1. P10511: Miniaturization of Xerography
Derek Meinke (ME, PM)
Matthew Liff (ME)
Tony Zhang (EE)
Zaw Htoo (ISE)

2. Project Description
The scope of P10511 is to create a test fixture that will allow the use of various charging devices along with multiple diameters of photoreceptors.
Test affect of charge uniformity with various device configurations and input parameters.
Xerox test fixture is currently limited in versatility.

3. Project Description (cont.)
Reasons for Reducing Drum Diameter
Advances in Charging Technologies
Reducing Wear Rate of Photoreceptor
Higher Rotational Speeds for Higher PPM
Reduced Footprint for Charging Devices
Cost Effective
Increased Reliability

4. System Objectives Different Charger Configurations
BCR versus Scorotron
Photoreceptor Diameter
Variable Drum Speed
Ion Transfer
Charge Measurement (ESV)

5. Roles and Responsibilities
Name
Discipline
Role / Skills
Mike Zona and Bill Nowak
Xerox
Faculty Guide, will work closely with the team on an on-going basis to facilitate success.
Marcos Esterman
Faculty Consultant, will provide discipline technical support on an intermittant basis.
Dale Mashtare
Industrial Consultant
Derek Meinke ME
Project Manager, fixture design, charge device mounting, drum to motor coupling.
Matthew Liff
Fixture design, charge device mounting, drum to motor coupling.
Tony Zhang EE
Electrical integration of high voltage and drive motor to data acquisition.
Zaw Htoo
ISE
Labview coder for user interface and system control/status.

6. Team Values and Norms
Reasonably late to meetings is acceptable but not repeatable. Leave a message for a team member if cannot attend.
At start of meeting, discuss team objectives for 5 to 10 minutes.
CC all group members when ing project information; respond within 24 hours.
An understood consensus must be made for all decision making.
Record meeting minutes.

7. Customer’s House of Quality
Customer Requirements
Customer Weights
Voltage Input (5-8kV)
Surface Speed (≤1m/s)
Drum Size (24-84mm)
Charger Type (BCR or Scorotron)
Charger Gap (1-2mm)
Dielectric Thickness (~25µm)
ESV distance (1-2mm)
Budget ($2k)
Uniform Erase Charge (-100V)
Surface Charge (-300 to -800V)
Allow any charge device config
13% 3 9 1
Easily changeable components
11%
Allow different dielectric thicknesses
Voltage reading across entire drum length 9%
Parallel ESV axis with photoreceptor 8%
Easy to use data acquisition menu
Repeatability
Data for both aluminum substrate and prod. PR
Uniform pre-charge erase 7%
Accurate drum speed control 6%
Proper safety measures 4%
Alignment of charger with photoreceptor
Accept multiple photoreceptor diameters 3%
Below target budget 1%
Generate minimal ozone 0%

8. Customer Needs List Customer Needs Important
Allow any charge device config
13%
Easily changeable components
11%
Allow different dielectric thicknesses
Voltage reading across entire drum length 9%
Parallel ESV axis with photoreceptor 8%
Easy to use data acquisition menu
Repeatability
Data for both aluminum substrate and prod. PR
Uniform pre-charge erase 7%
Accurate drum speed control 6%
Proper safety measures 4%
Alignment of charger with photoreceptor
Accept multiple photoreceptor diameters 3%
Below target budget 1%
Generate minimal ozone 0%

9. Engineering Specification
Specifications List
Engineering Specification
Importance
Voltage Input (5-8kV) 5%
Surface Speed (≤1m/s)
13%
Drum Size (24-84mm) 9%
Charger Type (BCR or Scorotron) 8%
Charger Gap (1-2mm)
15%
Dielectric Thickness (~25µm)
ESV distance (1-2mm)
10%
Budget ($2k)
11%
Uniform Erase Charge (-100V)
Surface Charge (-300 to -800V)

10. Risk Assessment *19 total risks so far
Risk Management Table - Revision /17/2009 ID
Risk Item
Likelyhood
Severity
Importance
Action to Minimize Risk
Owner 6
Faulty equipment 2 4
Obtain quality equipment, look into obtaining MSD locker
All members 7
ESV/Erase Lamp/Charger gap problems
Run multiple tests to determine best location, have faculty guide review fixture, make it variable
Mechanical Engineer 8
Weather affecting travel 1
Have good communication, use Tortoise SVN and EDGE, online chat discussions available 9
Customer priority changes
Constant communication with customer 14
Hard to change components 3
Create a manual, use more clips than screws
Mechnaical Engineer 15
Aluminum substrate is in contact with motor ground
Include a switch, use insulating material at contact, generate many concepts
Mechanical / Electrical Engineer 18
Lack of Labview skillset
Additional research time, utilize faculty expertise
Industrial Systems Engineer
*19 total risks so far

11. Project Plan

12. Concept Generation (ME)

13. Concept Generation (ME)

14. Concept Generation (ME)

16. Concept Generation (EE)
Power supplies will be provided to us from our customer, Xerox.
Trek Cor-a-trol Model 610C High Voltage Supply
High Voltage Supply (0 to ±10kV)
Current Supply (0 to 2mA rms)

17. Concept Generation (EE)
Recommended motors and specs have also been provided.
For Photoreceptor Drive (S83-93)
For ESV slide (S57-51)

18. Closer Look at the Motors
Photoreceptor Drive: S83-93
Minimal Required Torque
9 Pin Connector to Voltage Supply
Requires isolating motor ground from power supply.

19. Motors (cont.) ESV Drive: S57-51
Delivers required torque for rotating threaded shaft
See next slide for the workings of the ESV unit

20. Selecting a DAQ Device
Data Acquisition & Analysis requires a few steps: Factors for Consideration

21. Bill of Materials (EE & ISE)
FOR THE MOTORS
Motor Controller (NI PCI-7332)
$899.00
Description: PCI / 2-Axis
Stepper Motor Drive (NI P70530)
$ (x2) = $698.00
Description: 1-Axis / 300 Watts
Total = $

22. Bill of Materials (cont.)
FOR THE DAQ
Multifunction Data Acquisition Device (NI USB-6009)
$279.00
Inputs: 8 Analog / 12 Digital
Outputs: 2 Analog / 12 Digital
USB Connection
Total = $ $ = $

23. Input and Output (ISE & EE)
Input Data
Output (Uniformity)
Output (I-V Slope)
Start / Stop
Voltage
Current
Type of Test ( Uniformity / I-V Slope)
Range of Uniformity
Slope of Current Vs Voltage
Length of Device
Slope of Voltage Across P/R
Voltage Intercept
Diameter of Device (mm)
Graph (Voltage Vs length of P/R)
Graph (Current Vs Voltage)
Speed of P/R (m/s)
V-Plate Voltage (KV)
Report

24. LabView User Interface

25. System Flow (EE & ISE)

26. Unknowns and Open Issues

27. Action Items

28. Questions?