Post on 23-Feb-2016
description
transcript
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P12711 Parbake Mezzanine DDR
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Design Review ExpectationsReview feasibility of designImprove overall design based on
feedback and discussion
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Project Plan
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Risk Assessment UpdateNew risks associated with design
Risk Item Effect CauseLikelihoo
dSeveri
tyImportan
ce Mitigation
Counter does not accurately count
Reduction in overall effectiveness of system
Too much variety in product stream 2 3 6
Design a system that can account for all the different varieties of product
Unscheduled electrical component failure
Reduced throughput and potential loss of product
Component fatigue/degredation 2 3 6
Design electrical system around robust actuators/sensors
Failure of mechanical system component
Reduced throughput and potential loss of product
Component fatigue/degredation 1 3 3
FEA analysis and design machine components to infinite life
Bread guides create a blockage
Bread packaging hold up
Bread does not come down conveyor as expected 2 3 6
Test plan to cover all orientations bread can come down conveyor
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Functional Decomposition
Package Product
Get Box
Transfer Box
Stage Product
Align Product
Count Product
Inspect/Rejection
Inspect Product
Reject if Needed
Fill Box
Put Product in Box
Orient Product in Box
Stop When Full
Send Box"Close" Box
Move Box to Lower
Conveyor
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System Design Overview
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Box Transfer – Box Slide
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Box Transfer – Box Slide
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Box Slide InformationSloped, spiral conveyor extension
with rollersoMoves box for immediate product
fillingo20” Vertical Decline, 30” radius turnoEliminates operator effort – reachingoManufacturer – Northeast Conveyor,
Inc
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Next StepsMake Contact with Northeast
Conveyor, IncIs Design Plausible?Cost
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Counting Vertical Counters
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Counting - Vertical Counter
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Vertical CounterFlap rotation sensed by
potentiometer
Single flap size handles all products
Returns to neutral position after product travels through
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Counter Prototype
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Counter (electrical)Driven by a potentiometer which
outputs a voltage dependent on angular displacement
Positional voltage then differentiated to obtain angular velocity and run through a comparator to obtain a binary voltage output
Binary output feeds a 4-bit binary counter and seven-segment display to output count (for prototyping purposes)
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Testing (electrical)Circuit simulated to determine
component values and validate design
Circuit was then built in hardware to verify simulations; circuit outputs a count dependent on the speed at which the potentiometer is spun
Angular velocity threshold is adjustable to accommodate different size/shape breads
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Further TestingThe potentiometer will need to
be mocked up to the actual counter to verify the counter will count bread like we expect it to
This requires a fixture to be built so we can attach the potentiometer and flap to the fixture and perform more realistic testing
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Counter Assembly BOM
Counter AssemblyProduct Description Dimensions Length (in) Material Qty. Unit Cost ($) Total Cost ($)
Counter Flap 2.75"x1/16" 10.75 Stainless 2 66.86 133.71
Counter Rod 1/8" 11.50 Stainless 2 2.02 4.05
Counter Support, 2"x0.5" 6.00 Stainless 4 30.02 120.08
Set Screw 4-40 0.112" Stainless 3 0.33 0.98
Small Counter Guide 0.5"x2" 30.00 Stainless 1 51.77 51.77
Long Counter Guide 19.25"x0.5"x2" 19.25 Stainless 1 27.11 27.11
1K-Potentiometer 2 4.37 8.74
7-Seg LED Display 2 1.76 3.52
Dual 4-bit Binary Counter 2 0.61 1.22
2xBCD 7-Seg Driver 2 1.71 3.42
Box Exit Conveyor Chute 60"x52"x1/16" - Stainless 1 274.64 274.64
Counter Total 629.23
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Aligning Product
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Initial Testing• Rounds oHave been successfully guided and sorted
into single file rows that are countable• Rolls oHad problems with clogging up the lanes, but
it is possible to sort them• Baguettes oDifficult to keep from spinning around and
clogging up the sorter• Batards oNot as difficult to sort as baguettes, but they
can still spin around
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Video of Rounds Testing
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Video of Baguette Testing
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Batard Test
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Further Testing• Guide PrototypeoPrototype would allow for repeatable set ups and
would directly inform final designoPossible inclusion of ‘turning vanes’ to aid in
keeping certain breads (baguettes, batards) from spinning
• Experimenting with different conveyor speeds oBy increasing the speed of each successive
conveyor, the product spacing will increase, which will lead to less bottlenecking at the sorter
oWill also ensure that baguettes and batards will be straight when they arrive at aligning station
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Confidence Level• Rounds oCan be done• Rolls oVarying success depending on roll.
Showed promise but will require further testing
• Baguettes and Batards o If the ‘spin’ and ‘stick’ conditions can be
eliminated, the sorting can be done
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Guide Assembly BOM
Guide AssemblyProduct Description Dimensions Length (in) Material Qty. Unit Cost ($) Total Cost ($)
Support .5"x2"x8" 8.000 Aluminum 4 11.27 45.07Shaft .5" dia x 40" 7.854 Steel 2 11.06 22.12
Guide Holder 1"x1.5"x.5" 0.750 Aluminum 4 1.06 4.23HolderShaft .25" dia x 4" 0.196 Steel 4 0.28 1.11
3ft Guide 3"x.5"x36" 0.540 UHMW 2 0.76 1.52Guide to shaft .75"x1"x1.25" 0.938 UHMW 4 1.32 5.28
Guide Total 79.33
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Inspection
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InspectionHelp from Wegmans
◦Can we relocate the trash bins further upstream of the main conveyor?
