P09503 Electrophotographic Development and Transfer Station

Team Members NameDiscipline David SchwartzISE Ruth GayME Phillip LopezME Dan SummersME Rachel ChrashEE Min-Shi HsiaoEE Andrew KearnsEE Sasha OliverCE

Project Description The purpose of this project is to make an existing electrophotographic development and transfer station functional and to improve the usability, safety and sensing abilities. EDTS End Users  PRISM Lab ▫ Layered Manufacturing  Center for Imaging Science Deliverables 1.An inventory and status of current sub-systems, including needed support systems. 2.A working Electrophotographic Station. 3.Demonstrably improved device safety. 4.An improved user interface (includes control and display functions) 5.Device documented for use, maintenance and upgrade of the device (User & Lab Technician Manual) 6.Demonstrably Improved Sensing and Control Subsystem

Project Background Project Family ▫ Printing and Imaging Systems Technologies Track Customer ▫ Print Research and Imaging Science Modeling Laboratory (PRISM)  The Print Research and Imaging Systems Modeling lab will serve as a conduit between industry and academia, working to evaluate and anticipate the print systems research needs of printer and printing product companies, and directing relevant projects to researchers and students in the areas of Printers & Displays, Color Science, Vision Science, Systems Engineering, and Printing.  Contact: Dr. Marcos Esterman – Associate Professor, Industrial and Systems Engineering

What is Electrophotography? Electrophotography is base technology that is used in many modern day copiers and printers Six Step Process to transfer an electrostatic image to a final printed page ▫ Charging ▫ Exposure ▫ Development ▫ Transfer ▫ Fusing ▫ Cleaning P09503 only includes the first four

Electrophotographic and Development Station ChargingExposure Development Transfer Photoconductor

System Architecture

Critical Customer Needs 1. Is Operational 2. Is Safe 3. Minimize user Intervention 4. Can Monitor Key Process Parameters 5. Can operate and monitor machine from one interface 6. Easy to learn to use

Concept Summary Modifications and Improvements to EDTS Include ▫ Ozone Fan/ Filter Assembly Analysis ▫ Electrostatic Voltage Measurement Implementation ▫ LED Exposure System Implementation ▫ Paper Delivery System ▫ Photoconductor Imaging System Mount ▫ Electrophotographic Process Control and Automation  Control and Automation Hardware

Ozone Fan/ Filter Assembly Analysis Corona and Grid produce O 3 during operation Maximum allowed concentration indoors is ppm Methodology ▫ Verify system produces levels that are safe ▫ Device is verified if levels test below >0.2ppm ▫ Construct new mount and assembly for ozone fan if device produces ozone above >0.2ppm Test Results ▫ The device used was an ozone detector that can accurately detect once it reaches amounts of 0.5ppm. ▫ There were no detectable ozone amounts for both tests ran. ▫ It is noted that around 0.2ppm is when throat and nasal irritation may occur. (This was not experienced)

Electrostatic Voltage Measurement Implementation Monitoring the potential on the Photosensitive material increases the sensing abilities of the system Monitor process real time Photosensitive Dark Decay Research Implementation and Measurements ▫ 1 st measurement after charging ▫ 2 nd measurement after exposure Measurement limited to one dimension ▫ Process created for two dimensional measurement

ESVM Implementation

LED Exposure System LED Exposure system replaces current incandescent system Mounted directly under exposure lift Advantages ▫ More versatile and reliable light source ▫ Low Power Consumption ▫ Longer Bulb Life ▫ No potential for overheat ▫ Inexpensive to replace

Paper Delivery System Existing roller system required manually catching paper after application of toner from roller Risks of manual handling ▫ Human Shock/Short from High Voltage Roller ▫ Pinch Point of Rollers and Pneumatics ▫ Marred Image Quality from Handling Machined Paper Delivery System ▫ Clear tray to allow for Photoconductor Imaging

High Visibility Warning Signs Purpose of warning signs ▫ Alert user to specific hazard ▫ Identify how hazard can be avoided Previous signs did not accomplish this or were not present FMEA Analysis dictated locations ISO 3864 Formula dictated proper size and images Methodology ▫ Remove current warning signs ▫ Replace with ISO designed signs ▫ Add new ISO signs where needed Final FMEA Analysis verified all sign placments

Photoconductor Imaging System Mount Imaging of the Photoconductor System helps to gain understanding of how image is developed onto photoreceptive material Photoreceptive material imaged after development and before transfer Mount machined for camera to rest under Paper Delivery System

Electrophotographic Process Control and Automation Most critical part of the entire project LabView virtual instruments is used to control all devices All components connected ▫ High Voltage and Camera are on a separate system Two Modes of Operation Automatic ▫ Parameters are preset ▫ User only needs to press start to begin and stop to end Manual ▫ User can control any part of the system

Budget Project Budget: $1500 Budget Utilized ~$1480 (98%) Major Purchases ▫ National Instruments Data Acquisition Device  PCI-6515 – 64 Channel Digital I/O PCI Card, Cable and Terminal Block ▫ Sick|Stegman Encoders  2 X HD20  1024 Pulses/Rev ▫ Luxeon Star/O LED  Royal Blue Batwing, mA

Final Results All six deliverables were presented to the customer Total Design Specifications: 46 Specifications Met: 40 or 87% Specifications not Met: 4 or 9% Special Circumstances: 2 or 4% Electrophotographic Station has the ability to charge a Photoconductor, Expose the Photoconductor, Attract Toner, Deposit Toner onto a Transfer Drum and Transfer Toner to a Substrate

Electrophotographic and Development Station Before After

Future Improvements Transfer Drum Clutch Motor Speed Control Component Labeling X-Y PC Measurement Multiple Development Systems Camera Automation Light Curtain

Special Thanks RIT FacultyProfessional Jonathon Arney, Ph.D ▫ Center for Imaging Science  Physical & Optical Measurements Susan Farnand, Ph.D ▫ Center for Imaging Science  Color and Vision Science John D. Wellin ▫ Mechanical Engineering  Control Systems Marcos Esterman, Ph.D ▫ Industrial and Systems Engineering  Product & Process Development Bill Nowak – Xerox ▫ Principle Engineer  Motion and Quality Systems Gregory Miller – Kodak ▫ Software Engineer

Questions