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Open Source/Open Architecture Low-Energy
PrintingPrepared Multidisciplinary Senior Design
Projects
Dean Culver (ME)Shawn Hoskins (ME)Derek Meinke (ME)
Tim Salter (ME)
Something New to MSD
• Inventing a new family
• Free reign in proof of concept
Concept Generation
• Concepts that apply
– Through what product is the most printing energy consumed in developing countries?
• 11 Inventions
As a Result
• From Many, Few
– 11 Concepts » 15 Projects over 6 years
• Postponed Investigations
– Inkjet Technologies
Xerography Power Consumption
78%
6%4%
4%3%
5%
Fuser
Mechanical
Controls
DocumentHandling
Imaging
Miscellaneous
Paper
Trans
port
Paper
Trans
port
OS
/OA
Low
-E
Prin
ting
OS
/OA
Low
-E
Prin
ting
R10004: OS/OA Low-Energy Printing
Toner
Tunne
lTon
er
Tunne
l
Toner
Tunne
l 2
Toner
Tunne
l 2
Digita
l
FuserDigi
tal
Fuser
Test
Fixtur
esTes
t
Fixtur
es
Categ
ory
Categ
ory
Histor
y
Histor
y
Conce
pt
Conce
pt
N/AN/A
2009
2009
2010
2010
2011
2011
2012
2012
2013
2013
2014
2014
Proof of ConceptProof of Concept
Proof of ConceptProof of Concept
Proof of ConceptProof of Concept
Printin
g
Med
ia Roll
Printin
g
Med
ia Roll
Pro
of
of C
once
pt:
Mic
row
ave
Ton
er P
hase
Con
trol
Pro
of
of C
once
pt:
Mic
row
ave
Ton
er P
hase
Con
trol
*Improve*Improve
OptimizeOptimize
*Digital Fuser Test Bed
*Digital Fuser Test Bed
Objective TreeLow Energy
Printing Process or Component
Resources Economic
Scope Technological
Appeal to PrintingCompanies
Familiarize withMSD Support and
Past Projects
Design WorkAssembly/
Construction
What can this iteration do?
What should the goal of MSD be for
this concept?
Printer HeadTechnology
Other Interfaces
Staffing
Design Tools
Funding
Available Data
Digital FusingCharge-Chasing
Toner TunnelCoil PotentialToner Tunnel
P10509 Digital Fuser Roller
Project Overview– The initial project phase will consist of
devising preliminary fuser design concepts and options. The team will investigate, model, and test the various components and processes involved in the digital fusing process. The end goal of this phase is to produce quantitative test results to be used as the basis of fuser development for future senior design groups.
Motor
Gear drive
Bearing supports
Roller fuser & discrete heating elements
Commutator brushes
Background Information
• Conventional fuser roller – ~500-800 watts of energy
– Small surface area contacting toner
– Remaining surface area exposed to air
– Convection losses
qconvection
qconduction
Internal heat
source
Toner/media surface
ω
Digital Fuser Concept
• Discrete heating elements– Individually powered strips– Produce heat at toner
contact area– Only residual heat is
convected
• Other components– Roller drum– Bearing supports– Motor and gear drive– Pressure application
mechanism
qconvection
qconduction
Heated elements
ω
Toner/media surface
Digital Fuser Function TreeLow Energy
Digital Fuser Roller
Low Energy Digital Fuser Roller
Supply powerSupply power
Apply PressureApply PressureRotateRotate
Run motorRun motor
Compress tonerCompress toner
Fuse tonerFuse toner
Distribute heatDistribute heatFeed paperFeed paper
Heat elementsHeat elementsReduce energy
consumption
Reduce energy consumption
Selectively heatSelectively heat
StaffingName Discipline Role/Skill
TBD TBD Faculty Guide, Will work closely with the team on an on-going basis to facilitate success.
Gerry Garavuso
Printing Technology Faculty Consultant, Will provide technical support on an intermittent basis.
Dr. Edward Hensel
Department Head Primary Customer, Provide project requirements to ensure project results in relevant engineering data to be used by future design teams.
TBD ME Student Develop thermal and physical model of digital fuser roller. Determine energy required to heat toner to fusing temperature.
TBD ME Student Create multiple preliminary design options for fuser roller and test fixture. Design simplified prototype for the purpose of testing fuser concept and feasibility.
