Low Energy Printing

Project P09505
Mid-Project Review Senior Design I

July 9, 2013

Senior Design I Mid Project Review

1<1> 1

Project Team, Faculty, & Customer

Project Team:
Project Lead:
Joshua Jones (ME Year 5)

Team Members:
Whitney Domigan (ME Year 4) Jenna Kilroy (ISE - Year 5) Andrzej Lubaszka (EE Year 5)

Faculty:
Guide:
Bill Nowak (ME, Xerox Employee)

Consultant:
Marcos Esterman (ISE)

Customer:
Xerox Corp Marking Elements & Integration Lab
John Knapp

July 9, 2013

Senior Design I Mid Project Review

Agenda
Introduction Project Background Customer Requirements Project Deliverables Concept Selection Current Design Concept Bill of Materials Feasibility Checklist Key Risks From Design Reviews MSD 2 Project Plan

July 9, 2013

Senior Design I Mid Project Review

Project Background
Xerographic digital printers are very energy intensive, specifically the fusing sub-system. This is largely due to the fact that during the fusing process toner is heated to well above its melting point, to enable heat flow, and allow the toner to adhere to the paper. Senior Design Project as Stated on Edge: Re-consider the design of an extremely low power, non-thermal fusing system
https://edge.rit.edu/content/P09505/public/Home

July 9, 2013

Senior Design I Mid Project Review

How a Fusing Sub-System Works

Heat Discrete, loose toner Fused, adhered toner

Traditional Toner Fusion: Temperature + Pressure + Heat = Fused, Adhered Toner

Nip

Pressure

Image by: David Thompson, Xerox Corp. Information by: David Thompson, Xerox Corp. and Dinesh Tyagi, Eastman Kodak Company

July 9, 2013

Senior Design I Mid Project Review

Project Scope
The purpose of this project is develop a fusing sub-system that uses pressure instead of thermal energy to fuse toner to paper with the aim of fitting into the Xerox Workcentre Pro 45/55 printer.

July 9, 2013

Senior Design I Mid Project Review

Customer Requirements
Revised Customer Needs
Number: Need Type: Paper Quality 1 2 3 Compatibality Original Needs: Paper is not damage Image be Xerox quality Print has a low gloss Fit into current Xerox Workcentre 245/55 Pro Compatible with other Xerox models Technology can be used up and down along Xerox stream Standard office grade paper (20/24 pound paper) Accept paper in orientation it currently enters fuser (SHF / LHF) Sub-system cost less then current system Easy of manufacturing Use pressure only to fuse toner to paper Low Energy - non-thermal User must be able to safely clear jam in fuser Fuser last for at least 100,000 prints Needs within the Scope of Project: Paper can go through system without being damaged Fuser (minus the motor/drive system) fits into Workcentre Pro Technology may be able to be used up and down along Xerox stream Standard office paper (8.5 x 11") fits Accept paper in orientation it currently enters fuser (SHF / LHF) Sub-system cost less then current system Prototype cost less then $5,000.00 to complete Use pressure only to fuse toner to paper Pressure along the nip needs to be uniform User must be able to safely clear jam in fuser Fuser last for at least 100,000 prints Customer Weight: 9 3 1 9 3 3 3 9 9 1 1

4 5 6 Cost 7 8 9 10 11 Misc. Pressure

Most Important Customer Requirements:

Paper is not damaged Uniform pressure along nip Fit into current Xerox Workcentre 245/55 Pro Use pressure only to fuse toner to paper

July 9, 2013

Senior Design I Mid Project Review

Senior Design 2 Deliverables

Physical Hardware:
Working cold pressure fusing system One working prototype with multiple configurations

Parametric Analysis:
Effect of different roller skews on:
Uniformity of pressure across the nip Damage to paper Uniformity of pressure across the nip Damage to paper

Various loads and their effect on: Analytically test the max load design can handle Effects of paper thickness Analytically examine the effects of roller lengths

Verification of theory that additional rollers will generate a more uniform pressure across the nip

July 9, 2013

Senior Design I Mid Project Review

Concept Selection Process

PUGH 1 - Week 3 Preliminary Design PUGH 2 - Week 4 Loading Styles PUGH 3 - Week 6 How to Mechanically Apply Load

