P10505 – Cold Pressure Fusing IIFinal Design Review

Team Fusion2/22/2010

Project Team, Faculty, & Customer

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

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

• Faculty Guide o Mr. Bill Nowak - Xerox

Customer Needs

Customer Needs

Engineering Specifications

Updated DAQ and Electrical Schematics

Compliance• DOE calls for two levels of compliance to test effect on fusing

•  Springs must be capable of transmitting 150 lbs of force with additional FOS

Selection Criteria:• Must reach 200 lbs of load.• Spring constants must be significantly different. • Deflection to max load must be large to allow fine tuning.• Free length must not exceed 1.5 in.• Deflection cannot exceed 0.75 in. • This uses existing hardware

Supplier Part Number Maximum Load (lbs)

Deflection at Maximum Load

(in)

Spring Constant

(lb/in)Cost per

Unit

Lee Spring LHL 1000B 02 259 0.47 560 $4.54Lee Spring LHL 1250A 01 202.5 0.75 270 $5.37

Total $39.64

Final Design

End Block Redesign

End Plate Section View

Methods of Measuring Skew• ME machine shop can measure

skew easily using a dial indicator

• CMM is available as well

• Low tech option of a large caliper for quick measurement

Update on DeformationMain Roller

Deflection 0° 90° 180° 270°< 0.5 thou < 0.5 thou < 0.5 thou <0.5 thou

Runout 5/8” 4 1/8” 8 1/8” 11 3/8”< 0.5 thou < 0.5 thou < 0.25 thou 0.5 thou

Fusing Roller – 0.5° Skew

Deflection0° 90° 180° 270°< 0.5 thou < 0.5 thou < 2 thou < 1 thou

Runout3/8” 3 3/4 ” 8” 11 1/2”

2 thou 1.5 thou 1.5 thou 3 thou

Fusing Roller – 0° Skew

Deflection0° 90° 180° 270°< 0.5 thou < 0.25 thou 1 thou < 1 thou

Runout5/8” 4 1/8” 8 1/8” 11 3/8”

< 2.5 thou 1.5 thou < 1.5 thou < 1 thou

• ME machine shop can grind and polish rollers to tolerance. The diameter of the roller would be altered.

• The other option would be to remanufacture the fusing rollers.

Mechanical BOM

• Forms to purchase mechanical parts will be submitted today

Bill of MaterialsPart Part Number Supplier Qty. Base Price Total Price Lead Time

Self-Alignment Bearings 129TN9BDI USA, Simplybearings.co.uk 6 $25.55 $153.30 3-5 Days

Metal Stock (Rollers) 6628K461 McMaster-Carr 1 $47.59 $47.59 1-2 DaysMetal Stock (Skew Rollers) 6628K383 McMaster-Carr 2 $25.79 $51.58 1-2 DaysMetal Stock (Endplates) 8910K704 McMaster-Carr 1 $39.52 $39.52 1-2 DaysCompression Springs 9657K14 McMaster-Carr 4 $12.93 $12.93 1-2 DaysShell Cup Needle Bearings BA-88Z Bearings Direct 6 $4.98 $29.88 1-3 DaysPan Head Screws 91772A190 McMaster-Carr 16 $5.61 $5.61 1-2 DaysRetaining Rings 98408A138 McMaster-Carr 4 $6.12 $6.12 1-2 DaysRetaining Rings 98543A115 McMaster-Carr 4 $6.95 $6.95 1-2 DaysDowel Pins 98381A546 McMaster-Carr 4 $10.71 $10.71 1-2 DaysHex Head Cap Screws 91257A555 McMaster-Carr 4 $9.96 $9.96 1-2 DaysSprings LHL 1250A 01 Lee Spring 4 $5.37 $21.48 5-6 DaysSprings LHL 1000B 02 Lee Spring 4 $4.54 $18.16 5-6 Days1 1/4" OD x 1/4" ID washers 91090A109 McMaster-Carr 100 $5.52 $5.52 1-2 Days

 Mechanical

Total: $ 413.79

Electrical BOMBill of Materials

Part Part Number Supplier Qty. Base Price Total Price Lead TimeLoad Cell Amplifiers DPM- 3 *Provided By Xerox 5 $ 395.00 $ 1,975.00 NAMultifunction DAQ PCI 6014 *Provided By Xerox 1 $ 699.00 $ 699.00 NADAQ I/O Block SCB-68 *Provided By Xerox 1 $ 299.00 $ 299.00 NAPCI Interface Cable - *Provided By Xerox 1 $ 119.00 $ 119.00 NAWire NA *Provided By Student 1 $ - $ - NAWire NA *Provided By Student 1 $ - $ - NAPlastic Enclosure 613593 TheGreatHardwareStore.com 2 $ 16.78 $ 33.56 5-7 DaysSolid State Relay 6C900 W.W. Grainger 1 $ 20.60 $ 20.60 1-2 DaysTransformer 6WU91 W.W. Grainger 1 $ 16.73 $ 16.73 1-2 DaysCrimp Connector Assortment

4FRE3 W.W. Grainger 1 $ 14.69 $ 14.69 1-2 Days

C14 Power Extension Cord B0017UB5UG Amazon.com 2 $ 2.50 $ 5.00 5-7 DaysMechanical Relay 2UTT6 W.W. Grainger 1 $ 11.58 $ 11.58 1-2 DaysMisc. Hardware NA Local Hardware 1 $ 10.00 $ 10.00 NAC13 Panel Mount Adaptor CCM1404-ND Digi-Key 2 $ 2.52 $ 5.04 5-7 DaysDouble- Sided Tape 1F239 W.W. Grainger 1 $ 8.53 $ 8.53 1-2 DaysC14 Panel Mount Plug Adaptor

3792CCM1401-ND

Digi-Key 2 $ 2.06 $ 4.12 5-7 Days

Cable Connector 3LK50 W.W. Grainger 2 $ 2.13 $ 4.26 1-2 DaysWire Nuts 6LU36 W.W. Grainger 1 $ 2.70 $ 2.70 1-2 DaysCable Ties 6JU12 W.W. Grainger 1 $ 2.13 $ 2.13 1-2 Days        DAQ Total: $ 3,230.94  

  Grand Total $ 3,644.73    Gifted Items $ 3,092.00    Actual total $ 552.73  

• Electrical parts- waiting on trip to Xerox

MSD II Project Plan

Worst Case Plan

GREEN LIGHT FOR MSD 2!!