U.S. patent application number 10/937640 was filed with the patent office on 2005-02-10 for methods and apparatus for selectively processing eggs having identified characteristics.
Invention is credited to Chalker, B. Alan II, Ferrell, William Hayes III, Hebrank, John H., Phelps, Patricia V..
Application Number | 20050030521 10/937640 |
Document ID | / |
Family ID | 23089520 |
Filed Date | 2005-02-10 |
United States Patent
Application |
20050030521 |
Kind Code |
A1 |
Phelps, Patricia V. ; et
al. |
February 10, 2005 |
Methods and apparatus for selectively processing eggs having
identified characteristics
Abstract
Methods and apparatus for processing eggs based upon a
characteristic such as gender are provided. Material is extracted
from each of a plurality of live eggs, the extracted material is
assayed to identify eggs having the characteristic, and then eggs
identified as having the characteristic are processed
accordingly.
Inventors: |
Phelps, Patricia V.;
(Carrboro, NC) ; Chalker, B. Alan II; (Durham,
NC) ; Ferrell, William Hayes III; (Cary, NC) ;
Hebrank, John H.; (Durham, NC) |
Correspondence
Address: |
MYERS BIGEL SIBLEY & SAJOVEC
PO BOX 37428
RALEIGH
NC
27627
US
|
Family ID: |
23089520 |
Appl. No.: |
10/937640 |
Filed: |
September 9, 2004 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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10937640 |
Sep 9, 2004 |
|
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10076490 |
Feb 15, 2002 |
|
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60284267 |
Apr 17, 2001 |
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Current U.S.
Class: |
356/53 |
Current CPC
Class: |
A01K 45/00 20130101;
G01N 33/085 20130101; C12Q 1/34 20130101; G01N 1/34 20130101; A01K
45/007 20130101; B65G 37/00 20130101; A01K 43/00 20130101; A01K
43/04 20130101; G01N 33/08 20130101; B07C 2501/0081 20130101 |
Class at
Publication: |
356/053 |
International
Class: |
C12Q 001/00; G01N
033/08 |
Claims
1. A method of processing eggs having an identified characteristic,
comprising: extracting material from each of a plurality of eggs;
assaying the material extracted from each egg to identify eggs
having a characteristic; and selectively processing eggs identified
as having the characteristic.
2. The method of claim 1, further comprising: identifying live eggs
among the plurality of eggs prior to extracting material; and
extracting material from eggs identified as live eggs.
3. The method of claim 2, wherein identifying live eggs comprises
candling the eggs.
4. The method of claim 2, wherein identifying live eggs comprises:
illuminating each egg with light from a light source, wherein the
light includes light in both visible and infrared wavelengths;
receiving light passing through each egg at a detector positioned
adjacent each egg; determining intensity of the received light at
selected ones of the visible and infrared wavelengths for each egg;
generating a spectrum for each egg that represents light intensity
at the plurality of visible and infrared wavelengths; and comparing
the generated spectrum for each egg with a spectrum associated with
a live egg to identify live eggs.
5. The method of claim 4, wherein the step of illuminating each egg
with light comprises illuminating each egg with light at
wavelengths of between about three hundred nanometers and about
eleven hundred nanometers (300 nm-1,100 nm).
6. The method of claim 2, wherein identifying live eggs comprises:
measuring the opacities of the plurality of eggs; measuring the
temperatures of the plurality of eggs; and identifying live eggs
using the measured opacities and temperatures.
7. The method of claim 1, wherein extracting material from the eggs
comprises extracting allantoic fluid, amnion, yolk, shell, albumen,
tissue, membrane and/or blood from the eggs.
8. The method of claim 7, wherein extracting material from the eggs
comprises: positioning each of the eggs in a generally horizontal
orientation; inserting a probe into each egg through the shell of
the egg; and withdrawing a sample of allantoic fluid from the
allantois of each egg via each probe.
9. The method of claim 8, wherein positioning each of the eggs in a
generally horizontal orientation comprises positioning each of the
eggs such that a long axis of each egg is oriented at an angle
between about 10 degrees and about 180 degrees from vertical,
wherein zero degrees vertical is defined by a large end of an egg
in a vertically upward position.
10. The method of claim 8, further comprising: repositioning each
of the eggs from a generally horizontal orientation to a generally
vertical orientation after allantoic fluid is withdrawn therefrom;
and moving the generally vertically oriented eggs to another
location.
11. The method of claim 8, wherein assaying the material extracted
from each egg to identify one or more characteristics of each egg
comprises detecting a presence of an estrogenic compound in the
extracted allantoic fluid.
12. The method of claim 11, wherein detecting a presence of an
estrogenic compound comprises: dispensing allantoic fluid extracted
from the eggs into respective receptacles; dispensing a biosensor
into the receptacles, wherein the biosensor is configured to
chemically react with an estrogenic compound in the allantoic fluid
and change a color signal of the allantoic fluid; and detecting a
color signal change of the allantoic fluid within the
receptacles.
13. The method of claim 11, wherein detecting a presence of an
estrogenic compound comprises: dispensing allantoic fluid extracted
from the eggs into respective receptacles, wherein each receptacle
contains a biosensor configured to chemically react with an
estrogenic compound in the allantoic fluid and change a color
signal of the allantoic fluid; and detecting a color signal change
of the allantoic fluid within the receptacles.
14. The method of claim 1, wherein assaying the material extracted
from each egg to identify one or more characteristics of each egg
comprises identifying gender of each egg, and wherein selectively
processing the live eggs comprises selectively injecting a vaccine
into the eggs of gender.
15. The method of claim 13, further comprising injecting a first
vaccine into eggs identified as male, and injecting a second
vaccine into eggs identified as female.
16. The method of claim 1, wherein assaying the material extracted
from each egg to identify one or more characteristics of each egg
comprises identifying gender of each egg, and wherein processing
the live eggs comprises removing eggs identified as having the same
gender.
17. The method of claim 1, wherein assaying the material extracted
from each egg to identify one or more characteristics of each egg
comprises identifying one or more pathogens within each egg, and
wherein processing the live eggs comprises removing eggs identified
as having one or more pathogens.
18. The method of claim 1, wherein assaying the material extracted
from each egg to identify one or more characteristics of each egg
comprises performing genetic analysis on each egg.
19. A method of processing eggs based on gender, comprising:
identifying live eggs among a plurality of eggs; extracting
material from the eggs identified as live eggs; assaying the
material extracted from each live egg to identify gender of each
live egg; and selectively injecting a vaccine into the live eggs
according to gender.
20. The method of claim 19, further comprising sorting the live
eggs according to gender prior to selectively injecting a vaccine
into the live eggs.
21. The method of claim 19, further comprising sorting the live
eggs according to gender after selectively injecting a vaccine into
the live eggs.
22. The method of claim 19, wherein identifying live eggs comprises
candling the eggs.
23. The method of claim 19, wherein identifying live eggs
comprises: illuminating each egg with light from a light source,
wherein the light includes light in both visible and infrared
wavelengths; receiving light passing through each egg at a detector
positioned adjacent each egg; determining intensity of the received
light at selected ones of the visible and infrared wavelengths for
each egg; generating a spectrum for each egg that represents light
intensity at the plurality of visible and infrared wavelengths; and
comparing the generated spectrum for each egg with a spectrum
associated with a live egg to identify live eggs.
24. The method of claim 19, wherein the step of illuminating each
egg with light comprises illuminating each egg with light at
wavelengths of between about three hundred nanometers and about
eleven hundred nanometers (300 m-1,100 nm).
25. The method of claim 19, wherein identifying live eggs
comprises: measuring the opacities of the plurality of eggs;
measuring the temperatures of the plurality of eggs; and
identifying live eggs using the measured opacities and
temperatures.
26. The method of claim 19, wherein extracting material from the
eggs comprises extracting allantoic fluid, amnion, yolk, shell,
albumen, tissue, membrane and/or blood from the eggs.
27. The method of claim 26, wherein assaying the material extracted
from each live egg to identify gender of each live egg comprises
detecting the presence of an estrogenic compound in the allantoic
fluid extracted from each live egg.
28. The method of claim 26, wherein extracting material from the
eggs comprises: positioning each of the live eggs in a generally
horizontal orientation; inserting a probe into each egg through the
shell of the egg; and withdrawing a sample of allantoic fluid from
the allantois of each egg via each probe.
29. The method of claim 28, wherein positioning each of the live
eggs in a generally horizontal orientation comprises positioning
each of the live eggs such that a long axis of each egg is oriented
at an angle between about 10 degrees and about 180 degrees from
vertical, wherein zero degrees vertical is defined by a large end
of an egg in a vertically upward position.
30. The method of claim 28, further comprising: repositioning each
of the live eggs from a generally horizontal orientation to a
generally vertical orientation after allantoic fluid is withdrawn
therefrom; and moving the generally vertically oriented live eggs
to another location.
31. The method of claim 27, wherein detecting a presence of
estrogen compounds comprises: dispensing allantoic fluid extracted
from the live eggs into respective receptacles; dispensing a
biosensor into the receptacles, wherein the biosensor is configured
to chemically react with an estrogenic compound in the allantoic
fluid and change a color signal of the allantoic fluid; and
detecting a color signal change of the allantoic fluid within the
receptacles.
32. The method of claim 27, wherein detecting a presence of
estrogen compounds comprises: dispensing allantoic fluid extracted
from the eggs into respective receptacles, wherein each receptacle
contains a biosensor configured to chemically react with an
estrogenic compound in the allantoic fluid and change a color
signal of the allantoic fluid; and detecting a color signal change
of the allantoic fluid within the receptacles.
33. The method of claim 19, wherein detecting a presence of
estrogen compounds comprises: dispensing allantoic fluid extracted
from the eggs into respective receptacles, wherein each receptacle
contains a biosensor configured to chemically react with an
estrogenic compound in the allantoic fluid and produce a detectable
signal; and detecting a signal produced within one or more of the
receptacles.
34-180 (Cancelled).
181. A method of processing avian eggs, comprising: extracting
material from each of a plurality of eggs; assaying the material
extracted from each egg to identify eggs having one or more
pathogens therewithin; and removing eggs identified as having one
or more pathogens.
182. The method of claim 181, further comprising: identifying live
eggs among the plurality of eggs prior to extracting material; and
extracting material from eggs identified as live eggs.
183. A method of processing avian eggs, comprising: extracting
material from each of a plurality of eggs; assaying the material
extracted from each egg to identify gender of each egg; assaying
the material extracted from each egg to identify eggs having one or
more pathogens therewithin; and removing eggs identified as having
one or more pathogens.
184. The method of claim 183, further comprising: identifying live
eggs among the plurality of eggs prior to extracting material; and
extracting material from eggs identified as live eggs.
185. The method of claim 183, further comprising selectively
injecting a vaccine into the eggs based on gender.
186. The method of claim 185, further comprising injecting a first
vaccine into eggs identified as male, and injecting a second
vaccine into eggs identified as female.
187. The method of claim 183, further comprising removing eggs
identified as having the same gender.
188. A method of processing avian eggs, comprising: extracting
material from each of a plurality of eggs; performing genetic
analysis on the material extracted from each egg; assaying the
material extracted from each egg to identify gender of each egg;
assaying the material extracted from each egg to identify eggs
having one or more pathogens therewithin; and removing eggs
identified as having one or more pathogens.
189. The method of claim 188, further comprising: identifying live
eggs among the plurality of eggs prior to extracting material; and
extracting material from eggs identified as live eggs.
190. The method of claim 188, further comprising selectively
injecting a vaccine into the eggs based on gender.
191. The method of claim 190, further comprising injecting a first
vaccine into eggs identified as male, and injecting a second
vaccine into eggs identified as female.
192. The method of claim 188, further comprising removing eggs
identified as having the same gender.
193. A method of processing avian eggs, comprising: extracting
material from each of a plurality of eggs; performing genetic
analysis on the material extracted from each egg; assaying the
material extracted from each egg to identify eggs having one or
more pathogens therewithin; and removing eggs identified as having
one or more pathogens.
194. The method of claim 193, further comprising: identifying live
eggs among the plurality of eggs prior to extracting material; and
extracting material from eggs identified as live eggs.
195. A method of processing avian eggs, comprising: extracting
material from each of a plurality of eggs; performing genetic
analysis on the material extracted from each egg; and assaying the
material extracted from each egg to identify gender of each
egg.
196. The method of claim 195, further comprising: identifying live
eggs among the plurality of eggs prior to extracting material; and
extracting material from eggs identified as live eggs.
197. The method of claim 195, further comprising selectively
injecting a vaccine into the eggs based on gender.
198. The method of claim 197, further comprising injecting a first
vaccine into eggs identified as male, and injecting a second
vaccine into eggs identified as female.
199. The method of claim 197, further comprising removing eggs
identified as having the same gender.
200. A method of processing avian eggs, comprising: identifying
live eggs among a plurality of eggs; extracting material from eggs
identified as live eggs; and performing genetic analysis on the
material extracted from each egg.
Description
RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional
Application No. 60/284,267 filed Apr. 17, 2001, the disclosure of
which is incorporated herein by reference in its entirety as if set
forth fully herein.
FIELD OF THE INVENTION
[0002] The present invention relates generally to eggs and, more
particularly, to methods and apparatus for processing eggs.
BACKGROUND OF THE INVENTION
[0003] Discrimination between poultry eggs (hereinafter "eggs") on
the basis of some observable quality is a well-known and long-used
practice in the poultry industry. "Candling" is a common name for
one such technique, a term which has its roots in the original
practice of inspecting an egg using the light from a candle.
Although egg shells appear opaque under most lighting conditions,
eggs are actually somewhat translucent. Accordingly, when placed in
front of a light, the contents of an egg can be observed.
