P12711 Parbake Mezzanine DDR

1. P12711 Parbake Mezzanine DDR

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

3. Project Plan

4. Risk Assessment Update New risks associated with design

5. Functional Decomposition

6. System Design Overview

7. Box Transfer – Box Slide

8. Box Transfer – Box Slide

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

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

11. Counting Vertical Counters

12. Counting - Vertical Counter

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

14. Counter Prototype

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)

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

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

18. Counter Assembly BOM

19. Aligning Product

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

21. Video of Rounds Testing

22. Video of Baguette Testing

23. Batard Test

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

25. Confidence Level • Rounds • Can be done • Rolls • Varying success depending on roll. Showed promise but will require further testing • Baguettes and Batards • If the ‘spin’ and ‘stick’ conditions can be eliminated, the sorting can be done

26. Guide Assembly BOM

27. Inspection

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

29. Batching/Accumulating

30. Sorters

31. Gates

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

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)

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

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

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

37. Batching Assembly BOM

38. Support Frame BOM

39. End of Conveyor

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.

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

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

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.

44. Total Costs

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?

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

47. Questions? Comments?