Low Energy Printing

Project P09505
Mid-Project Review
Senior Design I

October 6, 2015

Senior Design I Mid Project Review

1<1>
1

Project Team, Faculty, &

Customer

Project Team:
Project Lead:

Joshua Jones (ME Year 5)

Team Members:
Whitney Domigan (ME Year 4)
Jenna Kilroy (ISE - Year 5)
Andrzej Lubaszka (EE Year 5)

Faculty:
Guide:
Bill Nowak (ME, Xerox Employee)

Consultant:
Marcos Esterman (ISE)

Customer:
Xerox Corp Marking Elements & Integration Lab
John Knapp

October 6, 2015

Senior Design I Mid Project Review

Agenda

Introduction
Project Background
Customer Requirements
Project Deliverables
Concept Selection
Current Design Concept
Bill of Materials
Feasibility Checklist
Key Risks From Design Reviews
MSD 2 Project Plan

October 6, 2015

Senior Design I Mid Project Review

Project Background
Xerographic digital printers are very energy
intensive, specifically the fusing sub-system.
This is largely due to the fact that during the
fusing process toner is heated to well above its
melting point, to enable heat flow, and allow the
toner to adhere to the paper.
Senior Design Project as Stated on Edge:
Re-consider the design of an extremely low
power, non-thermal fusing system
https://edge.rit.edu/content/P09505/public/Home

October 6, 2015

Senior Design I Mid Project Review

How a Fusing Sub-System

Works
Heat
Discrete, loose
toner

Fused,
adhered
toner

Nip

Pressure

Traditional Toner
Fusion:
Temperature
+
Pressure
+
Heat
=
Fused, Adhered Toner

Image by: David Thompson, Xerox Corp.

Information by: David Thompson, Xerox Corp. and Dinesh Tyagi, Eastman Kodak Company

October 6, 2015

Senior Design I Mid Project Review

Project Scope
The purpose of this project is develop
a fusing sub-system that uses
pressure instead of thermal energy
to fuse toner to paper with the aim of
fitting into the Xerox Workcentre Pro
45/55 printer.

October 6, 2015

Senior Design I Mid Project Review

Customer Requirements
Revised Customer Needs
Number:Need Type: Original Needs:
Needs within the Scope of Project:
Customer Weight:
Paper Quality Paper is not damage
1
Paper can go through system without being damaged
9
Image be Xerox quality
Print has a low gloss
2
Fit into current Xerox Workcentre 245/55 Pro
Fuser (minus the motor/drive system) fits into Workcentre Pro
3
Compatible with other Xerox models
3
Technology may be able to be used up and down along Xerox stream1
CompatibalityTechnology can be used up and down along Xerox stream
4
Standard office grade paper (20/24 pound paper)
Standard office paper (8.5 x 11") fits
9
5
Accept paper in orientation it currently enters fuser (SHFAccept
/ LHF) paper in orientation it currently enters fuser (SHF / LHF)
3
6
Sub-system cost less then current system
Sub-system cost less then current system
3
Cost
7
Easy of manufacturing
Prototype cost less then $5,000.00 to complete
3
Use pressure only to fuse toner to paper
8
Use pressure only to fuse toner to paper
9
Low Energy - non-thermal
Pressure
9
Pressure along the nip needs to be uniform
9
10
User must be able to safely clear jam in fuser
User must be able to safely clear jam in fuser
1
11 Misc.
Fuser last for at least 100,000 prints
Fuser last for at least 100,000 prints
1

Most Important Customer

Requirements:
Paper is not damaged
Uniform pressure along nip
Fit into current Xerox Workcentre
245/55 Pro
Use pressure only to fuse toner to
paper
October 6, 2015

Senior Design I Mid Project Review

Senior Design 2
Deliverables
Physical Hardware:
Working cold pressure fusing system
One working prototype with multiple configurations

Parametric Analysis:
Effect of different roller skews on:
Uniformity of pressure across the nip
Damage to paper

Various loads and their effect on:

