University of San Carlos – Technological Center

Nasipit, Talamban, Cebu City

Mechanical Engineering Department

IN PARTIAL FULFILLMENT OF THE REQUIREMENTS FOR THE DEGREE OF

BACHELOR OF SCIENCE IN MECHANICAL ENGINEERING

Design, Fabrication, and Testing of Two-Axis Paper Edge Guide Restraint Mechanism

Presented by:
Pino, Adam Aerol M.
Quiapo, Girlie J.
Velmonte, Lorenz Deniel L.

Advisers:
Engr. Gabriel Dominic Baygan
Engr. Jose Arvin Tordillo
 Table of Contents

DEFINITION OF TERMS .............................................................................................................v

NOMENCLATURE .................................................................................................................... vii
CHAPTER I ....................................................................................................................................1
INTRODUCTION .......................................................................................................................1

STATEMENT OF THE PROBLEM ...........................................................................................2

OBJECTIVES OF THE STUDY ................................................................................................2

SIGNIFICANCE OF THE STUDY ............................................................................................3

SCOPE AND LIMITATIONS ....................................................................................................3

THEORETICAL BACKGROUND ................................................................................................5

2.1 Newton’s Law of Motion ......................................................................................................5

2.1.1 Newton’s First Law .........................................................................................................5

2.1.2 Newton’s Second Law ....................................................................................................5
2.1.3 Newton’s Third Law .......................................................................................................6
2.2 Moment ..................................................................................................................................6

2.3 Free Body Diagram (FBD) ....................................................................................................6

2.3.1 Force ................................................................................................................................7

2.4 Roller Follower ......................................................................................................................8

2.4.1 Contact Stress on Roller in Contact with Flat Plate ........................................................8

2.5 Linear Cam ............................................................................................................................9

2.5.1 Uniform Velocity with Roller Follower ..........................................................................9

2.6 Force Reaction and Stresses on Beams ...............................................................................12

2.6.1 Flexural Stress ...............................................................................................................13

2.6.3 Shearing Stress ..............................................................................................................14
2.7 Paper Tray............................................................................................................................15
ii
 2.7.1 Center Feed Type ..........................................................................................................15
REVIEW OF RELATED LITERATURE ....................................................................................17
3.1 Simplified movement printer sheet stack guide ..............................................................17

3.2 Adjustable feed tray assembly ..........................................................................................17

3.3 Print media guide system ..................................................................................................18

3.4 Paper tray for a printing mechanism ..............................................................................18

3.5 Two-axis media guide system for an imaging device......................................................19

3.6 Multi-size paper tray having a sheet size indicator ........................................................19

3.7 Rehabilitation Act of 1973, Section 508 ...........................................................................20

RESEARCH GAP .....................................................................................................................20

METHODOLOGY .......................................................................................................................21
4.1 Design Concept Brainstorming ...........................................................................................22

4.2 Concept Selection ................................................................................................................22

4.2.1 Design Concepts ............................................................................................................23

4.2.2 Criteria for Concept Selection .......................................................................................26
4.2.3 Design concept selected ................................................................................................27
4.3 Design calculation ...............................................................................................................27

4.3.1 Forces on the rear paper edge guide restraint ................................................................28

4.3.2 Maximum angle constraint ............................................................................................29
4.3.3 Dimensions of the rear paper edge guide restraint roller axle slot ................................30
4.3.4 Forces and stresses on the roller....................................................................................32
4.3.5 Dimensions of the side paper edge guide restraint roller axle slot................................33
4.3.6 Diameter of the roller axle ............................................................................................34
4.3.7 Linear cam slot ..............................................................................................................34
4.4 Parts modelling ....................................................................................................................36
iii
 4.4.1 Parts ...............................................................................................................................36
4.5 Fabrication ...........................................................................................................................45

4.5.1 Materials ........................................................................................................................45

4.5.2 Equipment .....................................................................................................................47
4.5.3 Fabrication Procedure ...................................................................................................48
4.5.4 Assembly Procedure ......................................................................................................48
4.6 Testing .................................................................................................................................49

4.6.1 Materials ........................................................................................................................49

4.6.2 Equipment .....................................................................................................................49
4.6.3 Testing Procedure ..........................................................................................................51
4.7 Expected Output ..................................................................................................................56

4.8 GANTT CHART .................................................................................................................57

4.8.1 Thesis I: Proposal ..........................................................................................................57

4.8.2 Thesis II: Proposal .........................................................................................................59
APPENDIX ...................................................................................................................................61
Appendix A - Tables ..............................................................................................................61
Appendix B - Data gathered ...................................................................................................66
Appendix C - Calculations .....................................................................................................66
REFERENCES .............................................................................................................................95
BIBLIOGRAPHY .........................................................................................................................96

iv
 DEFINITION OF TERMS

Abscissa - x-coordinate or horizontal axis

Actuate - put into mechanical action or motion

Axis - fixed reference line of a coordinate system

Axle - a rod or spindle passing through the center of any circular

piece

Cam - rotating or sliding piece used in transforming rotary

motion into linear motion

Constraint - limitation or restriction

Contour - an outline or shape of something

Contour slot - elongated hole where the slot travels

Feed - transporting of paper from paper tray to printer or imaging

device

Flex - action or state of bending

Imaging device - other term for printer

Mechanism - system of parts working together in a machine

Media - other term for paper to be used for printing

Multi-feed - more than one paper fed into printer

v
Ordinate - y-coordinate or vertical axis

Paper edge guide restraint - adjustable guide used to guide and hold paper in specific

