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

2. 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.

3. 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

4. Roles and Responsibilities NameDisciplineRole / Skills Mike Zona and Bill Nowak Xerox Faculty Guide, will work closely with the team on an on-going basis to facilitate success. Marcos EstermanXerox Faculty Consultant, will provide discipline technical support on an intermittant basis. Dale MashtareXeroxIndustrial Consultant Derek MeinkeME Project Manager, fixture design, charge device mounting, drum to motor coupling. Matthew LiffMEFixture design, charge device mounting, drum to motor coupling. Tony ZhangEE Electrical integration of high voltage and drive motor to data acquisition. Zaw HtooISELabView coder for user interface and system control/status.

5. Customer Needs List Revision #: 4 (1/12/2010) Customer NeedImportanceDescription Allow any charge device config13% Fixture has to accommodate both BCR charger and Scorotron charger with easy interchangeability. Easily changeable components11% Charger and photoreceptor drum should be interchangeable with minimal or easy fixture teardown. Allow different dielectric thicknesses11% Accommodate various dielectric thicknesses on photoreceptor. Voltage reading across entire drum length9% ESV should have 0 point and scan across entire photoreceptor length. Parallel ESV axis with photoreceptor8% A fixture is required for the ESV. It must run lengthwise across the photoreceptor and create a uniform distance from the ESV to the photoreceptor for all distances across the photoreceptor. Easy to use data acquisition menu8% Control interface of the fixture has to be easy to use, with no training required. Repeatability8% Ability to perform the test multiple times with the same results. Data for both aluminum substrate and prod. PR8% The control system should be able to aquire different information of both aluminum substrate and production photoreceptor.

6. Customer Needs List (cont.) Uniform pre-charge erase7% Set photoreceptor surface potential to even charge across receptorlength before charging Accurate drum speed control6% Motor must output speed accurate within an acceptable margin. Proper safety measures4% Ozone and high voltages should be dealt with using all standards of safety and regulations. Alignment of charger with photoreceptor4% After charging process, there should be an equal charge across drum operating in steady state. Accept multiple photoreceptor diameters3% Our fixture must be able to perform the same function for varying diameters of photoreceptors, ranging from 24mm - 84mm Below target budget1% Our principle sponsor, Xerox Corporation, has allowed a $2,000 budget for motion control and data Acquisition components. Generate minimal ozone0% The type of material used in charging device should produce the least amount of ozone by balancing incoming voltage.

7. Customer Specifications List Revision #: 3 (12/11/2009) Engineering Specification Specification (description) Unit of Measure Marginal Value Ideal Value Voltage Input (5-8kV)High voltage power source.kV83 - 8 Surface Speed (≤1m/s) Photoreceptor drum must be controllable for different speeds. mm/se c<1000600 Drum Size (24-84mm) Drums of different diameters will be provided with known range.mm24 - 84 Charger Type (BCR or Scorotron) There are two different chargers we will be focusing on.N/A Charger Gap (1-2mm) Scorotron charger should be fixed with uniform gap.mm1 - 21.5 Dielectric Thickness (~25µm) Different layer thicknesses will be fitted with the photoreceptor.µm25µm ESV distance (1-2mm) The distance the ESV is from the outer surface of the photoreceptor. mm1 - 21.5 Budget ($2k) The amount of money available for purchasing components. $2000<$2000 Uniform Erase Charge (-100V) After being exposed to the erase lamp, the photoreceptor is expected to have an evenly distributed charge across it. V-100 Surface Charge (-300 to -800V) Charge across whole photoreceptor has to be the same.V -300 to - 800

8. 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 config13%333991 913 Easily changeable components11% 999 391 Allow different dielectric thicknesses11%133 191 33 Voltage reading across entire drum length9% 3 31 1 Parallel ESV axis with photoreceptor8% 3 191 9 Easy to use data acquisition menu8% Repeatability8% Data for both aluminum substrate and prod. PR8%991 391139 Uniform pre-charge erase7% 31 31 93 Accurate drum speed control6%193393 399 Proper safety measures4%91 1 Alignment of charger with photoreceptor4% 913919313 Accept multiple photoreceptor diameters3%1991939993 Below target budget1% 3991 19 1 Generate minimal ozone0%9 9 1 3 Customer House of Quality

