Xerox Bearing Tester Detailed Design Review [1] 8 February 2013 - - PowerPoint PPT Presentation

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Xerox Bearing Tester Detailed Design Review [1] 8 February 2013 - - PowerPoint PPT Presentation

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Xerox Bearing Tester Detailed Design Review [1] 8 February 2013 P13505 1 Project Team and Stakeholders Customer Erwin Ruiz Technical Specialist Project Manager Xerox Corporation Guide William Nowak Principle Engineer Xerox Corporation

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8 February 2013 P13505 1

Xerox Bearing Tester Detailed Design Review

[1]

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8 February 2013 P13505 2

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

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8 February 2013 P13505 3

Meeting Agenda

  • Project Background

1:05-1:10

  • Updated Customer Needs & Specs (Lauren)

1:10-1:20

  • Test Plan (Tyler)
  • MSA Plan (Tyler)
  • System Assembly

1:20-2:10

  • Overall Design (Kevin)
  • Motor Design (Andrew)
  • Motor Torque Requirements (Will)
  • Mandrel (Andrew)
  • Alignment System (Lauren)
  • Clamp (Andrew)
  • Frequency Analysis of Rails (Steve)
  • Data Acquisition

2:10-2:30

  • Accelerometer Mounting (Steve)
  • Signal Conditioner (Steve)
  • DAQ (Will)
  • LabVIEW (Will)
  • Budget/BOM (Tyler)

2:30-2:40

  • Risk Assessment (Lauren)

2:40-2:45

  • Questions
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8 February 2013 P13505 4

Project Background

  • There are 2 Bearings in the iGen Printer System supporting

the fuser roller

  • Every 200,000 prints the printers come in for remanufacturing
  • Bearing is reused a maximum of 5 times
  • Currently, there is no quantitative test to qualify bearings

– Current test is to hold the bearing up to your ear and see if you hear or feel anything – Potentially leads to many good bearings being scrapped

  • Customer wishes to test performance of other bearing

manufacturers against current product

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8 February 2013 P13505 5

Project Background

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8 February 2013 P13505 6

Updated Customer Needs

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8 February 2013 P13505 7

Specifications

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8 February 2013 P13505 8

Test Plans

  • SP1: Time To Train User

Ideal Value < 1 hour Plan: Gather a group of 10-15 people and teach them individually how to use the

  • system. Document how long it takes each person to gain competence with the
  • system. Ideally, the group will contain a broad range of knowledge bases with

regards to vibration and mechanical systems. This will help to get a better estimation on the time it would take to train someone with no engineering background. The individuals who were trained will be asked about areas that were unclear or difficult to understand. From their feedback, efforts will be made to streamline the process. This will occur whether or not the specification is met.

  • SP8: Use Xerox’s Machine to Get a Pass Fail Readings on Test Bearings

Ideal Value: Pass/Fail Plan: Xerox’s Acoustic machine will be setup and run according to the manual

  • specifications. Pass or fail values will be collected for all of the test bearings. Four

tests will be conducted on each bearing to make sure the result is repeatable since the machine has failed an MSA. The purpose of collecting these readings will be to compare them against the results from the vibration test stand that is being developed.

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8 February 2013 P13505 9

Test Plans

  • SP9: Measurement System Analysis on Vibration Machine

Ideal Value: Pass Plan: A measurement system analysis (MSA) will be conducted on the vibration

  • machine. If the vibration machine fails the MSA, efforts will be made to identify

areas where there are inconsistencies. These inconsistencies will be fixed and the MSA will be conducted again. This process will iterate until the vibration machine passes the MSA or until we run out of time.

  • SP10: Assess Health of Bearing

Ideal Value: Pass/Fail Plan: The results of the vibration collection will be dependent upon the pass and fail criteria that is developed using the test bearings. Vibration measurements will be conducted on each of these bearings and they will be correlated to the tests that were already conducted by Arnprior. The developed pass and fail criteria will then be input into the LabView interface and a pass or fail reading will be output at the end of each test.

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8 February 2013 P13505 10

MSA Plan

  • 16 Samples, 6 Operators, 3 Replicates

– Typically 10 Samples, 3 Operators and 2 Replicates is used – As we do not have historical data to compare to, more samples would be better if we could obtain more bearings in various states of wear – More operators will result in an improved precision for the reproducibility estimate[2]

  • Every operator will test each of the 16 samples, 3 times
  • The order of the tests will be done based off of a randomly

generated schedule

  • Minitab or another statistical package will be used to analyze the

data using the ANOVA method

  • The output value, pass/fail or some number, will be determined

based upon the failure criteria which is still to be determined

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8 February 2013 P13505 11

System Assembly

Motor Assembly Alignment Assembly Arbor Press Assembly

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8 February 2013 P13505 12

Motor Pugh

[6]

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8 February 2013 P13505 13

Motor Mount

  • Motor will be

mounted on a large aluminum block

  • The aluminum block

will rest on a rubber gasket

  • This is done in an

effort to attenuate any vibration

Motor Face Mounting Plates Motor Clamps Aluminum Block

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8 February 2013 P13505 14

Motor Clamps

  • These will wrap around the

motor so that it is not cantilevered

  • The top bolt can be used to

further tight the clamp once it has been bolted down

  • Trying to make the structure as

rigid as possible

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8 February 2013 P13505 15

Motor Torque Requirements

  • Tested the required motor torque for our bearings
  • Preliminary drop test predicted 37 in*lb at 1800 rpm based
  • n Newton’s Viscosity law – extrapolated from 43 rpm
  • New test with motor at 2000 rpm showed required torque
  • f 2.7 in*lb for high resistance bearing
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8 February 2013 P13505 16

