1. Test Rig Development Group
Voice of the Engineer
Project: R13301
Rochester Institute of Technology
Design Project Management ( & )

2. R13301 Teams & Members EP Printing Team Garlock Team
Jonathan Erbelding & Sakif Noor
Garlock Team
Usman Asad & Jessica Fuss
Polymer Membrane Team
Steven Lucchesi & Seaver Wrisley

3. Jonathan Erbelding Sakif Noor
EP Printing
Jonathan Erbelding
Sakif Noor

4. Functional Decomposition (scanline)
Expose Photoconductor According to Desired Pattern
Expose Entire Photoconductor
Move Photoconductor Carriage
Control Stepper Motor
Read Encoder
Order Stepper to Move
Synchronize Motion to Exposure
Order Stepper to Stop
Expose Scanline
Activate Light Source
Time Light Source
Deactivate Light Source
Generate File(s) of Desired Pattern
Convert File to Exposure Signal

5. Functional Decomposition (dot)
Expose Photoconductor According to Desired Pattern
Expose Entire Photoconductor
Move Photoconductor Carriage
Control Stepper Motor
Read Encoder
Order Stepper to Move
Synchronize Motion to Exposure
Order Stepper to Stop
Expose Scanline
Move Light Source with Other Motor
Control Motor
Expose Dot
Activate Light Source
Time Light Source
Deactivate Light Source
Generate File(s) of Desired Pattern
Convert File to Exposure Signal

6. Concepts - Using a Second Motor
Pros
Can choose any motor, even one that is known to work with the hardware, potentially making it easier to synchronize timings
Cons
Additional hardware to control/power
Limit to print area imposed by relying on moving the light source rather than the photoconductor

7. Concepts - Buying an entire printer
Pros
A set of components that work together
Known overall specs
Some hardware cannot be obtained separately
Cons
Don’t really know what’s inside in most cases.

8. Concepts - LED printer Pros
Potential to control by writing to underlying memory
Cheap (~$300)3
Cons
Need to buy an entire printer to obtain a print head.
Need to worry about synchronizing 1 dimension (Scanline)
Image from Reference 2

9. Concepts - LASER printer
Pros
Readily available hardware
Cheap (<$200) 3
Higher DPI available for a price
Cons
Additional moving parts
Complicated optics
Need to worry about synchronizing 2 dimensions (Dot)
Image from Reference 4

10. Concepts - Digital Micromirrors
Pros
Readily available hardware
Can potentially flash the entire photoreceptor at once (Flash)
Cons
Would have to make custom print head
Available only in very small arrays-harder to meet print area
Not a significant difference in DPI- “16 micrometres across”1 (<1600 mirrors/inch)
Image from Reference 5

11. Concept Selection - Pugh Analysis
EP Printing Pugh Diagram
Selection Criteria
Datum (Existing Rig)
LED (1D Bar) (Photoconductor moves via existing stepper motor)
LED (1D Bar)
(LED bar moves via additional motor)
Laser (0D Dot) (Photoconductor moves via existing stepper motor)
Micromirror (2D array treated as 0D and moved)
Micromirror (Without any movement)
Computer File Formats Supported D +
Meets Target Resolution (1200 dpi) -
Meets Ideal Resolution (2400 dpi) A
Integration to existing hardware
Integration to existing software T
Amount of Custom Parts
Print area U
Safe
Component Availability M
Driver Support
Sum +'s
---- 6 5
Sum 0's 1
Sum -'s 3 4

12. Potential Steps to assist in decisions for Senior Design
Control and characterize current rig’s motor/carriage system
Simplifies design if a second motor is not required
Can be done without purchasing anything
Acquire an entire printer early
Hard to get interface specs, geometry, etc of components can be worked without, experimentally.
Locks ~10% of the budget into a light source decision

13. References
1. "Digital micromirror device" Wikipedia.com. 12 Mar Apr 2013 < 2. Nuuja, Robert E., and Suma Potini. "The reinvention of LED printing: New Xerox HiQ LED delivers colourful, high-resolution output" Apr Xerox Corporation. 15 Mar 2013 < 3. "Laser Printers, Monochrome" Newegg.com. Newegg Inc.. 18 Apr 2013 < bop=And&Pagesize=100>. 4. Harris, Tom. "How Laser Printers Work" 14 March HowStuffWorks.com. < 15 March Lamb, Robert. "How LCD Projectors Work" 22 May HowStuffWorks.com. < 28 April 2013.

