iGen Fuser Bearing
Project P11511
Agenda
Meeting Timetable
Start Time
Review Topic
3:30
Introductions
3:35
Project Description
3:45
Customer Needs
4:00
Risk Assessments
4:10
Concept Selection
4:30
Houses of Quality
4:35
Timeline
4:40
Discussion
5:00
Meeting Adjourned
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 Corporation
Erwin Ruiz
Melissa Monahan
Project Background
• Xerox is looking to reduce costs caused by
replacing bearings
• Xerox originally looked into evaluating the
bearings of different
manufacturers
• The Fuser bearings on
Xerox iGen printers
currently undergo a
very subjective test
iGen Machine
Running Conditions of Fuser
When fuser assembly is fully
“cammed” in, the fuser roll
experiences an axial load of 1200lbs
(600lb/bearing)
Fuser rotates at 79.8RPM
Outer race of the fuser bearings
experience a temperature of 230°F
Bearing Life
• Based on bearing data sheet, minimum life is
1,000,000 revolutions
– LU10 DLIFE tested at 16,672N (3748lb)
• Due to current testing methods, bearings are
assumed “failed” after 200,000 revolutions
• Xerox Corporation’s goal is to achieve a life of
at least 800,000 revolutions
Customer Wants
• Want to reduce costs
– Want to better understand the capabilities of the
current bearings
– Want to compare bearings from different
manufacturers
– Ensure no bearings fail in the field
Project Scope
• Time constraints do not allow our team to
collect all the pertinent data
– To qualify with Xerox Corporation’s quality
standards, 1,000+ measurements are required
• Develop a test plan for Xerox Corporation to
collect and correlate physical data of bearings
• Propose test method for manufacturing to
implement that will replace current “spin test”
Customer Needs
• A method to characterize physical properties of bearings
over their physical life
• Collect data on bearing properties
–
–
–
–
–
Correlate physical property to failures
Characterize physical properties over the bearing's physical life
Determine running cost for each bearing
Create failure criteria for each bearing
Evaluate bearings from different manufacturers
• Develop method for manufacturing to test bearings for
immanent failures
– Document the procedure
– Testing bearings is quick and easy to do
Weighted Customer Needs
• Used a pairwise comparison chart
Create a method to characterize physical
properties of bearings over their physical life
Collect data on bearing properties
Correlate physical property to end of life
Characterize physical properties over the
bearing's physical life
Determine running cost for each bearing
Create end of life criteria for each bearing
Evaluate bearings from different manufacturers
Develop method for manufacturing to test
bearings for immanent end of life
Document the procedure (Testing)
Testing bearings is quick and easy to do
Document the procedure (Collecting Data)
CN1
CN2
CN3
c
c
r
CN4
CN5
CN6
CN7
c
c
c
c
c
c
r
c
c
c
r
c
c
r
c
r
c
c
CN8
CN9
CN10
CN11
c
c
c
c
C1
r
c
c
r
C2
r
c
c
r
C3
r
c
c
r
C4
r
c
c
r
C5
r
c
c
r
C6
Totals
Weight (%)
10
18.87
5
9.43
6
11.32
4
7.55
3
5.66
7
13.21
r
c
c
r
C7
c
c
r
C8
2
3.77
8
15.09
c
r
C9
r
C10
1
1.89
0
0.00
C11
9
16.98
• Most Important Needs:
– Create method to characterize bearing properties over
physical life
– Document the procedure for collecting data
Engineering Specs
Engineering Specs
Engineering Metrics
Measurement of Torque
Measurement of Sound Level
Measurement of Vibration
Measurement of Acceleration
Measurement of Temperature
Error of Measurements
Time to Take Measurements
Applied Load
Applied Temperature
Frequency
Units
in-lb
dbRMS
g
g
°F
%
s
lb
°F
RPM
Technical Targets
TBD
TBD
TBD
TBD
TBD
< 5%
< 10sec
600lb
230°F
79.8RPM
Risks
Risk
Cause
Mitigation
No relationship exists between Try multiple methods of data collection
physical metric and bearing life (acoustic, mag, proximity, etc..)