[0004] In poultry hatcheries, one purpose of candling eggs is to
identify and then segregate live eggs (i.e., eggs which are to be
hatched to live poultry) from non-live eggs (e.g., clear eggs, dead
eggs, rotted eggs, empty eggs, etc.). U.S. Pat. Nos. 4,955,728 and
4,914,672, both to Hebrank, describe a candling apparatus that uses
infrared detectors and the infrared radiation emitted from an egg
to identify live eggs. U.S. Pat. No. 4,671,652 to van Asselt et al.
describes a candling apparatus in which a plurality of light
sources and corresponding light detectors are mounted in an array,
and wherein eggs are passed between the light sources and the light
detectors to identify live eggs.
[0005] Once identified, live avian eggs may be treated with
medications, nutrients, hormones and/or other beneficial substances
while the embryos are still in the egg (i.e., in ovo). In ovo
injections of various substances into avian eggs have been employed
to decrease post-hatch morbidity and mortality rates, increase the
potential growth rates or eventual size of the resulting bird, and
even to influence the gender determination of the embryo. Injection
of vaccines into live eggs have been effectively employed to
immunize birds in ovo. It is further desirable in the poultry
industry to manipulate an embryo in ovo to introduce foreign
nucleic acid molecules (i.e., to create a transgenic bird) or to
introduce foreign cells (i.e., to create a chimeric bird) into the
developing embryo.
[0006] In ovo injection of a virus may be utilized to propagate the
particular virus for use in preparation of vaccines. Examples of
substances that have been used for, or proposed for, in ovo
injection include vaccines, antibiotics and vitamins. Examples of
in ovo treatment substances and methods of in ovo injection are
described in U.S. Pat. No. 4,458,630 to Sharma et al. and U.S. Pat.
No. 5,028,421 to Fredericksen et al.
[0007] Improved methods of injecting eggs containing an embryo may
be used to remove samples from eggs, including embryonic and
extra-embryonic materials. Further, for other applications it may
be desirable to insert a sensing device inside an egg containing an
embryo to collect information therefrom, for example, as described
in U.S. Pat. No. 6,244,214 to Hebrank, which is incorporated herein
by reference in its entirety.
[0008] In commercial hatcheries, eggs typically are held in setting
flats during incubation. At a selected time, typically on the
eighteenth day of incubation, the eggs are removed from an
incubator. Unfit eggs (namely, dead eggs, rotted eggs, empties, and
clear eggs) are identified and removed, live eggs are treated
(e.g., inoculated) and then transferred to hatching baskets.
[0009] In hatchery management, it may be desirable to separate
birds based upon various characteristics, such as gender, diseases,
genetic traits, etc. For example, it may be desirable to inoculate
male birds with a particular vaccine and inoculate female birds
with a different vaccine. Sex separation of birds at hatch may be
important for other reasons as well. For example, turkeys are
conventionally segregated by sex because of the difference in
growth rate and nutritional requirements of male and female
turkeys. In the layer or table egg industry, it is desirable to
keep only females. In the broiler industry, it is desirable to
segregate birds based on sex to gain feed efficiencies, improve
processing uniformity, and reduce production costs.
[0010] Unfortunately, conventional methods of sexing birds may be
expensive, labor intensive, time consuming, and typically require
trained persons with specialized skills. Conventional methods of
sexing birds include feather sexing, vent sexing, and DNA or blood
sexing. About three-thousand (3,000) chicks can be feather-sexed
per hour at a cost of about 0.7 to 2.5 cents per chick. About
fifteen hundred (1,500) chicks can be vent-sexed per hour at a cost
of about 3.6 to 4.8 cents per chick. DNA or blood sexing is
performed by analyzing a small sample of blood collected from a
bird.
[0011] It would be desirable to identify the sex of birds, as well
as other characteristics of birds, prior to hatching. Pre-hatch sex
identification could reduce costs significantly for various members
of the poultry industry. Although conventional candling techniques
can discriminate somewhat effectively between live and non-live
eggs, these conventional candling techniques may not be able to
reliably determine gender and other characteristics of unhatched
birds.
SUMMARY OF THE INVENTION
[0012] In view of the above discussion, embodiments of the present
invention provide methods of processing eggs having an identified
characteristic (e.g., gender) wherein material (e.g., allantoic
fluid, amnion, yolk, shell, albumen, tissue, membrane and/or blood,
etc.) is extracted from each of a plurality of live eggs, the
extracted material is assayed to identify eggs having a
characteristic, and then eggs identified as having the
characteristic are processed accordingly. For example, a method of
processing eggs based upon gender, according to embodiments of the
present invention, includes identifying live eggs among a plurality
of eggs, extracting allantoic fluid from the eggs identified as
live eggs, detecting a presence of an estrogenic compound in the
allantoic fluid extracted from each live egg to identify a gender
of each live egg, detecting a color change of the allantoic fluid
to identify the gender of each egg, and then selectively injecting
a vaccine into the live eggs according to gender.
[0013] According to embodiments of the present invention,
extracting allantoic fluid from the eggs includes positioning each
of the live eggs in a generally horizontal orientation whereby an
allantois of each egg is caused to pool and enlarge an allantoic
sac under an upper portion of each egg shell, inserting a probe
(e.g., a needle) into each egg through the shell of the egg and
directly into the enlarged allantoic sac, and withdrawing a sample
of allantoic fluid from the allantois of each egg via each probe.
According to embodiments of the present invention, detecting a
presence of an estrogenic compound in the allantoic fluid includes
dispensing allantoic fluid extracted from the live eggs into
respective receptacles, and dispensing a biosensor into the
receptacles, wherein the biosensor is configured to chemically
react with an estrogenic compound in the allantoic fluid and change
a color of the allantoic fluid.
[0014] According to embodiments of the present invention,
selectively injecting a vaccine into the live eggs according to
gender includes injecting a first vaccine into live eggs identified
as male, and injecting a second vaccine into live eggs identified
as female. Alternatively, selectively injecting a vaccine into the
live eggs according to gender includes injecting a vaccine into
live eggs identified as having the same gender.
[0015] According to other embodiments of the present invention,
material extracted from eggs may be assayed to identify one or more
pathogens within each egg. Eggs identified as having one or more
pathogens are subsequently removed from the remaining live
eggs.
[0016] According to other embodiments of the present invention,
genetic analyses may be performed on material extracted from
eggs.
[0017] According to embodiments of the present invention, an
automated gender sorting system is provided and includes three
independent modules linked via a network. The first module is an
allantoic fluid sampling module. Flats of eggs are removed from a
setting incubator, typically on Day 15, 16, or 17 of a 21-Day
incubation cycle, and fed onto a conveyor belt. An optical-based
sensor automatically identifies live eggs and the eggs (either only
live eggs or all eggs) are transferred into an array of egg
cradles. Each egg cradle is configured to reposition a respective
egg onto its side and to center the egg. A needle is then inserted
into each egg to a depth of about five to six millimeters (5-6 mm)
into about the midpoint of an egg, and allantoic fluid (e.g., about
20 .mu.l) is withdrawn. The fluid sample from each egg is deposited
into a respective well in a bar-coded assay template. The wells in
the template may be arranged in the same array as the array of the
egg flat, according to embodiments of the present invention. Each
sampling needle is sanitized before being used to sample material
from another egg.
[0018] The eggs are repositioned via the cradles to upright
positions and then returned to a bar-coded egg flat. The flats are
then typically returned to a setting incubator. The assay templates
containing the sampled material (e.g., allantoic fluid) from the
eggs are stacked for processing, and a data processor on the
network matches the barcodes of each egg flat and assay
template.
[0019] The second module is an automated assaying module. An
operator loads a plurality of assay templates containing sampled
material (e.g., allantoic fluid) from eggs into the assaying
module. Within the assaying module, each assay template is moved
via a conveyor system beneath a dispensing head which dispenses a
predetermined amount (e.g., about 75 .mu.l) of reagent (e.g., a
LiveSensors.TM. brand cell-based biosensor, LifeSensors, Inc.,
Malvern, Pa.) into each respective well. Each assay template then
progresses through an environmentally-controlled chamber for a
predetermined period of time (e.g., about 3.5 hours). Each assay
template is moved via a conveyor system beneath another dispensing
head which dispenses a predetermined amount of a color substrate
(e.g., ONPG-based substrate) into each well. Each assay template
then progresses through an environmentally-controlled chamber for a
predetermined period of time (e.g., about 45 minutes) to allow
color development within each well.
[0020] A CCD (charge-coupled device) camera then scans each well to
determine the gender of a respective egg whose sample material is
in the well. This information is stored via a data processor on the
network. According to embodiments of the present invention, the
reagent (e.g., a LiveSensors.TM. brand cell-based biosensor) within
each well is then destroyed (e.g., via heat and/or via chemical
treatment) prior to disposal of each assay template.
[0021] The third module is an egg treatment and sorting module.
According to embodiments of the present invention, the bar-coded
egg flats are removed from the setting incubator towards the end of
the 21-Day incubation cycle (e.g., Day 18 or 19, etc.) and placed
on a conveyor system. According to embodiments of the present
invention, a data processor on the network identifies which eggs
are male and which eggs are female based on information previously
stored. The male eggs are then vaccinated with a male-specific
vaccination and the female eggs are vaccinated with a
female-specific vaccination. According to embodiments of the
present invention, separate vaccination devices may be utilized for
male and female eggs. Once vaccinated, the eggs are sorted by
gender and transferred to gender-specific hatching baskets. The
hatching baskets are then transferred to hatching incubators.
According to embodiments of the present invention, eggs of one
gender can be discarded and not vaccinated or transferred into
hatching baskets.
[0022] According to embodiments of the present invention, eggs are
separated by gender (or other characteristic) first and then
processed. For example, eggs may be sorted by gender and then the
male and female eggs are processed separately.
[0023] According to embodiments of the present invention,
estrogenic compounds present in the allantoic fluid of female
embryos, but not male embryos, are detected. Avian embryos can be
gender sorted on the basis of the presence of estrogenic compounds
in the allantoic fluid of female embryos between days thirteen and
eighteen (13-18) of incubation, in broiler, broiler breeder,
turkey, and layer embryos, and regardless of flock age or
strain.
[0024] Embodiments of the present invention can facilitate
increased production efficiencies by contributing to savings in
incubation space (e.g., not hatching chicks identified as males
pre-hatch), by contributing to savings in vaccinations, by allowing
reduction in manual labor, and by increasing hatchery processing
speeds. For example, throughput rates of between about twenty
thousand and thirty thousand (20,000-30,000) eggs per hour can be
gender sorted and vaccinated via embodiments of the present
invention, and with an accuracy rate exceeding ninety-eight percent
(98%). Because the gender of eggs are known prior to vaccination,
savings in vaccination costs can be realized particularly when it
is desirable to vaccinate only a specific gender. In addition,
embodiments of the present invention can be easy to operate, even
by unskilled workers.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] FIG. 1 is a flowchart of operations for processing eggs,
according to embodiments of the present invention.
[0026] FIG. 2 is a flowchart of operations for identifying live
eggs from among a plurality of eggs, according to embodiments of
the present invention.
[0027] FIG. 3 is a flowchart of operations for candling eggs,
according to embodiments of the present invention.
[0028] FIG. 4 is a flowchart of operations for spectral candling of
eggs, according to embodiments of the present invention.
[0029] FIG. 5 illustrates exemplary spectra for three eggs
subjected to the spectral candling operations of FIG. 4.
[0030] FIG. 6 is a flowchart of operations for light and thermal
candling of eggs, according to embodiments of the present
invention.
[0031] FIG. 7 is a flowchart of operations for extracting material
from eggs, according to embodiments of the present invention.
[0032] FIG. 8 is a schematic illustration of an egg in a tilted
orientation and illustrating the pooling of the allantois under the
upper shell of the egg.
[0033] FIG. 9 is a flowchart of operations for assaying extracted
egg material to identify a characteristic of eggs, according to
embodiments of the present invention.
[0034] FIGS. 10A-10B are flowcharts of operations for selectively
processing eggs based on identified characteristics, according to
embodiments of the present invention.
[0035] FIG. 11 is a block diagram of systems and methods for
processing eggs, according to embodiments of the present
invention.
[0036] FIG. 12 is a schematic illustration of top-level controls
architecture for an egg processing system according to embodiments
of the present invention within a hatchery wherein individual PLCs
are utilized to control a material extraction station, an assaying
station, and treatment and sorting stations, respectively.
[0037] FIGS. 13A-13D are more detailed illustrations of a top-level
controls architecture for an egg processing system according to
embodiments of the present invention within a hatchery wherein
individual PLCs are utilized to control a material extraction
station (sampling module), an assaying module, and transfer module,
respectively.
[0038] FIG. 14 is a side elevation view of an apparatus for
extracting material (also referred to as a sampling module) from a
plurality of eggs, according to embodiments of the present
invention.
[0039] FIG. 15 is an enlarged view of the apparatus for extracting
material of FIG. 14 illustrating the transfer apparatus and two
sampling apparatus on opposite sides of the transfer apparatus.
[0040] FIG. 16 is a plan view of the egg flat conveyor systems and
egg cradles of the material extraction apparatus of FIG. 14 taken
along lines 16-16.
[0041] FIG. 17 is a side elevation view of the material extraction
apparatus of FIG. 14 illustrating lateral movement of the egg
transfer apparatus between the two egg flat conveyor systems and
the egg cradles.
[0042] FIG. 18A illustrates the loading of incoming egg flats onto
the incoming egg flat conveyor system and the loading of empty egg
flats onto the outgoing egg flat conveyor system. FIG. 18A also
illustrates an incoming egg flat positioned within the candling
area of the material extraction apparatus of FIG. 14.
[0043] FIG. 18B illustrates movement of incoming egg flats along
the incoming egg flat conveyor system to the picker area where the
egg transfer apparatus transfers eggs from incoming egg flats to
the egg cradles.
[0044] FIG. 18C illustrates a plurality of eggs seated within the
plurality of egg cradles after being transferred from an incoming
egg flat by the egg transfer apparatus.
