1. P12711 Parbake Mezzanine DDR 1

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

3. Project Plan 3

4. 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

5. 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

6. System Design Overview 6

7. Box Transfer – Box Slide 7

8. 8

9. 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

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

11. Counting Vertical Counters 11

12. Counting - Vertical Counter 12

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

14. Counter Prototype 14

15. 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

16. 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

17. 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

18. Counter Assembly BOM Counter Assembly Product DescriptionDimensionsLength (in)MaterialQty.Unit Cost ($)Total Cost ($) Counter Flap2.75"x1/16"10.75Stainless266.86133.71 Counter Rod1/8"11.50Stainless22.024.05 Counter Support,2"x0.5"6.00Stainless430.02120.08 Set Screw4-40 0.112" Stainless30.330.98 Small Counter Guide0.5"x2"30.00Stainless151.77 Long Counter Guide19.25"x0.5"x2"19.25Stainless127.11 1K-Potentiometer 24.378.74 7-Seg LED Display 21.763.52 Dual 4-bit Binary Counter 20.611.22 2xBCD 7-Seg Driver 21.713.42 Box Exit Conveyor Chute60"x52"x1/16"-Stainless1274.64 Counter Total629.23 18

19. Aligning Product 19

20. 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

21. Video of Rounds Testing 21

22. Video of Baguette Testing 22

23. Batard Test 23

24. 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

25. 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

26. Guide Assembly BOM Guide Assembly Product DescriptionDimensionsLength (in)MaterialQty.Unit Cost ($)Total Cost ($) Support.5"x2"x8"8.000Aluminum411.2745.07 Shaft.5" dia x 40"7.854Steel211.0622.12 Guide Holder1"x1.5"x.5"0.750Aluminum41.064.23 HolderShaft.25" dia x 4"0.196Steel40.281.11 3ft Guide3"x.5"x36"0.540UHMW20.761.52 Guide to shaft.75"x1"x1.25"0.938UHMW41.325.28 Guide Total79.33 26

27. Inspection 27

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

29. Batching/Accumulating 29

30. Sorters 30

31. Gates 31

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

33. 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

34. 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

35. 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

36. 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

37. Batching Assembly BOM 37 Batching Assembly Product DescriptionDimensionsLength (in)MaterialQty.Unit Cost ($)Total Cost ($) Bolt10" 1/4 -20-Stainless86.3350.64 Bolt2.25" 1/4 -20-Stainless17.04 Bolt1" 1/4 -20-Stainless17.69 U-Bolt1.625-Stainless123.2438.88 Nut1/4 " - 20-Stainless110.10 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 stock3Stainless177.68 90 Angle Stock1.25"2.25Stainless110.02 Threaded Rod1/4" -209.25Stainless27.6715.34 Big Gate.375" x 2" flat stock10.75UHMW27.6615.32 Small Gate.375" x 2" flat stock7.25UHMW211.3622.72 Sorting Gate.375" x 2" flat stock17.75UHMW218.7537.50 Pneumatic Actuator--Stainless636.04216.24 Solenoid Valve Stainless673.89443.34 Gate Piston Link7/8" round stock1.625Stainless139.51 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 stock150Stainless233.8067.60 Batching Total1,095.65

38. Support Frame BOM Support Frame Assembly Product DescriptionDimensionsLength (in)MaterialQty. Unit Cost ($) Total Cost ($) Main Beam.75" x.75" bar stock 39Stainless387.22261.66 Vertical Support.75" x.5" bar stock9Stainless134.03 Corner Support.75" x.5" bar stock4Stainless115.12 Side Support.75" x.5" bar stock11.25Stainless142.53 Crossover Beam.75" x.5" bar stock15Stainless156.71 Side Mount.25" x 2" flat stock2.75Stainless135.00 Support Frame Total445.05 38

39. End of Conveyor 39

40. 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

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

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

43. 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

44. 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 44

45. 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

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

47. Questions? Comments? 47