14. Usman Asad Jessica Fuss
Garlock Test Rig
Usman Asad
Jessica Fuss

15. “More specialized needs for research, more on that later”

16. Polymer Membrane Test Rig (PMTR)
Steven Lucchesi
Seaver Wrisley

17. Overview of VOC
Varying specification requirements of the individual customers led to the need for multiple test rigs.
Proposed test machines:
Biomaterials student test machine
Single-axis loading
Analog display
Lower accuracy
Manual control
Research quality test machine, incorporating ASSET concepts
Multi-axis loading
Fully automated interface (Matlab or LabView)
Closed loop control of loading
Higher accuracy
Environmental control capabilities
Aqueous environment capabilities
“More specialized needs for research, more on that later”

18. Functional Decomposition

19. Functional Decomposition

20. Metrics & Specifications
Functions highlighted in orange are those which are completely unrestrained and brainstorming was performed on.
1 = completely constrained
2 = limited set of options
3 = completely unrestrained
0 = N/A

21. House of Quality (Instructional)

22. House of Quality (ASSET)

23. Potential Concepts & Pugh Analysis (Instructional)
*See handout for concept descriptions

24. Potential Concepts & Pugh Analysis (ASSET)
*See handout for concept descriptions

25. Component Options

26. Areas of Uncertainty Road-mapping for ASSET:
We are considering dividing the researched based test rig into 3 distinct MSD projects:
Biaxial Tension Tester Redesign & Build
Indentation Tester Design & Build
Environmental Chamber Design & Build
Uncertain which of these projects can be run in parallel
Uncertain about resources
Hydraulic vs. Electromechanical Actuation:
Neither of us have experience with high frequency, low displacement actuation.

27. Questions? What questions do you still have?
Are we lacking any important information?
Do you see any potential problems with our proposed solutions, or any other solutions?
Who has experience with high frequency, low displacement hydraulic actuation?
Would you be interested in pursuing these projects in MSD I or MSD II?

28. TEST RIGS PRESENTATION 1(VOC) REFERENCE SLIDES
“More specialized needs for research, more on that later”

29. Jonathan Erbelding Sakif Noor
EP Printing
Jonathan Erbelding
Sakif Noor

30. Background
Electrophotographic Printing (EP) test rig originally from Kodak
P09503 modified for improved usability and automation
LabView controls implemented for automation
Has station for major steps: Charging, Exposure, Toner, Transfer Fusing occurs on a different rig
Exposure step is performed with a negative. Cannot print file from computer.
Our Problem: Test pattern cannot be specified from computer

31. EP Process (Part 1 of 2) Stepper motor to turn screw to move carriage
Photoconductor carriage
Screw to move carriage
Negative
Stepper controlled carriage: moves photoconductor from station to station as well as within each station where required. Photoconductor: Insulator unless exposed to light. Charging: High voltage applied to photoconductor to charge it. Insulating properties allow it to hold charge like a capacitor. Exposure: Light applied through negative, discharging photoconductor where light hits.
Charging Station
Exposure Station

32. EP Process (Part 2 of 2) Transfer drum Tray for paper Transfer Station
Toner Station: Very fine powdery toner attaches itself to charged parts of photoconductor due to static electricity Transfer Station: Toner is transferred to the paper. Photoconductor rolls against transfer drum, depositing its toner. Transfer drum rolls against paper depositing the toner there.
Transfer Station
Toner Station
Fusing: On one of several other rigs, heat and pressure are applied to fuse toner to paper.

33. Stakeholder Interviews
First Interview (Dr. Esterman & Alvaro)
Second Interview (Alvaro)
Prelim Specs
Convert computer file into light output
Accepts computer input to specify test pattern
Integrates into current rig (software:LabView and hardware)
Current exposure station has a space of 12" height, 10" along direction of carriage motion, and 15" width
Integrates into LabView software
Fits into 10"x15"x12" available space of current exposure system
Current Stepper motor should be sufficient if moving during exposure is required
Uses current stepper motor if motion is required
High resolution preferred
1200 DPI target; 600 DPI min. Higher is better.
1200*20±1 DPI Resolution
Controls exposure time OR intensity
Current exposure step takes a sec or two.
Controls exposure time or intensity
Current PC is 5" wide x 9" long
Capable of exposing entire PC
Exposes a min area of the 5"x9" photoconductor
$2-3k available to accomplish goal, but can potentially get more if required
Built within budget ($2-3K)
Powered from wall outlet, or off current 24V supply that powers exposure station and stepper controller
Powered by available sources (wall outlet, current power supply)

34. Voice of Customer - Needs
Accepts computer input to specify test pattern
Integrates into LabView software
Fits into 10"x15"x12" available space of current exposure system
Uses current stepper motor if motion is required
1200*20±1 DPI Resolution (1200 DPI target, 600 DPI min)
Controls exposure time or intensity
Exposes a min area of the 5"x9" photoconductor
Built within budget ($2-3K)
Powered by available sources (wall outlet, current power supply)

35. Moving Forward - Possible Solutions
Xerox HiQ LED Print Head
Can achieve resolutions of x 2400 dpi
The LEDS selectively flash to create a pattern of dots on the photo receptor drum
Laser Printing assembly
Common laser printers achieve 1200 dpi
Laser scans photo receptor drum as it rotates, creating the latent image

36. Usman Asad Jessica Fuss
Garlock Test Rig
Usman Asad
Jessica Fuss

37. Initial Problem Statement
“Garlock Sealing Technologies is a global leader in fluid sealing technologies, located in Palmyra, NY. As part of their product qualification process, they perform a gasket test according to ASTM F-37, which requires testing a specific type of gasket under a specific set of conditions, in order to measure permeation and leak rate. This is a manual process, with each test taking 20 minutes, and it is done one gasket at a time. Garlock engineers are in need of an automated test rig that will allow simultaneous testing of multiple gaskets. This test rig must follow an industry standard test procedure. While Garlock currently uses ASTM F-37, they are open to other options if they would facilitation automation of the process.”

