detailed design review p09711- automation/improvement of wegmans cookie line packaging
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EDGE™
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)
EDGE™
Project OverviewObjective:
• 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.
EDGE™
Customer Needs HierarchyNeed 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 RestrictionsNeed 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)
EDGE™
Target SpecificationsMetric No. Need Nos. Metric Importance Units Marginal value Ideal Value
1 Need 1.1, 1.2, 1.3, 1.4, 2.1
Percentage of packages with excess (2 or more) cookies (currently at 95%)
9 % 60% (elimination of
packages with 6 or more extra
cookies)
0% (elimination of packages
with 2 or more extra
cookies)2 Need 1.1, 2.1 Weight of cookie
package9 grams 420 397
3 Need 6.1, 6.2, 6.3, 6.4
Follows Wegmans' sanitation standard
3 Y/N N Y
4 Need 4.1, 5.1, 5.2, 5.3
Requires training that takes X minutes
5 minutes 60 15
5 Need 4.1, 4.2, 5.2 Changeover time 5 minutes 20 5
6 Need 1.1, 1.2, 1.3, 1.4, 3.1, 3.2
Creates clear separation of product for packaging
9 Y/N Y Y
7 Need 4.2 Throughput 5 average packages per hour
1500 1700
8 Need 7.1 Cost 9 $ < $10,000 < $5,000
EDGE™
System Related to Needs and Metrics
Sifting Bar:• Need 4.2• Metric 7
Push-Rod:• Metric 6
Weigh Station:• Need 1.1 & 2• Metric 1 & 2
Incline Gate: (not shown)• Need 3, 4.1 & 5• Metric 4 & 5
EDGE™
Economic Potential
EDGE™
Related Engineering SpecificationsMetric 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
1.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
EDGE™
Overall System
EDGE™
Sifting Bar System
EDGE™
Tunnel System
EDGE™
Drop Chute System
EDGE™
Weigh Station System
EDGE™
Material Comparison and Selection
SIFTER BARDIMENSIONS* 13" x 3" x .25"
VOLUMEUS (in^3) 9.8
Metric (cm^3) 159.8MATERIAL MASS (g)Polycarbonate 191.7Stainless Steel 1254.2HDPE 151.8Polypropylene 145.4
PUSH-ROD WALLDIMENSIONS* 10" x 1.25" x .25 "
VOLUMEUS (in^3) 3.1
Metric (cm^3) 51.2MATERIAL MASS (g)Polycarbonate 61.5Stainless Steel 402.0HDPE 48.6Polypropylene 46.6
DROP CHUTEVOLUME in^3 cm^3
US (in^3) 21.1 V1 4.0 65.5Metric (cm^3) 344.9 V2 3.0 49.2
MATERIAL MASS (g) V3 5.3 86.9Polycarbonate 413.9 V4 0.8 12.3Stainless Steel 2707.8 V5 8.0 131.1HDPE 327.7Polypropylene 313.9
EDGE™
Electronic System Overview
Altera DE2-70 FPGA Stepper Motor Drivers Bipolar Stepper Motors
Scales
Rotate Chute
Clear Scale 1
Clear Scale 2
• 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
Move Sifter
EDGE™
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.
EDGE™
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.
EDGE™
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.
EDGE™
Weighing Station ScaleDoran 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.
EDGE™
Stepper Motor Driver (EasyDriver V3)
• 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
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
EDGE™
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)
EDGE™
Motor Torque Calculations
Nf FF
Ns
mkgmaFN 9.4)8.9)(5.0( 2
NNFf 715.1)35.0)(9.4(
mNmNdF 08712.0)0508.0)(715.1(
cmgEmN 40197.11
cmgmEmNTorque 888)40197.1)(08712.0(
Torque required to push cookies off scale
Force due to friction:
Normal Force:
(Assuming max weight on scale is 500g)
(Coefficient of friction for stainless steel is 0.35)
Torque:
(Assume max gear radius of 2in (0.508m))Newton meters to gram centimeters:
22
12
1WLmI
telerationAngularAcc
elerationAngularAccITorque
)(
cmgmmNs
radmkgT
mkgmkgI
srad
ss
rads
rads
revrev
3940387.0)2)(0193.0(
0193.0)232.0)(5.0(12/1
25.0
01
0.11666.012/130
22
22
2
Torque required to rotate chute (insignificant)
Moment of Inertia:
(Using rectangular plate formula for easier calculation)
To rotate chute in less than 0.5s (max rotation 30 deg)need angular acceleration:
EDGE™
Bill of MaterialsProduct Number Vendor Product Desc. Quantity List Price
Total Part Price Lead Time
3005XL Doran Doran 10"x10"x2" weigh scale 2 $1,000.00 $2,000.00 <2 weeks
2342K81McMaster-Carr
Perma-Lube Steel Ball Bearing - ABEC-1 Double Sealed, No. R2 for 1/8" Shaft Dia, 3/8" OD 6 $12.45 $74.70 <1 week
