WO2021242737A1

WO2021242737A1 - Separator device for separating debris from newly hatched chicks

Info

Publication number: WO2021242737A1
Application number: PCT/US2021/034024
Authority: WO
Inventors: Michael MAHON; Jon THEURER; Shashank PATIL
Original assignee: Hatchery Planning Inc
Current assignee: Hatchery Planning Inc
Priority date: 2020-05-27
Filing date: 2021-05-25
Publication date: 2021-12-02
Anticipated expiration: 2022-11-27

Abstract

A separator device includes conveyor loop (300) extending in a conveyance direction (310), and including interlocking conveyor sections (320) each extending perpendicularly to the conveyance direction (310) and defining a width of the conveyor loop (300). The conveyor sections (320) interlock to form a substantially continuous planar surface (330), at least through a conveyance zone (340), and each conveyor section (320) defines perforations (350) extending therethrough. A suction hood (400) opposite the conveyance zone (340) and spaced apart from the planar surface (330), is arranged to impart a suction to the conveyance zone (340). A plenum (600) is disposed within the conveyor loop (300) and has a plenum outlet (610) disposed adjacent to the inner surface (360) of the conveyor loop (300) within the conveyance zone (340). The plenum (600) is arranged to cooperate with the conveyor loop (300) to direct air drawn by the suction through the perforations (350) of the conveyor sections (320) from the plenum outlet (610) to be substantially evenly distributed across the width of the conveyor loop (300).

Description

SEPARATOR DEVICE FOR SEPARATING DEBRIS FROM NEWLY HATCHED CHICKS

BACKGROUND

Field of the Disclosure

Aspects of the present disclosure relate to poultry processing and, more particularly, to a separator device for separating hatching debris such as eggshell remnants, feather down, and/or broken egg yolk from newly hatched chicks.

Description of Related Art

High volume poultry processing operations implement various machinery to handle the poultry through various life stages. One such piece of machinery, for example, implements a servo-controlled rotary drum that receives just-hatched chicks from a hatchery operation and spreads the chicks onto a shaker bed to remove larger hatchery debris such as larger shell pieces. The chicks are then transferred to a conveyor such that the live chicks can be conveyed to be counted and packed for subsequent distribution. The just-hatched chicks received by the conveyor, in some instances, may still have debris such as eggshell fragments, feather down, and/or broken egg yolk associated therewith, whether the debris remain on the chicks or is deposited along with the chicks on the conveyor. The machinery may thus implement an arrangement for separating the debris from the chicks such that the chicks, substantially free of debris, are transported to the counting and packing operation.

A schematic of an example piece of machinery, including a chick-shell separator, is shown in FIG. 1. Such a chick-shell separator generally implements a conveyor for conveying the chicks from the hatchery for subsequent processing. Disposed along the conveyance path is a suction hood for suctioning or vacuuming the eggshell fragments, feather down, and or broken egg yolk from the chicks as the chicks are transported under the suction hood by the conveyor. Due to the suction/vacuum imparted by the suction hood of some prior art chick-shell separators, the conveyor of those prior art chick-shell separators generally comprises an open structure conveyor belt formed from metallic (e.g., steel or stainless steel) belt components (see, e.g.,

FIGS. 2A and 2B). The open structure of the conveyor belt allows air flow to pass through the belt to help dislodge the debris from the chicks for removal by the suction hood, and also allows for some debris to fall through the conveyor belt for separation of the debris by gravity. Without the open structure of the conveyor belt, the suction hood would tend to draw air flow from space between the suction hood and the conveyor belt, particularly where the conveyor belt enters and exits the coverage area of the suction hood, resulting for example in densification of the chicks on the conveyor belt under the hood. In certain instances, the chicks could also be lifted from the conveyor belt by the suction hood.

