1. Low Energy Printing Project P09505
Mid-Project Review
Senior Design I
Josh 1
September 22, 2018
Senior Design I – Mid Project Review

2. Senior Design I – Mid Project Review
Agenda
Introduction
Project Background
Customer Requirements
Project Deliverables
Concept Selection
Current Design Concept
Bill of Materials
Feasibility Checklist
Key Risks From Design Reviews
MSD 2 Project Plan
Josh
September 22, 2018
Senior Design I – Mid Project Review 2

3. Project Team, Faculty, & Customer
Project Lead:
Joshua Jones (ME – Year 5)
Team Members:
Whitney Domigan (ME – Year 4)
Jenna Kilroy (ISE - Year 5)
Andrzej Lubaszka (EE – Year 5)
Faculty:
Guide:
Bill Nowak (ME, Xerox Employee)
Consultant:
Marcos Esterman (ISE)
Customer:
Xerox Corp – Marking Elements & Integration Lab
John Knapp
Josh
September 22, 2018
Senior Design I – Mid Project Review 3

4. Senior Design I – Mid Project Review
Project Background
Xerographic digital printers are very energy intensive, specifically the fusing sub-system. This is largely due to the fact that during the fusing process toner is heated to well above its melting point, to enable heat flow, and allow the toner to adhere to the paper.
Senior Design Project as Stated on Edge:
“Re-consider the design of an extremely low power, non-thermal fusing system”
Jenna
September 22, 2018
Senior Design I – Mid Project Review 4

5. Senior Design I – Mid Project Review
Project Scope
The purpose of this project is develop a fusing sub-system that uses pressure instead of thermal energy to fuse toner to paper. The new design should fit into the current Xerox Workcentre 245/55 Pro printer, however if due to design constraints the new design in unable to be fit internally it my be externally attached to the Xerox Workcentre 245/55 Pro printer.
Jenna
September 22, 2018
Senior Design I – Mid Project Review 5

6. How a Fusing Sub-System Works
Traditional Toner Fusion:
Temperature +
Pressure
Heat =
Fused, Adhered Toner
Heat
Discrete, loose toner
Fused, adhered toner
Nip
Andrzej
Pressure
Image by: David Thompson, Xerox Corp.
Information by: David Thompson, Xerox Corp. and Dinesh Tyagi, Eastman Kodak Company
September 22, 2018
Senior Design I – Mid Project Review 6

7. Customer Requirements
Most Important Customer Requirements:
Paper is not damaged
Uniform pressure along nip
Fit into current Xerox Workcentre 245/55 Pro
Use pressure only to fuse toner to paper
Jenna
September 22, 2018
Senior Design I – Mid Project Review 7

8. Senior Design 2 Deliverables
Physical Hardware:
Working cold pressure fusing system
One working prototype with multiple configurations
Parametric Analysis:
Effect of different roller skews on:
Uniformity of pressure across the nip
Damage to paper
Various loads and their effect on:
Analytically test the max load design can handle
Effects of paper thickness
Analytically examine the effects of roller lengths
Verification of theory that additional rollers will generate a more uniform pressure across the nip
September 22, 2018
Senior Design I – Mid Project Review

9. Concept Selection Process
PUGH 3 - Week 6
How to Mechanically
Apply Load
PUGH 1 - Week 3
Preliminary Design
PUGH 2 - Week 4
Loading Styles
Jenna
Concept Selection PUGH 1
Concept Selection PUGH 2
Concept Selection PUGH 3
September 22, 2018
Senior Design I – Mid Project Review 9

10. Current Design Concept
12 inches
Andrzej
September 22, 2018
Senior Design I – Mid Project Review 10

11. Current Design Concept
Josh
Current Fuser System’s Dimensions:
Length: 18.5 inches
Width: 4.5 inches
Height: 6.5 inches
Our Design’s Dimensions:
Length: 13 inches
Width: 3 inches
Height: 4 inches
September 22, 2018
Senior Design I – Mid Project Review

12. Current Design Concept Features
September 22, 2018
Senior Design I – Mid Project Review

13. Senior Design I – Mid Project Review
Budget
Jenna
BOM - Budget
September 22, 2018
Senior Design I – Mid Project Review

14. Key Risks: Identified During Design Reviews
Andrzej
Risk Tracking
September 22, 2018
Senior Design I – Mid Project Review

15. Senior Design I – Mid Project Review
MSD2 Project Plan
September 22, 2018
Senior Design I – Mid Project Review

16. Senior Design I – Mid Project Review
Questions
September 22, 2018
Senior Design I – Mid Project Review