iGen Fuser BearingProject P11511

AgendaMeeting Timetable

Start Time Review Topic

2:20 Introductions

2:25 Project Description

2:35 Customer Needs

2:40 Risk Assessments

2:55 Concept Selection

3:10 Houses of Quality

3:20 Timeline

3:30 Discussion

3:45 Meeting Adjourned

Project Team, Faculty, and Customer• Project Team:

–Project Lead:Kevin Argabright (ME)

–Team Members:John Fitch Dean (ME)Mike Buonaccorso (ME)Justin Eichenberger (ME)

–Project Guide:William Nowak (Xerox Corporation)

• Faculty:–Consultant

Dr. Stephen Boedo• Customer:

–Xerox CorporationErwin RuizMelissa Monahan

iGen Machine

Running Conditions of Fuser

Xroller forces are 184lbs eachReaction force of 360lbs/bearing

Fuser rotates at 79.8RPM

Outer race of the fuser bearings experience a temperature of 230°F

Customer Needs• Develop method to characterize physical properties of

bearings over their physical life• Collect data on bearing properties• Correlate physical property to end of life• Incorporate multiple sensors• Characterize physical properties over the bearing's

physical life• Create failure criteria• Document the procedure (Testing)• Testing bearings is quick and easy to do• Document the procedure (Collecting Data)

Weighted Customer Needs

• Used a pairwise comparison chart

• Most Important Needs:– Develop method to characterize physical

properties of bearings over their physical life– Document the procedure for collecting data

Develop method to characterize physical properties of bearings over their physical life CN1Collect data on bearing properties CN2 cCorrelate physical property to end of life CN3 c rEncorporate multiple sensors CN4 c r rCharacterize physical properties over the bearing's physical life CN5 c c c cCreate failure criteria CN6 c c c c cDocument the procedure (Testing) CN7 c r r r r rTesting bearings is quick and easy to do CN8 c c c c c c cDocument the procedure (Collecting Data) CN9 c r r r r r r r

CN1 CN2 CN3 CN4 CN5 CN6 CN7 CN8 CN9Totals 8 3 4 5 2 1 6 0 7Weight (%) 22.2 8.3 11.1 13.9 5.6 2.8 16.7 0.0 19.4

Project Scope

• Create a measuring tool to aid Xerox Corporation’s engineering team in collecting necessary data for characterizing bearing life in the iGen Fuser Assembly

Engineering Specs

Engineering Metrics Units Technical TargetsMeasurement of Torque in-lb TBDMeasurement of Vibration g TBDMeasurement of Acceleration g TBDMeasurement of Temperature °F TBDError of Measurements % < 5%Time to Take Measurements s TBDApplied Load lb 360lbApplied Temperature °F 230°FFrequency RPM 79.8RPM

Engineering Specs

Bearing Life

RisksRisk Cause Mitigation Severity Likelihood Total

Data does not correlateNo relationship exists between physical metric and bearing life

Try multiple methods of data collection (acoustic, mag, proximity, etc..) 3 2 6

Bearing life fixtures break Use, mechanical wearEnsure proper training and seek rapid repair 2 2 4

Our testing apparatus breaksDesign error, mechanical wear, user error

Design robustly and be prepared with replacement parts 2 2 4

Needed item's lead time goes outside of project time frame Manufacturing delays

Ask manufactures for an estimate for lead time and stay in contact for updates 2 2 4

No easy method for bearing testing on manufacturing floor

Data collection and analysis take to long to be feasible for the throughput of Xerox

Try multiple methods and speak with manufacturing to understand needs 2 2 4

Time to collect data is too slow

Data logging too slow, accelerated wear is insufficient

Seek accelerated wear and ensure data loggers are sensitive enough 2 2 4

Project goes over budget

Sensors, raw materials and tooling are more expensive than thought

Before purchasing submit a proposed budget to Xerox 2 2 4

Measurement system fails Xerox standards

Not enough collected data or to much inherent noise

Speak with Erwin and Melissa to ensure our measurement is up to spec 3 1 3

Sensors are lost, stolen or damaged Theft, accidents, neglect. Keep equipment secured at Xerox or RIT 3 1 3Customer is unhappy with deliverables Poor Communication

Maintain communications with Xerox throughout the project 3 1 3

Team member is seriously injured or ill Sickness, death in family, etc..