paper size position

Paper edge guide restraint - part of a paper edge guide restraint that points to the size

indicator label of the paper size sticker guide to indicate the paper

size

Paper size sticker guide - sticker with paper size labels pasted on the path of paper

edge guide restraint

Paper tray - hold paper before feeding into printer

Rear paper edge guide restraint - paper edge guide restraint used to guide length size of

paper

Roller follower - circular type of cam follower

Side paper edge guide restraint - paper edge guide restraint used to guide width size of

paper

Simultaneous - occurring or operating at the same time

Slot - elongated hole

vi
 NOMENCLATURE

Symbol Parameter Unit

θ Angle of inclination on linear cam slot degrees °

𝜏 Shearing stress 𝑀𝑃𝑎

𝜎 Flexural stress 𝑀𝑃𝑎

𝜎𝑐 Roller contact stress 𝑀𝑃𝑎

𝜇𝑠 Coefficient of static friction

𝜇𝑘 Coefficient of kinetic friction

𝐴 Area 𝑚2

𝑏 Base of roller axle slot 𝑚

𝑐 Distance from neutral axis 𝑚

𝐿 Distance from point of rotation 𝑚

𝑑𝑎 Diameter of roller axle 𝑚

𝐸 Modulus of elasticity 𝑀𝑃𝑎

𝐹𝑎𝑝𝑝 Force applied 𝑁

𝐹𝑓 Force due to friction 𝑁

𝐹𝑓𝑆𝑅 Force due to friction on side restraints 𝑁

𝐹𝑔 Force due to gravity 𝑁

𝐹𝑁 Force normal to the surface 𝑁

𝐹𝑁𝐸𝑇𝑅𝐸𝐴𝑅 Net force on rear edge guide restraint 𝑁

𝐹𝑅 Force reaction 𝑁

𝐹𝑅𝑆𝐼𝐷𝐸 Force reaction on side roller axle slot 𝑁

vii
𝐹𝑦𝑅𝑂𝐿𝐿𝐸𝑅 Net vertical force acted on roller axle 𝑁

∑ 𝐹𝑥 Net force along horizontal axis 𝑁

∑ 𝐹𝑦 Net force along vertical axis 𝑁

ℎ Height of roller axle slot 𝑚

𝐼 Moment of inertia of cross section 𝑚4

𝐿 Moment arm 𝑚

𝑀 Moment due to force 𝑁−𝑚

𝑟𝑎 Radius of roller axle 𝑚

𝑟𝑟 Radius of roller 𝑚

𝑆 Section modulus 𝑚3

𝑡𝑎 Thickness of roller axle at contact area 𝑚

𝑡𝑟 Thickness of roller at contact area 𝑚

𝑉 Shearing force 𝑁

𝑣 Poisson’s ratio

𝑤 Roller contact width 𝑚

viii
 CHAPTER I

INTRODUCTION

Reputable for designing and manufacturing military grade and user-friendly printers,

Lexmark International Inc. is a top contributor in the advancement of the printer industry. As

simple as a printer functions, Lexmark still pushes to research and develop technologies that

enhance the user experience.

A significant part of a printer is the paper tray which primarily holds the pile of papers

before it is fed for printing. Paper sizes to be used may vary according to the user’s demand

which incorporates the use of paper edge guide restraints which are movable and adjustable.

Releasable locks ensure that the paper edge guide restraints that constrain the paper are engaged

in place.

The existing Lexmark edge guide technology uses two paper edge guide restraints, rear and

side paper edge guide restraints, to hold the paper in place for proper feeding to the printer and

as a guide for the correct length and width dimensions of each specific paper size. With the use

of labels on the paper edge guide restraint path, each of the paper edge guide restraints are to be

manually adjusted according to the respective paper size. This existing technology requires two

separate actuations to achieve the paper size required which causes inconvenience and potential

mismatch of the dimensions. To address this problem, a two-axis paper edge guide restraint

mechanism that complies with Section 508 of the Rehabilitation Act of 1973 is considered as

this would simultaneously adjust one paper edge guide restraint as the other paper edge guide

restraint is manually adjusted.

1
 The Lexmark Linkage Program has handed the Mechanical Engineering students of the

University of San Carlos the opportunity to bring their concepts and ideas to fruition by

applying their skills and knowledge from the academe. Convenient solutions are to be developed

by the students to overcome the company’s actual product development problem.

STATEMENT OF THE PROBLEM

Lexmark International Inc. aims to enhance user experience to gain advantage over its

competitors. Individual adjustment of each paper edge guide restraint, which requires two

actuations, causes user inconvenience. Individual adjustment of each paper edge guide restraint

also causes potential mismatch of the length and width dimensions which leads to disorientation

in printing.

OBJECTIVES OF THE STUDY

This study aims to design, fabricate, and test a paper edge guide restraint mechanism for

printer paper tray. Furthermore, the study aims to:

 Design a mechanism that simultaneously adjusts both rear and side paper edge guide

restraints

 Fabricate and install the new paper edge guide restraint mechanism

 Test the functionality of the new paper edge guide restraint mechanism

 Test the new paper edge guide restraint mechanism in accordance to Section 508 of the

Rehabilitation Act of 1973

2
SIGNIFICANCE OF THE STUDY

This research will be beneficial to Lexmark Research and Development Corporation that

they may utilize the study for further enhancement of user experience. The enhancement of the

paper tray will serve as a foundation in designing a more convenient way in reloading medium.

