Return Master 150

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Design of magazine automated return management

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Return Master 150

  1. 1. ReturnMaster Automated Accurate Magazine Return Management Data Processing Services, Inc.
  2. 2. DESCRIPTION OF OPERATION <ul><li>The ReturnMaster 100 machine will accept a stack of magazines or magazine covers loaded by and operator. </li></ul><ul><li>The machine has devices to facilitate the separation of the magazines or magazine covers for individual feeding through a barcode reading section. </li></ul><ul><li>The barcode section will decode the barcode on the front or back of the magazines and determine disposition of the magazine and direct the magazine to 1 or more sort locations exiting the machine. </li></ul><ul><li>Magazine UPC barcodes will be collected and transmitted back to the host at intervals to close the loop in the return process. </li></ul>Data Processing Services, Inc.
  3. 3. Theory of Operation <ul><li>The basic design of the machine is similar to an older machine (RAMP) developed and sold by Electrocom Automation (currently a Siemens Company). The technology had been patented by Electrocom (patent number 5,655,667). As of 9/14/2005 the patent had expired due to lack of maintenance fees paid. </li></ul><ul><li>The original machine utilized a long belt section in feed con- veyor which allowed the operator to lay a shingled stack of magazine along the length of the conveyor. The conveyor would feed the stack along the length of the conveyor up to a traction drum roller. </li></ul><ul><li>The drum roller would energize to pull the lower magazines from the stack and move them onto a inclined roller conveyor. The drum roller would cycle on and off to feed the magazines until a photo eye was block indicating that too many magazines have been fed. </li></ul>Data Processing Services, Inc.
  4. 4. Roller Conveyor Incline <ul><li>Once the magazines are fed onto the roller conveyor the conveyor will individually energize each roller on and off to pull the magazines apart. The conveyor is on an incline to use gravity to help separate magazines that are still stacked on top of each other. There is a photo eye looking between each roller to determine whether there is a gap between the magazines and determine the length of the magazines. </li></ul>The magazines travel up the conveyor until that get to a barcode reading zone. Data Processing Services, Inc.
  5. 5. Barcode Scanning <ul><li>Once the magazines reach the input to the barcode section they are controlled to release into the scanner zone to maintain a proper gap and meter the magazines into the output sortation section. </li></ul>Data Processing Services, Inc.
  6. 6. Magazine Sortation <ul><li>Once the magazines are fed onto the roller conveyor the conveyor will individually energize each roller on and off to pull the magazines apart. The conveyor is on an incline to use gravity to help separate magazines that are still stacked on top of each other. There is a photo eye looking between each roller to determine whether there is a gap between the magazines and determine the length of the magazines. The magazines travel up the conveyor until they get to a barcode reading zone. </li></ul>Data Processing Services, Inc.
  7. 7. Design Improvements <ul><li>The ReturnMaster 100 machine will improve on the design aspects of the RAMP machine where required and utilize features of the RAMP where needed. The following is a list of operational areas of the machine that will see redesign and improvements. </li></ul>Data Processing Services, Inc.
  8. 8. In-feed Conveyor and Drum Roller <ul><li>Current Design - The current drum roller does a good job of pulling the lower magazines from the bottom of a stack. When feeding single magazines onto the incline roller conveyor of the machine the system can sustain a high throughput. However, when the drum roller pulls multiple magazines over the top it requires the incline roller conveyor to cycle on and off to separate the small stacks. Cycling the incline conveyor can drastically reduce the cycle time. </li></ul><ul><li>Improved Design - The ReturnMaster 100 will utilize two drum roller sections to help provide a higher percentage of single magazines onto the inclined roller section. This will help sustain and high throughput thru the machine. </li></ul>Data Processing Services, Inc.
  9. 9. Drum Roller Separation The current drum roller will be improved by the addition of a second drum roller section. The second conveyor and roller will be running faster then the first to pull the first roller separated magazines and further separate them on the second drum roller. Magazine separation drum roller video Data Processing Services, Inc.
  10. 10. Drum Roller Motor Drive <ul><ul><li>Current Design - The current design utilized a motor that is not considered a heavy duty motor for the type of on and off cycling required for this application. </li></ul></ul><ul><ul><li>Improved Design - The ReturnMaster 100 will utilize a robust motor design to provide long maintenance free operation. </li></ul></ul>Data Processing Services, Inc.
