P10505 – Cold Pressure Fusing II Performance Review Team Fusion 14 May 2010

1. P10505 – Cold Pressure Fusing IIPerformance ReviewTeam Fusion14 May 2010

2. Project Review Agenda • Presentation Outline • Design Summary • Evaluation of Project Goals • System Architecture • Design Schematics of Fuser • Project Development Process • Budget • Summary of Results • Project Wrap Up • Recommendations

3. Design Summary Dowel pins Main roller Gear Box (6:1) Load cells Motor Springs for compliance End blocks Fusing roller Skewed rollers Motor Mounting Brackets

4. Electronic Control System Transducer Box LabView Interface Motor Controller

5. System Architecture

6. High High High Low Low High Low Low Parallel Splayed Design Schematics of Fuser

7. Project Development Process MSD I MSD II

8. Budget • $3000 initial budget • Mechanical Expenses: $933.87 • Electrical Expenses: $750.00 • Total Spent: $1683.87 • Total Saved: $1316.13 • Gifted Items $ 3,487.00 • Total $5170.87

9. Comparison of Average Pressure and Standard Deviation across Skew Angles – Parallel Configuration

10. Optimizing Skew Angle

11. Expected variation @1.9 angle, loads between 130-270, 50/50 landscape/portrait, compliance set to 270 Uniformity goal was 390 psi at mean of 3900 psi. Current actual is ~2000 psi Running 10,000 pages at the above conditions yields pressure uniformity at the histogram on the right with a mean pressure above.

12. Best Configuration • The DOE analysis points to a 1.9° skew angle, 130 lb per bolt load, 270 lb/in compliance, and portrait orientation as the best configuration for achieving pressure uniformity • The parallel and splayed configurations produced almost identical pressure uniformity • Best case for the parallel agreed with the above configuration, producing a standard deviation of 1125 lbs and an average pressure of 3733 lbs for a ratio of 0.30 • Best case for the splayed produced a standard deviation of 1502 lbs and an average pressure of 4828 lbs producing a ratio of 0.31 • This is the same as the above configuration, except with 560 lb/in compliance. The standard deviation to pressure ratio with the 270 lb/in compliance is 0.33 (StDev: 1655 lbs, Pressure: 4996 lbs)

13. Comparison of Average Pressure and Standard Deviation across Skew Angles – Splayed Configuration

14. U21.4° skew angle, 270 lb/in compliance, 130 lb load, portrait orientation, Parallel Ground Standard Deviation: 1722 lbs Average Pressure: 3287 lbs Pressure Uniformity: 0.52 Un-ground Standard Deviation: 1638 lbs Average Pressure: 3979 lbs Pressure Uniformity: 0.41

15. U141.9° skew angle, 270 lb/in compliance, 130 lb load, portrait orientation, Parallel Ground Standard Deviation: 839 lbs Average Pressure: 3463 lbs Pressure Uniformity: 0.24 Un-ground Standard Deviation: 1124 lbs Average Pressure: 3733 lbs Pressure Uniformity: 0.30

16. U172.4° skew angle, 270 lb/in compliance, 130 lb load, portrait orientation, Parallel Ground Standard Deviation: 717 lbs Average Pressure: 3554 lbs Pressure Uniformity: 0.20 Un-ground Standard Deviation: 1662 lbs Average Pressure: 4056 lbs Pressure Uniformity: 0.41

17. Usp 21.9° skew angle, 270 lb/in compliance, 130 lb load, portrait orientation, Splayed

18. Project Metrics

19. Recommendations • Mount the motor on a solid, machined, right-angle bracket • Manufacture each skew angle as a complete unit to remove errors during assembly • Tolerances on rollers to 0.0000x”, per consult with Rob Kraynik • Thrust bearings to prevent rollers from traveling when rolling under load

20. Questions?

23. Comparison of Average Pressure and Standard Deviation across Skew Angles – Parallel Configuration

24. Signal to Noise Ratios • S/N = µ/σ = Std Dev/Mean

25. Average Pressure vs. Skew Angle Note: Standard deviation is not the analysis of variance between these average pressure data points. It is the analysis of pressure variations across the entire scan.

26. Standard Deviation vs. Skew Angle

27. Main Effects Plot for Standard Deviation

28. Skew Angle Curve Fit

29. ANOVA Assumptions • These assumptions must be justified to perform an Analysis of Variance. • Normal distribution • Constant variance • Constant mean • Independent data

30. Justification of ANOVA Assumptions

31. Justification of ANOVA Assumptions

32. ANOVA Table for Standard Deviation Legend Green: P-value < 0.005 Orange: P-value < 0.015 White: P-value > 0.010

33. Main Effects Plot for Standard Deviation

34. Interaction Plot for Standard Deviation

35. Interaction Plot for Standard Deviation

36. Interaction Plot for Standard Deviation

37. Interaction Plot for Standard Deviation

38. ANOVA Table for Average Pressure Legend Green: P-value < 0.005 Yellow: P-value < 0.010 Orange: P-value < 0.015 White: P-value > 0.010

39. Main Effects for Average Pressure

40. Interaction Plot of Average Pressures

41. Conclusions • Abaqus model was on target • Experimental results point to 1.91° as the optimal skew angle to maximize pressure uniformity • The average pressure value changes based on the configuration, but several configurations fell in the acceptable pressure range

42. Optimal Design • Standard Deviation • Main Effects: 1.9 deg, portrait, 130 lbs, k=270 • 2nd Order Effects: 1.9 deg, portrait, 170 lbs, k = 270

43. Optimal Design • Average Pressure • Main Effects: • Load is variable but ~140 lbs, • Orientation is variable, no specified preference • Compliance is variable but ~415 lbs/in, by interpolation • Interaction effects agree with main effects, except landscape orientation is preferred • P-value for the average pressure DOE is 0.105 • P-value for the standard deviation DOE is 0.000

44. Representative 1.4° skew angle pressure pattern (U4) 1.4° skew angle, k = 270 lb/in (gray), 170 lbs load, landscape

45. Representative 1.9° skew angle pressure pattern (U16) 1.9° skew angle, k = 270 lb/in (gray), 170 lbs load, landscape

46. Representative 2.4° skew angle pressure pattern (U24) 1.9° skew angle, k = 270 lb/in (gray), 170 lbs load, landscape

47. Average Pressure vs. Test Configuration

48. Standard Deviation vs. Test Configuration

49. Probability Plot of Average Pressure

50. Probability Plot of Standard Deviation