Post on 05-Feb-2016
description
P10511: Miniaturization of Xerography
Derek Meinke (ME, PM)Matthew Liff (ME)
Tony Zhang (EE)Zaw Htoo (ISE)
Project DescriptionThe scope of P10511 is to create a test fixture
that will allow the use of various charging devices along with multiple diameters of photoreceptors.
Test affect of charge uniformity with various device configurations and input parameters.
Xerox test fixture is currently limited in versatility.
Project Description (cont.)Reasons for Reducing Drum
Diameter Advances in Charging Technologies Reducing Wear Rate of
Photoreceptor Higher Rotational Speeds for Higher
PPM Reduced Footprint for Charging
Devices Cost Effective Increased Reliability
System ObjectivesDifferent Charger
Configurations BCR versus Scorotron
Photoreceptor Diameter
Variable Drum Speed Ion Transfer
Charge Measurement (ESV)
Roles and ResponsibilitiesName Discipline Role / Skills
Mike Zona and Bill Nowak
Xerox Faculty Guide, will work closely with the team on an on-going basis to facilitate success.
Marcos Esterman Xerox Faculty Consultant, will provide discipline technical support on an intermittant basis.
Dale Mashtare Xerox Industrial Consultant
Derek Meinke ME Project Manager, fixture design, charge device mounting, drum to motor coupling.
Matthew Liff ME Fixture design, charge device mounting, drum to motor coupling.
Tony Zhang EE Electrical integration of high voltage and drive motor to data acquisition.
Zaw Htoo ISE Labview coder for user interface and system control/status.
Team Values and NormsReasonably late to
meetings is acceptable but not repeatable. Leave a message for a team member if cannot attend.
At start of meeting, discuss team objectives for 5 to 10 minutes.
CC all group members when emailing project information; respond within 24 hours.
An understood consensus must be made for all decision making.
Record meeting minutes.
Customer’s House of Quality
Customer Requirements Customer Weights
Voltage
Input (5-
8kV)
Surface
Speed (≤1m/
s)
Drum Size (24-
84mm)
Charger
Type (BCR
or Scorot
ron)
Charger Gap
(1-2mm)
Dielectric
Thickness
(~25µm)
ESV distance (1-2mm)
Budget ($2k)
Uniform
Erase Charg
e (-100V)
Surface
Charge (-
300 to -
800V)
Allow any charge device config 13% 3 3 3 9 9 1 9 1 3
Easily changeable components 11% 9 9 9 3 9 1
Allow different dielectric thicknesses 11% 1 3 3 1 9 1 3 3
Voltage reading across entire drum length 9% 3 3 1 1
Parallel ESV axis with photoreceptor 8% 3 1 9 1 9
Easy to use data acquisition menu 8%
Repeatability 8%
Data for both aluminum substrate and prod. PR 8% 9 9 1 3 9 1 1 3 9
Uniform pre-charge erase 7% 3 1 3 1 9 3
Accurate drum speed control 6% 1 9 3 3 9 3 3 9 9
Proper safety measures 4% 9 1 1
Alignment of charger with photoreceptor 4% 9 1 3 9 1 9 3 1 3
Accept multiple photoreceptor diameters 3% 1 9 9 1 9 3 9 9 9 3
Below target budget 1% 3 9 9 1 1 9 1
Generate minimal ozone 0% 9 9 1 3
Customer Needs ListCustomer Needs Important
Allow any charge device config 13%
Easily changeable components 11%
Allow different dielectric thicknesses 11%
Voltage reading across entire drum length 9%
Parallel ESV axis with photoreceptor 8%
Easy to use data acquisition menu 8%
Repeatability 8%
Data for both aluminum substrate and prod. PR 8%
Uniform pre-charge erase 7%
Accurate drum speed control 6%
Proper safety measures 4%
