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					                       Nov. 11th, 2011


Wegman's Swirl Cake Process
      Improvement:

   Detailed Design Review

                    Aaron Delahanty
                        Ryan Norris
                       Arwen Sharp
                         Benson Yu
                      Kenyon Zitzka
                                        Overview
•   Actions Since SDR
•   Project Timeline
•   Risk Reassessment
•   Design
    o Mechanical
           Swirler
           Cart
           Head/Chassis
           Gate
    o   Electrical
           Overall System Logic
           Machine Logic
           Machine Control Unit
           Possible Sensor Locations
• Customer needs assessment
• BOM/Budget
• Questions
    Actions Addressing Feedback from SDR
• Food safety should be prioritized in the risk
  assessment.
   o Use of stainless steel.
   o Components selected are food-service rated (i.e.
     FDA or similar approval).
• Mobility/Portability
   o Quick-connect ("Kitchen-aid" style) components
     used on swirling mechanism.
   o We require your final input on mobility (cart,
     mounted directly to conveyor, etc).
• Consistency/Quality
   o Prototype developed and tested.
   o Feedback received from Sharon Penta
                                  Updated Timeline

• We are ~1 week behind schedule discussed at system
  design review.
   o Bill of Materials to be passed to purchasing by 18 Nov
                           Additional Risks Identified
• Parts/materials ordered are misplaced, damaged, or unusable.

    o   Based on previous design team experiences
    o   Set up a method to prevent loss of incoming parts

•   Unaware of ongoing production schedule

    o   Caused delay in our schedule (~1 week behind)
    o   Request that we are sent the schedule monthly

• Possibility of only one prototype being developed

    o   Mitigated by early prototype testing.

• Under swirled batter portion present in 1/2 sheet pans
               Mechanical Design Overview
• Overall Form and
  Function overview
• Swirler Design
   o Prototype 2.0
• Location and Mobility
• Chassis / Motor Modules
• Gate Mechanism
Overall Form and Function
                Overview
2nd Prototype Batter Testing: Results
2nd Prototype Batter Testing: Results
2nd Prototype Batter Testing: Results
            2nd Prototype Batter Testing: Results
1. Rotational motion only will provide sufficient swirling
2. Effects of experimental variables:
• Number of Contact Points
    o More points will reduce time req'd to swirl
    o Too many points causes 'mixing'
• Swirl Diameter
    o Larger diameter moved batter further and made larger
      swirl features
    o Smaller diameter moved less batter but created thinner
      more appealing marbling
• Swirler Angle
    o Little to no effect on the depth of the swirl
3. 1/2 Sheet pan gap is present and must be addressed
Swirler Design

• Based on feedback from Sharon
  Penta from 2nd prototype test.

• Variable diameter for maximum
  coverage.
• Yet to be designed: "Kitchen Aid" style quick-connectors for
  maintenance and cleaning.

   o   Proper nomenclature for this style connector?
Cart justification
                              Location / Mobility
• Permanently
  or temporarily mounted
  to the conveyor
• Swivel feature allows
  permanent mount, still
  capable of removing
  machine from space
  above product line
• Ergonomically design
  casters and handles
  allow for easy operator
  removal/set-up
• Conveyor mounting
  bracket allows for
  quick alignment after
  initial bracket mounting.
                     Conveyor bracket
• Allows for quick
  disconnect and
  alignment
• Relies on stable
  conveyor wall
• Assumes access
  to conveyor wall
The Rail Debate
Mount directly to rail
• Larger machine
  footprint
• Cantilevered machine
  head

Remove rail
• Plausible?
• Consequences
Swirling Synchronization
                                       Gate Design
A simple lever gate
 • Allows us to increase actuator stroke
 • Impact forces are seen by the lever and absorbed
   by the conveyor mounting point rather than
   actuator
         Chassis / Motor Module Design

• Mounting point for
  "swirling modules"
• Linear bearing for z-axis
  motion.
• .75" x .75" 304 Stainless
  Steel box tubing
• 1" x 1" T-bar for inner supports
Chassis / Motor Module Design
                    Overall Machine Summary

•   General Machine Dimensions:
   o Footprint - ~42" x ~28"
   o Overall Height: ~59"
• Total Machine Weight (Approximation) = ~110 lbs

• Processing capabilities:
  o Swirl process: 5 seconds (assuming 2 batter rotation)
                                                        Safety
• Sheet metal cover to prevent crush hazard and protect
  machine components.

• Fail-safe considerations incorporated into logic controls.

• Appropriate safety labels to be applied to machine.

• Water-tight enclosures for electric/electronic components.

• On-board circuit overload protection

• Emergency Stop

• Center of gravity analysis for cart mobility safety
           Electrical Design Overview
• Overall System Logic
• Swirl Logic
• Control Unit ("Brain")
  o   Motor Starter
  o   Relay / Contactor
  o   Sensor / Other PLC Signal
• Safety Actions
Overall System Logic
Swirling Machine Logic
                 Power Conversion Logic



                       Control the power to gate




Control the
power to
pneumatics and
motors
Motor Control Unit
Other Possible Controller
                       Electronics Components
• Starter Box
  o   Motor Starter
  o   Circuit Breaker
  o   Manual Starting Switch
• Relays
  o   Solid State Relays vs. Programmable Relays
• Sensors
  o   Photoelectric Sensors
                                                                  Sensors
Sensor Locations:
1.   At the clamp
2.   At the machine (Signals to Relay)
3.   At the pan queue
4.   Inside the machine (Signals to check if chassis back in starting position)
            Electrical Safety Actions
•   Circuit Breaker
•   Thermal Overload
•   NEMA Enclosure
•   Emergency Stop / Brake
       Electrical Design Related Questions

• Parts provided by Wegmans?
• Sensors Communication ?
• Professional Feedback on Components
• Comments on Control Units / Other
  Possibilities?
• NEMA Enclosure?
                       Customer Needs Assessment
Green - Feasibly achieved, as supported by current development
Yellow - Feasibly achieved, completion dependent on future development
Red - Not feasibly achieved
                                                   BOM
• Independently sourced parts
• Likely to change due to Wegmans part inventory
• Current projected current cost $2,446.32
                                                  Questions

•   labels & paint?
•   parts warehouse?
•   Kitchen-aid interface?
•   non-ferrous materials are okay?
•   Solenoid vs pneumatic gate actuation?
•   how to deal with pan gap!?
•   swivel desirable function?
•   Interfaces between PLC and the entire cart?
     o Power?
     o Air?

				
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posted:3/5/2013
language:English
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