1<1>April 18, 2023 Senior Design I – Mid Project Review

Mid-Project ReviewSenior Design I

Low Energy Printing Project P09505

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Project Team, Faculty, & Customer • Project Team:

–Project Lead:Joshua Jones (ME – Year 5)

–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

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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

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Project BackgroundXerographic 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

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How a Fusing Sub-System Works

Traditional Toner Fusion:

Temperature+

Pressure+

Heat=

Fused, Adhered Toner

Discrete, loose toner

Heat

Pressure

Fused, adhered toner

Image by: David Thompson, Xerox Corp.Information by: David Thompson, Xerox Corp. and Dinesh Tyagi, Eastman Kodak Company

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Nip

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Project ScopeThe 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.

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Customer Requirements

Most Important Customer Requirements:•Paper is not damaged•Uniform pressure along nip•Fit into current Xerox Workcentre 245/55 Pro•Use pressure only to fuse toner to paper

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Number: Need Type: Original Needs: Needs within the Scope of Project: Customer Weight:Paper Quality Paper is not damage

Image be Xerox qualityPrint has a low gloss

2 Fit into current Xerox Workcentre 245/55 Pro Fuser (minus the motor/drive system) fits into Workcentre Pro 3Compatible with other Xerox modelsTechnology 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 95 Accept paper in orientation it currently enters fuser (SHF / LHF) Accept paper in orientation it currently enters fuser (SHF / LHF) 36 Sub-system cost less then current system Sub-system cost less then current system 37 Easy of manufacturing Prototype cost less then $5,000.00 to complete 3

Use pressure only to fuse toner to paperLow Energy - non-thermal

9 Pressure along the nip needs to be uniform 910 User must be able to safely clear jam in fuser User must be able to safely clear jam in fuser 111 Misc. Fuser last for at least 100,000 prints Fuser last for at least 100,000 prints 1

Pressure

Cost

Paper can go through system without being damaged1

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Revised Customer Needs

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Technology may be able to be used up and down along Xerox stream 1

Use pressure only to fuse toner to paper 9

Compatibality

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

– Various loads and their effect on:• Uniformity of pressure across the nip• Damage to paper

– Analytically test the max load design can handle– Effects of paper thickness – Analytically examine the effects of roller lengths

• Verification of theory that additional rollers will generate a more uniform pressure across the nip

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Concept Selection Process

PUGH 1 - Week 3Preliminary Design

Concept Selection PUGH 1Concept Selection PUGH 2Concept Selection PUGH 3

PUGH 2 - Week 4 Loading Styles

PUGH 3 - Week 6How to Mechanically

Apply Load

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Current Design Concept

12 inches

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Current Design Concept

April 18, 2023 Senior Design I – Mid Project Review

Current Fuser System’s Dimensions:Length: 18.5 inchesWidth: 4.5 inchesHeight: 6.5 inches

Our Design’s Dimensions:Length: 13 inchesWidth: 3 inchesHeight: 4 inches

Current Design Concept Features

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Feature Customer Req. RationaleGenerate better uniformity of pressure through the nipTest effects of skews on pressure and paper damageCapable of fitting in Workcentre Pro 45Light weight

Load not directly applied to rollers contacting paper 1 Less paper damageTest various amount of loadAdjust for various paper thicknessesLess paper damageMore uniform pressure across the length of nipAdjust for various paper thicknessesInexpensiveResistant to corrosion resulting in less paper damageLong lastingCan withstand high pressure and stresses

Does not use heat to fuse toner 8 Low energy

Multiple top roller configurations

Compact

Flexiblity of applied load

Compliance of applied load

Stainless steel rollers

1,8,9

1,3

1,8,9

1,8,9

1,6,7,11

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Budget

April 18, 2023 Senior Design I – Mid Project Review

BOM - Budget

Part Number Part Description Part Supplier

Req. Quanity

Quanity Units Mat'l Cost ($)

Labor Cost ($/hr)

Tlt. Labor Cost ($)

Total Cost ($)

1 9298K253 Bottom A Roller McMaster Carr 1 Inches $274.52 $60/0.5 $30.00 $304.522 88955K753 Center B Roller McMaster Carr 1 Inches $98.79 $60/0.5 $30.00 $128.793 88955K292 Stabilizing C Roller McMaster Carr 2 Inches $29.58 $60/0.5 $30.00 $89.164 BA-887 Shell Cup Needle Ball Bearing Bearings Direct 10 Inches $4.98 0 $0.00 $49.80567 91251A451 Socket Cap Screw McMaster Carr 8 Inches 7.77 per pack of 25 0 $0.00 $7.778 Drive Motor Xerox 1 N/A $400.00 0 $0.00 $400.009 6545K113 End Plate Support Bar McMaster Carr 1 Inches $10.70 $60/0.25 $15.00 $25.70

10 96562A194 Pan Head Machine Screq McMaster Carr 1 Inches $5.71 0 $0.00 $5.7111 98408A138 Retaining E Ring McMaster Carr 1 Inches $6.12 0 $0.00 $6.1212 Pressure Sensitive Paper Xerox 2 $600.00 0 $0.00 $1,200.0013 $0.0014 $0.00

Total: $1,650.90

$1,033.33Inches $133.33 $60/15 $900.008992K973 Side Plate Stock McMaster Carr 1

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Key Risks:Identified During Design Reviews

April 18, 2023 Senior Design I – Mid Project Review

Risk Tracking

Risk/Issue Risk Level Mitigation PlanRevisit calculations, pressure should be more on the order of 6,000lbsRecalculate Black Box with 3inch rollers compare with Xerox engineer's numbersDetermine where heat losses goDevelop a heat management plan Perform FEA using ANSYSTest multiple bearing typesCalculate max nonuniform loading though screwsMeasure effect of nonuniform loading

Time dependence of fusing Low Waiting on unfused images to testComplete enginieering drawingsContact RIT's machine shop to get estimated lead times

MediumLoad limit of design that will maintain uniform pressure

High

Calculated applied pressure may be too low

LowHeat generated by system

Precision of applying loadHigh

MediumMachining parts

MSD2 Project Plan

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Week 11 Week 1 Week 2 Week 3 Week 4 Week 5 Week 6 Week 7 Week 8 Week 9 Week 10Finalize DesignEnsure ManufacturabilityOrder Raw StockDevelop Test ProceduresOrder Specific ComponentsAnalytical Testing and ResultsMaching of FuserAssemble FuserImplement Testing and AnalysisDesign ImprovementsVerification Testing and DebuggingImplement SolutionsContinue Testing with ImprovementsPut together documentationProject Poster and PaperFinal Project Review

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Questions

April 18, 2023 Senior Design I – Mid Project Review