an "as
required" or "on demand" basis.
29. A material handling method for a product to be manually
processed by an operator at a work-station, the method including
the steps of: automatically delivering individual packing
containers to the work-station for filling with the product after
manual processing by the operator on an "as required" or "on
demand" basis; and automatically dispatching each product-filled
packing container from the work-station on an "as required" or "on
demand" basis.
30. A material handling method according to claim 29, further
including the step of: automatically delivering discrete batch
containers of the product to the work-station for manual processing
by the operator on an "as required" or "on demand" basis.
31. A material handling method according to claim 30, further
including the step of: automatically dispatching the batch
containers from the work-station on an "as required" or "on demand"
basis.
32. A material handling system for a product to be manually
processed by an operator at a work-station, including: batch
delivery means for automatically delivering batch containers of the
product to the work-station on an "as required" or "on demand"
basis for manual processing by the operator; and batch container
dispatch means for automatically dispatching the batch containers
from the work-station on an "as required" or "on demand" basis.
33. A material handling method for a product to be manually
processed by an operator at a work-station, the method including
the steps of: automatically delivering discrete batch containers of
the product to the work-station on an "as required" or "on demand"
basis for manual processing by the operator; and automatically
dispatching the batch containers from the work-station on an "as
required" or "on demand" basis.
Description
TECHNICAL FIELD
[0001] The present invention relates generally to a material
handling system and method, and more particularly to a material
handling system and method for a product to be manually processed
by an operator at a work-station.
[0002] The present invention has particular application to the food
processing industry and, specifically, to the handling and
processing of meat and poultry prior to packaging for supermarket
shelves. It will therefore be convenient to hereafter describe the
invention in this context. It should be appreciated, however, that
the invention is not limited to use within the food processing
industry, but that it may also be suitable for use in the handling
and processing of a variety of other products.
BACKGROUND TO THE INVENTION
[0003] Cuts of meat and poultry, such as pork, lamb, beef and
chicken, are typically sold as pre-packaged items in supermarkets.
These pre-packaged cuts are usually supplied to the supermarkets by
meat and poultry processing and packaging specialists. To date, the
preparation of those packages has been very labour intensive, not
only in the necessary manual operations of trimming and cutting
larger meat portions to achieve the desired steaks, fillets and
other cuts, but also in handling of the product and packaging both
before and after the trimming and cutting operations. The present
invention therefore aims to provide an integrated material handling
system and method to improve the efficiency and economy of the
overall packaging and production process.
SUMMARY OF THE INVENTION
[0004] According to one aspect of a first inventive concept, the
invention provides a material handling system for a product to be
manually processed by an operator at a work-station, including:
[0005] batch delivery means for automatically delivering batches of
the product to the work-station on an "as required" or "on demand"
basis for manual processing by the operator; and
[0006] packing container delivery means for automatically
delivering individual packing containers to the work-station on an
"as required" or "on demand" basis for filling with the product
after manual processing by the operator.
[0007] In a preferred embodiment of the invention, the batch
delivery means includes means for sensing or identifying when a
batch of product is required at the work-station. Each batch of
product is preferably provided in a batch container, and the batch
delivery means preferably includes a shuttle device for
transporting a batch container from a product supply station to the
work-station when it is identified as requiring the product batch.
The means for sensing or identifying when a batch of product is
required at the work-station may be an optical or physical sensor
for detecting the presence (or absence) of a batch container at the
work-station. The batch delivery means also preferably includes a
mechanism for transferring the batch container from the shuttle
device to an access position for the operator at the
work-station.
[0008] Similarly, In a preferred embodiment of the invention the
packing container delivery means includes means for sensing or
identifying when a packing container is required at the
work-station, and means for conveying individual packing containers
to the work-station when it is identified as requiring the packing
container. The packing container delivery means furthermore
preferably includes means for guiding delivery of the packing
containers to a filling position at the operator work-stations. In
the filling position, the packing container is located where the
operator can fill it with the product (eg cuts of meat or poultry)
after that product has been manually processed (eg trimmed and
cut). The means for sensing or identifying when a packing container
is required at the work-station may be an optical or physical
sensor for detecting the presence (or absence) of a packing
container at the filling position.