By enhancing user experience, Lexmark will gain a marketing edge against its competitors.

This will serve as an opportunity for the researchers to apply their skills and knowledge

acquired in the academe in providing practical solutions for certain problems. Moreover, this

study will give researchers better understanding and additional knowledge on machine design

which is essential to their careers.

This study will serve as a basis of reference for future researchers who will pursue to come

up with a more convenient design of the paper tray edge guide restraint. This study will also

extend their knowledge on the printer paper tray. Moreover, this study may be incorporated to

different applications.

SCOPE AND LIMITATIONS

Scope

This study covers the two-axis paper edge guide restraint mechanism that

simultaneously adjusts both rear and side paper edge guide restraints with one actuation.

This study is applied to the Lexmark 35S2501 Center Feed Paper Tray. This study is done

in compliance to the requirement of Section 508 of the Rehabilitation Act of 1973.

3
Limitations

This study only focuses on the mechanism that simultaneously adjusts the paper edge

guide restraints. The study does not cover the complete design of the Lexmark 35S2501

Paper Tray that is to be sold in the market. The Lexmark 35S2501 Paper Tray caters paper

sizes A6, A5, B5, Executive, Letter, A4 and Legal. The mechanism caters all paper sizes

available on Lexmark 35S2501 Paper Tray excluding A6. This study does not consider the

durability for forces more than 5lb-force (22.24N) and fatigue life of the mechanism.

4
 CHAPTER II

THEORETICAL BACKGROUND

2.1 Newton’s Law of Motion

Engineering mechanics is formulated on the basis of Newton’s three laws of motion. These

laws are still valid and they are the basis for most engineering analysis today. [1] Formal

statements of Newton’s Three Laws are given below:

2.1.1 Newton’s First Law

Newton’s first law states that a particle originally at rest, or moving in a straight line

with constant velocity, tends to remain at rest provided the particle is not subjected to an

unbalanced force.[1] This law is also known as Law of Inertia. Inertia is the natural tendency

of an object to stay at rest or in constant motion along a straight line.[2]

2.1.2 Newton’s Second Law

Newton’s second law states that the sum of all forces on an object, or the net force,

equals mass times acceleration.[3]

𝐹 = 𝑚𝑎 (Eq. 2.1) [3]

Where: F - force, N

m - mass, kg

a - acceleration, m/s2

5
 2.1.3 Newton’s Third Law

Newton’s third law of motion states that for every force exerted there is an equal and

opposite force. The statement means that in every interaction, there is a pair of forces acting

on the two interacting objects. A force cannot be applied to an object unless something

resists the reaction of that force.[2]

2.2 Moment

A moment of a force is a measure of that force’s tendency to cause a rotational acceleration

in the same way that a force causes a linear acceleration.[11] In its simplest form, where a force

of magnitude F is acting a perpendicular distance d from the point of rotation, the torque about

that point is given by:

𝑀 = 𝐹𝐿 (Eq. 2.2) [11]

Where: 𝐹- force acting perpendicular to a body, N

𝐿- distance from point of rotation, m

2.3 Free Body Diagram (FBD)

The free-body diagram (FBD) of a body is a sketch of the body showing all forces that act

on it. The term free implies that all supports have been removed and replaced by the forces

(reactions) that they exert on the body.[4]

6
 Fig. 2.1 Free body diagram of body in contact with a surface

2.3.1 Force

Force is a push or a pull. It is an interaction between two bodies or between a body and

its environment. When a force involves direct contact between two bodies, such as a push or

pull that is exerted on an object, it is called contact force. There are three common types of

contact forces. The normal force is exerted on an object by any surface with which it is in

contact. The term “normal” means that the force always acts perpendicular to the surface of

contact, no matter what the angle of that surface. By opposition, the friction force exerted on

an object by a surface acts parallel to the surface, in the direction that opposes direction of

motion. In addition to contact forces, there are long-range forces that act even when the

bodies are separated by empty space. The earth pulls a dropped object toward it even though

there is no direct contact between the object and the earth. The gravitational force that the

earth exerts on a body is called weight.[5]

7
2.4 Roller Follower

There are four types of cam follower, knife-edge, roller, flat-faced and spherical faced.

Among the four, the roller follower is the most commonly used since it has the lowest

coefficient of friction.[3]

2.4.1 Contact Stress on Roller in Contact with Flat Plate

When a roller is in contact with a flat plate, a line contact is obtained, giving a

rectangular contact area of very small width, depending on the load and materials.[6]

Fig. 2.2 Roller on contact surface

The contact width is given by the equation:

(Eq. 2.3) [6]

32𝐹(1 − 𝑣 2 )𝑟
𝑤= √
𝜋𝑡𝐸

The contact stress is given by the equation:

4𝐹 (Eq. 2.4) [6]

𝜎𝑐 =
𝑤𝑡

Where: 𝑤 - contact width, m

8
 𝜎𝑐 - contact stress, MPa

E - Young’s modulus, MPa

F - load, N

r - radii, m

𝑡 - thickness, m

𝑣 - Poisson’s ratio

2.5 Linear Cam

The displacement diagram is in itself the profile of a linear cam. The displacement diagram

is a rectangular coordinate layout of the follower motion in one cycle of cam operation. The rise

of the follower is shown as the ordinate plotted against the length of the cam as the abscissa. The

abscissa is divided into equal cam angles or equal time divisions because the cam usually rotates

at a constant speed. The displacement diagram is generally drawn or sketched as the first step in

the development of the cam profile.[3]

2.5.1 Uniform Velocity with Roller Follower

The constant velocity or uniform displacement curve is the simplest of all. It has a

straight-line displacement at a constant slope giving the smallest length for a given rise of

all the curves.

