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Project P09505
Mid-Project Review
Senior Design I
October 6, 2015
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Project Team:
Project Lead:
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
October 6, 2015
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
October 6, 2015
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
October 6, 2015
Fused,
adhered
toner
Nip
Pressure
Traditional Toner
Fusion:
Temperature
+
Pressure
+
Heat
=
Fused, Adhered Toner
October 6, 2015
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.
October 6, 2015
Customer Requirements
Revised Customer Needs
Number:Need Type: Original Needs:
Needs within the Scope of Project:
Customer Weight:
Paper Quality Paper is not damage
1
Paper can go through system without being damaged
9
Image be Xerox quality
Print has a low gloss
2
Fit into current Xerox Workcentre 245/55 Pro
Fuser (minus the motor/drive system) fits into Workcentre Pro
3
Compatible with other Xerox models
3
Technology may be able to be used up and down along Xerox stream1
CompatibalityTechnology can be used up and down along Xerox stream
4
Standard office grade paper (20/24 pound paper)
Standard office paper (8.5 x 11") fits
9
5
Accept paper in orientation it currently enters fuser (SHFAccept
/ LHF) paper in orientation it currently enters fuser (SHF / LHF)
3
6
Sub-system cost less then current system
Sub-system cost less then current system
3
Cost
7
Easy of manufacturing
Prototype cost less then $5,000.00 to complete
3
Use pressure only to fuse toner to paper
8
Use pressure only to fuse toner to paper
9
Low Energy - non-thermal
Pressure
9
Pressure along the nip needs to be uniform
9
10
User must be able to safely clear jam in fuser
User must be able to safely clear jam in fuser
1
11 Misc.
Fuser last for at least 100,000 prints
Fuser last for at least 100,000 prints
1
Senior Design 2
Deliverables
Physical Hardware:
Working cold pressure fusing system
One working prototype with multiple configurations
Parametric Analysis:
Effect of different roller skews on:
Uniformity of pressure across the nip
Damage to paper
October 6, 2015
PUGH 2 - Week 4
Loading Styles
October 6, 2015
PUGH 3 - Week 6
How to Mechanically
Apply Load
9
Senior Design I Mid Project Review
October 6, 2015
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October 6, 2015
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October 6, 2015
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Budget
Part
Number
1 9298K253
2 88955K753
3 88955K292
4 BA-887
5
6 8992K973
7 91251A451
8
9 6545K113
10 96562A194
11 98408A138
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13
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Part Description
Req.
Quanity
Labor Cost Tlt. Labor Total
Part SupplierQuanity Units
Mat'l Cost ($) ($/hr)
Cost ($) Cost ($)
Bottom A Roller
Center B Roller
Stabilizing C Roller
Shell Cup Needle Ball Bearing
McMaster Carr
McMaster Carr
McMaster Carr
Bearings Direct
McMaster
McMaster
Xerox
McMaster
McMaster
McMaster
Xerox
Carr
Carr
Carr
Carr
Carr
1 Inches
1 Inches
2 Inches
10 Inches
1 Inches
8 Inches
1 N/A
1 Inches
1 Inches
1 Inches
2
$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
$30.00
$30.00
$30.00
$0.00
$304.52
$128.79
$89.16
$49.80
$900.00 $1,033.33
$0.00
$7.77
$0.00
$400.00
$15.00
$25.70
$0.00
$5.71
$0.00
$6.12
$0.00 $1,200.00
$0.00
$0.00
Total: $1,650.90
BOM - Budget
October 6, 2015
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Key Risks:
Risk Level
Mitigation Plan
Revisit calculations, pressure should be more on the order
6,000lbs
High
Recalculate Black Box with 3inch rollers compare with Xero
Calculated applied pressure may be too low
engineer's numbers
Determine where heat losses go
Low
Heat generated by system
Develop a heat management plan
Load limit of design that will maintain uniform
Perform FEA using ANSYS
Medium
pressure
Test multiple bearing types
Calculate max nonuniform loading though screws
High
Precision of applying load
Measure effect of nonuniform loading
Time dependence of fusing
Low
Waiting on unfused images to test
Complete enginieering drawings
Medium
Machining parts
Contact RIT's machine shop to get estimated lead times
Risk Tracking
October 6, 2015
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Questions
October 6, 2015
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