P10511: Miniaturization of Xerography

Derek Meinke (ME, PM)Matthew Liff (ME)

Tony Zhang (EE)Zaw Htoo (ISE)

Project DescriptionThe scope of P10511 is to create a test fixture

that will allow the use of various charging devices along with multiple diameters of photoreceptors.

Test affect of charge uniformity with various device configurations and input parameters.

Xerox test fixture is currently limited in versatility.

Project Description (cont.)Reasons for Reducing Drum

Diameter Advances in Charging Technologies Reducing Wear Rate of

Photoreceptor Higher Rotational Speeds for Higher

PPM Reduced Footprint for Charging

Devices Cost Effective Increased Reliability

System ObjectivesDifferent Charger

Configurations BCR versus Scorotron

Photoreceptor Diameter

Variable Drum Speed Ion Transfer

Charge Measurement (ESV)

Roles and ResponsibilitiesName Discipline Role / Skills

Mike Zona and Bill Nowak

Xerox Faculty Guide, will work closely with the team on an on-going basis to facilitate success.

Marcos Esterman Xerox Faculty Consultant, will provide discipline technical support on an intermittant basis.

Dale Mashtare Xerox Industrial Consultant

Derek Meinke ME Project Manager, fixture design, charge device mounting, drum to motor coupling.

Matthew Liff ME Fixture design, charge device mounting, drum to motor coupling.

Tony Zhang EE Electrical integration of high voltage and drive motor to data acquisition.

Zaw Htoo ISE Labview coder for user interface and system control/status.

Team Values and NormsReasonably late to

meetings is acceptable but not repeatable. Leave a message for a team member if cannot attend.

At start of meeting, discuss team objectives for 5 to 10 minutes.

CC all group members when emailing project information; respond within 24 hours.

An understood consensus must be made for all decision making.

Record meeting minutes.

Customer’s House of Quality

Customer Requirements Customer Weights

Voltage

Input (5-

8kV)

Surface

Speed (≤1m/

s)

Drum Size (24-

84mm)

Charger

Type (BCR

or Scorot

ron)

Charger Gap

(1-2mm)

Dielectric

Thickness

(~25µm)

ESV distance (1-2mm)

Budget ($2k)

Uniform

Erase Charg

e (-100V)

Surface

Charge (-

300 to -

800V)

