1. Xerox Project Paper Stacking Detection Group 5 Lisa Washakowski Samantha Harter Will Nauman

2. Our goal was to design an innovative method for detecting stack quality.

3. Customer Needs #StatementNeeds 1 Design a device that detects stack quality problems. The printer must be able to detect when a stack of paper is subpar. 2 1. A design and model/prototype of the stack quality detection system. Specifications and a physical model of a stack quality detection system. 3 2. The project must detect the two good stacks and two bad stacks as defined below. The printer must be able to distinguish between desired and undesired stacking quality. 4 All sheets in the stack cannot be offset from the bottom sheet in the stack by more than 5 mm in any direction The device must be able to detect when a stack is non-uniform by more than 5 mm in any direction. 5 b. A good stack of 200 sheets with a regular set offset of 5 mm every set (50 sheets) in the xplane and no set offset in the z ‐ plane. See Figure 2.1 The device must be able to detect stack detect offset differently in the x,y, and z- planes. 6 Within a set of 50 sheets, all sheets in the stack cannot be offset from the bottom sheet in the set by more than 5 mm in any direction. See Fig. 2.1 The device must be able to detect uniformity within a stack of sheets, while simultaneously detecting uniformity of staggered stacks. 7 Documentation of a step ‐ by ‐ step measurement procedure. Specifications for the procedure of using the device. 8Consideration will be given to projects that achieve the desired spec and also minimize cost. A device that achieves stacking quality detection at a low cost.

4. Needs-Metrics Matrix Need Metric Wall of photo eye laser 20 mm tall, 280 mm apart Two laser walls in x plane, placed 5 mm away from desired paper location Two laser walls in y plane, located 5 mm from desired paper location Two laser walls in z plane, located 5 mm from desired paper location Laser walls located on tracks, which move according to desired stack type (staggered or uniform) Low cost photo eye laser 1)The printer must be able to detect when a stack of paper is subpar. XXXXX 2) Specifications and a physical model of a stack quality detection system. 3) The printer must be able to distinguish between desired and undesired stacking quality. XXXXX 4)The device must be able to detect when a stack is non-uniform by more than 5 mm in any direction. XXXX 5)The device must be able to detect stack detect offset differently in the x,y, and z-planes. XXX 6)The device must be able to detect uniformity within a stack of sheets, while simultaneously detecting uniformity of staggered stacks. X 7) Specifications for the procedure of using the device. 8) A device that achieves stacking quality detection at a low cost. X

5. Concept Screening Concepts Metric #Selection Criteria A Laser Scanner B Pressure Sensor C Motion Sensor D Camera E Uniform Weight Detector 1Ease of Detection++0-- 2Printer Distinguishable+00-- 3Error Distance Detection000+- 4Plane of Error Recognition000++ 5Ease of manufacture+00-0 Sum +'s31021 Sum 0's24601 Sum -'s00033 Net Score310-2 Rank12345 Continue?Yes No

6. Concept Scoring Concepts A Laser Scanner B Pressure Sensor C Motion Sensor (Reference Concept) D Camera E Uniform Weight Detector MetricSelection CriteriaWeightRating Weighted Score Rating Weighted Score Rating Weighted Score Rating Weighted Score Rating Weighted Score 1Ease of Detection25%51.255 30.7520.52 2Printer Distinguishable15%40.630.453 10.151 3Error Distance Detection25%30.753 3 412 0.5 4Plane of Error Recognition25%30.753 3 414 1 5Ease of manufacture10%40.430.33 10.13 0.3 Total Score 3.753.532.752.45 Rank 12345 Continue? DevelopNo

7. Prototype Model Edge-to-Edge detection zone laser walls Motorized track Positioned 5 mm from desired alignment position

8. The most efficient means of detecting a position of a paper stack is by using a Photoelectric Sensor SL-V Series Safety Light Curtain Features: Edge-to-Edge Detection Zone [World’s First]

9. The sliding rail and electric motor allow the detector to adjust to the desired stacking specifications. Prime Line Products R7137 Mono-Rail Drawer Slide Kit DC 12V 10000RPM 0.13A 27mm Diameter Mini Electric Motor

10. Stacking detection is achieved effectively, but the simple design keeps expenses at a minimum. ItemCost of ItemItems Per UnitTotal Cost per Unit Mini Electric Motor$9.991 Mono-Rail Drawer Slide Kit$5.001 SL-V Series Safety Light Curtain$149.001 Total Cost $163.99 Cost Analysis

11. Resources http://www.keyence.com/products/safety/safety/sl v/slv_features_4.php http://www.amazon.com/Prime-Products-R7137- Mono-Rail-Drawer/dp/B000KKTH5Ohttp://www.amazon.com/Prime-Products-R7137- Mono-Rail-Drawer/dp/B000KKTH5O http://www.sourcingmap.com/12v-10000rpm- 013a-27mm-diameter-mini-electric-motor-p- 135626.htmlhttp://www.sourcingmap.com/12v-10000rpm- 013a-27mm-diameter-mini-electric-motor-p- 135626.html http://en.wikipedia.org/wiki/Photoelectric_sensor http://www.nextag.com/garage-door-safety- sensor/stores-htmlhttp://www.nextag.com/garage-door-safety- sensor/stores-html