Blade portioner calibration

Abstract

Calibrating the operation of a cutter used in a portioning system to cut workpieces into portions, wherein the work- piece is carried along a driven conveyance device past a scanner and then to a cutting apparatus. The calibration method employs a correction algorithm to correct for vari- ables or limitations in the condition of one or more com- ponents of the portioning system and/or variations or limi- tations in the operation or operational capabilities of the portioning system. The correction algorithm may also factor in the physical condition, configuration, or composition of the workpieces being portioned, as well as whether the workpieces move on the conveyance device prior to and/or during the portioning operation.

The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows: 
     
       1. A method for calibrating a cutting system for cutting variable-sized food workpieces into portions of selected physical parameters prior to operating the cutting system on a production basis, the cutting system having a conveyance device for conveying variable-sized sample food workpieces past a scanner used to physically characterize the variable-sized sample food workpieces and then to a cutting device to cut the variable-sized sample food workpieces into portions, the method calibrating the time span between when the variable-sized sample food workpieces are scanned by the scanner and the cutting of the variable-sized sample food workpieces with the cutting device, the method comprising:
 prior to the operation of the cutting system to cut variable-sized food workpieces on a production basis:
 a. scanning variable-sized sample food workpieces at a scanner while being transported on a conveyance device to produce data related to the physical condition and/or physical configuration and/or the physical composition of the variable-sized sample food workpieces; 
 b. thereafter using the data from the scanner to physically characterize the scanned variable-sized sample food workpieces as well as the portions to be cut from the variable-sized sample food workpieces based on one or more selected physical parameters; 
 c. thereafter portioning the representative variable-sized sample food workpieces using the cutting device in accordance with the one or more selected physical parameters while being transported on the conveyance device; 
 d. physically measuring the cut portions for compliance with the one or more selected physical parameters; 
 e. determining the variance between the one or more selected physical parameters of the cut portions as determined by the scanner and as physically measured; 
 f. adjusting the calibration of the cutting device by adjusting the time span between the scanning of the representative variable-sized sample food workpieces and operation of the cutting device without altering the speed of the conveyance device, based on the variance of the one or more selected physical parameters of the cut portions as determined by the scanner and as physically measured; and 
 
 g.thereafter during the operation of the cutting system to cut variable-sized food workpieces on a production basis maintaining the adjusted calibration of the cutting systemduring the subsequent cutting of the food workpieces on a production basis. 
 
     
     
       2. The method according to  claim 1 , wherein the one or more selected physical parameters are the weight of the portions cut from the variable-sized sample food workpiece. 
     
     
       3. The method according to  claim 2 , further comprising using a weight correction algorithm to correct for variations between the scanned weight of a portion cut from a variable-sized sample food workpiece and the physically measured weight of the cut portion. 
     
     
       4. The method according to  claim 3 , wherein the weight correction algorithm considers one or more physical specifications of the variable-sized sample food workpiece that are other than the measured weight of the variable-sized sample workpieces. 
     
     
       5. The method according to  claim 4 , wherein the weight correction algorithm considers one or more physical specifications of the variable-sized sample food workpiece selected from the group consisting of the length of the variable-sized sample food workpiece, the width of the variable-sized sample food workpiece, the maximum height of the variable-sized sample food workpiece, the length of each portion to be cut from the variable-sized sample food workpiece, the distance along length of the portion to be cut from the variable-sized sample food workpiece from the front of the variable-sized sample food workpiece to the location along the variable-sized sample food workpiece wherein the portioning cut is being made, variations in the thickness of the variable-sized sample food workpiece, and the temperature of the variable-sized sample food workpiece, the position of the skin of the sample food workpiece relative to the top of the food workpiece, and the condition of an edge of the sample food workpiece. 
     
