KGCOE MSD
Technical Review Agenda
Meeting Purpose: Detailed design review of P09711- Automation/Improvement of Packaging
on Cookie Line. The objectives of this are to present and receive feedback from others about our
final design and bill of materials.
Meeting Date: February 13th, 2009
Meeting Location: Building 09 Room 4435
Meeting time: 2:00 – 4:00 PM
Timeline:
Meeting Timeline
Start
time
Topic of Review
2:00
Project Background Recap
2:10
Design Specifications
2:30
3:00
Required Attendees
Overall System- Design, Selection
Reasoning & Feasibility
Electronics- Design, Selection Reasoning
& Feasibility
3:30
Bill of Materials & Risk Assessment
3:55
Wrap Up Discussion
KGCOE MSD
Prof Kaemmerlen, Dr. Hoople, Mr. Bryan,
Scott Young & Chris Isaacson
Prof Kaemmerlen, Dr. Hoople, Mr. Bryan,
Scott Young & Chris Isaacson
Prof Kaemmerlen, Dr. Hoople, Mr. Bryan,
Scott Young & Chris Isaacson
Prof Kaemmerlen, Dr. Hoople, Mr. Bryan,
Scott Young & Chris Isaacson
Prof Kaemmerlen, Dr. Hoople, Mr. Bryan,
Scott Young & Chris Isaacson
Prof Kaemmerlen, Dr. Hoople, Mr. Bryan,
Scott Young & Chris Isaacson
Page 1 of 25
Technical Review Agenda
Project Background
Mission Statement:
The mission of this project is to create an automated prototype that will separate mini cookies by
weight, while preventing cookies from moving on in the process until a specified weight is
reached. It will create a clear separation between the sets of cookies that go into each package
without substantially slowing down the packaging process.
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.
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Technical Review Materials
Updated Customer Needs Hierarchy with Importance Ranking
Need 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 Restrictions
Need 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)
Importance Scale:
9 = These needs have the highest importance and will be the main focus of the project.
5 = These needs are somewhat important and will be the secondary focus of the project if time allows.
3 = These needs are not as important as the rest of the needs and will only be focused on if the main and
secondary needs have been satisfied.
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Technical Review Materials
Updated Target Specifications
Metric
No.
1
Need
Nos.
Need 1.1,
1.2, 1.3,
1.4, 2.1
Metric
Importance
Units
2
Need 1.1,
2.1
3
Need 6.1,
6.2, 6.3,
6.4
4
Need 4.1,
5.1, 5.2,
5.3
Need 4.1,
4.2, 5.2
Percentage of
packages with
excess (2 or
more) cookies
(currently at
95%)
Weight of cookie
package
9
%
9
grams
Follows
Wegmans'
sanitation
standard
Requires training
that takes X
minutes
Changeover time
3
Y/N
N
Y
5
minutes
60
15
5
minutes
20
5
Creates clear
separation of
product for
packaging
Throughput
9
Y/N
Y
Y
7
Need 1.1,
1.2, 1.3,
1.4, 3.1,
3.2
Need 4.2
5
average
packages
per hour
1500
1700
8
Need 7.1
Cost
9
$
< $10,000
< $5,000
5
6
Marginal Ideal Value
value
60%
0%
(elimination (elimination
of packages of packages
with 6 or
with 2 or
more extra more extra
cookies)
cookies)
420
397
Importance Scale:
9 = These metrics will be the main focus of this project.
5 = These metrics will be a secondary focus of the project if time allows.
3 = These metrics will not be focused on unless the main and secondary metrics have been addressed.
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Technical Review Materials
System Related to Needs and Metrics
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Technical Review Materials
Economic Potential
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Technical Review Materials
Related Engineering Specifications
Metric 1: Percentage of cookies with excess packages (currently 95%)
1.
2.
3.
4.
5.
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
a. Tested at 15, 25, 30, 35 degrees
6. Scale must be able to send signal to board when correct weight is achieved
a. Scale has a RS232 output signal
Metric 6: Accurately separates product for packaging
1. Chute must have an angle of rotation of >=20 degrees
2. Push-rod must be able to clear the scale in ~ 7.5 seconds
3. Drop-off ramp must have an angle >= 30 degrees
Metric 7: Throughput
1.
