P10511: Miniaturization of Xerography Derek Meinke (ME, PM) Matthew Liff (ME) Tony Zhang (EE) Zaw Htoo (ISE)

Project Description The 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 Objectives Different Charger Configurations BCR versus Scorotron Photoreceptor Diameter Variable Drum Speed Ion Transfer Charge Measurement (ESV)

Roles and Responsibilities Name 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 Faculty Consultant, will provide discipline technical support on an intermittant basis. Dale Mashtare Industrial Consultant Derek Meinke ME Project Manager, fixture design, charge device mounting, drum to motor coupling. Matthew Liff 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 Norms Reasonably 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 Scorotron) Charger Gap (1-2mm) Dielectric Thickness (~25µm) ESV distance (1-2mm) Budget ($2k) Uniform Erase Charge (-100V) Surface Charge (-300 to -800V) Allow any charge device config 13% 3 9 1   Easily changeable components 11% Allow different dielectric thicknesses Voltage reading across entire drum length 9% Parallel ESV axis with photoreceptor 8% Easy to use data acquisition menu Repeatability Data for both aluminum substrate and prod. PR Uniform pre-charge erase 7% Accurate drum speed control 6% Proper safety measures 4% Alignment of charger with photoreceptor Accept multiple photoreceptor diameters 3% Below target budget 1% Generate minimal ozone 0%

Customer Needs List Customer Needs Important Allow any charge device config 13% Easily changeable components 11% Allow different dielectric thicknesses Voltage reading across entire drum length 9% Parallel ESV axis with photoreceptor 8% Easy to use data acquisition menu Repeatability Data for both aluminum substrate and prod. PR Uniform pre-charge erase 7% Accurate drum speed control 6% Proper safety measures 4% Alignment of charger with photoreceptor Accept multiple photoreceptor diameters 3% Below target budget 1% Generate minimal ozone 0%

Engineering Specification Specifications List Engineering 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) ESV distance (1-2mm) 10% Budget ($2k) 11% Uniform Erase Charge (-100V) Surface Charge (-300 to -800V)

Risk Assessment *19 total risks so far Risk Management Table - Revision 1 - 12/17/2009 ID Risk Item Likelyhood Severity Importance Action to Minimize Risk Owner 6 Faulty equipment 2 4 Obtain quality equipment, look into obtaining MSD locker All members 7 ESV/Erase Lamp/Charger gap problems Run multiple tests to determine best location, have faculty guide review fixture, make it variable Mechanical Engineer 8 Weather affecting travel 1 Have good communication, use Tortoise SVN and EDGE, online chat discussions available 9 Customer priority changes Constant communication with customer 14 Hard to change components 3 Create a manual, use more clips than screws Mechnaical Engineer 15 Aluminum substrate is in contact with motor ground Include a switch, use insulating material at contact, generate many concepts Mechanical / Electrical Engineer 18 Lack of Labview skillset Additional 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 High Voltage Supply (0 to ±10kV) 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 Motors Photoreceptor 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 Device Data 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#overview Total = $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?