[0009] In a preferred embodiment of the invention, the material
handling system further includes packing container dispatch means
for automatically dispatching product-filled packing containers
from the work-station on an "as required" or "on demand" basis. The
packing container dispatch means includes a mechanism to remove the
product-filled packing container from the filling position at the
work-station, and an actuator device for use by the operator to
actuate the removal mechanism when the operator decides the filled
packing container is ready for dispatch. A packing container is
typically ready for dispatch when the operator considers that
enough product has been placed in it. The removal mechanism of the
packing container dispatch means is preferably adapted to discharge
the product-filled packing container to a conveyor for carrying
that container to a final packaging station.
[0010] In a preferred embodiment of the invention, the material
handling system includes batch container dispatch means for
automatically dispatching the batch containers from the
work-station on an "as required" or "on demand" basis. The batch
container dispatch means includes a mechanism to remove the batch
container from its position at the work-station, and an actuator
device for use by the operator to actuate the removal mechanism
when that batch container is ready for dispatch. A batch container
is typically considered ready for dispatch from its position at the
work-station when the operator has emptied it and manually
processed all of its product. The mechanism to remove the emptied
batch container from the work-station is preferably adapted to
transfer that container to a conveyor, which carries it to a batch
container return station.
[0011] In a preferred embodiment of the invention, the work-station
is designed to ergonomically accommodate a human operator working
there. The work-station includes a work space in which the product
may be manually processed by the operator. This work space
preferably takes the form of bench space immediately in front of
the operator. The batch delivery means is adapted to deliver the
batches of the product to an access position at the work-station
within easy reach of the operator, and the packing container
delivery means is adapted to deliver the individual packing
containers to a filling position at the work-station within easy
reach of the operator. The access position to which the batch
containers of product are delivered is preferably adjacent to and
in front of the work space. The filling position to which the
packing containers are delivered is preferably adjacent to, and to
one side of, the work space.
[0012] In a particularly preferred embodiment of the invention, the
work-station is any one of a plurality of separate work-stations
belonging to the material handling system. For example, the
material handling system of the invention is preferably in the form
of a processing line having a plurality of separate operator
work-stations, with most of the system conveying and transporting
operations occurring along a substantially common, primary line of
direction. The work-stations are preferably spaced apart along that
primary line, and they may be located either on one side of, or
alternatively, on both sides of, that line.
[0013] The material handling system of the present invention is
desirably modular in nature. Accordingly, with little modification,
the system can be adapted from just one or two work-stations to
twelve, eighteen or even more.
[0014] The "as required" or "on demand" feature of the present
invention assists in the optimisation of operation of the system.
This feature facilitates almost continuous manual processing (eg
trimming and cutting) by the operators at the work-stations, and
eliminates timing consuming manual handling of batch containers
and/or packing containers. The system of the invention also has the
major advantage of facilitating precise tracking of meat and
poultry product throughout the processing operation. Each
individual packing container is traceable to the specific batch
container that was in the particular operator access position at
the time that packing container was filled, and the batch container
lots are themselves traceable to the bulk meat/poultry lots and/or
animal carcasses handled by the company.
[0015] In a preferred embodiment of the invention, this "as
required" or "on demand" feature of the present invention operates
in the following way. When an operator actuates the mechanism to
remove an empty batch container from the batch access position at
the work-station, the batch delivery means senses or identifies
that a new batch is required and proceeds to deliver another batch
container of product to that work-station when the access position
is vacant. The new batch is preferably transported from a product
supply station via a shuttle device. Similarly, when an operator
actuates the mechanism to remove a product-filled packing container
from the filling position at the work-station, the packing
container delivery means senses or identifies that a new packing
container is required and proceeds to deliver another one to the
work-station when the filling position is vacant.
[0016] To minimise time delays between removal of one batch
container or packing container and arrival of the next, the
material handling system of the invention preferably provides a
batch container buffer and/or a packing container buffer adjacent
the work-station. That is, the batch delivery means preferably
includes a batch container buffer that holds the next batch
container of product in a buffer position adjacent the
work-station. This results in the next batch container being ready
for deployment or delivery to the operator access position as soon
as dispatch of the current batch container is actuated.
