P12711 Parbake Mezzanine
DDR
1
Design Review Expectations
Review feasibility of design
 Improve overall design based on feedback
and discussion

2
Project Plan
3
Risk Assessment Update

Risk Item
Counter does not
accurately count
Unscheduled electrical
component failure
Failure of mechanical
system component
Bread guides create a
blockage
New risks associated with design
Effect
Reduction in overall
effectiveness of system
Reduced throughput and
potential loss of product
Reduced throughput and
potential loss of product
Bread packaging hold up
Cause
Too much variety in product
stream
Likelihood Severity Importance
2
3
6
Component fatigue/degredation
2
3
6
Component fatigue/degredation
Bread does not come down
conveyor as expected
1
3
3
2
3
6
Mitigation
Design a system that can account for all
the different varieties of product
Design electrical system around robust
actuators/sensors
FEA analysis and design machine
components to infinite life
Test plan to cover all orientations bread
can come down conveyor
4
Functional Decomposition
Transfer Box
Get Box
Align Product
Stage Product
Count Product
Inspect Product
Inspect/Rejection
Package
Product
Reject if
Needed
Put Product in
Box
Fill Box
Orient Product in
Box
Stop When Full
"Close" Box
Send Box
Move Box to
Lower Conveyor
5
System Design Overview
6
Box Transfer – Box Slide
7
Box Transfer – Box Slide
8
Box Slide Information

Sloped, spiral conveyor extension with
rollers
oMoves box for immediate product filling
o20” Vertical Decline, 30” radius turn
oEliminates operator effort – reaching
oManufacturer – Northeast Conveyor, Inc
9
Next Steps
Make Contact with Northeast Conveyor,
Inc
 Is Design Plausible?
 Cost

10
Counting Vertical Counters
11
Counting - Vertical Counter
12
Vertical Counter

Flap rotation sensed by potentiometer

Single flap size handles all products

Returns to neutral position after product
travels through
13
Counter Prototype
14
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)

15
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

16
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

17
Counter Assembly BOM
Counter Assembly
Dimensions
Length (in)
Material
Counter Flap
2.75"x1/16"
10.75
Stainless
2
66.86
133.71
Counter Rod
1/8"
11.50
Stainless
2
2.02
4.05
Counter Support,
2"x0.5"
6.00
Stainless
4
30.02
120.08
Set Screw
4-40 0.112"
Stainless
3
0.33
0.98
Small Counter Guide
0.5"x2"
30.00
Stainless
1
51.77
51.77
Long Counter Guide
19.25"x0.5"x2"
19.25
Stainless
1
27.11
27.11
1K-Potentiometer
2
4.37
8.74
7-Seg LED Display
2
1.76
3.52
Dual 4-bit Binary Counter
2
0.61
1.22
2xBCD 7-Seg Driver
2
1.71
3.42
1
274.64
274.64
Counter Total
629.23
Product Description
Box Exit Conveyor Chute
60"x52"x1/16"
-
Stainless
Qty. Unit Cost ($)
Total Cost ($)
18
Aligning Product
19
Initial Testing
• Rounds
o Have been successfully guided and sorted into single file
rows that are countable
• Rolls
o Had problems with clogging up the lanes, but it is
possible to sort them
• Baguettes
o Difficult to keep from spinning around and clogging up
the sorter
• Batards
o Not as difficult to sort as baguettes, but they can still
spin around
20
Video of Rounds Testing
21
Video of Baguette Testing
22
Batard Test
23
Further Testing
• Guide Prototype
o Prototype would allow for repeatable set ups and
would directly inform final design
o Possible inclusion of ‘turning vanes’ to aid in keeping
certain breads (baguettes, batards) from spinning
• Experimenting with different conveyor
speeds
o By increasing the speed of each successive conveyor,
the product spacing will increase, which will lead to
less bottlenecking at the sorter
o Will also ensure that baguettes and batards will be
straight when they arrive at aligning station
24
Confidence Level
• Rounds
o Can be done
• Rolls
o Varying success depending on roll. Showed promise
but will require further testing
• Baguettes and Batards
o If the ‘spin’ and ‘stick’ conditions can be eliminated,
the sorting can be done
25
Guide Assembly BOM
Product Description
Support
Shaft
Guide Holder
HolderShaft
3ft Guide
Guide to shaft
Guide Assembly
Dimensions
Length (in) Material Qty. Unit Cost ($) Total Cost ($)
.5"x2"x8"
8.000
Aluminum 4
11.27
45.07
.5" dia x 40"
7.854
Steel
2
11.06
22.12
1"x1.5"x.5"
0.750
Aluminum 4
1.06
4.23
.25" dia x 4"
0.196
Steel
4
0.28
1.11
3"x.5"x36"
0.540
UHMW
2
0.76
1.52
.75"x1"x1.25"
0.938
UHMW
4
1.32
5.28
Guide Total
79.33
26
Inspection
27
Inspection

