Download - Xerox Bearing Tester Final Project Review
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May 10, 2013 P13505 1
Xerox Bearing TesterFinal Project Review
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Project Team and StakeholdersCustomer
Erwin Ruiz Technical Specialist Project ManagerXerox Corporation
GuideWilliam Nowak Principle Engineer
Xerox Corporation
Faculty ConsultantJason Kolodziej RIT ME Faculty
Project TeamStephen Rugg Project ManagerWill Craig Project EngineerAndrew Shuman Project EngineerKevin Albino Project EngineerLauren Kaczor Project EngineerTyler Hill Project Engineer
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Project Background• There are 2 Bearings in the iGen Printer System supporting
the fuser roller• Every 200,000 prints the fuser roller assembly comes in for
remanufacturing• Bearing is reused a maximum of 4 times• Currently, there is no quantitative test to qualify bearings
– Potentially leads to many good bearings being scrapped
• Customer wishes to use the machine as a design tool
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Updated Customer Needs
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Specifications
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OperationAdobe Acrobat
Document
Alignment Procedure
Adobe Acrobat Document
Assembly Procedure
Testing Procedure
Adobe Acrobat Document
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Machining: Drawings are contained in drawing package
• Manual Machining– Motor Block– Mandrels (press and
slip fit)– Arbor press fixtures– Clamp attachment– Clamp frame
• CNC Machining– Clamp bore
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Data Acquisition• Designed a signal conditioner to power accelerometers• Pairs with NI 6210 DAQ• DAQ outputs accelerometer readings and motor speed• Saved $350
Concerns:•Imaginary signal at ~4300Hz•The signal is not AC coupled
Recommendations:Option 1•Use PICO 5A24S chip to increase voltage from 5 to 24V•Add a range of capacitors from voltage signal to act as dampersOption 2•Purchase a signal conditioner
Board Model Schematic.sch Board Model.pcb
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LabVIEW
• Bandpass filter from1000Hz to 7500Hz• Plots of raw data and FFT • Display averaged RMS values
Bearing Test Stand LabVIEW.vi
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0 5 10 15 20 250
0.05
0.1
0.15
0.2
0.25
0.3
0.35
0.4
0
20
40
60
80
100
120
Changes During Continuous Operation (1000 rpm)
Accelerometer 1Torque*10e-3Temperature
Time (min)
Vibr
ation
(g's
) ana
d To
rque
(in*
lbs)
Tem
pera
ture
(deg
rees
F)
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0 2 4 6 8 10 12 14 16 180
0.2
0.4
0.6
0.8
1
1.2
0
20
40
60
80
100
120
140
Changes During Continuous Operation (1500 rpm)
Accelerometer 1Torque*10e-3Temperature
Time (min)
Vibr
ation
(g's
) ana
d To
rque
(in*
lbs)
Tem
pera
ture
(deg
rees
F)
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Testing• Performed 10+ MSAs• Refined SOP• Passed MSA using 3 bearings and
7 operators
Testing Conditions:• Run for 15 sec at 1000rpm• Average 5 seconds of overall RMS
data• Collect a data point at 15 sec and
compare against pass/fail criteria
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Data
• RMS between 0.1 and 0.7 g’s• 13 ranges of resolution
– Differentiate ±0.025 g• Acoustic machine passed all “good” and “bad” bearings
0 5 10 15 200
0.05
0.1
0.15
0.2
0.25
0.3
0.35
0.4
0.45
Bearing Vibration Levels
Good BearingsScrap BearingsReused Bearings
Bearing
Vibr
ation
(g's
)
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Dry Bearing v. Greased Bearing• Grease acts as damping• Vibration relative to one another doesn’t change
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Calibration• Purchase a new bearing
and remove grease• Collect vibration readings
on the bearing• Bearing can be used to
calibrate the system
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Budget• Overall Budget - $1500-$3000
• Final Cost Breakdown– Data Collection $760.46– Physical Structure $602.91– Shipping $75.66– Total $1439.03
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Recommendations-Operations• Establish pass/fail threshold for bearings
– Send a range of bearings to Arnprior
• Further automate process– Use motor controller with computer input– Use an actuator to apply an axial load to the top and the bottom of
the clamp
• Purchase a new signal conditioner• Remove second accelerometer and drop down rails
– Stiffen the system, reduce outside vibration
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Recommendations - Hardware• Bearing Clamp– Harden bolt surface on the aluminum clamp or make a
new clamp out of steel– Enlarge dowel pins to restrict movement of the top plate
• Purchase a hardened shaft• Manufacture a second press-fit mandrel– May slightly increase test speed if desired
• Purchase larger arbor press– Easier to press bearings
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Thank You!• Xerox• Bill Nowak• Erwin Ruiz• Dr. Kolodziej• Dr. Boedo• Dr. Ghoneim• RIT Machine Shop-Rob Kraynik, Dave Hathaway, Jan
Maneti• MSD Lab
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References1. http://www.amazon.com/SKF-Bearing-Clearance-3600lbf-Capacity/dp/
B0071ARFWS
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Appendix: Bearing Slippage on Acoustic Machine
The slippage is noticeable on the bearing. If there was no slippage the two pink post-it notes would track together. The inside pink post-it disappears because it is spinning much faster than the outside one. Concerned that this will affect the accuracy and consistency of the measurement.
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Technical Paper• The technical paper discusses the whole of the
project in detail along with the testing that was conducted and the reason the current design was settled upon.
Microsoft Office Word Document