Systems Level Design Review Project #10715 1/15/09 Rev 01 1.

Systems Level Design ReviewProject #10715

1/15/09

Rev 01 1

Helen Jervey (ISE), Project Lead Charles Nicolosi (ME), Chief Engineer Brandon Sbordone (ME) George Kilger (EE) Ian Baker (ME) Ben Bouffard (EE)

Advised by John Kaemmerlen

Rev 01 2

Provide background information about the current system at the Culinary Innovation Center

Detail the progress made by the team from RIT

Receive feedback from faculty and Wegmans staff

Discuss the next steps in the process

Rev 01 3

Customer NeedsEngineering Specs

Rev 01 4

Wegmans is a food market with more than 70 stores in five states

The Culinary Innovation Center, or CIC, provides all premade sauces and marinated meat products to Wegmans stores

Rev 01 5

The current factory line requires seven people performing repetitive, injury prone tasks

Injuries have cost Wegmans more than $20,000 in the marinade area since the opening of the CIC

Unreliable labeling technology leads to rework, wasting the time of the employees

Rev 01 6

Reallocate direct labor from flipping, labeling◦ Allow employees to move to other areas of the

CIC Reduce ergonomic risks on line Perform all work within safety and quality standards

Rev 01 7

Primary◦ Meet AMA, OSHA, USDA and other relevant

standards◦ Maintain integrity of product

Secondary◦ Reallocate direct labor from flipping, aligning◦ Automate or improve flipping, aligning, and

labeling processes◦ Maintain or improve takt time

Rev 01 8

◦ 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

Rev 01 9

◦ 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: Meet x-ray specs of one piece at a time in

machine◦ 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 4.1C: Packages are conveyed in single-file

o Need 4.2: Avoid impact on other projects Need 4.2A: Keep allocation of floor space constant

Rev 01 10

and Feasibility Analysis

Rev 01 11

Constraints◦ Space◦ Feasibility◦ Alignment ◦ Efficiency◦ Mechanical/“Intelligent

”

Rev 01 12

System Concept SelectionSystem Concept Selection

Rev 01 13

Mechanical Process Allows for basic single file flow Engineered for product inconsistencies Will need future testing for jam concerns Basic frictional analysis shows it is feasible

Concept Concept ImprovementImprovement(Though Testing)(Though Testing)

• Rollers• Belts• Actuated

Rev 01 14

Frictional Feasibility AnalysisFrictional Feasibility Analysis

Rev 01 15

Mechanical process Reliably performs a uniform flip Handles different package sizes and configurations Handles constant stresses of use Need component life cycle analysis

Concept Concept ImprovementImprovement(Through Testing)(Through Testing)

• Adjustable Tray• Motor Choice• Tray Angle

Rev 01 16

Must consistently apply identifyer label Controlled label orientation and position Imaging/sensing system Implementation and modification of current

labelers to fit project Research has found feasible camera systems in

industry

Concept Concept ImprovementImprovement• Professor Meetings• Camera Selection

Rev 01 17

Rev 01 18

Rev 01 19

Pieces enter in 2 or 3 wide

Adjustable, offset guides

Actuated guides to align

pieces/accelerate alignment process

Proximity/contact sensors to

ensure guide return

Laser sensor for piece(s)

entering guide path

Guide actuates and pushes pieces

to center

Pieces align with belt friction

Rev 01 20

Fixed/Adjustable Guides◦ Solid rail◦ Roller guide◦ Belt guide

Powered/Adjustable Guides◦ Solid rail/roller guide◦ Hinge mount for guide◦ Actuator/Actuators◦ Proximity sensors◦ Laser sensors for track

Rev 01 21

Piece flows into flip tray

Laser sensor indicates

piece in tray

Stop arm for next piece

Motor/actuator

rotates flip tray

Piece is pushed out of

tray

Sensor indicates no piece in tray

Motor/actuator rotates flip tray

Stop arm retracts

Automated FlipperAutomated Flipper

Rev 01 22

Flipper Tray◦ Grated◦ Solid

Stop Arm◦ Actuator◦ Hinge◦ Proximity Sensor(s)

Flipper◦ Motor/Actuator◦ Mounting/Hinges◦ Piece sensor (laser)◦ Proximity sensors (up/down)◦ Product pusher

Fixed Mechanical

Proximity sensor Actuator

Rev 01 23

Single piece enters

Vision system identifies package

System outputs θ and

offset (x,y)

Motors align label head based on

output

Laser sensor

(possibly stops belt

and) activates

vision system

Label application

Label head retracts/

Returns to home

(Belt resumes)

Identifier Label ApplicatorIdentifier Label Applicator

Rev 01 24

Vision System◦ Laser product sensor◦ Visual comparator system

Camera Comparison logic controller

Label Applicator system◦ X-axis motor◦ Y-axis motor◦ θ motor◦ Label applicator head

Head actuator Labeler Foam presser

◦ Label loader Belt motion controller

Rev 01 25

Pieces From

Multivac

Trip Laser

sensor(s)

Guide Returns

Piece leaves beam

Single file flow to flip

Piece enters

flip tray

Piece prox.

sensor trigger

Stop arm

actuates

Tray actuator trigger

Tray rotates down

Trigger push prox.

Piece prox.

Trigger off

Tray rotates

up

Stop arm

retracts

Piece to lower

conveyer

Piece through

x-ray

Piece trips laser

Belt stops

Camera shoots image

Calculates θ, x, y

Labeler assembly offsets

x

Labeler assembly offsets

y

Labeler assembly offsets

θ

Remove label from spool

Label head

actuates down

Label head

retracts

Belt resumes

Guide actuator(s) activate

Rev 01 26

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Rev 01 29

Rev 01 30

Rev 01 31

Evaluate analyzing methods for the labeling device Gather data on packaging durability Research optimal methods of flipping and aligning Draft circuit designs for controls and sensors Draft schematics for mechanical devices Investigate costs of long lead time devices Physically implement designs Test "first run" designs on product Revise and improve designs

Detailed Design Review: Friday 2/12 (4 weeks)

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