TEST RIG DEVELOPMENT GROUPProblem Background & Voice Of the CustomerProject: R13301

Rochester Institute of Technology

Design Project Management (0303.735.01 & 0304.730.01 )

R13301 TEAMS & MEMBERS

EP Printing Team Jonathan Erbelding & Sakif Noor

Garlock Team Usman Asad & Jessica Fuss

Polymer Membrane Team Steven Lucchesi & Seaver Wrisley

EP PRINTINGJonathan Erbelding

Sakif Noor

BACKGROUND Electrophotographic Printing (EP) test rig

originally from Kodak P09503 modified for improved usability

and automation LabView controls implemented for

automation Has station for major steps:

Charging, Exposure, Toner, TransferFusing occurs on a different rig

Exposure step is performed with a negative. Cannot print file from computer.

Our Problem: Test pattern cannot be specified from computer

EP PROCESS (PART 1 OF 2)

Stepper motor to turn screw to move carriage

Photoconductor carriage

Charging Station Exposure Station

Negative

Screw to move carriage

EP PROCESS (PART 2 OF 2)

Transfer drum

Toner StationTransfer Station

Tray for paper

Fusing: On one of several other rigs, heat and pressure are applied to fuse toner to paper.

STAKEHOLDER INTERVIEWSFirst Interview (Dr. Esterman & Alvaro) Second Interview (Alvaro) Prelim Specs

Convert computer file into light output Accepts computer input to specify test pattern

Integrates into current rig (software:LabView and hardware)

Current exposure station has a space of 12" height, 10" along direction of carriage motion, and 15" width

Integrates into LabView softwareFits into 10"x15"x12" available space of current exposure system

Current Stepper motor should be sufficient if moving during exposure is required

Uses current stepper motor if motion is required

High resolution preferred 1200 DPI target; 600 DPI min. Higher is better. 1200*20±1 DPI Resolution

Controls exposure time OR intensity Current exposure step takes a sec or two. Controls exposure time or intensity

Current PC is 5" wide x 9" long Capable of exposing entire PC Exposes a min area of the 5"x9" photoconductor

$2-3k available to accomplish goal, but can potentially get more if required

Built within budget ($2-3K)

Powered from wall outlet, or off current 24V supply that powers exposure station and stepper controller

Powered by available sources (wall outlet, current power supply)

VOICE OF CUSTOMER - NEEDS Accepts computer input to specify test pattern Integrates into LabView software Fits into 10"x15"x12" available space of current

exposure system Uses current stepper motor if motion is required 1200*20±1 DPI Resolution (1200 DPI target, 600 DPI min) Controls exposure time or intensity Exposes a min area of the 5"x9" photoconductor Built within budget ($2-3K) Powered by available sources (wall outlet, current power

supply)

MOVING FORWARD - POSSIBLE SOLUTIONS Xerox HiQ LED Print

Head Can achieve resolutions

of 1200 x 2400 dpi The LEDS selectively

flash to create a pattern of dots on the photo receptor drum

Laser Printing assembly Common laser printers

achieve 1200 dpi Laser scans photo

receptor drum as it rotates, creating the latent image

GARLOCK TEST RIGUsman Asad

Jessica Fuss

INITIAL PROBLEM STATEMENT “Garlock Sealing Technologies is a global leader in

fluid sealing technologies, located in Palmyra, NY. As part of their product qualification process, they perform a gasket test according to ASTM F-37, which requires testing a specific type of gasket under a specific set of conditions, in order to measure permeation and leak rate. This is a manual process, with each test taking 20 minutes, and it is done one gasket at a time. Garlock engineers are in need of an automated test rig that will allow simultaneous testing of multiple gaskets. This test rig must follow an industry standard test procedure. While Garlock currently uses ASTM F-37, they are open to other options if they would facilitation automation of the process.”

BACKGROUND AND MOTIVATION

What are gaskets? What are gasket tests?