The procedures in creating a Uniform Velocity Displacement with Roller Follower are

as follows:

9
1.Plot ordinate axis with h equal to the maximum rise and abscissa axis with z the total

length of the cam. Project respective parallel lines to form a rectangle.

2. Choose a suitable scale of degree angle to length.

3. Plot angular displacement with respect to the chosen scale at which the followers rises

and falls and project lines vertically to the upper line of the rectangle.

Fig 2.3 Rectangular layout with h as ordinate and z as abscissa

4. Divide each angular displacement, excluding dwell, to any equal number. Each angular

displacement may have different number of divisions.

5. Set starting point of projection at r radius of roller on the ordinate.

Fig. 2.4 Equal division of each angular displacement and projection of point r

10
 6. Project these intercepts to their respective cam angle division, and connect points to yield

center of roller path.

Fig 2.5 Projection of center of roller path

7. Project roller follower at every intersection of angular displacement division and center

of roller path.

Fig. 2.6 Projection of roller follower at each intersection of center of follower path and angular

displacement division

11
 8. Project curve that touches the bottom outermost part of each circle starting from origin.

The curve yielded is the curve of the displacement diagram or the linear cam curve.

Fig. 2.7 Displacement Diagram

2.6 Force Reaction and Stresses on Beams

A cantilever has only one end supported. It is essential that the support be fixed because it

must provide vertical support for the externally applied loads along with a moment reaction to

resist the moment produced by the loads.[7]

Fig. 2.8 Schematic representation/ free-body diagram of a cantilever beam

12
2.6.1 Flexural Stress

The stresses caused by the bending moment are known as bending or flexure stresses,

and the relation between these stresses and the bending moment is expressed by the flexural

stress formula.[9]

𝑀𝑦 (Eq. 2.5) [9]

𝜎=
𝐼

Where: σ - Flexural stress, Pa

M – bending moment, Nm

y – distance from neutral axis, m

I – moment of inertia, m4

In a more common form of the flexure formula, y is replaced by the distance c, which is

defined as the distance from the neutral axis to the remotest element. With this change, the

maximum flexure stress in any section is given by:

𝑀𝑐 (Eq. 2.6) [9]

𝜎𝑚𝑎𝑥 =
𝐼

𝐼
If is called the section modulus and denoted by S, another common variation of the fl
𝑐

exure formula is:

𝑀 𝑀 (Eq. 2.7) [9]

𝜎𝑚𝑎𝑥 = =
𝐼 𝑆
𝑐

Where: S – section modulus, m3

13
2.6.2 Section Modulus[10]

The section modulus, S, predicts the capacity of a beam made from an elastic material

to resist bending forces and is relative to both the size and shape of a section.

Rectangle 𝑏ℎ2 (Eq. 2.8) [9]

𝑆=
6

Where: b – base, m

h – height, m

2.6.3 Shearing Stress

Shearing stress differs from both tensile and compressive stress in thatit is caused by

forces acting along or parallel to the area resisting the forces, whereas tensile and

compresses are caused by forces perpendicular to the areas where they act. For this reason,

tensile and compressive forces are frequently called normal stresses, whereas as a shearing

stress may be called a tangential stress.[9]

A shearing stress is produced whenever the applied loads cause one section of a body to

tend to slide past its adjacent section.

𝑉 (Eq. 2.9) [9]

𝜏=
𝐴

Where: 𝜏 - Shearing stress, Pa

V - Shearing force, N

A - Area, m2

14
2.7 Paper Tray

The paper tray is primarily used to hold paper that is to be fed into the printer. This allows

longer printing without reloading due to its 550-sheet capacity. It is where the paper is loaded to

be lifted to the imaging unit by a feeding mechanism. The tray includes adjustable paper edge

guide restraints that enables media versatility from A6 to Legal size paper. These paper edge

guide restraints are immovable during feeding due to a lock system that holds the paper edge

guide restraints in place.

There are two types of paper tray available at Lexmark. Both have the same function but

differ in construction and process of adjusting paper size. The two types are center feed and

reference edge.

2.7.1 Center Feed Type

The center feed type is the commonly used type. The paper is to be stacked in the

center of the paper tray with the use of a rack and pinion mechanism on the side

paper edge guide restraints for proper and accurate centering.

2.7.1.1 Lexmark 35S2501 Paper Tray

The Lexmark 35S2501 paper tray is a center feed type paper tray. It caters

paper sizes A6, A5, B5, Executive, Letter, A4 and Legal.

15
Fig 2.10 Actual image of Lexmark 35S2501 Center Feed Paper Tray (Courtesy of Lexmark

International Inc.)

2.7.2 Reference Edge Type

The reference edge type makes use of a reference edge for stacking papers. Unlike

the center feed, the reference edge has only one side paper edge guide restraint since

one side edge of the paper tray is to be used as a guide. With that, the papers are

stacked at the side of the paper tray.