     
       6. The method according to  claim 3 , wherein the weight correction algorithm corrects for one or more of:
 the density of the variable-sized sample workpiece, the length of the variable-sized sample food workpiece, and the distance along the variable-sized sample food workpiece at which a cut of the variable-sized sample food workpiece is being made; 
 the density of the variable-sized sample food workpiece based on the height of the portion being cut by the cutting device; 
 the volume of the variable-sized sample food workpiece, the length of the variable-sized sample food workpiece, and the distance along the variable-sized sample food workpiece at which a cut of the variable-sized sample food workpiece is being made; 
 the volume of the variable-sized sample food workpiece based on the height of the portion being cut by the cutting device; 
 the delay between the scanning of the variable-sized sample food workpiece and the operation of the cutting device, the delay is based on the overall length of the variable-sized sample food workpiece and the distance along the variable-sized sample food workpiece at which a cut of the variable-sized sample food workpiece is being made. 
 
     
     
       7. Calibrating a cutting system for cutting workpieces into portions as the workpiece is carried along a driven conveyance device, the calibration occurring prior to the production operation of the cutting system, comprising:
 prior to operating the cutting system to cut workpieces on a production basis: 
 (a) determining the position of a representative non-production sample workpiece on a driven conveyance device; 
 (b) physically characterizing the representative non-production sample workpiece; 
 (c) based on the results of physically characterizing the representative non-production sample workpiece, operating a cutter to cut the representative non-production sample workpiece into portions which are carried along on the driven conveyance device; and 
 (d) calibrating the cutting system to adjust the time span required for the non-production sample workpiece to travel on the conveyance device between the determined position of the representative non-production sample workpieces on the conveyance device and the operation of the cutter without altering the speed of the conveyance device based on one or more of:
 (i) variables or limitations in the condition of one or more components of the cutting system and/or in the operation or operational capabilities of the cutting system; 
 (ii) the physical condition and/or physical configuration and/or physical composition of the representative non-production sample workpiece; 
 (iii) the movement of the representative non-production sample workpiece relative to the conveyance device prior to and/or during the operation of the cutter; and 
 
 (iv)(e) maintaining the calibration of the cutting system during the production cutting of the workpieces. 
 
     
     
       8. Calibrating a cutting system according to  claim 7 , wherein the variations or limitations in the condition of components of the cutting system and/or the operation or operational capabilities of the cutting system include one or more variables selected from the group consisting of comprising:
 (i) variations in the speed of the conveyance device; 
 (ii) variations in the speed at which the conveyance device is driven; 
 (iii) whether the conveyance device is of continuous construction or composed of a plurality of sections or segments; and 
 (iv) inaccuracies in determining, or limitation in being able to determine, the position of the representative non-production sample workpiece on the conveyance device. 
 
     
     
       9. Calibrating a cutting system according to  claim 7 , wherein the physical condition and/or configuration and/or composition of the workpieces is selected from the group consisting of:
 (i) the type of representative non-production sample workpiece; 
 (ii) if a representative non-production sample workpiece is a food product, the type of food product; 
 (iii) if the representative non-production sample workpiece is meat, the type of meat; 
 (iv) the length of the representative non-production sample workpiece; 
 (v) the thickness of the representative non-production sample workpiece; 
 (vi) the condition of the perimeter of the representative non-production sample workpiece; 
 (vii) the condition of the leading edge of the representative non-production sample workpiece; 
 (viii) variations in the thickness of the representative non-production sample workpiece; 
 (ix) variations in the height of the top surface of the representative non-production sample workpiece; 
 (x) the temperature of the representative non-production sample workpiece; 
 (xi) the density of the representative non-production sample workpiece; 
 (xii) if the representative sample non-production workpiece is meat, the extent of marbling of the meat; and 
 (xiii) if the representative non-production sample workpiece is meat, the extent of fat within the meat; 
 (xiv) the position of the skin of the non-production sample workpiece relative to the top of the non-production sample workpiece; and 
 (xv) the condition of an edge of the non-production sample workpiece. 
 
