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基于轮廓自适应整形的猪外脊肉定量切片装置设计与试验

Design and test of quantitative slicing device for pork loin based on contour adaptive shaping

  • 摘要: 针对去骨原料肉定量切片过程中因肉品形状轮廓不规则导致的分切精度低、原料损耗大、相关装备缺乏等问题,该研究以猪外脊肉为对象,开发了一种基于轮廓自适应整形的猪外脊肉高精度定量切片装置。装置主要由扫描成像单元、轮廓自适应整形模块、分切执行模块和控制系统组成。利用激光扫描成像与轮廓整形协同提高分切性能,通过一次扫描获取肉品原始轮廓,建立轮廓-整形角度-整形力度-分切精度的回归模型,利用多传感器实时反馈来实现整形参数的自适应控制。肉品经整形产生形变后,利用二次扫描与分切路径规划算法估算出定量切片的路径,最后通过切刀转速与路径的动态匹配实现定量切片。基于PLC与多传感器开发了整体装置的时序控制系统。以猪外脊肉为试验样品,验证整形模块和切片装置的实际作业效果。结果显示,经整形处理后,猪外脊肉定量分切的平均相对误差(MRE)由无整形时的11.13%降低至6.24%,合格率q(设定分切质量±10%)由70.12%提升至91.43%,整形处理有效提升了装置的分切性能。在分切质量为100和150 g的连续作业试验中,当分切定量为100 g时,冷鲜肉切片的平均绝对百分比误差(MAPE)为5.57%,q为90.53%,微冻肉切片的MAPE为6.51%,q为85.42%;当分切定量为150 g时,冷鲜肉切片的MAPE为5.11%,q为89.69%,微冻肉切片的MAPE为5.94%,q为84.69%,总体加工效率为134片/min。研究结果表明该装置能够准确、稳定地完成定量切片任务,满足市场对肉类分切的作业要求,可为不规则肉类高精度定量分切装置的设计提供参考。

     

    Abstract: High precision equipment is often required in meat processing under ever-increasing livestock production at present. Current meat slicing equipment has also suffered from low slicing accuracy and high raw material loss, due to imaging occlusion during the quantitative slicing of irregular boneless meat. In contrast, the imaging after multi-view point cloud (Voint cloud) reconstruction is also plagued by high deployment costs and low adaptability to actual production scenarios. In this study, a high-precision quantitative slicing device was developed for pork loin using contour adaptive shaping. The pork loin was taken as the research object. The low imaging errors and high slicing accuracy were also obtained in the irregular meat products. (1) The device was composed of four components, including a scanning imaging unit, contour adaptive shaping, slicing execution, and a control system. The overall dimensions were defined to determine the key parameters. The effective range of shaping force Fmin, Fmax was derived for pork loin using force analysis. A shaping module was integrated with torque, force, and angle sensors to realize the adaptive closed-loop control of shaping parameters. (2) A PLC control system was constructed, including a perception subsystem with various sensors to acquire meat information and shaping motion data, a computing subsystem for image processing and path planning via a computer, and an execution subsystem for the movements of the shaping fixture and slicing mechanism. An adaptive motion of contour shaping and a non-equidistant slicing path planning were designed for the dynamic matching between the cutter and the conveyor belt speed. (3) Pork loin was used as the test sample to verify the actual performance of the shaping module and the slicing device. The conveyor belt and cutter speed matching test showed that the root mean square error (RMSE) of slicing positions ranged from 0.63 to 1.07 mm, and the mean absolute percentage error (MAPE) from 3.98% to 5.15%. There was a linear relationship (v=0.44Me+16.10) between the set slicing weight Me and the conveyor belt speed v, providing for an optimal speed matching scheme for different requirements of quantitative slicing. The verification of shaping effect indicated that the mean relative error (MRE) decreased from 11.13% to 6.24% in the quantitative slicing of pork loin after shaping treatment, whereas the qualification rate (q) increased from 70.12% to 91.43%, indicating an improvement of 4.89% in slicing accuracy and 21.31% in qualification rate, respectively. The optimal slicing effect was achieved in the 60° shaping angle, with the MRE of 6.61% and the q of 89.89%. The continuous slicing tests were conducted to verify the overall performance of the device with the set weights of 100 and 150 g. The slicing accuracy of chilled meat was superior to that of slightly frozen meat. In the quantitative slicing of 100 g chilled meat, the MAPE was 5.57%, and the q was 90.53%. In 150 g chilled meat, the MAPE was 5.11%, and the q was 89.69%. In view of the internal ice crystals and fiber breakage, the slightly frozen meat saw also shared an average increase of 0.76 g in RMSE and 0.84% in MAPE, where the q decreased by an average of 5.06%. The overall processing efficiency of the device reached 134 slices/min, fully meeting the demands of continuous production. In the stability test, the MRE of slicing with set weights of 70, 100, and 150 g ranged from 5.25% to 6.57%, and the coefficient of variation (CV) was all less than 10%, indicating excellent stability of the device. Contour adaptive shaping structure with multiple sensors reduced the slicing errors and raw material loss of conventional slicing equipment in irregular meat processing, thus promoting the transformation of the meat processing industry towards standardization and digitalization. The findings can provide technical references for high-precision quantitative slicing devices for irregular meat products.

     

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