[0045] FIG. 18D illustrates movement of the egg cradles to a
location where a sampling apparatus is configured to extract
material from the eggs positioned within the egg cradles.
[0046] FIG. 19 is a perspective view of a portion of an array of
egg cradles configured to receive eggs in a generally vertical
orientation and to cause the eggs to move to a generally horizontal
orientation, according to embodiments of the present invention.
[0047] FIG. 20 is an enlarged perspective view of a cradle in the
array of FIG. 19.
[0048] FIG. 21 is a top plan view of the egg cradle of FIG. 20
taken along lines 21-21.
[0049] FIG. 22 is a side elevation view of the egg cradle of FIG.
20 taken along lines 22-22.
[0050] FIG. 23 is a side view of an egg positioning apparatus,
according to alternative embodiments of the present invention, and
wherein an egg is in a generally horizontal position therein.
[0051] FIG. 24 illustrates the egg positioning apparatus of FIG.
23, wherein the egg is being urged to a generally vertical
orientation by an orientation member.
[0052] FIG. 25 is a partial top plan view of the egg positioning
apparatus of FIG. 23 taken along lines 25-25 and illustrating the
inclined upper ends of the first and second portions.
[0053] FIG. 26 is a partial end view of the egg positioning
apparatus of FIG. 25 taken along lines 26-26.
[0054] FIG. 27 is a top plan view of a lifting head of the egg
transfer apparatus of FIG. 14 illustrating an array of manifold
blocks and vacuum cups, wherein the array is in an expanded
configuration.
[0055] FIG. 28 is a top plan view of the lifting head of FIG. 27,
and wherein the array of manifold blocks and vacuum cups is
contracted along a first direction.
[0056] FIG. 29 is a side elevation view of the lifting head of FIG.
27 taken along lines 29-29.
[0057] FIG. 30 is an enlarged side view of one of the flexible cups
of the lifting head of FIG. 27 that is configured to transfer a
respective egg according to embodiments of the present
invention.
[0058] FIG. 31 is a side view of a sample head for extracting
material from an egg, according to embodiments of the present
invention.
[0059] FIG. 32 is a side section view of an egg cradle within the
illustrated array of FIG. 19 with an egg positioned therewithin in
a generally horizontal position, and illustrating a sample head in
contacting relationship with the egg.
[0060] FIG. 33 is a side view of a plurality of sample heads for
one of the four sampling apparatus in FIG. 14 wherein each sample
head is in contact with the shell of an egg within a respective egg
cradle prior to extracting material from the egg, and wherein a
sample needle within each sample head is in a retracted
position.
[0061] FIG. 34 illustrates the sample heads of FIG. 33 wherein the
sample needles are in a first extended position and have pierced
the shell of each respective egg and are in position to extract
material from each respective egg.
[0062] FIG. 35 illustrates the sample heads of FIG. 33 wherein the
sample needles are in a second extended position for dispensing
material extracted from respective eggs into respective sample
receptacles in an assay template.
[0063] FIG. 36A illustrates one of the sample heads of FIG. 33 with
a biasing member illustrated in phantom line.
[0064] FIG. 36B illustrates the sample head of FIG. 36A wherein the
biasing force of air in the lower half of the sample head cylinder
has been overcome such that the sample needle is in a first
extended position and has pierced the shell of the egg and is in
position to extract material from the egg.
[0065] FIG. 36C illustrates the sample head of FIG. 36B wherein the
biasing force of the biasing member has been overcome such that the
sample needle is in the second extended position and is configured
to dispense material extracted from the egg into a sample
receptacle and then be sanitized.
[0066] FIG. 36D illustrates an exemplary sanitizing fountain that
may be utilized to sterilize a respective sample needle, in
accordance with embodiments of the present invention.
[0067] FIG. 37 is a plan view of the array of sample heads of FIG.
33 taken along lines 37-37 and illustrating locking plates
according to embodiments of the present invention that are
configured to maintain each sample head in a vertically-locked
position relative to a respective egg as material is extracted from
the egg.
[0068] FIG. 38A is a plan view of the locking plates of FIG. 37
according to one embodiment of the present invention.
[0069] FIG. 38B is a plan view of locking plates according to an
alternative embodiment of the present invention.
[0070] FIG. 39A is a side view of a sample head from the array of
FIG. 33 illustrating the locking plate in a non-engaged position
relative to the sample head.
[0071] FIG. 39B illustrates the sample head of FIG. 39A wherein the
locking plate is being moved to the right and has engaged the
sample head to force the sample head against two stationary
plates.
[0072] FIG. 39C illustrates the sample head of FIG. 39A wherein the
locking plate has secured the sample head against the two
stationary plates such that vertical movement of the sample head is
restrained.
[0073] FIG. 40 is a plan view of a sample tray having a plurality
of sample receptacles configured to receive material extracted from
eggs according to embodiments of the present invention.
[0074] FIG. 41 is an enlarged partial plan view of the sample tray
of FIG. 40 illustrating material extracted from eggs dispensed
within respective sample receptacles of the sample tray.
[0075] FIGS. 42A-42B are top plan views of the sample tray handling
system according to embodiments of the present invention and
illustrating sample trays being moved relative to the sampling
apparatus of FIG. 14.
[0076] FIGS. 43-44 are block diagrams of systems and methods for
assaying material extracted from a plurality of eggs in order to
identify eggs having one or more characteristics, according to
embodiments of the present invention.
[0077] FIG. 45 is a plan view of a portion of a sample tray wherein
egg material in each receptacle has been assayed to reveal a
visible indication of a characteristic of a respective egg.
[0078] FIG. 46 is side elevation view of an assaying apparatus for
assaying material extracted from eggs contained within a plurality
of sample trays, according to embodiments of the present
invention.
[0079] FIG. 47 is side elevation view of a sorting apparatus
according to embodiments of the present invention.
[0080] FIG. 48 is a top plan view of the sorting apparatus of FIG.
47 taken along lines 48-48.
[0081] FIG. 49 is a top plan view of a backfill and injection
apparatus to be used in conjunction with the sorting apparatus of
FIG. 47 according to embodiments of the present invention.
[0082] FIG. 50 is a top plan view of a backfill apparatus to be
used in conjunction with the sorting apparatus of FIG. 47 and with
a processing apparatus according to embodiments of the present
invention.
[0083] FIG. 51 is a side elevation view of the backfill apparatus
of FIG. 50.
[0084] FIG. 52 is a perspective view of a treatment and sorting
station according to other embodiments of the present
invention.
[0085] FIG. 53 is a plan view of the egg flat conveyor systems and
egg cradles of the material extraction apparatus of FIG. 14 taken
along lines 16-16 that includes an assaying apparatus for assaying
material extracted from a plurality of eggs according to
embodiments of the present invention.
[0086] FIG. 54 is block diagram of the assaying apparatus of FIG.
53.
DETAILED DESCRIPTION OF THE INVENTION
[0087] The present invention now is described more fully
hereinafter with reference to the accompanying drawings, in which
preferred embodiments of the invention are shown. This invention
may, however, be embodied in many different forms and should not be
construed as limited to the embodiments set forth herein; rather,
these embodiments are provided so that this disclosure will be
thorough and complete, and will fully convey the scope of the
invention to those skilled in the art. Unless otherwise defined,
all technical and scientific terms used herein have the same
meaning as commonly understood by one of ordinary skill in the art
to which this invention belongs. The terminology used in the
description of the invention herein is for the purpose of
describing particular embodiments only and is not intended to be
limiting of the invention.
[0088] As used in the description of the invention and the appended
claims, the singular forms "a", "an" and "the" are intended to
include the plural forms as well, unless the context clearly
indicates otherwise.
[0089] All publications, patent applications, patents, and other
references mentioned herein are incorporated by reference in their
entirety.
[0090] The terms "bird" and "avian" as used herein, include males
or females of any avian species, but are primarily intended to
encompass poultry which are commercially raised for eggs or meat.
Accordingly, the terms "bird" and "avian" are particularly intended
to encompass chickens, turkeys, ducks, geese, quail and pheasant.
The term "in ovo," as used herein, refers to birds contained within
an egg prior to hatch. The present invention may be practiced with
any type of bird egg, including, but not limited to, chicken,
turkey, duck, goose, quail, and pheasant eggs.
[0091] As used herein, the terms "injection" and "injecting"
encompass methods of inserting a device (typically an elongate
device) into an egg or embryo, including methods of delivering or
discharging a substance into an egg or embryo, methods of removing
a substance (i.e., a sample) from an egg or embryo, and/or methods
of inserting a detector device into an egg or embryo.
[0092] As used herein, the term "allantoic fluid" encompasses
allantoic fluid with or without the presence of other egg
materials. For example, the term allantoic fluid may include a
mixture of blood and allantoic fluid.
[0093] As used herein, the term "predetermined location" indicates
a fixed position or depth within an egg. For example, a device may
be injected into an egg to a fixed depth and/or fixed position in
the egg. In alternative embodiments, the injection may be carried
out based on information obtained from the egg, e.g., regarding the
position of the embryo or the subgerminal cavity within the
egg.
[0094] Methods and apparatus according to embodiments of the
present invention may be utilized for identifying one or more
characteristics of an egg at any time during the embryonic
development period (also referred to as the incubation period)
thereof. Embodiments of the present invention are not limited to a
particular day during the embryonic development period.
[0095] Referring now to FIG. 1, methods of processing live eggs
based upon identified characteristics, according to embodiments of
the present invention, are illustrated. Initially, live eggs are
identified among a plurality of eggs undergoing incubation (Block
1000). For example, the eggs are candled to identify which eggs are
live eggs. Material is extracted from each live egg (Block 2000)
and the extracted material is assayed to identify one or more
characteristics (e.g., gender, pathogen content, genetic markers
related to bird health or performance, nutritional, endocrine or
immune indicators or factors, etc.) of the respective egg (Block
3000). The live eggs are then selectively processed based upon the
identified one or more characteristics (Block 4000). Each of these
operations are described in detail below.
[0096] Referring to FIG. 2, identifying live eggs among a plurality
of eggs (Block 1000) may involve various techniques including, but
not limited to, conventional candling (Block 1100), spectral
candling (Block 1200), and the combination of light and thermal
candling (Block 1300). Embodiments of the present invention may
utilize any method of determining whether an egg contains a live
embryo, and are not limited to only the methods described
herein.
[0097] Referring to FIG. 3, conventional candling techniques
include measuring the opacity of an egg to visible light, infrared
light, and/or other electromagnetic radiation (Block 1110), and
then identifying live eggs using measured opacity values (Block
1120). Exemplary candling methods and apparatus are described in
U.S. Pat. Nos. 4,955,728 and 4,914,672, both to Hebrank, and U.S.
Pat. No. 4,671,652 to van Asselt et al., which are incorporated
herein by reference in their entireties. Conventional egg candling
techniques are well understood by those of skill in the art and
need not be described further herein.
[0098] Referring to FIG. 4, spectral candling (Block 1200) includes
illuminating an egg with light in both visible and infrared
wavelengths (Block 1210) and then receiving light passing through
the egg at a detector positioned adjacent the egg (Block 1220). For
example, an egg may be illuminated with light at wavelengths of
between about three hundred nanometers and about eleven hundred
nanometers (300 nm-1,100 nm). Intensity of the received light is
determined at selected visible and infrared wavelengths for the egg
(Block 1230) and a spectrum is generated that represents light
intensity at the visible and infrared wavelengths (Block 1240). The
spectrum generated for the egg is then compared with a spectrum
associated with a live egg to identify whether the egg is a live
egg (Block 1250).
[0099] FIG. 5 illustrates three spectra for three respective eggs
candled via spectral candling techniques. Wavelength in nanometers
(nm) is plotted along the X axis, and light intensity counts are
plotted along the Y axis. Spectrum 2 is associated with a clear
egg. Spectrum 3 is associated with an early dead egg. Spectrum 4 is
associated with a live egg. Spectral candling is described in
co-assigned U.S. patent application Ser. No. 09/742,167, filed on
Dec. 20, 2000, which is incorporated herein by reference in its
entirety.
[0100] Referring to FIG. 6, light and thermal candling (Block 1300)
includes measuring the opacity of an egg (Block 1310), measuring
the temperature of the egg (Block 1320), and using the measured
opacity and temperature values to identify whether the egg is a
live egg (Block 1330). Light and thermal candling is described in
co-assigned U.S. patent application Ser. No. 09/563,218, filed May
2, 2000, which is incorporated herein by reference in its
entirety.
[0101] Referring to FIG. 7, operations for extracting material from
live eggs (Block 2000), according to embodiments of the present
invention, will now be described. A plurality of live eggs are
positioned in a generally horizontal orientation such that the
allantois of each egg is caused to pool within an allantoic sac
under an upper portion of each egg shell (Block 2100). The term
"generally horizontal orientation" as used herein means that an egg
is positioned such that a long axis thereof is oriented at an angle
between about ten degrees. (10.degree.) and about one-hundred
eighty degrees (180.degree.) from vertical, wherein zero degrees
(0.degree.) vertical is defined by a large end of the egg in a
vertically upward position. A probe (e.g., a needle, etc.) is
inserted into each egg through the shell of the egg and directly
into the allantoic sac under the upper portion of the egg shell
(Block 2200). FIG. 8 illustrates the pooling of the allantois 16 in
an egg 1 under the upper side of the egg as a consequence of
non-vertical orientation of the egg (e.g., the long axis A is
oriented between about 10.degree. and about 180.degree.).
[0102] As is known to those of skill in the art, during the final
stages of incubation, the allantois normally exists as a relatively
thin layer under the inner shell membrane of an egg, and
essentially surrounds the embryo therein. In later stage (third and
fourth quarter) embryonated eggs, the allantois can be a difficult
target to insert a needle or probe into with accuracy. According to
embodiments of the present invention, eggs are oriented generally
horizontally such that the allantois can be reliably targeted in
ovo. By repositioning eggs to a generally horizontal orientation,
accessibility of the allantois is enhanced. See for example, U.S.