Alignment of charger with photoreceptor 4%
Accept multiple photoreceptor diameters 3%
Below target budget 1%
Generate minimal ozone 0%
Specifications ListEngineering Specification Importance
Voltage Input (5-8kV) 5%
Surface Speed (≤1m/s) 13%
Drum Size (24-84mm) 9%
Charger Type (BCR or Scorotron) 8%
Charger Gap (1-2mm) 15%
Dielectric Thickness (~25µm) 5%
ESV distance (1-2mm) 10%
Budget ($2k) 11%
Uniform Erase Charge (-100V) 13%
Surface Charge (-300 to -800V) 11%
Risk AssessmentRisk Management Table - Revision 1 - 12/17/2009
ID Risk Item
Likelyhood
Severit
y
Importance Action to Minimize Risk Owner
6 Faulty equipment 2 2 4Obtain quality equipment, look into obtaining MSD locker All members
7ESV/Erase Lamp/Charger gap problems 2 2 4
Run multiple tests to determine best location, have faculty guide review fixture, make it variable Mechanical Engineer
8 Weather affecting travel 2 1 2
Have good communication, use Tortoise SVN and EDGE, online chat discussions available All members
9 Customer priority changes 1 2 2 Constant communication with customer All members
14 Hard to change components 2 3 6Create a manual, use more clips than screws Mechnaical Engineer
15Aluminum substrate is in contact with motor ground 1 3 3
Include a switch, use insulating material at contact, generate many concepts
Mechanical / Electrical Engineer
18 Lack of Labview skillset 3 2 6Additional research time, utilize faculty expertise
Industrial Systems Engineer
*19 total risks so far
Project Plan
Concept Generation (ME)
Concept Generation (ME)
Concept Generation (ME)
Concept Generation (EE)Power supplies will be provided to us from
our customer, Xerox.Trek Cor-a-trol Model 610C High Voltage
Supply o High Voltage Supply (0 to ±10kV)o Current Supply (0 to 2mA rms)
Concept Generation (EE)Recommended motors and specs have also
been provided. For Photoreceptor Drive (S83-93)
For ESV slide (S57-51)
Closer Look at the MotorsPhotoreceptor Drive: S83-
93
Minimal Required Torque 9 Pin Connector to Voltage
Supply Requires isolating motor
ground from power supply.
Motors (cont.)
ESV Drive: S57-51
Delivers required torque for rotating threaded shaft
See next slide for the workings of the ESV unit
Selecting a DAQ DeviceData Acquisition & Analysis requires a few
steps:
Factors for Consideration
Bill of Materials (EE & ISE)FOR THE MOTORS
Motor Controller (NI PCI-7332) $899.00 Description: PCI / 2-Axis http://sine.ni.com/nips/cds/view/p/lang/en/nid/14338
Stepper Motor Drive (NI P70530) $349.00 (x2) = $698.00 Description: 1-Axis / 300 Watts http://
sine.ni.com/nips/cds/view/p/lang/en/nid/203933
Total = $1597.00
Bill of Materials (cont.)FOR THE DAQ
Multifunction Data Acquisition Device (NI USB-6009) $279.00 Inputs: 8 Analog / 12 Digital Outputs: 2 Analog / 12 Digital USB Connection http://sine.ni.com/nips/cds/view/p/lang/en/nid/14605
#overviewTotal = $1597.00 + $279.00 = $1876.00
Input and Output (ISE & EE)Input Data Output (Uniformity) Output (I-V Slope)
Start / Stop Voltage Current
Type of Test ( Uniformity / I-V Slope)
Range of Uniformity Slope of Current Vs Voltage
Length of Device Slope of Voltage Across P/R
Voltage Intercept
Diameter of Device (mm)
Graph (Voltage Vs length of P/R)
Graph (Current Vs Voltage)
Speed of P/R (m/s)
V-Plate Voltage (KV)
Report
LabView User Interface
System Flow (EE & ISE)
Unknowns and Open Issues
Action Items
Questions?