     
     
       10. Calibrating a cutting system according to  claim 7 , wherein the movement of the representative non-production sample workpiece relative to the conveyance device is caused by one or more of the following:
 (i) the speed at which the representative non-production sample workpiece is carried along by the driven conveyance device is not uniform; 
 (ii) the conveyance device vibrates the representative non-production sample workpiece as the representative non-production sample workpiece is being carried along by the conveyance device; 
 (iii) the speed at which the cutter cuts the representative non-production sample workpiece; 
 (iv) the sharpness of the cutter; 
 (v) whether the representative non-production sample workpiece transfers from one section of a conveyance device to another; 
 (vi) the angle of cut of the cutter into the representative non-production sample workpiece; and 
 (vii) the number of portions cut from the representative non-production sample workpiece. 
 
     
     
       11. Calibrating a cutting system according to  claim 7 , wherein the position of the representative non-production sample workpiece on the conveyance device is determined by a scanning device. 
     
     
       12. Calibrating a cutting system according to  claim 11 , wherein the limitation in the operation of the cutting system comprises a limitation in the accuracy of the scanning device. 
     
     
       13. Calibrating a cutting system according to  claim 7 , wherein the representative non-production sample workpieces are physically characterized with a scanning device. 
     
     
       14. Calibrating a cutting system according to  claim 13 , wherein the limitation in the operation of the cutting system comprises a limitation in the accuracy of the scanning device. 
     
     
       15. Calibrating a cutting system according to  claim 13 , wherein the limitation of the components of the cutting system comprises limitations in the optical capabilities of the scanning device. 
     
     
       16. Calibrating a cutting system according to  claim 7 , wherein the cutting system is calibrated by using the cutting system to cut representative non-production sample workpieces into two equal weights as the representative non-production sample workpieces travel on the conveyance device without altering the speed of the conveyance device, weighing the cut halves, and adjusting the timing of the operation of the cutter based on deviations of the cut halves from being of equal weight. 
     
     
       17. Calibrating a cutting system according to  claim 7 , comprising:
 cutting representative non-production sample workpieces into a series of portions, 
 weighing the portions in the order in which the portions were cut; and 
 based on the variations in the weights of the portions cut, adjusting the timing of the operation of the cutter. 
 
     
     
       18. Calibrating a cutting system according to  claim 7 , wherein the cutting system is calibrated with the use of a weight correction algorithm taking into consideration one or more physical characteristics of the representative non-production sample workpiece. 
     
     
       19. Calibrating a cutting system according to  claim 18 , wherein the weight correction algorithm can be expressed as:
 a delay correction for each workpiece to correct a delay between the physical characterization of the representative non-production workpiece and the subsequent operation of the cutter; 
 a correction of the volume of the representative non-production sample workpiece for each portion cut from the representative non-production sample workpiece; 
 a correction of the density of the representative non-production sample workpiece for each portion cut from the representative non-production sample workpiece; and 
 a correction for the height for the representative non-production sample workpiece for each cross-sectional cut made in the representative non-production sample workpiece. 
 
     
     
       20. Calibrating a cutting system according to  claim 7 , wherein the cutting system is calibrated using a weight correction algorithm employing as variables one or more causes of movement of the representative non-production sample workpiece on the conveyance device. 
     
     
       21. Calibrating a cutter system for cutting variable-sized workpieces into portions of one or more physical parameters by first cutting a variable-sized sample workpiece into portions as the representative variable-sized sample workpiece is carried along a driven conveyance device prior to the operation of the cutter system on a production basis, wherein the representative variable-sized sample workpiece is scanned while traveling on the conveyance device at a constant speed with the scanner at a location along the conveyance device, and then the representative variable-sized sample workpiece is cut into portions by a cutter positioned downstream from the scanning device while traveling on the conveyance device, a calibration method comprising, prior to the operation of the cutter system on a production basis, adjusting the time delay period occurring between the scanning of the representative variable-sized sample workpiece and the subsequent operation of a cutter without altering the speed of the conveyance device to accommodate variations in the physical condition of the cutter system components and limitations in the operation or operational capabilities of the cutter system, whereby the adjusted time delay is used during the subsequent production cutting of the workpieces, including with changes occurring to the belt speed for throughput purposes. 
     