Pat. No. 6,176,199 to Gore et al., and U.S. Pat. No. 5,699,751 to
Phelps et al., which are incorporated herein by reference in their
entireties.
[0103] As is understood by those of skill in the art, the size of
the allantois is related to the stage of embryonic development of
the egg to be injected; thus the depth of insertion needed to reach
the allantois may vary depending on the developmental stage of the
egg as well as the species and strain of avian egg used. The depth
of insertion should be deep enough to place the sampling device
within the allantois, but not so deep as to pierce the amnion or
embryo. According to embodiments of the present invention, use of a
blunt-tip needle may help minimize piercing of the amnion or
embryo.
[0104] The precise location and angle of insertion of a sampling
device within an egg is a matter of choice and could be in any area
of an egg. Orientation of a sampling device will depend on the
orientation of the egg, the equipment available to carry out the
material extraction, as well as the purpose of the material
extraction.
[0105] Embodiments of the present invention are not limited to
extracting material from the allantois or from areas near the upper
surface of an egg. Removal of material from the allantois as
described herein is provided as merely one example of possible
embodiments of the present invention. Embodiments of the present
invention are not limited only to the extraction of allantoic
fluid. Various materials (e.g., amnion, yolk, shell, albumen,
tissue, membrane and/or blood, etc.) may be extracted from an egg
and assayed to identify one or more characteristics, as described
below. Moreover, it is not required that eggs be reoriented into a
generally horizontal position prior to extracting material
therefrom. Material may be extracted from eggs having virtually any
orientation.
[0106] Referring back to FIG. 7, a sample of allantoic fluid is
withdrawn from the allantois of each egg (Block 2300). The eggs are
then reoriented to a generally vertical position for easier
handling (Block 2400) and are moved to another location for
subsequent processing (Block 2500).
[0107] Referring to FIG. 9, operations for assaying material
extracted from each live egg to determine one or more
characteristics of the egg, such as gender (Block 3000), according
to embodiments of the present invention, will now be described.
Material, such as allantoic fluid, is extracted from each egg is
dispensed into respective sample receptacles in a template (Block
3100). A biosensor, which is configured to chemically react with
egg material and produce detectable signals (e.g., electromagnetic
signals, luminescence signals, fluorescence signals, conductivity
signals, colormetric signals, pH signals, etc.), is dispensed into
the respective sample receptacles (Block 3200). A color substrate
(e.g., ONPG-based substrate) that is configured to change a color
of the material in response to a chemical reaction between the egg
material and the biosensor may be added to each respective
receptacle (Block 3300).
[0108] The presence of a characteristic of an egg is then detected
(Block 3400). For example, a change in color may indicate that
estrogenic compounds are present in allantoic fluid within a
respective sample receptacle, thereby indicating the gender of a
respective egg from which the allantoic fluid was sampled from.
Operations represented by Block 3400 are intended to include
detection of electromagnetic signals produced within the sample
receptacles which provide an indication of the presence of a
characteristic of an egg. According to other embodiments of the
present invention, operations represented by Block 3400 are
intended to include detection of pathogens in egg material.
[0109] One or more additional analyses may be performed on the egg
material in the sample receptacles (Block 3500). For example,
genetic analysis may be performed on the material.
[0110] Referring to FIGS. 10A-10B, operations for selectively
processing live eggs based upon identified characteristics (Block
4000), according to embodiments of the present invention, will now
be described. One or more substances may be injected in ovo based
upon identified characteristics of each egg (Block 4100). For
example, a vaccine may be injected into eggs according to gender of
the eggs. Moreover, a first vaccine may be injected into eggs
identified as male, and a second vaccine may be injected into eggs
identified as female. In addition, the live eggs may be sorted
according to identified characteristics (Block 4200). For example,
if the identified characteristic is gender, male eggs may be
segregated from female eggs.
[0111] Sorting may occur before, after, or in lieu of in ovo
injection or other treatment or processing. As illustrated in FIG.
10B, the operations of Block 4100 and 4200 of FIG. 10A can be
reversed. For example, eggs may be sorted by gender first and then
injected with one or more substances based on gender (e.g., males
can be inoculated with a substance and females can be inoculated
with a different substance and/or at different times).
[0112] Referring now to FIG. 11, an egg processing system 10 for
processing eggs, according to embodiments of the present invention,
is illustrated. The illustrated system includes a classifier 12
that is configured to identify live eggs from among a plurality of
eggs 1 in an incoming egg flat 5. The classifier 12 is operatively
connected to a controller 20 which controls the classifier 12 and
stores information about each egg 1 (e.g., whether an egg is live,
clear, dead, rotted, etc.). As described above, the classifier 12
may include a conventional candling system, a spectral candling
system, a candling system that utilizes the combination of light
and thermal candling, or any other apparatus/technique for
identifying live eggs (and/or dead eggs, clear eggs, rotted eggs,
etc.). An operator interface (e.g., a display) 22 is preferably
provided to allow an operator to interact with the controller
20.
[0113] A material extraction station (also referred to as a
sampling module) 30, egg treatment station 40, and egg sorting
station 50 are provided downstream of the classifier 12 and are
each operatively connected to the controller 20. An assaying
station 60 is also operatively connected to the controller 20. The
material extraction station 30 is configured to extract material,
such as allantoic fluid, from selected eggs. Material extracted
from each egg is analyzed via the assaying station 60 to identify
one or more characteristics of each egg or for diagnostic or other
purposes. For example, the gender of each egg may be identified by
analyzing material extracted from an egg. Alternatively, the
presence of pathogens may be detected, and/or various genetic
analyses may be performed on the extracted material.
[0114] The treatment station 40 is configured to treat selected
eggs for example, by inoculation with a treatment substance (e.g.,
vaccines, nutrients, etc.). The treatment station 40 may include at
least one reservoir 42 for holding a treatment substance to be
injected into selected eggs. The controller 20 generates a
selective treatment signal for an egg (or a group of eggs) based
upon characteristics of an egg (or a group of eggs) identified via
the assaying station 60. For example, eggs identified as female may
be injected with a particular vaccine via the treatment station 40
upon receiving a treatment signal from the controller 20.
[0115] The sorting station 50 is configured to sort eggs based upon
identified characteristics. The controller 20 generates a selective
sorting signal for an egg (or a group of eggs) based upon
characteristics of an egg (or a group of eggs) identified via the
assaying station 60. For example, eggs identified as male may be
placed in a first hatching bin, and eggs identified as female may
be placed in a second hatching bin.
[0116] The assaying station 60 is configured to perform various
tests on material extracted from eggs in order to identify one or
more characteristics (e.g., gender) of each egg. Various tests may
be performed via the assaying station 60. The present invention is
not limited only to identifying the gender of eggs.
[0117] The controller 20 preferably includes a processor or other
suitable programmable or non-programmable circuitry including
suitable software. The controller 20 may also include such other
devices as appropriate to control the material extraction station
30, egg treatment station 40, egg sorting station 50, and assaying
station 60. Suitable devices, circuitry and software for
implementing a controller 20 will be readily apparent to those
skilled in the art upon reading the foregoing and following
descriptions and the disclosures of U.S. Pat. No. 5,745,228 to
Hebrank et al. and U.S. Pat. No. 4,955,728 to Hebrank.
[0118] The operator interface 22 may be any suitable user interface
device and preferably includes a touch screen and/or keyboard. The
operator interface 22 may allow a user to retrieve various
information from the controller 20, to set various parameters
and/or to program/reprogram the controller 20. The operator
interface 22 may include other peripheral devices, for example, a
printer and a connection to a computer network.
[0119] According to alternative embodiments of the present
invention, one or more of the stations described with respect to
FIG. 11 may be controlled by individual programmable logic
controllers (PLCs). Data may be transferred back and forth from a
PLC to a central computer database controller for storage. For
example, a central database may be provided to store information
such as gender (as well as other identified characteristics) of
eggs being processed. The central computer database controller is
configured to respond to individual PLCs when they request data or
send data. The central computer database need not directly control
the various stations under the control of respective PLCs.
[0120] FIG. 12 is a top-level controls architecture illustration of
an embodiment of the present invention within a hatchery wherein
individual PLCs are utilized to control various hatchery stations,
according to embodiments of the present invention. In the
illustrated embodiment, a plurality of PLCs 70a, 70b, 70c control a
material extraction station 30, an assaying station 60, and
treatment and sorting stations 40, 50, respectively. Each PLC 70a,
70b, 70c is connected to a server 72 via a local area network
(LAN). The server 72 is in communication with a database (which can
be local, remote, or a combination thereof) and stores/retrieves
data to/from the database in response to requests from the
individual PLCs 70a, 70b, 70c. The server 72 is capable of
communicating with remote devices via a communications network,
such as the Internet 90.
[0121] In the illustrated embodiment, the LAN is a wireless LAN and
the PLCs 70a, 70b, 70c communicate with the server 72 via wireless
LAN workgroup bridges 71a, 71b, 71c. However, it is understood that
any type of LAN may be utilized, including wired LANs. For example,
FIGS. 13A-13D illustrate a wired LAN embodiment.
[0122] In the illustrated embodiment, PLC 70a is configured to
control a material extraction station 30 for extracting material
from a plurality of eggs as described above. PLC 70a is also
configured to control a live/dead detector subsystem 74 (e.g., a
classifier 12, FIG. 11), an X-Y table stepper controller 75 that
controls the location of a sample tray for receiving material
extracted from eggs, an egg flat barcode reader 77, and an assay
sample tray barcode reader 78. According to embodiments of the
present invention, barcodes are utilized to track eggs within a
hatchery. As such, barcodes are placed on egg flats and are read
during various times during processing within a hatchery. Other
embodiments include RFID (radio frequency identification) tags in
lieu of barcodes and on-the-fly printed/applied identifiers either
on the egg flats or on the eggs themselves.
[0123] PLC 70b is configured to control an assaying station 60 for
identifying one or more characteristics of each egg as described
above. PLC 70b is also configured to control an assay reader
subsystem 80 (e.g., a CCD camera system that scans each sample
receptacle in an assay template to determine the gender of a
respective egg whose sample material is in the receptacle), an
assay reader stepper controller 81, a substrate dispenser stepper
controller 82, a yeast dispenser stepper controller 83, and an
assay barcode reader 84. Moreover, PLC 70b may be configured to
control an assaying station 60 that is directly connected to the
material extraction station 30 or that is a stand-alone
apparatus.
[0124] PLC 70c is configured to control a treatment station 40 and
a sorting station 50 as described above. In addition, PLC 70c
controls an egg flat barcode reader 85 that identifies egg flats
passing through the treatment and sorting stations 40, 50.
[0125] FIGS. 13A-13D are more detailed illustrations of a top-level
controls architecture for an egg processing system according to
embodiments of the present invention within a hatchery wherein
individual PLCs are utilized to control a material extraction
station (sampling module), an assaying module, and transfer module,
respectively. The illustrated embodiment of FIGS. 13A-13D utilizes
a wired LAN embodiment wherein a system server (FIG. 13A)
communicates with (and controls) a sampling module (FIG. 13B), an
assay module (FIG. 13C), and a transfer module (FIG. 13D).
Material Extraction Station
[0126] Turning now to FIGS. 14-17, a material extraction station 30
for extracting material from a plurality of eggs, according to
embodiments of the present invention, is illustrated. The material
extraction station 30 includes a frame 100 with an incoming egg
flat conveyor system 102 and an outgoing egg flat conveyor system
104 extending along respective, opposite sides 100a, 100b of the
frame 100, as illustrated in FIG. 16. The material extraction
station 30 also includes a classifier 12 (FIG. 16) that is
configured to identify live eggs from among a plurality of eggs, an
egg cradle table 110 movably mounted to the frame 100, an egg
transfer apparatus 130, a sample tray handling system 150, four
sets of sampling apparatus 160, and a sanitizer system (not shown)
for sanitizing sampling portions of the apparatus.
[0127] The incoming egg flat conveyor system 102 is configured to
transport incoming flats 5 of eggs 1 through the classifier 12 and
to the egg transfer apparatus 130. As will be described below,
according to an embodiment of the present invention, live eggs are
removed from the incoming egg flats 5. Non-live eggs remain within
the incoming egg flats 5 and are carried away by the incoming egg
flat conveyor system 102 for disposal or other processing. The
outgoing egg flat conveyor system 104, according to an embodiment
of the present invention, is configured to transport flats 7 of
eggs that have had material extracted therefrom to an incubator for
incubation, and/or to subsequent treatment and/or sorting
stations.
[0128] Embodiments of the present invention are not limited to the
removal of live eggs only from an incoming egg flat 5. For example,
all eggs may be removed from an incoming egg flat 5 and placed
within an array of egg cradles. Live eggs may be segregated from
non-live eggs via the sorting station 50 (FIG. 11). For example,
only live eggs may be transferred to hatching baskets via the
sorting station 50.
[0129] The incoming egg conveyor system 102 may utilize belts
and/or other conveyor system components that allow light to pass
through a portion thereof to facilitate candling at the classifier
12. Egg flat conveyor systems are well known to those skilled in
the art and need not be described further herein. Moreover,
embodiments of the present invention are not limited to the
illustrated orientation, configuration, and/or travel directions of
the incoming and outgoing conveyor systems 102, 104. Incoming and
outgoing egg flats may travel in various directions relative to
various apparatus of the present invention, and may have various
configurations and orientations.
[0130] Although eggs conventionally are carried in egg flats, any
means of conveying a plurality of eggs to the classifier 12 for
identifying live eggs can be used. Eggs may pass one at a time
through the classifier 12 or the classifier 12 may be configured so
that a number of eggs (i.e., within a flat) can pass through the
classifier 12 simultaneously.