However, newly-hatched chicks are relatively fragile, being prone to physical injury possibly resulting in permanent disfigurement or mortality, but also at risk for stress-related mortality, if not carefully handled. In this regard, prior art open structure conveyor belt expose chicks to toe and leg damage related to the toes/legs falling through the open structure while the conveyor belt is moving. For example, toes or toe nails could be severed or the legs stressed to the point of developing microfractures. Any physical injury to recently-hatched chicks limits the chicks’ mobility to feed and water while also elevating stress, thereby significantly increasing the risk of the injured chicks’ morbidity. Densification (e.g., crowding together) of the chicks on the open structure conveyor belt could further increase the risk of injury to the chicks, as well as increase stress levels.

Thus, there exists a need for an improved chick-shell separator device for separating debris such as eggshell fragments, feather down, and/or broken egg yolk from newly-hatched chicks while the chicks are being conveyed from a hatchery to be counted and packed. Such a separator device should desirably decrease the risk of physical injury, stress, and morbidity to the chicks being processed, while also effectively separating debris from the chicks that comprises remnants of the hatching process.

SUMMARY

The above and other needs are met by aspects of the present disclosure which, in some aspects, provides a separator device, comprising an endless conveyor loop arranged to convey an object in a conveyance direction. The conveyor loop includes a plurality of interlocking conveyor sections each extending perpendicularly to the conveyance direction and defining a width of the conveyor loop. The conveyor sections are arranged to interlock so as to form a substantially continuous planar surface of the conveyor loop, at least through a conveyance zone, and each conveyor section defines perforations extending between inner and outer surfaces of the conveyor loop. A suction hood is disposed opposite the conveyance zone and is spaced apart from the planar surface so as to allow the object to be conveyed by the conveyor loop between the suction hood and the conveyor sections in the conveyance zone. The suction hood is further arranged to impart a suction to the conveyance zone. A plenum is disposed within the conveyor loop and has a plenum outlet disposed adjacent to the inner surface of the conveyor loop within the conveyance zone so as to separate and remove debris from the object conveyed therebetween. The plenum is arranged to cooperate with the conveyor loop to direct air drawn by the suction through the perforations of the conveyor sections from the plenum outlet to be substantially evenly distributed across the width of the conveyor loop.

The present disclosure thus includes, without limitation, the following example embodiments:

Example Embodiment 1: A separator device, comprising an endless conveyor loop arranged to convey an object in a conveyance direction, the conveyor loop including a plurality of interlocking conveyor sections each extending perpendicularly to the conveyance direction and defining a width of the conveyor loop, the conveyor sections being arranged to interlock so as to form a substantially continuous planar surface of the conveyor loop, at least through a conveyance zone, and each conveyor section defining perforations extending between inner and outer surfaces of the conveyor loop; a suction hood disposed opposite the conveyance zone and spaced apart from the planar surface so as to allow the object to be conveyed between the suction hood and the conveyor sections in the conveyance zone, the suction hood being arranged to impart a suction to the conveyance zone so as to separate and remove debris from the object conveyed therebetween; and a plenum disposed within the conveyor loop and having a plenum outlet disposed adjacent to the inner surface of the conveyor loop within the conveyance zone, the plenum opposing the suction hood and being arranged to cooperate with the conveyor loop to direct air drawn by the suction through the perforations of the conveyor sections from the plenum outlet to be substantially evenly distributed across the width of the conveyor loop.

Example Embodiment 2: The device of any preceding or subsequent example embodiment, or combinations thereof, comprising an air flow generator in communication with the plenum and arranged to direct an air flow through the plenum outlet and through the perforations of the conveyor sections within the conveyance zone.

Example Embodiment 3: The device of any preceding or subsequent example embodiment, or combinations thereof, wherein each perforation is configured as or acts as a venturi such that the air flow exiting the perforation has a higher flow rate and lower pressure than the flow rate and pressure of the air flow entering the perforation from the plenum outlet.

Example Embodiment 4: The device of any preceding or subsequent example embodiment, or combinations thereof, comprising a seal engaged between the plenum outlet and the conveyor sections within the conveyance zone such that the air flow from the air flow generator produces a positive pressure within the plenum, the positive pressure within the plenum directing the air flow through the perforations of the conveyor sections to be substantially evenly distributed across the width of the conveyor loop.

