Inexpensive IntelliQ/Accuglide Brake (Intelligrated)

Transcription

1 Inexpensive IntelliQ/Accuglide Brake (Intelligrated) A Baccalaureate thesis submitted to the Department of Mechanical and Materials Engineering College of Engineering and Applied Science University of Cincinnati in partial fulfillment of the requirements for the degree of Bachelor of Science in Mechanical Engineering Technology by April 2014 Thesis Advisor: Professor Amir Salehpour

2 ABSTRACT Intelligrated, a world leader in the conveyor and sortation solution industry, offers many types of products. The majority of which consists of various conveyors, sorters, and palletizers. The company has created a good name throughout the industry, while only being a little over ten years old. The company s success can be attributed to the products performing as the sales teams preaches they can. Intelligrated offers various types of conveyor, all of which perform well, but there is always room to improve. Intelligrated s accumulation conveyors, which include the IntelliQ and Accuglide product lines, are all powered pneumatically. Currently, the company dedicates one system to powering the drive and brake system. The issue with having both the drive and brake powered from the same source pneumatically is the slight delay in switching power between the drive and brake. For example, if air is being pumped through the drive system and suddenly the brake needs to activate, the air must first be released from the drive system and then diverted to the brake before the brake can operate. This process of diverting air takes about 1.5 seconds. During those 1.5 seconds, the system is moving purely on inertia and control is removed. This project is designed to provide Intelligrated with a cheaper brake alternative that can also remove the 1.5 seconds of lost control. The idea of the project was to step away from the pneumatic styling of the conveyor and move forward with a mechanical/electrical approach. This decision was made based on customer feedback and input from management at Intelligrated. Moving away from pneumatics would prevent the need to duplicate the already existing control system to create the independent drive and brake set up, which would help keep overall prices down. After researching existing accumulation conveyor brakes and developing design alternatives, a selection was made. The chosen design was then manufactured, painted, assembled and then installed on existing conveyor. The brake was then tested against the current pneumatic brake, making sure it could bring product on the conveyor to a stop within the same timeframe. It was also tested to make sure there was minimal time delay between the conveyor being powered (moving) and having the brake applied. Figure 1 - Completed Installed Brake ii

3 Inexpensive Intelligrated Brake ACKNOWLEDGEMENTS TABLE OF CONTENTS ABSTRACT... II ACKNOWLEDGEMENTS... 1 TABLE OF CONTENTS... 1 LIST OF FIGURES... 3 LIST OF TABLES... 3 INTRODUCTION AND RESEARCH... 4 PROBLEM STATEMENT... 4 DEMATIC ACCUMULATION CONVEYOR... 5 INTERVIEW: KEVIN KLUEBER... 6 SHUTTLEWORTH ACCUMULATION AND BUFFERING... 7 INTELLIGRATED CASE CONVEYOR... 8 SHUTTLEWORTH BLADE STOPS AND BRAKES... 9 CUSTOMER FEEDBACK, FEATURES, AND OBJECTIVES SURVEY ANALYSIS PRODUCT FEATURES AND OBJECTIVES ENGINEERING CHARACTERISTICS DESIGN ITERATION AND SELECTION HALF CLAMP DESIGN O-BELT ACTUATION DESIGN WEIGHTED DECISION MATRIX ASSEMBLED DESIGN AND BILL OF MATERIALS FABRICATION AND ASSEMBLY FABRICATION ASSEMBLY TESTING CACULATIONS FORCE, ENERGY, AND TIME CALCULATIONS SCHEDULE AND BUDGET SCHEDULE BUDGET CONCLUSION WORKS CITED

4 Inexpensive Intelligrated Brake APPENDIX A - RESEARCH APPENDIX B - SURVEY APPENDIX C - QFD APPENDIX D OBJECTIVES APPENDIX E SCHEDULE APPENDIX F BUDGET APPENDIX G ASSEMBLY AND DETAIL DRAWINGS

5 Inexpensive Intelligrated Brake LIST OF FIGURES Figure 1 - Completed Installed Brake... ii Figure 2 Dematic Accumulation Conveyor... 5 Figure 3 Shuttleworth Low Pressure Accumulation Conveyor... 7 Figure 4 Intelligrated Conveyors with Brakes... 8 Figure 5 Shuttleworth Blade Stop... 9 Figure 6 Half Clamp Design Figure 7 O-Belt Actuation Design Figure 8 Brake Installed Figure 9 Wired Relay Switch Figure 10 3-D Model Figure 11 Assembled Top Plate Mount Bracket Figure 12 Assembled O-Bands LIST OF TABLES Table 1 Survey Results 10 Table 2 Engineering Characteristics 12 Table 3 Weighted Decision Matrix 15 Table 4 Bill of Materials 16 Table 5 - Schedule 21 Table 6 - Budget 22 3

