iGen Fuser Bearing Project P11511

Agenda Meeting Timetable Start Time Review Topic 2:20Introductions 2:25Project Description 2:35Customer Needs 2:40Risk Assessments 2:55Concept Selection 3:10Houses of Quality 3:20Timeline 3:30Discussion 3:45Meeting Adjourned

Project Team, Faculty, and Customer Project Team: – Project Lead: Kevin Argabright (ME) – Team Members: John Fitch Dean (ME) Mike Buonaccorso (ME) Justin Eichenberger (ME) – Project Guide: William Nowak (Xerox Corporation) Faculty: – Consultant Dr. Stephen Boedo Customer: – Xerox Corporation Erwin Ruiz Melissa Monahan

iGen Machine

Running Conditions of Fuser Xroller forces are 184lbs each Reaction force of 360lbs/bearing Fuser rotates at 79.8RPM Outer race of the fuser bearings experience a temperature of 230°F

Customer Needs Develop method to characterize physical properties of bearings over their physical life Collect data on bearing properties Correlate physical property to end of life Incorporate multiple sensors Characterize physical properties over the bearing's physical life Create failure criteria Document the procedure (Testing) Testing bearings is quick and easy to do Document the procedure (Collecting Data)

Weighted Customer Needs Used a pairwise comparison chart Most Important Needs: – Develop method to characterize physical properties of bearings over their physical life – Document the procedure for collecting data

Project Scope Create a measuring tool to aid Xerox Corporation’s engineering team in collecting necessary data for characterizing bearing life in the iGen Fuser Assembly

Engineering Specs

Bearing Life

Risks RiskCauseMitigationSeverityLikelihoodTotal Data does not correlate No relationship exists between physical metric and bearing life Try multiple methods of data collection (acoustic, mag, proximity, etc..)326 Bearing life fixtures breakUse, mechanical wear Ensure proper training and seek rapid repair224 Our testing apparatus breaks Design error, mechanical wear, user error Design robustly and be prepared with replacement parts224 Needed item's lead time goes outside of project time frameManufacturing delays Ask manufactures for an estimate for lead time and stay in contact for updates224 No easy method for bearing testing on manufacturing floor Data collection and analysis take to long to be feasible for the throughput of Xerox Try multiple methods and speak with manufacturing to understand needs224 Time to collect data is too slow Data logging too slow, accelerated wear is insufficient Seek accelerated wear and ensure data loggers are sensitive enough224 Project goes over budget Sensors, raw materials and tooling are more expensive than thought Before purchasing submit a proposed budget to Xerox224 Measurement system fails Xerox standards Not enough collected data or to much inherent noise Speak with Erwin and Melissa to ensure our measurement is up to spec313 Sensors are lost, stolen or damagedTheft, accidents, neglect.Keep equipment secured at Xerox or RIT313 Customer is unhappy with deliverablesPoor Communication Maintain communications with Xerox throughout the project313 Team member is seriously injured or illSickness, death in family, etc.. Be prepared to delegate that person's responsibilities across the team212 Software is lost or corruptedLoss of flash drive or virusKeep multiple, up to date copies212 Team arguments cause delaysPoor Communication Allow for time to discuss ideas and concerns212 Travel to Xerox is prevented Weather, Xerox emergency, RIT emergency. Leave room in project timeline so that project does not hinge on any single day at Xerox111

Concept Generation

Concept Selection

Design chosen – Fixed Outer Race – Camshaft – DC motor – Conduction to outer surface – Belt – Accelerometer – Thermistor – Microcontroller – Labview

House of Quality

System Level Drawing

Timeline

Questions?

P11511 Senior Design Review Thank you for attending!

Loading the Bearing Total load seen by the bearing = 360lbs – Pressure roll force: 600lb – Heat roll force: 184lb/roll – Angle between heat rolls: 60° Using a pneumatic cylinder to apply load – Sized according to force needed (plus weight of object applying load) – Pressure regulator will be used to adjust air pressure applied to cylinder – Maximum pressure available = ~75psi

Sizing the pneumatic cylinder

Parker “Pancake Style” pneumatic cylinder (3.0NLPR9X1.00) – Bore size: 3.00” – Stroke size: 1.00” – Rod thread size: 5/8-18 female – Length: 2.625” – Cost: $ – Source: MSC Direct Pneumatic Cylinder

Pressure Regulator Jupiter Pneumatics Air pressure regulator with pressure gauge ( JP) – Port Size: 1/4” – Maximum PSI: 120psi – Width: 1.97” – Height: 1.97” – Cost: $11.36 – Source: MSC Direct

Pushing Rod 5/8”-18 Threaded Stud (91187A650) – Thread: 5/8”-18 – Material: 18-8 SS – Overall Length: 12” – Cost: $13.33 – Source: McMaster-Carr

Bearing “Pusher” and Sensor Holder Made from (1) 6” x 6” x 1” Aluminum Plate (89155K971) – Material: Aluminum 6061 – Both pieces cut from 1 plate – 1/8” width x 1/16” depth keys on both sides for guide rails – Oversized hole for pushing rod on bottom

Guide Rails Precision shaft with keyhole (7398K22) – Shaft diameter: 1/2” – Material: 304 SS – Overall Length: 12” – 1/8” width x 1/16” depth keyhole – Will need to tap hole into bottom for mounting – Cost: $44.32 ($22.16ea) – Source: McMaster-Carr

Mounting Plate Made from (1) 8” x 8” x 1” Aluminum Plate (9246K61) – Material: Aluminum 6061 – Holes mount guide rails and pneumatic cylinder – Countersunk holes from the bottom allow mounting to another table – Mounting holes spaced at 3” and 6” distances for mounting to table with inch spacing mounting holes – Cost: $47.00 – Source: McMaster-Carr

Loading Bearing BOM

Mica Band Heater Cost=~$200

Thermal Simulation-No Thermal Barrier

Thermal Resistant Coating Swain Tech Coatings Inc. 963 North Road Scottsville, NY Recommends Zirconia Coating Excellent Thermal Insulation Approx. $175 for both parts 2-2 ½ week turn around time

Thermal Simulation-Assuming Perfect Insulation

Attaching heater to Sensor Holder/Pusher JB Weld Resistant up to 500 deg F Bonds to virtually any material including aluminum, steel, and ceramic McMaster-Carr Part #7605A11-$5.91