Example Embodiment 5: The device of any preceding or subsequent example embodiment, or combinations thereof, wherein the suction imparted by the suction hood is equal to or greater than a positive pressure of the air flow exiting the perforations of the conveyor sections within the conveyance zone.

Example Embodiment 6: The device of any preceding or subsequent example embodiment, or combinations thereof, wherein the plenum outlet extends across the width of the conveyor loop and extends in the conveyance direction for a length of at least two conveyor sections.

Example Embodiment 7: The device of any preceding or subsequent example embodiment, or combinations thereof, wherein the suction hood is arranged to oppose the plenum outlet within the conveyance zone, to extend across the width of the conveyor loop, and to extend for a length of the plenum outlet relative to the conveyance direction.

Example Embodiment 8: The device of any preceding or subsequent example embodiment, or combinations thereof, wherein the suction hood is arranged to oppose the plenum outlet within the conveyance zone, to extend across the width of the conveyor loop, and to extend upstream and downstream of the plenum outlet relative to the conveyance direction.

Example Embodiment 9: The device of any preceding or subsequent example embodiment, or combinations thereof, wherein the suction hood further includes a baffle engaged therewith about an upstream side or a downstream side of the suction hood relative to the conveyance direction, the baffle being arranged to direct external air being drawn into the suction hood to interact with the object conveyed by the conveyor so as to facilitate separation and removal of the debris from the object. Example Embodiment 10: The device of any preceding or subsequent example embodiment, or combinations thereof, wherein each perforation defined by each conveyor section includes an outlet port defined by the outer surface of the conveyor loop, the outlet port being configured as an elongate slot arranged substantially parallel to the conveyance direction.

Example Embodiment 11: The device of any preceding or subsequent example embodiment, or combinations thereof, wherein the conveyor loop is a modular plastic belt formed from the conveyor sections.

Example Embodiment 12: The device of any preceding or subsequent example embodiment, or combinations thereof, comprising a separator device engaged with the suction hood, the separator device being arranged to separate and retain the debris separated and removed from the objects.

These and other features, aspects, and advantages of the present disclosure will be apparent from a reading of the following detailed description together with the accompanying drawings, which are briefly described below. The present disclosure includes any combination of two, three, four, or more features or elements set forth in this disclosure, regardless of whether such features or elements are expressly combined or otherwise recited in a specific embodiment description herein. This disclosure is intended to be read holistically such that any separable features or elements of the disclosure, in any of its aspects and embodiments, should be viewed as intended, namely to be combinable, unless the context of the disclosure clearly dictates otherwise.

It will be appreciated that the summary herein is provided merely for purposes of summarizing some example aspects so as to provide a basic understanding of the disclosure. As such, it will be appreciated that the above described example aspects are merely examples and should not be construed to narrow the scope or spirit of the disclosure in any way. It will be appreciated that the scope of the disclosure encompasses many potential aspects, some of which will be further described below, in addition to those herein summarized. Further, other aspects and advantages of such aspects disclosed herein will become apparent from the following detailed description taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the described aspects.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S) Having thus described the disclosure in general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein:

FIG. 1 schematically illustrates an example chick-shell separator device;

FIGS. 2 A and 2B schematically illustrate two examples of a prior art conveyor belt for a conveyor of a chick-shell separator device of the type shown in FIG. 1;

FIG. 3 schematically illustrates a chick-shell separator device, according to one aspect of the present disclosure;

FIG. 4 schematically illustrates a modular plastic conveyor belt including a plurality of interlocking conveyor sections, according to one aspect of the present disclosure; and

FIG. 5-8 schematically illustrates various views of a plenum and suction hood arrangement for separating debris such as eggshell fragments, feather down, and/or broken eg yolk from chicks in a chick-shell separator device, according to one aspect of the present disclosure.

DETAILED DESCRIPTION OF THE DISCLOSURE The present disclosure now will be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all aspects of the disclosure are shown. Indeed, the disclosure may be embodied in many different forms and should not be construed as limited to the aspects set forth herein; rather, these aspects are provided so that this disclosure will satisfy applicable legal requirements. Like numbers refer to like elements throughout.

