P10511: Miniaturization of Xerography

Derek Meinke (ME, PM)Matthew Liff (ME)

Tony Zhang (EE)Zaw Htoo (ISE)

Project Description• The 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

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.

Customer Needs ListRevision #: 4 (1/12/2010)

Customer Need Importance Description

Allow any charge device config 13%Fixture has to accommodate both BCR charger and

Scorotron charger with easy interchangeability.

Easily changeable components 11%

Charger and photoreceptor drum should be interchangeable with minimal or easy fixture

teardown.

Allow different dielectric thicknesses 11%Accommodate various dielectric thicknesses on

photoreceptor.

Voltage reading across entire drum length 9%ESV should have 0 point and scan across entire

photoreceptor length.

Parallel ESV axis with photoreceptor 8%

A fixture is required for the ESV. It must run lengthwise across the photoreceptor and create a

uniform distance from the ESV to the photoreceptor for all distances across the photoreceptor.

Easy to use data acquisition menu 8%Control interface of the fixture has to be easy to use,

with no training required.

Repeatability 8%Ability to perform the test multiple times with the

same results.

Data for both aluminum substrate and prod. PR 8%

The control system should be able to aquire different information of both aluminum substrate and

production photoreceptor.

Customer Needs List (cont.)Uniform pre-charge erase 7%

Set photoreceptor surface potential to even charge across receptorlength before charging

Accurate drum speed control 6%Motor must output speed accurate within an

acceptable margin.

Proper safety measures 4%Ozone and high voltages should be dealt with using

all standards of safety and regulations.

Alignment of charger with photoreceptor 4%After charging process, there should be an equal charge across drum operating in steady state.

Accept multiple photoreceptor diameters 3%

Our fixture must be able to perform the same function for varying diameters of photoreceptors, ranging from

24mm - 84mm

Below target budget 1%

Our principle sponsor, Xerox Corporation, has allowed a $2,000 budget for motion control and data

Acquisition components.

Generate minimal ozone 0%

The type of material used in charging device should produce the least amount of ozone by balancing

incoming voltage.

Customer Specifications ListRevision #: 3 (12/11/2009)

Engineering Specification Specification (description)Unit of Measur

eMarginal

ValueIdeal Value

Voltage Input (5-8kV) High voltage power source. kV 8 3 - 8

Surface Speed (≤1m/s)

Photoreceptor drum must be controllable for different

speeds.mm/sec <1000 600

Drum Size (24-84mm)

Drums of different diameters will be provided with known

range. mm 24 - 84 24 - 84

Charger Type (BCR or Scorotron)

There are two different chargers we will be focusing

on. N/A N/A N/A

Charger Gap (1-2mm)Scorotron charger should be

fixed with uniform gap. mm 1 - 2 1.5

Dielectric Thickness (~25µm)

Different layer thicknesses will be fitted with the

photoreceptor. µm 25µm 25µm

ESV distance (1-2mm)

The distance the ESV is from the outer surface of the

photoreceptor. mm 1 - 2 1.5

Budget ($2k)

The amount of money available for purchasing

components. $ 2000<$200

0

Uniform Erase Charge (-100V)

After being exposed to the erase lamp, the photoreceptor is expected to have an evenly distributed charge across it. V -100 -100

Surface Charge (-300 to -800V)

Charge across whole photoreceptor has to be the

same. V-300 to

-800

-300 to -800

Customer RequirementsCustomer Weights

Voltage

Input (5-8kV)

Surface Spe

ed (≤1

m/s)

Drum

Size (24-84m

m)

Charger Type (BCR or Scorotro

n)

Charger Gap

(1-2mm)

Dielectri

c Thickne

ss (~2

5µm)

ESV distanc

e (1-2mm)

Budget

($2k)

Uniform Eras

e Charge

(-100

V)

Surface Charge

(-300 to -800

V)Allow any charge device config 13% 3 3 3 9 9 1  9 1 3Easily changeable components 11%     9 9 9  3 9 1 Allow different dielectric thicknesses 11% 1 3 3  1 9 1  3 3Voltage reading across entire drum length 9%     3      3 1  1Parallel ESV axis with photoreceptor 8%     3    1 9 1  9Easy 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 9Uniform pre-charge erase 7%   3 1  3 1    9 3Accurate drum speed control 6% 1 9 3 3 9 3  3 9 9Proper safety measures 4% 9 1  1           Alignment of charger with photoreceptor 4%   9 1 3 9 1 9 3 1 3Accept multiple photoreceptor diameters 3% 1 9 9 1 9 3 9 9 9 3Below target budget 1%   3 9 9 1  1 9  1Generate minimal ozone 0% 9    9      1  3

