In poultry plants in the United States, a water chiller is used to chill WOGs (de-feathered birds without giblets). After exiting the chiller these birds are manually transferred from a conveyor belt to shackles for further processing. The current process is less than ideal. The labor pool for jobs such as these is continuing to shrink and labor turnover is a constant problem. The rates of repetitive motion injury reported are high and are continuing to rise. In addition, many poultry producers see this as a bottleneck in the process. Automation has the potential to alleviate these problems. The high variability of this task, cost restrictions, and special design considerations associated with meat handling equipment make automation of this task challenging. Industrial robots have traditionally been limited to tasks with low variability. This task has high variability. They are presented on the conveyor belt in a wide variety of positions and orientations. Most robotic automation systems consist of a commercially available industrial robot, a specialized end effector and a control scheme. The economics of this task prohibit the use of a commercially available industrial robot, as there are no industrial robots on the market that will offer a short enough payback. Robots have not yet been adapted to meat handling processes, and existing robotic designs are not well suited to the task. In designing a low cost, high-speed robot for poultry processing the requirements of the robot are defined and a variety of robot architectures, constructions, and materials are explored. Simple modifications to the existing shackle and conveyor setup to make the task easier for a robot are also explored. After the robot requirements are defined a large group of possible designs are developed. The possible designs are systematically evaluated and/or eliminated until a single design is selected. The forward and reverse kinematics for this robot are developed. A singularity analysis is carried out. A proof of concept model is built. A prototype is modeled and a dynamic analysis of that prototype is carried out. The design is finalized based on the results of the dynamic analysis.

This thesis is motivated by practical problems encountered in handling live products in the poultry processing industry, where live birds are manually transferred by human labors. As the task of handling live products is often unpleasant and hazardous, it is an ideal candidate for automation. To reduce the number of configurations and live birds to be tested, this thesis focuses on developing analytical models based on the Lagrange method to predict the effect of mechanical inversion on the shackled bird. Unlike prior research which focused on the effect of different inversion paths on the joint force/torque of a free-falling shackled bird, this thesis research examines the effect of kinematic constraints (designed to support the bird body) on the shackled bird. Unlike free-falling, the imposed kinematic constraints enable the shackled bird to rotate about its center of mass, and thus minimize wing flapping. In this thesis, birds are geometrically approximated as ellipsoids while the lower extremity is modeled as a pair of multi-joint serial manipulators. With the constraint equations formulated into a set of differential algebraic equations, the equations of motion as well as Lagrange multipliers characterizing kinematical constraints are numerically solved for the bird motion, specifically the position, velocity, and orientation and hence the forces and torques of the joints. The dynamic models are verified by comparing simulation results against those obtained using a finite element method. The outcomes of this thesis will provide some intuitive insights essential to design optimization of a live-bird transfer system.