  11. 11. Inclined Roller conveyor <ul><li>Current Design - The current roller design utilizes around 70 light-duty brushed motors. The motors utilize a small rubber band to drive the rollers. The current design requires frequent replacement of the motors to sustain the operation of the machine. This represents a significant maintenance burden to keep the machine operational. </li></ul><ul><li>Improved Design - The ReturnMaster 100 will utilize either a single continuous running motor attached to a belt drive system or “power roller” conveyor. The individual rollers will be engaged against the belt to drive the rotation of the rollers. The other option which will be investigated are commercially available “ power roller ” conveyor rollers which have built in brushless motors for extremely long life. We will evaluate the two options for the best performance and reliability </li></ul>Data Processing Services, Inc.
  12. 12. Inclined Roller Coating <ul><li>Current Design - The original design had limitation and maintenance issues with the roller coating. This would require frequent cleaning or replacement of the roller covers. </li></ul><ul><li>Improved Design - We will use information obtained for current users of the RAMP machine who have developed and test better roller covers. </li></ul>Data Processing Services, Inc.
  13. 13. Incline Conveyor Sensor Array <ul><ul><li>Current Design - The current sensor array is comprised of around 70 individual photo eye devices. Each photo eye requires an individual wire that is connected to an individual input to the control system. The presents maintenance issues and requires a large number of devices and complexity. </li></ul></ul><ul><ul><li>Improved Design - The ReturnMaster 100 will utilize an “ light curtain ” array which is a integrated linear sensing device which provides the same discrete detection along it’s linear axis of something blocking the beam. The “ light curtain ” requires a single serial interface vs. the 70 plus individual inputs thus simplifying the design. </li></ul></ul>Data Processing Services, Inc.
  14. 14. Barcode Scanning Array <ul><li>Current Design - The current design is limited by the “State of the Art” in barcode technology at the time machine was designed. The original scanners were very expensive and were limited in the ability to read difficult barcodes. </li></ul><ul><li>Improved Design - The ReturnMaster 100 will utilize the latest technology in barcode reading technology which will provide higher read rates (ability to read a barcode) at a lower cost. </li></ul>Data Processing Services, Inc.
  15. 15. Top Hold Down Rollers <ul><li>Current Design - The current design utilized different materials for the hold down roller wheels. The materials did not last long and were mostly ineffective at helping hold down the magazines through the system. The bearings were not adequate for the amount of use they would see. </li></ul><ul><li>Improved Design - The ReturnMaster 100 will utilized better materials and bearing to provide long life and better hold down characteristics and in some position utilizes active rollers. </li></ul>Data Processing Services, Inc.
  16. 16. Control System <ul><li>Current Design - The current design requires a barcode transmit and a reply for determining the disposition of a magazine. This process takes time and could be limiting the throughput of the current design. </li></ul><ul><li>Improved Design - The ReturnMaster 100 will obtain all the information required to determine the disposition of each magazine locally to provide the fasted throughput. The machine will utilize the latest technology in controls systems hardware to help avoid early obsolescence. </li></ul>Data Processing Services, Inc.
  17. 17. Design Specifications <ul><li>The following pages summarize the design specification and design goals of the ReturnMaster 100 . The specifications and goals do not limit the attempts to produce the highest throughput possible. They are only the lowest acceptable level of performance designed. </li></ul>Data Processing Services, Inc.
  18. 18. Product Sizes <ul><li>Magazine Sizes The ReturnMaster 100 will be sized to handle all the common sizes of magazines. This would include the cover area as well as thickness of typical magazines. </li></ul><ul><li>Magazine Full Copy vs. Covers The ReturnMaster 100 will be designed to handle full copy magazines. Please advise IF covers only requirements are needed. </li></ul>Data Processing Services, Inc.
  19. 19. Barcode Scanning Performance <ul><li>The scanner Array will utilize a combination of laser scanners to read the barcodes in any orientation on the top of the magazines. The barcode read rate should be in the high 99% rate if the barcodes are of good quality. </li></ul><ul><li>The fact that the barcode focal distance from the scanner is very constant, this will allow for optimal setup for the barcode scanner. Vision (optical picture capture) based scanners will also be evaluated to determine the best scanner configuration for the highest read rate. </li></ul>Data Processing Services, Inc.
