Open Source/Open Architecture Low-Energy

PrintingPrepared Multidisciplinary Senior Design

Projects

Dean Culver (ME)Shawn Hoskins (ME)Derek Meinke (ME)

Tim Salter (ME)

Something New to MSD

• Inventing a new family

• Free reign in proof of concept

Concept Generation

• Concepts that apply

– Through what product is the most printing energy consumed in developing countries?

• 11 Inventions

As a Result

• From Many, Few

– 11 Concepts » 15 Projects over 6 years

• Postponed Investigations

– Inkjet Technologies

Xerography Power Consumption

78%

6%4%

4%3%

5%

Fuser

Mechanical

Controls

DocumentHandling

Imaging

Miscellaneous

Paper

Trans

port

Paper

Trans

port

OS

/OA

Low

-E

Prin

ting

OS

/OA

Low

-E

Prin

ting

R10004: OS/OA Low-Energy Printing

Toner

Tunne

lTon

er

Tunne

l

Toner

Tunne

l 2

Toner

Tunne

l 2

Digita

l

FuserDigi

tal

Fuser

Test

Fixtur

esTes

t

Fixtur

es

Categ

ory

Categ

ory

Histor

y

Histor

y

Conce

pt

Conce

pt

N/AN/A

2009

2009

2010

2010

2011

2011

2012

2012

2013

2013

2014

2014

Proof of ConceptProof of Concept

Proof of ConceptProof of Concept

Proof of ConceptProof of Concept

Printin

g

Med

ia Roll

Printin

g

Med

ia Roll

Pro

of

of C

once

pt:

Mic

row

ave

Ton

er P

hase

Con

trol

Pro

of

of C

once

pt:

Mic

row

ave

Ton

er P

hase

Con

trol

*Improve*Improve

OptimizeOptimize

*Digital Fuser Test Bed

*Digital Fuser Test Bed

Objective TreeLow Energy

Printing Process or Component

Resources Economic

Scope Technological

Appeal to PrintingCompanies

Familiarize withMSD Support and

Past Projects

Design WorkAssembly/

Construction

What can this iteration do?

What should the goal of MSD be for

this concept?

Printer HeadTechnology

Other Interfaces

Staffing

Design Tools

Funding

Available Data

Digital FusingCharge-Chasing

Toner TunnelCoil PotentialToner Tunnel

P10509 Digital Fuser Roller

Project Overview– The initial project phase will consist of

devising preliminary fuser design concepts and options. The team will investigate, model, and test the various components and processes involved in the digital fusing process. The end goal of this phase is to produce quantitative test results to be used as the basis of fuser development for future senior design groups.

Motor

Gear drive

Bearing supports

Roller fuser & discrete heating elements

Commutator brushes

Background Information

• Conventional fuser roller – ~500-800 watts of energy

– Small surface area contacting toner

– Remaining surface area exposed to air

– Convection losses

qconvection

qconduction

Internal heat

source

Toner/media surface

ω

Digital Fuser Concept

• Discrete heating elements– Individually powered strips– Produce heat at toner

contact area– Only residual heat is

convected

• Other components– Roller drum– Bearing supports– Motor and gear drive– Pressure application

mechanism

qconvection

qconduction

Heated elements

ω

Toner/media surface

Digital Fuser Function TreeLow Energy

Digital Fuser Roller

Low Energy Digital Fuser Roller

Supply powerSupply power

Apply PressureApply PressureRotateRotate

Run motorRun motor

Compress tonerCompress toner

Fuse tonerFuse toner

Distribute heatDistribute heatFeed paperFeed paper

Heat elementsHeat elementsReduce energy

consumption

Reduce energy consumption

Selectively heatSelectively heat

StaffingName Discipline Role/Skill

TBD TBD Faculty Guide, Will work closely with the team on an on-going basis to facilitate success.

Gerry Garavuso

Printing Technology Faculty Consultant, Will provide technical support on an intermittent basis.

Dr. Edward Hensel

Department Head Primary Customer, Provide project requirements to ensure project results in relevant engineering data to be used by future design teams.

TBD ME Student Develop thermal and physical model of digital fuser roller. Determine energy required to heat toner to fusing temperature.

TBD ME Student Create multiple preliminary design options for fuser roller and test fixture. Design simplified prototype for the purpose of testing fuser concept and feasibility.