Customer House of Quality

Risk AssessmentRisk Management Table - Revision 1 - 12/17/2009

ID Risk Item

Likelyhood

Severity

Importance Action to Minimize Risk Owner

6Faulty 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

8Weather affecting travel 2 1 2

Have good communication, use Tortoise SVN and EDGE, online chat discussions available All members

9Customer priority changes 1 2 2Constant communication with customer All members

14Hard 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

18Lack of Labview skillset 3 2 6Additional research time, utilize faculty expertise

Industrial Systems Engineer

Objective Tree

Concept Generation: Charger

Concept Generation: Charger

Concept Generation: Charger

Concept Screening: Charger  Concepts (Charger Mount)

 Plunger Method

Plunger Method w/

HairclipThe Doors

Double-sided Tape

w/ SlideSelection Criteria (reference)      Accept multiple PR diameters 0 0 0 0Easily changeable components 0 + - +Below target budget 0 - - +Allows multiple configurations 0 0 - +Manufacturability 0 - - +Robustness 0 0 + 0Alignment of charger with PR 0 0 - +Repeatability 0 0 - +Proper safety measures 0 0 0 0Sum + 's 0 1 1 6Sum 0's 9 6 2 3Sum -'s 0 2 6 0Net Score 0 -1 -5 6Rank 2 3 4 1

Continue? yes no no yes

Concept Selection: Charger    Concepts (Charger Mount)  Plunger

MethodDouble-sided Tape w/ Slide 

 

Selection Criteria Weight RatingWeighted

Score RatingWeighted Score

Accept Multiple PR Diameters 5% 3 0.15 3 0.15Easily Changeable Components 18% 2 0.36 4 0.72Below Target Budget 3% 2 0.06 4 0.12Allows Multiple Configurations 21% 3 0.63 4 0.84Manufacturability 13% 2 0.26 4 0.52Robustness 13% 2 0.26 4 0.52Alignment of Charger with PR 7% 2 0.14 4 0.28Repeatability 13% 1 0.13 3 0.39Proper Safety Measures 7% 3 0.21 3 0.21

 Total

Score 2.20 3.75  Rank 2 1  Continue? no yes

Concept Generation: Photoreceptor

Concept Screening: Photoreceptor  Concepts (Photoreceptor Mount)

 V-Flange w/ Shaft Pins

Custom Endcaps w/ Shaft Pins

Spring Clamp

V-Flange w/ Tooth Grips

Selection Criteria   (reference)    Centering ability 0 0 - 0Easily changeable components + 0 0 +Below target budget + 0 + +Accept multiple diameters - 0 - -Manufacturability + 0 + +Robustness + 0 0 +Voltage reading across PR - 0 0 -Parallel ESV axis 0 0 - 0Alignment of charger w/ PR - 0 - -Proper safety measures 0 0 0 0Repeatability 0 0 - 0Accurate drum speed control - 0 - +Switch btn voltage and ground 0 0 0 0Uniform pre-charge erase - 0 - -Sum + 's 4 0 2 5Sum 0's 5 14 5 5Sum -'s 5 0 7 4Net Score -1 0 -5 1Rank 3 2 4 1

Continue? no yes no yes

Concept Selection: Photoreceptor    Concepts (P/R Mount)  Custom

Endcaps w/ Shaft Pins

V-Flange w/ Tooth Grips

Spring Loaded Concentric V's

 

 

Selection Criteria Weight RatingWeighted

Score RatingWeighted Score Rating

Weighted Score

Centering Ability 11% 5 0.55 4 0.44 4 0.44Easily Changeable Components 11% 2 0.22 3 0.33 5 0.55Below Target Budget 1% 0 0 3 0.03 3 0.03Accept multiple Diameters 4% 5 0.2 3 0.12 4 0.16Manufacturability 8% 1 0.08 4 0.32 3 0.24Robustness 8% 3 0.24 4 0.32 4 0.32Voltage Reading across PR 9% 5 0.45 2 0.18 5 0.45Parallel ESV axis 8% 5 0.4 3 0.24 5 0.4Alignment of charger w/ PR 5% 5 0.25 3 0.15 5 0.25Proper safety measures 5% 4 0.2 4 0.2 4 0.2Repeatability 9% 4 0.36 2 0.18 4 0.36Accurate drum speed control 6% 4 0.24 3 0.18 3 0.18Switch btn voltage and ground 8% 5 0.4 3 0.24 3 0.24Uniform Pre-charge Erase 7% 5 0.35 3 0.21 5 0.35

