1. Agenda Introduction12:00 Ozone Fan/Filter Assembly12:15 Monitoring Charge on Photoconductor12:30 LED Exposure System12:45 Paper Delivery System1:00 High Visibility Warning Signs1:15 Camera System1:30 Transfer Roller Speed Measurement1:45 Labview Control Interface2:00 Additional Issues2:15

2. Detailed Design Review P09503 – Electrophotographic Development and Transfer Station Friday, October 31, 2008 12:00PM-3:00PM 76-A120

3. Team Members NameDisciplineRoleEmail David SchwartzISETeam Lead – Warning Signsdrs8889@rit.edu Ruth GayMEPaper Delivery Systemrip4474@rit.edu Phillip LopezMEOzone Filterpml6464@rit.edu Dan SummersMEME Supportdcs5083@rit.edu Rachel ChrashEELED Exposure Systemrec0678@rit.edu Min-Shi HsiaoEEPC Voltage Measurementmxh7790@rit.edu Andrew KearnsEETransfer Drum Speed Measurement, Camera System amk0477@rit.edu Sasha OliverCEUser Interfaceaas1878@rit.edu

4. Introduction to Electrophotography Electrophotography is base technology used in modern day copy printers Six Step Process – Charging – Exposure – Development – Transfer – Fusing – Cleaning EDTS only includes first four

5. Project Introduction EDTS will contribute to understanding of current EP technology – Manipulation of input parameters Objective is to take existing EDTS and – Make it functional – Improve Usability – Automate Control of Machine – Additional Performance Improvements

6. Project Deliverables 1 – An inventory and status of current sub-systems, including needed support systems. 2 – A working EDTS. 3 – Demonstrably improved device safety. 4 – An improved user interface (includes control and display functions) 5 – Device documented for use, maintenance and upgrade of the device (User & Lab Technician Manual) 6 – Demonstrably Improved Sensing and Control Subsystem

7. System Level Overview Photoconductor – Hold Photosensitive Material – Photosensitive Material Increased conductivity during exposure to light – Traverse EDTS – Interact Photosensitive Material with Charge Discharge Development Transfer

8. System Level Overview Charging – Establish an electrical field within the area of the Photoconductor – Photoconductor passes at very small distance – Corona Wires subjected to up to 10,000 Volts – Grid Distribute charge of corona

9. System Level Overview Exposure – Expose Photosensitive material to light – Reduce charge on exposed areas – Electrostatic latent image remains

10. System Level Overview Development – Deposit charged toner particles onto charged areas of photosensitive material – Magnetic Developer creates a “wall” of toner and developer

11. System Level Overview Transfer – Transfer toner from photosensitive material to paper – Transfer Drum is Charged – Two Steps Toner to Transfer Drum Transfer Drum to Paper

12. System Level Functional Diagram Functional Diagram shows areas for improvement

13. Customer Needs 1. Is Operational 2. Is Safe 3. Minimizes user intervention during Charging 4. Minimizes user intervention during Discharge 5. Minimizes user intervention during Development 6. Minimizes user intervention during Transfer 7. Minimizes user intervention during maintenance 8. Can monitor key process parameters 9. Automation of Parameter Settings 10. Can operate and monitor machine from one interface 11. Easy to learn to use 12. Areas for system upgrades are identified and documentation for upgrade procedures available where applicable 13. Maintenance of system is documented 14. Both drawings and Bills of Materials document device 15. Operation of Device Is Documented 16. Toner clean up 17. Inventory and Status Report of current systems 18. Vary charging voltage 19. Vary charging current 20. Vary exposure 21. Can accommodate different toner materials 22. Vary development voltage 23. Vary development current 24. Can use multiple toner stations 25. Vary transfer voltage 26. Vary transfer current 27. Improve exposure subsystem 28. Monitor charge of the Photoconductor 29. Incorporate other manufacturers development systems 30. Paper delivery system Ability to accommodate different types of media

14. Engineering Specifications Please see documentation

15. Ozone Fan/Filter Assembly Phil Lopez

16. Description Reduce and Secure Ozone Test Stand – Ozone hazardous to humans if exposed to enough – Law states maximum ozone in A/C Space is 0.05 ppm [1] – >0.200 ppm increases risk of health issues [1] Two Options – Verify current system or – Implementation of further improvement to control Ozone Levels [1] http://www.ozoneservices.com/articles/007.htm http://www.ozoneservices.com/articles/007.htm

17. Ozone Customer Needs Satisfied and Associated Specifications Customer Need Satisfied SpecificationIdeal ValueMarginal Value Is SafeAmount of Ozone Present in Air 0.001ppm0.050ppm Maintenance of System is Documented Number of screws needed to detach ozone filter for removal and cleaning 44

