P 10505 Cold Pressure Fusing II System Design

P 10505 – Cold Pressure Fusing II System Design Review Team Fusion 1/15/2010

Agenda • • • Introduce Team [1 minute] Project Description [3 -4 minutes] Project Flowchart [3 -4 minutes] Customer Needs [5 minutes] Engineering Specifications [10 minutes] House of Quality [5 minutes] Functional Decomposition [10 minutes] System Architecture [5 minutes] Concept Selection Flowchart [2 -3 minutes] • Concept Selection [20 minutes] o Skew [10 minutes] o Skew Support [5 minutes] o Paper Weight Adjustability [1 -2 minutes] o Compliance [1 -2 minutes] • Final Design [5 minutes] • Risk Assessment [5 minutes] • Design Risks [5 minutes] • Action Items [1 -2 minutes] • Next Steps [1 -2 minutes] • Questions [5 minutes] Questions and comments are encouraged throughout the presentation

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

Project Background/Description • Changing customer expectations from printers. • Focus on sustainability (low energy consumption). • Energy Star • Heat fusing consumes a considerable portion of energy. • Hence, Cold Pressure Fusing. • P 09505 developed an initial prototype. • Issues with pressure uniformity

Project Flowchart MSD 1 Research Past work Establishing Customer Needs Project Planning Patent Research Past work from P 09505 Concept Selection Project Schedule WBS Generation Pugh Concept Selection Concept Improvement Modeling Present Design Calculate Nip Pressure Analyze Roller Deflection Torsion Analysis Create CAD Model DAQ System Create Realtime DAQ System Interface DAQ with hardware

Customer Needs

Customer Needs

Engineering Specifications Engr. Spec. # Importance ES 1 1 ES 2 1 ES 3 1 ES 4 1 ES 5 1 ES 6 Source Specification (description) Customer Need Prototype will fuse print across 100% of the page Customer Need Prototype will vary in nip pressure less than 10% Prototype must be capable of adjusting to three skew Customer Need angles Prototype must adhere to Abaqus model created by Customer Need Xerox Unit of Measure Marginal Value Ideal Value Percentage fused, Width of unfused, N/A 100% fusing Width of Pressure Indication, Xerox Metric 10% variation 5% variation Number of Settings 2 angles Analog Yes/No N/A Yes Degrees 1. 8°-2. 0° 1 Customer Need Prototype must be able to reach a 1. 9° skew angle Prototype must be adjustable to the same skew angle Customer Need to a 1/10 th degree for ~25 runs Standard Deviation 1/5 th degree variation 1. 9° 1/10 th degree variation ES 7 1 Prototype must accommodate 120 gsm (80# text) Digital Color Elite Gloss coated media while meeting Customer Need all other specifications Yes/No N/A Accomodates all paper weights ES 8 2 Qualitative ES 9 2 Number Moderate 1 wrinkle every 10 prints ES 11 3 Force Vibration ES 10 3 Torque 10% reduction of speed Stationary 5% reduction of speed ES 12 3 Implied 4 weeks 2 week ES 13 3 Implied Prototype must be manufacturable within ~2 week Time Required, Y/N Prototype will take less than 60 secs of user time to set up print Time Required 120 secs ES 14 3 Implied Prototype must be able to print >1000 copies without failure Life Cycle (Number of Prints) 500 copies 1000 ES 15 4 Dollars $3, 000 $1, 500 Customer Need Prototype will minimally calendar print Prototype will produce trailing edge wrinkles less than Customer Need once every twenty prints Implied Prototype must be stable for a load of 4000 psi Customer Need Feed rate must not decrease by more than 5% Customer Need Prototype must cost less than $3000 None No wrinkles ever

System Architecture

Concept Selection Flowchart Mechanism of Adjustment Skew Adjustment Brainstorming ideas to meet needs Assessing Customer Needs Support of Adjustment First Concept selection Paperweight adjustment Swapping End Blocks Adjustable End Blocks Swapping Pillow Saw Tooth Blocks End Blocks with Multiple holes Crank Adjustment Sliding Channel Push Bolt Compliance Pull Bolt in channel Hook and Frictional Coating Pinion Pull Shelf with Bolts and Ridged Channel

Concept Selection – Preliminary Skew Mechanism

Concept Selection – Secondary Skew Mechanism Skew Adjustment Swappable End Blocks Adjustable End Blocks Cost 0 + 0 Fixability 0 0 - Manufacturability 0 + 0 Durability 0 - - Skew Alignment 0 ++ 0 Complexity 0 - 0 Ease of Assembly 0 - 0 Score: 0 1 -2 Concepts End Blocks with Multiple Holes Metrics

Preliminary Concept CAD Models Figure 1. Side view of End Block

Preliminary Concept CAD Assembly Figure 2. Assembly Model

Concept Selection – Skew Support

Concept Selection – Paper Weight Adjustability Adjusting for Paper Weights Metrics Current Prototype Compliance Speed Optimize Gap Manually Optimize Paper Filler Dimension roller diameter Calendaring 0 + 0 + Print Fusing 0 - 0 + + 0 Visual Defects 0 0 0 + + 0 Uniform Nip Pressure 0 0 + 0 Paper Weight Accommodation 0 + - + User Friendly 0 + 0 - Abaqus Model 0 + 0 - - + Paper Stubbing 0 + 0 - Score 0 4 0 3 1 4

Concept Selection - Compliance Metrics Washers (Various Materials) Coated Elastomer Springs Rollers Manually Adjust Pressure Hydraulics Cost 2 2 1 3 1 Durability 2 2 Constraint 3 1 Load Strength 2 2 1 3 2 Complexity Ease of Construction Ease of Operation 3 3 1 3 1 3 3 3 1 3 Total: 15 15 7 16 9

Final Design

Risk Assessment

Design Risk Assessment

Action Items • Action Items: o Eric: Model Detailed CAD Models o David: ANSYS o Aniket: DOE Planning o Tom: DAQ System o Jon: Calculate Nip Pressure and Deflection

Next Steps Midterm Design Review Purchase Components as Confirmed Calculate Nip pressure Analyze Roller Deflection Torsion Analysis Create CAD Model Create Real-time Data Acquisition system Interface DAQ with Hardware Create Test Plan Review and Improve on System Design Week 5 (1/11 -1/17) Week 6 (1/18 -1/24) Week 7 (1/25 -1/31) Midweek Friday