1. P10505 – Cold Pressure Fusing II Final Design Review Team Fusion 2/22/2010

2. 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 Thomas Stojanov – EE Customer o Mr. John Knapp - Xerox o Mr. Tony Condello - Xerox Faculty Guide o Mr. Bill Nowak - Xerox

3. Customer Needs

5. Engineering Specifications

6. Updated DAQ and Electrical Schematics

10. Compliance DOE calls for two levels of compliance to test effect on fusing Springs must be capable of transmitting 150 lbs of force with additional FOS SupplierPart Number Maximum Load (lbs) Deflection at Maximum Load (in) Spring Constant (lb/in) Cost per Unit Lee SpringLHL 1000B 022590.47560$4.54 Lee SpringLHL 1250A 01202.50.75270$5.37 Total$39.64

11. Final Design

12. End Block Redesign

13. End Plate Section View

14. Methods of Measuring Skew ME machine shop can measure skew easily using a dial indicator CMM is available as well Low tech option of a large caliper for quick measurement

15. Update on Deformation Main Roller Deflection 0°0° 90 ° 180 ° 270 ° < 0.5 thou Runout 5/8”4 1/8”8 1/8”11 3/8” < 0.5 thou < 0.25 thou0.5 thou Fusing Roller – 0.5 ° Skew Deflection 0°0° 90 ° 180 ° 270 ° < 0.5 thou < 2 thou< 1 thou Runout 3/8”3 3/4 ”8”11 1/2” 2 thou1.5 thou 3 thou Fusing Roller – 0 ° Skew Deflection 0°0° 90 ° 180 ° 270 ° < 0.5 thou< 0.25 thou1 thou< 1 thou Runout 5/8”4 1/8”8 1/8”11 3/8” < 2.5 thou1.5 thou< 1.5 thou< 1 thou ME machine shop can grind and polish rollers to tolerance. The diameter of the roller would be altered. The other option would be to remanufacture the fusing rollers.

16. Update Risk Assessment?

17. Mechanical BOM Forms to purchase mechanical parts will be submitted today Bill of Materials PartPart NumberSupplierQty.Base PriceTotal PriceLead Time Self-Alignment Bearings129TN9 BDI USA, Simplybearings.co.uk6 $25.55 $153.303-5 Days? Metal Stock (Rollers)6628K461McMaster-Carr1 $47.59 1-2 Days Metal Stock (Skew Rollers)6628K383McMaster-Carr2 $25.79 $51.581-2 Days Metal Stock (Endplates)8910K704McMaster-Carr1 $39.52 1-2 Days Compression Springs9657K14McMaster-Carr4 $12.93 1-2 Days Shell Cup Needle BearingsBA-88ZBearings Direct6 $4.98 $29.881-3 Days Pan Head Screws91772A190McMaster-Carr16 $5.61 1-2 Days Retaining Rings98408A138McMaster-Carr4 $6.12 1-2 Days Retaining Rings98543A115McMaster-Carr4 $6.95 1-2 Days Dowel Pins98381A546McMaster-Carr4 $10.71 1-2 Days Hex Head Cap Screws 91257A555McMaster-Carr4 $9.96 1-2 Days SpringsLHL 1250A 01Lee Spring4 $5.37 $21.48* SpringsLHL 1000B 02Lee Spring4 $4.54 $18.16* 1 1/4" OD x 1/4" ID washers91090A109McMaster-Carr100 $5.52 1-2 Days Mechanical Total: $ 413.79

18. Electrical BOM Bill of Materials PartPart NumberSupplierQty.Base PriceTotal PriceLead Time Load Cell AmplifiersDPM- 3*Provided By Xerox5 $ 395.00 $ 1,975.00NA Multifunction DAQPCI 6014*Provided By Xerox1 $ 699.00 NA DAQ I/O BlockSCB-68*Provided By Xerox1 $ 299.00 NA PCI Interface Cable-*Provided By Xerox1 $ 119.00 NA WireNA*Provided By Student1 $ - NA WireNA*Provided By Student1 $ - NA Plastic Enclosure613593TheGreatHardwareStore.com2 $ 16.78 $ 33.565-7 Days Solid State Relay6C900W.W. Grainger1 $ 20.60 1-2 Days Transformer6WU91W.W. Grainger1 $ 16.73 1-2 Days Crimp Connector Assortment 4FRE3W.W. Grainger1 $ 14.69 1-2 Days C14 Power Extension CordB0017UB5UGAmazon.com2 $ 2.50 $ 5.005-7 Days Mechanical Relay2UTT6W.W. Grainger1 $ 11.58 1-2 Days Misc. HardwareNALocal Hardware1 $ 10.00 NA C13 Panel Mount AdaptorCCM1404-NDDigi-Key2 $ 2.52 $ 5.045-7 Days Double- Sided Tape1F239W.W. Grainger1 $ 8.53 1-2 Days C14 Panel Mount Plug Adaptor 3792CCM1401- ND Digi-Key2 $ 2.06 $ 4.125-7 Days Cable Connector3LK50W.W. Grainger2 $ 2.13 $ 4.261-2 Days Wire Nuts6LU36W.W. Grainger1 $ 2.70 1-2 Days Cable Ties6JU12W.W. Grainger1 $ 2.13 1-2 Days DAQ Total: $ 3,230.94 Grand Total $ 3,644.73 Gifted Items $ 3,092.00 Actual total $ 552.73 Electrical parts- waiting on trip to Xerox

19. MSD II Project Plan

20. Worst Case Plan

21. GREEN LIGHT FOR MSD 2!!