     
       22. Calibrating a cutter system according to  claim 21 , wherein the variations in the physical condition of one or more components of the cutter system and/or one or more limitations in the operation or operational capabilities of the cutter system include one or more variables selected from the group consisting of comprising:
 (i) variations in the speed of the conveyance device; 
 (ii) variations in the speed at which the conveyance device is driven; 
 (iii) whether the conveyance device is composed of a unitary conveyance length or composed of a plurality of conveyance length sections; and 
 (iv) inaccuracies in determining the position of the workpiece on the conveyance device via the scanner. 
 
     
     
       23. A method of calibrating a rotary cutter system for cutting variable-sized workpieces into portions of desired physical parameters by first cutting a representative variable-sized sample workpiece into portions as the representative variable-sized sample workpiece is carried along a driven conveyance device prior to operating the rotary cutter system on a production basis to cut workpieces, the rotary cutter system comprising a scanner for scanning the repreentative variable-sized sample workpiece being conveyed on the conveyance device and a rotary cutter positioned downstream from the scanner to cut the representative variable-sized sample workpieces while being carried by the conveyance device into portions, the scanner being in position along the conveyance device, the method comprising, prior to the operating of the rotary cutter system on a production basis, calibrating the rotary cutter system by:
 adjusting the time delay period occurring between the scanning of the representative variable-sized sample workpiece and the subsequent operation of the rotary cutter without adjusting the speed of the conveyance device; and 
 using a weight adjustment algorithm employing one or more variables to accommodate the physical condition, configuration, and/or composition of the representative variable-sized sample workpiece, whereby the adjusted time delay period is used during the subsequent cutting of the workpieces by the rotary cutter system on a production basis, including with changes occurring to the belt speed for throughput purposes. 
 
     
     
       24. The calibration method according to  claim 23 , wherein the weight adjustment algorithm utilizes one or more factors pertaining to the physical condition, configuration and/or composition of the representative variable-sized sample workpiece selected from the group consisting of:
 (i) the type of representative variable-sized sample workpiece; 
 (ii) if the representative variable-sized sample workpiece is a food product, the type of food product; 
 (iii) if the representative variable-sized sample workpiece is meat, the type of meat; 
 (iv) the length of the representative variable-sized sample workpiece; 
 (v) the width of the representative variable-sized sample workpiece 
 (vi) the thickness of the representative variable-sized sample workpiece; 
 (vii) the condition of the perimeter of the representative variable-sized sample workpiece; 
 (viii) the condition of the leading edge of the representative variable-sized sample workpiece; 
 (ix) variations in the thickness of the representative variable-sized sample workpiece; 
 (x) variations in the height of the top surface of the representative variable-sized sample workpiece; 
 (xi) the temperature of the representative variable-sized sample workpiece; 
 (xii) the density of the representative variable-sized sample workpiece; 
 (xiii) if the representative variable-sized sample workpiece is meat, the extent of marbling of the meat; and 
 (xiv) if the representative variable-sized sample workpiece is meat, the extent of fat within the meat; 
 (xv) the position of the skin of the variable-sized sample workpiece relative to the top of the variable-sized sample workpiece; and 
 (vi) the condition of an edge of the variable-sized sample workpiece. 
 
     
     
       25. The method of  claim 1 , comprising maintaining the adjusted calibration of the cutting system during the subsequent cutting of the food workpieces on a production basis, including with changes occurring to the belt speed for throughput purposes. 
     
     
       26. Calibrating a cutting system according to  claim 7 , comprising maintaining the calibration of the cutting system during the production cutting of the workpieces including with changes occurring to the belt speed for throughput purposes.