Detailed Design Review Project # /12/10 1Rev 01

 Helen Jervey (ISE), Project Lead  Charles Nicolosi (ME), Chief Engineer  Ian Baker (ME)  Ben Bouffard (EE)  Brandon Sbordone (ME)  George Kilger (EE)  Advised by John Kaemmerlen (ISE) 2Rev 01

 Detail progress made by RIT team  Present final design changes  Receive feedback from faculty and Wegmans staff  Discuss next steps 3Rev 01

Customer Needs Engineering Metrics Projected System Cost 4Rev 01

 Need 1: Product & Process are Safe ◦ Need 1.1: Product integrity is maintained ◦ Need 1.2: Equipment satisfies USDA Regulations as well as the AMI Checklist ◦ Need 1.3: OSHA Safety requirements are met  Need 1.3A: Remove ergonomic issues and concerns  Need 2: Reallocate Direct Labor ◦ Need 2.1: Reallocate direct flipping labor ◦ Need 2.2: Reallocate direct alignment labor ◦ Need 2.3: Reallocate direct labeling labor ◦ Need 2.4: Camera labeling system is low priority  Need 3: Improve Processing Time ◦ Need 3.1: Maintain or decrease takt time ◦ Need 3.2: All packages get scanned by the x-ray at desired belt speed ◦ Need 3.3: Control flow to scaling operation. (Control flow-rate variance)  Need 3.3A: Packages must flow in a format that works with the X-ray  Need 4: Control orientation and flow-mechanics ◦ Need 4.1: Packages are in the proper orientation  Need 4.1A: Label is in proper orientation position relative to the package  Need 4.1B: All packages are centered in the x-ray beam  Need 4.1Ba: Packages are conveyed in single-file ◦ Need 4.2: Keep allocation of floor space constant 5Rev 01

NeedThe ProductNeeds toImp. N 1.1Product integrity is maintainedMeet specifications5 N 1.2 Equipment satisfies USDA Regulations as well as the AMI checklist Meet specifications5 N 1.3OSHA Safety requirements are metMeet specifications4 N 2.1Reallocate direct flipping laborDecrease man-hours4 N 2.2Reallocate direct alignment laborDecrease man-hours4 N 2.3Reallocate direct labeling laborDecrease man-hours4 N 2.4Camera labeling system is low priorityControl project scope4 N 3.1Maintain or decrease takt timeDecrease processing time4 N 3.2 All packages get scanned by the x-ray at desired belt speed Scan all packages3 N 4.2Keep allocation of floor space constantFit within specified area3 N 3.3 Control flow to scaling operation(Control flow-rate variance) Minimize variance3 Importance Scale: 5 = Most Important, 1 = Preference Only 6Rev 01

NeedThe ProductNeeds toImp. N 4.1A Label is in proper orientation and position relative to the package Be aligned3 N 4.1BAll packages are centered in the x-ray beamScan entire package3 N 3.3A Packages must flow in a format that works with the X-ray Meet specification2 N 4.1Packages are in the proper orientationBe aligned2 N 4.1BaPackages are conveyed in single-fileMeet specification2 N 1.3ARemove ergonomic issues and concernsMinimize risks1 Importance Scale: 5 = Most Important, 1 = Preference Only 7Rev 01

MetricNeed MetDescriptionImp.Units Marginal Value Ideal Value 5N 1,2FDA/USDA Specs5Pass/FailPass 6N 1,2,15AMI Sanitary Design Checklist5Pass/FailPass 7N 1,3OSHA Safety Specs5Pass/FailPass 10N 6,7Direct Flip/Align Man Hours5hours<75% Current<50% Current 11N 1Keep Product Integrity5Pass/FailPass 8N 9,12Flip4Pass/FailPass 9N 4,8Belt Speed (X-Ray)4m/s or ft/sCurrent 10N 5Direct Label Man Hours4Hours<75% Current<50% Current 12N 15Ergonomic Risk4CIC Risk Assess unitsCurrent<24 1N 4,13Flow Rate3pc/min7>7 4N 9,12Label Orientation3Deg N 9,10,12,13,14Pc. Alignment2in from centerTBD0 3N 9,12Pc. Perpendicularity2Deg N 11,14Flow Rate Variance1% of Rate+/ %+/- 0-25% 8Rev 01

