May 11, 2009Design Project Management Project Review Low Energy Printing MSD Project P David Hatch, ME

Project Statement To develop a low energy printing fuser system, using cold pressure technology, capable of supplying a uniform pressure to sinter, coalesce, and adhere toner to print media May 11, 20092Design Project Management Project Review Original Image: Waseda University

Background Information May 11, 2009Design Project Management Project Review3 Project Name and Number Low Energy Printing Project, P10505 Guide and Consultant Bill Nowak, Xerox Corporation, Principal Engineer - Motion Quality Systems Primary Customer John Knapp, Xerox Corporation, Research Fellow P10505 is a continuation of P The current project builds on the work completed in P09505.

Project Relevance Fusing is the most energy intensive portion of the printing process. Xerox has expressed interest in decreasing energy use to open markets where electricity is expensive. Brazil, Russia, India, and China (“BRIC countries”) are targets for this printing technology. A fuser that uses cold pressure fusing will reduce maintenance needs due to wear. May 11, 2009Design Project Management Project Review4

Intellectual Property Xerox is protective of its intellectual property rights. Since MSD is in the public domain, some information may be limited. The project scope should not be affected by this since our role is well defined. May 11, 2009Design Project Management Project Review5

Staffing Requirements This primary need in this project is to decrease deflection in the fuser roller system. There is the added difficulty of complicating factors that cannot be directly computed (paper wrinkles, tears, etc). Three ME students: Strong background in CAD design, statics, dynamics, and finite element analysis. Two ISE students: Capable in design of experiment and design optimization. May 11, 2009Design Project Management Project Review6

Paper is Undamaged No wrinkles or tears No paper gloss Paper is Unchanged Fuser accepts standard paper orientations Fuser accepts standard paper weights Xerox Quality Image Low toner gloss Uniformly bonded image User Safety User can easily clear paper jams. Compatible Fits into Xerox Workstation 245/55 Integrable with current Xerox technology Profitable Competitive Lifespan Easily Manufactured Low Manufacturing Cost Affinity Diagram May 11, 2009Design Project Management Project Review7

Objective Tree Highly Marketable Low Energy Fuser Good Image Quality Paper is Undamaged No Tears No Wrinkles Low Paper Gloss Uniformly Bonded Image Low Toner Gloss Compatible Fuser Accepts Standard Paper Orientation Fuser Accepts Standard Paper Weights Fuser is Integrable in Current Xerox Printers User Safety User can Safely Clear a Paper Jam from the Fuser Profitable Easily Manufactured Longer Lifespan May 11, 2009Design Project Management Project Review8

Objective Statement Xerox Corporation wants to develop a cold pressure fuser because a fuser that uses less energy and has increased durability will make printers more marketable. May 11, 2009Design Project Management Project Review9

Function Tree Highly Marketable Low Energy Fuser Good Print Image Uniform Pressure Variable Pressure Low Manufacturing Costs Manufactured using Common Materials Easily Manufactured Durability Manufactured Using Tough Materials Designed for Low Wear Fusing Accomplished by Cold Pressure May 11, 2009Design Project Management Project Review10

May 11, 2009Design Project Management Project Review11 Paper Wrinkle Correlation Codes Paper Tear ++ Very Positive Uniform Pressure ++ NO INPUT IN THIS AREA +Positive Toner Gloss + -Negative Fuser Size - Very Negative Paper Gloss +++ Simplicity of Design -- - Energy Use Manufacturing Cost Ease of Manufacture ++ User safety + Lifespan + PreferredDwn UpDwn UpDwn Up Customer Perception Engineering Metrics Customer Weights Paper Wrinkle Paper Tear Uniform Pressure Toner Gloss Fuser Size Paper Gloss Simplicity of Design Energy Use Manufactur- ing Cost Ease of Manufacture User safety Lifespan 1 Worse Better Customer Requirements Paper is not damaged 399 ABCD Image is Xerox quality ABCD Fit into current Xerox Workcenter 245/55 Pro s ss ss Use pressure only to fuse toner to paper ABCD Accept paper in orientation it currently enters fuser SSSSS Compatible with other Xerox models SSSSS Fuser cost lower than current fusers Easy to manufacture ABCD User able to safely clear paper jams in fuser 1 9 BC A Low energy / non-thermal 9 9 ABCD Technology can be used up and down Xerox product line SSSSS Comparable fuser lifespan 1 9 ABCD Use standard office grade paper (20/24 pound paper) SSSSS Technical Targets No wrinkles No tears ∆pressure < ±8-1 0% Minimal gloss Fits in 245/55 Minimal gloss No metric available <current fuser <current fuser No metric Available 3 million prints (at least 100,000) Better 5 ABCD N/A ABCD S - A: Hot Roll Fuse 4 N/A S - B: Radiant Heat Fuse Technical Benchmarking3 N/A S - C: Flash Fuse 2 N/A S - D:Solvent Fusing Worse 1 N/A S ABCD - Raw score Relative Weight 8%8% 8%8% 12 % 7%7% 2%2% 23 % 4%4% 4%4% 3%3% 5%5%

