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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: The growth in meat production has raised higher requirements for the precision and automation of meat processing equipment. Current meat slicing equipment suffers 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 method based on multi-view point cloud reconstruction is plagued by high deployment costs and poor adaptability to actual production scenarios. To address these issues, this study took pork loin as the research object and developed a high-precision quantitative slicing device based on contour adaptive shaping, aiming to solve the problems of large imaging errors and low slicing accuracy in the quantitative slicing of irregular meat products, and to provide technical references for the design of high-precision quantitative slicing devices for other types of irregular meat. First, the pork loin quantitative slicing device composed of a scanning imaging unit, a contour adaptive shaping module, a slicing execution module and a control system was designed, with the overall dimensions of the device and the parameters of key components defined clearly. Through force analysis, the effective range of shaping force Fmin, Fmax for pork loin was derived, and a shaping module integrated with torque, force and angle sensors was built to realize the adaptive closed-loop control of shaping parameters. Second, a PLC-based control system was constructed, which included a perception subsystem integrating various sensors to acquire meat information and shaping motion data, a computing subsystem completing image processing and path planning via a computer, and an execution subsystem controlling the movements of the shaping fixture and slicing mechanism respectively. An adaptive contour shaping motion control algorithm as well as a non-equidistant slicing path planning algorithm were designed to achieve the dynamic matching between the cutter speed and the conveyor belt speed. Finally, pork loin was used as the test sample to verify the actual operating performance of the shaping module and the slicing device. The test results showed that in the conveyor belt and cutter speed matching test, the root mean square error (RMSE) of slicing positions ranged from 0.63mm to 1.07 mm and the mean absolute percentage error (MAPE) from 3.98% to 5.15%. A linear relationship v=0.44Me+16.10 between the set slicing weight Me and the conveyor belt speed v was fitted, providing an optimal speed matching scheme for different quantitative slicing requirements. The verification of shaping effect indicated that after shaping treatment, the mean relative error (MRE) of quantitative slicing of pork loin decreased from 11.13% to 6.24%, and the qualification rate (q) increased from 70.12% to 91.43%, representing an improvement of 4.89% in slicing accuracy and 21.31% in qualification rate respectively. In the tests with different shaping angles, the 60°shaping angle achieved the optimal slicing effect, with the MRE was 6.61% and the q was 89.89%. In the overall performance verification of the device, the continuous slicing tests with set weights of 100 and 150 g showed that the slicing accuracy of chilled meat was superior to that of slightly frozen meat. For the quantitative slicing of 100 g chilled meat, the MAPE was 5.57% and the q was 90.53%. For 150 g chilled meat, the MAPE was 5.11% and the q was 89.69%. Due to internal ice crystals and fiber breakage, slightly frozen meat saw an average increase of 0.76 g in RMSE and 0.84% in MAPE, with the q decreasing by an average of 5.06%. The overall processing efficiency of the device reached 134 slices/min, 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%, demonstrating good operational stability of the device. This study successfully developed a quantitative slicing device for pork loin based on contour adaptive shaping. By designing a contour adaptive shaping structure integrated with multiple sensors, the device effectively solves the problems of large slicing errors and serious raw material loss of traditional slicing equipment in processing irregular meat products, thus promoting the transformation of the meat processing industry towards standardization and digitalization.

     

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