 Total

Score 3.94 3.14 4.17  Rank 2 3 1  Continue? no no yes

Concept Generation: Erase

Concept Screening: Erase  Concepts (Erase Mount)

 Attach Rod

Slots Doors SlidersSelection Criteria (reference)    Lightweight 0 - 0Easily Changeable Components 0 - 0Below Target Budget 0 - -Uniform Precharge Erase 0 - +Manufacturability 0 - 0Robustness 0 + 0Accept Multiple PR Diameters 0 + +Repeatability 0 - -Sum + 's 0 2 2Sum 0's 8 0 4Sum -'s 0 6 2Net Score 0 -4 0Rank 1 2 1

Continue? yes no yes

Concept Selection: Erase    Concepts (Erase Mount) 

Attach Rod Slots The Doors Sliders 

 

Selection Criteria Weight RatingWeighted

Score RatingWeighted Score Rating

Weighted Score

Lightweight 12% 3 0.36 1 0.12 3 0.36Easily Changeable Components 17% 4 0.68 3 0.51 4 0.68Below Target Budget 7% 4 0.28 2 0.14 4 0.28Uniform Precharge Erase 14% 4 0.56 2 0.28 3 0.42Manufacturability 14% 4 0.56 2 0.28 4 0.56Robustness 12% 3 0.36 4 0.48 3 0.36Accept Multiple PR Diameters 10% 4 0.4 3 0.3 5 0.5Repeatability 14% 5 0.7 2 0.28 4 0.56  Total Score 3.90 2.39 3.72  Rank 1 3 2  Continue? yes no no

Concept Generation: ESV

Concept Screening: ESV  Concepts (ESV Mount)

 

Spacing Blocks w/ Leadscrew

Driven Slots w/

Leadscrew

Spacing Blocks w/

Pulley Drive

Spacing Blocks w/

Gear TrackSelection Criteria (reference)      Lightweight 0 - + -Easily Changeable Components 0 - 0 0Below Target Budget 0 - + -Gap Distance 0 - 0 0Manufacturability 0 - - -Robustness 0 - - 0Voltage Reading Across PR 0 0 0 0Parallel ESV Axis 0 0 0 0Repeatability 0 0 - 0Sum + 's 0 0 2 0Sum 0's 9 3 4 6Sum -'s 0 6 3 3Net Score 0 -3 -1 -3Rank 1 3 2 3

Continue? yes no yes no

Concept Selection: ESV    Concepts (ESV Mount)  Spacing Blocks

w/ LeadscrewSpacing

Blocks w/ Pulley Drive

  

Selection Criteria Weight RatingWeighted

Score RatingWeighted Score

Lightweight 10% 2 0.2 4 0.4Easily Changeable Components 16% 3 0.48 3 0.48Below Target Budget 4% 4 0.16 2 0.08Gap Distance 12% 3 0.36 3 0.36Manufacturability 12% 4 0.48 2 0.24Robustness 9% 5 0.45 2 0.18Voltage Reading Across PR 13% 4 0.52 3 0.39Parallel ESV Axis 12% 3 0.36 3 0.36Repeatability 12% 4 0.48 3 0.36  Total Score 3.49 2.85  Rank 1 2  Continue? yes no

System Level Concept

Some Dimensions

• Length of PR: 360 mm

• Diameters: 30, 40, 60, 84 mm

• Charger Width: ≤50 mm

• Charger Height:Scorotron: ≤30 mmBCR: ≤20 mm

Input and Output (ISE & EE)

Input Data Output (Uniformity) Output (I-V Slope)Start / Stop Voltage CurrentType 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 GUI

Signal Processing and Flow

Closer Look at the Motors

9-Pin Connector from Motor to Voltage Supply Requires isolating motor ground from voltage supply to aluminum

substrate for the S83-93 Indexer will be incorporated in the 2-Axis PCI Motor Controller Speeds:

ESV Drive: Constant Speed P/R Drive: Automatically adjusted via LabView according to P/R diameter input and

desire speed input (<1 m/s)

Motors Dimensions

Photoreceptor Drive: S83-93ESV Unit Drive: S57-51

Selecting a DAQ DeviceData Acquisition & Analysis requires a few steps:

Factors for Consideration

Bill of Materials (EE)

Project Plan

Concerns

• Budget already at $1876– Only includes motor components and DAQ

• Substrate isolation is a concern

• LabView knowledge may not be sufficient

Further Questions?