Document Sample
DDR Powered By Docstoc
					                       Nov. 11th, 2011

Wegman's Swirl Cake Process

   Detailed Design Review

                    Aaron Delahanty
                        Ryan Norris
                       Arwen Sharp
                         Benson Yu
                      Kenyon Zitzka
•   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
   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
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
• 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
• Conveyor mounting
  bracket allows for
  quick alignment after
  initial bracket mounting.
                     Conveyor bracket
• Allows for quick
  disconnect and
• Relies on stable
  conveyor wall
• Assumes access
  to conveyor wall
The Rail Debate
Mount directly to rail
• Larger machine
• Cantilevered machine

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
         Chassis / Motor Module Design

• Mounting point for
  "swirling modules"
• Linear bearing for z-axis
• .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)
• 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
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
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
• 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
• Independently sourced parts
• Likely to change due to Wegmans part inventory
• Current projected current cost $2,446.32

•   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?

Shared By: