Electrophotographic Development and Transfer Station Team Members Name Discipline David Schwartz ISE Ruth Gay ME Phillip Lopez ME Dan Summers ME Rachel Chrash EE MinShi Hsiao EE Andrew Kearns ID: 260377
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P09503Electrophotographic Development and Transfer StationSlide2
Team Members
Name
Discipline
David SchwartzISERuth GayMEPhillip LopezMEDan SummersMERachel ChrashEEMin-Shi HsiaoEEAndrew KearnsEESasha OliverCESlide3
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 LabLayered ManufacturingCenter for Imaging ScienceDeliverablesAn 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 SubsystemSlide4
Project BackgroundProject 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 Slide5
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 pageChargingExposureDevelopmentTransferFusing CleaningP09503 only includes the first fourSlide6
Electrophotographic and Development Station
Charging
Exposure
DevelopmentTransferPhotoconductorSlide7
System ArchitectureSlide8
Critical Customer Needs1.
Is Operational
2. Is Safe
3. Minimize user Intervention4. Can Monitor Key Process Parameters5. Can operate and monitor machine from one interface6. Easy to learn to useSlide9
Concept SummaryModifications and Improvements to EDTS Include
Ozone Fan/ Filter Assembly Analysis
Electrostatic Voltage Measurement Implementation
LED Exposure System ImplementationPaper Delivery SystemPhotoconductor Imaging System MountElectrophotographic Process Control and AutomationControl and Automation HardwareSlide10
Ozone Fan/ Filter Assembly AnalysisCorona and Grid produce O
3
during operation
Maximum allowed concentration indoors is 0.050 ppm MethodologyVerify system produces levels that are safeDevice is verified if levels test below >0.2ppmConstruct new mount and assembly for ozone fan if device produces ozone above >0.2ppmTest ResultsThe 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)Slide11
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 ResearchImplementation and Measurements1st measurement after charging2nd measurement after exposureMeasurement limited to one dimensionProcess created for two dimensional measurementSlide12
ESVM
Implementation Slide13
LED Exposure System
LED Exposure system replaces current incandescent system
Mounted directly under exposure lift
AdvantagesMore versatile and reliable light sourceLow Power ConsumptionLonger Bulb LifeNo potential for overheatInexpensive to replaceSlide14
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 RollerPinch Point of Rollers and PneumaticsMarred Image Quality from HandlingMachined Paper Delivery SystemClear tray to allow for Photoconductor ImagingSlide15
High Visibility Warning Signs
Purpose of warning signs
Alert user to specific hazard
Identify how hazard can be avoidedPrevious signs did not accomplish this or were not presentFMEA Analysis dictated locationsISO 3864 Formula dictated proper size and imagesMethodologyRemove current warning signsReplace with ISO designed signsAdd new ISO signs where neededFinal FMEA Analysis verified all sign placmentsSlide16
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 SystemSlide17
Electrophotographic Process Control and Automation
Most critical part of the entire project
LabView
virtual instruments is used to control all devicesAll components connectedHigh Voltage and Camera are on a separate systemTwo Modes of OperationAutomaticParameters are presetUser only needs to press start to begin and stop to endManualUser can control any part of the systemSlide18
BudgetProject Budget: $1500
Budget Utilized ~$1480 (98%)
Major Purchases
National Instruments Data Acquisition DevicePCI-6515 – 64 Channel Digital I/O PCI Card, Cable and Terminal BlockSick|Stegman Encoders2 X HD201024 Pulses/RevLuxeon Star/O LEDRoyal Blue Batwing, 220 mW @ 350mASlide19
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 SubstrateSlide20
Electrophotographic and Development Station
Before
AfterSlide21
Future Improvements Transfer Drum Clutch
Motor Speed Control
Component Labeling
X-Y PC MeasurementMultiple Development SystemsCamera AutomationLight CurtainSlide22
Special Thanks
RIT Faculty
Professional
Jonathon Arney, Ph.DCenter for Imaging SciencePhysical & Optical MeasurementsSusan Farnand, Ph.DCenter for Imaging ScienceColor and Vision ScienceJohn D. WellinMechanical EngineeringControl SystemsMarcos Esterman, Ph.DIndustrial and Systems EngineeringProduct & Process DevelopmentBill Nowak – XeroxPrinciple EngineerMotion and Quality SystemsGregory Miller – KodakSoftware EngineerSlide23
Questions