1. Electrophotographic Cascade Development Apparatus Detailed Design Review December 9th, 2014 Dalton Mead Michael Warren Thomas Wossner Bridget Kearney Ruishi Shen Zachary Foggetti

2. Outline ● Customer Requirements ● Engineering Requirements ● Process Flow Diagram ● Subsystems o Hopper o Transfer Surface o Development Zone o Angle Control System o Recirculation System ● BOM ● LabVIEW Program Outline ● Test Plan ● Plan for MSD II

3. Customer Requirements

4. Engineering Requirements

5. Process Flow Diagram

7. Subsystem: Hopper

9. Subsystem Interfacing Vertical Pivot Mount ○ Calculated Center of Mass of Hopper ○ Will always hang vertical due to COM ● Allows flexibility of angle for experiment ● 1/4” diameter will be strong enough ● Attached to outside edges of Transfer Surface Subsystem: Hopper

10. PA-14-1-50 MINI LINEAR ACTUATOR (STROKE SIZE 1", FORCE 50 LBS, SPEED 1.18"/SEC) STROKE: 1 INCH FORCE: 50 LBS SPEED: 1.18"/SEC ●Linear Actuator ● Slide open door at bottom of Hopper ○ Only needed to push/pull 3.8 N of force ●Mounted on backside of Hopper ●Controlled by Labview UI

11. Risks Subsystem: Hopper

12. Bill of Materials

13. Transfer Surface & Development Zone

14. Functions: ●Provide structural strength to bear forces of hopper/lever arm ○ Yield strength - 276 MPa ○ Density - 2,700 kg/m 3 ●Electrically conductive for grounding ○ 5 times more conductive than steel ●Smooth surface to reduce friction Transfer Surface

15. ❖ Opens completely for user to expose the face of each surface ➢ Allows for easy access of removable development zone ❖ Inhibits movement of plates relative to each other in x & y directions Transfer Surface

16. Edges prevent particle loss Main transfer surface Main top plate Hinge mounts Charged plates Insulating layer

17. Subsystem Connections: ● Supports structure of hopper ● Closely tied with development zone ● Moved by angle control system underneath ● Bottom edge leads directly to recirculation Transfer Surface

18. Plate Mating: Development Zone

19. Design ●Two surfaces set parallel ●3 in. x 3 in.x 0.12 in. aluminum plates surrounded by ¼ in. of insulating material inserted on the transfer surface ●Polarity of both plates can be changed to either positive or negative ○ Charging both plates will allow for experimentation with the separation of toner from the carrier beads Development Zone Removable Aluminium Plates ●Plates will be easily removable inserts for inspection of test results ●Spring tab has two functions: 1.Press insert flush to transfer surface a.Must be flush to avoid particles getting caught on edge 2.Transfer electric charge to the aluminum insert a.Screws connect the bottom tab to the transfer surface and top tab to top plate -- both connected to power ●Tabs will be made of strip metal in machine shop

20. Development Zone Parallel Spacing Between Plates ● Space must be big enough for both toner particles and carrier beads to flow through freely ● According to the field intensity formula, E=v/d o If the space is too small, the carrier beads may begin to develop o If the space is too large, the toner particles may not develop at all ● A plate gap of approximately 2mm is desired to begin testing toner particles with 90μm http://www.regentsprep.org

21. Development Zone Parallel Spacing Between Plates ● Adjustable, steel, parallel shims ● Easily expand and contract to desired size in opening ● Range in height from ⅜ in. to 2.25 in. Automation of Plate Spacing ● Automate spacing between parallel plates using a 12V DC linear actuator ● Motor is mounted to the top surface of the top plate and connects to the parallel shims via metal brackets ● Vertical gap distance required for adjustment is approximately 2 mm (<.1 in.) ● Adjustable Parallel sets have a slope of approx. ⅕, so minimum stroke required is about.5 in. PA-14-1-50 MINI LINEAR ACTUATOR (STROKE SIZE 1", FORCE 50 LBS, SPEED 1.18"/SEC) STROKE: 1 INCH FORCE: 50 LBS SPEED: 1.18"/SEC

22. Movement Setup: Development Zone

23. Plate Distance Actuation Animation Development Zone

24. Bill Of Materials

25. 1 Voltage arcing between the two parallel plates Shock injury, damage to device, exhaust hood or nearby equipment Misuse of power source233 Practice caution when using the device at all timesBridget 2 Aluminum plates not flush to plastic Buildup of toner particles on edges Spring contactor tab loosens133 Ensure that plate is flush before each test. Bridget IDRisk ItemEffect Failure ModeLikelihoodSeverityImportance Action to Minimize RiskOwner Risks of Development Zone and Transfer Surface 3 Linear actuator malfunctio ns Developme nt zone not set correctly Failure of linear actuator, power supply or labview to work232Bridget

26. Angle Control System

27. Chosen method: Motorized rack/pinion arm Reasoning: ● Rack rests on ground surface -- prevents slipping ● Low torque required to hold position ● Stepper motors inexpensive Angle Control System

28. ❖ Generate enough torque to hold position or raise transfer surface angle (est: 11 Nm for hold) ❖ Gear teeth must not slip ❖ Should minimize space under transfer surface ❖ Lift arm must bear some load

