1. iGen Fuser Bearing Project P11511

2. Agenda Meeting Timetable Start Time Review Topic 3:30Introductions 3:35Project Description 3:45Customer Needs 4:00Risk Assessments 4:10Concept Selection 4:30Houses of Quality 4:35Timeline 4:40Discussion 5:00Meeting Adjourned

3. 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 Corporation Erwin Ruiz Melissa Monahan

4. Project Background Xerox is looking to reduce costs caused by replacing bearings Xerox originally looked into evaluating the bearings of different manufacturers The Fuser bearings on Xerox iGen printers currently undergo a very subjective test

5. iGen Machine

7. Running Conditions of Fuser When fuser assembly is fully “cammed” in, the fuser roll experiences an axial load of 1200lbs (600lb/bearing) Fuser rotates at 79.8RPM Outer race of the fuser bearings experience a temperature of 230°F

8. Bearing Life Based on bearing data sheet, minimum life is 1,000,000 revolutions – LU10 DLIFE tested at 16,672N (3748lb) Due to current testing methods, bearings are assumed “failed” after 200,000 revolutions Xerox Corporation’s goal is to achieve a life of at least 800,000 revolutions

9. Customer Wants Want to reduce costs – Want to better understand the capabilities of the current bearings – Want to compare bearings from different manufacturers – Ensure no bearings fail in the field

10. Project Scope Time constraints do not allow our team to collect all the pertinent data – To qualify with Xerox Corporation’s quality standards, 1,000+ measurements are required Develop a test plan for Xerox Corporation to collect and correlate physical data of bearings Propose test method for manufacturing to implement that will replace current “spin test”

11. Customer Needs A method to characterize physical properties of bearings over their physical life Collect data on bearing properties – Correlate physical property to failures – Characterize physical properties over the bearing's physical life – Determine running cost for each bearing – Create failure criteria for each bearing – Evaluate bearings from different manufacturers Develop method for manufacturing to test bearings for immanent failures – Document the procedure – Testing bearings is quick and easy to do

12. Weighted Customer Needs Used a pairwise comparison chart Most Important Needs: – Create method to characterize bearing properties over physical life – Document the procedure for collecting data

13. Engineering Specs

14. Risks RiskCauseMitigationSeverityLikelihoodTotal Data does not correlate No relationship exists between physical metric and bearing life Try multiple methods of data collection (acoustic, mag, proximity, etc..)326 Bearing life fixtures breakUse, mechanical wear Ensure proper training and seek rapid repair224 Our testing apparatus breaks Design error, mechanical wear, user error Design robustly and be prepared with replacement parts224 Needed item's lead time goes outside of project time frameManufacturing delays Ask manufactures for an estimate for lead time and stay in contact for updates224 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 needs224 Time to collect data is too slow Data logging too slow, accelerated wear is insufficient Seek accelerated wear and ensure data loggers are sensitive enough224 Project goes over budget Sensors, raw materials and tooling are more expensive than thought Before purchasing submit a proposed budget to Xerox224 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 spec313 Sensors are lost, stolen or damagedTheft, accidents, neglect.Keep equipment secured at Xerox or RIT313 Customer is unhappy with deliverablesPoor Communication Maintain communications with Xerox throughout the project313 Team member is seriously injured or illSickness, death in family, etc.. Be prepared to delegate that person's responsibilities across the team212 Software is lost or corruptedLoss of flash drive or virusKeep multiple, up to date copies212 Team arguments cause delaysPoor Communication Allow for time to discuss ideas and concerns212 Travel to Xerox is prevented Weather, Xerox emergency, RIT emergency. Leave room in project timeline so that project does not hinge on any single day at Xerox111

15. Concept Generation

16. Concept Selection

17. Helped isolate design concepts that had merit for project There were multiple viable solutions A major risk of the project is that there could be no correlation between data – Reduce this risk by pursuing several measurement technologies

18. Concept Selection Acoustic Fixture Attach accelerometers to current life fixture Making a fixture to subject bearings to expected loads – Will be designed with attaching accelerometers and thermocouples in mind Torque Fixture – Quantify data from “spin test”

19. Acoustic House of Quality

20. Life Tester House of Quality

21. Torque House of Quality

23. Questions?

24. P11511 Senior Design Review Thank you for attending!