Low Energy Printing Project P09505

1. Low Energy PrintingProject P09505 Mid-Project Review Senior Design I 1 Senior Design I – Mid Project Review

2. Project Team, Faculty, & Customer Senior Design I – Mid Project Review • Project Team: • Project Lead: Joshua Jones (ME – Year 5) • Team Members: Whitney Domigan (ME – Year 4) Jenna Kilroy (ISE - Year 5) Andrzej Lubaszka (EE – Year 5) • Faculty: • Guide: Bill Nowak (ME, Xerox Employee) • Consultant: Marcos Esterman (ISE) • Customer: • Xerox Corp – Marking Elements & Integration Lab John Knapp 2

3. Agenda Senior Design I – Mid Project Review Introduction Project Background Customer Requirements Project Deliverables Concept Selection Current Design Concept Bill of Materials Feasibility Checklist Key Risks From Design Reviews MSD 2 Project Plan 3

4. Project Background https://edge.rit.edu/content/P09505/public/Home Senior Design I – Mid Project Review Xerographic digital printers are very energy intensive, specifically the fusing sub-system. This is largely due to the fact that during the fusing process toner is heated to well above its melting point, to enable heat flow, and allow the toner to adhere to the paper. • Senior Design Project as Stated on Edge: “Re-consider the design of an extremely low power, non-thermal fusing system” 4

5. How a Fusing Sub-System Works Traditional Toner Fusion: Temperature + Pressure + Heat = Fused, Adhered Toner Heat Discrete, loose toner Fused, adhered toner Nip Pressure Image by: David Thompson, Xerox Corp. Information by: David Thompson, Xerox Corp. and Dinesh Tyagi, Eastman Kodak Company Senior Design I – Mid Project Review 5

6. Project Scope The purpose of this project is develop a fusing sub-system that uses pressure instead of thermal energy to fuse toner to paper with the aim of fitting into the Xerox Workcentre Pro 45/55 printer. Senior Design I – Mid Project Review 6

7. Customer Requirements • Most Important Customer Requirements: • Paper is not damaged • Uniform pressure along nip • Fit into current Xerox Workcentre 245/55 Pro • Use pressure only to fuse toner to paper Senior Design I – Mid Project Review 7

8. Senior Design 2 Deliverables Senior Design I – Mid Project Review • Physical Hardware: • Working cold pressure fusing system • One working prototype with multiple configurations • Parametric Analysis: • Effect of different roller skews on: • Uniformity of pressure across the nip • Damage to paper • Various loads and their effect on: • Uniformity of pressure across the nip • Damage to paper • Analytically test the max load design can handle • Effects of paper thickness • Analytically examine the effects of roller lengths • Verification of theory that additional rollers will generate a more uniform pressure across the nip

9. Concept Selection Process PUGH 3 - Week 6 How to Mechanically Apply Load PUGH 1 - Week 3 Preliminary Design PUGH 2 - Week 4 Loading Styles Concept Selection PUGH 1 Concept Selection PUGH 2 Concept Selection PUGH 3 Senior Design I – Mid Project Review 9

10. Current Design Concept 12 inches Senior Design I – Mid Project Review 10

11. Current Design Concept • Current Fuser System’s Dimensions: • Length: 18.5 inches • Width: 4.5 inches • Height: 6.5 inches • Our Design’s Dimensions: • Length: 13 inches • Width: 3 inches • Height: 4 inches Senior Design I – Mid Project Review

12. Current Design Concept Features Senior Design I – Mid Project Review

13. Budget BOM - Budget Senior Design I – Mid Project Review

14. Key Risks:Identified During Design Reviews • Risk Tracking Senior Design I – Mid Project Review

15. MSD2 Project Plan Senior Design I – Mid Project Review

16. Questions Senior Design I – Mid Project Review