p10511: miniaturization of xerography derek meinke (me, pm) matthew liff (me) tony zhang (ee) zaw...

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P10511: Miniaturization of Xerography Derek Meinke (ME, PM) Matthew Liff (ME) Tony Zhang (EE) Zaw Htoo (ISE)

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Page 1: P10511: Miniaturization of Xerography Derek Meinke (ME, PM) Matthew Liff (ME) Tony Zhang (EE) Zaw Htoo (ISE)

P10511: Miniaturization of Xerography

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

Tony Zhang (EE)Zaw Htoo (ISE)

Page 2: 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.

Page 3: P10511: Miniaturization of Xerography Derek Meinke (ME, PM) Matthew Liff (ME) Tony Zhang (EE) Zaw Htoo (ISE)

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

Page 4: P10511: Miniaturization of Xerography Derek Meinke (ME, PM) Matthew Liff (ME) Tony Zhang (EE) Zaw Htoo (ISE)

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.

Page 5: P10511: Miniaturization of Xerography Derek Meinke (ME, PM) Matthew Liff (ME) Tony Zhang (EE) Zaw Htoo (ISE)

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.

Page 6: P10511: Miniaturization of Xerography Derek Meinke (ME, PM) Matthew Liff (ME) Tony Zhang (EE) Zaw Htoo (ISE)

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.

Page 7: P10511: Miniaturization of Xerography Derek Meinke (ME, PM) Matthew Liff (ME) Tony Zhang (EE) Zaw Htoo (ISE)

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

Engineering Specification Specification (description)Unit of Measur

e

Marginal Value

Ideal 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

Page 8: P10511: Miniaturization of Xerography Derek Meinke (ME, PM) Matthew Liff (ME) Tony Zhang (EE) Zaw Htoo (ISE)

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 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 House of Quality

Page 9: P10511: Miniaturization of Xerography Derek Meinke (ME, PM) Matthew Liff (ME) Tony Zhang (EE) Zaw Htoo (ISE)

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

Page 10: P10511: Miniaturization of Xerography Derek Meinke (ME, PM) Matthew Liff (ME) Tony Zhang (EE) Zaw Htoo (ISE)

Objective Tree

Page 11: P10511: Miniaturization of Xerography Derek Meinke (ME, PM) Matthew Liff (ME) Tony Zhang (EE) Zaw Htoo (ISE)

Concept Generation: Charger

Page 12: P10511: Miniaturization of Xerography Derek Meinke (ME, PM) Matthew Liff (ME) Tony Zhang (EE) Zaw Htoo (ISE)

Concept Generation: Charger

Page 13: P10511: Miniaturization of Xerography Derek Meinke (ME, PM) Matthew Liff (ME) Tony Zhang (EE) Zaw Htoo (ISE)

Concept Generation: Charger

Page 14: P10511: Miniaturization of Xerography Derek Meinke (ME, PM) Matthew Liff (ME) Tony Zhang (EE) Zaw Htoo (ISE)

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 0

Easily changeable components 0 + - +

Below target budget 0 - - +

Allows multiple configurations 0 0 - +

Manufacturability 0 - - +

Robustness 0 0 + 0

Alignment of charger with PR 0 0 - +

Repeatability 0 0 - +

Proper safety measures 0 0 0 0

Sum + 's 0 1 1 6

Sum 0's 9 6 2 3

Sum -'s 0 2 6 0

Net Score 0 -1 -5 6

Rank 2 3 4 1

Continue? yes no no yes

Page 15: P10511: Miniaturization of Xerography Derek Meinke (ME, PM) Matthew Liff (ME) Tony Zhang (EE) Zaw Htoo (ISE)

Concept Selection: Charger    Concepts (Charger Mount) 

Plunger Method

Double-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 0.72

Below Target Budget 3% 2 0.06 4 0.12Allows Multiple Configurations 21% 3 0.63 4 0.84

Manufacturability 13% 2 0.26 4 0.52

Robustness 13% 2 0.26 4 0.52Alignment of Charger with PR 7% 2 0.14 4 0.28

Repeatability 13% 1 0.13 3 0.39

Proper Safety Measures 7% 3 0.21 3 0.21

 Total

Score 2.20 3.75

  Rank 2 1

  Continue? no yes

Page 16: P10511: Miniaturization of Xerography Derek Meinke (ME, PM) Matthew Liff (ME) Tony Zhang (EE) Zaw Htoo (ISE)

Concept Generation: Photoreceptor

Page 17: P10511: Miniaturization of Xerography Derek Meinke (ME, PM) Matthew Liff (ME) Tony Zhang (EE) Zaw Htoo (ISE)

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 0

Uniform pre-charge erase - 0 - -Sum + 's 4 0 2 5Sum 0's 5 14 5 5

Sum -'s 5 0 7 4Net Score -1 0 -5 1Rank 3 2 4 1

Continue? no yes no yes

Page 18: P10511: Miniaturization of Xerography Derek Meinke (ME, PM) Matthew Liff (ME) Tony Zhang (EE) Zaw Htoo (ISE)

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

Page 19: P10511: Miniaturization of Xerography Derek Meinke (ME, PM) Matthew Liff (ME) Tony Zhang (EE) Zaw Htoo (ISE)

