P09503Electrophotographic Development and Transfer Station

Team MembersName Discipline Role

David Schwartz ISE Team Lead – Warning Signs

Ruth Gay ME Paper Delivery System

Phillip Lopez ME Ozone Filter

Dan Summers ME ME Support

Rachel Chrash EE LED Exposure System

Min-Shi Hsiao EE PC Potential Measurement

Andrew Kearns EE Transfer Drum Speed Measurement, Camera System

Sasha Oliver CE User Interface

Project Background• Project 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

Project Description• Working Electrophotographic

station to vary both the printing material and the printing process parameters as to better understand and improve the performance of similar printing systems.

• End Users PRISM Lab Center for Imaging Science

Deliverables1. An inventory and status of current

sub-systems, including needed support systems.

2. A working Electrophotographic Station.

3. Demonstrably improved device safety.

4. An improved user interface (includes control and display functions)

5. Device documented for use, maintenance and upgrade of the device (User & Lab Technician Manual)

6. Demonstrably Improved Sensing and Control Subsystem

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 page▫ Charging▫ Exposure▫ Development▫ Transfer▫ Fusing ▫ Cleaning

• P09503 only includes the first four

Electrophotographic and Development Station

Electrophotographic and Development Station

ChargingExposure

Development Transfer

ConsultantsRIT Faculty Professional

• Jonathon Arney, Ph.D▫ Center for Imaging Science

Physical & Optical Measurements• Susan Farnand, Ph.D

▫ Center for Imaging Science Color and Vision Science

• John D. Wellin▫ Mechanical Engineering

Control Systems• Marcos Esterman, Ph.D

▫ Industrial and Systems Engineering Product & Process Development

• Bill Nowak – Xerox▫ Principle Engineer

Motion and Quality Systems• Gregory Miller – Kodak▫ Software Engineer

Customer Needs & Functional Diagram1. Is Operational2. Is Safe3. Minimize user

Intervention4. Can Monitor Key

Process Parameters5. Can operate and

monitor machine from one interface

6. Easy to learn to use

Ozone Fan/Filter Assembly•Reduce and Secure Ozone

Test Stand▫Ozone hazardous to

humans if exposed to enough

▫ Law states maximum ozone in A/C Space is 0.05 ppm

▫>0.200 ppm increases risk of health issues

•Two Options▫Verify current system or ▫ Implementation of further

improvement to control Ozone Levels

Monitoring Potential on Photoconductor

•Monitoring potential of photosensitive material will help characterize exposure input noise source

•Charge v. Exposure plot after measurement can be viewed

•Dark Decay Research Possible

LED Exposure System• LED Print Heads used in

copiers and printers to expose Photosensitive Material are commonly used

• LED Exposure system to replace current incandescent system

• Advantages▫ More versatile and reliable light

source▫ Low Power Consumption▫ Longer Bulb Life▫ No potential for overheat▫ Inexpensive to replace

incandescentlight source

collimatinglens

image planewith modulating masks

image planewith modulating masks

4x4 array of LEDs

Current System Better LED system

incandescentlight source

collimatinglens

image planewith modulating masks

image planewith modulating masks

4x4 array of LEDs

Current System Better LED system

Paper Delivery System•Existing roller system

requires manually catching paper after application of toner from roller

•Possible risks of manual handling▫Shock Short from High

Voltage Roller▫Pinch Point of Rollers and

Pneumatics▫Marred Image Quality

High Visibility Warning Signs• Purpose of warning signs

▫ Alert user to specific hazard▫ Identify how hazard can be

avoided• Current signs do not accomplish

this• Remove current warning signs• Replace with ISO designed signs• Add new ISO signs where needed

Camera System•Purpose is to gain

understanding of how image is developed onto photoreceptive material

•Photoreceptive material imaged after development and before transfer

Transfer Roller Speed Measurement• Speed of transfer roller critical to

timing control and image quality• Need to assure that transfer

drum rotates at the same speed as the moving photoconductor as to not elongate/condense the image

• Need to assure that the transfer roller will be in the proper position for transfer to paper

Labview Control Interface• Current control system is done

via PLC• Better solution needed to replace

current system with a new user friendly interface▫ Automatic and Manual Setting

• Labview uses dataflow programming to define inputs/outputs and execution sequence of the virtual instrument

• Connect devices directly to DAQ to allow for more robust control

Technical Risk Assessment•Data Acquisition Implementation – Coding

Complications / Integration with Subsystems▫Mitigation: Primary Focus During SD II

•Obtaining Optimal Parameters (>10) for EP Process▫Mitigation: Experimental Design to optimize

parameters, Consult with Xerox and CIS•Toner and Developer Contamination▫Mitigation: Implement Air Filtration System and

Warning Signs

Current State of Design•Current design meets all feasible customer needs▫Customer understands unfeasible needs

•Current design meets all engineering specifications•Budget = $1500▫Total Expenditures < $900

•Schedule▫On Schedule, no Design Delays

Product Development Process Phase•Phase 0: Planning▫Completed

•Phase 1: Concept Development▫Completed

•Phase 2: System Level Design▫Completed

•Phase 3: Detailed Design▫Completed

•Phase 4: Testing and Refinement▫Will begin in SD II

Senior Design II Schedule and MilestonesMilestone Duration Completion Date

User Manual Complete 14 Days 12/18/08

Ozone Decision 39 Days 1/9/09

PC Potential Measurement Device Complete

35 Days 2/10/09

LED Complete 29 Days 2/2/09

Paper Delivery System Complete

43 Days 2/20/09

Warning Signs Complete 18 Days 1/7/09

Labview/Camera/Speed Complete

73 Days 3/25/08

Questions