TBD EE Student Create model of power supplied to fuser and drive motor. Determine methods of power control and distribution for heating elements and motor.

TBD EE Student Investigate brush commutator mechanism and review optional methods of contact system. Source and select potential electrical components for proof-of-concept prototype.

ResourcesCategory Source Description Availabl

e

Faculty TBD Consult with faculty who are knowledgeable with regard to the particular project or individual task at hand. Making informed decisions will increase the likelihood of project success.

TBD

Environment

Electronics Lab

The fuser incorporates electrical components which will need to be assembled using tools and materials commonly found in the electronics lab. The lab also provides a clean working environment which is useful when assembling delicate or sensitive components.

Yes

Environment

Machine Shop

Equipment and tooling in the machine shop will be needed when the time comes to create a device that will test the concepts of fuser operation. This environment will be more important for future design teams who may eventually build a prototype roller fuser and test fixture.

Yes

Equipment Fabrication equipment

Lathe, upright mill, as well as assorted power and hand tools. Much of this can be found in the machine shop.

Yes

Equipment Electronics equipment

Soldering equipment, power meter, ohm meter, etc. Likely to be found in electronics lab.

Yes

Materials KGCOE Consult faculty/advisers to determine availability of materials at hand (not vendor sourced materials.)

TBD

Preliminary Work Breakdown Structure

Person Week 0->1 Tasks Week 1->2 Tasks Week 2->3 Tasks

Group •Group introductions•Review team values and norms•Layout goals for the quarter

•Previous meeting review•Present individual work and•Acquire xerographic printer

•Previous meeting review•Address new issues•Delegate responsibilities to each team member as needed

ME Student

•Begin planning thermal and physical models•Begin research on toner fusing process

•Refine preliminary models•Continue fusing research and requirements

•Complete thermal and physical models•Create document containing all information needed to fuse toner

ME Student

•Researching design concepts for fuser roller and test fixture•Develop simplified prototype concepts for discrete heating

•Create design concepts for working components of fuser •Continue simple prototype design and narrow scope.

•Narrow design concepts to one or two options•Compile design concepts for initial fuser design prototype

EE Student

•Begin modeling of power supply and distribution•Start researching methods of power control for fuser

•Continue modeling of power supply•Create ideas for power supply and distribution

•Design and source power supply and associated materials for simple fuser prototype

EE Student

•Start researching power transfer from commutator to heating elements•Compile electronics vendor list

•Continue commutator development•Create list of electrical components and costs

•Continue commutator research •Document all materials and costs for electrical components required for simplified prototype

Risk Assessment Category Description of

RiskPossible

ConsequencesContingency Plan

Staffing Group member is unavailable for short period of time due to illness or other reason.

Individual tasks for the week will not be accomplished.

EE and ME students should work together closely and swap information regarding their individually assigned tasks on a frequent basis. This will allow the remaining student to take over tasks that are specific to their respective major.

Staffing Group member is unavailable for remainder of quarter or extended time period.

Individual tasks will not be accomplished. Loss of individual's specific skills and knowledge.

Students should work closely with other members of the same major, as well as keep group up to date on individual tasks during each group meeting. All work will be documented so the group can divide up the work in the event that a team member is not available.

Vendor and Materials

Vendor cannot supply material, or materials do not arrive as scheduled

Project development cannot progress until materials are acquired.

Source multiple vendors for parts. Do not plan on using parts or materials that are available from only one or two vendors. It would also be helpful to source reputable companies that have a history of prompt shipping and a good in-stock availability of products.

Equipment Required equipment is unavailable at time of need.

Project development cannot progress until equipment becomes available.

Try not to rely on using uncommon or unique tools and equipment. Prototype and test fixture should be constructed using commonly available tools and equipment.

Facilities Required facility is occupied or unavailable.

Unable to complete tasks specifically performed in particular facility.

Plan ahead and do not wait until the last minute to perform a task that can only be accomplished in a specific environment. Look into availability of facilities and plan on completing a task a week ahead of schedule.