Concept Generation: Erase

Page 20: P10511: Miniaturization of Xerography Derek Meinke (ME, PM) Matthew Liff (ME) Tony Zhang (EE) Zaw Htoo (ISE)

Concept Screening: Erase  Concepts (Erase Mount)

 Attach Rod

Slots Doors Sliders

Selection Criteria (reference)    

Lightweight 0 - 0

Easily Changeable Components 0 - 0

Below Target Budget 0 - -

Uniform Precharge Erase 0 - +

Manufacturability 0 - 0

Robustness 0 + 0

Accept Multiple PR Diameters 0 + +

Repeatability 0 - -

Sum + 's 0 2 2

Sum 0's 8 0 4

Sum -'s 0 6 2

Net Score 0 -4 0

Rank 1 2 1

Continue? yes no yes

Page 21: P10511: Miniaturization of Xerography Derek Meinke (ME, PM) Matthew Liff (ME) Tony Zhang (EE) Zaw Htoo (ISE)

Concept Selection: Erase    Concepts (Erase Mount)

 Attach Rod

SlotsThe 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 0.68

Below Target Budget 7% 4 0.28 2 0.14 4 0.28

Uniform Precharge Erase 14% 4 0.56 2 0.28 3 0.42

Manufacturability 14% 4 0.56 2 0.28 4 0.56

Robustness 12% 3 0.36 4 0.48 3 0.36

Accept Multiple PR Diameters 10% 4 0.4 3 0.3 5 0.5

Repeatability 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

Page 22: P10511: Miniaturization of Xerography Derek Meinke (ME, PM) Matthew Liff (ME) Tony Zhang (EE) Zaw Htoo (ISE)

Concept Generation: ESV

Page 23: P10511: Miniaturization of Xerography Derek Meinke (ME, PM) Matthew Liff (ME) Tony Zhang (EE) Zaw Htoo (ISE)

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

Page 24: P10511: Miniaturization of Xerography Derek Meinke (ME, PM) Matthew Liff (ME) Tony Zhang (EE) Zaw Htoo (ISE)

Concept Selection: ESV    Concepts (ESV Mount) 

Spacing Blocks w/ Leadscrew

Spacing 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 0.48

Below Target Budget 4% 4 0.16 2 0.08

Gap Distance 12% 3 0.36 3 0.36

Manufacturability 12% 4 0.48 2 0.24

Robustness 9% 5 0.45 2 0.18

Voltage Reading Across PR 13% 4 0.52 3 0.39

Parallel ESV Axis 12% 3 0.36 3 0.36

Repeatability 12% 4 0.48 3 0.36

  Total Score 3.49 2.85

  Rank 1 2

  Continue? yes no

Page 25: P10511: Miniaturization of Xerography Derek Meinke (ME, PM) Matthew Liff (ME) Tony Zhang (EE) Zaw Htoo (ISE)

System Level Concept

Page 26: P10511: Miniaturization of Xerography Derek Meinke (ME, PM) Matthew Liff (ME) Tony Zhang (EE) Zaw Htoo (ISE)
Page 27: P10511: Miniaturization of Xerography Derek Meinke (ME, PM) Matthew Liff (ME) Tony Zhang (EE) Zaw Htoo (ISE)

Some Dimensions

• Length of PR: 360 mm

• Diameters: 30, 40, 60, 84 mm

• Charger Width: ≤50 mm

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

Page 28: P10511: Miniaturization of Xerography Derek Meinke (ME, PM) Matthew Liff (ME) Tony Zhang (EE) Zaw Htoo (ISE)

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

Page 29: P10511: Miniaturization of Xerography Derek Meinke (ME, PM) Matthew Liff (ME) Tony Zhang (EE) Zaw Htoo (ISE)

LabVIEW GUI

Page 30: P10511: Miniaturization of Xerography Derek Meinke (ME, PM) Matthew Liff (ME) Tony Zhang (EE) Zaw Htoo (ISE)

Signal Processing and Flow

Page 31: P10511: Miniaturization of Xerography Derek Meinke (ME, PM) Matthew Liff (ME) Tony Zhang (EE) Zaw Htoo (ISE)

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)

Page 32: P10511: Miniaturization of Xerography Derek Meinke (ME, PM) Matthew Liff (ME) Tony Zhang (EE) Zaw Htoo (ISE)

Motors Dimensions

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

Page 33: P10511: Miniaturization of Xerography Derek Meinke (ME, PM) Matthew Liff (ME) Tony Zhang (EE) Zaw Htoo (ISE)

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

Factors for Consideration

Page 34: P10511: Miniaturization of Xerography Derek Meinke (ME, PM) Matthew Liff (ME) Tony Zhang (EE) Zaw Htoo (ISE)

Bill of Materials (EE)

Page 35: P10511: Miniaturization of Xerography Derek Meinke (ME, PM) Matthew Liff (ME) Tony Zhang (EE) Zaw Htoo (ISE)

Project Plan

Page 36: P10511: Miniaturization of Xerography Derek Meinke (ME, PM) Matthew Liff (ME) Tony Zhang (EE) Zaw Htoo (ISE)

Concerns

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

• Substrate isolation is a concern

• LabView knowledge may not be sufficient

Page 37: P10511: Miniaturization of Xerography Derek Meinke (ME, PM) Matthew Liff (ME) Tony Zhang (EE) Zaw Htoo (ISE)

Further Questions?