9. Risk Assessment Risk Management Table - Revision 1 - 12/17/2009 IDRisk Item Likelyhood Severity Importance Action to Minimize RiskOwner 6Faulty equipment224 Obtain quality equipment, look into obtaining MSD lockerAll members 7 ESV/Erase Lamp/Charger gap problems224 Run multiple tests to determine best location, have faculty guide review fixture, make it variableMechanical Engineer 8Weather affecting travel212 Have good communication, use Tortoise SVN and EDGE, online chat discussions availableAll members 9Customer priority changes122Constant communication with customerAll members 14Hard to change components236 Create a manual, use more clips than screwsMechnaical Engineer 15 Aluminum substrate is in contact with motor ground133 Include a switch, use insulating material at contact, generate many concepts Mechanical / Electrical Engineer 18Lack of Labview skillset326 Additional research time, utilize faculty expertise Industrial Systems Engineer

10. Objective Tree

11. Concept Generation: Charger

14. Concept Screening: Charger Concepts (Charger Mount) Plunger Method Plunger Method w/ Hairclip The Doors Double-sided Tape w/ Slide Selection Criteria(reference) Accept multiple PR diameters0000 Easily changeable components0+-+ Below target budget0--+ Allows multiple configurations00-+ Manufacturability0--+ Robustness00+0 Alignment of charger with PR00-+ Repeatability00-+ Proper safety measures0000 Sum + 's0116 Sum 0's9623 Sum -'s0260 Net Score0-56 Rank2341 Continue?yesno yes

15. Concept Selection: Charger Concepts (Charger Mount) Plunger Method Double-sided Tape w/ Slide Selection CriteriaWeightRating Weighted ScoreRating Weighted Score Accept Multiple PR Diameters5%30.153 Easily Changeable Components18%20.3640.72 Below Target Budget3%20.0640.12 Allows Multiple Configurations21%30.6340.84 Manufacturability13%20.2640.52 Robustness13%20.2640.52 Alignment of Charger with PR7%20.1440.28 Repeatability13%10.1330.39 Proper Safety Measures7%30.213 Total Score2.203.75 Rank21 Continue?noyes

16. Concept Generation: Photoreceptor

17. Concept Screening: Photoreceptor Concepts (Photoreceptor Mount) V-Flange w/ Shaft Pins Custom Endcaps w/ Shaft PinsSpring Clamp V-Flange w/ Tooth Grips Selection Criteria (reference) Centering ability00-0 Easily changeable components+00+ Below target budget+0++ Accept multiple diameters-0-- Manufacturability+0++ Robustness+00+ Voltage reading across PR-00- Parallel ESV axis00-0 Alignment of charger w/ PR-0-- Proper safety measures0000 Repeatability00-0 Accurate drum speed control-0-+ Switch btn voltage and ground0000 Uniform pre-charge erase-0-- Sum + 's4025 Sum 0's51455 Sum -'s5074 Net Score0-51 Rank3241 Continue?noyesnoyes

18. Concept Selection: Photoreceptor Concepts (P/R Mount) Custom Endcaps w/ Shaft Pins V-Flange w/ Tooth Grips Spring Loaded Concentric V's Selection CriteriaWeightRating Weighted ScoreRating Weighted ScoreRating Weighted Score Centering Ability11%50.5540.444 Easily Changeable Components11%20.2230.3350.55 Below Target Budget1%0030.033 Accept multiple Diameters4%50.230.1240.16 Manufacturability8%10.0840.3230.24 Robustness8%30.2440.324 Voltage Reading across PR9%50.4520.1850.45 Parallel ESV axis8%50.430.2450.4 Alignment of charger w/ PR5%50.2530.1550.25 Proper safety measures5%40.24 4 Repeatability9%40.3620.1840.36 Accurate drum speed control6%40.2430.183 Switch btn voltage and ground8%50.430.243 Uniform Pre-charge Erase7%50.3530.2150.35 Total Score3.943.144.17 Rank231 Continue?no yes

