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Xerox Bearing Tester Final Project Review

Xerox Bearing Tester Final Project Review. 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

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Xerox Bearing Tester Final Project Review

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  1. Xerox Bearing TesterFinal Project Review

  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 Project Engineer Andrew Shuman Project Engineer Kevin Albino Project Engineer Lauren Kaczor Project Engineer Tyler Hill Project Engineer

  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

  4. Updated Customer Needs

  5. Specifications

  6. Operation Alignment Procedure Assembly Procedure Testing Procedure

  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

  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 dampers • Option 2 • Purchase a signal conditioner

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

  10. 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

  11. 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

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

  13. Calibration • Purchase a new bearing and remove grease • Collect vibration readings on the bearing • Bearing can be used to calibrate the system

  14. Budget • Overall Budget - $1500-$3000 • Final Cost Breakdown • Data Collection $760.46 • Physical Structure $602.91 • Shipping $75.66 • Total $1439.03

  15. 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

  16. 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

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

  18. References • http://www.amazon.com/SKF-Bearing-Clearance-3600lbf-Capacity/dp/B0071ARFWS

  19. 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.

  20. 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.

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