May 10, 2013 P13505 1

Xerox Bearing TesterFinal Project Review

May 10, 2013 P13505 2

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

May 10, 2013 P13505 3

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

May 10, 2013 P13505 4

Updated Customer Needs

May 10, 2013 P13505 5

Specifications

May 10, 2013 P13505 6

OperationAdobe Acrobat

Document

Alignment Procedure

Adobe Acrobat Document

Assembly Procedure

Testing Procedure

Adobe Acrobat Document

May 10, 2013 P13505 7

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

May 10, 2013 P13505 8

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

May 10, 2013 P13505 9

LabVIEW

• Bandpass filter from1000Hz to 7500Hz• Plots of raw data and FFT • Display averaged RMS values

Bearing Test Stand LabVIEW.vi

May 10, 2013 P13505 10

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)

May 10, 2013 P13505 11

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)

May 10, 2013 P13505 12

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

May 10, 2013 P13505 13

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

)

May 10, 2013 P13505 14

Dry Bearing v. Greased Bearing• Grease acts as damping• Vibration relative to one another doesn’t change

May 10, 2013 P13505 15

Calibration• Purchase a new bearing

and remove grease• Collect vibration readings

on the bearing• Bearing can be used to

calibrate the system

May 10, 2013 P13505 16

Budget• Overall Budget - $1500-$3000

• Final Cost Breakdown– Data Collection $760.46– Physical Structure $602.91– Shipping $75.66– Total $1439.03

May 10, 2013 P13505 17

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

May 10, 2013 P13505 18

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

May 10, 2013 P13505 19

Thank You!• Xerox• Bill Nowak• Erwin Ruiz• Dr. Kolodziej• Dr. Boedo• Dr. Ghoneim• RIT Machine Shop-Rob Kraynik, Dave Hathaway, Jan

Maneti• MSD Lab

May 10, 2013 P13505 20

References1. http://www.amazon.com/SKF-Bearing-Clearance-3600lbf-Capacity/dp/

B0071ARFWS

May 10, 2013 P13505 21

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.

May 10, 2013 P13505 22

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