Stack Quality Detection device Team 4: Justin Choi, Joseph Kurtz, Matt Felleman, Ajay Chandrashekar
Table of Contents • Problem Definition • Problem Statement • Mission Statement • Customer Needs Analysis • Background Research • Product Specifications • Concept Generation • Brainstorming • Evaluation • Design Matrices • Prototype/Model • Cost Analysis • Conclusion Figure 1: iGen 4
Problem Definition Problem Statement: Stack quality is crucial in many aspects- It provides easier handling of papers for later processes and conveys a professional product to customers. Xerox needs a component that can ensure stack quality and accuracy. Mission Statement: We are going to create a stack quality detection device that is cost efficient, accurate, effective, and adaptable to the iGen 4 for the Xerox company.
Problem Definition • Primary Market • Xerox is the primary customer: product is being designed for Xerox’s iGen 4 printer. • Secondary Market • Businesses Xerox is selling the iGen 4 to, these would include publishing companies, graphic arts companies, etc. Figure 2: Xerox logo
Problem Definition • Customer Needs Analysis • Device must be cost effective. • Must be able to detect two types of good stacks and bad stacks with various offsets. • Must be efficient and conduct process quickly.
Problem Definition • Background Research: • Average paper thickness: 0.1 mm • No patents exist for any other device like our device. • Aluminum is the ideal material for construction \ • approximately $1/lb. • Lightweight • Cost effective Figure 3: Clip Art
Product Specifications • Good Stack • A good simple stack of 200 sheets with no set offset. There cannot be an error greater than 5mm in any direction. Figure 4.1
Product Specifications • Good Stack • A stack of 200 sheets with a regular set offset of 5 mm every set (50 sheets) in the x-plane and no set offset in the z‐plane. All sheets in the stack cannot be offset more than 5 mm in any direction. Figure 4.2
Product Specifications • Bad Stack • A stack of 200 sheets with set offset of 5 mm every set (50 sheets) in the x‐plane and no set offset in the z‐plane. However, the set offset is not regular. Figure 4.3
Product Specifications • Bad Stack • Within a stack of 200 sheets, at least one sheet is offset from the bottom sheet in the set by more than 5 mm in any direction. Figure 4.4
Concept Generation • Light sensors and a reflector on a movable arm which would move across the stack to detect the offsets in the stacks.
Concept Generation • System that detects stack quality through physical contact and switches.
Concept Generation • System that detects stack quality through emitting radio waves which would measure the offset distance.
Concept Generation • Set Lasers which would be emitted and sensors which would detect the offsets in the stacks.
Concept Generation • System where light is emitted from one side of the stack and the shadow created on the other side would create an image which could be seen for quality.
Concept Generation • Stack quality device where the stacks would enter a cube with a couple walls of sensors which would measure the stacks on the x and z axis.
Evaluation • The concept we chose was the idea involving set wide beam lasers that would detect offsets in both the x/y planes and z plane. • Most simple, cost effective, and accurate.
Prototype/Model • Functionality • X Offset: velocity x time= distance. • Velocity= speed of the belt. • Time= amount of time that the offset appears in the laser. • Y Offset: Blocks wide beam laser from transmitter. • Z Offset: If offset exists it will trigger top lasers. X Z Y
Cost Analysis • The base price of the iGen4 is $250,000 • The costs of our product will be relatively insignificant compared to the overall printer cost. • This makes relative cost of our component insignificant. • Estimated Supply Cost:
In Conclusion… • Our product will effectively measure the quality of paper stack with various offsets in an accurate, efficient and cost effective manner. • This device will be a perfect fit for the Xerox iGen 4.
References • Figure 1: http://packprintnews.com/wp-content/uploads/2009/03/xerox-igen4-press1.jpg • Figure 2: http://info.instantis.com/Portals/37019/images/Xerox_Logo_2008Jan7.jpg • Figure 3: http://www.clipartpal.com/_thumbs/pd/education/look_it_up_T.png • Figure 4.1-4.4: https://cms.psu.edu/section/default.asp?id=201112FAUP%5F%5F%5FREDSGN100%5F001