P11511 Project Review

Project Team, Faculty, and Customer• Project Team:

–Project Lead:Kevin Argabright (ME)

–Team Members:John Fitch Dean (ME)Mike Buonaccorso (ME)Justin Eichenberger (ME)

–Project Guide:William Nowak (Xerox Corporation)

• Faculty:–Consultant

Dr. Stephen Boedo• Customer:

–Xerox CorporationErwin RuizMelissa Monahan

Project Description

• Create a measuring tool to aid Xerox Corporations engineering team in collecting necessary data for characterizing bearing life in the iGen Fuser assembly.

Customer Needs

• Used a pairwise comparison chart

• Most Important Needs:– Develop method to characterize physical

properties of bearings over their physical life ✓– Document the procedure for collecting data ✓

Develop method to characterize physical properties of bearings over their physical life CN1Collect data on bearing properties CN2 cCorrelate physical property to end of life CN3 c rEncorporate multiple sensors CN4 c r rCharacterize physical properties over the bearing's physical life CN5 c c c cCreate failure criteria CN6 c c c c cDocument the procedure (Testing) CN7 c r r r r rTesting bearings is quick and easy to do CN8 c c c c c c cDocument the procedure (Collecting Data) CN9 c r r r r r r r

CN1 CN2 CN3 CN4 CN5 CN6 CN7 CN8 CN9Totals 8 3 4 5 2 1 6 0 7Weight (%) 22.2 8.3 11.1 13.9 5.6 2.8 16.7 0.0 19.4

Customer Needs – cont’d• Develop method to characterize physical properties of

bearings over their physical life ✓• Collect data on bearing properties ✗• Correlate physical property to end of life ✗• Incorporate multiple sensors ✓• Characterize physical properties over the bearing's

physical life ✗• Create failure criteria ✗• Document the procedure (Testing) ✓• Testing bearings is quick and easy to do ✓• Document the procedure (Collecting Data) ✓

Engineering SpecsEngineering Specs

Engineering Metrics Units Technical TargetsMeasurement of Vibration g TBDMeasurement of Acceleration g TBDMeasurement of Temperature °F TBDError of Measurements % < 5%Time to Take Measurements s TBDApplied Load lb 360lbApplied Temperature °F 230°FFrequency RPM 79.8RPM

Notes:No longer heating the bearingTemperature measurements will still be takenTime to take measurements is still TBD

Concept Summary

• Design chosen– Fixed Outer Race– Loading the bearing - Pneumatic cylinder– Rotating the bearing - DC motor– Heating the bearing - Conduction to outer surface– Driving shaft - Belt– Measuring vibration - Accelerometer– Measuring heat - Thermistor– Microcontroller– Labview

Final Product

Project Status

• Working– Motor spins bearing at specified speed– Pneumatic cylinder loads bearing at specified load– Accelerometer measures vibrations– Thermistors measure temperature– LabView collects data

• Not Working– Bearing is not heated to spec

Project Schedule

• The project is 2 weeks behind, with first round of testing occurring in week 10 instead of week 8

• Data is not going to be collected by our group

Project Budget

• Starting budget was $3000• Ending balance is $88.95• Used ~97%

System Architecture

LabVIEW Interface• Labview Interface

displaying running conditions, waveforms, and expected frequencies.

• Likely to be updated as debugging and refinement is continued

• Industry Standard for easy portability and future modifications

• Waveforms shown are from sample data.

Control System

• All electronics and pnumatic controls housed in enclosed PVC “junction box”

• Device fed on a single standard wall outlet • Warning and status indicators on front panel• Emergency stop button that will kill all power

to system• Modular architecture will allow for portability

and quick set up and tear down.

Project Wrap UpSuccesses

• Established a working relationship with multiple engineers at the Xerox Corporation• Gained extensive experience in different

machining operations• Became more familiar with the LabVIEW

program as well as interfacing hardware with software• Design met most specifications• Worked together well as a team throughout the

project

Project Wrap UpFailures

• Due to the uneven geometry, we decided to eliminate the heater due to concerns of interference in the fixture• Due to time constraints, extensive data was not

able to be collected• We were not able to correlate bearing life with

the data our fixture provided

Future Work• Heating the bearing– As described previously, the mica band heater was

eliminated from the tester– A different type of heater (cartridge heater) or

alternate manufacture can be selected but care must be taken that the tolerances are tighter than the one previously chosen

• Correlating bearing life with data– Extensive testing must be performed before

bearing life can be coordinated with the data provided by the tester

Future Work Cont’d

• LabVIEW Interface– Further debugging and refinement required

• Mounted bearings–Mounting bearings create interference and it

would be ideal to eliminate them in a future design if possible

• Loading/Unloading bearings– Bearings can be made easier to replace to

streamline testing procedures

Lessons Learned

• Take what manufacturers say with a grain of salt.• Lead times and design specs

• Customer needs can be more ambitious than time allows.

• Keeping good meeting minutes is important for staying organized.

P11511 Senior Project Review

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