[0131] Incoming and outgoing egg flats 5, 7 of virtually any type
may be used in accordance with embodiments of the present
invention. Flats may contain any number of rows, such as seven rows
of eggs, with rows of six and seven being most common. Moreover,
eggs in adjacent rows may be parallel to one another, as in a
"rectangular" flat, or may be in a staggered relationship, as in an
"offset" flat. Examples of suitable commercial flats include, but
are not limited to, the "CHICKMASTER 54" flat, the "JAMESWAY 42"
flat and the "JAMESWAY 84" flat (in each case, the number indicates
the number of eggs carried by the flat). Egg flats are well known
to those skilled in the art and need not be described further
herein.
[0132] In addition, the egg array configuration of incoming egg
flats 5 may be different from that of outgoing egg flats 7. The egg
transfer apparatus 130 is configured to adjust to different egg
array configurations of different egg flats, as described
below.
[0133] The illustrated egg cradle table 110 includes first, second
and third sets of cradles 112 arranged in adjacent respective
first, second, and third arrays 113a, 113b, and 113c. The
illustrated egg cradle table 110 is slidably mounted to the frame
100 between the incoming and outgoing conveyor systems 102, 104 and
is movable relative to the egg transfer apparatus 130 and each of
the four illustrated sampling apparatus 160 along the direction
indicated by arrows A.sub.1. The egg cradle table 110 is configured
to move such that when one cradle array (e.g., 113a or 113b or
113c) is positioned beneath the egg transfer apparatus 130, another
cradle array (e.g., 113a or 113b or 113c) is positioned beneath one
of the sampling apparatus 160, as will be described in detail
below.
[0134] Although illustrated with three cradle arrays 113a, 113b,
113c and four sampling apparatus 160, an apparatus for extracting
material from eggs according to embodiments of the present
invention may have one or more arrays of cradles 112 and one or
more sampling apparatus 160. For example, an apparatus for
extracting material from eggs according to embodiments of the
present invention may have a single array of cradles 112 and a
single sampling apparatus 160.
[0135] Referring now to FIG. 15, lifting head 132 of the
illustrated transfer apparatus 130 and two of the sampling
apparatus 160 of FIG. 14 on opposite sides of the transfer
apparatus 130 are illustrated in enlarged detail. The illustrated
lifting head 132 includes an expandable and collapsible array of
manifold blocks and vacuum cups 137 that are supported by a
generally rectangular frame 138. The lifting head 132 is configured
to lift a plurality of eggs from an array of cradles 112 and place
the eggs within outgoing egg flats 7.
[0136] The illustrated egg cradle table 110 includes a plurality of
elongated rods 118 that are simultaneously controlled by an
actuator device 122 which moves the elongated rods 118 between
retracted and extended positions (indicated by arrow A.sub.2)
within respective cradles 112 to reposition eggs from horizontal to
vertical positions, as will be described below. Each sampling
apparatus 160 includes an array of sampling heads 162 that are
configured to extract material from a respective egg positioned
within an egg cradle 112. Each sampling head is configured for
generally vertical movement (indicated by arrows A.sub.3) relative
to the egg cradle table 110, as will be described below.
[0137] FIG. 17 is a side elevation view of the material extraction
apparatus of FIG. 14 illustrating the two lifting heads 132, 134 of
the egg transfer apparatus 130. As illustrated, the lifting heads
132, 134 are configured for lateral movement (indicated by arrows
A.sub.4) between the incoming and outgoing egg flat conveyor
systems 102, 104 and the egg cradle table 110.
[0138] FIGS. 18A-18D illustrate the progression of eggs through the
material extraction station 30. FIG. 18A illustrates the loading of
incoming egg flats 5 which contain a plurality of eggs 1 onto the
incoming egg flat conveyor system 102, and the loading of empty egg
flats 7 onto the outgoing egg flat conveyor system 104. FIG. 18A
also illustrates an incoming egg flat 5 containing a plurality of
eggs 1 positioned within the candling area (i.e., beneath the
classifier 12 illustrated in FIG. 16) of the material extraction
apparatus 30.
[0139] FIG. 18B illustrates movement of an incoming egg flat 5
along the incoming egg flat conveyor system from the candling area
to the picker area. In the picker area, egg transfer head 134 is
configured to pick up a plurality of the eggs 1 from an egg flat 5
and place the eggs 1 within an array of cradles 112 on the slidable
egg cradle table 110. An empty outgoing egg flat 7 is positioned
adjacent the array of cradles 112.
[0140] FIG. 18C illustrates a plurality of eggs 1 seated within the
plurality of egg cradles 112 after being transferred from an
incoming egg flat 5. For ease of illustration, the eggs 1 are
illustrated in a generally vertical orientation within the egg
cradles 112. However, as will be described below, the eggs 1 are
repositioned to a generally horizontal orientation by the egg
cradles 112 prior to removing material from the eggs 1. The egg
cradles 112 are also configured to reposition the eggs after
material has been removed therefrom to a generally vertical
orientation prior to being transferred to an outgoing egg flat
7.
[0141] The eggs 1' from which material has been extracted are
transferred to an outgoing egg flat 7. An outgoing flat 7 into
which eggs just sampled may thereupon be placed in an incubator for
incubation according to conventional procedures while awaiting
results from the assaying station 60 (FIG. 11). When assaying
results are completed, and characteristics of each egg identified
(e.g., gender) the eggs may be moved from the incubator to one or
more treatments stations 40 (FIG. 11) and/or to a sorting station
50 (FIG. 11). According to embodiments of the present invention
described below, an assaying station 60 may be connected to the
material extraction station 30 and may be configured to assay
material extracted from eggs quickly. As such, flats of eggs from
which material has been extracted may be held in one or more
accumulation modules instead of being returned to incubators prior
to being transported to a treatment/sorting station(s).
[0142] FIG. 18D illustrates movement of the egg cradle table 110 in
the direction indicated by arrow A.sub.1 to a location where the
array of egg cradles 112 containing eggs 1 is positioned beneath
one of the sampling apparatus 160 (FIG. 14).
[0143] FIG. 19 illustrates a portion of an exemplary array of
cradles 112 that can be included on the illustrated egg cradle
table 110. Each cradle 112 is configured to receive an egg in a
generally vertical orientation and to cause the egg to move to a
generally horizontal and centered orientation.
[0144] An enlarged perspective view of a cradle 112 in the
illustrated partial array of FIG. 19 is illustrated in FIG. 20 and
is representative of each cradle in the partial array. The
illustrated cradle 112 includes an inclined, arcuate surface 114
that defines a receptacle for receiving an egg. The illustrated
arcuate surface 114 of the cradle 112 has an inclined upper portion
114a, a lower portion (or floor) 114b, and opposite side portions
115a, 115b.
[0145] The cradle arcuate surface 114 may have a generally concave
configuration between opposite side portions 115a, 115b. The
generally concave configuration of the arcuate surface 114 helps
maintain an egg in a generally centered position on the arcuate
surface 114. The arcuate surface upper portion 114a is configured
to receive an end of a vertically oriented egg and to cause the egg
to slide to the arcuate surface lower portion 114b such that the
egg becomes positioned on the arcuate surface lower portion 114b in
a generally inclined orientation.
[0146] Embodiments of the present invention are not limited to the
illustrated cradle 112 or to the illustrated configuration of the
arcuate surface 114. The arcuate surface 114 of the cradle 112 may
be a substantially smooth, continuous arcuate surface.
Alternatively, the arcuate surface 114 may include a plurality of
flat, adjacent surfaces arranged so as to form a generally arcuate
configuration. In addition, the cradle arcuate surface may have a
generally flat configuration between opposite side portions 115a,
115b.
[0147] Egg cradles that are configured to receive an egg in a
generally vertical orientation, to cause the egg to move to a
generally horizontal orientation, and to reorient the egg to a
generally vertical orientation for removal are described in detail
in co-assigned U.S. patent application Ser. No. 09/835,990
entitled, Apparatus and Method for Reorienting an Egg Between
Vertical and Horizontal Orientations, which is incorporated herein
by reference in its entirety.
[0148] Each illustrated cradle 112 also includes a pair of
elongated retaining arms 119 secured to the cradle 112 in
spaced-apart relation along the respective arcuate surface side
portions 115a, 115b, as illustrated. Each of the illustrated
elongated arms 119 has a respective end 119a that is secured to the
cradle 112 via fasteners 120 and an opposite free end 119b.
Fasteners 120 may be various known fastening devices including, but
not limited to, threaded fasteners (e.g., screws, bolts, etc.) and
unthreaded fasteners (e.g., rivets, tapered studs, untapered studs,
etc.). Alternatively, retaining arms 119 may be adhesively secured
to a cradle 112, or secured to a cradle 112 via welding, brazing,
soldering, or various other known methods.
[0149] The retaining arms 119 help to prevent an egg from rolling
or falling off of a cradle arcuate surface 114. Moreover, the
retaining arms 119 help stabilize an egg that is being repositioned
from a generally horizontal position to a generally vertical
position, as described below. The retaining arms 119 are configured
to flex outwardly, as illustrated in FIG. 21, to accommodate large
eggs, while at the same time providing support for narrow eggs. In
addition, the retaining arms 119 help to center an egg laterally on
the cradle arcuate surface 114 so that the long axis of the egg is
aligned with the long axis of the cradle while the egg is in a
generally horizontal position.
[0150] Embodiments of the present invention are not limited to the
illustrated retaining arms 119. Retaining arms may have various
configurations and may be attached to a cradle 112 in various
locations and configurations. Moreover, embodiments of the present
invention may not require retaining arms.
[0151] Each cradle 112 is secured to the cradle table 110 via
fastening devices including, but not limited to, threaded fasteners
(e.g., screws, bolts, etc.) and unthreaded fasteners (e.g., rivets,
tapered studs, untapered studs, etc.). Alternatively, each cradle
112 may be adhesively secured to the cradle table 110, or secured
to the cradle table 110 via welding, brazing, soldering, or various
other known methods. FIG. 22 illustrates threaded passageways 121
in a cradle 112 that are configured to threadingly engage
respective threaded fastening members (not shown) for securing a
cradle 112 to the cradle table 110 according to embodiments of the
present invention.
[0152] A plurality of passageways 116 extend through each cradle
112 and terminate at respective apertures 117 in the arcuate
surface 114 as illustrated. An elongated rod 118, which serves as
an orientation member, is configured for reciprocal movement
between a retracted position and an extended position within each
passageway 116. In an extended position, the elongated rods 118 for
each cradle 112 urge an egg horizontally positioned (or otherwise
inclined relative to vertical) on the arcuate surface lower portion
114b to a vertical orientation so that the egg can be removed from
the cradle 112 via the egg transfer apparatus 130.
[0153] Embodiments of the present invention are not limited to the
illustrated elongated rods 118 or to the orientation of the
elongated rods 118 with respect to each cradle 112. Orientation
members may have various configurations and may be positioned
within a cradle 112 for reciprocal movement between retracted and
extended positions in various ways and in various orientations.
[0154] As illustrated in FIG. 15, the elongated rods 118 are
arranged in an array and are simultaneously controlled by an
actuator device 122 which moves the elongated rods 118 between
retracted and extended positions within respective cradles 112.
When the array of rods 118 are in a retracted position, eggs within
the cradles 112 have a generally horizontal orientation as
described above. When the rods 118 are moved to an extended
position, the rods extend upwardly through the cradles as described
above and cause the eggs to move to a generally vertical
orientation. The actuator 122 for moving the rods 118 between
retracted and extended positions may be operated pneumatically,
hydraulically, magnetically, and/or electromechanical actuators may
be utilized.
[0155] FIGS. 23-26 illustrate an egg cradle 212 that may be
utilized in accordance with other embodiments of the present
invention and that is configured to reposition an egg from a
vertically oriented position to a horizontal position and then back
to a vertically oriented position, according to an alternative
embodiment of the present invention. The illustrated cradle 212 has
first and second portions 220a, 220b that define a receptacle for
receiving an egg. The illustrated first portion 220a has a pair of
opposite, spaced-apart members 222, 224 with inclined upper ends
222a, 224a. Each inclined upper end 222a, 224a has an inwardly
sloping surface 226, 228. The illustrated second portion 220b has a
pair of opposite, spaced-apart members 232, 234 with inclined upper
ends 232a, 234a. Each inclined upper end 232a, 234a has an inwardly
sloping surface 236, 238.
[0156] The inclined upper ends 232a, 234a of the second portion
220b are configured to receive an end of a vertically oriented egg
and to cause the egg to slide downwardly such that the egg becomes
positioned on the first and second portions 220a, 220b in a
generally inclined orientation. The configuration of the inclined
upper ends 222a, 224a, 232a, 234a of the first and second portions
220a, 220b help maintain an egg in a generally centered position in
the cradle 212.
[0157] The second portion 220b serves as an orientation member and
is configured for reciprocal movement between a retracted position
(FIG. 23) and an extended position (FIG. 24). In an extended
position, the second portion 220b urges an egg horizontally
positioned (or otherwise inclined relative to vertical) within the
cradle 212 to a vertical orientation.
[0158] As illustrated in FIG. 17, the egg transfer apparatus 130 of
the material extraction station 30 of FIG. 14 includes first and
second, adjacent lifting heads 132, 134 which operate in tandem.
The first lifting head 134 is configured to simultaneously lift a
plurality of generally vertically oriented eggs 1 from an incoming
egg flat 5 on the incoming egg flat conveyor system 102 and place
the plurality of eggs 1 within a first array of cradles 112. Eggs
are typically positioned within an incoming egg flat with the large
end of the egg facing in a generally upward direction. The first
lifting head 134 can be controlled to pick up selected eggs 1 from
an incoming egg flat 5. For example, the first lifting head 134 can
be directed to only pick up live eggs, as identified by the
classifier 12.
[0159] The adjacent second lifting head 132 is configured to
simultaneously lift and remove a plurality of eggs 1 from a
plurality of cradles 112 on the egg cradle table 110 and place the
eggs 1 within an outgoing egg flat 7 on the outgoing egg flat
conveyor system 104. The eggs 1 are reoriented to a generally
vertical orientation to facilitate removal from the cradles 112.
