P09503Electrophotographic Development and Transfer Station
Team MembersName Discipline
David Schwartz ISE
Ruth Gay ME
Phillip Lopez ME
Dan Summers ME
Rachel Chrash EE
Min-Shi Hsiao EE
Andrew Kearns EE
Sasha Oliver CE
Project Description• The purpose of this project is to
make an existing electrophotographic development and transfer station functional and to improve the usability, safety and sensing abilities. • EDTS End Users
PRISM Lab▫ Layered Manufacturing
Center for Imaging Science
Deliverables1. An inventory and status of current
sub-systems, including needed support systems.
2. A working Electrophotographic Station.
3. Demonstrably improved device safety.
4. An improved user interface (includes control and display functions)
5. Device documented for use, maintenance and upgrade of the device (User & Lab Technician Manual)
6. Demonstrably Improved Sensing and Control Subsystem
Project Background• Project Family▫Printing and Imaging Systems Technologies Track
• Customer▫Print Research and Imaging Science Modeling Laboratory (PRISM)
The Print Research and Imaging Systems Modeling lab will serve as a conduit between industry and academia, working to evaluate and anticipate the print systems research needs of printer and printing product companies, and directing relevant projects to researchers and students in the areas of Printers & Displays, Color Science, Vision Science, Systems Engineering, and Printing.
Contact: Dr. Marcos Esterman – Associate Professor, Industrial and Systems Engineering
What is Electrophotography?• Electrophotography is base
technology that is used in many modern day copiers and printers
• Six Step Process to transfer an electrostatic image to a final printed page▫ Charging▫ Exposure▫ Development▫ Transfer▫ Fusing ▫ Cleaning
• P09503 only includes the first four
Electrophotographic and Development Station
Charging ExposureDevelopment
Transfer
Photoconductor
System Architecture
Critical Customer Needs
1. Is Operational2. Is Safe3. Minimize user Intervention4. Can Monitor Key Process Parameters5. Can operate and monitor machine from one
interface6. Easy to learn to use
Concept Summary•Modifications and Improvements to EDTS Include▫Ozone Fan/ Filter Assembly Analysis▫Electrostatic Voltage Measurement Implementation▫LED Exposure System Implementation▫Paper Delivery System▫Photoconductor Imaging System Mount▫Electrophotographic Process Control and Automation
Control and Automation Hardware
Ozone Fan/ Filter Assembly Analysis• Corona and Grid produce O3
during operation • Maximum allowed concentration
indoors is 0.050 ppm • Methodology
▫ Verify system produces levels that are safe
▫ Device is verified if levels test below >0.2ppm
▫ Construct new mount and assembly for ozone fan if device produces ozone above >0.2ppm
• Test Results▫ The device used was an ozone
detector that can accurately detect once it reaches amounts of 0.5ppm.
▫ There were no detectable ozone amounts for both tests ran.
▫ It is noted that around 0.2ppm is when throat and nasal irritation may occur. (This was not experienced)
Electrostatic Voltage Measurement Implementation•Monitoring the potential on the Photosensitive
material increases the sensing abilities of the system•Monitor process real time•Photosensitive Dark Decay Research• Implementation and Measurements▫1st measurement after charging▫2nd measurement after exposure
•Measurement limited to one dimension▫Process created for two dimensional measurement
ESVM Implementation
LED Exposure System• LED Exposure system
replaces current incandescent system
•Mounted directly under exposure lift
•Advantages▫ More versatile and reliable light
source▫ Low Power Consumption▫ Longer Bulb Life▫ No potential for overheat▫ Inexpensive to replace
Paper Delivery System• Existing roller system required
manually catching paper after application of toner from roller
• Risks of manual handling▫ Human Shock/Short from High
Voltage Roller▫ Pinch Point of Rollers and
Pneumatics▫ Marred Image Quality from
Handling• Machined Paper Delivery System▫ Clear tray to allow for
Photoconductor Imaging
High Visibility Warning Signs• Purpose of warning signs
▫ Alert user to specific hazard▫ Identify how hazard can be avoided
• Previous signs did not accomplish this or were not present
• FMEA Analysis dictated locations• ISO 3864 Formula dictated proper
size and images• Methodology
▫ Remove current warning signs▫ Replace with ISO designed signs▫ Add new ISO signs where needed
• Final FMEA Analysis verified all sign placments
Photoconductor Imaging System Mount• Imaging of the
Photoconductor System helps to gain understanding of how image is developed onto photoreceptive material
• Photoreceptive material imaged after development and before transfer
•Mount machined for camera to rest under Paper Delivery System
Electrophotographic Process Control and Automation
• Most critical part of the entire project
• LabView virtual instruments is used to control all devices
• All components connected▫ High Voltage and Camera are on a
separate system• Two Modes of Operation• Automatic
▫ Parameters are preset▫ User only needs to press start to
begin and stop to end• Manual
▫ User can control any part of the system
Budget• Project Budget: $1500• Budget Utilized ~$1480 (98%)•Major Purchases▫National Instruments Data Acquisition Device
PCI-6515 – 64 Channel Digital I/O PCI Card, Cable and Terminal Block
▫Sick|Stegman Encoders 2 X HD20 1024 Pulses/Rev
▫ Luxeon Star/O LED Royal Blue Batwing, 220 mW @ 350mA
Final Results All six deliverables were presented to the customer Total Design Specifications: 46
Specifications Met: 40 or 87% Specifications not Met: 4 or 9% Special Circumstances: 2 or 4%
Electrophotographic Station has the ability to charge a Photoconductor, Expose the Photoconductor, Attract Toner, Deposit Toner onto a Transfer Drum and Transfer Toner to a Substrate
Electrophotographic and Development Station
Before After
Future Improvements•Transfer Drum Clutch•Motor Speed Control•Component Labeling•X-Y PC Measurement•Multiple Development Systems•Camera Automation• Light Curtain
Special ThanksRIT Faculty Professional
• Jonathon Arney, Ph.D▫ Center for Imaging Science
Physical & Optical Measurements• Susan Farnand, Ph.D
▫ Center for Imaging Science Color and Vision Science
• John D. Wellin▫ Mechanical Engineering
Control Systems• Marcos Esterman, Ph.D
▫ Industrial and Systems Engineering Product & Process Development
• Bill Nowak – Xerox▫ Principle Engineer
Motion and Quality Systems• Gregory Miller – Kodak▫ Software Engineer
Questions