6 Inexpensive Intelligrated Brake INTRODUCTION AND RESEARCH PROBLEM STATEMENT Intelligrated currently has two products of interest for this project; the first being IntelliQ, which is a belt-driven, zero-pressure accumulation conveyor. The second is Accuglide, a chain-driven, zero-pressure accumulation conveyor. The IQ or IntelliQ system currently has no braking system, therefore resulting in a coast to stop method. Coasting is typically not a big issue when dealing with accumulation, but it does limit the types of products the conveyor can handle because of back pressure among the flowing packages. This limitation removes the possibility of handling fragile products with this conveyor. When dealing with a coast to stop accumulation conveyor, there will always be some amount of back pressure as the products begin to accumulate. With the introduction of a brake system, back pressure will be removed and a greater variety of products will be able to travel on the conveyor. There is a need to create a braking system for placement into the IQ and Accuglide systems. Most of the components would be universal, with some variance simply because of the difference in product lines. The braking system would allow for control of the entire conveyor system. For example, power on brake off or brake on power off. This is a feature the company currently does not offer with these lines of products that could possibly turn into a big selling point. 4

7 Inexpensive Intelligrated Brake DEMATIC ACCUMULATION CONVEYOR Intelligrated s largest competitor is Dematic. Both companies offer products that will accomplish the same goal, but will reach those goals through differentiating designs. Dematic claims to be the first company to offer an accumulation conveyor without pressure buildup (1). This is a main goal hoping to be achieved by this break design for Intelligrated s Accuglide and IQ product lines. Dematic is only able to say they have an accumulation conveyor without pressure build up because of their brake system built into the conveyor. Below is Figure 2 showing an example of Dematic s accumulation conveyor. Figure 2 Dematic Accumulation Conveyor Since Dematic does not provide designs and layouts of products to the public, only assumptions can be made as to how they would achieve zero pressure buildup. Timing and location of brakes on a conveyor are integral factors when accumulating product. For Dematic to prevent pressure build up, there must be a fairly complex and extensive system of brakes throughout their conveyor. Dematic and Intelligrated share a close price point on most of their conveyors. Intelligrated offers brakes for its accumulation conveyor and it s an expensive addition to the product, so it would be safe to assume Dematic charges close to the same for their accumulation brake. Dematic and Intelligrated have a healthy level of competition when it comes to booking jobs, which greatly encourages each company to become more innovative than the other. 5

8 Inexpensive Intelligrated Brake INTERVIEW: KEVIN KLUEBER Product Development Manager, Kevin Klueber, (2) was the first individual at Intelligrated to introduce the company s desire for a new braking system. Kevin has plenty of background with all the products within Intelligrated s portfolio, more information can be found about Kevin in Appendix A. Kevin made a point during the interview to focus on two points of the brake system. First he stated how Intelligrated customers want an inexpensive brake system, something that will keep the price from jumping too far over the two lines current price range. His second focus was on its overall functionality. One goal of creating the brake system is the hopes of being able to have fragile products travel on the IQ and Accuglide lines. That feature alone will keep the customer from having to choose another; more expensive product line in place of the IQ or Accuglide, and most importantly it should help keep the customer from dropping Intelligrated s quote and moving forward with a competitor. Versatility at a low price point is what Kevin Klueber wants to see. 6

9 Inexpensive Intelligrated Brake SHUTTLEWORTH ACCUMULATION AND BUFFERING Shuttleworth is another company in the conveyor industry. Although they are not in much competition with Intelligrated, they do offer an accumulation conveyor that has a few interesting design aspects. Shuttleworth conveyors primarily handle smaller products than Intelligrated conveyors, but the same general concepts can be applied to the Intelligrated braking system. They offer what is called a low pressure accumulating conveyor which is great for lowering the risk for product damage. Figure 3 shows the low pressure accumulating conveyor moving exposed cookies, which are typically brittle. Figure 3 Shuttleworth Low Pressure Accumulation Conveyor Shuttleworth claims that non-contact accumulation is vital for fragile products (3). This is not necessarily true for the boxed product that Intelligrated moves, but it might be something to strive for when trying to prevent back pressure. More information about Shuttleworth products can be found in Appendix A with a link to their website. 7