Eggs are typically placed within an outgoing egg flat 7 with the
large end in a generally upward direction.
[0160] The illustrated egg cradle table 110 is slidably mounted to
the frame 100, and is and movable relative to the first and second
lifting heads 134, 132 such that the first, second, or third arrays
113a, 113b, 113c of egg cradles 112 can be positioned beneath the
egg transfer device 130 at any given time so that the lifting heads
132, 134 can place/remove eggs within/from the cradles 112 as
described above.
[0161] The slidable configuration of the egg cradle table 110
allows one array of cradles to receive eggs from one of the lifting
heads 132, 134 while another array of cradles is positioned beneath
a respective sampling apparatus 160 such that material can be
extracted from the eggs, as will be described below. The use of
multiple arrays of egg cradles along with reciprocal motion of the
egg cradle table facilitates processing throughput.
[0162] Referring to FIGS. 27-29, each lifting head 132, 134 of the
illustrated egg transfer apparatus 130 includes an expandable and
collapsible array of manifold blocks 136 and vacuum cups 137 that
are supported by a generally rectangular frame 138. The illustrated
frame 138 includes opposite side members 139a, 139b that extend
along a first direction L.sub.1 and opposite end members 140a, 140b
that extend along a second direction L.sub.2 that is substantially
perpendicular to L.sub.1.
[0163] Each manifold block 136 and vacuum cup 137 is supported from
a respective cross rail 142 that extends between the side members
140a, 140b, as illustrated. A middle one of the cross rails is
fixed between the side members 140a, 140b. The cross rails 142 on
either side of the fixed middle cross rail are slidably supported
by the frame 138 and are configured to move along the second
direction L.sub.2. Adjacent cross rails 142 are connected via a
pair of restraining members 143.
[0164] Actuator members 144a, 144b are connected to rails 142 as
illustrated and are used to collapse and expand the array of
manifold blocks 136 and vacuum cups 137 along the second direction
L.sub.2. Each of the actuator members 144a, 144b are controlled by
an actuator device 145 which is in communication with a controller
(e.g., PLC 70a of FIG. 12). The actuator 145 may be operated
pneumatically, hydraulically, magnetically, and/or
electromechanical actuators may be utilized.
[0165] FIG. 27 illustrates the array of manifold blocks 136 and
vacuum cups 137 in an expanded configuration and FIG. 28
illustrates the array of manifold blocks 136 and vacuum cups 137 in
a contracted configuration. In FIG. 28, the restraining members 143
are not shown for clarity. The expandable and contractible nature
of the array of manifold blocks 136 and vacuum cups 137 for each
lifting head 132, 134 allows a plurality (or "clutch") of eggs to
be lifted from, and inserted into, egg flat and egg cradle arrays
of different sizes and configurations.
[0166] According to embodiments of the present invention, the array
of manifold blocks 136 and vacuum cups 137 may be expandable and
contractible in two directions. For example, a particular style of
incoming egg flat may allow one inch (1") between adjacent eggs on
a row, and one inch (1") between adjacent rows. An array of egg
cradles 112 in the egg cradle table 110 may have a different
configuration. For example, an array of egg cradles may allow only
one-half inch (0.5") between adjacent eggs on a row, and one and
one-half inches (1.5") between adjacent rows. Similarly, an
outgoing egg flat may have a different array configuration from an
egg cradle array configuration. An array that is expandable and
contractible in two directions can accommodate such differences in
egg flat and cradle arrays.
[0167] The array configuration of each lifting head 132, 134 is
adjustable via a controller, such as a central controller (PLC) or
a dedicated controller (PLC) (e.g., PLC 70a of FIG. 12) so that
eggs can be transferred among egg flats and cradles having
different sizes and/or array configurations. Each lifting head 132,
134 is also preferably easily removable as a unit to facilitate
cleaning.
[0168] Referring now to FIG. 30, each manifold block 136 includes
an end portion 136a and an internal passageway 144 that terminates
at a nozzle 149 extending from the end portion 136a. The internal
passageway 144 of each manifold block 136 is in fluid communication
with a vacuum source (not shown) and an air source via respective
vacuum and air lines connected to respective fittings on top of
each manifold block 136, as would be understood to those skilled in
the art. Preferably, each manifold block 136 and vacuum cup 137 is
in fluid communication with a separate vacuum supply to allow for
selective transfer of eggs.
[0169] A flexible vacuum cup 137 is secured to each respective
manifold block nozzle 149. Each flexible vacuum cup 137 is
configured to engage and retain an egg in seated relation therewith
when vacuum is provided within the flexible cup 137 via a
respective internal passageway 144 and to release a respective egg
when vacuum within the respective internal passageway 144 is
destroyed. Air from an air source may be provided within the
internal passageway 144 to facilitate removal of eggs from the
flexible vacuum cup 137.
[0170] Lifting heads 132, 134 of the egg transfer apparatus 130 may
utilize various suction-type lifting devices. Moreover, any
suitable means for transferring eggs from a flat to an array of egg
cradles, and from the array of egg cradles to a flat, may be
utilized in accordance with embodiments of the present
invention.
[0171] Each sampling apparatus 160 of the material extraction
apparatus 30 of FIG. 14 includes an array or set 161 of sample
heads 162. Each sample head 162 is configured to extract material
from an egg and deposit the extracted material within a respective
sample receptacle 152 in a sample tray 150 (FIG. 40). Each sampling
apparatus 160 in the illustrated embodiment of FIG. 14 are fixed
and the cradle table 110 moves relative thereto as described above.
Accordingly, when a set of cradles 112 containing eggs 1 is
positioned beneath a sampling apparatus 160, each sample head 162
is configured to extract material from a respective egg 1 and then
deposit the extracted material into a respective sample receptacle
152 of a sample tray 150.
[0172] Referring to FIG. 31, each sample head 162 according to the
illustrated embodiment, includes an elongated housing 163 having
opposite first and second ends 163a, 163b and an elongated
passageway (guide) 164 that extends therebetween. An elongated
needle 165 is disposed within the elongated passageway 164 and is
movable between a retracted position and first and second extended
positions. The tip 166 of the needle 165 is contained within the
passageway 164 when the needle 165 is in the retracted position,
and the tip 166 of the needle 165 extends from the housing first
end 163a when the needle 165 is in the first and second extended
positions. The needle 165, when in the first extended position, is
configured to punch through the shell of an egg and extract
material (e.g., allantoic fluid) from the egg. The needle 165, when
in the second extended position, is configured to deliver extracted
egg material into a respective sample receptacle of a sample tray,
as will be described below.
[0173] The needle 165 may be a hypodermic needle having an eggshell
piercing tip configuration. According to embodiments of the present
invention, a needle tip 166 may have a beveled or blunt
configuration to facilitate punching through an egg shell.
According to embodiments of the present invention, a needle 165 may
have an aperture formed in a side portion thereof in lieu of the
tip 166 to help prevent blockage of the needle lumen caused by
punching through an egg shell. Sampling head needles 165 according
to embodiments of the present invention are particularly adapted to
withdraw allantoic fluid from eggs.
[0174] As is known to those skilled in the art, allantoic fluid is
an excretory medium for the nitrogenous metabolites of an avian
embryo. Allantoic fluid begins to form around Day 5 of incubation.
It attains a maximum volume on about Day 13 of incubation and then
wanes in volume as incubation continues dues to moisture loss and
fluid resorbtion, but is still present in significant volumes on
Day 18 of incubation.
[0175] Allantoic fluid is separated from the eggshell by the inner
and outer shell membranes and the chorioallantoic membranes.
Although the allantoic fluid encompasses the entire periphery of an
embryonated egg, the allantoic fluid accumulates at the top of an
egg directly underneath the membranes overlying the air cell. The
accumulation of the allantoic fluid at the top of the egg is due to
gravity and displacement by the dense embryo and yolk sac.
Attempting to accurately sample the allantoic fluid through the top
of an egg while the egg is upright may be difficult due to the
variability of the air space from egg to egg. Gravity can be used
to pool the allantoic fluid in a localized site. When an egg is
turned on its longitudinal axis, the allantoic fluid will pool at
the top side of the egg, directly underneath the shell. Laying the
egg on its longitudinal axis renders the allantoic fluid an easier
target to access.
[0176] The extraction of material, such as allantoic fluid, from
eggs may be performed in various ways according to embodiments of
the present invention. For example, if only live eggs are initially
placed within the cradles 112 of the egg cradle table 110, all eggs
will be sampled. However, if non-live eggs are also placed within
the cradles 112 of the egg cradle table 110, only the live eggs
will be sampled. Alternatively, the shell of all eggs, including
non-live eggs, may be punched, but material only sampled from live
eggs. According to alternative embodiments, each sample head 162
may comprise a biosensor or other device designed to analyze egg
material (e.g., allantoic fluid) in situ. As will be described
below, according to other embodiments of the present invention, egg
material extraction and assaying of extracted material may be
performed by the same sampling apparatus
[0177] Each sample head 162 of the illustrated embodiment of FIG.
31 also includes an alignment member 168. The illustrated alignment
member 168 includes a body portion 169 that is movably secured to
the sample head housing first end 163a. Two pair of opposed wheels
170a, 170b are mounted to opposite end portions 171a, 171b of the
body portion 169.
[0178] As illustrated in FIG. 32, an egg 1 is held in position
within a cradle 112 by the alignment member 168 when a sample head
162 is brought into contact with an egg within a cradle 112. The
alignment member 168 adjusts the egg position and centers it within
the cradle 112. In the illustrated embodiment, opposing wheels
170a, 170b are in contact with the egg shell along with the sample
head housing first end 163a.
[0179] Embodiments of the present invention are not limited to the
illustrated configuration of the sample head of FIG. 31. For
example, a sample head may have an alignment member without the
pair of opposed wheels 170a, 170b. Moreover, embodiments of the
present invention may utilize alignment members having various
shapes, sizes and configurations.
[0180] Sample head operations are illustrated in FIGS. 33-35. FIG.
33 is a side view of a plurality of sample heads 162 for one of the
four illustrated sampling apparatus 160 in FIG. 14. Each sample
head is in contact with the shell of an egg 1 within a respective
egg cradle 112 prior to extracting material from the egg 1, and a
sample needle 165 within each sample head is in a retracted
position. In addition, an actuator 180 is illustrated moving arm
182 via actuator piston 181 from a first position to a second
position, as indicated by arrow A.sub.5. Arm 182 is linked to
sampling head locking plates 185 that are movably sandwiched
between stationary plates 186 and 187. As will be described below,
locking plates 185 are configured to maintain each sample head 162
in a vertically-locked position relative to a respective egg 1
within a cradle 112 as material is extracted from the egg 1.
[0181] In FIG. 34, arm 182 has moved to the second position such
that the locking plates 185 are spread apart to the locked position
so as to restrain vertical movement of the sample heads 162. The
sample needles 165 have been extended to a first extended position
and have pierced the shell of each respective egg. In the first
position the sample needles 165 are in position to extract material
(e.g., allantoic fluid) from each respective egg.
[0182] In FIG. 35, the arm 182 has moved back to the first position
such that the locking plates 185 do not restrain vertical movement
of the sample heads 162. The sample needles 165 have been extended
to a second extended position and are in position to dispense
material extracted from respective eggs into respective sample
receptacles 152 in a sample template 150. The second extended
position provides adequate clearance beyond the sample head 162
and/or alignment member 168 so that the needles 165 can reach the
sample receptacles 152 in a sample tray 150 and so that the needles
165 can reach sanitation nozzles or other apparatus that deliver
sanitizing fluid to the needles 165.
[0183] Embodiments of the present invention are not limited to
sample heads wherein needles have first and second extended
positions. According to alternative embodiments, a needle may move
from a retracted position to only one extended position for
extracting material from eggs. For dispensing extracted material
into a sample receptacle, a sample tray may be moved upwardly to
the needle. Similarly, a sanitizing nozzle or other apparatus may
move upwardly to the needle.
[0184] Movement of a sample needle 165 within a sample head 162 is
illustrated in greater detail in FIGS. 36A-36C. Each sample head
162 includes a biasing member (e.g., a spring) 190, as illustrated
in FIG. 36A. Movement of each sample needle 165 from a retracted
position to both the first and second extended positions is
facilitated by air pressure (or other fluid pressure) that is
provided from a compressed air source (or other fluid source). To
move the sample needle 165 from the retracted position to the first
extended position (FIG. 36B), air (or other fluid) pressure is
supplied at a level sufficient (e.g., 28 psi) to overcome the
biasing force of air in the lower half of the sample head 162, but
not sufficient to overcome the combined biasing forces of air in
the lower half of the sample head and the biasing member 190. To
move the sample needle 165 from the retracted position to the
second extended position (FIG. 36C), air (or other fluid) pressure
is supplied via one or more fittings (not shown) on the sample head
162 at a level sufficient (e.g., 75 psi) to overcome the combined
biasing forces of the air in the lower half of the sample head and
the biasing member 190.
[0185] In the illustrated embodiment, the biasing member 190 is
configured to urge the sample needle 165 from the second extended
position to the first extended position when air pressure within
the lower half of the sample head 162 is reduced. Air pressure is
increased in the lower half of the sample head 162 to move the
sample needle 165 to the retracted position. The biasing member 190
may have various shapes, configurations and/or sizes and is not
limited to a particular embodiment.
[0186] In the illustrated embodiment, air is supplied via nozzle
192 to each sample head 162 to dry outside portions of each
respective sample needle 165 after sanitizing each respective
sample needle 165.