Fig 2.11 Actual reference edge paper tray

16
 CHAPTER III

REVIEW OF RELATED LITERATURE

This chapter presents the literature and related studies which have direct influence on this

study. The theories tackled in the following research papers have helped the researchers in

designing a two-axis paper edge guide restraint.

3.1 Simplified movement printer sheet stack guide

This patent presents a more intuitive and easier adjusting of paper edge guide restraints with

the use of latching guide mechanism. Conventional paper edge guide restraints mechanism

requires two actions to be repositioned, first is to pinch a member to unlatch from the latching

guide and second is to move or reposition the guide while maintaining the first action. This

design presents a pinch-free adjustment of the paper edge guide restraints. As the latching part

of the paper edge guide restraint, where the latching teeth are located, is lifted, the paper edge

guide is unlocked from the latching guide rack which then allows easy repositioning. As the

paper edge guide restraint is released, the teeth of the edge guide latch with the teeth of the

latching guide causing the paper edge guide restraint to be locked and immovable.

3.2 Adjustable feed tray assembly

This patent incorporates a rack and pinion mechanism onto the paper tray which makes it

self-centering and capable of rapid and easy adjustment. The paper holder is adjustable through

equidistant sliding of two parallel guide members. The mechanism consists of two paper edge

17
guide restraints which are mounted on a rack and are coupled for reciprocal movement, and a

pinion on the center, which is mated with the two racks. Movement of one paper edge guide

restraint rotates the pinion which then moves the opposite paper edge guide restraint equally to

the one actuated. With equal movement and distance covered, the paper stack is properly

positioned for feeding.

3.3 Print media guide system

This patent improves the rack and pinion mechanism on paper trays. The system basically

works the same with the conventional rack and pinion edge guide mechanism, expect that a

cluster of gears, two pinions and an idle gear on the center, is used, instead of one pinion, to

expand number of paper sizes covered.

3.4 Paper tray for a printing mechanism

This patent presents a simultaneous adjuster for both side and rear paper edge guide

restraints. The tray has one side paper edge guide restraint and one rear paper edge guide

restraint, which are both movable relative to the wall it is facing. The side paper edge guide

restraint movement is dependent to the movement of the rear paper edge guide restraint. The

rear paper edge guide restraint is integrated with a rack that is mated with a pinion which has a

cam attached to it. The side paper edge guide restraint has a cam follower. As the rear paper

edge guide restraint is adjusted, the rack rotates the pinion and the cam being attached to the

pinion, also rotates. The cam follower of the side paper edge guide restraint, which is always

biased towards the side wall with the use of a spring, follows the cam which then causes the side

paper edge guide restraint to be adjusted.

18
3.5 Two-axis media guide system for an imaging device

The system is an existing mechanism that translate the vertical motion from the rear guide

to the side guide of the tray. The process is done to ensure that the dimensions of the medium is

in proper or exact position to prevent any problem upon operation such as paper jams. Common

paper trays consist only of manually operated rear and side guide and that these operations are

independent with each other.

The study presents a mechanism of a removable tray with a two-axis media restraint system

having a user-actuated rear media restraint operatively coupled to a side media restraint via a

camming member. The rear restraint consists of a camming profile which is attach to the guide

in order for it move as the user move the rear guide. The camming profile is designed that when

it engages with the first and second cam follower in the side media restraint causing a movement

in the side edge of the media stack. Corresponding movement of the side edge and the rear guide

are calculated in a way that the side guides is in proper position with the rear guide considering

the paper size to be used. The mechanism uses a telescopic process to minimize the area covered

by the rear guide.

3.6 Multi-size paper tray having a sheet size indicator

This patent incorporates a cammed shaft member having a predefined contour slot where

it is mounted on the side wall of the paper tray. A stationary driver pin engages within the

contoured slot back and forth while the adjoining paper receiving shelf is driven during paper

size adjustment. The paper tray further includes side guide restraint which is mounted in another

contour slot placed on the paper receiving surface. This side guide restraint moves perpendicular

to the edge of the paper as the shelf slides along the floor of the cassette. In this operation, the

19
adjustment members come to rest at the correct paper width and corresponding to the correct

paper length visual indication on the cassette front wall.

3.7 Rehabilitation Act of 1973, Section 508

The Rehabilitation Act of 1973 prohibits discrimination on the basis of disability in

programs conducted by federal agencies, in programs receiving federal financial assistance, in

federal employment and in the employment practices of federal contractors. Section 508 outlines

the requirement of electronic and information technology to be accessible to people with

disabilities, including employees and members of the public. Consequently, Section 508 requires

the actuation of any device, gadget or appliance to be no more than 5lb-force (22.24N).

RESEARCH GAP

Most of the related literature presents patents with the same function as this study. The

literatures reviewed consist of different mechanisms to achieve one actuation to adjust the paper

edge guide restraints. In fact, Lexmark International, Inc. already has a patent that does the same

function, two-axis media guide system for an imaging device, but only caters three paper sizes,

Letter, A4 and Legal. This paper presents a study that requires only one actuation to adjust the

paper edge guide restraints, caters paper sizes A5, B5, Executive, Letter, A4 and Legal and is

specifically applied to the Lexmark 35S2501 Paper Tray.

20
 CHAPTER IV

METHODOLOGY

The process flow will serve as a step by step guide for the researchers that must be followed

in order to achieve the objectives needed in the design, fabrication and testing of a two-axis

paper edge guide restraint.

