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iGen Fuser Bearing Project P11511

iGen Fuser Bearing Project P11511. Agenda. Project Team, Faculty, and Customer. Project Team: Project Lead: Kevin Argabright (ME) Team Members: John Fitch Dean (ME) Mike Buonaccorso (ME) Justin Eichenberger (ME) Project Guide: William Nowak (Xerox Corporation) Faculty:

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iGen Fuser Bearing Project P11511

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  1. iGen Fuser BearingProject P11511

  2. Agenda

  3. Project Team, Faculty, and Customer • Project Team: • 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

  5. 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

  6. 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)

  7. 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

  8. 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

  9. Engineering Specs

  10. Bearing Life

  11. Risks

  12. Concept Generation

  13. Concept Selection

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

  15. House of Quality

  16. System Level Drawing

  17. Timeline

  18. Questions?

  19. P11511 Senior Design Review Thank you for attending!

  20. Loading the Bearing • Total load seen by the bearing = 360lbs • Pressure roll force: 600lb • 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

  21. Sizing the pneumatic cylinder

  22. 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 • Length: 2.625” • Cost: $181.67 • Source: MSC Direct

  23. Pressure Regulator • Jupiter Pneumatics Air pressure regulator with pressure gauge (4710302535JP) • Port Size: 1/4” • Maximum PSI: 120psi • Width: 1.97” • Height: 1.97” • Cost: $11.36 • Source: MSC Direct

  24. 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

  25. 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

  26. 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

  27. 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

  28. Loading Bearing BOM

  29. Mica Band Heater Cost=~$200

  30. Thermal Simulation-No Thermal Barrier

  31. Thermal Resistant Coating • Swain Tech Coatings Inc.963 North RoadScottsville, NY 14546 • Recommends Zirconia Coating • Excellent Thermal Insulation • Approx. $175 for both parts • 2-2 ½ week turn around time

  32. Thermal Simulation-Assuming Perfect Insulation

  33. Attaching heater to Sensor Holder/Pusher • JB Weld • Resistant up to 500 deg F • Bonds to virtually any material including aluminum, steel, and ceramic • McMaster-Carr Part #7605A11-$5.91

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