2.
3.
4.
5.
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
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Technical Review Materials
Overall System
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Technical Review Agenda
Sifting Bar System
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Technical Review Materials
Tunnel System
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Technical Review Materials
Drop Chute System
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Technical Review Materials
Weigh Station System
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Technical Review Materials
Material Comparison and Selection
Material Densities
Density Polycarbonate (g/cm^3)=
Density Stainless Steel (g/cm^3)=
Density HDPE (g/cm^3)=
Density Polypropylene (g/cm^3)=
Material Coefficient of Friction
Polycarbonate =
0.38
Stainless Steel =
0.35
HDPE =
0.28
Polypropylene =
-
1.2
7.85
0.95
0.91
*Data collected from table online with
sliding material of Steel
Tensile Strength
Material
psi
Polycarbonate =
9000
Stainless Steel =
89900
HDPE =
3250
Polypropylene =
1000
PUSH-ROD WALL
DIMENSIONS*
10" x 1.25" x .25 "
VOLUME
US (in^3)
3.1
Metric (cm^3)
51.2
MATERIAL
MASS (g)
Polycarbonate
61.5
Stainless Steel
402.0
HDPE
48.6
Polypropylene
46.6
Polycarbonate is the material we chose
to use for the drop chute, line chute, sifter
bar, sifter motor gear, sifter linkage,
pusher, and weight station box. The
reason for this is because polycarbonate is
easily machined, its lightweight, strong,
has a high impact resistance, and has a
similar kinetic coefficient of friction as
stainless steel. Polycarbonate is also fairly
inexpensive compared to other materials,
and it can easily be bonded together using
methylene chloride, or Weld-On #3
adhesive.
SIFTER BAR
DIMENSIONS*
13" x 3" x .25"
VOLUME
US (in^3)
9.8
Metric (cm^3)
159.8
MATERIAL
MASS (g)
Polycarbonate
191.7
Stainless Steel
1254.2
HDPE
Polypropylene
151.8
145.4
DROP CHUTE
VOLUME
US (in^3)
Metric (cm^3)
MATERIAL
Polycarbonate
Stainless Steel
HDPE
Polypropylene
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21.1
344.9
MASS (g)
413.9
2707.8
327.7
313.9
V1
V2
V3
V4
V5
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in^3
4.0
3.0
5.3
0.8
8.0
cm^3
65.5
49.2
86.9
12.3
131.1
Technical Review Agenda
Electronic System Overview
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Technical Review Materials
Board Selection Process
The board chosen is an Altera DE2-70 University Developmental board (sold through Terasic).
This board was chosen for a number of reasons. First being the versatility of the board itself. This board is
covered with multiple different interfaces as well as hardware that can handle any task that needs to be
performed for this project. The FPGA on this board is the largest in its class and has the highest speed and
capacity for its device class. The number of different I/O pins on this device equal 622. These pins are
fully customizable to change the output between over 7 different signal types. The different capacities of
the ram inside the FPGA, the performance specs, and structure of the memory allow for fast accurate data
to be stored, and read off the memory that is structured inside the FPGA. The advantage of this is that
there is still more than sufficient room to run multiple programs of which we will not come close to the
complexity of. The true advantage of this board is that we will have the two SDRAM devices and Flash
memory to use as memory space instead of the so-called “on-chip” (inside the FPGA) memory.
This board is flexible enough to be able to add a user interface into the code or even the system,
which will include a monitor, and either keyboard or mouse or possibly both. The main purpose in
choosing an FPGA over a micro-controller is that an FPGA is easily adaptable and can have; VHDL,
Verilog, C or even C++ code run on it. This allows the user to adapt to the environment and be able to
configure the code in any way they wish as well as configure the hardware in any way they choose. A
second reason for using the FPGA over the micro-controller is because the EE team has used this exact
FPGA device previously and has familiar knowledge in this process which will make the coding, debugging, and explaining/teaching of code/process easier. This board is also deigned to be used in a
university environment, which means that it provides example code and great support for the user. There
is more than sufficient documentation or support through Altera to make sure that use of this device is as
easy as possible for any user. In choosing a board that has the most flexibility and the most adaptability,
with room to expand the board through its 2 header 40 pin connectors this board surpasses the others.
