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Automation of Wegmans Cookie Line Packaging

Develop an automated prototype to accurately separate and package mini cookies by weight, reducing waste and improving efficiency in the packaging process.

scottbsmith
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Automation of Wegmans Cookie Line Packaging

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  1. Detailed Design ReviewP09711- Automation/Improvement of Wegmans Cookie Line Packaging Project Team: Stephanie Rager (IE), Bruno Coelho (ME), Mark Voss (ME), Chukwuma Morah (IE), Brian Duffy (EE), Benjamin Powell (EE)

  2. Project Overview Objective: • Present our final detailed design and bill of materials • Receive feedback about our final design and BOM Project Description: Wegmans bakes and packages all of their mini cookies at their bakeshop located here in Rochester on Brookes Avenue. Currently the packaging is done by six or seven people who stand around a conveyor and pull the cookies into the clam-shell packages. This leads to the problem of packing more cookies than needed into a package. The mini-cookie package calls for 397 grams worth of cookies but employees sometimes package up to 450 grams. This is a loss for Wegmans because customers are receiving more cookies than they are paying for. This project will look into building an automated prototype that will separate the cookies into the correct amount by weight, which the employees can then package.

  3. Customer Needs Hierarchy • Need 1: Separates Products by Weight • Need 1.1 Must separate Mini-Chocolate Chip Cookies by weight (9) • Need 1.2 Should separate other Mini-Cookies by weight (5) • Need 1.3 Should separate Mini-Muffins by weight (3) • Need 1.4 Should separate Brownie Bites by weight (3) • Need 2: Waste Reduction • Need 2.1 Must reduce the amount of excess Mini-Cookies in package (9) • Need 3: Separates Products by Count • Need 3.1 Want to be able to separate Cookie Chunks by count (3) • Need 3.2 Want to be able to separate other products by count that are packaged in that way on this line (3) • Need 4: Long Term Solution • Need 4.1 Should be adjustable for other products (5) • Need 4.2 Must not substantially slow down the process (9) • Need 5: Labor/Employee Use • Need 5.1 Must be simplistic for employees to use (9) • Need 5.2 Must not create a substantial amount of extra labor for employees (9) • Need 5.3 Should be repeatable for employees (5) • Need 6: Food Environment Restrictions • Need 6.1 Production floor ready product must be stainless steel (3) • Need 6.2 Production floor ready product must not be painted (3) • Need 6.3 Production floor ready product must be water tight (3) • Need 6.4 Production floor ready product must meet the NEMA4 level (will take a light water hose spray) (3) • Need 7: Budget/Cost • Need 7.1 Must not be considered a capital investment (> $10,000) (9)

  4. Target Specifications

  5. System Related to Needs and Metrics • Incline Gate: • (not shown) • Need 3, 4.1 & 5 • Metric 4 & 5 • Sifting Bar: • Need 4.2 • Metric 7 • Push-Rod: • Metric 6 • Weigh Station: • Need 1.1 & 2 • Metric 1 & 2

  6. Economic Potential

  7. Related Engineering Specifications • Metric 1: Percentage of cookies with excess packages (currently 95%) • Scale must be capable of measuring 397 +25 grams accurately • Scale resolution must be <= 1 gram • Scale response time (settling time) must be <=0.5 seconds • Drop-chute must switch between weigh stations in < 0.5 seconds • Angle of drop-chute must be at a great enough incline in order to prevent backlog of cookies on chute • Tested at 15, 25, 30, 35 degrees • Scale must be able to send signal to board when correct weight is achieved • Scale has a RS232 output signal • Metric 6: Accurately separates product for packaging • Chute must have an angle of rotation of >=20 degrees • Push-rod must be able to clear the scale in ~ 7.5 seconds • Drop-off ramp must have an angle >= 30 degrees • Metric 7: Throughput • Sifter bar must move at 60 cycles per second • Sifter bar must have teeth with width of at least 0.25 inches • Sifter bar must have spacing areas of 2.5 inches • The funnel must have an angle of 30 degrees or less • The chute must have an angle of 30 degrees

  8. Overall System

  9. Sifting Bar System

  10. Tunnel System

  11. Drop Chute System

  12. Weigh Station System

  13. Material Comparison and Selection

  14. Electronic System Overview • This is a top level view of each component that the FPGA will be controlling • In the following slides each component will be covered in depth Scales Rotate Chute Clear Scale 1 Clear Scale 2 Move Sifter Altera DE2-70 FPGA Stepper Motor Drivers Bipolar Stepper Motors

  15. Board Selection • DE2-70 is a flexible adaptable control device. • User friendly with great support from Altera. • Interfaces with each device and has expandability. • Able to incorporate an interactive interface. • Low cost for the amount, and quality of components. Comes with; Power supply, Programming software, programming cables, extra cables.