10 Inexpensive Intelligrated Brake INTELLIGRATED CASE CONVEYOR Intelligrated currently offers a brake system for the Accuglide and IQ lines, but they are unfortunately both a coast to stop system (4). Coast to stop means the conveyor gradually slows to a stop rather than a more immediate stop. This design works and is effective, but it only allows non-fragile products to travel on the conveyor. For that simple reason, the company wants to create a more effective braking system that will provide near immediate stopping and the possibility for fragile products to be used on the conveyor. The company offers braking systems that are more of an immediate stop with the other product lines, but they tend to be a little more expensive. Figure 4 provides a glimpse at some of those conveyors containing complex braking systems. Figure 4 Intelligrated Conveyors with Brakes This new system is meant to keep the IQ and Accuglide lines within their current price range, while increasing their versatility with product travel. The IQ and Accuglide lines don t contain as many mechanical components as most other offerings, which really aid in keeping the price lower. 8

11 Inexpensive Intelligrated Brake SHUTTLEWORTH BLADE STOPS AND BRAKES Shuttleworth again introduces another interesting concept with blade stops. This is not very practical for heavy boxes moving along a conveyor, but it without a doubt suits their needs. The blade concept looks exactly how it sounds; looking at Figure 5 the blades can be seen. Figure 5 Shuttleworth Blade Stop When a section of product reaches a point where the operator wants it to stop, a thin sheet metal blade pops up between the rollers stopping the product (5). As stated earlier this would most likely not stop the type of product moving along Intelligrated conveyor lines. 9

12 Inexpensive Intelligrated Brake CUSTOMER FEEDBACK, FEATURES, AND OBJECTIVES SURVEY ANALYSIS The purpose behind the survey was to receive feedback as to what the most desired features are for the new Intelligrated brake. Appendix B provides an example of the provided survey and the corresponding results. The survey was handed out to twenty associates at Intelligrated. Each question was given the possibility of six different responses, ranging from 1-5 with 5 being of the most importance. Surveyors were also given the option of N/A. To complete the survey, surveyors were given a range of prices they would be willing to pay for the brake system, which results showed most surveyors would be willing to pay in the range of $100-$150. The total points from all the surveys were used to find the average value of each feature to the right of each question. The results of the survey have been summed up in Table 1 below. By looking at the results, the main focus should be having a retail price between $ , while also being able to have fragile products on the conveyor, and limit visibility of the brake system once installed on the conveyor. Table 1 Survey Results Customer Features Customer Importance Compactness 1.00 Safety 2.55 Visibility Once Installed 3.00 Function Simplicity 1.75 Durability 2.15 On/Off Switch 1.60 Appearance (paint) 2.85 Allow for use of fragile product on conveyor 3.25 Allow for start, stop, hold function with little to no coast 1.80 Easy access for repair

13 Inexpensive Intelligrated Brake PRODUCT FEATURES AND OBJECTIVES The following product objectives come straight from the list of customer features determined from the survey. The features and objectives are listed in order of most to least importance backed by the percentages found through the survey and QFD. Each heading (feature) contains a number of sub headed product objectives. These are what will take place in order to meet the customer feature requirements. Product objectives can also be found in Appendix D. 1. Cheaper System than current offerings (17%) a. Smaller design than current offerings, also made of sheet metal b. Fewer components in Bill of Materials than current systems 2. Brake System will allow fragile items to travel along conveyor (15%) a. Coated rollers prevent products on conveyor from sliding on rollers b. Brake system will stop almost immediately, thus preventing moving product from coasting into one another 3. Appearance (15%) a. Parts will be painted to color of customers choosing 4. No Visibility Once Installed (13%) a. Rollers will block top view from customer b. Rails will block side view from customer c. Brake system will not hang below base of side rail d. Entire brake system will fit between the base of a 6.5 rail and the bottom of the rollers, which sit at the top of the 6.5 rail 5. Basic function offerings (12%) a. Programmed into PLC b. Physical on/off switch to bypass PLC when necessary c. Have function inputs of start, stop, and hold 6. Safety (11%) a. Tested in prototyping lab to see how worn/failing components will affect rest of conveyor system. b. Guards in place to prevent brake parts from contacting undesired components within the whole conveyor system. c. Warning label placed on rail 7. Durability (10%) a. Components made from sheet metal (common practice within industrial conveyor community) b. Testing done in prototyping lab to rate durability. Product will be assembled and installed on a small section of Accuglide/IntelliQ conveyor where it will run continuously for 5-7 days. 8. Repairs and Maintenance (6%) a. Can be accessed from top by removing section of rollers b. Accessible from under side of conveyor unit by removing guards c. Compact design to be repaired or serviced by one person d. Requires sockets and wrenches for repairs 11