SubsystemComponentComponent CostSubsystem Cost Flipping Parts & labor$2,600 MountingTBD$2,600+ Aligning Parts$2,100 LaborTBD ConveyorTBD$2,100+ Camera SystemTBD 2-18TBD Labeling Cal-PakTBD 2-18 Label assist$660 + enclosureTBD 9Rev 01

Problem Definition Changes Justification Compromises Revised Footprint 10Rev 01

 Flow Rate ◦ With current layout the flip must occur in 2/3 second  Footprint ◦ With current proposal system footprint would force the X-ray back 18in ◦ Need to include an secondary transport belt 2/3 sec 6 sec 11Rev 01

Previous: Now: AlignFlipX-RayLabelFlipAlignX-RayLabel 12Rev 01

 Flow Rate ◦ With new layout the flip must occur in 4 seconds ◦ Trailing edge/leading edge  Footprint ◦ Removes secondary flip belt ◦ Allows for a more compact flip angle ◦ Removes wall clearance issues  Flipper Feed  Take advantage of the MultiVac step output 13Rev 01

 X-Ray machine location ◦ Move the X-ray back maximum 6in ◦ Drop the X-ray to lowest height setting  Flip will be located on MultiVac side of the wall 14Rev 01

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Problem Definition Options Proposal Risks Flipper Assembly Controls Bill of Materials 17Rev 01

 Currently, packages from the MultiVac are flipped by hand – this requires excessive labor and presents an ergonomic issue. The flipper must complete the task of flipping packages that come off of the MultiVac in a safe manner to the operators and the product.  Customer needs addressed: 1.1, 1.2, 1.3, 2.1, 3.1, Rev 01

 High speed flipper after the alignment ◦ Keeps old process path ◦ Flips the product so quickly that it will be unsafe  Lower speed, higher load and capacity flipper before the alignment process ◦ Flipper will be heavier, but move slower ◦ Slower motion will be much safer and easier to control ◦ Lower risk of damaging the packaging 19Rev 01

 Flipping mechanism similar to what was shown last week. ◦ As product is sent off the MultiVac conveyer 2 pieces at a time, they slide onto the flipper tray. The tray then actuates via two pneumatic cylinders. ◦ The product rotates about a point slightly below the mass center of the packages well past vertical onto the lower dual conveyer belts. ◦ Once the packages clear the flipper, it returns to the original position to accept the next 2 packages. ◦ Product entering the tray, flipping, exiting and return occurs within a 4 second timeframe. 20Rev 01

 Risk 1: The flipper cannot handle the load ◦ Solution: The flipping tray and hinge mechanisms are robust enough to handle higher loads. Dual ¾” air cylinders are utilized to provide a uniform load.  Risk 2: The flipper moves packages in such a manner that the motion is uncontrolled ◦ Solution: Control the actuation rate such that is slow enough that a minimal force is applied to the package. The product rotates about or near to its center of gravity, so that a minimal rotational force is applied.  Risk 3: The package does not exit the flipper ◦ Solution: The exit side of the flipper is less than ½ the length of the shortest package, providing enough surface area for all of the packages to be pulled off by the exit belt.  Risk 4: The packages slide off the flipper or become misaligned ◦ Solution: Guards are placed on either side of the flipper to maintain their alignment throughout the flipping process.  Risk 5: The flipper becomes jammed or disabled ◦ Solution: An emergency stop will evacuate all air from the system, allowing the flipper to be moved freely by hand.  Risk 6: Air pressure is lost or the product does not need to be flipped ◦ Solution: A bypass slide can be placed over the flipping mechanism when it is in the retracted position that will allow the product to slide from the upper to lower conveyer without assistance. 21Rev 01

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Negative solenoid activates for short time Positive solenoid activates for short time Laser beam reconnects Laser beam broken 26Rev 01

 Standalone system that controls flipper ◦ Inputs: Supply voltage, emergency stop, sensor output ◦ Outputs: Two control voltages to external relays  External relays each cost about $40  2 separate voltage rails must be provided, both capable of delivering high current ◦ At least 2 amps estimated, more than most IC’s can output 27Rev 01

 MSP430 ◦ Advantages: Fully programmable with materials at RIT, comes with board ◦ Disadvantages: $60, requires external relays  555 Timer ◦ Advantages: $5, easy to construct ◦ Disadvantages: May degrade over time, requires a prototyping board, no software components, requires external relays 28Rev 01