Sealability: ASTM F37 (A and B) Gas Permeability: DIN 3535 Creep Relaxation: ASTM F38 Compressibility Range: ASTM F36 Tensile Strength: ASTM D1708

STAKEHOLDERS

Garlock Sealing Technologies Wayne Evans

Product Engineer Randel Hill

Test rig operator

EXISTING TEST SETUP

CUSTOMER NEEDS

Save the operator time Increase accuracy and repeatability of tests Test results should be comparable to

industrial standards Record and store data Test large volume of gaskets for R&D

purposes

REFINED PROBLEM STATEMENT

“To develop an automated test rig that saves the operator time and measures gasket leak rate with high quality, precision and accuracy.”

OBJECTIVE TREE

1.1 Test rig measurements need to be accurate1.2 Test rig needs to produce repeatable results comparable to standard tests1.3 Needs to have quality in the results1.4 Needs to be able to measure flow rate in finer precision than 0.1 cc/hr

2.1 Testing rig needs to have good value for cost2.2 Total cost should not exceed $10-15K

3.1 Test rig needs to reduce operator time and effort3.2 Test rig needs to have high rate of gasket testing

4.1 Needs to measure leakage rate in cc/hour4.2 Needs to record gasket load and internal pressure4.3 Test results need to be digitally recorded4.4 Test needs to measure gaskets 12" x 12" and smaller

Outputs

Time

Cost

Accuracy

FUNCTIONAL DECOMPOSITION TREE

FUNCTIONAL DECOMPOSITION INPUT / OUTPUT

EXISTING TECHNOLOGIES

Cixi CAZ Group CorporationCost: 6800 USD

AUTOMATION OF TEST-RIG

Load application (up to 3000 psig) Load / strain measurement Flow measurement (0-1 ml/hr, at 0-30psig) Pressure sensor Control Valves Level measurement Data Acquisition Control System

QUESTIONS

Any questions about existing setup? Any suggestions about our approach to the

problem? Any suggestions about instrumentation

needs for this project?

POLYMER MEMBRANE TEST RIG (PMTR)Steven Lucchesi

Seaver Wrisley

PMTR MOTIVATION & BACKGROUND

Mission Statement: The Mechanical and Biomedical Engineering Departments

at the Rochester Institute of Technology (RIT) have developed a need for a test device capable of measuring the mechanical properties of biologically relevant materials.

Principle Needs: Ability to run simple experiments, demonstrating non-

linear stress-strain responses, creep, and stress relaxation.

More specialized needs for research.

PMTR STAKEHOLDERS & NEEDS

PMTR GOALS & VOC

We have split the goals of this project into several categories: Measured Properties Controlled Properties Specimen Accommodation Interface Ease of Use Portability Cost Environmental Health & Safety

All customers have expressed similar needs with varying levels of specification.

PMTR CURRENT TECHNOLOGY Currently, there is no lab

equipment available for educational use in the two Biomaterials courses. Typical tensile testers damage

biomaterials at the clamping points, rendering the test invalid

Previous/Current RIT Projects: Lowell Smoger’s Biaxial Test Rig P06218 Bausch & Lomb Eye

Membrane Indenter Bill Spath’s ASSET machine for

EAP (Electroactive Polymer) Research

Transverse Plunger

Axial Servo Driver

Environmental Tank

Figure 1: Automated Smart Sensing EAP Tank

Transverse Plunger Linkage Box

EAP

PMTR CURRENT TECHNOLOGY: ASSET (AUTOMATED SMART SENSING EAP TANK )

Preliminary design by Bill Spath Acts like typical tensile tester in horizontal direction for in-

plane loading Indenter for out-of-plane loading

Capable of being completely filled with solution

Interior would be made of biologically inert materials

PMTR PROPOSED SOLUTIONS Varying specification requirements of the individual

customers led to the need for multiple test rigs. Proposed test machines:

Biomaterials student test machine Single-axis loading Simple display (analog, ruler, etc.) Lower accuracy Manual control

Research quality test machine, incorporating ASSET concepts Multi-axis loading Fully automated interface (Matlab or LabView) Closed loop control of loading, load or deflection controlled Higher accuracy Environmental control capabilities Aqueous environment capabilities

QUESTIONS?

What questions do you still have? Are we lacking any important information? Proposed solutions?