Transcript Final Project Presentation

P09503
Electrophotographic Development and
Transfer Station
Team Members
Name
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
1.
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6.
Deliverables
An inventory and status of
current sub-systems, including
needed support systems.
A working Electrophotographic
Station.
Demonstrably improved device
safety.
An improved user interface
(includes control and display
functions)
Device documented for use,
maintenance and upgrade of
the device (User & Lab
Technician Manual)
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
Photoconductor
Charging
Exposure
Development
Transfer
System Architecture
Critical Customer Needs
1. Is Operational
2. Is Safe
3. Minimize user Intervention
4. Can Monitor Key Process Parameters
5. Can operate and monitor machine from one
interface
6. Easy to learn to use
Concept Summary
• Modifications and Improvements to EDTS Include
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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
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Transfer Drum Clutch
Motor Speed Control
Component Labeling
X-Y PC Measurement
Multiple Development Systems
Camera Automation
Light Curtain
Special Thanks
RIT Faculty
• 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
Professional
• Bill Nowak – Xerox
▫ Principle Engineer
 Motion and Quality Systems
• Gregory Miller – Kodak
▫ Software Engineer
Questions