Allow any charge device config 13% 3 3 3 9 9 1  9 1 3

Easily changeable components 11%     9 9 9  3 9 1 

Allow different dielectric thicknesses 11% 1 3 3  1 9 1  3 3

Voltage reading across entire drum length 9%     3      3 1  1

Parallel ESV axis with photoreceptor 8%     3    1 9 1  9

Easy to use data acquisition menu 8%                    

Repeatability 8%                    

Data for both aluminum substrate and prod. PR 8% 9 9 1  3 9 1 1 3 9

Uniform pre-charge erase 7%   3 1  3 1    9 3

Accurate drum speed control 6% 1 9 3 3 9 3  3 9 9

Proper safety measures 4% 9 1  1           

Alignment of charger with photoreceptor 4%   9 1 3 9 1 9 3 1 3

Accept multiple photoreceptor diameters 3% 1 9 9 1 9 3 9 9 9 3

Below target budget 1%   3 9 9 1  1 9  1

Generate minimal ozone 0% 9    9      1  3

Customer Needs ListCustomer Needs Important

Allow any charge device config 13%

Easily changeable components 11%

Allow different dielectric thicknesses 11%

Voltage reading across entire drum length 9%

Parallel ESV axis with photoreceptor 8%

Easy to use data acquisition menu 8%

Repeatability 8%

Data for both aluminum substrate and prod. PR 8%

Uniform pre-charge erase 7%

Accurate drum speed control 6%

Proper safety measures 4%

Alignment of charger with photoreceptor 4%

Accept multiple photoreceptor diameters 3%

Below target budget 1%

Generate minimal ozone 0%

Specifications ListEngineering Specification Importance

Voltage Input (5-8kV) 5%

Surface Speed (≤1m/s) 13%

Drum Size (24-84mm) 9%

Charger Type (BCR or Scorotron) 8%

Charger Gap (1-2mm) 15%

Dielectric Thickness (~25µm) 5%

ESV distance (1-2mm) 10%

Budget ($2k) 11%

Uniform Erase Charge (-100V) 13%

Surface Charge (-300 to -800V) 11%

Risk AssessmentRisk Management Table - Revision 1 - 12/17/2009

ID Risk Item

Likelyhood

Severit

y

Importance Action to Minimize Risk Owner

6 Faulty equipment 2 2 4Obtain quality equipment, look into obtaining MSD locker All members

7ESV/Erase Lamp/Charger gap problems 2 2 4

Run multiple tests to determine best location, have faculty guide review fixture, make it variable Mechanical Engineer

8 Weather affecting travel 2 1 2

Have good communication, use Tortoise SVN and EDGE, online chat discussions available All members

9 Customer priority changes 1 2 2 Constant communication with customer All members

14 Hard to change components 2 3 6Create a manual, use more clips than screws Mechnaical Engineer

15Aluminum substrate is in contact with motor ground 1 3 3

Include a switch, use insulating material at contact, generate many concepts

Mechanical / Electrical Engineer

18 Lack of Labview skillset 3 2 6Additional research time, utilize faculty expertise

Industrial Systems Engineer

*19 total risks so far

Project Plan

Concept Generation (ME)

Concept Generation (ME)

Concept Generation (ME)

Concept Generation (EE)Power supplies will be provided to us from

our customer, Xerox.Trek Cor-a-trol Model 610C High Voltage

Supply o High Voltage Supply (0 to ±10kV)o Current Supply (0 to 2mA rms)

Concept Generation (EE)Recommended motors and specs have also

been provided. For Photoreceptor Drive (S83-93)

For ESV slide (S57-51)

Closer Look at the MotorsPhotoreceptor Drive: S83-

93

Minimal Required Torque 9 Pin Connector to Voltage

Supply Requires isolating motor

ground from power supply.

Motors (cont.)

ESV Drive: S57-51

Delivers required torque for rotating threaded shaft

See next slide for the workings of the ESV unit

Selecting a DAQ DeviceData Acquisition & Analysis requires a few

steps:

Factors for Consideration

Bill of Materials (EE & ISE)FOR THE MOTORS

Motor Controller (NI PCI-7332) $899.00 Description: PCI / 2-Axis http://sine.ni.com/nips/cds/view/p/lang/en/nid/14338

Stepper Motor Drive (NI P70530) $349.00 (x2) = $698.00 Description: 1-Axis / 300 Watts http://

sine.ni.com/nips/cds/view/p/lang/en/nid/203933

Total = $1597.00

Bill of Materials (cont.)FOR THE DAQ

Multifunction Data Acquisition Device (NI USB-6009) $279.00 Inputs: 8 Analog / 12 Digital Outputs: 2 Analog / 12 Digital USB Connection http://sine.ni.com/nips/cds/view/p/lang/en/nid/14605

#overviewTotal = $1597.00 + $279.00 = $1876.00

Input and Output (ISE & EE)Input Data Output (Uniformity) Output (I-V Slope)

Start / Stop Voltage Current

Type of Test ( Uniformity / I-V Slope)

Range of Uniformity Slope of Current Vs Voltage

Length of Device Slope of Voltage Across P/R

Voltage Intercept

Diameter of Device (mm)

Graph (Voltage Vs length of P/R)

Graph (Current Vs Voltage)

Speed of P/R (m/s)

V-Plate Voltage (KV)

Report

LabView User Interface

System Flow (EE & ISE)

Unknowns and Open Issues

Action Items

Questions?