P10503 Preliminary Test Plan Document

Top Customer Needs: Ensure Safety, Functional Subsystems, Ease of Use, Hardware Specifications

I) Ensure Safety

a. Determine safe high voltages

b. Determine velocity of carriage and lifting systems to avoid damage to operator or product

II) Functional Subsystems, Hardware Specifications

a. Determine nominal values

b. Determine if ‘expose in dark’ concept chosen adequately fits project needs in terms of stray light, allowed wavelengths

III) Ease of Use

a. Ensure that operator can easily use user interface with minimal to no documentation although documentation will be provided Test Plans to meet above Needs:

I) Perform Experiment (generally for testing mechanical parts/wiring)

Sample of an experiment:

EXPERIMENT PERFORMED BY: Jeff Robble

PROBLEM: After DAQ hook-up, both paper feed and transfer drum would activate simulataneously. Reason why is what needs to be found out by this experiment.

HYPOTESIS: Possibly some wires were crossed or both paper feed/transfer drum hooked up to same relay.

OBSERVATIONS:

NI DAQ 6602 PFI36 / CTR0 out (pin 5) - paper feed control PFI32 / CTR1 out (pin 9) - transfer drum control

When both controls hooked from DAQ to respective relays the following behaviors are observed:

1. Generating continuous pulses on PFI36 activates paper feed only. [EXPECTED] 2. Generating continuous pulses on PFI32 activates transfer drum only. [EXPECTED] 3. Generating N pulses on PFI36 activates both paper feed and transfer drum. [NOT EXPECTED] 4. Generating N pulses on PFI32 activates both paper feed and transfer drum. [NOT EXPECTED]

When the transfer drum control is disconnected the following behaviors are observed:

1. Generating continuous pulses on PFI36 activates paper feed only. [EXPECTED] 2. Generating continuous pulses on PFI32 does nothing. [EXPECTED] 3. Generating N pulses on PFI36 activates paper feed only. [EXPECTED] 4. Generating N pulses on PFI32 activates paper feed only. [NOT EXPECTED]

When the paper feed control is disconnected the following behaviors are observed:

1. Generating continuous pulses on PFI36 does nothing. [EXPECTED] 2. Generating continuous pulses on PFI32 activates transfer drum only. [EXPECTED] 3. Generating N pulses on PFI36 activates transfer drum only. [NOT EXPECTED] 4. Generating N pulses on PFI32 activates transfer drum only. [EXPECTED]

EXPLANATION:

25 of the NI DAQ 6602 Manual shows a table of counter pairs:

CTR0 <-> CTR1 CTR2 <-> CTR3 CTR4 <-> CTR5 CTR6 <-> CTR7

"This pairing allows some counter signals to connect to signals on the other counter."

The NI website (http://digital.ni.com/public.nsf/allkb/485201B647950BF886257537006CEB89#case 3) explains:

"Generating a finite pulse train and another counter task on the same device in LabVIEW with NI-DAQmx. For any device which uses the STCII chip (CompactDAQ, E and M Series) a finite pulse train generation reserves both counters.

When performing a finite pulse train generation, one counter generates the pulse train, and the other counter generates a pulse that acts as a gate for the first counter. If you change the pulse train to generate continuously or only generate one pulse, you can run two counter tasks at the same time without error."

In other words, generating finite pulses on CTR0 uses CTR1 as a gate which also generates pulses, and vice-versa. This is why the transfer drum and paper feed are both activated when either is controlled using N pulse generation.

As a side note, the 6602 DAQ is only capable of operating two counters at a time (whether for acquiring or generating signals, or both). Thus, if the DAQ is instructed to perform N pulse generation that is all it can do because it uses two counters.

SOLUTION:

Use non-paired counters or use continuous pulse generation on each counter in a pair. Also look into purchasing another counter/timer DAQ card for access to more counters (Jeff: “not necessary at this time”). II) Use built-in i/o system (generally for safety, wiring, and determining nominal values)

On user interface, there is the ability to set pre-defined values for controllable variables in the xerographic system such as velocities, bias, etc. These values can be stored in separate input .ini files and the results of running the system under these settings can be saved in output files through the user interface as well.

Sample of an input .ini file:

[Charging Station Parameters]

PC Velocity Across Coronode (mm/s)=110

Coronode Bias (v)=-650

Grid Bias (v)=-650

[Exposure Station Parameters]

Expose Time (s)=2

[Developer Station Parameters]

PC Velocity Across Developer (mm/s)=110

Toner Bias (v)=-525

[Pre-Transfer Station Parameters]

PC Velocity Across Pre-Transfer LEDs (mm/s)=110

[Transfer Station Parameters]

PC Velocity Across Transfer Drum (mm/s)=110

Number of Transfer Drum Rotations=3

Transfer Bias (v)=2000

Transfer Drum Velocity (mm/s)=110 Sample of an output .csv (excel) file: (Note: only a small portion of output shown here because it is generally very large.

Time PC Velocity (s) (mm/s) 0.1 34.272 0.2 84.481 0.3 110.772 0.4 110.772 0.5 110.772 0.6 110.772 0.7 110.772 0.8 110.772 0.9 110.772 1 110.772 1.1 110.772 1.2 110.772 1.3 110.772 1.4 110.772 1.5 110.772 1.6 110.772 1.7 110.772 1.8 110.772 1.9 110.772 2 110.772 2.1 110.772 2.2 110.772 2.3 110.772 2.4 110.772 2.5 110.772 2.6 110.772 2.7 110.772 2.8 110.772 2.9 110.772 3 110.772 3.1 110.772 3.2 110.772 3.3 110.772 3.4 110.772 3.5 110.772 3.6 0 3.7 0 Proposed Excel Macro Output:

80 ) s / m m (

t 60 i c o l e V

C 40 P

0 0 0.5 1 1.5 2 2.5 3 3.5 4 Time (sec)