[0187] Referring to FIG. 36D, an exemplary sanitizing fountain 200
that may be utilized to sterilize a respective sample needle 165,
in accordance with embodiments of the present invention, is
illustrated. The illustrated fountain 200 has a bore 201 formed
therein that is configured to receive a respective sample needle
165 therein. Sanitizing fluid is supplied to the fountain from a
source via a supply line 202. The fountain 200 contains one or more
nozzles (not shown) that are configured to spray the sample needle
165 with sanitizing fluid. According to embodiments of the present
invention, an array of fountains 200 are provided such that sample
needles 165 from a respective array of sample heads 162 can be
lowered into respective fountains 200 at the same time after
dispensing extracted egg material into sample receptacles of a
sample tray. Embodiments of the present invention, however, are not
limited to the illustrated sanitizing fountain 200. Sanitizing
systems utilizing various types of devices for applying sanitizing
fluid to a sample needle may be utilized.
[0188] Referring now to FIGS. 37, 38A-38B and 39A-39C, the locking
plates 185 will now be described. FIG. 37 is a plan view of an
array of sample heads 162 taken along lines 37-37 of FIG. 33 that
illustrates the locking plates 185. The illustrated locking plates
185 include a plurality of apertures 300 formed therein in the
array pattern of the array of sample heads 162. Each sample head
162 is configured to be slidably disposed within a respective
aperture 300 and is configured to move freely in a vertical
direction when the locking plates 185 are not in the locked
position.
[0189] Within each illustrated aperture are a pair of resilient
arms 302 that are configured to apply a biasing force to a
respective sampling head 162 when the locking plates 185 are moved
to the locked position. The resilient arms 302 are configured to
prevent one sampling head that is slightly larger than other
sampling heads from binding the whole apparatus and preventing
other sampling heads from being locked in place. In the illustrated
embodiment of FIG. 38A, the locking plates 185 move away from each
other when moved to the locked position. However, embodiments of
the present invention are not limited to the illustrated locking
plates 185 or to their direction of movement.
[0190] FIG. 38B illustrates locking plates 185' according to other
embodiments of the present invention. The illustrated locking
plates 185' include a plurality of apertures 300 formed therein the
array pattern of the array of sample heads 162. Each sample head
162 is configured to be slidably disposed within a respective
aperture 300 and is configured to move freely in a vertical
direction when the locking plates 185' are not in the locked
position. In the illustrated embodiment of FIG. 38B, the locking
plates 185' also move away from each other when moved to the locked
position.
[0191] Within each illustrated aperture are a pair of resilient
arms 302', a support block 303, and springs 304 connected to the
resilient arms 302' that are configured to apply a biasing force to
the support block 303. When the locking plates 185' are moved
relative to the fixed upper and lower plates, the resilient arms
302' engage a respective sampling head and the springs 304 apply a
biasing force to the block 303 which restrains the sampling head
from vertical movement. As with the embodiment of FIG. 38A, the
resilient arms 302' are configured to prevent one sampling head
that is slightly larger than other sampling heads from binding the
whole apparatus and preventing other sampling heads from being
locked in place.
[0192] Embodiments of the present invention are not limited to the
illustrated locking plates 185 of FIGS. 38A-38B. Locking plates
having different configurations may be utilized as well. In
addition, other ways of restraining sampling head movement may be
utilized (e.g., see U.S. Pat. No. 5,136,979 to Paul et al., which
is incorporated herein by reference in its entirety).
[0193] Movement of the locking plates 185 are illustrated in FIGS.
39A-39C. In FIG. 39A, a locking plate 185 is in an unlocked
position and the sampling head 162 is free to move vertically
within the aperture 300 of the locking plate 185 and the respective
apertures 186a, 187a in the upper and lower stationary plates 186,
187, as illustrated. In FIG. 39B, the locking plate is being moved
to the locked position (indicated by arrows A.sub.6) such that the
locking plate 185 pushes the sampling head 162 towards the upper
and lower stationary plates 186, 187. In FIG. 39C, the sampling
head 162 is wedged against the stationary upper and lower plates
186, 187 by the locking plate 185 such that vertical movement of
the sampling head 162 is restrained.
[0194] Referring now to FIG. 40, an exemplary sample tray 151
containing a plurality of sample receptacles 152 formed therein in
various arrays is illustrated. Each sample receptacle 152 is
configured to receive a sample of material extracted from a
respective egg, such as allantoic fluid. Sample trays having
various configurations and arrays of sample receptacles may be
utilized in accordance with embodiments of the present invention.
Sample trays may be formed from various materials and via various
techniques. The present invention is not limited to the illustrated
sample tray 150.
[0195] FIG. 41 is an enlarged partial plan view of the sample tray
of FIG. 40 illustrating material extracted from eggs dispensed
within respective sample receptacles of the sample tray. Material
extracted from eggs may be disposed within respective sample
receptacles 152 of a sample tray 150 according to various
dispensing patterns. For example, as illustrated in FIG. 41,
material from eggs from a particular flat can be disposed within
the first receptacle 152a in the first row of a grouping of
receptacles. Material from eggs in a subsequent flat can be
disposed in the second receptacle 152b in the first row, etc.
Dispensing patterns are preferably controlled via a controller
(e.g., PLC 70a of FIG. 12).
[0196] FIGS. 42A-42B are top plan views of the sample tray handling
system 150 according to embodiments of the present invention and
illustrating sample trays 151 being moved (indicated by arrows
A.sub.7) relative to (i.e., beneath) a sampling apparatus 160 of
FIG. 14. Because each sampling apparatus 160 of the illustrated
material extraction apparatus of FIG. 14 is fixed, the sample tray
handling system 150 is configured to move sample receptacles 152
beneath respective sampling heads 162 such that material extracted
from eggs can be dispensed within appropriate sample receptacles.
Once the sample receptacles 152 of a sample tray 151 have received
extracted egg material, the sample trays 151 are offloaded (either
manually or automatically) and the extracted egg material is
allowed to dry. Once a sample tray 151 is offloaded, the sample
tray handling system 150 moves back to receive a new sample tray
151 loaded by an operator.
[0197] Although not illustrated, a sanitizer system is preferably
provided with the illustrated material extraction apparatus 30 of
FIG. 14. For example, a sanitizer system may be operably associated
with the sampling heads 162 of each sampling apparatus 160 and
configured to pump sanitizing fluid through and around the outside
of the sample heads 162, including the elongated needles 165 and
needle passageways 164. For example, see the illustrated fountain
200 of FIG. 36D which is configured to apply sanitizing fluid to a
sample needle 165. Sanitizing fluid is preferably applied to each
portion of a sample head 162 that comes into contact with an egg
after depositing material extracted from an egg into a respective
sample receptacle 152 in the sample tray 150. Preferably, means for
drying each sample head 162, needle 165, and passageway 164 are
provided after sanitizing fluid has been applied thereto. For
example, a system for directing air at each sample head 162, needle
165, and passageway 164 may be provided. In the illustrated
embodiment of FIGS. 36A-36C, drying air is provided via nozzle
192.
[0198] Exemplary sanitizing fluid systems for providing sanitizing
fluid and which may be utilized in accordance with embodiments of
the present invention are described in U.S. Pat. No. 5,176,101, and
RE 35,973, which are incorporated herein by reference in their
entireties.
[0199] Embodiments of the present invention are not limited to the
illustrated material extraction apparatus 30 of FIG. 14, or to the
exact process described above. Each of the components (egg transfer
apparatus 130, egg cradle table 110, sampling apparatus 160, egg
flat conveyor systems 102, 104) may operate in various ways as long
as material extracted from an egg can be identified as coming from
that particular egg.
Assaying Station
[0200] Referring now to FIGS. 43-46, an assaying station 60 and
methods of using the assaying station 60 to determine
characteristics of eggs, according to embodiments of the present
invention, will now be described. The illustrated assaying station
60 is configured to process a plurality of sample trays containing
material extracted from eggs as described above in order to
determine one or more characteristics of the eggs.
[0201] Referring initially to FIGS. 43-44, a holding area 410 is
configured to receive and hold a plurality of sample trays
containing material extracted from a plurality of eggs for a
predetermined period of time. Each sample tray is then transferred
from the holding area 410 into the biosensor (e.g., yeast)
application area 420 where a biosensor is added to the sample
receptacles in each sample tray. Each sample tray then passes into
the color application area 430 where a color substrate (e.g., OPNG
substrate) is added to the sample receptacles in each sample tray.
Broadly speaking, a biosensor and a color substrate are added to
the dried material (e.g., allantoic fluid) extracted from an egg to
cause a chemical reaction that can change the color of the dried
material based upon a characteristic (e.g., gender) of an egg.
After a predetermined period of time, each sample tray is
transferred 440 to the "read" area 450 and the color of the
material in each sample receptacle is analyzed to determine the
characteristic. For example, if the characteristic to be determined
is gender, the material extracted from a female egg may have a
color that is easily distinguishable from that of a male egg.
Before a sample tray is disposed of, it is preferable to destroy
the biosensor via the decontamination area 460.
[0202] According to embodiments of the present invention, the
assaying station 60 is particularly adaptable to determine gender
of eggs. An operator loads a plurality of sample templates
containing material (e.g., allantoic fluid) extracted from eggs
into the assaying station 60. Within the assaying module 60, each
sample template is moved via a conveyor system beneath a dispensing
head which dispenses a predetermined amount (e.g., about 75 .mu.l)
of reagent (e.g., a LiveSensors.TM. brand cell-based biosensor,
LifeSensors, Inc., Malvern, Pa.) into each respective sample
receptacle. Each sample template then progresses through an
environmentally-controlled chamber for a predetermined period of
time (e.g., about 3.5 hours). Each sample template is moved via a
conveyor system beneath another dispensing head which dispenses a
predetermined amount of a color substrate (e.g., ONPG-based
substrate) into each sample receptacle. Each sample template then
progresses through an environmentally-controlled chamber for a
predetermined period of time (e.g., about 45 minutes) to allow
color development within each well.
[0203] The LiveSensors.TM. brand cell-based biosensor is utilized
to detect estrogenic compounds in allantoic fluid. An exemplary
LiveSensors.TM. brand cell-based biosensor is a genetically
modified yeast transformed with yeast expression vector for the
human estrogen receptor, the reporter gene that contains promoter
with estrogen response elements coupled with E. coli
.beta.-galactosidase. In the presence of estrogens, the estrogen
receptor binds to the estrogen response elements and initiates
transcription of the reporter gene. The concentration of estrogens
in the allantoic fluid is correlative with the level of induction
of the reporter gene. The activity of the reporter gene product,
B-galactosidase, is measured using an ONPG-based substrate, which
yields a yellow calorimetric signal. LiveSensors.TM. brand
cell-based biosensor can detect femtomolar levels of estrogens. The
strain of yeast of the LiveSensors.TM. brand cell-based biosensor
is comprised of the same strain commonly used in the baking
industry, Saccharomyces cerevisiae. The LiveSensors.TM. brand
cell-based biosensor can distinguish between male and female
embryos using only about four microliters (4 .mu.l) of allantoic
fluid.
[0204] Specifically, the extracted allantoic fluid contains
estradiol conjugates which are cleaved by an enzyme (glucuronidase)
secreted by the yeast during an initial allantoic fluid/yeast
sensor incubation. The presence of "free" estradiol readily induces
the reporter gene system within the yeast to produce
Beta-galactosidase. The Beta-galactosidase then reacts with an
ONPG-based substrate, added after the allantoic fluid/yeast sensor
incubation, to generate a color signal.
[0205] According to alternative embodiments of the present
invention, the yeast may be induced to secrete GFP instead of
Beta-Gal, which is fluorescent by itself and doesn't require the
addition of a calorimetric substrate.
[0206] The color of the material in each sample receptacle can be
determined in various ways. One technique may include illuminating
the extracted material with a white light and using a CCD (charge
coupled device) camera that scans each sample receptacle and
electronically filters out all color signals but the specific color
signal (e.g., yellow, pink, etc.) that identifies a gender (e.g.,
females). Preferably, each sample tray is transparent and the
extracted material within each sample tray is illuminated from
below. A CCD camera may be configured to count the number of pixels
of a color in a respective sample receptacle to determine if the
pixel number exceeds a certain threshold. If so, the CCD camera can
output a digital signal signifying a female at that location. This
information is stored via a data processor on the network.
[0207] FIG. 45 depicts an assay conducted with a LiveSensors.TM.
brand cell-based biosensor for various amounts of allantoic fluid
(i.e., 4, 10, 20 .mu.l). The intensity of the color (e.g., yellow)
as measured in pixels by a CCD camera is indicated under each
sample receptacle. As illustrated, females have a greater yellow
color intensity than males.
[0208] According to embodiments of the present invention, the
reagent (e.g., a LiveSensors.TM. brand cell-based biosensor) within
each well is then destroyed (e.g., via heat and/or via chemical
treatment) in the decontamination area 460 prior to disposal of
each sample template.
[0209] According to embodiments of the present invention utilizing
a LiveSensors.TM. brand cell-based biosensor, a sample of material
such as allantoic fluid withdrawn from an egg may contain upwards
of about twenty percent (20%) blood contamination. Moreover, the
incubation temperature may fluctuate by about five degrees
Centigrade (.+-.5.degree. C.), and sample incubation times can
fluctuate by thirty minutes or more. In addition, samples withdrawn
from eggs can be held for certain periods of time (e.g., over
night) prior to initiating assaying procedures according to
embodiments of the present invention.
[0210] Another technique may involve illuminating the extracted
material with a white light and utilizing an array of photodiodes
with color filters. Each photodiode will output a signal based on
the intensity of the color it sees.
[0211] Embodiments of the present invention are not limited to the
yeast-based assaying techniques. Moreover, embodiments of the
present invention are not limited to identifying gender of eggs.