In buying a pre-designed board we are ensuring that all the components work together and that
the hardware is working properly. This allows the EE team to focus mainly on the coding and
performance process rather than board functionality process. The components chosen on this board have
been designed to perform at the maximum rating possible for each part. The memory capacity well
exceeds our needs. There is no true metric for the amount of memory required or the speed at which the
memory must be at a minimum of. This is due to the fact that it is a prototype in which we are not yet sure
of the codes necessities or length or even performance until we write the code. However we have the
ability to add to this board anything that we would need because of the I/O headers. This allows us to
have the confidence to choose this board knowing there are no bounds or limitations that we have when
using this product. The board can even stack multiple boards off of this one to have master and slave
configurations allowing endless possibilities for daughter boards. Because this board is 100 percent
adaptable and configurable it allows us to choose this board and use it for any application in which we
would need it.
The output currents and voltages match the requirements of the driver boards for our stepper
motors. The current required for the driver device is 20 µamps and the voltage required to drive the logic
is 3.3 V. The voltage out of the DE2-70 is 3.3V and the current is around 4mA max.
Other boards were considered however none of them had the capability, flexibility, adaptability,
or even “bang for their buck” that the DE2-70 board has.
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Technical Review Materials
Selected Board Specifications
Items that come on the DE2-70 right from the Terasic website
 USB Blaster (on board) for programming and user API control;
both JTAG and Active Serial (AS) programming modes are supported
 2-Mbyte SSRAM
 Two 32-Mbyte SDRAM
 8-Mbyte Flash memory
 SD Card socket
 4 pushbutton switches
 18 toggle switches
 18 red user LEDs
 9 green user LEDs
 50-Mhz oscillator and 28.63-Mhz oscillator for clock sources
 24-bit CD-quality audio CODEC with line-in, line-out, and microphone-in jacks
 VGA DAC (10-bit high-speed triple DACs) with VGA-out connector
 2 TV Decoder (NTSC/PAL) and TV-in connector
 10/100 Ethernet Controller with a connector
 USB Host/Slave Controller with USB type A and type B connectors
 RS-232 transceiver and 9-pin connector
 PS/2 mouse/keyboard connector
 IrDA transceiver
 1 SMA connector
 Two 40-pin Expansion Headers with diode protection
DE2-70 kit includes;
 Altera DE2-70 Board
 Altera Quartus II DVD with Nios II - Version 7.2
(We provide Quartus II Web Edition software. To learn more about the details please
visit Quartus II Software—Subscription Edition and Web Edition Comparison )
 1 USB Cable
 1 Adapter DC 12V/2A
 6 Silicon Footstands
 2 Cables (black- and red-colored)
 2 PIN Headers, 1P1N
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Technical Review Materials
Currently Selected Scale
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Technical Review Materials
Weigh Station Scale Options Quote (for Discussion)
ROCHESTER SCALE WORKS, INC.
100 Sherer Street
Rochester, NY 14611
Phone (585) 235-5882 Fax (585) 235-5885
www.rochesterscale.com
February 10, 2009
RIT / Wegmans
1 Lomb Drive
Build 9
Rochester, NY 14623
ATT: Brian Duffy
SUBJECT: Electronic Bench Scale
Email: brianduffy86@gmail
Dear Brian:
We are pleased to propose the following for your consideration.
One (1) Doran Model 7000XL Stainless Steel Bench Scale.