Customer Requirements Cus

tom

er W

eigh

ts

Red

uce

ener

gy n

eeds

Rea

ch to

ner

fusi

ng te

mpe

ratu

re

Red

uce

# of

par

ts

Min

imiz

e co

sts

Com

plet

e do

cum

enta

tion

Team

mee

tings

and

dis

cuss

ion

Uses less energy 5% 9Proves fuser concept 29% 9 3 1Makes progress in printing track 24% 3 1 9 3Produce data and numerical results 10% 1 3 1 1 9 3Build foundation for next group 19% 1 1 1 3 9 3Repeatable and reproducable 14% 1 3 9 1

Functional Performance Specifications Unitswatts

degrees # $ # hours

Technical Targets

Better 54

Technical Benchmarking 32

Worse 1

Raw score 4 1.57

0.43

1.1

6.29

1.71

Relative Weight 26%

10%

3% 7% 42%

11%

House of QualityDigital Fuser

Roller

Final comments• The initial phase of senior design for the

digital fuser project should…

– Produce quantitative results

– Demonstrate the value of work

– Build a foundation for future SD groups

Toner Tunnel: Charge Chasing

• What is a Toner Tunnel?

• What is the Mission?

• What are the potential benefits?

• What are some intrinsic challenges?

Function Tree (Over Iterations)

Toner TunnelToner Tunnel

AcceptAccept AccelerateAccelerate

DirectDirectTransformTransform

Integrate withInjection

Integrate withInjection

Measure IntakeMeasure Intake

Identify ErrorIdentify Error

Self-CorrectSelf-Correct

ErrorError

Apply EM ForceApply EM Force Eject TonerEject Toner

Manipulate EM Field

Manipulate EM Field

Observe DefectsObserve Defects

Self-CorrectSelf-Correct ErrorError

Melt TonerMelt Toner

House of QualityToner Tunnel

Risk Assessment

Risk Description Consequences ContingencyInconsistent Dynamic Injection

Inability to standardize particle placement control

Static Injection

Failed Advancing Field Generators

Inability to maintain pseudo-constant electromagnetic force

Static Field Generators

Failed Particle Velocity Data Acquisition System

Inability to measure the particle speed at design acceleration

Decrease Design AccelerationORInfer Analytically from Position and Time

Scope Overshoots Budget

Inability to purchase components or services needed

Revise Scope

Project Readiness Package OverviewStaffing

– 2 Mechanical Engineers

– 2 Electrical Engineers– 1 PM (ME/IE)

Business Aspects

– Budget– Supplementary

Resources– Marketing

Preliminary WBS

Resources

Category Source DescriptionResource

Available(mark with X)

Faculty RITIndividual familiar with particle dynamics, injection,

and tracking.

RITIndividual familiar with fields, particularly generation

and manipulation.X

Environment

RIT

Design Center Cube: Area designated for team meetings and workshops.

Design Center Storage Locker: Locker for hardware, document, and resource storage.

X

Equipment RITOld printers designated for recycling or waste. To be

used for familiarizing with current xerographic processes.

XeroxOld printers designated for recycling or waste. To be

used for familiarizing with current xerographic processes.

Toner Tunnel: Coil Potential Method• Xerography fuser uses 78% of total energy

consumption.

• How can we remove fuser?– Apply energy to toner particles before media– Impact paper with velocity

• Accelerate charged particles with electromagnetic field.

• Use a EM coil like a solenoid to eject ink

TT: CPM Mission Statement

• Provide a means to accelerate and direct toner particles onto a media with enough energy to fuse the toner to that media without the need of an additional fusing process. The accelerating and directing will be conducted using a tunnel with an electro-magnetic field created by a coil potential.

• Show proof that toner particles can be accelerated into a media so that a fuser can be eliminated in the Xerography process.

TT: CPM Staffing Requirements• Team Lead / Particle Tracking

– ME, Coordinate and facilitate the planning of deliverables between team members.

• Coil Structure Engineer– ME, Infrastructure to support wire coil

• Particle Motion Control– ME, Toner entrance and exit

• Power Supply Engineer– EE, Determine power and electrical requirements

• EM Field Specialist– EE, Particle acceleration

Person Week 0>1 Tasks Week 1>2 Tasks Week 2>3 Tasks

Team Lead/Particle Tracking

Team building, planning, and research team values and norms.

Research different surrogates of the toner particle .

Determine optimal sizing and material for particle

Coil Structure Engineer

Team building, Xerography familiarization, team values and norms.

Begin sizing of test fixture and understand customer requirements.

Interface with electrical components

Particle Motion Control

Team building, Xerography familiarization, team values and norms.

Understand the motion of a charged particle in an EM field Research methods of particle discharge from reservoir.