Motor Test Results

0.5 1 1.5 2 2.5 3 500 1000 1500 2000 Required Torque (in*lbs) Angular Velocity (RPM)

Torque Required To Rotate Test Bearings

High Resistance Bearing Low Resistance Bearing

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8 February 2013 P13505 17

Xerox Acoustic Machine

  • Xerox machine has a slip fit mandrel
  • Found that the bearing slipped on the

mandrel when the motor rotated

  • Show video
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8 February 2013 P13505 18

Two Mandrel Designs

Slip Fit Mandrel Press Fit Mandrel

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8 February 2013 P13505 19

Arbor Press Assembly

  • ½ Ton Press
  • 4.5” working range
  • Cost: $40
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8 February 2013 P13505 20

Arbor Press Assembly

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8 February 2013 P13505 21

Clamp Alignment System

Brake (2) Bearing Clamp 80/20 Rails (4) Carriage (2) Rail Adapter (2) Bearing Accelerometer (2) L-Bracket (8)

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8 February 2013 P13505 22

T-adapters

  • Aluminum

– Easy to machine – Higher damping coefficient than steel

  • Transfers holes from horizontal

to vertical position

  • Connects lower half clamp to

the carriage

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8 February 2013 P13505 23

Outer Race Bearing Clamp

  • Will be made out of

steel to improve vibration transmission

  • Because of tight

tolerances the Brinkman Lab is going to manufacture it

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8 February 2013 P13505 24

ANSYS Clamp Analysis

  • ANSYS analysis

shows a very small deflection: 0.0002 in

  • This proves that

displacement control is not a feasible option and a force control method should be implemented.

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8 February 2013 P13505 25

80/20 Rail Natural Frequencies

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8 February 2013 P13505 26

80/20 Natural Frequency Calculations

4 5 6 7 8 9 10 11 12 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 Length of Beam (in) Natural Frequency (Hz) Natural Frequency v. Length (Mass of Center)

Assumptions:

  • Applied mass is larger than the beam mass
  • Applied mass is located at 0.80*L
  • Both ends are clamped
  • Constant loading can be simulated as

additional mass

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8 February 2013 P13505 27

80/20 Natural Frequency Calculations

4 5 6 7 8 9 10 11 12 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2 2.2 x 10

4

Length of Beam (in) Natural Frequency (Hz) Natural Frequency v. Length (No Mass) First Mode

For the first mode: Β1l=4.7300 ρ=mass per unit length A=cross-sectional area L=beam length E=Elastic modulus I=Moment of Inertia

  • No mass applied other than the

beam mass

  • This is the highest natural

frequency that could be reached without stiffening the beam

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8 February 2013 P13505 28

Accelerometer Mounting

  • 100 mV/g
  • ICP Accelerometer
  • Frequency Range:

0.5-10,000 Hz

  • Attach with wax or glue
  • If needed the

accelerometer could be stud mounted

[3]

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8 February 2013 P13505 29

Accelerometer Mounting - Feasibility

  • Outer support accelerometer mounting has been successfully

applied in industry and other test stands

[4] [5]

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8 February 2013 P13505 30

SKF Condition Monitoring

  • Accelerometer Signal

Conditioner

  • Power ICP Circuit
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8 February 2013 P13505 31

Signal Conditioner - Schematic

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8 February 2013 P13505 32

Signal Conditioner – Board/Enclosure

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8 February 2013 P13505 33

LabView 6210 DAQ

  • 16 analog inputs
  • 250kS/s
  • 4 voltage ranges
  • Maximum voltage range

accuracy: 2.69 mV

  • Minimum voltage range

accuracy: 0.088 mV

[7]

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8 February 2013 P13505 34

LabView Feasibility Test

Current LabVIEW code has been tested in the systems lab

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8 February 2013 P13505 35

LabView

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8 February 2013 P13505 36

LabView Block Diagram

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8 February 2013 P13505 37

Bill Of Materials

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8 February 2013 P13505 38

Bill Of Materials

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8 February 2013 P13505 39

Budget

  • Overall Budget - $1500-$3000
  • Original Total

$3171.96

  • Savings from:

– Custom Signal Conditioner $327.10 – Provided Motor and Controller $611.80

  • Final Cost Breakdown

– Data Collection $1467.90 – Physical Structure $445.16 – Manufacturing Costs $200.00 – Shipping $120.00 – Total $2233.06

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8 February 2013 P13505 40

Risk Assessment

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8 February 2013 P13505 41

Project Schedule

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8 February 2013 P13505 42

References

1. http://www.amazon.com/SKF-Bearing-Clearance-3600lbf- Capacity/dp/B0071ARFWS 2. http://www.minitab.com/support/documentation/Answers/Assistant%20 White%20Papers/GageRR_MtbAsstMenuWhitePaper.pdf 3. http://www.pcb.com/products.aspx?m=352C33 4. Machinery Messages Research Test Results Part 1: Performance of REBAM during ball bearing failure 5. The application of spectral kurtosis on Acoustic Emission and vibrations from a defective bearing By: B. Eftekharnejad n, M.R. Carrasco, B. Charnley, D. Mba 6. http://www.anaheimautomation.com/3D/pdf/brushless/BLK32%20Serie s.PDF 7. http://sine.ni.com/nips/cds/view/p/lang/en/nid/203223

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8 February 2013 P13505 43

Questions?