14 Inexpensive Intelligrated Brake ENGINEERING CHARACTERISTICS Following the development of the product objectives was the Quality Function Deployment (QFD). The QFD took all the product features and objectives and determined the importance of each to the total design. A simplified version of the QFD can be found below (Table 2), where they are listed in order from highest to lowest importance. The full QFD can be found in Appendix C. Table 2 Engineering Characteristics Engineering Characteristic Importance (%) Fewer Components in BOM than current 12 Smaller design than current offerings 9 Guards in place 9 Fits between 6.5" rail and base of rollers 7 Sheet metal components 7 Brake programmed into PLC 7 Immediate stop/cost prevention 6 System does not hang below base of side rail 6 Coated Rollers 5 Rails block side view 5 Painted parts 5 Input functions of start, stop, hold 4 Completed testing on durability 3 On/Off switch to bypass PLC when necessary 3 Compact design for single person repairs 3 Roller block top view 2 Limited effects on entire system when brake fails 2 Warning label on rail 2 Accessible from top by removing rollers 2 Accessible by removing guards from under side 2 Only requires sockets and wrenches for repairs 2 12

15 Inexpensive Intelligrated Brake DESIGN ITERATION AND SELECTION HALF CLAMP DESIGN This first design is a basic build. As shown in Figure 6, the braking surface will be composed of rubber to contact the underside of the roller. The grooved rubber will be adhered to a sheet metal plate which will be raised and lowered based on when the brake application is desired. The grooved rubber will have cut-outs to fit around a standard Intelligrated roller. The cut-outs will be spaced at two and three inch centers; this will also depend on the layout of the overall assembly. Having a range of configurations can become expensive to stock, rather than having a single standard brake plate. The sheet metal plate and rubber grooves will need an actuator to apply an upward force desired to contact and brake the rollers. Figure 6 Half Clamp Design 13

16 Inexpensive Intelligrated Brake O-BELT ACTUATION DESIGN This second concepts is a basic lever design. As shown in Figure 7, there are few components required to complete this build, with the majority of that coming from hardware. This design will require an electromagnetic actuator mounted to the side rail of the conveyor in the upside down position. The actuating rod is connected to the lever arm, which will be pinned at a position giving it the desired mechanical advantage. Lastly the end of the lever arm opposite of the actuator will be attached to a brake plate. The plate is composed of sheet metal and contains four 83A durometer o-belts stretched across its stop. The o-bands are the contacting surface of the brake system. O-bands are commonly used at Intelligrated, are cheap and easy to come by, and can be replaced without issue. This design requires few components and can be assembled by a single person. Figure 7 O-Belt Actuation Design 14

17 Inexpensive Intelligrated Brake WEIGHTED DECISION MATRIX The two design iterations shown about were further evaluated through a weighted design matrix to decide which would better suit the needs of this application. The designs were weighted based on price, durability, and ease of repair. These weights were adjusted to be representative of the values found in the QFD (See Appendix C). The scores for each weighted category were added together to obtain the final rating for both designs. By looking at the results documented in Table 3, the O-Belt Actuation design is most applicable. Design Criterion Table 3 Weighted Decision Matrix Weight Factor Half Clamp O-Belt Actuation Score Rating Score Rating Cost Durability Ease of Repair Total

18 Inexpensive Intelligrated Brake ASSEMBLED DESIGN AND BILL OF MATERIALS Figure 8 Brake Installed Figure 9 Wired Relay Switch Figure 10 3-D Model Table 4 Bill of Materials SEQ QTY DESCRIPTION 1 12 BOLT CAR X.750 SHORT SQ NECK 2 12 NUT FLANGE JOINING PIN 4 4 O-RING 1/4 X A V ACTUATOR 6 1 LIFT TRAY REST 7 1 LEVER ARM 8 1 BRAKE TOP PLATE 9 1 LIFT TRAY REST PIVOT SUPPORT ANGLE 11 1 TOP PLATE MOUNT BRACKET 12 4 PIVOT PIN BRACKET 16