Come up with ways to enter particles into tunnel, ways to stop the particle with marking ability

Power Supply Engineer

Team building, Xerography familiarization, team values and norms.

Come up with power supply options to power EM coil.

Work with power coil structure engineer in interfacing electrical components with structure

EM Field Specialist

Team building, Xerography familiarization, team values and norms.

Develop math model for EM field Understand motion of charged particle in an EM field.

Charge of particle manipulation

TT: CPM Work Breakdown Structure

TT: CPM Risk Assessment

Description of Risk

Possible Consequences

Contingency Plan

Particles are too small to capture particle motion effectively.

Unknown velocity will not demonstrate proof of concept of generating enough kinetic energy.

Use a surrogate particle with larger diameter for easier image capture and velocity measurement.

Power requirements for particle acceleration are relatively higher compared to current technologies.

No improvement in energy usage for a low energy design project.

Demonstrate that change in design parameters follows theoretical model to prove that principles are correct.

Project becomes too specialized and is comprised mainly of one-off parts

Easily repeatable open source/open architecture aspect is compromised

Use as many generic parts as possible such as breadboard designs vs printed boards. Detailed documentation of everything is critical.

TT: CPM Business Plan

• Operate within KGCOE MSD budget

• Show proof of concept!– Inputs, function, desired outcomes

• Novel concepts attract attention

• Increase/generate corporate and internal infrastructure

P10506: Print Media Transport

• Continuous Paper Transport Operation Overview– Differences from traditional paper transport

systems

• Ultimate Objective of Project– Primary: Successfully interface with other

low-energy printing projects– Secondary: Minimize energy used to

transport print media

• Potential Iterations of Project

Paper Transport Staffing

Name Discipline Role/Skill

TBD TBD Faculty Guide

Gerry Garavuso Printing Technology (ME) Faculty ConsultantDr. Ed Hensel ME Department Head Primary Customer

TBD ME Student Team Lead

TBD ME Student Mechanical Interface

TBD ME Student Mechanical Design

TBD EE Student

Power Supply/Electrical System

TBD EE Student Electronics Interface

Paper Transport WBS

Person

Week 0 -> 1 Week 1 -> 2 Week 2 -> 3

Group 1. Group Introductions2. Project Introduction3. Review EDGE website4. Determine goals and

deliverables for quarter

5. Set weekly meeting times

6. Discuss norms and values

7. Establish roles

1. Meet with customers/stakeholders to clarify needs

2. Meet with interfacing project teams to determine needs

3. Begin to develop design concepts

1. Meet with interfacing project teams for updates

2. Share individual findings/design concepts

ME 1 Lead group in above activities

Facilitate group tasks Review each team member’s status/progress

ME 2 Follow group activities Meet with interfacing team to address individual concerns

Review design ideas with interfacing team

ME 3 Follow group activities Investigate existing designs Begin mechanical design

EE 1 Follow group activities Investigate power supply options Begin power supply design

EE 2 Follow group activities Meet with interfacing team to address individual concerns

Review design ideas with interfacing team

Paper Transport Risk Assessment

Risk Possible Consequences

Contingency Plan

Interfacing team is unavailable to meet

Final product will not interface successfully

Develop an understanding with the other team early on that frequent collaborative meetings will be necessary

Device destroys print media

Media is not delivered as required

Develop multiple design concepts and plans for backup use

Print media is in an incorrect position

Ink is not transferred to print media as intended

Conduct multiple tests of integrated system

Required parts and materials do not arrive as planned

Project cannot move forward as scheduled

1. Use commonly stocked parts

2. Search for multiple vendors

Team member is unavailable and absent from meetings

Goals and deliverables will not be completed on time

1. Hold frequent meetings to keep track of individuals’ progress

2. Ensure team members know what other members are doing

3. Document

House of Quality

Paper Transport

Paper Transport Function TreeContinuous Print Media

Transport

Continuous Print Media Transport

Supply PowerSupply Power

InterfaceInterfaceRotate RollerRotate Roller

Run motorRun motor

Follow Commandsof Printer

Follow Commandsof Printer

Position MediaCorrectly

Position MediaCorrectlyFeed mediaFeed media

Does Not TearMedia

Does Not TearMedia

Does Not WarpMedia

Does Not WarpMedia

DPM Concluding Statements

• Senior Design: Personally Prepared

• Unique Skill Set

• Learning to Learn

Questions?

• P10506

• P10507

• P10508

• P10509