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