18. Current System

19. Current Mount

20. New Mount (If Necessary)

21. Proof of Concept Measure ozone at various locations to determine if measurements are within limits Test/Experimental – TBD due to insufficient equipment = Test Areas

22. Proof of Concept

23. Set values – 0-1.0 kV at increments of 0.1 kV for Grid and Corona – 1-10kV at increments of 0.5 kV for Grid and Corona Will Measure – Ozone Produced without Fan – Ozone Produced with Fan At original height and two inches higher

24. Proof of Concept Material Selected Al 2024 Stress found to be ~520 psi Less than Yield Stress of 45ksi Less than Ultimate Stress of 65ksi

25. Bill of Materials ItemPriceLead TimeSupplier Sheet of Al 2024$97AvailableMcMaster

26. Risk Assessment Description of Risk Possible Consequences Probability of Risk (H/M/L) Severity of Risk (H/M/L) Overall Risk (H/M/L) Contingency Plan Loose FanOzone over EPA regulations MHMReattach Particulate Build Up or Clogging Ozone over EPA regulations MHMExamine and do required maintenance Power Loss to Fan Ozone over EPA regulations MHLN/A Ozone Measurement Device Unable to measure Ozone levels LHMNot Available

27. Monitoring the Charge on Photoconductor Min-Shi Hsiao

28. Description Output quality determined by functionality of each subsystem Monitoring charge of photosensitive material will help characterize exposure input noise source Can also help create charge v. exposure plot after measurement Measuring device is Trek 344 Electrostatic Volt Meter (ESVM) Probe functions like capacitor that charges up to same level as object being measured

29. Customer Needs Satisfied and Associated Specifications Customer Need Satisfied SpecificationIdeal ValueMarginal Value 1.20: Monitor key process parameter Charge on photoconductor after charging same as the applied voltage +/- 10% of the ideal value Charge on photoconductor after discharge (exposure) Proportional to the exposure level +/- 10% of the ideal value 1.70: Monitor charge of the Photoconductor Measurement resolution 2.5 dpi+/- 0.254

30. Drawings/Schematics Probe must be placed 2mm from PC surface Cannot be held by hand – Could result in short or shock Position should be fixed during measurement Existing Camera Mounts used – Allows for easy adjustment – Intermediate probe mount needed to attach probe to camera mount

31. Probe

32. Current Camera Mounts

33. Intermediate Mount

34. Current Camera Mount with Probe Fixture

35. Location of Measurements

36. Proof of Concept Mylar used for testing instead of PC Material – Mylar not sensitive to light, no exposure necessary Mylar glued to PC plate and driven down EDTS Begin with 500 Volts at charging Measurements taken after charging and exposure

37. Risk Assessment Description of Risk Possible Consequences Probability of Risk (H/M/L) Severity of Risk (H/M/L) Overall Risk (H/M/L) Contingency Plan Manually moving the brick Electric shockLHLAvoid contact when machine is powered, user manual, warning sign, wear insulating gloves

38. LED Exposure System Rachel Chrash

39. Description LED Print Heads used in copiers and printers to expose Photosensitive Material are commonly used LED Exposure system to replace current incandescent system Advantages – More versatile and reliable light source – Low Power Consumption – Longer Bulb Life – No potential for overheat – Inexpensive to replace

40. Customer Needs Satisfied and Associated Specifications Customer Need Satisfied SpecificationIdeal ValueMarginal Value 3.2: Improve exposure subsystem Ratio of Intensities1<100

41. Current System vs. LED System Current System – Incandescent light uses collimating lens to collect light and direct toward image plane LED System – Provide more direct source of light to image plane

42. LED Array

43. Relative Intensity vs. Wavelength Plot shows intensity, or relative spectral power distribution w.r.t. wavelenth PC Material most sensitive to blue light which has shortest wavelength Explains why system can be successfully operated in yellow light without large impact on PC exposure

44. Proof of Concept Most successful exposure results in even light distribution across entire image plane Three light sources tested using Gossen PanLUX Analog Lux Meter LUX = intensity (lumen/m 2 ) Grid constructed over image plane at level where exposure takes place Light intensity and uniformity measured every 1x1 inch Pinpoint measurements were then taken of the current system – 2x2 LED Array – 2x3 LED Array

45. Proof of Concept Intensity (Lux)Intensity Ratio Current System5600NA 2x2 LED Array10056 <100 2x3 LED Array14539 < 100