38. Background and Motivation
What are gaskets?
What are gasket tests?
Sealability: ASTM F37 (A and B)
Gas Permeability: DIN 3535
Creep Relaxation: ASTM F38
Compressibility Range: ASTM F36
Tensile Strength: ASTM D1708
Market position: No. 1 manufacturer of industrial gaskets in the United States”

39. Stakeholders Garlock Sealing Technologies Wayne Evans Randel Hill
Product Engineer
Randel Hill
Test rig operator
Part of the EnPro Industries family of Companies. Located in Palmyra, NY
“The Garlock family of companies provides solutions that seal the most demanding fluid-handling equipment and processes, with more than 100,000 sealing solutions for a diverse range of industries such as hydrocarbon production, processing and refining, power generation, pulp and paper, metals and mining, and water and waste water.

40. Existing Test Setup

41. Customer Needs Save the operator time
Increase accuracy and repeatability of tests
Test results should be comparable to industrial standards
Record and store data
Test large volume of gaskets for R&D purposes

42. Refined Problem Statement
“To develop an automated test rig that saves the operator time and measures gasket leak rate with high quality, precision and accuracy.”

43. Objective tree

44. Functional Decomposition Tree

45. Functional decomposition Input / Output

46. Existing Technologies
Cixi CAZ Group Corporation
Cost: 6800 USD

47. Automation of Test-Rig
Load application (up to 3000 psig)
Load / strain measurement
Flow measurement (0-1 ml/hr, at 0-30psig)
Pressure sensor
Control Valves
Level measurement
Data Acquisition
Control System

48. Questions Any questions about existing setup?
Any suggestions about our approach to the problem?
Any suggestions about instrumentation needs for this project?

49. Polymer Membrane Test Rig (PMTR)
Steven Lucchesi
Seaver Wrisley

50. PMTR Motivation & Background
Mission Statement:
The Mechanical and Biomedical Engineering Departments at the Rochester Institute of Technology (RIT) have developed a need for a test device capable of measuring the mechanical properties of biologically relevant materials.
Principle Needs:
Ability to run simple experiments, demonstrating non-linear stress-strain responses, creep, and stress relaxation.
More specialized needs for research.
“More specialized needs for research, more on that later”

51. PMTR Stakeholders & Needs
During the process of defining our customer needs we interviewed the people listed in this slide.
The stakeholder needs tend to fall into one of two categories: Instructional, and Research.

52. PMTR Goals & VOC
We have split the goals of this project into several categories:
Measured Properties
Controlled Properties
Specimen Accommodation
Interface
Ease of Use
Portability
Cost
Environmental Health & Safety
All customers have expressed similar needs with varying levels of specification.
Have handout of the Customer Needs breakdown Excel sheet.
In class we’ve discussed ranking needs, and that some needs are absolutely necessary in order for the project to be successful.
Each customer has the same overall goals with different specifications.

53. PMTR Current Technology
Currently, there is no lab equipment available for educational use in the two Biomaterials courses.
Typical tensile testers damage biomaterials at the clamping points, rendering the test invalid
Previous/Current RIT Projects:
Lowell Smoger’s Biaxial Test Rig
P06218 Bausch & Lomb Eye Membrane Indenter
Bill Spath’s ASSET machine for EAP (Electroactive Polymer) Research

54. PMTR Current Technology: ASSET (Automated Smart Sensing EAP Tank )
Preliminary design by Bill Spath
Acts like typical tensile tester in horizontal direction for in-plane loading
Indenter for out-of-plane loading
Capable of being completely filled with solution
Interior would be made of biologically inert materials
Transverse Plunger
Axial Servo Driver
Environmental Tank
Figure 1: Automated Smart Sensing EAP Tank
Transverse Plunger Linkage Box
EAP
Tensile tester stretches the specimen in the horizontal direction, and then the indenter comes down and can deflect it in the transverse direction. Could theoretically replace the lower uni-axial tensile tester stage with a biaxial similar to Lowell’s rig, and then you could test using either loading method, and uni-axial testing could still be done by simply not using the 2nd set of grips.

55. PMTR Proposed Solutions
Varying specification requirements of the individual customers led to the need for multiple test rigs.
Proposed test machines:
Biomaterials student test machine
Single-axis loading
Analog display
Lower accuracy
Control
Research quality test machine, incorporating ASSET concepts
Multi-axis loading
Fully automated interface (Matlab or LabView)
Closed loop control of loading
Higher accuracy
Environmental control capabilities
Aqueous environment capabilities

56. Questions? What questions do you still have?
Are we lacking any important information?
Proposed solutions?