P10505 – Cold Pressure Fusing II System Design Review Team Fusion 1/15/2010.

P10505 – Cold Pressure Fusing IISystem Design Review

Team Fusion1/15/2010

Agenda• Introduce Team [1 minute]• Project Description [3-4 minutes]• Project Flowchart [3-4 minutes]• Customer Needs [5 minutes]• Engineering Specifications [10

minutes]• House of Quality [5 minutes]• Functional Decomposition [10

minutes]• System Architecture [5 minutes]• Concept Selection Flowchart [2-3

minutes]

• Concept Selection [20 minutes]o Skew [10 minutes]o Skew Support [5 minutes]o Paper Weight Adjustability [1-2

minutes]o Compliance [1-2 minutes]

• Final Design [5 minutes]• Risk Assessment [5 minutes]• Design Risks [5 minutes]• Action Items [1-2 minutes]• Next Steps [1-2 minutes]• Questions [5 minutes]

Questions and comments are encouraged throughout the presentation

Project Team, Faculty, & Customer

• Project Memberso Aniket Arora – Project Manager – ISEo David Hatch – Lead Engineer – MEo Jon Burville – MEo Eric Wilcox – MEo Tom Stojanov – EE

• Customero Mr. John Knapp - Xeroxo Mr. Tony Condello - Xerox

• Faculty Guide o Mr. Bill Nowak - Xerox

Project Background/Description• Changing customer

expectations from printers.

• Focus on sustainability (low energy consumption).• Energy Star

• Heat fusing consumes a considerable portion of energy.• Hence, Cold Pressure

Fusing.

• P09505 developed an initial prototype.• Issues with pressure

uniformity

MSD 1

Research Past work

Patent Research

Past work from P09505

Establishing Customer

Needs

Concept Selection

Generation Pugh Concept Selection

Concept Improvement Modeling

Calculate Nip Pressure

Analyze Roller Deflection

Torsion Analysis

Create CAD Model DAQ System

Create Real-time DAQ

System

Interface DAQ with hardware

Present Design

Project Planning

Project Schedule WBS

Project Flowchart MSD 1

Customer Needs

Customer Needs

Engineering SpecificationsEngr. Spec. # Importance Source Specification (description) Unit of Measure Marginal Value Ideal Value

ES1 1 Customer Need Prototype will fuse print across 100% of the pagePercentage fused, Width of unfused, N/A 100% fusing

ES2 1 Customer Need Prototype will vary in nip pressure less than 10%

Width of Pressure Indication, Xerox

Metric 10% variation 5% variation

ES3 1 Customer NeedPrototype must be capable of adjusting to three skew angles Number of Settings 2 angles Analog

ES4 1 Customer NeedPrototype must adhere to Abaqus model created by Xerox Yes/No N/A Yes

ES5 1 Customer Need Prototype must be able to reach a 1.9° skew angle Degrees 1.8°-2.0° 1.9°

ES6 1 Customer NeedPrototype must be adjustable to the same skew angle to a 1/10th degree for ~25 runs Standard Deviation 1/5th degree variation

1/10th degree variation

ES7 1 Customer Need

Prototype must accommodate 120gsm (80# text) Digital Color Elite Gloss coated media while meeting all other specifications Yes/No N/A

Accomodates all paper weights

ES8 2 Customer Need Prototype will minimally calendar print Qualitative Moderate None

ES9 2 Customer NeedPrototype will produce trailing edge wrinkles less than once every twenty prints Number

1 wrinkle every 10 prints No wrinkles ever

ES11 3 Implied Prototype must be stable for a load of 4000 psi Force Vibration Stationary

ES10 3 Customer Need Feed rate must not decrease by more than 5% Torque10% reduction of

speed5% reduction of

speed

ES12 3 Implied Prototype must be manufacturable within ~2 week Time Required, Y/N 4 weeks 2 week

ES13 3 ImpliedPrototype will take less than 60 secs of user time to set up print Time Required 120 sec 0 secs

ES14 3 ImpliedPrototype must be able to print >1000 copies without failure

Life Cycle (Number of Prints) 500 copies 1000

ES15 4 Customer Need Prototype must cost less than $3000 Dollars $3,000 $1,500

System Architecture

Assessing Customer Needs

Brainstorming ideas to meet

needs

First Concept selection

Skew Adjustment

Mechanism of Adjustment

Support of Adjustment

Paperweight adjustment Compliance

Concept Selection Flowchart

Swapping Pillow Blocks Saw Tooth Crank Adjustment Sliding Channel Frictional Coating

Hook and Pinion Bolts

Bolts and Ridged Channel

Swapping End Blocks

Adjustable End Blocks

End Blocks with Multiple holes

Push Bolt Pull Bolt in channel

Pull Shelf with Bolt

Concept Selection – Preliminary Skew Mechanism

Concept Selection – Secondary Skew Mechanism

Skew Adjustment

Concepts Swappable End Blocks Adjustable End Blocks End Blocks with Multiple Holes

Metrics

Cost 0 + 0

Fixability 0 0 -

Manufacturability 0 + 0

Durability 0 - -

Skew Alignment 0 ++ 0

Complexity 0 - 0

Ease of Assembly 0 - 0

Score: 0 1 -2

Preliminary Concept CAD Models

Figure 1. Side view of End Block

Preliminary Concept CAD Assembly

Figure 2. Assembly Model

Concept Selection – Skew Support

Adjusting for Paper Weights

Metrics Current Prototype

Compliance SpeedOptimize Gap

DimensionManually Optimize

roller diameterPaper Filler

Calendaring 0 + 0 + 0 +

Print Fusing 0 - 0 + + 0

Visual Defects 0 0 0 + + 0

Uniform Nip Pressure 0 0 0 0 + 0

Paper Weight Accommodation 0 + 0 + - +

User Friendly 0 + 0 - 0 -

Abaqus Model 0 + 0 - - +

Paper Stubbing 0 + 0 + 0 -

Score 0 4 0 3 1 4

Concept Selection – Paper Weight Adjustability

Metrics Washers (Various

Materials) Springs Coated Elastomer

Rollers Manually Adjust

Pressure Hydraulics

Cost 2 2 1 3 1

Durability 2 2 Constraint 3 1

Load Strength 2 2 1 3 2

Complexity 3 3 1 3 1 Ease of Construction 3 3 1 3 1 Ease of Operation 3 3 3 1 3

Total: 15 15 7 16 9

Concept Selection - Compliance

Final Design

Risk Assessment

Design Risk Assessment

Action Items

• Action Items:o Eric: Model Detailed CAD Modelso David: ANSYSo Aniket: DOE Planningo Tom: DAQ Systemo Jon: Calculate Nip Pressure and Deflection

Next Steps Week 5 (1/11-1/17) Week 6 (1/18-1/24) Week 7 (1/25-1/31)

Midweek Friday Midweek Friday Midweek Friday

Midterm Design Review        

Purchase Components as Confirmed

Calculate Nip pressure

Analyze Roller Deflection

Torsion Analysis

Create CAD Model

Create Real-time Data Acquisition system            

Interface DAQ with Hardware            

Create Test Plan

Review and Improve on System Design