Furthermore, the packing container delivery means also preferably
includes a packing container buffer that holds the next one or more
(eg three or four) packing container(s) in another buffer position
adjacent the work-station. The next packing container is thereby
also ready for delivery to the filling position as soon as dispatch
of the current product-filled packing container is actuated. As the
batch container buffer or the packing container buffer becomes
depleted, the respective batch or packing container delivery means
described above re-supplies it.
[0017] The material handling system of the invention preferably
includes a computer controller for controlling the various
automatic operations of the system. For example, the computer
controller instructs the batch delivery means to deliver a batch
container of product to a particular workstation as required, or
instructs the packing container delivery means to deliver one or
more packing containers to a particular workstation as required.
Similarly, the computer controller instructs the batch container
dispatch mechanism to discharge an empty batch container when the
batch container dispatch actuator device is activated by the
operator; and instructs the packing container dispatch mechanism to
discharge a filled packing container when the packing container
dispatch actuator device is activated by the operator.
[0018] According to another aspect of the first inventive concept,
the invention provides a material handling method for a product to
be processed manually by an operator at a work-station, the method
including the steps of:
[0019] automatically delivering discrete batches of the product to
the work-station on an "as required" or "on demand" basis for
manual processing by the operator; and
[0020] automatically delivering individual packing containers to
the work-station on an "as required" or "on demand" basis for
filling with the product processed by the operator.
[0021] In a preferred embodiment of the invention, the material
handling method further includes the step of: automatically
dispatching each product-filled packing container from the
work-station on an "as required" or "on demand" basis.
[0022] In a preferred embodiment of the invention, each batch of
product is supplied in a batch container and the method further
includes the step of: automatically dispatching the batch container
from the work-station on an "as required" or "on demand" basis.
[0023] According to one aspect of a second related inventive
concept, the invention provides a material handling system for a
product to be manually processed by an operator at a work-station,
including:
[0024] batch delivery means for automatically delivering batch
containers of the product to the work-station on an "as required"
or "on demand" basis for manual processing by the operator; and
[0025] batch container dispatch means for automatically dispatching
the batch containers from the work-station on an "as required" or
"on demand" basis.
[0026] In a preferred embodiment of the second related concept, the
material handling system includes packing container delivery means
for automatically delivering individual packing containers to the
work-station on an "as required" or "on demand" basis for filling
with the product after manual processing by the operator.
Furthermore, In a preferred embodiment of the second inventive
concept, the material handling system further includes packing
container dispatch means for automatically dispatching
product-filled packing containers from the work-station on an "as
required" or "on demand" basis.
[0027] In a very preferred form of the second inventive concept,
the work-station is any one of a plurality of separate
work-stations belonging to the material handling system.
[0028] According to another aspect of the second inventive concept,
the invention provides a material handling method for a product to
be manually processed by an operator at a work-station, the method
including the steps of:
[0029] automatically delivering discrete batch containers of the
product to the work-station on an "as required" or "on demand"
basis for manual processing by the operator; and
[0030] automatically dispatching the batch containers from the
work-station on an "as required" or "on demand" basis.
[0031] In a preferred embodiment of the second inventive concept,
the material handling method further includes the step of:
automatically delivering individual packing containers to the
work-station for filling with the product after manual processing
by the operator on an "as required" or "on demand" basis.
[0032] In a preferred embodiment of the second inventive concept,
the material handling method further includes the step of:
automatically dispatching each product-filled packing container
from the work-station on an "as required" or "on demand" basis.
[0033] According to one aspect of a third inventive concept, the
invention provides a material handling system for a product to be
manually processed by an operator at a work-station, including:
[0034] packing container delivery means for automatically
delivering individual packing containers to the work-station on an
"as required" or "on demand" basis for filling with the product
after manual processing by the operator;
[0035] packing container dispatch means for automatically
dispatching product-filled packing containers from the work-station
on an "as required" or "on demand" basis.
[0036] In a preferred embodiment of the third inventive concept,
the material handling system includes batch delivery means for
automatically delivering batch containers of the product to the
work-station on an "as required" or "on demand" basis for manual
processing by the operator. Furthermore, In a preferred embodiment
of the third inventive concept, the material handling system
includes batch container dispatch means for automatically
dispatching the batch containers from the work-station on an "as
required" or "on demand" basis.
[0037] In a very preferred embodiment of the third inventive
concept, the work-station is any one of a plurality of separate
work-stations belonging to the material handling system.