BRAINSTORMING

SELECTION OF
DESIGN CONCEPT

DESIGN
CALCULATIONS

PARTS MODELLING

FABRICATION

TESTING

Did it meet NO
the design
requirement
s?

YES

FINAL OUTPUT

Fig. 4.1 Process flow of research methodology

21
4.1 Design Concept Brainstorming

The researchers are presented with different topics to pursue for the thesis study. The topics

presented were design, fabrication, and testing of two-axis paper edge guide restraint

mechanism, design, fabrication, and testing of actuation-free paper tray guide and design,

fabrication, and testing of paper tray paper pre-separator. The two-axis paper edge guide

restraint mechanism and actuation-free paper tray guide mechanism are seen to improve user

experience and paper tray media pre-separator mechanism is seen to address media multi-

feeding problems. The researchers have chosen to pursue on the two-axis paper edge guide

restraint mechanism since it has a greater bearing on the theories ascribed in the mechanical

engineering study than that of the other two mentioned.

With agreement upon researchers and co-advisers that no ideas are wrong, different design

concepts of the two-axis paper edge guide restraint mechanism are generated. The compliance to

the requirement of Section 508 of the Rehabilitation Act of 1973 is also being considered in this

design conceptualization process. These concepts will be assessed based on a design criteria

presented in the concept selection.

4.2 Concept Selection

Three design concepts for two-axis paper edge guide restraint mechanism are generated

through the brainstorming process. Five design criteria are considered during concept selection.

The design concepts are tabulated versus the design criteria. The design concepts are ranked

from 1-3, 1 as highest and 3 as lowest, at each criteria. The sum of each design concept is

determined and the design concept having the lowest total score is selected.

22
4.2.1 Design Concepts

4.2.1.1 Rack and pinion mechanism

The first design concept shown in Fig. 4.2 uses a rack and pinion mechanism. Rear

paper edge guide restraint A is integrated with a rack which is mated with pinion D.

When pinion D rotates due to an actuation force on the rear paper edge guide restraint

A, it drives pinion E and thus, rotating it. In cooperation with the rotation of pinion E,

pinion F and G rotates the same way because a shaft C joins them vertically. The side

restraints B are both associated with a rack which is mated to either pinion F and G,

depending on the paper size requirement at the time of the actuation. These racks have

specific length such that each side guide displaces equally in opposite direction and that

it meets the width dimension of the desired paper size. The number of pinions to be

used is equal to the number of paper sizes to be covered by the mechanism.

A - rear edge guide with rack B – side edge guides with rack
23
 C - shaft D – pinion (driver) E, F, G – pinion (driven)

Fig. 4.2 Isometric view of rack and pinion mechanism

4.2.1.2 Cam and roller mechanism

The second design concept shown in Fig. 4.3 uses a cam and roller mechanism.

Paper edge guide restraint A is integrated with a rack. Pinion B, which is mated with

the rack of edge guide A, drives the cam C. Cam C actuates paper edge guide restraint

with the use of roller follower D. As paper edge guide restraint A is adjusted, the rack

rotates pinion B along with cam C. As cam C rotates, roller follower D follows thus,

paper edge guide restraint E is adjusted.

A - rear edge guide with rack B - pinion C - cam

D - roller follower E - side edge guide

24
 Fig. 4.3 Isometric view of cam and roller mechanism

4.2.1.3 Stationary Linear Cam and Roller Mechanism

The third design concept shown in Fig. 4.3 uses a roller and a stationary linear cam

mechanism to simultaneously adjust the rear paper edge guide restraint A and the side

paper guide restraint E. Upon moving the rear paper edge guide restraint A, the link B

which is connected to the rear paper edge guide restraint A moves making the roller

travel along the stationary linear cam H. With the stationary linear cam H, the roller

follows the path thus making a horizontal motion. The horizontal motion is applied

into the side link D which is connected to the side paper edge guide restraint E thus

making it move. Since the side paper edge guide restraint E has a rack which is mated

with pinion F, it simultaneously drives the side paper edge guide restraint G to its

proper position.

A-Rear paper edge guide restraint B-Rear link C-Roller follower D-Side link

E-Right paper edge guide restraint F-Pinion G-Left paper edge guide restraint

25
 H-Stationary linear cam

Fig. 4.4 Isometric view of stationary linear cam and roller mechanism

4.2.2 Criteria for Concept Selection

4.2.2.1 Number of parts

The estimated number of parts of each design concept is conceived to affect the

complexity of the design, fabrication and testing. The more number of parts increase the

cost. Therefore, it is desired for the mechanism to have lesser parts.

4.2.2.2 Space requirement

This criterion accounts for the size (height, width and length) of the mechanism to

be installed in the printer assembly. It is desired for the mechanism to be minimal.

4.2.2.3 Conservation of printer architecture

This criterion accounts for the alterations that must be made in the printer

architecture during the mechanism’s installation. It is desired that alterations are

constricted from little to no alterations.

4.2.2.4 Number of paper sizes covered

This criterion accounts for the number of paper sizes the design can support. It is

desired for the mechanism to support more paper sizes.

4.2.2.5 Feasibility to two types of paper trays available at Lexmark International Inc.

26
 This criterion accounts for the feasibility of the design to be incorporated with the

two types of paper tray available at Lexmark. Even though the study is to be applied on

the center paper tray, it is desired that the design is feasible to both types of paper trays

for future application. Ranking at this criterion will only be 1 and 2 since there are only

two possible outcomes, feasible to one type and feasible to two types.