Ensure proper training and seek rapid
Bearing life fixtures break
Use, mechanical wear
repair
Design error, mechanical wear, Design robustly and be prepared with
Our testing apparatus breaks user error
replacement parts
Data does not correlate
Needed item's lead time goes
outside of project time frame Manufacturing delays
Ask manufactures for an estimate for
lead time and stay in contact for updates
Severity Likelihood Total
3
2
6
2
2
4
2
2
4
2
2
4
Data collection and analysis take
No easy method for bearing to long to be feasible for the
Try multiple methods and speak with
testing on manufacturing floor throughput of Xerox
manufacturing to understand needs
2
2
4
Time to collect data is too
slow
Data logging too slow,
accelerated wear is insufficient
2
2
4
Project goes over budget
Sensors, raw materials and
tooling are more expensive than Before purchasing submit a proposed
thought
budget to Xerox
2
2
4
Not enough collected data or to Speak with Erwin and Melissa to ensure
much inherent noise
our measurement is up to spec
3
1
3
Theft, accidents, neglect.
3
1
3
3
1
3
2
2
1
1
2
2
2
1
2
1
1
1
Measurement system fails
Xerox standards
Sensors are lost, stolen or
damaged
Customer is unhappy with
deliverables
Team member is seriously
injured or ill
Software is lost or corrupted
Poor Communication
Sickness, death in family, etc..
Loss of flash drive or virus
Team arguments cause delays Poor Communication
Travel to Xerox is prevented
Seek accelerated wear and ensure data
loggers are sensitive enough
Keep equipment secured at Xerox or RIT
Maintain communications with Xerox
throughout the project
Be prepared to delegate that person's
responsibilities across the team
Keep multiple, up to date copies
Allow for time to discuss ideas and
concerns
Leave room in project timeline so that
Weather, Xerox emergency, RIT project does not hinge on any single day
emergency.
at Xerox
Concept Generation
Concept Selection
Functions
Measure
Physical
Properties
Methods
Acoustic
Accelerometers
Higher Load
(accelerated wear)
Actual Load
Faster
Printing Speed (accelerated wear) slower
Bearing Loading No Load
Frequency
Temperature
Proximity
Not Heated
Where to collect In life test
fixture
data
Same as printer
Hotter (better
FOS)(accelerated
wear)
On new test
fixture
by hand (current
spin test)
Thermocouple Torque
Mag Sensor
Ultrasonic
Hybrid
Set up
Concept Selection
Senior Design Team P11511 Pugh Matrix, January 2011
Concept Name:
Measured on life fixture?
Concept Description:
Acoustic Fixture
Torque Fixture
NO
NO
Proximity
Sensors
YES
Fixture that spins the bearing
Fixture that measures the
Uses sensors to build a
at a given speed and load
amount of torque required to
"map" of the bearing. This
and measures the noise
spin the bearing at a given map is investigated for signs
from the bearing. Noise
load.
of weak chaos
measured in dbRMS.
Mag Pickup
Sensors
No
Ultrasonic
Sensors
No
Measure and record
vibration data of bearings
during life in the fixture.
Detects the voltage induced
by a spinning metal shaft
Pulses a ultrasonic pulse
and reads the return as a
function of density and depth
Thermocouples
Accelerometers
Accelerometers
YES
YES
No
Measure and record
temperature of bearings
during their life in the fixture.
Measure and record
vibration data of bearings
during life in the fixture.