[0038] According to another aspect of the third related inventive
concept, the invention provides a material handling method for a
product to be processed manually by an operator at a work-station,
the method including the steps of:
[0039] automatically delivering individual packing containers to
the work-station for filling with the product after manual
processing by the operator on an "as required" or "on demand"
basis; and
[0040] automatically dispatching each product-filled packing
container from the work-station on an "as required" or "on demand"
basis.
[0041] In a preferred embodiment of the third inventive concept,
the material handling method further includes the step of:
automatically delivering discrete batch containers of the product
to the work-station for manual processing by the operator on an "as
required" or "on demand" basis.
[0042] In a preferred embodiment of the third inventive concept,
the material handling method further includes the step of:
automatically dispatching the batch containers from the
work-station on an "as required" or "on demand" basis.
[0043] For assistance in arriving at an understanding of the
inventive concepts above, a preferred embodiment of the material
handling system and method of the present invention is hereafter
described with reference to the accompanying drawings. The
preceding description of the system and apparatus may also be read
with reference to those drawings. However, as the drawings
illustrate one example only, their particularity is not to be
understood as superseding the generality of the preceding
description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0044] FIG. 1 is a plan view of a material handling system
according to the invention in the form of a processing and/or
production line;
[0045] FIG. 2 is a side elevation of the material handling system
in FIG. 1 showing details of the system at a work-station; and
[0046] FIG. 3 is a detailed end view of that part of the packing
container dispatch means identified as "A" in FIG. 2.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0047] With reference to FIG. 1 and FIG. 2, the particular example
of the material handling system illustrated is a processing line
100, along which portions of meat and poultry are manually trimmed
and cut by operators 0 at a plurality of work-stations 10. The
operators then place the resultant cuts of meat in packing
containers, typically trays, destined for the shelves of
supermarkets.
[0048] The processing line 100 includes a central frame 1, which
supports the primary conveying or transport mechanisms of the
system. The frame 1 extends generally longitudinally of the
processing line and the operator work-stations 10 are positioned
next to one another along the length of the frame 1 and at each of
its opposite sides. In this example, the material handling system
of the invention has twelve work-stations 10, with six arranged
along either side of the central frame 1. Because each of the
work-stations in this example is configured and operates
essentially identically, it will be convenient to now focus the
description of the system at a single work-station, with reference
to FIGS. 2 and 3.
[0049] The material handling system 100 includes a batch delivery
means 20 for delivering batches of meat portions to be trimmed and
cut to each of the work-stations 10. Each of the batches is
provided in a container 21 called a tote crate and the batch
delivery means 20 includes a shuttle device 22 for transporting a
full tote crate 21 to a work-station 10 identified as requiring a
new batch of product for processing. The shuttle device 22 is
mounted on the frame 1 and includes a carriage 23, which supports
the full tote crate 21 for transport along a linear drive unit 24.
The carriage 23 is adapted for travel on the linear drive unit 24
from a supply station 25 to any one of the work-stations 10. The
batch delivery means 20 further includes a mechanism 26 for
transferring the full tote crate from the carriage 23 to an
operator access position 11 at the designated work-station. The
access position 11 is directly in front and within easy reach of
the operator 0 at the work-station. The transfer mechanism 26
includes a pneumatic cylinder 27 and is adapted to tilt the
carriage 23 to either side of the linear drive unit 24 (as
required) so that the tote crate slides off the carriage towards
the work-station 10.
[0050] The batch delivery means 20 also includes a tote crate
buffer 30 adjacent the work-station for holding a full tote crate
21 in reserve, ready for immediate delivery to the operator access
position 11 when required. The mechanism 26 actually transfers the
full tote crate from the carriage 23 to the buffer 30 as an interim
position before reaching the access position 11 at the work-station
10. The tote crate buffer 30 includes a sloped support plate 31 and
a removable stop 32 for selectively retaining a tote crate in the
buffer. If the access position already has a tote crate, the stop
32 will hold the buffer crate in check. When the tote crate in the
access position 11 is removed, the stop 32 is deactivated, eg moved
pivotally out of the way, thereby releasing the crate on the buffer
support plate 31 to slide into the access position 11 at the
work-station.