19 Inexpensive Intelligrated Brake FABRICATION AND ASSEMBLY FABRICATION All sheet metal components were composed of 7, 10, and 12 gauges that had been hot rolled and pickled and oiled. The components were laser cut and machine formed. After being properly formed and cut, the sheet metal components were run through the paint line. All fasteners were purchased through Fastenal and the actuator was a special order from China. All Sheet metal parts were made by Intelligrated shop employees, as manufacturing and fabrication at the facility is unionized and does not allow non-union members to operate the machinery. ASSEMBLY The assembly of the entire brake was completed by a single person in less than 3 hours. Mounting of the brake onto the side rail of the conveyor can also be handled by a single person. The only required tools for assembly are a ratcheting socket wrench and a regular wrench. Figure 11 and Figure 12 show some stages of the assembly. Once the supports and actuator are mounted to the side rail, all that s left is to align the top plate and pivot arm, and slide the connecting pins into place. All of the leveling and checking of leveling can be done with a standard level and measuring tape. After all the mechanical parts have been installed, the only remaining assembly is connecting the wires to the proper relay, control module, and photo eye. Once everything has been installed, it is necessary to check everything over making sure it is correct and then start the system. Figure 12 Assembled O-Bands Figure 11 Assembled Top Plate Mount Bracket 17

20 Inexpensive Intelligrated Brake TESTING Two tests were performed on the brake system. The first of which was a test of how quickly the brake would be applied once the photo eye was blocked. This test was key in determining if the new brake was capable of removing or nearly removing the 1.5 seconds of switch time found in the pneumatic brake. After taking 15 readings, the new brake was activated and applying a braking force in an average of.45 seconds. This is an improvement of 1.05 seconds, which is exactly what management was looking for. With the time delay being greatly reduced, the loss of control is nearly eliminated. The second test was cut short due to the overheating and eventual failure of the actuator. During that test, a single 10lb package was sent down the conveyor with the system set at 1000rpm. The goal of this test was to compare the time it took for the package to stop once the brake was applied to the current pneumatic brake. Only seven readings were able to be accepted before the actuator declined, but the average of those results came to.60 seconds. These were comparable numbers to the pneumatic which resulted in an average of.53 seconds. Overall it seems the new mechanical brake provides a comparable stopping time and also gives management the option of removing the 1.5 seconds of lag. Because of the independent system set up, the brake is capable of being applied before the drive is turned off just as management had hoped. 18

21 Inexpensive Intelligrated Brake CACULATIONS FORCE, ENERGY, AND TIME CALCULATIONS Below are a series of computed values followed by their detailed calculations. Roller Weight (lb) 4.45 Roller Mass (slug) Gravity (ft/s^2) 32.2 Friction Coefficient 0.7 Linear Velocity (ft/m) 200 Linear Velocity (ft/s) Angular Velocity (rad/s) Single Box Weight (lb) 50 Actuator Force (lbf) MA (mechanical advantage) 3 Force Applied by Brake (lbf) Single Roller K.E. (ft lb) The force being applied by the brake can be calculated by using the output force from the actuator and using the two lengths each side of the pivot point on the lever arm. ( ) ( ) ( ) ( ) ( ) Calculated values are being figured on the basis of having products moving along the conveyor at a velocity of 200ft/min or 3.33ft/s. ( ) ( ) ( ) ( ) ( ) 19

22 Inexpensive Intelligrated Brake ( )( ) The following calculation is the time it will take once the brake has been applied for the rollers to come to a stop. This calculation is also taking into effect the weight of the packages on the rollers. [ ( )( ) ] ( ) ( )( )( ) 20

23 Sep 29-Oct 5 Oct 6-12 Oct Oct Oct 27 - Nov 2 Nov 3 - Nov 9 Nov Nov Nov Dec 1-7 Dec 8-14 Inexpensive Intelligrated Brake SCHEDULE AND BUDGET SCHEDULE The schedule for this build spans from Sept. 13 to April 14. This provides about 30 weeks to design build and test the brake system. The core of this project will take place in the design stage. A sample of the schedule has been provided below in Table 5, while Appendix E shows a completion date of April 23 rd. As shown in the full schedule, the actual schedule stayed on track with the proposed schedule expect for the delay in arrival of the actuator. The actuator was shipped from China and took an extra week than expected to reach the US. This caused for a delay in final testing. Intelligrated Brake Table 5 - Schedule TASKS Content review (advisor) 9 Proof of Design Agree (advisor) 16 Concepts/Selection (advisor) 16 3D Model - (Internal Components) 23 3D Model - (Brake Housing) 6 3D Model - (Installed on Rail) 20 Design Calculations 27 Design Freeze 14 21