46. Proof of Concept

47. Mounting System Array can be contained inside projector casing – Located at bottom or – Located on Small Shelf at height TBD by testing Larger than 3x3 array could pose issue due to size – Modify Projector Case

48. Bill of Materials Item Number DescriptionModel NumberQty 1Luxeon Blue LEDLXHL-BR024 24 Pin High Brightness LED276-2034

49. Risk Assessment Description of Risk Possible Consequences Probability of Risk (H/M/L) Severity of Risk (H/M/L) Overall Risk (H/M/L) Contingency Plan Lead Time if Parts need to be ordered Time DelayLLLOrder Ahead Uniform Light Distribution Uneven ExposureHHHFurther LED Testing Mounting Current LED System Not Centered and Time LLLTesting Larger LED Array Doesn’t Fit Inside Projector Case HHHModify Projector Case

50. Paper Delivery System Ruth Gay

51. Description Existing roller system requires manually catching paper after application of toner from roller Possible risks of manual handling – Shock Short from High Voltage Roller – Pinch Point of Rollers and Pneumatics – Marred Image Quality Paper Delivery System Solution – Hold 4.25” x 5.5” paper samples – Fit in available space

52. Customer Needs Satisfied and Associated Specifications Customer Need SatisfiedSpecificationIdeal ValueMarginal Value Is safe Human Shock/Short Faults Identified during FMEA Analysis 0<5 Is safe Pinch Point Faults Identified during FMEA Analysis 0<2 Is safe Insufficient or Not Present Warning Labels identified during FMEA Analysis 0<1 Minimizes user intervention during Transfer Human Shock/Short Faults Identified during FMEA Analysis 0<5 Minimizes user intervention during Transfer Pinch Point Faults Identified during FMEA Analysis 0<2 Minimizes user intervention during Transfer Insufficient or Not Present Warning Labels identified during FMEA Analysis 0<1 Paper Delivery System Pass standard “EP Process Test” N/A

53. Detailed Drawing/Schematic

54. Tray Drawing

55. Right Side Bar Drawing

56. Left Side Bar Drawing

57. Cross Bar

58. Support Leg (x 2)

59. Proof of Concept

60. BOM PartP/NMat'lSpecsQtyPricePackage size Socket Cap Screws 92185A991stainless steel 5/32" hex socket, 10-32 thd, 3/4" length, fully threaded, head: dia.32" ht.190" 8$8.8625.032" Aluminum Sheet 1651T11 6061 Aluminum 12"x12", brushed Finish,.032" Thk 1$12.761.375" Thick Aluminum Sheet 9246K23 6061 Aluminum 12"x12", Unpolished finish,.375" Thk 1$31.981 Aluminum Rod 6750K131 6061 Aluminum 12" length, 1/4" dia. 1$3.411 Total Material Cost $57.01

61. Risk Assessment Description of Risk Possible Consequences Probability of Risk (H/M/L) Severity of Risk (H/M/L) Overall Risk (H/M/L) Contingency Plan Lead time of parts Not completed soon enough MMMMake at in- house shop CostExceed budgetLMMChange part design to minimize cost, use available stock material

62. Implementation of High Visibility Warning Signs David Schwartz

63. Description Purpose of warning signs – Alert user to specific hazard – Identify how hazard can be avoided Remove current warning signs Replace with ISO designed signs Add new ISO signs where needed

64. Customer Needs and Associated Specifications Customer Need Satisfied SpecificationMarginal ValueIdeal Value Is SafePinch Point Faults Identified during FMEA Analysis <20 Is SafeInsufficient or Not Present Warning Labels Identified During FMEA Analysis <10 Is SafeHuman Shock/Short Faults Identified during FMEA Analysis <50

65. New High Voltage Sign Old High Voltage SignNew High Voltage Sign Actual Height of Sign = 1.5”

66. Pinch Point Sign Actual Height of Sign = 1.5”

67. System Warning Signs Actual Height of Sign = 1.25’

68. Before and After BeforeAfter

69. Proof of Concept Signs Designed under guidance of ISO-3864 – Establishes the safety identification colors and design principles for safety signs to be used in workplaces and in public areas Danger - signal word used to indicate an imminently hazardous situation that, if not avoided, will result in death or serious injury – Chosen for High Voltage and Pinch Point Caution - signal word used to indicate a potentially hazardous situation which, if not avoided could result in minor or moderate injury – Chosen for overall system warning

70. Size of Signs ISO Equation: H = D/40 – H = Height of Sign (mm) – D = safe viewing distance (mm) Pinch Point / Electrical Hazard – Safe Viewing Distance is 5 feet – Results in sign height of 1.5 inches Avoid Injury – Safe Viewing Distance of 50 feet – Results in sign height of 1.25 feet

