P12711 Parbake Mezzanine DDR 1

Design Review Expectations Review feasibility of design Improve overall design based on feedback and discussion 2

Project Plan 3

Risk Assessment Update New risks associated with design Risk ItemEffectCauseLikelihoodSeverityImportanceMitigation Counter does not accurately count Reduction in overall effectiveness of system Too much variety in product stream236 Design a system that can account for all the different varieties of product Unscheduled electrical component failure Reduced throughput and potential loss of productComponent fatigue/degredation236 Design electrical system around robust actuators/sensors Failure of mechanical system component Reduced throughput and potential loss of productComponent fatigue/degredation133 FEA analysis and design machine components to infinite life Bread guides create a blockageBread packaging hold up Bread does not come down conveyor as expected236 Test plan to cover all orientations bread can come down conveyor 4

Functional Decomposition Package Product Get BoxTransfer BoxStage ProductAlign ProductCount ProductInspect/Rejection Inspect Product Reject if Needed Fill Box Put Product in Box Orient Product in Box Stop When FullSend Box"Close" Box Move Box to Lower Conveyor 5

System Design Overview 6

Box Transfer – Box Slide 7

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Box Slide Information Sloped, spiral conveyor extension with rollers o Moves box for immediate product filling o 20” Vertical Decline, 30” radius turn o Eliminates operator effort – reaching o Manufacturer – Northeast Conveyor, Inc 9

Next Steps Make Contact with Northeast Conveyor, Inc Is Design Plausible? Cost 10

Counting Vertical Counters 11

Counting - Vertical Counter 12

Vertical Counter Flap rotation sensed by potentiometer Single flap size handles all products Returns to neutral position after product travels through 13

Counter Prototype 14

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) 15

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 16

Further Testing The 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 17

Counter Assembly BOM Counter Assembly Product DescriptionDimensionsLength (in)MaterialQty.Unit Cost ($)Total Cost ($) Counter Flap2.75"x1/16"10.75Stainless Counter Rod1/8"11.50Stainless Counter Support,2"x0.5"6.00Stainless Set Screw " Stainless Small Counter Guide0.5"x2"30.00Stainless Long Counter Guide19.25"x0.5"x2"19.25Stainless K-Potentiometer Seg LED Display Dual 4-bit Binary Counter xBCD 7-Seg Driver Box Exit Conveyor Chute60"x52"x1/16"-Stainless Counter Total

Aligning Product 19

Initial Testing Rounds o Have been successfully guided and sorted into single file rows that are countable Rolls o Had problems with clogging up the lanes, but it is possible to sort them Baguettes o Difficult to keep from spinning around and clogging up the sorter Batards o Not as difficult to sort as baguettes, but they can still spin around 20

Video of Rounds Testing 21

Video of Baguette Testing 22

Batard Test 23

Further Testing Guide Prototype o Prototype would allow for repeatable set ups and would directly inform final design o Possible inclusion of ‘turning vanes’ to aid in keeping certain breads (baguettes, batards) from spinning Experimenting with different conveyor speeds o By increasing the speed of each successive conveyor, the product spacing will increase, which will lead to less bottlenecking at the sorter o Will also ensure that baguettes and batards will be straight when they arrive at aligning station 24

Confidence Level Rounds o Can be done Rolls o Varying 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 25

Guide Assembly BOM Guide Assembly Product DescriptionDimensionsLength (in)MaterialQty.Unit Cost ($)Total Cost ($) Support.5"x2"x8"8.000Aluminum Shaft.5" dia x 40"7.854Steel Guide Holder1"x1.5"x.5"0.750Aluminum HolderShaft.25" dia x 4"0.196Steel ft Guide3"x.5"x36"0.540UHMW Guide to shaft.75"x1"x1.25"0.938UHMW Guide Total

Inspection 27

Inspection Help from Wegmans ◦ Can we relocate the trash bins further upstream of the main conveyor? 28

Batching/Accumulating 29

Sorters 30

Gates 31

Main Beam deflection comparison.75” (w) x.5” (h) cross section.75” square cross section 32

Batching/Accumulating The 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) 33

Batching/Accumulating A 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 34

How The Counters/Gates Will Work The 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 35

Further Testing We 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 36

Batching Assembly BOM 37 Batching Assembly Product DescriptionDimensionsLength (in)MaterialQty.Unit Cost ($)Total Cost ($) Bolt10" 1/4 -20-Stainless Bolt2.25" 1/4 -20-Stainless17.04 Bolt1" 1/4 -20-Stainless17.69 U-Bolt1.625-Stainless Nut1/4 " - 20-Stainless Rod Support a -Long0.125" x 2" flat stock1.25Stainless14.52 Rod Support A0.125" x 2" flat stock0.75Stainless12.71 Rod Support B0.125" x 2" flat stock1.5Stainless15.42 Sorting Piston Mount0.125" x 2" flat stock2.25Stainless18.14 Sort. Piston Mount Receiver0.125" x 3" flat stock3Stainless Angle Stock1.25"2.25Stainless Threaded Rod1/4" Stainless Big Gate.375" x 2" flat stock10.75UHMW Small Gate.375" x 2" flat stock7.25UHMW Sorting Gate.375" x 2" flat stock17.75UHMW Pneumatic Actuator--Stainless Solenoid Valve Stainless Gate Piston Link7/8" round stock1.625Stainless Set Screw1/4" - 20-Stainless15.50 Stop.08" x 2" flat stock0.375Stainless10.24 Divider.08" x 2" flat stock15Stainless19.51 Lane Walls.08" x 2" flat stock150Stainless Batching Total1,095.65

Support Frame BOM Support Frame Assembly Product DescriptionDimensionsLength (in)MaterialQty. Unit Cost ($) Total Cost ($) Main Beam.75" x.75" bar stock 39Stainless Vertical Support.75" x.5" bar stock9Stainless Corner Support.75" x.5" bar stock4Stainless Side Support.75" x.5" bar stock11.25Stainless Crossover Beam.75" x.5" bar stock15Stainless Side Mount.25" x 2" flat stock2.75Stainless Support Frame Total

End of Conveyor 39

Boxing Product After 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. 40

Chute that attaches to the rail on the side of the conveyor This stops the box from sliding off the Lazy Susan. 41

This is what the stopper would attach to. Place of attachment 42

Close and Send Box To Freezer The 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. 43

Total Costs Counter Total $ Support Frame Total $ Batching Total $ 1, Guide Total $ Grand Total $ 2,

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? 45

Next Steps Update designs based on meeting Start prototyping all designs Identify vendors for all components with Wegmans’ buyers 46

Questions? Comments? 47