TBD EE Student Create model of power supplied to fuser and drive motor. Determine methods of power control and distribution for heating elements and motor.
TBD EE Student Investigate brush commutator mechanism and review optional methods of contact system. Source and select potential electrical components for proof-of-concept prototype.
ResourcesCategory Source Description Availabl
e
Faculty TBD Consult with faculty who are knowledgeable with regard to the particular project or individual task at hand. Making informed decisions will increase the likelihood of project success.
TBD
Environment
Electronics Lab
The fuser incorporates electrical components which will need to be assembled using tools and materials commonly found in the electronics lab. The lab also provides a clean working environment which is useful when assembling delicate or sensitive components.
Yes
Environment
Machine Shop
Equipment and tooling in the machine shop will be needed when the time comes to create a device that will test the concepts of fuser operation. This environment will be more important for future design teams who may eventually build a prototype roller fuser and test fixture.
Yes
Equipment Fabrication equipment
Lathe, upright mill, as well as assorted power and hand tools. Much of this can be found in the machine shop.
Yes
Equipment Electronics equipment
Soldering equipment, power meter, ohm meter, etc. Likely to be found in electronics lab.
Yes
Materials KGCOE Consult faculty/advisers to determine availability of materials at hand (not vendor sourced materials.)
TBD
Preliminary Work Breakdown Structure
Person Week 0->1 Tasks Week 1->2 Tasks Week 2->3 Tasks
Group •Group introductions•Review team values and norms•Layout goals for the quarter
•Previous meeting review•Present individual work and•Acquire xerographic printer
•Previous meeting review•Address new issues•Delegate responsibilities to each team member as needed
ME Student
•Begin planning thermal and physical models•Begin research on toner fusing process
•Refine preliminary models•Continue fusing research and requirements
•Complete thermal and physical models•Create document containing all information needed to fuse toner
ME Student
•Researching design concepts for fuser roller and test fixture•Develop simplified prototype concepts for discrete heating
•Create design concepts for working components of fuser •Continue simple prototype design and narrow scope.
•Narrow design concepts to one or two options•Compile design concepts for initial fuser design prototype
EE Student
•Begin modeling of power supply and distribution•Start researching methods of power control for fuser
•Continue modeling of power supply•Create ideas for power supply and distribution
•Design and source power supply and associated materials for simple fuser prototype
EE Student
•Start researching power transfer from commutator to heating elements•Compile electronics vendor list
•Continue commutator development•Create list of electrical components and costs
•Continue commutator research •Document all materials and costs for electrical components required for simplified prototype
Risk Assessment Category Description of
RiskPossible
ConsequencesContingency Plan
Staffing Group member is unavailable for short period of time due to illness or other reason.
Individual tasks for the week will not be accomplished.
EE and ME students should work together closely and swap information regarding their individually assigned tasks on a frequent basis. This will allow the remaining student to take over tasks that are specific to their respective major.
Staffing Group member is unavailable for remainder of quarter or extended time period.
Individual tasks will not be accomplished. Loss of individual's specific skills and knowledge.
Students should work closely with other members of the same major, as well as keep group up to date on individual tasks during each group meeting. All work will be documented so the group can divide up the work in the event that a team member is not available.
Vendor and Materials
Vendor cannot supply material, or materials do not arrive as scheduled
Project development cannot progress until materials are acquired.
Source multiple vendors for parts. Do not plan on using parts or materials that are available from only one or two vendors. It would also be helpful to source reputable companies that have a history of prompt shipping and a good in-stock availability of products.
Equipment Required equipment is unavailable at time of need.
Project development cannot progress until equipment becomes available.
Try not to rely on using uncommon or unique tools and equipment. Prototype and test fixture should be constructed using commonly available tools and equipment.
Facilities Required facility is occupied or unavailable.
Unable to complete tasks specifically performed in particular facility.
Plan ahead and do not wait until the last minute to perform a task that can only be accomplished in a specific environment. Look into availability of facilities and plan on completing a task a week ahead of schedule.