97395A525McMaster-Carr
Type 316 Stainless Steel Dowel Pin 3/8" Diameter, 1-1/4" Length 3 $2.82 $8.46 <1 week
6007K36McMaster-Carr Hardened Precision Tubular Shaft 1" OD, .6" ID, 12" Length 1 $40.50 $40.50 <1 week
90631A411McMaster-Carr
Znc-Pltd Grade 2 Stl Nylon-Insert Hex Locknut 10-32 Thread Size, 3/8" Width, 15/64" Height 1 $2.60 $2.60 <1 week
99154A390McMaster-Carr
18-8 SS Low Profile Precision Shoulder Screw Slotted Head, 1/4" Shldr Dia, 1/2" L Shldr, 10-32 Thrd 1 $5.77 $5.77 <1 week
N/A Wegmans Wegmans Mini-Chocolate Chip Cookies 397g 10 $1.30 $13.00 <1 week
57655K34McMaster-Carr
Molded Nylon 14-1/2 Deg Angle Spur Gear 32 Pitch, 16 Teeth, 0.5" Pitch Dia, 3/16" Bore 2 $3.00 $6.00 <1 week
57655K62McMaster-Carr
Molded Nylon 14-1/2 Deg Angle Spur Gear Rack, 32 Pitch, 3/16" Face Width, 3/16" H O'all, 1'L 2 $4.63 $9.26 <1 week
97633A200McMaster-Carr
Black-Phosphate Steel External Retaining Ring for 1/2" Shaft Diameter 1 $8.56 $8.56 <1 week
7528A13McMaster-Carr Weld-on #3 Cement for Acrylics 1 Pint Can 2 $12.77 $25.54 <1 week
EDGE™
Bill of Materials (Cont…)Product Number Vendor Product Desc. Quantity List Price
Total Part Price Lead Time
P0304
Terasic Technologies Altera DE2-70 Development and Education Board 1 $599.00 $599.00 <1 week
M-200-ROB-08368
Trossen Robotics EasyDriver V3 Stepper Motor Driver 4 $14.95 $ 59.80 <1 week
237472Jameco Valuepro MOTOR,STEP,12VDC/.4A, 2100 GM-CM 4 $21.49 $85.96 <1 week
8585K33McMaster-Carr Polycarbonate Round Tube 3-1/2" OD, 3-1/4" ID, Clear 1 $15.29 $15.29 <1 week
8585K17McMaster-Carr Polycarbonate Round Tube 1-3/4" OD, 1-1/2" ID, Clear 1 $7.66 $7.66 <1 week
8574K55McMaster-Carr Polycarbonate Sheet 1/4" Thick, 24" X 24", Clear 6 $33.89 $203.34 <1 week
HWS50-12/A
Arrow Electronics AC/DC Power Supply Single-OUT 12V 4.3A 1 $130.58 $130.58 <1 week
N/A N/A Miscellaneous Components (Resistors, Capacitors, etc.) 1 $100.00 $100.00 N/A
Total$3,396.0
2
EDGE™
Risk AssessmentRisk Severity Probability Overall Contingency Plan
Team won't have enough time to create to entire prototype
5 4 20Create only a fourth of the working
prototype
Long lead times on ordered parts may push prototype production back
4 3 12
Order parts by week 11, Set up meeting with Wegmans after detailed design review to arrange the ordering of all long lead time
materials
Weighing technology does not meet expectations
4 2 8Extensively research alternative weighing devices, spend more money on improved
weighing device
Insufficient funds to produce full design
5 1 5
Create only a fourth of the working prototype, perform economic analysis to
demonstrate the savings that could be realized from investing in this project
Mechanical and Electrical systems don’t interface well with each other
5 3 15Be aware of the interface between the two,
constant communication between electrical and mechanical engineers
Cookies don’t get pulled by incline gate
3 3 9 Replace incline gate with conveyor
Incline gate does not switch up 1 3 3 Replace incline gate with conveyor
Cookies get stuck in tunnel section 5 5 25Use sifting bar to put cookies into lines
which can be more easily handled by the tunnels
EDGE™
Risk Assessment (Cont…)Risk Severity Probability Overall Contingency Plan
Weigh station doesn’t push out cookies quickly enough
3 3 9Use alternative pushing method instead of push rods, use air at a
high pressure
Chutes don’t switch quickly enough 5 3 15Use one weigh station and close
chute while cookies back up
Settling time is too long 5 3 15Purchase scales with a short
settling time
Chute doors don’t open/close at right time
3 3 9Prioritize electrical-mechanical
interfacing issues
Conveyor failure 5 3 15 Create emergency stop switch
Difficulty controlling push rod using motors
4 2 8Use air compression to control
push rod
Force of cookies falling on scale from chute gives a false reading on scale 3 5 15
Take an average of the weight samples when deciding when to
push cookies out of weigh station
Importance Scale: 1 through 51 = Consequences from risk have little effect on the cookie line’s flow5 = Consequences from risk halt the entire cookie line or project
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