Low Energy Printing
Project P09505
Mid-Project Review
Senior Design I
July 31, 2017
Senior Design I – Mid Project Review
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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 31, 2017
Senior Design I – Mid Project Review
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Agenda
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•
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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 31, 2017
Senior Design I – Mid Project Review
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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 31, 2017
Senior Design I – Mid Project Review
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How a Fusing Sub-System Works
Traditional Toner Fusion:
Heat
Discrete, loose
toner
Fused, adhered
toner
Nip
Pressure
Temperature
+
Pressure
+
Heat
=
Fused, Adhered Toner
Image by: David Thompson, Xerox Corp.
Information by: David Thompson, Xerox Corp. and Dinesh Tyagi, Eastman Kodak Company
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Senior Design I – Mid Project Review
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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.
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Senior Design I – Mid Project Review
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Customer Requirements
Revised Customer Needs
Number: Need Type:
Paper Quality
1
2
3
Compatibality
4
5
6
Cost
7
8
Pressure
9
10
11 Misc.
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:
Customer Weight:
Paper can go through system without being damaged
9
Fuser (minus the motor/drive system) fits into Workcentre Pro
3
Technology may be able to be used up and down along Xerox stream
1
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
9
3
3
3
Use pressure only to fuse toner to paper
9
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
9
1
1
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
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Senior Design I – Mid Project Review
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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
– Various loads and their effect on:
•
•
Uniformity of pressure across the nip
Damage to paper
– 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
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Senior Design I – Mid Project Review
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Concept Selection Process
PUGH 1 - Week 3
Preliminary Design
PUGH 2 - Week 4
Loading Styles
Concept Selection PUGH 1
Concept Selection PUGH 2
Concept Selection PUGH 3
July 31, 2017
PUGH 3 - Week 6
How to Mechanically
Apply Load
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Current Design Concept
12 inches
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Current Design Concept
Current Fuser System’s Dimensions:
Length: 18.5 inches
Width: 4.5 inches
Height: 6.5 inches
July 31, 2017
Our Design’s Dimensions:
Length: 13 inches
Width: 3 inches
Height: 4 inches
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Current Design Concept Features
Feature
Customer Req.
Multiple top roller configurations
Compact
1,3
Load not directly applied to rollers contacting paper
1
Flexiblity of applied load
1,8,9
Compliance of applied load
1,8,9
Stainless steel rollers
1,6,7,11
Does not use heat to fuse toner
July 31, 2017
1,8,9
8
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
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Budget
Part
Number
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Part Description
Part Supplier
Req.
Quanity
Quanity
Units
9298K253
88955K753
88955K292
BA-887
Bottom A Roller
Center B Roller
Stabilizing C Roller
Shell Cup Needle Ball Bearing
McMaster Carr
McMaster Carr
McMaster Carr
Bearings Direct
1
1
2
10
Inches
Inches
Inches
Inches
8992K973
91251A451
Side Plate Stock
Socket Cap Screw
Drive Motor
End Plate Support Bar
Pan Head Machine Screq
Retaining E Ring
Pressure Sensitive Paper
McMaster Carr
McMaster Carr
Xerox
McMaster Carr
McMaster Carr
McMaster Carr
Xerox
1
8
1
1
1
1
2
Inches
Inches
N/A
Inches
Inches
Inches
6545K113
96562A194
98408A138
Mat'l Cost ($)
Labor Cost
($/hr)
$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
$600.00
Tlt. Labor
Cost ($)
0
0
0
0
0
0
$30.00
$30.00
$30.00
$0.00
Total
Cost ($)
$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
Total: $1,650.90
$900.00
$0.00
$0.00
$15.00
$0.00
$0.00
$0.00
BOM - Budget
July 31, 2017
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 Fuser
Assemble Fuser
Implement Testing and Analysis
Design Improvements
Verification Testing and Debugging
Implement Solutions
Continue Testing with Improvements
Put together documentation
Project Poster and Paper
Final Project Review
July 31, 2017
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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