Customer Requirements Cus
tom
er W
eigh
ts
Red
uce
ener
gy n
eeds
Rea
ch to
ner
fusi
ng te
mpe
ratu
re
Red
uce
# of
par
ts
Min
imiz
e co
sts
Com
plet
e do
cum
enta
tion
Team
mee
tings
and
dis
cuss
ion
Uses less energy 5% 9Proves fuser concept 29% 9 3 1Makes progress in printing track 24% 3 1 9 3Produce data and numerical results 10% 1 3 1 1 9 3Build foundation for next group 19% 1 1 1 3 9 3Repeatable and reproducable 14% 1 3 9 1
Functional Performance Specifications Unitswatts
degrees # $ # hours
Technical Targets
Better 54
Technical Benchmarking 32
Worse 1
Raw score 4 1.57
0.43
1.1
6.29
1.71
Relative Weight 26%
10%
3% 7% 42%
11%
House of QualityDigital Fuser
Roller
Final comments• The initial phase of senior design for the
digital fuser project should…
– Produce quantitative results
– Demonstrate the value of work
– Build a foundation for future SD groups
Toner Tunnel: Charge Chasing
• What is a Toner Tunnel?
• What is the Mission?
• What are the potential benefits?
• What are some intrinsic challenges?
Function Tree (Over Iterations)
Toner TunnelToner Tunnel
AcceptAccept AccelerateAccelerate
DirectDirectTransformTransform
Integrate withInjection
Integrate withInjection
Measure IntakeMeasure Intake
Identify ErrorIdentify Error
Self-CorrectSelf-Correct
ErrorError
Apply EM ForceApply EM Force Eject TonerEject Toner
Manipulate EM Field
Manipulate EM Field
Observe DefectsObserve Defects
Self-CorrectSelf-Correct ErrorError
Melt TonerMelt Toner
House of QualityToner Tunnel
Risk Assessment
Risk Description Consequences ContingencyInconsistent Dynamic Injection
Inability to standardize particle placement control
Static Injection
Failed Advancing Field Generators
Inability to maintain pseudo-constant electromagnetic force
Static Field Generators
Failed Particle Velocity Data Acquisition System
Inability to measure the particle speed at design acceleration
Decrease Design AccelerationORInfer Analytically from Position and Time
Scope Overshoots Budget
Inability to purchase components or services needed
Revise Scope
Project Readiness Package OverviewStaffing
– 2 Mechanical Engineers
– 2 Electrical Engineers– 1 PM (ME/IE)
Business Aspects
– Budget– Supplementary
Resources– Marketing
Preliminary WBS
Resources
Category Source DescriptionResource
Available(mark with X)
Faculty RITIndividual familiar with particle dynamics, injection,
and tracking.
RITIndividual familiar with fields, particularly generation
and manipulation.X
Environment
RIT
Design Center Cube: Area designated for team meetings and workshops.
Design Center Storage Locker: Locker for hardware, document, and resource storage.
X
Equipment RITOld printers designated for recycling or waste. To be
used for familiarizing with current xerographic processes.
XeroxOld printers designated for recycling or waste. To be
used for familiarizing with current xerographic processes.
Toner Tunnel: Coil Potential Method• Xerography fuser uses 78% of total energy
consumption.
• How can we remove fuser?– Apply energy to toner particles before media– Impact paper with velocity
• Accelerate charged particles with electromagnetic field.
• Use a EM coil like a solenoid to eject ink
TT: CPM Mission Statement
• Provide a means to accelerate and direct toner particles onto a media with enough energy to fuse the toner to that media without the need of an additional fusing process. The accelerating and directing will be conducted using a tunnel with an electro-magnetic field created by a coil potential.
• Show proof that toner particles can be accelerated into a media so that a fuser can be eliminated in the Xerography process.
TT: CPM Staffing Requirements• Team Lead / Particle Tracking
– ME, Coordinate and facilitate the planning of deliverables between team members.
• Coil Structure Engineer– ME, Infrastructure to support wire coil
• Particle Motion Control– ME, Toner entrance and exit
• Power Supply Engineer– EE, Determine power and electrical requirements
• EM Field Specialist– EE, Particle acceleration
Person Week 0>1 Tasks Week 1>2 Tasks Week 2>3 Tasks
Team Lead/Particle Tracking
Team building, planning, and research team values and norms.
Research different surrogates of the toner particle .
Determine optimal sizing and material for particle
Coil Structure Engineer
Team building, Xerography familiarization, team values and norms.
Begin sizing of test fixture and understand customer requirements.
Interface with electrical components
Particle Motion Control
Team building, Xerography familiarization, team values and norms.
Understand the motion of a charged particle in an EM field Research methods of particle discharge from reservoir.
