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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?