May 10, 2013P Xerox Bearing Tester Final Project Review

May 10, 2013P Project Team and Stakeholders Customer Erwin RuizTechnical Specialist Project Manager Xerox Corporation Guide William NowakPrinciple Engineer Xerox Corporation Faculty Consultant Jason KolodziejRIT ME Faculty Project Team Stephen Rugg Project Manager Will CraigProject Engineer Andrew ShumanProject Engineer Kevin AlbinoProject Engineer Lauren KaczorProject Engineer Tyler HillProject Engineer

May 10, 2013P Project Background There are 2 Bearings in the iGen Printer System supporting the fuser roller Every 200,000 prints the fuser roller assembly comes in for remanufacturing Bearing is reused a maximum of 4 times Currently, there is no quantitative test to qualify bearings – Potentially leads to many good bearings being scrapped Customer wishes to use the machine as a design tool

May 10, 2013P Updated Customer Needs

May 10, 2013P Specifications

May 10, 2013P Operation Alignment Procedure Assembly Procedure Testing Procedure

May 10, 2013P Machining: Drawings are contained in drawing package Manual Machining – Motor Block – Mandrels (press and slip fit) – Arbor press fixtures – Clamp attachment – Clamp frame CNC Machining – Clamp bore

May 10, 2013P Data Acquisition Designed a signal conditioner to power accelerometers Pairs with NI 6210 DAQ DAQ outputs accelerometer readings and motor speed Saved $350 Concerns: Imaginary signal at ~4300Hz The signal is not AC coupled Recommendations: Option 1 Use PICO 5A24S chip to increase voltage from 5 to 24V Add a range of capacitors from voltage signal to act as dampers Option 2 Purchase a signal conditioner

May 10, 2013P LabVIEW Bandpass filter from1000Hz to 7500Hz Plots of raw data and FFT Display averaged RMS values

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May 10, 2013P Testing Performed 10+ MSAs Refined SOP Passed MSA using 3 bearings and 7 operators Testing Conditions: Run for 15 sec at 1000rpm Average 5 seconds of overall RMS data Collect a data point at 15 sec and compare against pass/fail criteria

May 10, 2013P Data RMS between 0.1 and 0.7 g’s 13 ranges of resolution – Differentiate ±0.025 g Acoustic machine passed all “good” and “bad” bearings

May 10, 2013P Dry Bearing v. Greased Bearing Grease acts as damping Vibration relative to one another doesn’t change

May 10, 2013P Calibration Purchase a new bearing and remove grease Collect vibration readings on the bearing Bearing can be used to calibrate the system

May 10, 2013P Budget Overall Budget - $1500-$3000 Final Cost Breakdown – Data Collection$ – Physical Structure$ – Shipping$75.66 – Total$

May 10, 2013P Recommendations-Operations Establish pass/fail threshold for bearings – Send a range of bearings to Arnprior Further automate process – Use motor controller with computer input – Use an actuator to apply an axial load to the top and the bottom of the clamp Purchase a new signal conditioner Remove second accelerometer and drop down rails – Stiffen the system, reduce outside vibration

May 10, 2013P Recommendations - Hardware Bearing Clamp – Harden bolt surface on the aluminum clamp or make a new clamp out of steel – Enlarge dowel pins to restrict movement of the top plate Purchase a hardened shaft Manufacture a second press-fit mandrel – May slightly increase test speed if desired Purchase larger arbor press – Easier to press bearings

May 10, 2013P Thank You! Xerox Bill Nowak Erwin Ruiz Dr. Kolodziej Dr. Boedo Dr. Ghoneim RIT Machine Shop-Rob Kraynik, Dave Hathaway, Jan Maneti MSD Lab

May 10, 2013P References 1. Capacity/dp/B0071ARFWS

May 10, 2013P Appendix: Bearing Slippage on Acoustic Machine The slippage is noticeable on the bearing. If there was no slippage the two pink post-it notes would track together. The inside pink post-it disappears because it is spinning much faster than the outside one. Concerned that this will affect the accuracy and consistency of the measurement.

May 10, 2013P Technical Paper The technical paper discusses the whole of the project in detail along with the testing that was conducted and the reason the current design was settled upon.