[0051] Importantly, the batch delivery means 20 includes means for
sensing or identifying when a new tote crate is required at any one
of the work-stations 10, ie when the access position 11 has been
vacated. That is, an optical or physical sensor is provided to
detect whether or not a tote crate 21 is currently in the access
position. This enables the tote crates to be delivered to the
work-stations on an "as required" or "on demand" basis. The tote
crate 21 in the buffer 30 is available to immediately re-supply the
operator at the work-station when the tote crate currently being
accessed by the operator is emptied and then removed. The stop 32
is deactivated enabling the tote crate 21 in the buffer 30 to slide
off the support plate 31 and into the operator access position 11.
At the same time, the batch delivery means 20 is cued to deliver a
new full tote crate to the work-station to re-supply the buffer 30,
which was depleted to fill the vacant access position 11.
[0052] At the access position 11, a tote crate sits on a support
plate 12 within easy reach of the work-station operator, positioned
at an angle to facilitate access to its contents. The operator
typically takes meat portions from the tote crate one at a time,
places them on the chopping board 13, cuts off the fat and discards
it through an aperture 14 at the side of the board, and slices the
portion into fillets, steaks etc. for packing. Any small off-cuts
of meat (called trim) are also discarded, but through a separate
aperture 15 at the top of the board. Each work-station 10 is
mounted or supported on a separate frame 2 laterally spaced from
the central frame 1, and the work-station frame 2 supports an
off-cuts conveyor 3 which passes beneath each work-station to
collect the fat and trim off-cuts discarded through the apertures
14,15. The off-cuts conveyor 3 is longitudinally divided by a
partition 4 into a region for fat and a region for trim, and each
is carried to a specific collection bin, as shown in FIG. 1. A
small partition wall 18 is also provided at each of the
work-stations 10 to ensure that no off-cut fat is accidentally
`flicked` from one work-station to another as it is directed to the
aperture 14.
[0053] Once an operator at a work-station 10 has finished
processing all of the meat or poultry portions in the tote crate 21
currently at the access position 11, the operator needs to remove
the now empty tote crate and make room for delivery of the next
full one. The material handling system 100 therefore also includes
a tote crate dispatch means 40 for automatically dispatching the
tote crates 21 from the access position 11 on demand or as
required. The tote crate dispatch means 40 includes an actuator
device 41 for use by the operator to actuate a removal mechanism 42
when the operator has finished processing the entire contents of
the current tote crate.
[0054] The removal mechanism 42 includes a pneumatic cylinder 43
and is adapted to downwardly pivot the support plate 12, which is
hinged to the work-station 10, to a discharge position 44 shown in
dashed lines in FIG. 2. In the discharge position 44, the tote
crate 21 slides off the support plate 12 and onto the elevated
transfer plate 45. The support plate 12 may then return to its
original orientation defining the access position 11, ready to
receive the next full tote crate from the buffer 30. The transfer
plate 45 meanwhile is lowered by a pneumatic mechanism 46 to the
horizontal position shown, and a pneumatic ram 47 is provided to
push the empty tote crate onto a conveyor 48 adapted to carry the
crate to a crate return station (not shown). The conveyor 48 is
preferably divided or partitioned into a plurality of discrete
crate-carrying segments, and the pneumatic ram device 47 is
desirably controlled to delay advancing the crate onto the conveyor
48 until such time as the segment of the conveyor passing the crate
is free or available, ie not already occupied.
[0055] The system 100 of the invention also includes a packing tray
delivery means 60 for automatically delivering individual packing
trays 61 to each work-station 10 identified as requiring another
tray. The packing tray delivery means 60 includes conveyor means in
the form of two separate belt conveyors 62 mounted on top of the
frame 1. Each of the belt conveyors 62 transports packing trays 61
from a tray supply station 63 along the processing line to the
work-stations 10, and each belt conveyor services the work-stations
10 on one side of the line 100. At each of the work-stations, the
packing tray delivery means 60 further includes a feed ram 64
(again preferably pneumatically driven) and a chute or ramp 65 for
guiding delivery of the packing trays 61 from the respective belt
conveyor 62 to a filling position 16 at each work-station.