Help from Wegmans
◦ Can we relocate the trash bins further
upstream of the main conveyor?
28
Batching/Accumulating
29
Sorters
30
Gates
31
Main Beam deflection comparison

.75” (w) x .5” (h) cross
section

.75” square cross section
32
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)

33
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

34
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

35
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

36
Batching Assembly BOM
Batching Assembly
Product Description
Dimensions
Length (in)
Bolt
10" 1/4 -20
Bolt
2.25" 1/4 -20
Bolt
1" 1/4 -20
U-Bolt
1.625
Nut
1/4 " - 20
Rod Support a -Long
0.125" x 2" flat stock
1.25
Rod Support A
0.125" x 2" flat stock
0.75
Rod Support B
0.125" x 2" flat stock
1.5
Sorting Piston Mount
0.125" x 2" flat stock
2.25
Sort. Piston Mount Receiver 0.125" x 3" flat stock
3
90 Angle Stock
1.25"
2.25
Threaded Rod
1/4" -20
9.25
Big Gate
.375" x 2" flat stock
10.75
Small Gate
.375" x 2" flat stock
7.25
Sorting Gate
.375" x 2" flat stock
17.75
Pneumatic Actuator
Solenoid Valve
Gate Piston Link
7/8" round stock
1.625
Set Screw
1/4" - 20
Stop
.08" x 2" flat stock
0.375
Divider
.08" x 2" flat stock
15
Lane Walls
.08" x 2" flat stock
150
Material Qty. Unit Cost ($) Total Cost ($)
Stainless
8
6.33
50.64
Stainless
1
7.04
7.04
Stainless
1
7.69
7.69
Stainless 12
3.24
38.88
Stainless
1
10.10
10.10
Stainless
1
4.52
4.52
Stainless
1
2.71
2.71
Stainless
1
5.42
5.42
Stainless
1
8.14
8.14
Stainless
1
77.68
77.68
Stainless
1
10.02
10.02
Stainless
2
7.67
15.34
UHMW
2
7.66
15.32
UHMW
2
11.36
22.72
UHMW
2
18.75
37.50
Stainless
6
36.04
216.24
Stainless
6
73.89
443.34
Stainless
1
39.51
39.51
Stainless
1
5.50
5.50
Stainless
1
0.24
0.24
Stainless
1
9.51
9.51
Stainless
2
33.80
67.60
Batching Total
1,095.65
37
Support Frame BOM
Support Frame Assembly
Unit Cost
($)
Total Cost
($)
3
87.22
261.66
Stainless
1
34.03
34.03
4
Stainless
1
15.12
15.12
.75" x.5" bar stock
11.25
Stainless
1
42.53
42.53
Crossover Beam
.75" x.5" bar stock
15
Stainless
1
56.71
56.71
Side Mount
.25" x 2" flat stock
2.75
Stainless
1
35.00
35.00
Support Frame Total
445.05
Product Description
Dimensions
Length (in) Material Qty.
Main Beam
.75" x .75" bar
stock
39
Stainless
Vertical Support
.75" x.5" bar stock
9
Corner Support
.75" x.5" bar stock
Side Support
38
End of Conveyor
39
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.
40
Chute that attaches to the rail
on the side of the conveyor
This stops the box from sliding off the
Lazy Susan.
41
Place of attachment
This is what the stopper would attach to.
42
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.
43
Total Costs
Counter Total
$
629.23
Support Frame Total
$
445.05
Batching Total
$ 1,095.65
Guide Total
$
79.33
Grand Total
$ 2,249.26
44
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?

45
Next Steps
Update designs based on meeting
 Start prototyping all designs
 Identify vendors for all components with
Wegmans’ buyers

46
Questions? Comments?
47