Xerox Bearing Tester Final Project Review [1] May 10, 2013 P13505 - PowerPoint PPT Presentation

Xerox Bearing Tester Final Project Review [1] May 10, 2013 P13505 1

Project Team and Stakeholders Customer Erwin Ruiz Technical Specialist Project Manager Xerox Corporation Guide William Nowak Principle Engineer Xerox Corporation Faculty Consultant Jason Kolodziej RIT ME Faculty Project Team Stephen Rugg Project Manager Will Craig Co-lead Engineer Andrew Shuman Co-lead Engineer Kevin Albino Team Facilitator/Project Engineer Lauren Kaczor Project Engineer Tyler Hill Project Engineer May 10, 2013 P13505 2

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 3

Updated Customer Needs May 10, 2013 P13505 4

Specifications May 10, 2013 P13505 5

System Assembly May 10, 2013 P13505 6

Operation May 10, 2013 P13505 7

Machining • 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 May 10, 2013 P13505 9

LabVIEW • Plots of raw data and FFT • Display RMS values May 10, 2013 P13505 10

Testing • Performed 10+ MSAs • Refined SOP • Passed MSA using 3 bearings and 7 operators May 10, 2013 P13505 11

Data Bearing Vibration Levels 0.7 0.6 0.5 Vibration (g's) 0.4 Good Bearings 0.3 Scrap Bearings 0.2 Reused Bearings 0.1 0 0 5 10 15 20 Bearing • 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 May 10, 2013 P13505 12

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 13

Recommendations-Operations • Establish pass/fail threshold for bearings – Send a range of bearing to Arnprior • Further automate process – Use motor controller with computer input • Purchase new signal conditioner • Remove second accelerometer and drop down rails May 10, 2013 P13505 14

Recommendations - Hardware • Make bearing clamp out of steel • Enlarge dowel pins • Hardened shaft • Second press-fit mandrel • Larger arbor press May 10, 2013 P13505 15

What We Learned • Concept selection process • The importance of backup plans • LabVIEW – Signal Processing • Machining • Measurement system analysis • Teamwork • Team management May 10, 2013 P13505 16

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 17

References 1. http://www.amazon.com/SKF-Bearing-Clearance-3600lbf- Capacity/dp/B0071ARFWS May 10, 2013 P13505 18