4.2.3 Design concept selected

Table 4.1 Selection of design concept for two-axis paper edge guide restraint

DESIGN CRITERIA
CONCEPT TOTAL
No. of parts Space Conservation Paper sizes Feasibility
Gear 3 3 2 3 2 13
Cam and
2 1 3 1 2 9
roller
Linear
cam and 1 2 1 2 1 7
roller

Design concept 4.2.1.3 - Stationary linear cam and roller mechanism incurred the

lowest total as seen in Table 4.1. This design is the most desired out of the 3. Therefore,

this design concept is selected. (To be elaborated by Pino)

4.3 Design calculation

The study is to be applied to the Lexmark 35S2501 center feed paper tray since lesser force

is needed to actuate the mechanism. This is due to the steep slope yielded if the mechanism is

applied to the reference edge paper tray. With the center feed paper tray type having a rack and

pinion mechanism, half of the width adjustment is only to be taken account. With that, the rise

27
of the slope would be divided by 2 which yields a less steeper slope. Table of comparison of the

slopes between center feed and reference edge paper tray is shown in Appendix A.3.

The concept selected caters all paper sizes on Lexmark 35S2501 Paper Tray except A6 (A5,

B5, Executive, Letter, A4 and Legal). Paper size A6 is ruled out due to space constraints. The

mechanism would interfere with the side paper edge guide restraint if A6 would be included.

Fig. 4.5 Area of interference between mechanism and side paper edge guide restraint if A6

is included

4.3.1 Forces on the rear paper edge guide restraint

The forces on the rear paper edge guide restraint are to be calculated. The actuation

force on the rear paper edge guide restraint is the force applied, Fapp on the system.

Considering the frictional force, Ff , normal force, FN , and gravitational force, Fg , the net

force, FNETREAR on the rear paper edge guide restraint is to be calculated. Fig. 4.6 shows the
28
free-body diagram of the rear paper edge guide restraint during actuation, when Fapp is

applied.

Fig. 4.6 Rear paper edge guide restraint force diagram

∑𝐹𝑦 = 𝐹𝑁 − 𝐹𝑔 = 0 (no vertical motion)

∑𝐹𝑥 = 𝐹𝑁𝐸𝑇𝑅𝐸𝐴𝑅 = 𝐹𝑎𝑝𝑝 − 𝐹𝑓

∑𝐹𝑥 = 𝐹𝑁𝐸𝑇𝑅𝐸𝐴𝑅 = 𝐹𝑎𝑝𝑝 − 𝜇𝑘 𝐹𝑁

The calculated value of the FNETREAR is 21.980154 N which is shown in Appendix C.1.

4.3.2 Maximum angle constraint

The maximum angle , 𝜃, of the linear cam slot is to be considered to observe the 5lb-

force (22.24N) requirement of Section 508 of the Rehabilitation Act of 1973. Considering

the frictional force of the side paper edge guide restraints, FfSR, the net force on the rear

paper edge guide restraint, FNETREAR, normal force, FN, and frictional force, Ff, the maximum

angle is to be calculated.

29
 Fig. 4.7 Free body diagram of roller and cam with unknown maximum angle

∑ 𝐹𝑥 = 𝐹𝑁𝐸𝑇𝑅𝐸𝐴𝑅 − 𝐹𝑁 sin 𝜃 − 0.38𝐹𝑁 cos 𝜃 = 0

∑ 𝐹𝑦 = 𝐹𝑁 cos 𝜃 − 0.260956 N − 0.38𝐹𝑁 sin 𝜃 = 0

The maximum angle at which the FNETREAR is to be applied is 68.5130, shown in

Appendix C.2. All angles at each paper size position does not exceed the maximum angle as

shown in Appendix A.4.

4.3.3 Dimensions of the rear paper edge guide restraint roller axle slot

In calculating the dimensions of the rear paper edge guide restraint roller axle slot, the

forces acting on the roller axle slot are to be analyzed using a free-body diagram.

Considering that the largest moment is when the moment arm of the force application is

farthest from the point of reference, the free-body diagram is to be constructed and analyzed

such that the axle is farthest from the reference point and that it experiences the largest

moment.

30
 Fig. 4.8 Force body diagram on roller axle slot

𝐹𝑁𝐸𝑇𝑅𝐸𝐴𝑅 = 𝐹𝑅

Using the Eq. 2.7, the base and height of the roller axle slot is to be determined.

A flexural stress of 74MPa is to be used.

𝑀𝑦 𝑀 𝑀
𝜎= = =
𝐼 𝐼 𝑆
𝑐

Using Eq. 2.8 for a rectangular cross section,

6𝑀
𝜎=
𝑏2ℎ

The height of the roller axle slot is 4 mm since it is the available height for it to be

attached to the rear paper edge guide restraint and the calculated base of the roller axle

slot is 5.818 mm, thus, a base of 6 mm is to be used shown in Appendix C.4.

31
4.3.4 Forces and stresses on the roller

The contact stress at each inclination on the linear cam slot is to be calculated.

Each calculated contact stress is to be used to check the suitability of an existing roller

having dimensions of d = 15 mm and t = 6 mm.

The value of FN, which is the force perpendicular to the contact area of the roller

and linear slot, at each adjacent paper size adjustment is obtained. The calculated

maximum FN is to be used to calculate the maximum contact width and contact stress

using Eq. 2.3 and Eq. 2.4, respectively.

