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P09503 Electrophotographic Development and Transfer Station

P09503 Electrophotographic Development and Transfer Station. Team Members. Project Description. The purpose of this project is to make an existing electrophotographic development and transfer station functional and to improve the usability, safety and sensing abilities. EDTS End Users

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P09503 Electrophotographic Development and Transfer Station

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  1. P09503Electrophotographic Development and Transfer Station

  2. Team Members

  3. Project Description • The purpose of this project is to make an existing electrophotographic development and transfer station functional and to improve the usability, safety and sensing abilities. • EDTS End Users • PRISM Lab • Layered Manufacturing • Center for Imaging Science Deliverables • An inventory and status of current sub-systems, including needed support systems. • A working Electrophotographic Station. • Demonstrably improved device safety. • An improved user interface (includes control and display functions) • Device documented for use, maintenance and upgrade of the device (User & Lab Technician Manual) • Demonstrably Improved Sensing and Control Subsystem

  4. Project Background • Project Family • Printing and Imaging Systems Technologies Track • Customer • Print Research and Imaging Science Modeling Laboratory (PRISM) • The Print Research and Imaging Systems Modeling lab will serve as a conduit between industry and academia, working to evaluate and anticipate the print systems research needs of printer and printing product companies, and directing relevant projects to researchers and students in the areas of Printers & Displays, Color Science, Vision Science, Systems Engineering, and Printing. • Contact: Dr. Marcos Esterman – Associate Professor, Industrial and Systems Engineering

  5. What is Electrophotography? • Electrophotography is base technology that is used in many modern day copiers and printers • Six Step Process to transfer an electrostatic image to a final printed page • Charging • Exposure • Development • Transfer • Fusing • Cleaning • P09503 only includes the first four

  6. Electrophotographic and Development Station Photoconductor Charging Exposure Transfer Development

  7. System Architecture

  8. Critical Customer Needs 1. Is Operational 2. Is Safe 3. Minimize user Intervention 4. Can Monitor Key Process Parameters 5. Can operate and monitor machine from one interface 6. Easy to learn to use

  9. Concept Summary • Modifications and Improvements to EDTS Include • Ozone Fan/ Filter Assembly Analysis • Electrostatic Voltage Measurement Implementation • LED Exposure System Implementation • Paper Delivery System • Photoconductor Imaging System Mount • Electrophotographic Process Control and Automation • Control and Automation Hardware

  10. Ozone Fan/ Filter Assembly Analysis • Corona and Grid produce O3 during operation • Maximum allowed concentration indoors is 0.050 ppm • Methodology • Verify system produces levels that are safe • Device is verified if levels test below >0.2ppm • Construct new mount and assembly for ozone fan if device produces ozone above >0.2ppm • Test Results • The device used was an ozone detector that can accurately detect once it reaches amounts of 0.5ppm. • There were no detectable ozone amounts for both tests ran. • It is noted that around 0.2ppm is when throat and nasal irritation may occur. (This was not experienced)

  11. Electrostatic Voltage Measurement Implementation • Monitoring the potential on the Photosensitive material increases the sensing abilities of the system • Monitor process real time • Photosensitive Dark Decay Research • Implementation and Measurements • 1st measurement after charging • 2nd measurement after exposure • Measurement limited to one dimension • Process created for two dimensional measurement

  12. ESVMImplementation

  13. LED Exposure System • LED Exposure system replaces current incandescent system • Mounted directly under exposure lift • Advantages • More versatile and reliable light source • Low Power Consumption • Longer Bulb Life • No potential for overheat • Inexpensive to replace

  14. Paper Delivery System • Existing roller system required manually catching paper after application of toner from roller • Risks of manual handling • Human Shock/Short from High Voltage Roller • Pinch Point of Rollers and Pneumatics • Marred Image Quality from Handling • Machined Paper Delivery System • Clear tray to allow for Photoconductor Imaging

  15. High Visibility Warning Signs • Purpose of warning signs • Alert user to specific hazard • Identify how hazard can be avoided • Previous signs did not accomplish this or were not present • FMEA Analysis dictated locations • ISO 3864 Formula dictated proper size and images • Methodology • Remove current warning signs • Replace with ISO designed signs • Add new ISO signs where needed • Final FMEA Analysis verified all sign placments

  16. Photoconductor Imaging System Mount • Imaging of the Photoconductor System helps to gain understanding of how image is developed onto photoreceptive material • Photoreceptive material imaged after development and before transfer • Mount machined for camera to rest under Paper Delivery System

  17. Electrophotographic Process Control and Automation • Most critical part of the entire project • LabView virtual instruments is used to control all devices • All components connected • High Voltage and Camera are on a separate system • Two Modes of Operation • Automatic • Parameters are preset • User only needs to press start to begin and stop to end • Manual • User can control any part of the system

  18. Budget • Project Budget: $1500 • Budget Utilized ~$1480 (98%) • Major Purchases • National Instruments Data Acquisition Device • PCI-6515 – 64 Channel Digital I/O PCI Card, Cable and Terminal Block • Sick|Stegman Encoders • 2 X HD20 • 1024 Pulses/Rev • Luxeon Star/O LED • Royal Blue Batwing, 220 mW @ 350mA

  19. Final Results • All six deliverables were presented to the customer • Total Design Specifications: 46 • Specifications Met: 40 or 87% • Specifications not Met: 4 or 9% • Special Circumstances: 2 or 4% • Electrophotographic Station has the ability to charge a Photoconductor, Expose the Photoconductor, Attract Toner, Deposit Toner onto a Transfer Drum and Transfer Toner to a Substrate

  20. Electrophotographic and Development Station After Before

  21. Future Improvements • Transfer Drum Clutch • Motor Speed Control • Component Labeling • X-Y PC Measurement • Multiple Development Systems • Camera Automation • Light Curtain

  22. Special Thanks RIT Faculty Professional • Jonathon Arney, Ph.D • Center for Imaging Science • Physical & Optical Measurements • Susan Farnand, Ph.D • Center for Imaging Science • Color and Vision Science • John D. Wellin • Mechanical Engineering • Control Systems • Marcos Esterman, Ph.D • Industrial and Systems Engineering • Product & Process Development • Bill Nowak – Xerox • Principle Engineer • Motion and Quality Systems • Gregory Miller – Kodak • Software Engineer

  23. Questions

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