Ease of Use
0
+
-
+
+
+
-
0
Cost
0
+
-
+
+
+
+
+
Accuracy
0
-
0
-
-
0
0
0
Complexity
0
+
-
+
0
0
+
-
Technology Risk
0
+
-
+
+
+
0
+
Total Positives:
0
4
0
4
3
3
2
2
Total Negatives:
0
1
4
0
1
0
1
1
Concept Selection
• Helped isolate design concepts that had merit
for project
• There were multiple viable solutions
• A major risk of the project is that there could
be no correlation between data
– Reduce this risk by pursuing several measurement
technologies
Concept Selection
• Acoustic Fixture
• Attach accelerometers to current life fixture
• Making a fixture to subject bearings to
expected loads
– Will be designed with attaching accelerometers
and thermocouples in mind
• Torque Fixture
– Quantify data from “spin test”
Acoustic House of Quality
Measures acoustic properties of bearings
Amount of error in measurements
Time to take measurements
Measures acoustic properties of bearings
Amount of error in measurements
Time to take measurements
++
Weights
Develop method to characterize physical properties of bearings over their physical life
Collect data on bearing properties
Correlate physical property to end of life
Evaluate bearings from different manufacturers
Characterize physical properties over the bearing's physical life
Determine running cost for each bearing
Create end of life criteria for each bearing
Develop method for manufacturing to test bearings for immanent failures
Document the procedure (Testing)
Testing bearings is quick and easy to do
Document the procedure (Collecting Data)
+++
+
18.87
9.43
11.32
7.55
5.66
13.21
3.77
15.09
1.89
0
16.98
9
3
3
1
3
1
3
3
1
1
1
1
3
1
1
3
1
1
3
3
1
3
1
3
1
1
1
1
1
9
3
9
1
Importance
3.452513 2.018679 2.471279
Life Tester House of Quality
++
+
+
+
1
3
3
3
9
3
3
3
3
3
3
3
3
3
1
3
1
3
1
1
Amount of error in measurements
3
3
3
1
3
3
3
3
3
Applied frequency of bearings
3
3
3
1
3
3
3
1
3
3
3
1
1
1
1
3
3
3
3
3
9
3
3
3
3
3
3
3
1
9
Time to take measurements
++
Measures torque of bearings
+
Measures temperature of bearings
+
Applied temperature of bearings
18.87
9.43
11.32
7.55
5.66
13.21
3.77
15.09
1.89
0
16.98
++
+
+
Applied load of bearings
Weights
Develop method to characterize physical properties of bearings over their physical life
Collect data on bearing properties
Correlate physical property to end of life
Evaluate bearings from different manufacturers
Characterize physical properties over the bearing's physical life
Determine running cost for each bearing
Create failure criteria for each bearing
Develop method for manufacturing to test bearings for immanent failures
Document the procedure (Testing)
Testing bearings is quick and easy to do
Document the procedure (Collecting Data)
++
+
+++
+
+
+
+
Measures amount of vibration in bearings
Applied load of bearings
Applied temperature of bearings
Applied frequency of bearings
Measures amount of vibration in bearings
Measures temperature of bearings
Measures torque of bearings
Amount of error in measurements
Time to take measurements
1
1
1
1
3
3
1
3
1
Importance 1.735738 1.735738 1.735738 3.452638 2.660238 2.962038 2.943438 1.226179
Torque House of Quality
Measures amount of torque of bearings
Amount of error in measurements
Time to take measurements
Measures amount of torque of bearings
Amount of error in measurements
Time to take measurements
++
Weights
Develop method to characterize physical properties of bearings over their physical life
Collect data on bearing properties
Correlate physical property to end of life
Evaluate bearings from different manufacturers
Characterize physical properties over the bearing's physical life
Determine running cost for each bearing
Create failure criteria for each bearing
Develop method for manufacturing to test bearings for immanent failures
Document the procedure (Testing)
Testing bearings is quick and easy to do
Document the procedure (Collecting Data)
+++
+
18.87
9.43
11.32
7.55
5.66
13.21
3.77
15.09
1.89
0
16.98
9
3
3
1
3
1
3
3
1
1
1
1
3
1
1
3
1
1
3
3
1
3
1
3
1
1
1
1
1
9
3
9
1
Importance 3.452513 2.018679 2.471279
Questions?
P11511 Senior Design Review
Thank you for attending!