19. Concept Generation: Erase

20. Concept Screening: Erase Concepts (Erase Mount) Attach Rod SlotsDoorsSliders Selection Criteria(reference) Lightweight0-0 Easily Changeable Components0-0 Below Target Budget0-- Uniform Precharge Erase0-+ Manufacturability0-0 Robustness0+0 Accept Multiple PR Diameters0++ Repeatability0-- Sum + 's022 Sum 0's804 Sum -'s062 Net Score0-40 Rank121 Continue?yesnoyes

21. Concept Selection: Erase Concepts (Erase Mount) Attach Rod SlotsThe DoorsSliders Selection CriteriaWeightRating Weighted ScoreRating Weighted ScoreRating Weighted Score Lightweight12%30.3610.1230.36 Easily Changeable Components17%40.6830.5140.68 Below Target Budget7%40.2820.1440.28 Uniform Precharge Erase14%40.5620.2830.42 Manufacturability14%40.5620.2840.56 Robustness12%30.3640.4830.36 Accept Multiple PR Diameters10%40.430.350.5 Repeatability14%50.720.2840.56 Total Score3.902.393.72 Rank132 Continue?yesno

22. Concept Generation: ESV

23. Concept Screening: ESV Concepts (ESV Mount) Spacing Blocks w/ Leadscrew Driven Slots w/ Leadscrew Spacing Blocks w/ Pulley Drive Spacing Blocks w/ Gear Track Selection Criteria(reference) Lightweight0-+- Easily Changeable Components0-00 Below Target Budget0-+- Gap Distance0-00 Manufacturability0--- Robustness0--0 Voltage Reading Across PR0000 Parallel ESV Axis0000 Repeatability00-0 Sum + 's0020 Sum 0's9346 Sum -'s0633 Net Score0-3-3 Rank1323 Continue?yesnoyesno

24. Concept Selection: ESV Concepts (ESV Mount) Spacing Blocks w/ Leadscrew Spacing Blocks w/ Pulley Drive Selection CriteriaWeightRating Weighted ScoreRating Weighted Score Lightweight10%20.240.4 Easily Changeable Components16%30.483 Below Target Budget4%40.1620.08 Gap Distance12%30.363 Manufacturability12%40.4820.24 Robustness9%50.4520.18 Voltage Reading Across PR13%40.5230.39 Parallel ESV Axis12%30.363 Repeatability12%40.4830.36 Total Score3.492.85 Rank12 Continue?yesno

25. System Level Concept

27. Some Dimensions Length of PR: 360 mm Diameters: 30, 40, 60, 84 mm Charger Width: ≤50 mm Charger Height:  Scorotron: ≤30 mm  BCR: ≤20 mm

28. Input and Output (ISE & EE) Input DataOutput (Uniformity)Output (I-V Slope) Start / StopVoltageCurrent Type of Test ( Uniformity / I-V Slope) Range of UniformitySlope of Current Vs Voltage Length of DeviceSlope of Voltage Across P/RVoltage 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

29. LabVIEW GUI

30. Signal Processing and Flow

31. Closer Look at the Motors  9-Pin Connector from Motor to Voltage Supply  Requires isolating motor ground from voltage supply to aluminum substrate for the S83-93  Indexer will be incorporated in the 2-Axis PCI Motor Controller  Speeds:  ESV Drive: Constant Speed  P/R Drive: Automatically adjusted via LabView according to P/R diameter input and desire speed input (<1 m/s)

32. Motors Dimensions Photoreceptor Drive: S83-93ESV Unit Drive: S57-51

33. Selecting a DAQ Device Data Acquisition & Analysis requires a few steps: Factors for Consideration

34. Bill of Materials (EE)

35. Project Plan

36. Concerns Budget already at $1876 – Only includes motor components and DAQ Substrate isolation is a concern LabView knowledge may not be sufficient

37. Further Questions?