29. Angle Control System Assumptions: m S = 15 kg m A = 1 kg d 1 = 4” d 2 = 9” d 3 = 2” d 4 = 3” r = 0.75” 45° ≤ Θ ≤ 80° Holding torque ≈10.28 Nm

30. Subsystem Connections: ● Interfaces directly with the transfer surface ● Structural stability provided by connection with base Angle Control System

32. Bill of Materials: Rack Gear (McMaster) - $25.39 Pinion Gear (McMaster) - $23.00 Stepper Motor (Kollmorgen KM series) Aluminum bar stock (machined in shop) Pin connections Ball Bearing (McMaster) - $4.57 Angle Control System

33. Risk ID # Risk ItemRisk Category EffectFailure Mode LSIAction to Minimize Owner 1Pinion gear cannot support load Product risk Angle adjustment / holding becomes impossible Design failure 133Ensure proper gears are selected Mike 2Lift arm deforms under load Product risk Angle adjustments become inaccurate / impossible Design failure 133Ensure materials properties and geometry are appropriate Mike 3Motor has insufficient power Product risk Raising / maintaining angle becomes impossible Design failure 133Ensure motor to be purchased is sufficiently powerful Mike 4Purchase parts are too expensive Project risk Project goes over budget Logistics failure 224Ensure that all parts to be purchased are affordable All

34. Two components: 1.Automated System (Screw Conveyor) 2.Manual System (Buckets) Why both systems? 1.Manual system provides reliable backup 2.Calculations show that screw becomes unreliable at steep angles (>70 degrees) Recirculation System Design

36. R ecirculation System - Flowdown

37. Needs: 1.Move 1.3L/min of particles at a 70 degree slope 2.Must not strip particles of charge → must be insulative 3.Must not be so large that it interferes with testing and/or exceeds space constraint Design: 1.L=Length of Screw: 26’’ 2.=Angle between centerline & edge of screw (must be greater than slope of conveyor): 70 deg. 3.Ro=Radius of Screw: 1.4’’ 4.Ri=Radius of Shaft: 0.75’’ 5.# of Blades: 3 6.Pitch: 2.17’’ Recirculation System - Screw

38. Design Feasibility - Screw Fabricate-ability For the sizes we will need: -Can buy solid PVC rods -Can machine into auger/screw shape (acc. to Rob Kraynik in the ME machine shop) Technical Feasibility -Similar systems commonly used to move powder, water -At 70 degree slope, benchmark particle movement rate of 1.3L/min is achieved @ 71 RPM

39. Needs: 1.Must maximize the run time before recirculation is required (>1 min) 2.Must not strip particles of charge → must be insulative 3.Must not be so large that it interferes with testing 4.Must prevent particle overflow 5.Must “dam” particles while bucket is not present Design: 1.2 buckets (one small, one large) made from plexiglass 2.Small bucket funnels particles into large bucket 3.Small bucket can be plugged to contain particles while manual recirc occurs 4.Large bucket drains into screw and can be sealed 5.Large bucket - holds up to 1.6L of particles when sealed a.when not sealed, funnels into opening in screw Recirculation System - Buckets

40. Top Bucket Internal Dimensions: -h=Height: 2’’ -w=Width: 6’’ -d=Depth: 4’’ Sloped bottom Volume = hwd = 48 in 3 = 0.8L -User has ~40 sec to perform manual recirc Bottom Bucket Internal Dimensions: -h=Height: 4’’ -w=Width: 3’’ -d=Depth: 6.5’’ Volume = hwd = 96 in 3 = 1.6L -Ramp to funnel particles into screw -Slightly larger than hopper -Ensures no overflow -Insert slider to seal large bucket Manual Design

41. Design Feasibility - Bucket Fabricate-ability -It’s a bucket, so not difficult Technical Feasibility -Volume of 1.6L is slightly larger than hopper, preventing overflow -At benchmark flow rate of 1.3L/min, recirculation interval is ~1min 20sec

42. Connections: 1.Hopper a.Screw rests in semi-circular cutout on top of hopper; Particles drain from screw into hopper b.Bucket can be manually dumped into hopper 2.Transfer Surface a.Bucket hinged to transfer surface b.Funnels particles into large bucket c.Bucket funnel is plugged to stop flow while manual recirculation occurs d.Particles flow through rectangular cutout in large bucket into screw e.Screw is fastened to ground Recirculation System

43. Parts required for subsystem: 1.3’’ Diameter, 5’ long PVC rod 2.198 RPM, 6.3 ft-lb gearmotor 3.2’x3’ plexiglass sheet 4.2.75’’ ID PVC pipe 5.Sliders to plug buckets Parts required to connect to other subsystems 1.Hinge Recirculation System

44. Recirculation System Risks

45. BOM

46. LabVIEW Program Outline

47. Test Plan

48. ● Finalize and document build procedure and assembly process ● Format and organize all drawings/sketches ● Start filling out the purchase forms ● Update Edge Project Checklist: MSD I Unfinished

49. Project Plan - MSD II

50. Summary ● Customer Requirements ● Engineering Requirements ● Process Flow Diagram ● Subsystems o Hopper o Transfer Surface o Development Zone o Angle Control System o Recirculation System ● BOM ● LabVIEW Program Outline ● Test Plan ● Plan for MSD II

51. Questions?