Be prepared to delegate that person's responsibilities across the team 2 1 2

Software is lost or corrupted Loss of flash drive or virus Keep multiple, up to date copies 2 1 2

Team arguments cause delays Poor CommunicationAllow for time to discuss ideas and concerns 2 1 2

Travel to Xerox is preventedWeather, Xerox emergency, RIT emergency.

Leave room in project timeline so that project does not hinge on any single day at Xerox 1 1 1

Concept Generation Ideas Functions 1 2 3 4 5 6

Mount Bearing On Fuser Roll Vice: Fixed Inner Race Vice: Fixed Outer Race Short fuser

Load Bearing Pnumatic Cylinder Camshaft 600lb weight spring gear strap load

Heat Bearing forced convection lasers conduction to outer surface conduction to inner surface lasers preheat

Motor Type DC DC w/encoder DC w/feedback AC

Rotate bearing at speed belt motor with gear box motor directly driven chain driven spin by hand

Measure Vibration accelerometer accoustics proximity listening

Measure Temperature thermocouple thermister IR sensor Feel

Acquire Data Data Logger (A to D) Microcontroller Pen and Paper

Process Data Custom Program Matlab LabView

Concept SelectionSenior Design Team P11511 Pugh Matrix, January 2011

Option 1 Option 2 Option 3 Option 4Vice: Fixed Inner Race Vice: Fixed Outer Race Vice: Fixed Outer Race Vice: Fixed Outer RacePnumatic Cylinder spring strap load CamshaftDC w/encoder DC DC w/encoder ACconduction to outer surface lasers preheat preheatbelt Linked to gear box Linked to gear box chain drivenaccelerometer proximity accelerometer accoustics

thermocouple IR sensor thermister thermocoupleData Logger (A to D) Microcontroller Microcontroller Microcontroller

LabView Custom Program LabView LabView

+ - 0 0

- - + 0+ + + 0

Ease of use 0 0 0 00 - 0 0

Safety + - 0 0Sampling time 0 0 0 0Cost 0 - + 0Modularity/Adaptability 0 0 - 0Durability - + - 0Mobilty 0 0 0 0Repairbility - - - 0

Total Positives: 3 2 3 0Total Negatives: 3 6 3 0

Concept Name:

Mount Bearing

Signal Noise

Accuracy

Motor type

Complexity

Technology Risk

Load Bearing

Heat BearingRotate bearing at Measure Vibration

Measure Temperature

Acquire Data

Process Data

Concept Selection

• Design chosen– Fixed Outer Race– Camshaft– DC motor– Conduction to outer surface– Belt– Accelerometer– Thermistor– Microcontroller– Labview

House of QualityMount BearingLoad Bearing +Heat Bearing +Motor TypeRotate bearing at speed - + ++Measure Vibration + + + -Measure Temperature ++ +Acquire Data + +Process Data +

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Develop method to characterize physical properties of bearings over their physical life 22.2 3 3 3 1 3 9 9 9 9Collect data on bearing properties 8.3 1 3 3 1 3 9 9 9 9Correlate physical property to end of life 11.1 0 1 1 1 1 3 3 3 3Encorporate multiple sensors 13.9 0 0 0 1 0 9 9 9 3Characterize physical properties over the bearing's physical life 5.6 0 9 9 1 3 9 9 9 9Create failure criteria 2.8 0 1 1 1 1 1 1 9 9Document the procedure (Testing) 16.7 1 0 0 1 1 3 3 3 9Testing bearings is quick and easy to do 0.0 3 0 0 3 1 0 0 0 0Document the procedure (Collecting Data) 19.4 1 0 0 1 1 3 3 3 9

Importance 1.11 1.558 1.558 1 1.583 5.944 5.944 6.168 7.5

System Level Drawing

Timeline

Questions?