 CS82C54Z96 ◦ Advantages: Fully programmable, $7, stand alone ◦ Disadvantages: Requires external relays, programming device not yet located at RIT  Z2681 ◦ Advantages: Fully programmable via USB, will not need external relays ◦ Disadvantages: $105, relatively large device 29Rev 01

30 Bill of Materials PNVendorDescriptionQtyCostTotal SSM DWBimba SS Bimba 3/4" Cylinder2$106.65$ D SSBimbaSS Rod Clevis and Nut2$24.95$49.90 D SSBimbaSS Cylinder Pivot Bracket2$19.40$ K33McMaster Space-Saver Stacked Air Filter/Regulator Stainless Steel, 1/4" Pipe, 12 Max 100 PSI1$ K56McMaster.104" 304SS 24x241$ K36McMaster.104" 304SS 12x241$ K166McMaster.125" 304SS 12x41$ K62McMaster.25" 304SS 6x61$ K556McMaster3/8" x 6' 304SS Tube1$ A530McMaster10-32 SS Weld Nut 10 Pack1$ A330McMaster10-32 SS SHCS, 5 Pack1$ K243McMaster Body-Ported Solenoid Air Control Valve Dbl Solenoid, 4-Way, 2-Pos, 1 Cv, 1/4" NPT, 24 VDC1$ K21McMaster Chemical-Resistant PVDF Tube Fitting Adapter for 1/4" Tube OD X 1/8" NPTF Male Pipe4$2.62$ K18 Polybutylene Manifold Swivel Tube Fitting 2 Outlets, for 1/4" Tube OD, 1/4" NPT Thread2$12.26$24.52 Rev 01

31 Bill of Materials PNVendorDescriptionQtyCostTotal 9066K31McMaster Corrosion Resistant Air Flow Control Valve 1/4" Tube to 1/4" Tube Flow Control Direction2$20.60$ K31McMaster 3-A Sanitary White PVDF Tubing 1/8" ID, 1/4" OD, 1/16" Wall Thk, Semi-Clear20$2.10$ K548McMaster Polybutylene & Brass Push-to- Connect Fitting Wye for 1/4" Tube OD, Gray4$4.91$19.64 LaborProcessPart/DescriptionTimeRate All labor is estimate only Cut/FormFlipper Tray5$80.00$ WeldingFlipper Tray2$80.00$ Cut/FormFlipper Mount3$80.00$ WeldingFlipper Mount2$80.00$ MachineMounts3$80.00$ BuildPneumatics/Controls4$40.00$ TOTAL$2, Rev 01

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 Outside vendor to supply conveyor system  Possible Vendors: ◦ Kleenline Corporation ◦ Lipe Automation  Lead Time: Unknown  Capabilities: Full/Half-width product  Cost: Unknown 34Rev 01

 Electric linear actuators are triggered by object detection beam.  Sliding pusher-plate contacts product and gently pushes to center of conveyor.  Logic controller allows for use on all product lines.  Products end up in single file line, to safely continue through x-ray detection.  Very compact system 35Rev 01

 Pusher System has marginal impact on space constraints  Variable speed twin belt conveyor system 36Rev 01

Preliminary Bill of Materials to order from McMaster-Carr Rev-01 Item Part Number Quan tity Unit PriceTotal FDA-Compliant Rulon-Lined Guide Block, 1" Width9728K34$29.36$ " Long Rail for 1" Width FDA-Compliant Rulon-Lined Guide Block9728K624$27.30$ Space-Saver Stacked Air Filter/Regulator Stainless Steel, 1/4" Pipe, 12 Max 100 PSI4331K331$ Body-Ported Solenoid Air Control Valve Dbl Solenoid, 4- Way, 2-Pos, 1 Cv, 1/4" NPT, 24 VDC6196K2431$ Chemical-Resistant PVDF Tube Fitting Adapter for 1/4" Tube OD X 1/8" NPTF Male Pipe1901K214$2.62$10.48 Polybutylene Manifold Swivel Tube Fitting 2 Outlets, for 1/4" Tube OD, 1/4" NPT Thread5203K182$12.26$24.52 Corrosion Resistant Air Flow Control Valve 1/4" Tube to 1/4" Tube Flow Control Direction9066K312$20.60$ A Sanitary White PVDF Tubing 1/8" ID, 1/4" OD, 1/16" Wall Thk, Semi-Clear5390K3120$2.10$42.00 General-Purpose Track Roller with Stud Stainless Steel, 89 lb Dynamic Load Capacity60135K514$36.65$ ' Rail for 89 lb Dynamic Load Capacity, SS General- Purpose Track Roller wth Stud60135K5211$ ' 1.25"x1.25" 304 SS L-Channel, 3/16" Thick8993K455$67.49$ Multipurpose Stainless Steel (Type 304) #2B Mill Finish,.060" Thick, 24" X 36"8983K333$54.01$ mm Dia Body Light Beam Sensing Switch NPN, DC Input, Object Reflecting with Male Plug65845K222$94.73$ Washdown Stainless Steel Air Cylinder 3/4" Bore, 6" Stroke Length6239K1152$123.56$ Miscelaneous Stainless Steel Hardware (Panels, Bolts, Wasters…etc)N/A1$ Materials Total Estimated Cost $2, Rev 01