Come up with ways to enter particles into tunnel, ways to stop the particle with marking ability
Power Supply Engineer
Team building, Xerography familiarization, team values and norms.
Come up with power supply options to power EM coil.
Work with power coil structure engineer in interfacing electrical components with structure
EM Field Specialist
Team building, Xerography familiarization, team values and norms.
Develop math model for EM field Understand motion of charged particle in an EM field.
Charge of particle manipulation
TT: CPM Work Breakdown Structure
TT: CPM Risk Assessment
Description of Risk
Possible Consequences
Contingency Plan
Particles are too small to capture particle motion effectively.
Unknown velocity will not demonstrate proof of concept of generating enough kinetic energy.
Use a surrogate particle with larger diameter for easier image capture and velocity measurement.
Power requirements for particle acceleration are relatively higher compared to current technologies.
No improvement in energy usage for a low energy design project.
Demonstrate that change in design parameters follows theoretical model to prove that principles are correct.
Project becomes too specialized and is comprised mainly of one-off parts
Easily repeatable open source/open architecture aspect is compromised
Use as many generic parts as possible such as breadboard designs vs printed boards. Detailed documentation of everything is critical.
TT: CPM Business Plan
• Operate within KGCOE MSD budget
• Show proof of concept!– Inputs, function, desired outcomes
• Novel concepts attract attention
• Increase/generate corporate and internal infrastructure
P10506: Print Media Transport
• Continuous Paper Transport Operation Overview– Differences from traditional paper transport
systems
• Ultimate Objective of Project– Primary: Successfully interface with other
low-energy printing projects– Secondary: Minimize energy used to
transport print media
• Potential Iterations of Project
Paper Transport Staffing
Name Discipline Role/Skill
TBD TBD Faculty Guide
Gerry Garavuso Printing Technology (ME) Faculty ConsultantDr. Ed Hensel ME Department Head Primary Customer
TBD ME Student Team Lead
TBD ME Student Mechanical Interface
TBD ME Student Mechanical Design
TBD EE Student
Power Supply/Electrical System
TBD EE Student Electronics Interface
Paper Transport WBS
Person
Week 0 -> 1 Week 1 -> 2 Week 2 -> 3
Group 1. Group Introductions2. Project Introduction3. Review EDGE website4. Determine goals and
deliverables for quarter
5. Set weekly meeting times
6. Discuss norms and values
7. Establish roles
1. Meet with customers/stakeholders to clarify needs
2. Meet with interfacing project teams to determine needs
3. Begin to develop design concepts
1. Meet with interfacing project teams for updates
2. Share individual findings/design concepts
ME 1 Lead group in above activities
Facilitate group tasks Review each team member’s status/progress
ME 2 Follow group activities Meet with interfacing team to address individual concerns
Review design ideas with interfacing team
ME 3 Follow group activities Investigate existing designs Begin mechanical design
EE 1 Follow group activities Investigate power supply options Begin power supply design
EE 2 Follow group activities Meet with interfacing team to address individual concerns
Review design ideas with interfacing team
Paper Transport Risk Assessment
Risk Possible Consequences
Contingency Plan
Interfacing team is unavailable to meet
Final product will not interface successfully
Develop an understanding with the other team early on that frequent collaborative meetings will be necessary
Device destroys print media
Media is not delivered as required
Develop multiple design concepts and plans for backup use
Print media is in an incorrect position
Ink is not transferred to print media as intended
Conduct multiple tests of integrated system
Required parts and materials do not arrive as planned
Project cannot move forward as scheduled
1. Use commonly stocked parts
2. Search for multiple vendors
Team member is unavailable and absent from meetings
Goals and deliverables will not be completed on time
1. Hold frequent meetings to keep track of individuals’ progress
2. Ensure team members know what other members are doing
3. Document
House of Quality
Paper Transport
Paper Transport Function TreeContinuous Print Media
Transport
Continuous Print Media Transport
Supply PowerSupply Power
InterfaceInterfaceRotate RollerRotate Roller
Run motorRun motor
Follow Commandsof Printer
Follow Commandsof Printer
Position MediaCorrectly
Position MediaCorrectlyFeed mediaFeed media
Does Not TearMedia
Does Not TearMedia
Does Not WarpMedia
Does Not WarpMedia
DPM Concluding Statements
• Senior Design: Personally Prepared
• Unique Skill Set
• Learning to Learn
Questions?
• P10506
• P10507
• P10508
• P10509
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