1. P10505 – Cold Pressure Fusing II System Design Review Team Fusion 1/15/2010

2. Agenda Introduce Team [1 minute] Project Description [3-4 minutes] Project Flowchart [3-4 minutes] Customer Needs [5 minutes] Engineering Specifications [10 minutes] House of Quality [5 minutes] Functional Decomposition [10 minutes] System Architecture [5 minutes] Concept Selection Flowchart [2-3 minutes] Concept Selection [20 minutes] o Skew [10 minutes] o Skew Support [5 minutes] o Paper Weight Adjustability [1-2 minutes] o Compliance [1-2 minutes] Final Design [5 minutes] Risk Assessment [5 minutes] Design Risks [5 minutes] Action Items [1-2 minutes] Next Steps [1-2 minutes] Questions [5 minutes] Questions and comments are encouraged throughout the presentation

3. Project Team, Faculty, & Customer Project Members o Aniket Arora – Project Manager – ISE o David Hatch – Lead Engineer – ME o Jon Burville – ME o Eric Wilcox – ME o Tom Stojanov – EE Customer o Mr. John Knapp - Xerox o Mr. Tony Condello - Xerox Faculty Guide o Mr. Bill Nowak - Xerox

4. Project Background/Description Changing customer expectations from printers. Focus on sustainability (low energy consumption). Energy Star Heat fusing consumes a considerable portion of energy. Hence, Cold Pressure Fusing. P09505 developed an initial prototype. Issues with pressure uniformity

5. MSD 1 Research Past work Patent Research Past work from P09505 Establishing Customer Needs Concept Selection Generation Pugh Concept Selection Concept Improvement Modeling Calculate Nip Pressure Analyze Roller Deflection Torsion Analysis Create CAD Model DAQ System Create Real- time DAQ System Interface DAQ with hardware Present Design Project Planning Project Schedule WBS Project Flowchart MSD 1

6. Customer Needs

8. Engineering Specifications Engr. Spec. #ImportanceSource Specification (description)Unit of MeasureMarginal ValueIdeal Value ES11Customer NeedPrototype will fuse print across 100% of the page Percentage fused, Width of unfused,N/A100% fusing ES21Customer NeedPrototype will vary in nip pressure less than 10% Width of Pressure Indication, Xerox Metric10% variation5% variation ES31Customer Need Prototype must be capable of adjusting to three skew anglesNumber of Settings2 anglesAnalog ES41Customer Need Prototype must adhere to Abaqus model created by XeroxYes/NoN/AYes ES51Customer NeedPrototype must be able to reach a 1.9° skew angleDegrees1.8°-2.0°1.9° ES61Customer Need Prototype must be adjustable to the same skew angle to a 1/10th degree for ~25 runsStandard Deviation1/5th degree variation 1/10th degree variation ES71Customer Need Prototype must accommodate 120gsm (80# text) Digital Color Elite Gloss coated media while meeting all other specificationsYes/NoN/A Accomodates all paper weights ES82Customer NeedPrototype will minimally calendar printQualitativeModerateNone ES92Customer Need Prototype will produce trailing edge wrinkles less than once every twenty printsNumber 1 wrinkle every 10 printsNo wrinkles ever ES113ImpliedPrototype must be stable for a load of 4000 psiForceVibrationStationary ES103Customer NeedFeed rate must not decrease by more than 5%Torque 10% reduction of speed 5% reduction of speed ES123ImpliedPrototype must be manufacturable within ~2 weekTime Required, Y/N4 weeks2 week ES133Implied Prototype will take less than 60 secs of user time to set up printTime Required120 sec0 secs ES143Implied Prototype must be able to print >1000 copies without failure Life Cycle (Number of Prints) 500 copies1000 ES154Customer NeedPrototype must cost less than $3000Dollars$3,000$1,500

14. System Architecture

15. Assessing Customer Needs Brainstorming ideas to meet needs First Concept selection Skew Adjustment Mechanism of Adjustment Support of Adjustment Paperweight adjustment Compliance Concept Selection Flowchart Swapping Pillow Blocks Saw Tooth Crank Adjustment Sliding Channel Frictional Coating Hook and Pinion Bolts Bolts and Ridged Channel Swapping End Blocks Adjustable End Blocks End Blocks with Multiple holes Push BoltPull Bolt in channel Pull Shelf with Bolt

16. Concept Selection – Preliminary Skew Mechanism

17. Concept Selection – Secondary Skew Mechanism Skew Adjustment Concepts Swappable End BlocksAdjustable End BlocksEnd Blocks with Multiple Holes Metrics Cost0+0 Fixability00- Manufacturability0+0 Durability0-- Skew Alignment0++0 Complexity0-0 Ease of Assembly0-0 Score:01-2

18. Preliminary Concept CAD Models Figure 1. Side view of End Block

19. Preliminary Concept CAD Assembly Figure 2. Assembly Model

20. Concept Selection – Skew Support

21. Adjusting for Paper Weights Metrics Current Prototype ComplianceSpeed Optimize Gap Dimension Manually Optimize roller diameter Paper Filler Calendaring0+0+0+ Print Fusing0-0++0 Visual Defects000++0 Uniform Nip Pressure0000+0 Paper Weight Accommodation0+0+-+ User Friendly0+0-0- Abaqus Model0+0--+ Paper Stubbing0+0+0- Score040314 Concept Selection – Paper Weight Adjustability

22. Concept Selection - Compliance

23. Final Design

24. Risk Assessment

26. Design Risk Assessment

27. Action Items Action Items: o Eric: Model Detailed CAD Models o David: ANSYS o Aniket: DOE Planning o Tom: DAQ System o Jon: Calculate Nip Pressure and Deflection

28. Next Steps Week 5 (1/11-1/17) Week 6 (1/18-1/24) Week 7 (1/25-1/31) Midweek Friday Midweek Friday Midweek Friday Midterm Design Review Purchase Components as Confirmed Calculate Nip pressure Analyze Roller Deflection Torsion Analysis Create CAD Model Create Real-time Data Acquisition system Interface DAQ with Hardware Create Test Plan Review and Improve on System Design