House of Quality Conclusions The main focus of the project should be on pressure application, followed by paper quality. Cold pressure fusing is advantageous in regards to manufacturing cost, durability, and energy use. Its main disadvantage is a low quality image. John Knapp has indicated that a low quality image is expected and considered acceptable for most office use. May 11, 2009Design Project Management Project Review12

Faculty Resource Allocation Faculty ResourcesSourceDescriptionAvailable Project Guide Xerox Corp. Bill Nowak worked with P09505 this year and will be guiding P next year. Yes CustomerXerox Corp. John Knapp, division head of the “Green” Department at Xerox will be the customer for this project. Yes Technical AssistantRITGerry Garavuso will be available for technical advice during the project. Yes May 11, 2009Design Project Management Project Review13

May 11, 2009Design Project Management Project Review14 Equipment Resources DescriptionAvailable CNC machiningThe Brinkman lab is available on a first come first served basis. However, Xerox prefers to do most machining personally and will be the primary source. Yes Manual machining The Brinkman lab also has capabilities for students to do manual machining. Yes Outsourced machining If needed, Rochester has over a hundred machining shops which are potential resources in an emergency. As needed Miscellaneous hand tools Hand tools will be needed during SD II. Tools are available by loan from the MSD center. The Brinkman Labs and project members will also be resources for hand tools. Yes Equipment Resource Allocation

May 11, 2009Design Project Management Project Review15 Materials Resources SourceDescriptionAvailable Miscellaneous components. McMaster Carr, Reid Supply etc. Components can be ordered from supply companies as needed. As needed Manufacturing materials. Brinkman Lab, Individual Purchase Small orders of manufacturing materials can be made through Online Metals, Metals Depot, Instant Metals, etc. if the Brinkman Lab does not have a supply of the needed material. Rochester Steel is also a known supplier of metals in the area. As needed Materials Resource Allocation

May 11, 2009Design Project Management Project Review16 Week One 11/30-12/5Week Two 12/6-12/12Week Three 12/13-12/18 Winter Break Week Four 1/4-1/9Week Five 1/10-1/16Week Six 1/17-1/23 SMT Midweek Th Friday SSMT Midweek Th Friday SSMT Midweek Th Friday SSMT Midweek Th Friday SSMT Midweek Th Friday SSMT Midweek Th Friday S LOW ENERGY PRINTING PROJECT SCHEDULE Project Start Introduce team Introduce project Meet customer - Bill Nowak, John Knapp Assess customer needs Create customer statement of need Product Design Develop product concepts Benchmark competitive products Perform Pugh analysis Select optimum design DESIGN REVIEW Present preliminary product design to sponsor Solicit feedback Modify product design as needed Re-present product design to sponsor Analysis Create CAD model Analyze product with FEA Modify product design as needed Document Develop product documentation - Project description - BOM - FEA analysis - Product CAD drawings MID-PROJECT REVIEW Present Midterm Review to Customer

Risk Assessment May 11, 2009Design Project Management Project Review17 RiskForesight SolutionContingency Solution Winter break occurs three weeks into SD1. The team will likely lose momentum over the break. Create a sense of urgency about completing work following winter break. Use immediate, easily accomplished goals following break to get the team back up to speed quickly. A necessary tool goes missing. Keep team equipment in storage when not in use. Find or purchase a replacement tool. The team unexpectedly loses a member with a valuable skill set. Plan redundancy into team member selection and select a large enough team to take up slack. Re-assign roles so a team member can assume the needed responsibility. The project scope is unexpectedly changed. Maintain communication with the customer and stay informed of the project requirements. Manage customer expectations so requirements can be completed in remaining time. A necessary component goes missing without time to manufacture or order a new one. Order duplicates of all parts. Locate a local supplier or outsource machining to a local machine shop to acquire the part in the required time. Either the Brinkman Lab or Xerox suddenly cannot machine a needed part. Try to complete machining as early as possible to allow time to manage difficulties. Consult early with the Brinkman staff about machining to stay in front of issues. Outsource to a local machine shop or attempt machining personally with the help of faculty elsewhere at RIT. A supplier is late in shipping a part or cancels the order without time to order a new one. Use redundancy in ordering parts. Follow up on orders to be aware of delays. Find a replacement part based on delivery time instead of function requirements. Use local suppliers.

Summary The project will be successful when we have created a design that applies a pressure to the print media that does not vary by more than 10%. Secondary goals are decreasing paper damage from gloss and wrinkles. May 11, 2009Design Project Management Project Review18

Questions May 11, 2009Design Project Management Project Review19

Deflection in P09505 Roller Design

P09505 Cold Pressure Fuser Prototype

May 11, 2009Design Project Management Project Review 22 P09505 Cold Pressure Fuser Design

May 11, 2009Design Project Management Project Review 23 P09505 FEA Deflection in Fuser Design Image: Chicago Postcard Museum