P09503 Electrophotographic Development and Transfer Station

Team Members NameDisciplineRole David SchwartzISETeam Lead – Warning Signs Ruth GayMEPaper Delivery System Phillip LopezMEOzone Filter Dan SummersMEME Support Rachel ChrashEELED Exposure System Min-Shi HsiaoEEPC Potential Measurement Andrew KearnsEETransfer Drum Speed Measurement, Camera System Sasha OliverCEUser Interface

Project Background Project Family ▫ Printing and Imaging Systems Technologies Track Customer ▫ Print Research and Imaging Science Modeling Laboratory (PRISM)  The Print Research and Imaging Systems Modeling lab will serve as a conduit between industry and academia, working to evaluate and anticipate the print systems research needs of printer and printing product companies, and directing relevant projects to researchers and students in the areas of Printers & Displays, Color Science, Vision Science, Systems Engineering, and Printing.  Contact: Dr. Marcos Esterman – Associate Professor, Industrial and Systems Engineering

Project Description Working Electrophotographic station to vary both the printing material and the printing process parameters as to better understand and improve the performance of similar printing systems. End Users  PRISM Lab  Center for Imaging Science Deliverables 1.An inventory and status of current sub-systems, including needed support systems. 2.A working Electrophotographic Station. 3.Demonstrably improved device safety. 4.An improved user interface (includes control and display functions) 5.Device documented for use, maintenance and upgrade of the device (User & Lab Technician Manual) 6.Demonstrably Improved Sensing and Control Subsystem

What is Electrophotography? Electrophotography is base technology that is used in many modern day copiers and printers Six Step Process to transfer an electrostatic image to a final printed page ▫ Charging ▫ Exposure ▫ Development ▫ Transfer ▫ Fusing ▫ Cleaning P09503 only includes the first four

Electrophotographic and Development Station

Charging Exposure DevelopmentTransfer

Consultants RIT FacultyProfessional Jonathon Arney, Ph.D ▫ Center for Imaging Science  Physical & Optical Measurements Susan Farnand, Ph.D ▫ Center for Imaging Science  Color and Vision Science John D. Wellin ▫ Mechanical Engineering  Control Systems Marcos Esterman, Ph.D ▫ Industrial and Systems Engineering  Product & Process Development Bill Nowak – Xerox ▫ Principle Engineer  Motion and Quality Systems Gregory Miller – Kodak ▫ Software Engineer

Customer Needs & Functional Diagram 1. Is Operational 2. Is Safe 3. Minimize user Intervention 4. Can Monitor Key Process Parameters 5. Can operate and monitor machine from one interface 6. Easy to learn to use

Ozone Fan/Filter Assembly Reduce and Secure Ozone Test Stand ▫ Ozone hazardous to humans if exposed to enough ▫ Law states maximum ozone in A/C Space is 0.05 ppm ▫ >0.200 ppm increases risk of health issues Two Options ▫ Verify current system or ▫ Implementation of further improvement to control Ozone Levels

Monitoring Potential on Photoconductor Monitoring potential of photosensitive material will help characterize exposure input noise source Charge v. Exposure plot after measurement can be viewed Dark Decay Research Possible

LED Exposure System LED Print Heads used in copiers and printers to expose Photosensitive Material are commonly used LED Exposure system to replace current incandescent system Advantages ▫ More versatile and reliable light source ▫ Low Power Consumption ▫ Longer Bulb Life ▫ No potential for overheat ▫ Inexpensive to replace

Paper Delivery System Existing roller system requires manually catching paper after application of toner from roller Possible risks of manual handling ▫ Shock Short from High Voltage Roller ▫ Pinch Point of Rollers and Pneumatics ▫ Marred Image Quality

High Visibility Warning Signs Purpose of warning signs ▫ Alert user to specific hazard ▫ Identify how hazard can be avoided Current signs do not accomplish this Remove current warning signs Replace with ISO designed signs Add new ISO signs where needed

Camera System Purpose is to gain understanding of how image is developed onto photoreceptive material Photoreceptive material imaged after development and before transfer

Transfer Roller Speed Measurement Speed of transfer roller critical to timing control and image quality Need to assure that transfer drum rotates at the same speed as the moving photoconductor as to not elongate/condense the image Need to assure that the transfer roller will be in the proper position for transfer to paper

Labview Control Interface Current control system is done via PLC Better solution needed to replace current system with a new user friendly interface ▫ Automatic and Manual Setting Labview uses dataflow programming to define inputs/outputs and execution sequence of the virtual instrument Connect devices directly to DAQ to allow for more robust control

Technical Risk Assessment Data Acquisition Implementation – Coding Complications / Integration with Subsystems ▫ Mitigation: Primary Focus During SD II Obtaining Optimal Parameters (>10) for EP Process ▫ Mitigation: Experimental Design to optimize parameters, Consult with Xerox and CIS Toner and Developer Contamination ▫ Mitigation: Implement Air Filtration System and Warning Signs

Current State of Design Current design meets all feasible customer needs ▫ Customer understands unfeasible needs Current design meets all engineering specifications Budget = $1500 ▫ Total Expenditures < $900 Schedule ▫ On Schedule, no Design Delays

Product Development Process Phase Phase 0: Planning ▫ Completed Phase 1: Concept Development ▫ Completed Phase 2: System Level Design ▫ Completed Phase 3: Detailed Design ▫ Completed Phase 4: Testing and Refinement ▫ Will begin in SD II

Senior Design II Schedule and Milestones MilestoneDurationCompletion Date User Manual Complete14 Days12/18/08 Ozone Decision39 Days1/9/09 PC Potential Measurement Device Complete 35 Days2/10/09 LED Complete29 Days2/2/09 Paper Delivery System Complete 43 Days2/20/09 Warning Signs Complete18 Days1/7/09 Labview/Camera/Speed Complete 73 Days3/25/08

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