Concept Selection PUGH 1 Concept Selection PUGH 2 Concept Selection PUGH 3

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Current Design Concept

12 inches

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Senior Design I Mid Project Review

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Current Design Concept

Current Fuser Systems Dimensions: Length: 18.5 inches Width: 4.5 inches Height: 6.5 inches

Our Designs Dimensions: Length: 13 inches Width: 3 inches Height: 4 inches

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Senior Design I Mid Project Review

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Current Design Concept Features

Feature Multiple top roller configurations Compact Load not directly applied to rollers contacting paper Flexiblity of applied load Compliance of applied load Customer Req. 1,8,9 1,3 1 1,8,9 1,8,9 Rationale Generate better uniformity of pressure through the nip Test effects of skews on pressure and paper damage Capable of fitting in Workcentre Pro 45 Light weight Less paper damage Test various amount of load Adjust for various paper thicknesses Less paper damage More uniform pressure across the length of nip Adjust for various paper thicknesses Inexpensive Resistant to corrosion resulting in less paper damage Long lasting Can withstand high pressure and stresses Low energy

Stainless steel rollers Does not use heat to fuse toner

1,6,7,11 8

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Senior Design I Mid Project Review

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Budget
Part Number
1 2 3 4 5 6 7 8 9 10 11 12 13 14 9298K253 88955K753 88955K292 BA-887 8992K973 91251A451 6545K113 96562A194 98408A138

Part Description
Bottom A Roller Center B Roller Stabilizing C Roller Shell Cup Needle Ball Bearing Side Plate Stock Socket Cap Screw Drive Motor End Plate Support Bar Pan Head Machine Screq Retaining E Ring Pressure Sensitive Paper

Part Supplier
McMaster Carr McMaster Carr McMaster Carr Bearings Direct McMaster Carr McMaster Carr Xerox McMaster Carr McMaster Carr McMaster Carr Xerox

Req. Quanity
1 1 2 10 1 8 1 1 1 1 2

Quanity Units
Inches Inches Inches Inches Inches Inches N/A Inches Inches Inches

Mat'l Cost ($)

Labor Cost ($/hr)

Tlt. Labor Cost ($)

$30.00 $30.00 $30.00 $0.00 $900.00 $0.00 $0.00 $15.00 $0.00 $0.00 $0.00

Total Cost ($)

$304.52 $128.79 $89.16 $49.80 $1,033.33 $7.77 $400.00 $25.70 $5.71 $6.12 $1,200.00 $0.00 $0.00 $1,650.90

$274.52 $60/0.5 $98.79 $60/0.5 $29.58 $60/0.5 $4.98 $133.33 $60/15 7.77 per pack of 25 $400.00 $10.70 $60/0.25 $5.71 $6.12 $600.00

0 0 0 0 0

Total:

BOM - Budget

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Senior Design I Mid Project Review

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Key Risks:
Identified During Design Reviews
Risk/Issue Risk Level High Calculated applied pressure may be too low Heat generated by system Load limit of design that will maintain uniform pressure Precision of applying load Time dependence of fusing Machining parts Low Medium High Low Medium Mitigation Plan Revisit calculations, pressure should be more on the order of 6,000lbs Recalculate Black Box with 3inch rollers compare with Xerox engineer's numbers Determine where heat losses go Develop a heat management plan Perform FEA using ANSYS Test multiple bearing types Calculate max nonuniform loading though screws Measure effect of nonuniform loading Waiting on unfused images to test Complete enginieering drawings Contact RIT's machine shop to get estimated lead times

Risk Tracking

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Senior Design I Mid Project Review

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MSD2 Project Plan

Week 11 Week 1 Week 2 Week 3 Week 4 Week 5 Week 6 Week 7 Week 8 Week 9 Week 10 Finalize Design Ensure Manufacturability Order Raw Stock Develop Test Procedures Order Specific Components Analytical Testing and Results Maching of Fus er Assemble Fuser Implement Tes ting and Analys is Design Improvements Verification Testing and Debugging Implement Solutions Continue Testing with Improvements Put together documentation Project Poster and Paper Final Project Review

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Senior Design I Mid Project Review

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Questions

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Senior Design I Mid Project Review

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