[0056] When the filling position 16 at a work-station is
unoccupied, a packing tray slides down the guide chute 65 and,
assisted by carefully directed air jets, glides into a movable tray
caddy 66 aligned with the chute at the work-station 10. The caddy
66 then lifts the new tray 61 into the filling position 16. At the
filling position 16, the packing tray is positioned with its open
top facing up and is accessible through an aperture in a cover
plate 17 adjacent to the chopping board 13 at the work-station. An
outwardly projecting flange-type rim 67 of the tray is pressed
against the underside of the cover plate 17 when the caddy 66
raises the tray into position. This not only firmly secures the
tray in the filling position, but also keeps the rim hidden or
covered, thereby keeping it clean for sealing with a film layer in
a later, final packaging step. At the filling position 16, the tray
61 is within easy reach to one side of the work-station operator
and, after trimming and cutting the meat portions taken from the
tote crate in the access position, the operator places the fillets,
steaks or other cuts of meat and poultry within the empty tray.
[0057] The packing tray delivery means 60 also includes a packing
tray buffer 70 for holding a number of packing trays in reserve,
ready for immediate delivery to the filling position 16 when
required. The feed ram 64 actually feeds the packing trays 61 into
the buffer 70, which is located on the guide chute 65. The buffer
70 in this particular case holds four packing trays 61, with the
first buffer tray isolated from the filling position by a first
tray stop 71, and from the other trays in the buffer 70 by a second
tray stop 72. In this example the tray stops 71,72 are retractable
rod-like elements which project upwardly from below the chute or
ramp 65 to engage a front of the trays and thereby prevent their
further progress towards the filling position. Each of the tray
stops 71,72 may be deactivated or retracted to prevent their
interference with the trays.
[0058] The packing tray delivery means 60 furthermore includes
means for sensing or identifying when a packing tray is required at
one of the work-stations, ie when the filling position 16 has been
vacated. That is, a sensor (optical or physical) is provided to
detect whether or not a packing tray 61 is currently in the filling
position 16. This enables the packing trays to be delivered to the
work-stations as required or on demand. The packing trays in the
buffer 70 are available to immediately re-supply the operator at
the work-station when the tray currently being filled by the
operator is removed from the filling position. When the filling
position is identified as empty, and therefore as requiring a new
packing tray, the first tray stop 71 is deactivated (ie retracted)
enabling the first packing tray in the buffer 70 to slide down the
guide chute 65 and into the caddy 66 to be raised into the operator
filling position 16. The first tray stop 71 is then reactivated and
the second tray stop 72 deactivated, enabling the packing tray
previously in the second buffer position to move forward into the
first buffer position. The second tray stop 72 is then also
reactivated to again isolate what is now the first buffer packing
tray from the other trays 61 in the buffer 70. At the same time,
the packing tray delivery means 60 is cued to deliver a new empty
packing tray 61 from the belt conveyor 62 to re-supply the buffer
70, which was depleted to supply the vacant filling position
16.
[0059] As an operator at a work-station cuts and trims the meat
and/or poultry portions from the tote crate 21 in the access
position, the resultant choice cuts are placed in the packing tray
61 at the filling position 16. Naturally, each packing tray will
only contain one or two, or perhaps three, separate cuts, so each
packing tray will be filled and require replacement relatively
quickly. For example, for each single tote crate of product
processed by the operator, many separate packing trays will be
required. The system of the invention therefore also includes a
packing tray dispatch means 80 for automatically dispatching
product-filled packing trays from the work-station on demand or as
required. The packing tray dispatch means 80 includes an actuator
device 81 for use by the operator to actuate a removal mechanism 82
adapted to automatically remove a product-filled packing tray 61
from the filling position 16 when the operator considers that
enough product has been placed in it.
[0060] The removal mechanism 82 is illustrated in FIGS. 2 and 3 and
is adapted to lower the packing tray caddy 66 and deposit the
filled tray on a transit surface 83 directly below the filling
position 16. The removal mechanism 82 further includes a pusher 84,
which is designed to engage the tray at this location and drive it
out of the caddy 66 and along the transit surface 83 towards a
conveyor 85 mounted on the central frame 1. The packing tray caddy
66 is then free to return to its initial position in alignment with
the guide chute or ramp 65 to receive a new packing tray 61 from
the tray buffer 70. The conveyor 85 is arranged to carry the filled
tray to a final packaging station (not shown) where a film covering
will be applied to the upper rim of the tray and the product will
be weighed and priced. Like conveyor 48, the conveyor 85 is
preferably divided or partitioned into a plurality of discrete
tray-carrying segments, and the pusher 84 is desirably controlled
to pause or delay actually advancing the tray onto the conveyor
until the segment of the conveyor passing the tray is free or
available, ie not already occupied. Furthermore, the conveyor 85 is
divided longitudinally by partition 86 so that use of a single
conveyor can be maximised by the work-stations at either side of
the central frame 1.
