Detailed Design ReviewProject #10715

2/12/10

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 NeedsEngineering MetricsProjected 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

Need The Product Needs to Imp.N 1.1 Product integrity is maintained Meet specifications 5

N 1.2 Equipment satisfies USDA Regulations as well as the AMI checklist Meet specifications 5

N 1.3 OSHA Safety requirements are met Meet specifications 4 N 2.1 Reallocate direct flipping labor Decrease man-hours 4 N 2.2 Reallocate direct alignment labor Decrease man-hours 4 N 2.3 Reallocate direct labeling labor Decrease man-hours 4 N 2.4 Camera labeling system is low priority Control project scope 4 N 3.1 Maintain or decrease takt time Decrease processing time 4

N 3.2 All packages get scanned by the x-ray at desired belt speed Scan all packages 3

N 4.2 Keep allocation of floor space constant Fit within specified area 3

N 3.3 Control flow to scaling operation(Control flow-rate variance) Minimize variance 3

Importance Scale: 5 = Most Important, 1 = Preference Only

6Rev 01

Need The Product Needs to Imp.

N 4.1A Label is in proper orientation and position relative to the package Be aligned 3

N 4.1B All packages are centered in the x-ray beam Scan entire package 3

N 3.3A Packages must flow in a format that works with the X-ray Meet specification 2

N 4.1 Packages are in the proper orientation Be aligned 2 N 4.1Ba Packages are conveyed in single-file Meet specification 2 N 1.3A Remove ergonomic issues and concerns Minimize risks 1

Importance Scale: 5 = Most Important, 1 = Preference Only

7Rev 01

Metric Need Met Description Imp. Units Marginal Value Ideal Value

5 N 1,2 FDA/USDA Specs 5 Pass/Fail Pass Pass

6 N 1,2,15 AMI Sanitary Design Checklist 5 Pass/Fail Pass Pass

7 N 1,3 OSHA Safety Specs 5 Pass/Fail Pass Pass

10 N 6,7 Direct Flip/Align Man Hours 5 hours <75% Current <50% Current

11 N 1 Keep Product Integrity 5 Pass/Fail Pass Pass 8 N 9,12 Flip 4 Pass/Fail Pass Pass 9 N 4,8 Belt Speed (X-Ray) 4 m/s or ft/s Current Current

10 N 5 Direct Label Man Hours 4 Hours <75% Current <50% Current

12 N 15 Ergonomic Risk 4 CIC Risk Assess units Current <24 1 N 4,13 Flow Rate 3 pc/min 7 >7 4 N 9,12 Label Orientation 3 Deg 85-95 902 N 9,10,12,13,14 Pc. Alignment 2 in from center TBD 03 N 9,12 Pc. Perpendicularity 2 Deg 85-95 90

13 N 11,14 Flow Rate Variance 1 % of Rate +/- 25-50% +/- 0-25%

8Rev 01

Subsystem

Component

Component Cost

Subsystem Cost

Flipping

Parts & labor

$2,600

Mounting TBD $2,600+

Aligning

Parts $2,100

Labor TBD

Conveyor TBD $2,100+

Camera

System TBD 2-18 TBD

Labeling

Cal-Pak TBD 2-18

Label assist $660 + enclosure TBD 9Rev 01

Problem DefinitionChangesJustificationCompromisesRevised 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:

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

15Rev 01

16Rev 01

Problem DefinitionOptionsProposalRisksFlipper AssemblyControlsBill 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, 4.2

18Rev 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

22Rev 01

23Rev 01

24Rev 01

25Rev 01

Negative solenoidactivates for short

time

Positive solenoid activates for short

time

Laser beamreconnects

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 MaterialsPN Vendor Description Qty Cost Total

SSM-042.75-DW Bimba SS Bimba 3/4" Cylinder 2 $106.65 $213.30D-54565-SS Bimba SS Rod Clevis and Nut 2 $24.95 $49.90D-55203-SS Bimba SS Cylinder Pivot Bracket 2 $19.40 $38.80

4331K33 McMaster

Space-Saver Stacked Air Filter/Regulator Stainless Steel, 1/4" Pipe, 12 Max SCFM @ 100 PSI 1 $277.02 $277.02

9785K56 McMaster .104" 304SS 24x24 1 $163.21 $163.219785K36 McMaster .104" 304SS 12x24 1 $86.00 $86.00

8992K166 McMaster .125" 304SS 12x4 1 $14.12 $14.126620K62 McMaster .25" 304SS 6x6 1 $21.65 $21.65

8457K556 McMaster 3/8" x 6' 304SS Tube 1 $32.89 $32.8998697A530 McMaster 10-32 SS Weld Nut 10 Pack 1 $6.73 $6.7394912A330 McMaster 10-32 SS SHCS, 5 Pack 1 $4.53 $4.53

6196K243 McMaster

Body-Ported Solenoid Air Control Valve Dbl Solenoid, 4-Way, 2-Pos, 1 Cv, 1/4" NPT, 24 VDC 1 $117.42 $117.42