71. Other Sign Details Signs will be placed on both sides of identified hazard areas Hazard Areas identified during Failure Modes Effect Analysis (FMEA) Signs will be placed as not to disturb operation and maintenance of machine Signs made from laminated paper Signs attached using double sided tape

72. Risk Assessment Description of Risk Possible Consequences Probability of Risk (H/M/L) Severity of Risk (H/M/L) Overall Risk (H/M/L) Contingency Plan User Ignores Sign Shock/Short or Pinch MMMAssure the signs are the proper size Signs DetachNo sign present LLLAttach all signs securely, print extra

73. Camera System Andrew Kearns

74. Description Purpose is to gain understanding of how image is developed onto photoreceptive material Photoconductor system stopped Photoreceptive material imaged after development and before transfer Nikon D50 Camera used to Study Process as it occurs Mirror will reflect image of photoconductor to camera lens

75. Customer Needs and Associated Specifications Customer Need Satisfied SpecificationIdeal ValueMarginal Value Can Monitor Key Process Parameters Take image the size of PC 9”x4.75”7”x4”

76. Camera System in Machine

77. Proof of Concept Utilize one of three existing mounts Third Magnetic Sensor will tell Labview when to stop Photoconductor for image capture Camera will interface with computer via USB Labview will call command to Nikon Software to capture image LED Bar may be removed if paper delivery system occupies too much space

78. Risk Assessment Description of Risk Possible Consequences Probability of Risk (H/M/L) Severity of Risk (H/M/L) Overall Risk (H/M/L) Contingency Plan Camera Space Less space for paper delivery HMMUse front surface mirrors to Capture a reflected image Picture Timing Image decay on PC LLLSpeed up PC Mount Deterioration Mount is unstable MHHNew Mounting System

79. Transfer Roller Speed Measurement Andrew Kearns

80. Description Speed of transfer roller critical to timing control and image quality Need to assure that transfer drum rotates at the same speed as the moving photoconductor as to not elongate/condense the image Need to assure that the transfer roller will be in the proper position for transfer to paper Encoder provides feedback as to current speed of drum

81. Customer Needs Satisfied and Associated Specifications Customer Needs Satisfied SpecificationsIdeal ValueMarginal Value Can Monitor Key Process Parameters % difference between speed of PC and Speed of Drum 0%+/- 5%

82. Proof of Concept Optical Encoder sends 1024 pulses / rev

83. Proof of Concept A & B Outputs of Drum Encoder at 1.74kHz Measurements Taken for Encoder B Output Signal Vpp2.20E+00 Frequency1.74E+03 Period5.74E-04 Pulse Width+2.82E-04 Pulse Width-2.92E-04

84. Risk Assessment Description of Risk Possible Consequences Probability of Risk (H/M/L) Severity of Risk (H/M/L) Overall Risk (H/M/L) Contingency Plan Inability to interface with DAQ Decreased image quality LHMDrive a seven segment display with the encoder output Inability to read A and M outputs Unknown direction of motion HMHVerify proper acquisition of signals

85. Labview Control Interface Sasha Oliver

86. Description Current control system is done via KV300 PLC Better solution needed to replace current system with a new user friendly interface Labview uses dataflow programming to define inputs/outputs and execution sequence of the virtual instrument Connect devices directly to DAQ to allow for more robust control

87. Customer Needs Satisfied and Associated Specifications Customer Need SatisfiedSpecificationIdeal ValueMarginal Value Can monitor key process parameters Ability to view current status of machine during operation Yes Automation of Parameter Settings UI Includes Automatic and Manual Control of Device Yes Can operate and monitor machine from one interface Ability to control system with current controls and improved controls Yes Easy to learn to useLEEERS Usability Test Result Extremly East to UseEasy to use

88. UI with Automatic Setting Enabled

89. UI with Manual Settings Enabled

90. Proof of Concept

91. Risk Assessment Description of Risk Possible Consequences Probability of Risk (H/M/L) Severity of Risk (H/M/L) Overall Risk (H/M/L) Contingency Plan Interface may not be able to control system as the PLC did Some parts of the system may not work MHHRefine system The previous state machine is not replicated correctly (incorrect parameters passed into device) Damaged partsLHMRefine State machine

92. Further Issues Tilting or Machining the Development System Development System Toner Uniformity Documentation of a user manual Identification of a DAQ for purchase Toner Bias Test Plan with Critical Parameters Table Transfer Roller Height Restriction Air Filtration System