Xerox Bearing Tester Systems Level Design Review (1) 12/1/2018 P13505

Project Team and Stakeholders Customer Erwin Ruiz Technical Specialist Project Manager Xerox Corporation Guide William Nowak Principle Engineer Faculty Consultant Jason Kolodziej RIT ME Faculty Project Team Stephen Rugg Project Manager Will Craig Co-lead Engineer Andrew Shuman Co-lead Engineer Kevin Albino Team Facilitator/Project Engineer Lauren Kaczor Project Engineer Tyler Hill Project Engineer 12/1/2018 P13505

Meeting Agenda Mission Statement (Steve) 10:00-10:05 Project Background (Steve) 10:05-10:10 Review of Customer Needs (Tyler, Will) 10:10-10:20 Initial Customer Needs New Customer Needs Pairwise Comparison Background Research (Steve, Andrew, Will) 10:20-10:30 Review of Specifications, Overview of HOQ (Lauren) 10:30-10:40 Concept Generation and Selection 10:40-11:00 Functional Decomposition (Andrew) Pugh Selection Matrices Full Concept (Kevin) Clamping /Alignment (Kevin) Vibration Sensor (Steve) Coupling (Tyler) Current Design (Tyler) Risk Assessment (Andrew) 11:00-11:05 Project Plan Review (Lauren) 11:05-11:15 Questions 11:15-11:30 12/1/2018 P13505

Mission Statement We will create a fixture that will allow for bearings to be qualified for continued use based on their vibration signatures. Additionally, we will compare Xerox’s current acoustic bearing tester against ours using a measurement system analysis (MSA) to investigate which is more repeatable. 12/1/2018 P13505

Project Background There are 2 Bearings in the iGen Printer System supporting the fuser roller Every 200,000 prints the printers come in for remanufacturing Currently, there is no quantitative test to qualify bearings Current test is to hold the bearing up to your ear and see if you hear or feel anything Potentially leads to many good bearings being scrapped 12/1/2018 P13505

Project Background 12/1/2018 P13505

Project Background Each set of 2 bearings cost about $200 A printer could be returned for remanufacturing a maximum of 5 times Potentially $1000 of unnecessary cost over the life of the printer Xerox has previously purchased a machine that measures acoustics and would like us to qualify it as well 12/1/2018 P13505

Xerox Acoustic Tester 12/1/2018 P13505

Initial Customer Needs 12/1/2018 P13505

Updated Customer Needs   Customer Need # Importance* Description CN1 9 Rotate bearing at a range of speeds CN2 Apply load to rotating bearing CN3 Collect vibration data of bearing CN4 Pass/Fail Bearings CN5 Allow for quick/easy changover of bearings CN6 Understand how to use Xerox's current bearing tester CN7 Compare results from Xerox's machine against new machine CN8 Provide graphical user interface for data that is collected CN9 Easy to learn how to use CN10 Uses standard outlet power CN11 3 Work with two bearing sizes CN12 Allow user to input different operating conditions CN13 Post processing of data to determine pass/fail CN14 Collect acoustic data of bearing CN15 1 Collect temperature data of bearing CN16 Automate the process *9 is the most important and 1 is the least important 12/1/2018 P13505

Pairwise Comparison 12/1/2018 P13505

12/1/2018 P13505

Most Important Customer Needs Pass or Fail Bearings Collect Vibration Data on Bearings Understand How to Use Xerox’s Acoustic Machine Compare Results from Xerox’s Acoustic Machine Against our Machine 12/1/2018 P13505

Research (7) (7) 12/1/2018 P13505

Bearing Pass Frequencies Bearing frequencies of interest calculated Bearing Pass Frequency Outer Race (BPFO) of most interest Prime spike region between 1 and 7 times BPFO At 3500 rpm, BPFO becomes 286 Hz, and will show peaks up to 2000 Hz

Loading Initially inclined to load the bearing Research and intuition steered us away REBAM Testing by GE Bentley Nevada (9)

Acoustic Emissions Under Varying Conditions By comparing the measured characteristic frequency with the analytical solution, the location of the defect can be determined. This does not give information on the character of the defect. (8)

Specifications 12/1/2018 P13505

House of Quality Potentially added a column to specs talking about pass or failing a bearing 12/1/2018 P13505

House of Quality 12/1/2018 P13505

12/1/2018 P13505

All of the specifications trend in the Results of HOQ The most important Specifications to meet are: Results of vibration analysis (Pass/Fail) Having the machine be easy for someone to learn how to use Output and save the collected data All of the specifications trend in the same direction 12/1/2018 P13505

Concept Development Functional Decomposition Assess Bearing Health Input Bearing Receive Bearing Support Bearing Collect Usable Data Receive Signal Choose Sensors Attach Sensors Accept Signal Post-Process Signal Create Test Conditions Load Bearing Spin Bearing Input Pass/Fail Criteria 12/1/2018 P13505

Concept Development Initial Concepts 12/1/2018 P13505

Concept Development Initial Concepts 12/1/2018 P13505

Concept Development Broad Concept Selection – Pugh Matrix 12/1/2018 P13505

Concept Development Bearing Clamping Methods 12/1/2018 P13505

Concept Development Bearing Clamping Methods - Pugh 12/1/2018 P13505

Concept Development Bearing Alignment Method 12/1/2018 P13505

Bearing Alignment Method 12/1/2018 P13505

Concept Development Vibration Sensor Selection - Pugh (4) (3) (3) 12/1/2018 P13505

Concept Development Accelerometer Sensor Selection (2) (2) 12/1/2018 P13505

Concept Development Coupling Selection Soft vs Rigid Soft coupling could dampen out motor vibrations Minimizing the radial and angle offsets is the number one priority Rigid – Set Screw vs Clamp-On Set screw could damage shaft Clamp-On with tight tolerances will easily meet the requirements without damaging the shaft Top (5), Bottom (6) 12/1/2018 P13505

Current Concept 12/1/2018 P13505

Risk Assessment Add owners 12/1/2018 P13505

Top 5 Risks Data Acquisition Software Fails Noisy Data Sensor Failure Track Misalignment and Misalignment of Bearing Accelerometer Miscalibration

Project Plan 12/1/2018 P13505

Questions? 12/1/2018 P13505

Citations http://www.amazon.com/SKF-Bearing-Clearance-3600lbf-Capacity/dp/B0071ARFWS http://www.exvalos.cz/soubory/File/SKF/SNIMACE_VIBRACI.pdf http://www.provibtech.com/accelerometers-velocity-sensors.htm www.pcb.com http://www.lord.com/Images/North_America/English/Products_and_Solutions/Shear-Type-Couplings.jpg http://cfnewsads.thomasnet.com/images/large/018/18591.jpg Detecting Faulty Roller Element Bearings, Bruel Kjaer Yongyong He, Defect Diagnosis for Roller Element Bearings Using Acoustic Emissions http://www.ge-mcs.com/download/orbit-archives/1991-1995/September%201992/992page22.pdf 12/1/2018 P13505