Team Vision for Problem Definition Phase
During this opening phase, the team planned on creating the project definition and solidifying customer expectations. Not only were these accomplished, but preliminary assessments were also completed such as a House of Quality and a Risk Analysis. Furthermore a project plan was created. Due to the very open nature of the project, the plan won't be able to be fully completed until after brainstorming sessions have occurred and a final solution is chosen.
The current Kodak dry ink station (DIS) currently incorporates two “Oldham” couplings to transmit power and high quality motion from the gear box to the appropriate output shafts. These couplings currently experience two modes of failure: complete fracture, causing stoppage of the DIS, and misalignment, causing motion quality degradation. While fractures are easy to spot, misalignments are difficult to diagnose, and many Kodak Field Engineers are not comfortable in diagnosing and replacing misaligned couplings, so instead they will replace the entire DIS system. There is a significantly larger cost to replacing the entire DIS system when simply replacing the coupling would suffice. Kodak aims to lower the cost of maintenance and net replacements in the field.
The goal of this project is to design and build a test fixture that standardizes the measurement of key values of a coupling system within the DIS in order to better understand the modes of coupling failure, with the ultimate goal of minimizing maintenance cost for Kodak. The physical test fixture, along with any design documents, technical papers, final poster, and required code is to be the main deliverable to Kodak. All code compiled must be done in LabView and total project budget is not to exceed $4k. The project also must be completed by the end of Fall semester 2017.
Below are linked pictures of the current Oldham Coupling for reference:
- RIT MSD Project Team (and MSD Department)
- Tim Young - Kodak Project Sponsor
- Dave Bettel - Kodak Director of Engineering EPS
- Dave Pascucci - Service Support Group
- Mike Dowerton - Engineer
- Kodak Field Engineers
- Kodak Finance Department
- Kodak Customers
Preliminary Project Plan image extracted from full project plan file here.
Image extracted from 'Use_Scenarios.vsdx', not able to be viewed within EDGE.
Project Goals and Key Deliverables
The goals of this project are as follows:
- Create a test fixture that collects measurements of a DIS coupling system
- Better understand the modes of coupling failure
- Ultimate goal of minimizing maintenance cost
This goal will be carried out through the following deliverables:
- A DIS Coupling Test Fixture that is to be Adjustable, Capable of life testing, Easy to use, & Accurate
- A measurement and analysis protocol to evaluate different coupling concepts
- A preliminary selection of “Best Performing” coupling designs
Customer Requirements (Needs)
A copy of the live document of Customer Requirements can be found here
- The entire MSD project team was invited to Kodak for an overview of the relevant hardware and overall project on Jan 26 2017. Meeting notes taken by Cara Heise are compiled here.
- A phone call clarifying project definitions and scope was scheduled and occurred between Ryan Mraz and Tim Young on Feb 2nd 2017. Notes taken by Ryan during the meeting are compiled here.
Engineering Requirements (Metrics & Specifications)
PurposeCreate a contract between the engineer and the customer where indisputable satisfaction of the engineering requirements equates to customer satisfaction
A copy of the live document of Engineering Requirements can be found here
A copy of the live document of Benchmarking can be found Here.
- NOTE: The current Oldham center disc is injection molded ABS.
- Code in Labview
- Fixture Operation - Must
- Analysis SW - Optional (but first choice)
- Select coupling which fits within existing DIS subsystem
- Cost <$4000
- Coupling - function at 1200 & 150 RPM
- Motor - Minimum RPM - 1200
House of Quality
- Confirm that satisfaction of the Engineering Requirements implies that all of the Customer Requirements are met.
- Facilitate design trade off decisions
A copy of the live document of HOQ can be found here
Preliminary Risk Assessment
A copy of the live document of Risk Management can be found here.
Design Review MaterialsInclude links to:
- Presentation and/or handouts
- Notes from review
- Action Items
Plans for next phase
In the upcoming weeks as a team, we look forward to more in-depth review and research of material, setting up given hardware from Kodak, and finally, brainstorming/selecting final solutions to our given problem statement.