P11511 Senior Design Review

Thank you for attending!

Loading the Bearing

• Total load seen by the bearing = 360lbs– Pressure roll force: 1200lb (600lb/bearing)– Heat roll force: 184lb/roll– Angle between heat rolls: 60°

• Using a pneumatic cylinder to apply load– Sized according to force needed (plus weight of object applying load)– Pressure regulator will be used to adjust air pressure applied to

cylinder– Maximum pressure available = ~75psi

Sizing the pneumatic cylinder• Force needed = 370lb (assuming 10lb weight of bearing “pusher”)• Distance to apply force = small• Pressure available = 75psi• Formulas used:

– F = P * A– A = π * r2

• Cylinder bore needed for 75psi = 2.506in2

• Want to stay under maximum pressure available Use 3.00” bore• Pressure needed for 3.00” bore cylinder = 52.3psi• Use pressure regulator to adjust pressure if needed

– Pressure regulator can have pressure gauge attached

• Parker “Pancake Style” pneumatic cylinder (3.0NLPR9X1.00)– Bore size: 3.00”– Stroke size: 1.00”– Rod thread size: 5/8-18 female– Height: 2.625”– Cost: $181.67– Source: MSC Direct

Pneumatic Cylinder

Pressure Regulator• Jupiter Pneumatics Air pressure regulator with pressure gauge

(4710302535JP)– Port Size: 1/4”– Maximum PSI: 120psi– Width: 1.97”– Height: 1.97”– Cost: $11.36– Source: MSC Direct

Pushing Rod• 5/8”-18 Threaded Stud (91187A650)

– Thread: 5/8”-18– Material: 18-8 SS– Overall Length: 12”– Cost: $13.33– Source: McMaster-Carr

Bearing “Pusher” and Sensor Holder

• Made from (1) 6” x 6” x 1” Aluminum Plate (89155K971)

– Material: Aluminum 6061– Both pieces cut from 1 plate– 1/8” width x 1/16” depth keys on both sides

for guide rails– Oversized hole for pushing rod on bottom

Guide Rails• Precision shaft with keyhole (7398K22)

– Shaft diameter: 1/2”– Material: 304 SS– Overall Length: 12”– 1/8” width x 1/16” depth keyhole– Will need to tap hole into bottom for

mounting– Cost: $44.32 ($22.16ea)– Source: McMaster-Carr

Mounting Plate• Made from (1) 8” x 8” x 1” Aluminum Plate (9246K61)

– Material: Aluminum 6061– Holes mount guide rails and pneumatic cylinder– Countersunk holes from the bottom allow mounting to another

table– Mounting holes spaced at 3” and 6” distances for mounting to table

with inch spacing mounting holes– Cost: $47.00– Source: McMaster-Carr

Loading Bearing BOM

Item Part Description Supplier Part # # Needed Price Per Unit Total Price Part

1 "Pancake Style" Pneumatic Cylinder (3.00" Bore, 1.0" Stroke) MSC 3.0NLPR9X1.00 1 $181.67 each $181.67 Pneumatic Cylinder2 Air Regulator with Pressure Gauge MSC 4710302535JP 1 $11.36 each $11.36 Pressure Regulator3 Threaded Rod - 5/8-18 x 12" McMaster 91187A650 1 $13.33 each $13.33 Pushing Rod4 6" x 6" x 1" Aluminum Plate McMaster 89155K971 1 $35.53 each $35.53 Pushing Half and Sensor Half5 Precision Shaft 304SS 1/2" x 12" McMaster 7398K22 2 $22.16 each $44.32 Guide Rails6 8" x 8" x 1" Aluminum Plate McMaster 9246K61 1 $47.00 each $47.00 Mounting Plate

Total: $333.21