1. iGen Fuser Bearing Project P11511

2. Agenda Meeting Timetable Start Time Review Topic 2:20 Introductions
2:25
Project Description
2:35
Customer Needs
2:40
Risk Assessments
2:55
Concept Selection
3:10
Houses of Quality
3:20
Timeline
3:30
Discussion
3:45
Meeting Adjourned

3. Project Team, Faculty, and Customer
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

4. iGen Machine

6. Running Conditions of Fuser
Xroller forces are 184lbs each
Reaction force of 360lbs/bearing
Fuser rotates at 79.8RPM
Outer race of the fuser bearings experience a temperature of 230°F

7. Customer Needs
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)

8. Weighted 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

9. Project Scope
Create a measuring tool to aid Xerox Corporation’s engineering team in collecting necessary data for characterizing bearing life in the iGen Fuser Assembly

10. Engineering Specs

11. Bearing Life

12. Risks Risk Cause Mitigation Severity Likelihood Total
Data does not correlate
No relationship exists between physical metric and bearing life
Try multiple methods of data collection (acoustic, mag, proximity, etc..) 3 2 6
Bearing life fixtures break
Use, mechanical wear
Ensure proper training and seek rapid repair 4
Our testing apparatus breaks
Design error, mechanical wear, user error
Design robustly and be prepared with replacement parts
Needed item's lead time goes outside of project time frame
Manufacturing delays
Ask manufactures for an estimate for lead time and stay in contact for updates
No easy method for bearing testing on manufacturing floor
Data collection and analysis take to long to be feasible for the throughput of Xerox
Try multiple methods and speak with manufacturing to understand needs
Time to collect data is too slow
Data logging too slow, accelerated wear is insufficient
Seek accelerated wear and ensure data loggers are sensitive enough
Project goes over budget
Sensors, raw materials and tooling are more expensive than thought
Before purchasing submit a proposed budget to Xerox
Measurement system fails Xerox standards
Not enough collected data or to much inherent noise
Speak with Erwin and Melissa to ensure our measurement is up to spec 1
Sensors are lost, stolen or damaged
Theft, accidents, neglect.
Keep equipment secured at Xerox or RIT
Customer is unhappy with deliverables
Poor Communication
Maintain communications with Xerox throughout the project
Team member is seriously injured or ill
Sickness, death in family, etc..
Be prepared to delegate that person's responsibilities across the team
Software is lost or corrupted
Loss of flash drive or virus
Keep multiple, up to date copies
Team arguments cause delays
Allow for time to discuss ideas and concerns
Travel to Xerox is prevented
Weather, Xerox emergency, RIT emergency.
Leave room in project timeline so that project does not hinge on any single day at Xerox

13. Concept Generation

14. Concept Selection

15. Concept Selection Design chosen Fixed Outer Race Camshaft DC motor
Conduction to outer surface
Belt
Accelerometer
Thermistor
Microcontroller
Labview

16. House of Quality

17. System Level Drawing

18. Timeline

19. Questions?

20. Thank you for attending!
P11511 Senior Design Review
Thank you for attending!

21. Loading the Bearing Total load seen by the bearing = 360lbs
Pressure roll force: 1200lb (600lb/bearing)
Heat roll force: 184lb/roll
Angle between heat rolls: 60°
Using a pneumatic cylinder to apply load
Sized according to force needed (plus weight of object applying load)
Pressure regulator will be used to adjust air pressure applied to cylinder
Maximum pressure available = ~75psi

22. Sizing the pneumatic cylinder
Force needed = 370lb (assuming 10lb weight of bearing “pusher”)
Distance to apply force = small
Pressure available = 75psi
Formulas used:
F = P * A
A = π * r2
Cylinder bore needed for 75psi = 2.506in2
Want to stay under maximum pressure available  Use 3.00” bore
Pressure needed for 3.00” bore cylinder = 52.3psi
Use pressure regulator to adjust pressure if needed
Pressure regulator can have pressure gauge attached

23. Pneumatic Cylinder
Parker “Pancake Style” pneumatic cylinder (3.0NLPR9X1.00)
Bore size: 3.00”
Stroke size: 1.00”
Rod thread size: 5/8-18 female
Height: 2.625”
Cost: $181.67
Source: MSC Direct

24. Pressure Regulator
Jupiter Pneumatics Air pressure regulator with pressure gauge ( JP)
Port Size: 1/4”
Maximum PSI: 120psi
Width: 1.97”
Height: 1.97”
Cost: $11.36
Source: MSC Direct

25. Pushing Rod 5/8”-18 Threaded Stud (91187A650) Thread: 5/8”-18
Material: 18-8 SS
Overall Length: 12”
Cost: $13.33
Source: McMaster-Carr

26. Bearing “Pusher” and Sensor Holder
Made from (1) 6” x 6” x 1” Aluminum Plate (89155K971)
Material: Aluminum 6061
Both pieces cut from 1 plate
1/8” width x 1/16” depth keys on both sides for guide rails
Oversized hole for pushing rod on bottom

27. Guide Rails Precision shaft with keyhole (7398K22)
Shaft diameter: 1/2”
Material: 304 SS
Overall Length: 12”
1/8” width x 1/16” depth keyhole
Will need to tap hole into bottom for mounting
Cost: $44.32 ($22.16ea)
Source: McMaster-Carr

28. Mounting Plate Made from (1) 8” x 8” x 1” Aluminum Plate (9246K61)
Material: Aluminum 6061
Holes mount guide rails and pneumatic cylinder
Countersunk holes from the bottom allow mounting to another table
Mounting holes spaced at 3” and 6” distances for mounting to table with inch spacing mounting holes
Cost: $47.00
Source: McMaster-Carr

29. Loading Bearing BOM