P11511 Project Review

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

Project Description Create a measuring tool to aid Xerox Corporations engineering team in collecting necessary data for characterizing bearing life in the iGen Fuser assembly.

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 ✓

Customer Needs – cont’d 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) ✓

Engineering Specs Engineering MetricsUnitsTechnical Targets Measurement of VibrationgTBD Measurement of AccelerationgTBD Measurement of Temperature °F TBD Error of Measurements%< 5% Time to Take MeasurementssTBD Applied Loadlb360lb Applied Temperature °F230°F FrequencyRPM79.8RPM Notes: No longer heating the bearing Temperature measurements will still be taken Time to take measurements is still TBD

Concept Summary Design chosen – Fixed Outer Race – Loading the bearing - Pneumatic cylinder – Rotating the bearing - DC motor – Heating the bearing - Conduction to outer surface – Driving shaft - Belt – Measuring vibration - Accelerometer – Measuring heat - Thermistor – Microcontroller – Labview

Final Product

Project Status Working – Motor spins bearing at specified speed – Pneumatic cylinder loads bearing at specified load – Accelerometer measures vibrations – Thermistors measure temperature – LabView collects data Not Working – Bearing is not heated to spec

Project Schedule The project is 2 weeks behind, with first round of testing occurring in week 10 instead of week 8 Data is not going to be collected by our group

Project Budget Starting budget was $3000 Ending balance is $88.95 Used ~97%

System Architecture

LabVIEW Interface Labview Interface displaying running conditions, waveforms, and expected frequencies. Likely to be updated as debugging and refinement is continued Industry Standard for easy portability and future modifications Waveforms shown are from sample data.

Control System All electronics and pnumatic controls housed in enclosed PVC “junction box” Device fed on a single standard wall outlet Warning and status indicators on front panel Emergency stop button that will kill all power to system Modular architecture will allow for portability and quick set up and tear down.

Project Wrap Up Successes Established a working relationship with multiple engineers at the Xerox Corporation Gained extensive experience in different machining operations Became more familiar with the LabVIEW program as well as interfacing hardware with software Design met most specifications Worked together well as a team throughout the project

Project Wrap Up Failures Due to the uneven geometry, we decided to eliminate the heater due to concerns of interference in the fixture Due to time constraints, extensive data was not able to be collected We were not able to correlate bearing life with the data our fixture provided

Future Work Heating the bearing – As described previously, the mica band heater was eliminated from the tester – A different type of heater (cartridge heater) or alternate manufacture can be selected but care must be taken that the tolerances are tighter than the one previously chosen Correlating bearing life with data – Extensive testing must be performed before bearing life can be coordinated with the data provided by the tester

Future Work Cont’d LabVIEW Interface – Further debugging and refinement required Mounted bearings – Mounting bearings create interference and it would be ideal to eliminate them in a future design if possible Loading/Unloading bearings – Bearings can be made easier to replace to streamline testing procedures

Lessons Learned Take what manufacturers say with a grain of salt. Lead times and design specs Customer needs can be more ambitious than time allows. Keeping good meeting minutes is important for staying organized.

P11511 Senior Project Review Thank you for attending!