1. Xerox Bearing Tester Systems Level Design Review
(1)
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2. 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
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3. 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 :15-11:30
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4. 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.
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5. 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
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6. Project Background
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7. 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
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8. Xerox Acoustic Tester
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9. Initial Customer Needs
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10. 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
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11. Pairwise Comparison
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12. 12/1/2018
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13. 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
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14. Research
(7)
(7)
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15. 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

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

17. 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)

18. Specifications
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19. House of Quality
Potentially added a column to specs talking about pass or failing a bearing
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20. House of Quality
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22. 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
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23. 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
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24. Concept Development Initial Concepts
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25. Concept Development Initial Concepts
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26. Concept Development Broad Concept Selection – Pugh Matrix
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27. Concept Development Bearing Clamping Methods
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28. Concept Development Bearing Clamping Methods - Pugh
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29. Concept Development Bearing Alignment Method
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30. Bearing Alignment Method
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31. Concept Development Vibration Sensor Selection - Pugh
(4)
(3)
(3)
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32. Concept Development Accelerometer Sensor Selection
(2)
(2)
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33. 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)
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34. Current Concept
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35. Risk Assessment
Add owners
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36. Top 5 Risks Data Acquisition Software Fails Noisy Data Sensor Failure
Track Misalignment and Misalignment of Bearing
Accelerometer Miscalibration

37. Project Plan
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38. Questions?
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39. Citations
Detecting Faulty Roller Element Bearings, Bruel Kjaer
Yongyong He, Defect Diagnosis for Roller Element Bearings Using Acoustic Emissions
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