Download - Test Rig Development Group
TEST RIG DEVELOPMENT GROUPProblem Background & Voice Of the CustomerProject: R13301Rochester Institute of TechnologyDesign 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 ErbeldingSakif 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 AsadJessica 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 LucchesiSeaver 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?