  20. 20. Rate Performance <ul><li>Minimum Throughput 6000 magazines/covers per hour </li></ul><ul><li>The rate of the ReturnMaster 100 is dependent on the quality of the magazines that are loaded into the machine. The rate is also dependent on how well the operator loads the magazines. The machine will be designed and optimized to provide the most robust separation and feeding speeds but can be allowed to run at the best speed by proper operator feeding. The machine should be able to sustain capacity through put of 6000 whole copy Magazines per hour with proper quality magazines and operator feeding. The machine will be optimized to achieve even higher throughput if possible. </li></ul>Data Processing Services, Inc.
  21. 21. ReturnMaster Physical Size Data Processing Services, Inc.
  22. 22. ReturnMaster ISO View Data Processing Services, Inc.
  23. 23. Design Details <ul><li>The following Slides describe some of the design details and techniques that will be utilized to enable the ReturnMaster 100 to achieve the required specifications. </li></ul>Data Processing Services, Inc.
  24. 24. Magazine Separation <ul><li>One of the techniques available to assist in the singulation process and to help with all the different sizes of magazines is a variable speed top pinch roller. The pinch rollers will be powered to roll at the same speed as the drum roller. When a large gap is detected between the pinch roller and the drum roller the pinch roller can be stop to provide drag to the magazines on top to help in the separation process. </li></ul><ul><li>This same technique using adjustable pinch roller will allow the feeding of covers only. The roller conveyor will utilize multiple pinch or top rollers to maintain down pressure on the covers and magazines to allow them to track true through the feeding system. </li></ul><ul><li>Other techniques might be utilized to help separate covers upon any challenges in separating the covers. One technique could be the use of controlled air jets to help separate and hold down the covers as they move on the roller conveyor. Another approach would be the use of brushes to agitate the stack of covers to help separate the covers. </li></ul>Data Processing Services, Inc.
  25. 25. Magazine Separation Continued <ul><li>The height of the drum roller might be adjustable to allow a greater impact on the different surfaces and full copy vs. covers. </li></ul><ul><li>The different magazine surface types has an effect on how well the magazines separate. Factors that effect the separation are speed, incline angle, external friction (pinch rollers), and other ways to increase traction against the belt or rollers. </li></ul><ul><li>Using a vacuum assisted drum roller or belt section is another method that will be investigated to provide the best method for separation. The vacuum roller or belt is a device that pulls air through it and contains a number of holes around the surface of the belt or roller. </li></ul><ul><li>The holes come in contact with the magazine or cover and help to adhere the material to the roller or belt. This can all the system to use a steeper incline to more aggressive pinch roller to apply added pull on the top magazines. </li></ul>Vacuum Roller Data Processing Services, Inc.
  26. 26. Roller Speeds <ul><li>The different stages of magazine transportation will run at different speeds. The first in feed conveyor where the operator stacks the incoming magazines will run at the slowest speed. The first drum roller will turn at a faster speed then the in feed conveyor belt. The second drum section will operator at an even faster speed. The rollers conveyor will run at the fastest speed to allow more separation and will also cycle on and off to create gaps. Once the magazines have the proper gap they will travel at the same speed through the scanner array and sortation section. All motors have variable speed controllers. This will allow the ability to finally tune the proper speed to maximize overall throughput. The actual required speed through the scanner is no more then 200 feet per minute to sustain 6000 magazines per hour. The key approach of the ReturnMaster 100 is to utilize a more efficient pre separation section (dual drum) to allow the roller conveyor to run at a slower and more consistent speed as apposed to a fast conveyor with many start stops. </li></ul>Data Processing Services, Inc.
  27. 27. Roller Start – Stop Cycling Reduction <ul><li>One of the goals that will help increase throughput is to eliminate the roller conveyor start - stop and feed more magazines already pre separated onto the roller conveyor to allow a smooth continuous running feeding the scanning and sortation functions. The video is an example of the current frequent start – stop cycling that plagues increased throughput. </li></ul>Conveyor roller start – stop cycling video Data Processing Services, Inc.
  28. 28. Customers Use DPS and CASI Solutions! Data Processing Services, Inc.
  29. 29. ReturnMaster Automated Accurate Magazine Return Management We team with you! 19345 US Hwy 19N, Suite 206 Clearwater, FL 33764 www.goDPS.com Tel: 727-532-9481 Fax: 727-532-9723 Email: Guy@goDPS.com Data Processing Services, Inc.

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