Particular aspects of the present disclosure are directed to a separator device 100 (see, e.g., FIGS. 1 and 3) for separating debris from a conveyed object 200, namely, for example, separating eggshell fragments, feather down, and/or broken egg yolk from newly-hatched chicks in a poultry processing operation. In some aspects, the separator device 100 includes an endless conveyor loop 300 arranged to convey the object 200 in a conveyance direction 310.

In some aspects, the conveyor loop 300 includes a plurality of interlocking conveyor sections 320 (see, e.g., FIG. 4) each extending perpendicularly to the conveyance direction 310 and defining a width of the conveyor loop 300. The conveyor sections 320, in some instances, are arranged to interlock so as to form a substantially continuous planar surface 330 of the conveyor loop 300, wherein the substantially continuous planar surface 330 extends at least through a conveyance zone 340 through which the objects 200 are conveyed. In some aspects, each conveyor section 320 forming the conveyor loop 300 defines a plurality of perforations 350 extending between an inner surface 360 and an outer surface 365 of the conveyor loop 300. In other aspects, each perforation 350 defined by each conveyor section 320 includes an outlet port 355 (see, e.g., FIGS. 4 and 5) defined by the outer surface 365 of the conveyor loop 300, wherein the outlet port 355 is configured as an elongate slot arranged substantially parallel to the conveyance direction 310.

Such a conveyor loop 300, as disclosed herein can be, for example, a modular plastic belt formed from the interlocking conveyor sections 320. In particular aspects, the conveyor loop 300 can be, for example, an open hinge, flat mesh top polypropylene modular belt manufactured by Intralox, LLC of Dallas, TX.

In some aspects, a suction hood 400 (see, e.g., FIGS. 1, 3, and 5-8) is disposed opposite the conveyance zone 300 such that the suction hood 400 is spaced apart from the planar surface 330. The suction hood 400 is sufficiently spaced apart from the planar surface 330 to allow the object 200 to be conveyed between the suction hood 400 and the conveyor sections 320 in the conveyance zone 340. The suction hood 400 includes a leading edge 410 where the conveyor loop 300 first coincides with the suction hood 400 in the conveyance direction 310, and a trailing edge 420 where the conveyor loop 300 leaves the area under the suction hood 400 (see, e.g., FIG.

3)·

In some aspects, a fan assembly 500 (see, e.g., FIGS. 3 and 6) is engaged with the suction hood 400 and arranged to generate suction that is realized as air flow drawn into the suction hood 400 from the conveyance zone 340. The suction hood 400 is thus arranged to impart the suction to the conveyance zone 340 so as to separate and remove debris from the object 200 conveyed therebetween, such as, for example, the eggshell fragments, feather down, and/or broken egg yolk from the chicks.

In conjunction with the conveyor loop 300 comprised of the perforated interlocking conveyor sections 320, a plenum 600 is disposed within the conveyor loop 300 and includes a plenum outlet 610 disposed adjacent to the inner surface 360 of the conveyor loop 300 within the conveyance zone 340. The plenum 600, particularly the plenum outlet 610, opposes the suction hood 400, wherein the conveyor loop 300 extends therebetween. As such, in particular aspects, the plenum 600 / plenum outlet 610 are arranged to cooperate with the conveyor loop 300 to direct air drawn by the suction from the suction hood 400, through the perforations 350 of the conveyor sections 320 and from the plenum outlet 610 to be substantially evenly distributed across the width of the conveyor loop 300.

In some aspects, the plenum outlet 610 extends across the width of the conveyor loop 300, and extends in the conveyance direction 310 for a length of at least two conveyor sections. Generally, the suction hood 400 is arranged to oppose the plenum outlet 610 within the conveyance zone 340. More particularly, the suction hood 400 can be arranged to extend across the width of the conveyor loop 300, and to extend for a length of the plenum outlet 610 relative to the conveyance direction 310. In other instances, the suction hood 400 can be arranged to extend across the width of the conveyor loop 300, and to extend upstream and downstream of the plenum outlet 610 relative to the conveyance direction 310.