Uniformity of pressure across the nip
Damage to paper

Analytically test the max load design can handle

Effects of paper thickness
Analytically examine the effects of roller lengths

Verification of theory that additional rollers will

generate a more uniform pressure across the nip

October 6, 2015

Senior Design I Mid Project Review

Concept Selection Process

PUGH 1 - Week 3
Preliminary Design

PUGH 2 - Week 4
Loading Styles

Concept Selection PUGH 1

Concept Selection PUGH 2
Concept Selection PUGH 3

October 6, 2015

PUGH 3 - Week 6
How to Mechanically
Apply Load

9
Senior Design I Mid Project Review

Current Design Concept

12
inches

October 6, 2015

Senior Design I Mid Project Review

10

Current Design Concept

Current Fuser Systems

Dimensions:
Length: 18.5 inches
Width: 4.5 inches
Height: 6.5 inches

October 6, 2015

Our Designs Dimensions:

Length: 13 inches
Width: 3 inches
Height: 4 inches

Senior Design I Mid Project Review

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Current Design Concept

Features

October 6, 2015

Senior Design I Mid Project Review

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Budget
Part
Number
1 9298K253
2 88955K753
3 88955K292
4 BA-887
5
6 8992K973
7 91251A451
8
9 6545K113
10 96562A194
11 98408A138
12
13
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Part Description

Req.
Quanity
Labor Cost Tlt. Labor Total
Part SupplierQuanity Units
Mat'l Cost ($) ($/hr)
Cost ($) Cost ($)

Bottom A Roller
Center B Roller
Stabilizing C Roller
Shell Cup Needle Ball Bearing

McMaster Carr
McMaster Carr
McMaster Carr
Bearings Direct

Side Plate Stock

Socket Cap Screw
Drive Motor
End Plate Support Bar
Pan Head Machine Screq
Retaining E Ring
Pressure Sensitive Paper

McMaster
McMaster
Xerox
McMaster
McMaster
McMaster
Xerox

Carr
Carr
Carr
Carr
Carr

1 Inches
1 Inches
2 Inches
10 Inches
1 Inches
8 Inches
1 N/A
1 Inches
1 Inches
1 Inches
2

$274.52$60/0.5
$98.79$60/0.5
$29.58$60/0.5
$4.98
$133.33$60/15
7.77 per pack of 25
$400.00
$10.70$60/0.25
$5.71
$6.12
$600.00

0
0
0
0
0

$30.00
$30.00
$30.00
$0.00

$304.52
$128.79
$89.16
$49.80

$900.00 $1,033.33
$0.00
$7.77
$0.00
$400.00
$15.00
$25.70
$0.00
$5.71
$0.00
$6.12
$0.00 $1,200.00

$0.00
$0.00
Total: $1,650.90

BOM - Budget

October 6, 2015

Senior Design I Mid Project Review

13

Key Risks:

Identified During Design Reviews

Risk/Issue

Risk Level
Mitigation Plan
Revisit calculations, pressure should be more on the order
6,000lbs
High
Recalculate Black Box with 3inch rollers compare with Xero
Calculated applied pressure may be too low
engineer's numbers
Determine where heat losses go
Low
Heat generated by system
Develop a heat management plan
Load limit of design that will maintain uniform
Perform FEA using ANSYS
Medium
pressure
Test multiple bearing types
Calculate max nonuniform loading though screws
High
Precision of applying load
Measure effect of nonuniform loading
Time dependence of fusing
Low
Waiting on unfused images to test
Complete enginieering drawings
Medium
Machining parts
Contact RIT's machine shop to get estimated lead times

Risk Tracking

October 6, 2015

Senior Design I Mid Project Review

14

MSD2 Project Plan

Week 11 Week 1 Week 2 Week 3 Week 4 Week 5 Week 6 Week 7 Week 8 Week 9 Week 10
Finalize Design
Ensure Manufacturability
Order Raw Stock
Develop Test Procedures
Order Specific Components
Analytical Testing and Results
Maching of Fuser
Assemble Fuser
Implement Testing and Analysis
Design Improvements
Verification Testing and Debugging
Implement Solutions
Continue Testing with Improvements
Put together documentation
Project Poster and Paper
Final Project Review

October 6, 2015

Senior Design I Mid Project Review

15

Questions

October 6, 2015

Senior Design I Mid Project Review

16