[0061] In operation, the processing line 100 enables the operators
at the work-stations to devote their time almost exclusively to the
task of manually processing the meat and poultry delivered to the
work-stations. Tote crates full of product to be processed are
delivered automatically when a work-station is identified a
requiring one, and the operator actuates the tote crate's automatic
dispatch (by pressing a knee-activated button 41, for example) when
all of the product it contained has been processed. This actuation
itself may serve as the control system trigger for sensing or
detecting when a new batch crate of product should be delivered to
that work-station. Similarly, packing trays to be filled by the
operators are also automatically delivered one at a time to the
work-station when the work-station is identified a requiring one.
And the operator actuates each packing tray's automatic dispatch
(again, for example, by pressing a knee-activated button 81) when
the operator considers it has been sufficiently filled. This
actuation may also serve as the control system trigger for sensing
or detecting when a new packing tray should be delivered to that
work-station.
[0062] Since the delivery and dispatch of product both before and
after processing is automatically controlled, the system of the
invention lends itself to monitoring or tracking the passage of
product throughout the system. Each packing tray filled and
dispatched can be traced to a particular work-station and the
particular tote crate from which the meat or poultry came. And the
tote crates can themselves be traced to a particular bulk meat or
poultry lot and/or animal carcass handled by the processing and
packaging company.
[0063] The processing line 100 includes a computer controller (not
shown) for controlling all of the automatic operations of the
system. For example, the computer controller instructs the shuttle
device 22 to deliver a tote crate 21 of product to a particular
work-station or buffer 30 as required, or instructs a particular
feed ram 64 to deliver one or more packing trays 61 into a guide
chute 65 to supply a particular work-station as required.
Similarly, the computer controller instructs the tote crate removal
mechanism 42 to discharge an empty tote crate 21 when the actuator
button 41 is activated by the operator; and instructs the packing
tray removal mechanism 82 to discharge a filled packing tray 61
when the actuator button 81 is activated by the operator.
[0064] The computer controller functions as a virtual "nerve
centre" for the entire material handling system of the invention.
In addition to controlling the routine operations for normal
running of the machine, it preferably enables each of the plurality
of work-stations to be individually switched on or off, ie to be
brought on-line or off-line within the handling system. It is able
to control the automatic emptying of all batch containers and/or
packaging containers (whether full or empty) from the system, to
enable a change of either. It also preferably enables a problem
analysis to be carried out at any one or more of the work-stations
in the event of a processing problem.
[0065] Another major advantage of the computer controller is its
usefulness in tracking tote crates 21 and packing trays 61
throughout the processing line 100. This can have very significant
benefits for quality assurance in the material handling system. The
system of the invention not only enables tracking and recording of
which tote crates 21 of meat or poultry were processed at which
work-station 10, but also of which packing trays 61 were filled
from which tote crates. It is also possible to monitor and record
which operator worked at a particular work-station and handled the
contents of particular packing trays. Accordingly, a thorough
record of the meat in each tray and who it was handled by can be
maintained.
[0066] The processing line 100 described is preferably fabricated
substantially entirely from stainless steel since it will need to
be washed-down once every day to ensure sanitary standards are
maintained. The electric and electronic power and control systems
built into the material handling system of the invention will
desirably be fully housed within water-tight enclosures for their
protection. For example, elevated casings 90 shown in FIG. 2 may
house the electric and electronic power and control systems. The
computer controller desirably has a cleaning mode in which it
ensures positive pressurisation of all the pneumatic cylinders to
prevent ingress of water during washing of the processing line.
[0067] Finally, it will be understood that various modifications
and/or additions may be made to the system and method described
above without departing from the spirit or ambit of the present
invention as defined in the appended claims.
* * * * *