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Batching/Accumulating
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Sorters
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Gates
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Main Beam deflection comparison
.75” (w) x .5” (h) cross section
.75” square cross section
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Batching/AccumulatingThe batching function is completed
using a series of counters and gates to fill batching lanes with the correct quantity of product required for each box
The total system will consist of two counters, each of which fill two batching lanes (total of four batching lanes), two sorting gates (one for each counter), and four blocking gates (at the end of the batching lanes)
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Batching/AccumulatingA sorting gate will be situated
directly after the counter and will change the batching lane the product fills
A blocking gate will be situated and the end of each batching lane to stop product from flowing into the chute and box
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How The Counters/Gates Will WorkThe counters and sorting gates will work
together through a logic set implemented with a microcontroller
After a product is counted it will flow into a batching line. The product will continue to flow until the batching lane is filled with enough product to fill a box. The sorting gate will then move to fill the adjacent lane.
The blocking gates at the end of each batching lane will be operated independently of the counters/sorting gates. The boxing operator will control these gates allowing the operator full control over the flow into the boxes
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Further TestingWe will need to prototype
batching lanes to determine if the product will bunch together and clog the batching lanes
We will need to test each type of gate with air cylinders to determine if the design is feasible
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Batching Assembly BOMBatching Assembly
Product Description Dimensions Length (in) Material Qty. Unit Cost ($) Total Cost ($)Bolt 10" 1/4 -20 - Stainless 8 6.33 50.64 Bolt 2.25" 1/4 -20 - Stainless 1 7.04 7.04 Bolt 1" 1/4 -20 - Stainless 1 7.69 7.69
U-Bolt 1.625 - Stainless 12 3.24 38.88 Nut 1/4 " - 20 - Stainless 1 10.10 10.10
Rod Support a -Long 0.125" x 2" flat stock 1.25 Stainless 1 4.52 4.52 Rod Support A 0.125" x 2" flat stock 0.75 Stainless 1 2.71 2.71 Rod Support B 0.125" x 2" flat stock 1.5 Stainless 1 5.42 5.42
Sorting Piston Mount 0.125" x 2" flat stock 2.25 Stainless 1 8.14 8.14 Sort. Piston Mount Receiver 0.125" x 3" flat stock 3 Stainless 1 77.68 77.68
90 Angle Stock 1.25" 2.25 Stainless 1 10.02 10.02 Threaded Rod 1/4" -20 9.25 Stainless 2 7.67 15.34
Big Gate .375" x 2" flat stock 10.75 UHMW 2 7.66 15.32 Small Gate .375" x 2" flat stock 7.25 UHMW 2 11.36 22.72
Sorting Gate .375" x 2" flat stock 17.75 UHMW 2 18.75 37.50 Pneumatic Actuator - - Stainless 6 36.04 216.24
Solenoid Valve Stainless 6 73.89 443.34 Gate Piston Link 7/8" round stock 1.625 Stainless 1 39.51 39.51
Set Screw 1/4" - 20 - Stainless 1 5.50 5.50 Stop .08" x 2" flat stock 0.375 Stainless 1 0.24 0.24
Divider .08" x 2" flat stock 15 Stainless 1 9.51 9.51 Lane Walls .08" x 2" flat stock 150 Stainless 2 33.80 67.60
Batching Total 1,095.65
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Support Frame BOM
Support Frame Assembly
Product Description Dimensions Length (in) Material Qty. Unit Cost ($)
Total Cost ($)
Main Beam .75" x .75" bar stock 39 Stainless 3 87.22 261.66
Vertical Support .75" x.5" bar stock 9 Stainless 1 34.03 34.03
Corner Support .75" x.5" bar stock 4 Stainless 1 15.12 15.12
Side Support .75" x.5" bar stock 11.25 Stainless 1 42.53 42.53
Crossover Beam .75" x.5" bar stock 15 Stainless 1 56.71 56.71
Side Mount .25" x 2" flat stock 2.75 Stainless 1 35.00 35.00
Support Frame Total 445.05
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End of Conveyor
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Boxing ProductAfter being sorted and counted, the
bread will slide off the end of the conveyor on a chute . The chute will be attached to the end of the conveyor. As the bread enters the box, the operator will orient the bread, if need be.
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Chute that attaches to the railon the side of the conveyor
This stops the box from sliding off the Lazy Susan.
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This is what the stopper would attach to.
Place of attachment
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Close and Send Box To FreezerThe box will be closed by the
worker when box is full. Then, using the Lazy Susan, the box will be pushed off to the lower conveyor.
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Total Costs
Counter Total $ 629.23
Support Frame Total $ 445.05
Batching Total $ 1,095.65
Guide Total $ 79.33
Grand Total $ 2,249.26
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What’s needed From Wegmans:
Can we modify the conveyor length other than the 96” sections?
Possibility of Wegmans support for prototype development
Can we start more involved testing using prototypes?
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Next StepsUpdate designs based on
meetingStart prototyping all designsIdentify vendors for all
components with Wegmans’ buyers
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Questions? Comments?