  16. Board Selection (Cont…) • Over view of board specifications and what is included for our primary purposes. • Cyclone II FPGA • Two 32 Mbyte SDRAM • 8 Mbyte Flash Memory • 50 Mhz oscillator • USB host/slave configurations • RS232 • Ethernet • Two 40 pin expansion headers • Miscellaneous other de-bug help devices on the board and in the software. • Motor control and weight interface • Interfaces with RS232 or USB for weight stations. Also can interface with Ethernet which is an option on weight stations. • 40 pin expansion headers have an output voltage of 3.3V TTL logic and a current max of 4mA load off the FPGA. Which interfaces with the motor drivers input requirements. • Other Reasons for choosing board. • EE’s have familiarity with Altera components and their support; which allows for faster use of board and more functionality to be implemented.

  17. Power Supply Selection • Lambda HWS50-12/A • 12 Volt, 4.2A, AC to DC supply • Protects against over current by 104% or greater of designed current value. • Immunity to stepper voltage and current fluctuation • Referred to this product by a sales rep at Arrow Gary Fredricks.

  18. Weighing Station Scale Doran 7000XL series • 10” x 10” x 2” high. • Max load of either 4.5kg or 2.3kg depending on model. • Resolution of 0.5g with the 2.3kg max and 1g with the 4.5kg max. • 1000% overload protection with NEMA4X and IP69K washdown protection. • 6 Digit red LED display • 304 Stainless Steel • 115VAC 50/60Hz power required • Cost for scale is attached in quote package • Communication Interface Options. • RS232, USB, and washdown Ethernet. • Speeds correlating to each connection are RS232 115.2kbps, USB 2.0 480Mbps, and Cat 5e Ethernet 1Gbps. • Options available for this series are chosen as such either USB, RS232, or Ethernet. There can only be one connection per weight station with this series.

  19. Stepper Motor Driver (EasyDriver V3) Inputs: Step Input – digital logic pulses 0V to 5V supplied by board Direction – digital logic 0V to 5V supplied by board Power – 6V to 30V DC supplied by AC to DC adapter Output: Excitation of motor coils to correctly turn rotor the desired number of steps • Chopper microstepping driver based on the Allegro A3967 driver chip • Very flexible board, can control a broad range of stepper motors • Allegro A3967 data sheet: http://www.sparkfun.com/datasheets/Robotics/A3967.pdf • EasyDriver V3 schematic: http://www.sparkfun.com/datasheets/Robotics/EasyDriver-v3-Schematic.pdf • Designed to operate bipolar stepper motors in full-, half-, quarter-, and eighth-step modes, with output drive capability of 30 V and ±750 mA • By simply inputting one pulse on the STEP input the motor will take one step (1.8 degrees), to increase the speed of the motor, the frequency of the step inputs in increased • By inputting a low or high on the DIRECTION pin will determine the direction of rotation of the motor

  20. Stepper Motor (Jameco Valuepro 39BYG401A-R) Inputs: Motor Coil A – Signal supplied by stepper driver Motor Coil B – Signal supplied by stepper driver Power – 12VDC supplied by AC to DC adapter Output: Precise rotation of the rotor corresponding to inputs • 12VDC, 400mA, Step Angle 1.8 degrees, 2100 g-cm torque • Jamco Valupro Stepper Motor datasheet: http://www.jameco.com/Jameco/catalogs/c291/P74.pdf • The current needed by the stepper is within the 150-750mA current range of the stepper driver • The rotor speed and position can be programmed and is adjustable • Can easily be controlled by the driver board, it will provide enough torque to meet the chute and scale clearing specs (on next slide)

  21. Motor Torque Calculations Torque required to push cookies off scale Force due to friction: Torque required to rotate chute (insignificant) Moment of Inertia: Normal Force: (Using rectangular plate formula for easier calculation) (Assuming max weight on scale is 500g) (Coefficient of friction for stainless steel is 0.35) Torque: To rotate chute in less than 0.5s (max rotation 30 deg) need angular acceleration: (Assume max gear radius of 2in (0.508m)) Newton meters to gram centimeters:

  22. Bill of Materials

  23. Bill of Materials (Cont…)

  24. Risk Assessment

  25. Risk Assessment (Cont…) Importance Scale: 1 through 5 1 = Consequences from risk have little effect on the cookie line’s flow 5 = Consequences from risk halt the entire cookie line or project

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