Various assaying techniques may be utilized for analyzing material
extracted from eggs to identify various characteristics (e.g.,
gender, pathogen content, genetic markers related to bird health or
performance) of eggs. For example, antibody-based systems and
methods (e.g., commercial pregnancy testing systems and methods)
may be utilized to detect estrogen in egg material. Moreover,
antibody-based systems may be utilized to detect pathogens (e.g.,
salmonella and Marek's disease). As another example, PCR (polymer
chain reaction) analysis may be utilized to detect the
presence/absence of W chromosomes in egg material. Moreover, PCR
analysis may be utilized to detect various genetic traits/flaws in
egg material. Accordingly, assaying modules may be provided that
facilitate pathogen detection and genetic analysis of avian
eggs.
[0212] Referring now to FIG. 46, an assaying station apparatus 60,
according to embodiments of the present invention, that is
configured to assay material extracted from eggs contained within
sample receptacles in a plurality of sample trays 151 is
illustrated. The illustrated apparatus 60 includes a plurality of
chambers or areas that are connected via conveyor systems that are
configured to transport sample trays sequentially through the
areas. Preferably, the areas are maintained at predetermined
temperature and humidity levels. Additional environmental controls
may be utilized as well. For example, air can be exhausted from the
apparatus 60 via fan 416 at a designated flow rate, and may be
filtered via a HEPA ("high efficiency particulate arresting")
filtration system.
[0213] As illustrated in FIG. 46, a plurality of sample trays 151
are loaded from a cart 405 into the holding area 410. The holding
area 410 includes a first endless conveyor system 411 that is
configured to transport a plurality of sample trays in spaced-apart
relationship upwardly to the biosensor application area 420 within
a predetermined period of time. At the top of the holding area,
each uppermost sample tray on the first endless conveyor system is
pulled into the biosensor application area 420 and beneath
dispensers (not shown) configured to dispense a biosensor (e.g.,
yeast) into the respective sample receptacles of the sample
tray.
[0214] After a biosensor has been dispensed into the sample
receptacles of a sample tray, the sample tray is conveyed by a
second endless conveyor system 412 downwardly towards a color
substrate application area 430. At the bottom of the second endless
conveyor system 412, each lowermost sample tray is pulled into the
color substrate application area 430 and beneath dispensers (not
shown) that are configured to dispense a color substrate (e.g.,
ONPG-based substrate) into the respective sample receptacles of the
sample tray.
[0215] After a color substrate has been dispensed into the sample
receptacles of a sample tray, the sample tray is conveyed by a
third endless conveyor system 413 downwardly towards a reading area
450. At the bottom of the third endless conveyor system 413, each
lowermost sample tray is pulled into the reading area 450 and
beneath one or more CCD cameras 415 that are configured to "read"
the color of extracted material in each sample receptacle as
described above. The biosensor in each sample receptacle is then
destroyed by dispensing a chemical thereinto via dispensing head
417.
Treatment Station
[0216] The treatment station 40 of the illustrated embodiment of
FIG. 11 may be configured to selectively treat eggs in any desired,
suitable manner. It is particularly contemplated that the treatment
station 40 inject live eggs with a treatment substance. As used
herein, the term "treatment substance" refers to a substance that
is injected into an egg to achieve a desired result. Treatment
substances include but are not limited to vaccines, antibiotics,
vitamins, virus, and immunomodulatory substances. Vaccines designed
for in ovo use to combat outbreaks of avian diseases in hatched
birds are commercially available. Typically, the treatment
substance is dispersed in a fluid medium, (e.g., is a fluid or
emulsion) or is a solid dissolved in a fluid, or a particulate
dispersed or suspended in a fluid.
[0217] A preferred treatment station 40 for use in accordance with
embodiments of the present invention is the INOVOJECT.RTM.
automated injection system (Embrex, Inc., Research Triangle Park,
N.C.). However, any in ovo injection device capable of being
operably connected, as described herein, to a controller is
suitable for use according to embodiments of the present invention.
Suitable injection devices preferably are designed to operate in
conjunction with commercial egg carrier devices or flats, examples
of which are described above.
Sorting Followed by Treatment
[0218] Referring to FIGS. 47-51, sorting and transferring of eggs
1' prior to treatment, according to embodiments of the present
invention, are illustrated. Referring initially to FIG. 47, a
sorting station 500 includes an endless conveyor system 502 and a
pair of transfer heads 504, 506 operably associated therewith. Eggs
with identified characteristics (e.g., gender) are placed on the
conveyor system 502 at one end 502a thereof in flats or other
holding containers and are moved along the conveyor system in the
direction indicated by arrow A.sub.8. Transfer head 504 includes an
array of vacuum cups 137 as described above with respect to FIGS.
27-29 that are configured to simultaneously lift a plurality of
eggs from the conveyor system 502 and place the eggs on a first
conveyor belt 508 (FIG. 48). Transfer head 506 includes an array of
vacuum cups 137 that are configured to simultaneously lift a
plurality of eggs from the conveyor system 502 and place the eggs
on a second conveyor belt 510 (FIG. 48).
[0219] Each transfer head 504, 506 may be configured to selectively
lift eggs from the conveyor system 502 based upon characteristics
of the eggs (e.g., gender). For example, transfer head 504 may be
configured to only lift male eggs, while transfer head 506 is
configured to only lift female eggs. Transfer heads 504, 506 and
conveyor system 502 are preferably under computer control (e.g.,
PLC 70c of FIG. 12).
[0220] As illustrated in FIG. 48, the transfer heads 504, 506 are
configured to move in the direction indicated by arrows A.sub.9
such that eggs can be placed on respective conveyor belts 508, 510.
The direction of travel of conveyor belts 508, 510 is also
indicated by arrows A.sub.9.
[0221] Referring now to FIG. 49, each conveyor belt 508, 510 is
operably associated with a respective backfill apparatus 520. Each
backfill apparatus 520 is configured to orient and hold eggs in a
predetermined position for processing (e.g., injection, etc.). Each
illustrated backfill apparatus 520 includes an endless conveyor 522
which has a plurality of parallel rollers 524 which are rotatably
connected at their ends with a drive mechanism (e.g., chains,
etc.). The rollers 524 move in the direction indicated by arrows
A.sub.9 while also rotating in the clockwise direction as viewed
from FIG. 51. Under the effect of the movement and rotation of the
rollers 524, eggs 1' travel along the direction indicated by arrow
A.sub.9 (with their narrow ends generally perpendicular to the
direction of travel indicated by arrow A.sub.9) and are fed into
respective channels 528 and then into respective receiving cups 530
with their narrow ends pointing downwards, as illustrated in FIG.
51. The receiving cups 530 are mounted on an endless conveyor
system 540 that moves the cups in the direction indicated by arrows
A.sub.9. An exemplary backfill apparatus 520 is described in U.S.
Pat. No. 3,592,327, which is incorporated herein by reference in
its entirety.
[0222] Each receiving cup 530 transports a respective egg 1' to a
treatment station 40, such as the INOVOJECT.RTM. automated
injection system. For example, in the illustrated embodiment of
FIG. 49, eggs 1' within respective receiving cups 530 are
transported through respective treatment and transfer stations 40,
50. Each treatment station 40 contains a set of injection delivery
devices that are configured to inject a substance into eggs 1'. A
transfer station 50 is provided downstream of each treatment
station 40 and is configured to transfer eggs 1' into respective
baskets (not shown).
[0223] Backfill apparatus according to embodiments of the present
invention may have various configurations, and are not limited to
the illustrated embodiments. Backfill apparatus may include
different numbers of channels and may include receiving cups of
varying sizes and/or configurations. Moreover, various types of
rollers and conveyor systems may be utilized without
limitation.
Treatment Followed by Sorting
[0224] Referring to FIG. 52, treatment and sorting/transfer
stations 40, 50 according to other embodiments of the present
invention are illustrated. As a flat 7 of post-sampled eggs 1' is
conveyed through the treatment station 40, the controller 20 (FIG.
11) selectively generates an injection signal to the treatment
station 40 to inject those eggs 1' which have been identified as
having a particular characteristic. As will be apparent to those
skilled in the art, generation of a selective injection signal may
be achieved by various approaches, including generating a signal
that causes the injection of selected eggs, or generating a signal
that prevents the injection of non-selected eggs.
[0225] In the illustrated embodiment, a pair of injection stations
41, 42, such as the INOVOJECT.RTM. automated injection system, are
employed. The first injection station 41 contains a first set of
injection delivery devices that are configured to inject a
substance into eggs 1' identified as having a first characteristic.
The second injection station 42 contains a first set of injection
delivery devices that are configured to inject a substance into
eggs 1' identified as having a second characteristic. For example,
if gender is the identified characteristic, the first injection
station 41 can inject a vaccine or other substance into male eggs,
and the second injection station 42 can inject a vaccine or other
substance into female eggs.
[0226] A sorting/transfer station 50 may be provided downstream of
the treatment station 40. The controller 20 generates a selective
removal signal to cause the sorting/transfer station 50 to remove
eggs having various identified characteristics (e.g., gender). The
sorting/transfer station 50 may employ suction-type lifting devices
as described above with respect to the lifting heads 132, 134 of
the material extraction apparatus 30. Any other suitable means for
removing the eggs may be used as well, such apparatus being known
to those of ordinary skill in the art.
[0227] In the illustrated embodiment, eggs identified according to
gender are sorted. Male eggs are transferred from egg flats 7 to
respective baskets 51 and female eggs are transferred from egg
flats 7 to respective baskets 52. Any non-live eggs may be left in
the egg flats 7 for subsequent processing or disposal.
[0228] The sorting/transfer station 50 preferably operates
automatically and robotically. Alternatively, selected eggs may be
identified on the operator interface 22, optionally marked, and
removed by hand.
[0229] According to embodiments of the present invention, eggs may
be sorted based on viability, pathogen content, and/or genetic
analysis. For example, eggs that contain pathogens can be pulled
out of the normal population and not transferred to the hatcher,
thereby preventing horizontal transmission of disease agents.
Information Collection
[0230] Systems according to embodiments of the present invention
can provide valuable information to those in the poultry industry.
For example, identification and compilation of classes of embryonic
mortality can provide feedback on breeder flock management, egg
handling and incubation conditions. Knowledge of number of viable
eggs and sex can provide an accurate prediction of product and
streamline and optimize logistics. Identification of pathogen
detection and compilation of data can help manage disease.
Identification of genetic markers can be utilized by breeders.
Identification of nutritional elements within the egg can be used
to optimize feeding diets and regimes. Identification of proteins
or small molecules can be used to track or predict or optimize
performance or immunity. In addition, one could use information
from embodiments of the present invention to track egg constituents
and then relate them to bird performance and use this information
for product development.
Material Extraction/Assaying Combination
[0231] According to embodiments of the present invention, a
material extraction station may be configured to perform various
assaying techniques for determining characteristics of eggs. FIGS.
53-54 illustrate a module 600 that is configured to attach to the
material extraction apparatus 30 of FIG. 14. An exemplary module
600 for assaying material in accordance with embodiments of the
present invention, and specifically using the competitive antibody
assay procedure described below, is manufactured by Luminex
Corporation, Austin, Tex.
[0232] The illustrated module 600 is configured to pull small
samples of material extracted from eggs out of respective sample
receptacles and feed them into a reader system for analysis.
Preferably, a sample tray 151 having a plurality of sample
receptacles 152 that contain material extracted from eggs is fed
into the illustrated module 600 from the sample tray handling
system 150.
[0233] A competitive antibody assay procedure is utilized by the
module 600 and is based on antibody coupled to internally dyed
"beads". The illustrated module 600 may be configured to handle any
number if sample trays 151 at a time. For each sample tray 151, the
module 600 includes a liquid handler that is configured to pull
small samples from respective sample receptacles in a sample tray
151 and feed them into a reader system.
[0234] Specifically, if allantoic fluid is the material that has
been extracted from eggs, the module 600 takes allantoic fluid and
mixes it with polystyrene microspheres, or beads (available from
Luminex, Inc., Austin, Tex.) which are coupled to estradiol
molecules. Fluorescently-labeled anti-estradiol antibody is added
to the bead/allantoic fluid mixture and mixed. This mixture is then
incubated at room temperature in the dark for 15-30 minutes. An
amount of the mixture (e.g., 50 .mu.l-60 .mu.l) is withdrawn and
the assay results are provided by an analyzer (Luminex, Inc.,
Austin, Tex.) which utilizes lasers to detect a fluorescent
signal.
[0235] This assay procedure is based on competitive inhibition. A
competition for the fluorescently labeled anti-estradiol antibody
is established between the estradiol coupled to the beads and the
estradiol in the allantoic sample. If the allantoic sample is from
a female embryo and contains estradiol, the estradiol in the sample
will compete for the fluorescently tagged antibody and less
antibody will bind to the beads. The assay signal, dependent upon
the amount of antibody bound to the beads, will be lower from a
female-derived sample (inhibition of fluorescent signal). If the
allantoic sample is from a male embryo and does not contain
estradiol, there will be much less competition from estradiol in
the sample and more beads will have the antibody bound. The more
antibody bound to the beads, the higher the signal.
[0236] According to embodiments of the present invention, coupled
beads and antibody may be already present within sample receptacles
of a sample tray. By eliminating the additional steps of adding
beads and antibody with extracted allantoic fluid, assaying time
may be decreased, which may be commercially advantageous.
[0237] Referring to FIG. 54, the illustrated module 600 includes a
template handling system 602, a high throughput reader system 604
for analyzing samples, controls 606, and a fluid supply and drain
system 608.
[0238] The foregoing is illustrative of the present invention and
is not to be construed as limiting thereof. Although a few
exemplary embodiments of this invention have been described, those
skilled in the art will readily appreciate that many modifications
are possible in the exemplary embodiments without materially
departing from the novel teachings and advantages of this
invention. Accordingly, all such modifications are intended to be
included within the scope of this invention as defined in the
claims. Therefore, it is to be understood that the foregoing is
illustrative of the present invention and is not to be construed as
limited to the specific embodiments disclosed, and that
modifications to the disclosed embodiments, as well as other
embodiments, are intended to be included within the scope of the
appended claims. The invention is defined by the following claims,
with equivalents of the claims to be included therein.
* * * * *