24 Inexpensive Intelligrated Brake BUDGET The budget is the anticipated amount of money to be spent on the project. This takes in account all of the material, fabrication, build, and testing costs. With an approximate build less than $140, as shown in Table 6; Intelligrated will have some leeway with the final retail price. There should be little trouble keeping it below the customer desired $ The full budget can be viewed in Appendix F. Table 6 - Budget Components/Labor Forecasted Amount ($) Actual Amount ($) Sheet Metal $30.00 $20.00 Tooling (labor) $50.00 $40.00 Paint $10.00 $5.00 Wiring/Hosing $5.00 $2.00 Hardware/Fasteners $12.00 $4.00 O-Bands $10.00 $4.00 Miscellaneous Parts (actuator) $20.00 $30.00 Total $ $

25 Inexpensive Intelligrated Brake CONCLUSION After completing the testing, there is definite reason to look for a more quality built actuator. The brake itself was capable of making the product moving on the conveyor come to a stop in a time almost matching the current brake. More importantly the brake was able to give the independent functionality that management was looking for. The brake was able to be engaged before the drive stopped, almost completely eliminating the 1.5 seconds of switch time. On pure function through the limited tests completed, the brake performed as expected. Another bonus was the overall build cost of $105, coming in lower than the current pneumatic brake price of $150. Having matched and surpassed the product objectives, this brake design give Intelligrated a viable option as an alternative to their current brake moving forward. The only real issue was the faulty actuator. The specs showed online when purchased did not seem to match its actual performance. This required a change in how the actuator was to be powered. It was originally to be powered from the control module/photo eye through a relay. This proved to not provide enough power, so a separate power supply was brought in to handle the actuator. Once the power supply was connected to the actuator, the desired movement and brake force occurred. Unfortunately using the independent power supply caused the actuator to overheat, which eventually caused permanent damage to the actuator. Testing was able to be performed before the actuator became of no use, but results were simply not gathered in the volume as originally desired. Moving forward with the project, there would need to be a change in the selected actuator. This would most likely cause the overall price of the brake to increase. There would also be the need to design a small guide/guard to keep the top plate from moving in directions other than up and down. Other than those few changes, the brake has a chance at a promising future with Intelligrated. 23

26 Inexpensive Intelligrated Brake WORKS CITED 1. Dematic. Accumulation Conveyor. Dematic.com. [Online] Dematic Corp. [Cited: August 25, 2013.] 2. Klueber, Kevin. Inexpensive IntelliQ/Accuglide Brake. West Chester, April 19, Shuttleworth. Accumulation & Buffering. Shuttleworth Integrated Product Handling Solutions. [Online] Shuttleworth. [Cited: September 9, 2013.] 4. Intelligrated. Case Conveyor. Intelligrated. [Online] [Cited: September 9, 2013.] 5. Shuttleworth. Blade Stops and Brakes. Shuttleworth Integrated Product Handling Solutions. [Online] [Cited: September 9, 2013.] 24

27 APPENDIX A - RESEARCH Interview with Product Development Manager: Kevin Klueber of Intelligrated. He has been at his current position for a year and a half. He has experience with all offered product lines at Intelligrated. He has spent time with manufacturing, research and development, commercialization, and currently product development. Kevin has experience with all aspects of Intelligrated s mechanical engineering. Kevin introduced the company s desire to offer an inexpensive brake for the IntelliQ (IQ) and Accuglide (ACG) lines. He described how they are two of Intelligrated s more popular lines, but most customers want the brake feature. This leads to the customer having to spend more money by switching to the Motor Driven Roller (MDR) line. The increase in price does occasionally occur to lost jobs. Kevin feels in order for the brake to be successful and a valuable part of the company, it must be fairly inexpensive to keep build costs close to their current state. Intelligrated offers brakes for other lines, but unfortunately they cannot be altered to be applicable with the IQ and ACG lines. He liked the idea of trying to make the brake universal between the two lines. Most feels the development of the brake will be a great addition to the lines. The break will allow for fragile products to be used on those systems, which is exactly what the customer has been wanting. Kevin did also state that other conveyor companies do have brake systems, but our IQ and ACG lines are patented designs, which means there hasn t been anything designed to work with them. 25

