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Xerox Bearing TesterDetailed Design Review

[1]

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Project Team and StakeholdersCustomer

Erwin Ruiz Technical Specialist Project ManagerXerox Corporation

GuideWilliam Nowak Principle Engineer

Xerox Corporation

Faculty ConsultantJason Kolodziej RIT ME Faculty

Project TeamStephen Rugg Project ManagerWill Craig Co-lead EngineerAndrew Shuman Co-lead EngineerKevin Albino Team Facilitator/Project EngineerLauren Kaczor Project EngineerTyler Hill Project Engineer

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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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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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Project Background

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Updated Customer Needs

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Specifications

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Test Plans• SP1: Time To Train User

Ideal Value < 1 hourPlan: 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 BearingsIdeal Value: Pass/FailPlan: 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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Test Plans• SP9: Measurement System Analysis on Vibration Machine

Ideal Value: PassPlan: 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/FailPlan: 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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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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System Assembly

Motor Assembly

Alignment Assembly

Arbor Press Assembly

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Motor Pugh

[6]

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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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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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Motor Torque Requirements• Tested the required motor torque for our bearings• Preliminary drop test predicted 37 in*lb at 1800 rpm based

on Newton’s Viscosity law – extrapolated from 43 rpm• New test with motor at 2000 rpm showed required torque

of 2.7 in*lb for high resistance bearing

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Motor Test Results

0 500 1000 1500 20000

0.5

1

1.5

2

2.5

3

Torque Required To Rotate Test Bearings

High Resistance BearingLow Resistance Bearing

Angular Velocity (RPM)

Req

uire

d To

rque

(in*

lbs)

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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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Two Mandrel DesignsSlip Fit Mandrel Press Fit Mandrel

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Arbor Press Assembly• ½ Ton Press• 4.5” working range• Cost: $40

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Arbor Press Assembly

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Clamp Alignment System

Brake (2)Bearing Clamp

80/20 Rails (4)

Carriage (2)

Rail Adapter (2)

BearingAccelerometer (2)

L-Bracket (8)

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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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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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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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80/20 Rail Natural Frequencies

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80/20 Natural Frequency Calculations

4 5 6 7 8 9 10 11 12500

1000

1500

2000

2500

3000

3500

4000

4500

5000

Length of Beam (in)

Nat

ural

Fre

quen

cy (

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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80/20 Natural Frequency Calculations

4 5 6 7 8 9 10 11 120.2

0.4

0.6

0.8

1

1.2

1.4

1.6

1.8

2

2.2x 10

4

Length of Beam (in)

Nat

ural

Fre

quen

cy (

Hz)

Natural Frequency v. Length (No Mass)

First Mode

For the first mode: Β1l=4.7300

ρ=mass per unit lengthA=cross-sectional areaL=beam lengthE=Elastic modulusI=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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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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Accelerometer Mounting - Feasibility• Outer support accelerometer mounting has been successfully

applied in industry and other test stands

[4] [5]

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SKF Condition Monitoring• Accelerometer Signal

Conditioner• Power ICP Circuit

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Signal Conditioner - Schematic

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Signal Conditioner – Board/Enclosure

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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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LabView Feasibility TestCurrent LabVIEW code has been tested in the systems lab

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LabView

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LabView Block Diagram

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Bill Of Materials

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Bill Of Materials

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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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Risk Assessment

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Project Schedule

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References1. http://www.amazon.com/SKF-Bearing-Clearance-3600lbf-Capacity/dp/

B0071ARFWS2. http://www.minitab.com/support/documentation/Answers/Assistant

%20White%20Papers/GageRR_MtbAsstMenuWhitePaper.pdf3. http://www.pcb.com/products.aspx?m=352C334. Machinery Messages Research Test Results Part 1: Performance of REBAM

during ball bearing failure5. 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%20Series.PDF

7. http://sine.ni.com/nips/cds/view/p/lang/en/nid/203223

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Questions?