In particular aspects, an air flow generator 700 (see, e.g., FIG. 5) is arranged in communication with the plenum 600 so as to provide an air flow thereto. The air flow generator 700 can be, for example, a fan or blower unit. In some particular instances, the air flow can be provided by the exhaust side 505 (see, e.g., FIG. 6) of the fan assembly 500 associated with the suction hood 400 (e.g., the air flow generator 700 is the exhaust side 505 of the fan assembly 500). In any instance, in particular aspects of the disclosure, the air flow generator 700 is arranged to direct the air flow through the plenum outlet 610 and through the perforations 350 of the conveyor sections 320 within the conveyance zone 340. As previously disclosed herein, the plenum 600 / plenum outlet 610 are arranged to cooperate with the conveyor loop 300 such that the air flow from the plenum outlet 610 through the perforations 350 of the conveyor sections 320 is substantially evenly distributed across the width of the conveyor loop 300.

In such aspects in which the separator device 100 includes an air flow generator 700, each perforation 350 defined by each of the conveyor sections 320 of the conveyor loop 300 acts as or is configured as a venturi. As such, the air flow directed through the conveyor sections 320 and exiting the perforations 350 has a higher flow rate and lower pressure than the flow rate and pressure of the air flow entering the perforations 350 from the plenum outlet 610. In some instances, a seal 620 (see, e.g., FIGS. 7 and 8) is engaged between the plenum outlet 610 and the conveyor sections 320 (e.g., extending about a perimeter of the plenum outlet 610) within the conveyance zone 340 such that the air flow from the air flow generator 700 produces a positive pressure within the plenum 600. The positive pressure within the plenum 600 thus promotes or facilitates that the air flow directed through the perforations 350 of the conveyor sections 320 to be substantially evenly distributed across the width of the conveyor loop 300. In some aspects, the suction imparted by the suction hood 400 is equal to or greater than a positive pressure of the air flow exiting the perforations 350 of the conveyor sections 320 within the conveyance zone 340, for example, so as to prevent the debris dislodged from the objects 200 from being blown out upstream or downstream of the conveyance zone 340. In particular aspects, a debris containment device 900 (see, e.g., FIG. 6) is engaged with the suction hood 400, and arranged to separate and retain the debris separated and removed from the object(s) 200 such that the contained debris can subsequently be removed for subsequent disposal.

In some aspects, in order to direct the external air being drawn into the suction hood 400 by the suction/vacuum generated thereby, the suction hood 400 further includes a baffle 800 engaged therewith about an upstream side 410 or a downstream side 420 of the suction hood 400 relative to the conveyance direction 310 (see, e.g., FIGS. 7 and 8). In such aspects, the baffles 800 are arranged to direct external air being drawn into the suction hood 400 to interact with the object 200 conveyed by the conveyor 300 so as to facilitate separation and removal of the debris from the object 200. In other instances, the external air being drawn into the suction hood 400, as directed by the baffles 800, may facilitate constraining of the suction/vacuum to primarily affect the air flow through the perforations 350 defined by the conveyor sections 320, whether drawn in response to the suction or facilitated by positive air flow directed through the plenum 600/plenum outlet 610, to facilitate removal of the debris from the chicks/objects 200. In other instances, the baffles 800 may also help to prevent the debris dislodged from the objects 200 from being blown out upstream or downstream of the conveyance zone 340.

Aspects of the present disclosure thus provide a separator device 100 that decreases the risk of physical injury, stress, and morbidity to the chicks being processed, while also effectively separating debris such as eggshell fragments, feather down, and/or broken egg yolks from the chicks that are remnants of the hatching process.

Many modifications and other embodiments of the inventions set forth herein will come to mind to one skilled in the art to which these disclosed embodiments pertain having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that embodiments of the invention are not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the invention. Moreover, although the foregoing descriptions and the associated drawings describe example embodiments in the context of certain example combinations of elements and/or functions, it should be appreciated that different combinations of elements and/or functions may be provided by alternative embodiments without departing from the scope of the disclosure. In this regard, for example, different combinations of elements and/or functions than those explicitly described above are also contemplated within the scope of the disclosure. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.

