P10511: Miniaturization of Xerography

Derek Meinke (ME, PM)Matthew Liff (ME)

Tony Zhang (EE)Zaw Htoo (ISE)

Agenda

• Project Description• Final Design Concept• System Architecture• Project Development• Current State of Design• Summary of Test Results• Conclusions• Questions

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.

• Obtain device characteristics using I-V curve.

Project Description

Charger Gap (1

-2mm)

Surface

Charge (-300 to

-800V)

Budget ($2k)

Drum Size

(30-84mm)

Surface

Speed (≤1m/s)

Charger Type (B

CR or Sco

rotro

n)

Dielectric T

hickness

(~25µm)

Uniform

Erase Charge (-100V)

ESV distance

(1-2mm)

Coronode Curre

nt (0-2mA)

0%1%2%3%4%5%6%7%8%9%

10%11%12%13%14%

Engineering Specifications

Final Design Concept

Photoreceptor (84mm)

ESVThreaded rod end for easy changeability

Coronode/Grid/Plate Power Supplies

Charger Mount

Erase Mount

Final Design Concept

System Architecture

Project Development ProcessDefine Needs and

SpecificationsConcept Generation

and Selection

MSD 1Weeks 1 - 2

MSD 1Weeks 3 - 5

Detailed Design

MSD 1Weeks 6 - 10

- Define Customer Needs- Develop Eng. Specifications- Perform QFD Analysis

- Concept Generation and sketches

- Concept Screening and selection

-Part Drawings-Bill of Materials-Calculations

Building Testing

-Material Acquisition-Part Machining-Design Adjustments-Wiring Connections

MSD 2Weeks 1-8

-Uniformity Plots-I-V Curves-LabVIEW Optimization-Part Modifications

MSD 2Weeks 9-10

Current State of Project

• Testing is complete– Smooth uniformity plot– I-V Curves with slope of around 0.6

• Photoreceptor sizes– Only tested 84mm and 30mm diameters (largest and smallest)– The 60mm and 40mm diameters are unavailable

• Budget– $548.21 was used of $2000.00 available– Includes extra material for PR endcaps– Donated equipment cost was tracked but not purchased on budget

Summary of Results

Grid Voltage: -655VESV Readings/PR Rotation: 1ESV Readings/PR Length: 50Speed of PR: 0.1

Average Reading: 497.16VRange of Uniformity: 92.28V

Uniformity Test IV Test

Grid Voltage: -655VVoltage Step: 20V

Intercept: -722.6Slope: -0.6

Summary of Results

IV Test -665V Applied

Voltage Increment

(V)Sample

Voltage Intercept

(V)Slope

(uA/V-m)Theoretical Intercept Error (%)

10

1 -678.7 -0.66 2.062 -708 -0.64 6.473 -703 -0.64 5.714 -659.1 -0.66 0.895 -683.5 -0.64 2.786 -893 -0.47 34.297 -654 -0.66 1.658 -693 -0.62 4.219 -893.5 -0.51 34.36

10 -693.3 0.62 4.2611 -683 -0.61 2.71

20

1 -683 -0.64 2.712 -722.6 -0.6 8.663 -678.7 -0.63 2.064 -703.1 -0.64 5.735 -717.7 -0.6 7.92

Uniformity Test -665V Applied

Speed (m/s) Sample Average Voltage (V)

Range of Uniformity

Slope of Voltage

Across P/R

Mean of Voltage

(V)

Mean of Uniformity Range (V)

0.1

1 -481.68 56.64 -0.03

-466.08 119.112 -497.16 92.28 0.033 -473.48 68.84 0.064 -454.52 160.10 0.065 -423.56 217.70 -0.02

0.2

1 -435.14 59.57 0.01

-470.15 81.342 -477.66 47.36 0.033 -478.72 86.91 0.204 -460.20 156.70 -0.045 -499.04 56.15 0.10

0.3

1 -380.51 68.84 0.22

-407.51 132.382 -437.29 203.60 0.423 -393.18 162.50 0.184 -424.68 64.45 0.105 -401.90 162.50 0.12

0.5

1 -285.13 105.90 0.31

-261.91 120.862 -312.54 147.40 0.403 -225.82 96.67 -0.114 -257.52 167.40 0.495 -228.54 86.91 0.12

1

1 -153.06 239.20 -0.59

-140.02 229.442 -152.50 264.10 -0.543 -140.68 279.70 -0.654 -126.10 182.60 -0.395 -127.74 181.60 -0.36

Conclusions• Design Modifications

– Charger mount slots were opened on PR end for increased charger range of motion

– Original retaining mechanism for PR compression spring used c-clip; changed to threaded rod with nut for assembly considerations

– Cut down spring by 3 loops for lower compression force and easier assembly– Shaft mounts now use gussets over flimsy L-brackets for alignment– Individually sized endcaps vs. v-flange design– Dovetail design optimized for machinability

• Improvement ideas– Lengthen charger mounting assembly for less interference– Implement third shaft mount on free end to eliminate cantilever design– Alligator clips with higher breakdown threshold– Make charger slide plastic to eliminate arcing problems

Further Questions?