1901K21 McMaster

Chemical-Resistant PVDF Tube Fitting Adapter for 1/4" Tube OD X 1/8" NPTF Male Pipe 4 $2.62 $10.48

5203K18

Polybutylene Manifold Swivel Tube Fitting 2 Outlets, for 1/4" Tube OD, 1/4" NPT Thread 2 $12.26 $24.52

Rev 01

31

Bill of MaterialsPN Vendor Description Qty Cost Total

9066K31 McMaster

Corrosion Resistant Air Flow Control Valve 1/4" Tube to 1/4" Tube Flow Control Direction 2 $20.60 $41.20

5390K31 McMaster

3-A Sanitary White PVDF Tubing 1/8" ID, 1/4" OD, 1/16" Wall Thk, Semi-Clear 20 $2.10 $42.00

5111K548 McMaster

Polybutylene & Brass Push-to-Connect Fitting Wye for 1/4" Tube OD, Gray 4 $4.91 $19.64

Labor Process Part/Description Time Rate All labor is estimate

onlyCut/Form Flipper Tray 5 $80.00 $400.00Welding Flipper Tray 2 $80.00 $160.00

Cut/Form Flipper Mount 3 $80.00 $240.00 Welding Flipper Mount 2 $80.00 $160.00 Machine Mounts 3 $80.00 $240.00 Build Pneumatics/Controls 4 $40.00 $160.00

TOTAL $2,523.41

Rev 01

32Rev 01

33Rev 01

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

ItemPart

NumberQuantity

Unit Price Total

FDA-Compliant Rulon-Lined Guide Block, 1" Width 9728K3 4 $29.36 $117.4413" Long Rail for 1" Width FDA-Compliant Rulon-Lined Guide Block 9728K62 4 $27.30 $109.20Space-Saver Stacked Air Filter/Regulator Stainless Steel, 1/4" Pipe, 12 Max SCFM @ 100 PSI 4331K33 1 $277.02 $277.02Body-Ported Solenoid Air Control Valve Dbl Solenoid, 4-Way, 2-Pos, 1 Cv, 1/4" NPT, 24 VDC 6196K243 1 $117.42 $117.42Chemical-Resistant PVDF Tube Fitting Adapter for 1/4" Tube OD X 1/8" NPTF Male Pipe 1901K21 4 $2.62 $10.48Polybutylene Manifold Swivel Tube Fitting 2 Outlets, for 1/4" Tube OD, 1/4" NPT Thread 5203K18 2 $12.26 $24.52Corrosion Resistant Air Flow Control Valve 1/4" Tube to 1/4" Tube Flow Control Direction 9066K31 2 $20.60 $41.203-A Sanitary White PVDF Tubing 1/8" ID, 1/4" OD, 1/16" Wall Thk, Semi-Clear 5390K31 20 $2.10 $42.00General-Purpose Track Roller with Stud Stainless Steel, 89 lb Dynamic Load Capacity 60135K51 4 $36.65 $146.601' Rail for 89 lb Dynamic Load Capacity, SS General-Purpose Track Roller wth Stud 60135K521 1 $34.16 $34.167' 1.25"x1.25" 304 SS L-Channel, 3/16" Thick 8993K45 5 $67.49 $337.45Multipurpose Stainless Steel (Type 304) #2B Mill Finish, .060" Thick, 24" X 36" 8983K33 3 $54.01 $162.0318mm Dia Body Light Beam Sensing Switch NPN, DC Input, Object Reflecting with Male Plug 65845K22 2 $94.73 $189.46Washdown Stainless Steel Air Cylinder 3/4" Bore, 6" Stroke Length 6239K115 2 $123.56 $247.12Miscelaneous Stainless Steel Hardware (Panels, Bolts, Wasters…etc) N/A 1 $200.00 $200.00 

Materials Total Estimated Cost $2,056.10

37Rev 01

38Rev 01

Estimates for time requirements of human resources

ItemQuantit

y Hours TotalDesign 1 30.00 30.00Programming of Actuation System 1 10.00 10.00Diagnostics and Trouble Shooting 1 10.00 10.00Miscelaneous Welded Connections 1 6.00 6.00Conveyor System Modification 1 5.00 5.00Cover Box Assembly with Pivot Support Bridge 2 2.00 4.00Pivoting Arm Assembly 2 2.00 4.00Miscelaneous Bolted Connections 1 2.00 2.00Mounting of Actuation System 1 2.00 2.00Actuator Support Brace 2 1.50 3.00Actuator Mounting Bracket 2 1.50 3.00Pusher Plate Assembly 2 1.00 2.00Guide Rail Bracket 4 0.75 3.00Guide Rail Mounting 2 0.50 1.00 

Total Estimated Time 85.00

39Rev 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 DefinitionOptionsFully Automated SystemPartially Automated SystemCal-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

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

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

52Rev 01

53Rev 01