P10511: Miniaturization of Xerography Derek Meinke (ME, PM) Matthew Liff (ME) Tony Zhang (EE) Zaw...
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Transcript of P10511: Miniaturization of Xerography Derek Meinke (ME, PM) Matthew Liff (ME) Tony Zhang (EE) Zaw...
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
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
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
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 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
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
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 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
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 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
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
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/ 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
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 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
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?