Capacity:
10 lb x 0.001 lb / 4.5 kg x 1 g or
5 lb x 0.001 lb / 2.3 kg x 0.5 g
Platform Size:
10” x 10”
Features:
6 Digit Red LED display 0.56” high
Zero, units and print
304 stainless steel
NEMA 4X and IP-69K washdown protection
Standard RS-232
PRICE…$1,050.00 less 10% ($105.00) = $945.00 + FOB Factory
Optional USB…Add $175.00
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Technical Review Materials
One (1) Doran Model 2200 Stainless Steel Digital Bench Scale.
Capacity:
10 lb x 0.002 lb / 4.5 kg x 1 g or
5 lb x 0.001 lb / 2.3 kg x 0.5 g
Platform Size:
10” x 10”
Features:
6 Digit red LED display
304 Stainless steel construction
NEMA 4X and IP-69K washdown protection
Standard RS-232
Full numeric keypad
PRICE…$1,125.00 less 10% ($112.50) = $1,012.50 + FOB Factory
Optional USB…Add $175.00
No additional charge for setup, delivery and calibration.
RIT to setup communications.
Delivery:
Warranty:
TERMS:
1 Week from receipt of your order.
1-Year Electronics
NET 30 DAYS
If this purchase is NYS tax exempt, an exempt certificate must be
provided at time of order, otherwise applicable sales tax will be added.
Thank you for asking us to quote.
Sincerely,
Christopher H. Sudore
Christopher H. Sudore
CHS/lm
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Technical Review Materials
Selected Stepper Motor Driver
Allegro A3967 data sheet: http://www.sparkfun.com/datasheets/Robotics/A3967.pdf
EasyDriver V3 schematic: http://www.sparkfun.com/datasheets/Robotics/EasyDriver-v3Schematic.pdf
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Technical Review Materials
Selected Stepper Motor
Jamco Valupro Stepper Motor datasheet:
http://www.jameco.com/Jameco/catalogs/c291/P74.pdf
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Technical Review Materials
Motor Torque Calculations
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Technical Review Materials
Bill of Materials
Product
Number
3005XL
Vendor
Doran
6007K36
McMasterCarr
McMasterCarr
McMasterCarr
90631A411
McMasterCarr
99154A390
McMasterCarr
N/A
Wegmans
57655K34
McMasterCarr
2342K81
97395A525
57655K62
97633A200
7528A13
KGCOE MSD
McMasterCarr
McMasterCarr
McMasterCarr
Product Desc.
Quantity
List Price
Total Part
Price
Lead Time
Doran 10"x10"x2" weigh scale
Perma-Lube Steel Ball Bearing - ABEC-1
Double Sealed, No. R2 for 1/8" Shaft Dia,
3/8" OD
Type 316 Stainless Steel Dowel Pin 3/8"
Diameter, 1-1/4" Length
Hardened Precision Tubular Shaft 1" OD,
.6" ID, 12" Length
Znc-Pltd Grade 2 Stl Nylon-Insert Hex
Locknut 10-32 Thread Size, 3/8" Width,
15/64" Height
18-8 SS Low Profile Precision Shoulder
Screw Slotted Head, 1/4" Shldr Dia, 1/2" L
Shldr, 10-32 Thrd
Wegmans Mini-Chocolate Chip Cookies
397g
Molded Nylon 14-1/2 Deg Angle Spur
Gear 32 Pitch, 16 Teeth, 0.5" Pitch Dia,
3/16" Bore
Molded Nylon 14-1/2 Deg Angle Spur
Gear Rack, 32 Pitch, 3/16" Face Width,
3/16" H O'all, 1'L
Black-Phosphate Steel External Retaining
Ring for 1/2" Shaft Diameter
Weld-on #3 Cement for Acrylics 1 Pint
Can
2
$1,000.00
$2,000.00
<2 weeks
6
$12.45
$74.70
<1 week
3
$2.82
$8.46
<1 week
1
$40.50
$40.50
<1 week
1
$2.60
$2.60
<1 week
1
$5.77
$5.77
<1 week
10
$1.30
$13.00
<1 week
2
$3.00
$6.00
<1 week
2
$4.63
$9.26
<1 week
1
$8.56
$8.56
<1 week
2
$12.77
$25.54
<1 week
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Technical Review Agenda
P0304
Terasic
Altera DE2-70 Development and
Technologies Education Board
M-200ROB-08368
8574K55
HWS5012/A
Trossen
Robotics
Jameco
Valuepro
McMasterCarr
McMasterCarr
McMasterCarr
Arrow
Electronics
N/A
N/A
237472
8585K33
8585K17
EasyDriver V3 Stepper Motor Driver
MOTOR,STEP,12VDC/.4A, 2100 GMCM
Polycarbonate Round Tube 3-1/2" OD, 31/4" ID, Clear
Polycarbonate Round Tube 1-3/4" OD, 11/2" ID, Clear
Polycarbonate Sheet 1/4" Thick, 24" X
24", Clear
AC/DC Power Supply Single-OUT 12V
4.3A
Miscellaneous Components (Resistors,
Capacitors, etc.)