28 Dematic offers little information about their exact specification with their accumulation conveyors, along with pricing. Based on information provided by co-workers at Intelligrated, Dematics brake system is highly integrated into the conveyor system and carries a heavy price. My design will be much simpler thus lowering the expense. umulation-conveyor 8/25/

29 oducts/blade-stops-and-brakes/ 9/9/2013 Shuttleworth seems to take two approaches to stopping material. The blade stop system doesn t seem suitable for an accumulation conveyor. The brakes themselves seem like a decent idea. This could work with accumulation, but it seems like you would need multiple sections of brakes installed which could get expensive. I m looking at more of an overall brake that could stop the desired line. oducts/solutions-byapplication/accumulationbuffering-conveyors/ 9/9/2013 Although Shuttleworth primarily works with smaller products than Intelligrated, I did find aspects of their accumulation conveyor system that I would like to adopt for my brake addition. Non contact accumulation is key for fragile products. Minimal line or back pressure. Mention of accumulating glass panels. 27

30 utions_services/case_conveyor 9/9/2013 Both of the products highlighted state they are zero pressure accumulation. This is true to an extent because it meets CEMA standards for zero pressure. They both also state they contain a brake system. These systems are actually coast to stop. It is considered a brake system, but not good enough for fragile products. My product will be immediate stop. Coast to stop is more time consuming, less efficient, and less versatile. 28

31 APPENDIX B - SURVEY INTELLIGRATED ACCUGLIDE/INTELLIQ BRAKE CUSTOMER SURVEY This survey will be used to decide on features to be included in the design of the Intelligrated Brake. This project will consist of a new braking system for Intelligrated s Accuglide & IntelliQ products. The braking system will make the current products more versatile. How important is each feature to you for the design of an Intelligrated Accuglide/IntelliQ brake? Please circle the appropriate answer. 1 = low importance 5 = high importance Average Compactness 1(19) N/A(1) 1.00 Safety 1(1) 2(8) 3(10) 4(1) 5 N/A 2.55 Visibility once installed 1 2(2) 3(15) 4(2) 5 N/A(1) 3.00 Function Simplicity 1(7) 2(12) 3 4(1) 5 N/A 1.75 Durability 1 2(17) 3(3) 4 5 N/A 2.15 On/Off Switch 1(10) 2(8) 3(2) 4 5 N/A 1.60 Appearance (paint) 1 2(4) 3(15) 4(1) 5 N/A 2.85 Allow for use of fragile 1 2(3) 3(11) 4(4) 5(2) N/A 3.25 product on conveyor Allow for start, stop, 1(5) 2(14) 3(1) 4 5 N/A 1.80 and hold function with little to no coast Easy access for repair 1(14) 2(6) N/A 1.30 How satisfied are you with the current accumulation brake system? Please circle the appropriate answer. 1 = very UNsatisfied 5 = very satisfied Compactness 1 2(17) 3(3) 4 5 N/A 2.15 Safety 1 2 3(8) 4(10) 5(2) N/A 3.70 Visibility once installed 1(1) 2(5) 3(12) 4(2) 5 N/A 2.75 Function Simplicity 1 2(2) 3(11) 4(6) 5(1) N/A 3.30 Durability 1 2 3(16) 4(4) 5 N/A 3.20 On/Off Switch 1 2(3) 3(10) 4 5 N/A(7) 1.80 Appearance (paint) 1 2 3(2) 4(4) 5(14) N/A 4.60 Allow for use of fragile 1(16) 2(3) N/A(1) 1.10 product on conveyor Allow for start, stop, 1(17) 2(2) N/A(1) 1.05 and hold function with little to no coast Easy access for repair (15) 5(5) N/A

32 How much would you be willing to spend (retail) for this project? $100-$150(12) $150-$250(7) $250-$500(1) $500-$1000 $1000-$2000 Thank you for your time. 30