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Estimates for time requirements of human resources Item Quantit yHoursTotal Design Programming of Actuation System Diagnostics and Trouble Shooting Miscelaneous Welded Connections16.00 Conveyor System Modification15.00 Cover Box Assembly with Pivot Support Bridge Pivoting Arm Assembly Miscelaneous Bolted Connections12.00 Mounting of Actuation System12.00 Actuator Support Brace Actuator Mounting Bracket Pusher Plate Assembly Guide Rail Bracket Guide Rail Mounting Total Estimated Time Rev 01

 Risk 1: TheAligner cannot handle the load ◦ Solution: The current actuators operate with a factor of safety of 10.  Risk 2: TheAligner moves packages in such a manner that the motion is uncontrolled ◦ Solution: Control the actuation rate such that is fast/slow enough that a minimal force is applied to the package, but product is aligned at a sufficient rate to have desired flow rate.  Risk 3: Product aligning improperly ◦ Solution: Actuator control devices will minimize the risk of over or under pushing product.  Risk 4: Jamming of product ◦ Solution: An emergency stop will evacuate air from the system, allowing thealignerto beretracted byhand.  Risk 5: Air pressure is lost and aligning process is delayed ◦ Solution: The emergency relief system will allow aligner to return to its retracted position and the product can be aligned with manual assistance.  Risk 6: Pinch points regarding moving parts ◦ Solution: Protective covers in place over all moving components. The emergency relief system will allow aligner to be stopped immediately should a pinch occur.  Risk 7: Aligner system is not serviceable ◦ Solution: Standard parts and components have been specified from preferred suppliers and the assembly has been designed an a manner that allow maintenance easy access to system. 40Rev 01

Problem Definition Options Fully Automated System Partially Automated System Cal-Pak 41Rev 01

 Current method of hand labeling can be time consuming and has the potential to cause ergonomic problems  Development of a fully or partially automated labeling system would eliminate or alleviate these issues 42Rev 01

 Fully automated labeling system ◦ Uses optical system to determine position of package ◦ Applies label to package  Partially automated label assist system ◦ Removes label from backing paper roll 43Rev 01

 Cost: TBD ◦ Meeting with Cal-Pak set up for Thursday 2/18  Benefits ◦ Current labor required to hand label product can be reallocated  Need 2.3 ◦ Increased speed  Need 3.1 ◦ Ergonomic issues of process removed  Need 1.3A Fully Automated System 44Rev 01

 Risks ◦ Loss of air pressure could effect system ◦ System would need to be made to handle area cleaning procedures ◦ Possible safety concerns need to be addressed Fully Automated System 45Rev 01

 Cost: ~$660  Benefits ◦ Improves speed of labeling  Need 3.1 ◦ Ergonomic improvement  Need 1.3A ◦ Fast implementation ◦ Controls backing of removed labels 46Rev 01

 Shortfalls ◦ Does not allow for complete reallocation of required labor  Need 2.3  Risks ◦ Enclosure would need to be made to handle area cleaning procedures 47Rev 01

 Founded 1993, based in North Andover, Massachusetts  Designers of packaging equipment including automatic labelers  Current contacts ◦ Tom Coburn, representative in MA ◦ Ted Trump, local representative  Meeting scheduled for Thursday, February 18 48Rev 01

 CAD automation  Individual component test builds ◦ Prototype construction ◦ Lifecycle testing ◦ Strength test ◦ Functionality test ◦ Statistical analysis  Component integration ◦ Flow rate ◦ Functionality testing ◦ Statistical analysis  More detailed document week 11 49Rev 01

 Order parts  Preliminary testing  Build prototype  Final prototype testing  Product implementation 50Rev 01

Stress Analysis 51Rev 01

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