1
$599.00
$599.00
<1 week
4
$14.95
$ 59.80
<1 week
4
$21.49
$85.96
<1 week
1
$15.29
$15.29
<1 week
1
$7.66
$7.66
<1 week
6
$33.89
$203.34
<1 week
1
$130.58
$130.58
<1 week
1
$100.00
$100.00
N/A
Total
$3,396.02
Material Links:
Ball Bearing: http://www.mcmaster.com/#2342k81/=iij54
Board: http://www.terasic.com.tw/cgi-bin/page/archive.pl?Language=English&CategoryNo=39&No=226
Gear Motor: http://www.grainger.com/Grainger/items/2L011
Stepper Motor:
http://www.jameco.com/webapp/wcs/stores/servlet/ProductDisplay?langId=1&storeId=10001&catalogId=10001&productId=237472&
Stepper Motor Driver: http://www.trossenrobotics.com/easydriver-v3-stepper-motor-driver.aspx?feed=Froogle
Round Polycarb: http://www.mcmaster.com/#8585k33/=j7qh9
Arrow Electronics: http://app.arrownac.com/aws/pg_webc?s=P
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Technical Review Materials
Updated Risk Assessment
Risk
Team won't have enough
time to create to entire
prototype
Severity
Probability
Overall
Contingency Plan
5
4
20
Create only a fourth of the
working prototype
Long lead times on ordered
parts may push prototype
production back
4
3
12
Weighing technology does
not meet expectations
4
2
8
Insufficient funds to produce
full design
5
1
5
Mechanical and Electrical
systems don’t interface well
with each other
5
3
15
3
3
9
1
3
3
Cookies get stuck in tunnel
section
5
5
25
Weigh station doesn’t push
out cookies quickly enough
3
3
9
Chutes don’t switch quickly
enough
5
3
15
Settling time is too long
5
3
15
3
3
9
5
3
15
4
2
8
3
5
15
Cookies don’t get pulled by
incline gate
Incline gate does not switch
up
Chute doors don’t open/close
at right time
Conveyor failure
Difficulty controlling push
rod using motors
Force of cookies falling on
scale from chute gives a false
reading on scale
Order parts by week 11, Set up
meeting with Wegmans after
detailed design review to arrange
the ordering of all long lead time
materials
Extensively research alternative
weighing devices, spend more
money on improved weighing
device
Create only a fourth of the
working prototype, perform
economic analysis to demonstrate
the savings that could be realized
from investing in this project
Be aware of the interface
between the two, constant
communication between
electrical and mechanical
engineers
Replace incline gate with
conveyor
Replace incline gate with
conveyor
Use sifting bar to put cookies into
lines which can be more easily
handled by the tunnels
Use alternative pushing method
instead of push rods, use air at a
higher pressure
Use one weigh station and close
chute while cookies back up
Purchase scales with a short
settling time
Prioritize electrical-mechanical
interfacing issues
Create emergency stop switch
Use air compression to control
push rod
Take an average of the weight
samples when deciding when to
push cookies out of weigh station
Importance Scale:
1= Consequences from risk have little effect on the cookie line’s flow and project’s success
5= Consequences from risk halt the entire cookie line and/or project
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Technical Review Agenda