33 Smaller Design than current offerings Fewer compnents in BOM than current Coated Rollers Immediate Stop/Coast Prevention Rollers block top view Rails block side view System does not hang below base of side rail Fits between 6.5" rail and base of rollers Painted parts Limited effects on entire system when brake fails Guards in place Warning Label on rail Sheet Metal components Completed testing on durability Brake programmed into PLC On/Off switch to bypass PLC when necessary Input functions of start, stop, and hold Accessible from top by removing rollers Accessible by removing guards from under side Compact design for single person repairs Only requires sockets and wrenches for repairs Customer importance Designer's Multiplier Current Satisfaction Planned Satisfaction Improvement ratio Modified Importance Relative weight Relative weight % APPENDIX C - QFD Intelligrated Brake 9 = Strong 3 = Moderate 1 = Weak Cheaper Than Current Offerings % Fragile Product Travel on Conveyor % No Visibility Once Installed % Appearance % Safety % Durability % Basic Function Offerings % Repairs and Maintenance % Abs. importance Rel. importance

34 APPENDIX D OBJECTIVES Objectives Based on survey results, the objectives are a list of features that receive the most attention during the design process. Below is a list of product objectives and a short description of how those objectives will be met. 9. Cheaper System than current offerings (17%) c. Smaller design than current offerings, also made of sheet metal d. Fewer components in Bill of Materials than current systems 10. Brake System will allow fragile items to travel along conveyor (15%) c. Coated rollers prevent products on conveyor from sliding on rollers d. Brake system will stop almost immediately, thus preventing moving product from coasting into one another 11. Appearance (15%) b. Parts will be painted to color of customers choosing 12. No Visibility Once Installed (13%) e. Rollers will block top view from customer f. Rails will block side view from customer g. Brake system will not hang below base of side rail h. Entire brake system will fit between the base of a 6.5 rail and the bottom of the rollers, which sit at the top of the 6.5 rail 13. Basic function offerings (12%) d. Programmed into PLC e. Physical on/off switch to bypass PLC when necessary f. Have function inputs of start, stop, and hold 14. Safety (11%) d. Tested in prototyping lab to see how worn/failing components will affect rest of conveyor system. e. Guards in place to prevent brake parts from contacting undesired components within the whole conveyor system. f. Warning label placed on rail 15. Durability (10%) c. Components made from sheet metal (common practice within industrial conveyor community) d. Testing done in prototyping lab to rate durability. Product will be assembled and installed on a small section of Accuglide/IntelliQ conveyor where it will run continuously for 5-7 days. 16. Repairs and Maintenance (6%) e. Can be accessed from top by removing section of rollers f. Accessible from under side of conveyor unit by removing guards g. Compact design to be repaired or serviced by one person h. Requires sockets and wrenches for repairs 32

35 Sep 29-Oct 5 Oct 6-12 Oct Oct Oct 27 - Nov 2 Nov 3 - Nov 9 Nov Nov Nov Dec 1-7 Dec 8-14 Dec Dec Dec 29 - Jan 4 Jan 5- Jan 11 Jan12-18 Jan Jan 26 - Feb 1 Feb 2-8 Feb 9-15 Feb Feb 23 - Mar 1 Mar 2-8 Mar 9-15 Mar Mar Mar 30 - Apr 5 Apr 6-12 Apr Apr APPENDIX E SCHEDULE Intelligrated Brake TASKS Content review (advisor) 9 Proof of Design Agree (advisor) 16 Concepts/Selection (advisor) 16 3D Model - (Internal Components) 23 3D Model - (Brake Housing) 6 3D Model - (Installed on Rail) 20 Design Calculations 27 Design Freeze 14 Bill of Materials 8 Shop Drawings 15 Order Parts 22 Design Presentation - Faculty 29 Report Due to Advisor 5 Fabrication 12 Assembly 19 Testing 26 Modification 5 Final Testing 12 Advisor Demonstration 26 Delay in actuator Arrival Tech Expo 3 Oral Faculty Presentation 9 Presentation Day 4/16 16 Review for Library Submission 15 PDF File 23 33

36 APPENDIX F BUDGET Components/Labor Forecasted Amount ($) Actual Amount ($) Sheet Metal $30.00 $20.00 Tooling (labor) $50.00 $40.00 Paint $10.00 $5.00 Wiring/Hosing $5.00 $2.00 Hardware/Fasteners $12.00 $4.00 O-Bands $10.00 $4.00 Miscellaneous Parts (actuator) $20.00 $30.00 Total $ $

37 APPENDIX G ASSEMBLY AND DETAIL DRAWINGS 35

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