Senior Design Review Andrew Beasten Greg Feather Alex Phillips Brendan Moran Wegmans Bread Tray Lift Assist

Goal: Improve ergonomics for operator during the task of stacking loaded bread trays at the Wegmans Bakery

Critical Needs Enable good ergonomic practices in terms of lifting and body position Meet Wegmans safety requirements in terms of mechanical operation and physical aspects (sharp edges, pinch points) Meet Wegmans requirements in terms of cleaning and food contamination risks Ease of use for operator The unit should be durable and reliable

Specifications Minimize process time Mechanical components are constructed from food safe material Allow for food to descend no closer to the floor than ½ foot

Hold first and subsequent trays until dolly touches floor Hold Trays Reset Lift Release from system Constant force mechanism Keep relatively horizontal Mechanical reset Continuous reset Dolly slides off Tray Slides onto dolly Maintain loading at waist height Lower each tray from waist level Ramping mechanism Keep dolly with trays Functional Decomposition

Holding Trays Lifting Trays Remove from System Reset Lifter Position Tray Collapse Forks Clips Magnet Flat base Hooks Spring Weight PistonRack PinionPulley Motor Fall Push/Pull Lift Magnet Pedal Switch Lever Button Pull Cord Walls Guide Rail Slots/Grooves Rubber Stopper HingeCotter Pin Screw Tab wedge Magnet Manually clips

Pugh Matrix Results For Lifting Trays Criteria Considered: Ease of use, resetability, durability, portability, cost, safety, storage, maintenance, simplicity, and input required Ranking system: 1-3

Pugh Matrix Results For Reset Mechanism Criteria Considered: Cost, feasibility, practicality, maintenance, safety, simplicity, endurance and adaptability

Why Not Electric Skill set – Programming and Controls Safety – Eye wash station for battery – Cords are tripping hazard Maintenance Source of power/Tethered Less versatile More complex

Proposed Design Skeleton Frame Sheet metal wrap Springs and Damper Track guided system Lockable wheels Lock at bottom position Lever vs. foot pedal

Variation in Design Side guard material Overall material Foot pedal release Fork vs. plat form Wall vs. leg support

Risks Design Risks: Spring failure Metal bending Pinch points Sharp edges Fast movement/impact risk Trip hazards Design failure/product does not work Visibility Incorrect guarding Tipping/fall danger Lubrication concerns Metal shavings Ergonomic failures Unstable product

Project Plan

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