It should be understood that although the terms first, second, etc. may be used herein to describe various steps or calculations, these steps or calculations should not be limited by these terms. These terms are only used to distinguish one operation or calculation from another. For example, a first calculation may be termed a second calculation, and, similarly, a second step may be termed a first step, without departing from the scope of this disclosure. As used herein, the term “and/or” and the “/” symbol includes any and all combinations of one or more of the associated listed items.

As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises”, “comprising”, “includes”, and/or “including”, when used herein, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. Therefore, the terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting.

Claims

THAT WHICH IS CLAIMED:

1. A separator device, comprising: an endless conveyor loop arranged to convey an object in a conveyance direction, the conveyor loop including a plurality of interlocking conveyor sections each extending perpendicularly to the conveyance direction and defining a width of the conveyor loop, the conveyor sections being arranged to interlock so as to form a substantially continuous planar surface of the conveyor loop, at least through a conveyance zone, and each conveyor section defining perforations extending between inner and outer surfaces of the conveyor loop; a suction hood disposed opposite the conveyance zone and spaced apart from the planar surface so as to allow the object to be conveyed between the suction hood and the conveyor sections in the conveyance zone, the suction hood being arranged to impart a suction to the conveyance zone so as to separate and remove debris from the object conveyed therebetween; and a plenum disposed within the conveyor loop and having a plenum outlet disposed adjacent to the inner surface of the conveyor loop within the conveyance zone, the plenum opposing the suction hood and being arranged to cooperate with the conveyor loop to direct air drawn by the suction through the perforations of the conveyor sections from the plenum outlet to be substantially evenly distributed across the width of the conveyor loop.

2. The device of Claim 1, comprising an air flow generator in communication with the plenum and arranged to direct an air flow through the plenum outlet and through the perforations of the conveyor sections within the conveyance zone.

3. The device of Claim 2, wherein each perforation is configured as or acts as a venturi such that the air flow exiting the perforation has a higher flow rate and lower pressure than the flow rate and pressure of the air flow entering the perforation from the plenum outlet.

4. The device of Claim 2, comprising a seal engaged between the plenum outlet and the conveyor sections within the conveyance zone such that the air flow from the air flow generator produces a positive pressure within the plenum, the positive pressure within the plenum directing the air flow through the perforations of the conveyor sections to be substantially evenly distributed across the width of the conveyor loop.

5. The device of Claim 4, wherein the suction imparted by the suction hood is equal to or greater than a positive pressure of the air flow exiting the perforations of the conveyor sections within the conveyance zone.

6. The device of Claim 1, wherein the plenum outlet extends across the width of the conveyor loop and extends in the conveyance direction for a length of at least two conveyor sections.

7. The device of Claim 1, wherein the suction hood is arranged to oppose the plenum outlet within the conveyance zone, to extend across the width of the conveyor loop, and to extend for a length of the plenum outlet relative to the conveyance direction.

8. The device of Claim 1, wherein the suction hood is arranged to oppose the plenum outlet within the conveyance zone, to extend across the width of the conveyor loop, and to extend upstream and downstream of the plenum outlet relative to the conveyance direction.

9. The device of Claim 7, wherein the suction hood further includes a baffle engaged therewith about an upstream side or a downstream side of the suction hood relative to the conveyance direction, the baffle being arranged to direct external air being drawn into the suction hood to interact with the object conveyed by the conveyor so as to facilitate separation and removal of the debris from the object.

10. The device of Claim 1, wherein each perforation defined by each conveyor section includes an outlet port defined by the outer surface of the conveyor loop, the outlet port being configured as an elongate slot arranged substantially parallel to the conveyance direction.

11. The device of Claim 1, wherein the conveyor loop is a modular plastic belt formed from the conveyor sections.

12. The device of Claim 1, comprising a debris containment device engaged with the suction hood, the debris containment device being arranged to separate and retain the debris separated and removed from the objects.