Fig. 4.9 Free-body diagram of roller on steepest angle

∑ 𝐹𝑥 = 21.980154 𝑁 − 0.38𝐹𝑁 cos(𝜃) − 𝐹𝑁 sin(𝜃) = 0

32𝐹𝑁 (1 − 𝑣 2 )𝑟
𝑤= √
𝜋𝑡𝐸

32
 4𝐹𝑁
𝜎𝑐 =
𝑤𝑡

All calculated stresses, as shown in Appendix C.5, have not exceeded the

maximum compressive yield strength of 65MPa as shown in Appendix A.6. Therefore,

the existing roller is suitable for the design.

4.3.5 Dimensions of the side paper edge guide restraint roller axle slot

The vertical acceleration, ∑ 𝐹𝑦 , is to be calculated at each inclination on the linear

cam slot which is to be used in calculating the moment. The largest calculated moment is

0.805 N-m, shown in Appendix C.6 which is to be used for the calculation of the

dimensions of the side paper edge guide restraint roller axle slot.

∑ 𝐹𝑥 = 𝐹𝑁𝐸𝑇𝑅𝐸𝐴𝑅 − 𝐹𝑓 cos(𝜃) − 𝐹𝑁 sin(𝜃)

∑ 𝐹𝑦 = 𝐹𝑁 cos(𝜃) − 𝐹𝑓 sin(𝜃) − 𝐹𝑓𝑆𝑅

𝐹𝑦
tan (𝜃) =
𝐹𝑥

𝑀 = (𝐿)𝐹𝑦𝑅𝑂𝐿𝐿𝐸𝑅

6𝑀
𝜎=
𝑏2ℎ

The height to be used for the side edge guide roller axle slot is 4 mm for

fabrication purposes while the calculated base is 3.9378619 mm, thus, a base of 4 mm is

to be used. Calculation for the side paper edge guide restraint roller axle slot dimension

is shown in Appendix C.7.

33
4.3.6 Diameter of the roller axle

The axial length of the roller axle is too short to be subjected to the flexural stress

thus, shearing stress is considered in calculating the diameter of the roller axle.

Considering the shear strength of ABS plastic to be 0.28 MPa and a shear force

which is the FNETREAR, the diameter of the roller axle is to be calculated using Eq. 2.9.

𝒅𝒂

Fig. 4.10 Roller axle subjected to shear force

𝑉
𝜏=
𝐴

The calculated roller axle diameter is 10 mm which is shown in Appendix C.8.

Thus, the roller axle diameter to be used is 10 mm.

4.3.7 Linear cam slot

The rise and run of each paper size is to be determined with A5 as reference. The

dimensions of the each paper size is shown in Appendix A.1. The rise and run at each

paper size is tabulated as shown in Appendix A.9 using the following equations:

34
 Width papersize  WidthA5
Rise 
2

Run  Lengthpapersize  LengthA5

In making the linear cam or displacement diagram, the rise is to be plotted as the

ordinate and the run as abscissa. The endpoints are to be connected to form the

displacement diagram which is also the linear cam. Circles, with the radius of the roller,

are to be plotted along the displacement diagram. The circles are to be connected

tangentially to form the slot. The thickness of the linear cam slot is equal to the

thickness of the roller. The calculations and steps in designing is shown in Appendix

C.9.

Fig. 4.11 Linear cam slot

35
4.4 Parts modelling

Using Solidworks 2016, each component of the two-axis paper edge guide restraint

mechanism is modeled. The modeled components are assembled to the Lexmark 35S2501 paper

tray design file which was acquired from Lexmark International Inc. The components and

assembly are modeled based on the dimensions calculated and designed on Chapter 4.3 Design

Calculations.

The 3D isometric view and engineering drawing of each components are presented. The

models presented only show the dimensions of the new components and parts of the current

components that are modified. Moreover, the dimensions of the Lexmark 35S2501 paper tray

and paper edge guide restraints that are not shown in the engineering drawing, remain the same.

4.4.1 Parts

4.4.1.1 Linear cam slot

Fig. 4.12 Isometric view of linear cam slot

36
 Fig. 4.13 Engineering drawing of linear cam slot

4.4.1.2 Right side paper edge guide restraint integrated with roller axle slot

Fig. 4.14 Isometric view of right side paper edge guide restraint integrated with roller axle

slot

37
 Fig. 4.15 Engineering drawing of right side paper edge guide restraint integrated with

roller axle slot

4.4.1.3 Rear paper edge guide restraint integrated with roller axle slot

Fig. 4.16 Isometric view of rear paper edge guide restraint integrated with roller axle slot
38
Fig. 4.17 Engineering drawing of rear paper edge guide restraint integrated with roller axle slot

4.4.1.4 Roller

Fig. 4.18 Isometric view of roller

39
 Fig. 4.19 Engineering drawing of roller

4.4.1.4 Modified Lexmark 35S2501 Paper Tray

Fig. 4.20 Isometric view of the modified Lexmark 35S2501 Paper Tray
40
 The Lexmark 35S2501 Paper Tray is slightly modified for the installation of the

mechanism. The right paper stack rest is extruded to 10mm which leaves a base of

2mm. The right paper stack rest is also extended by 5.16mm in length. A 3mm hole,

that is concentric with the roller at A5 position, is cut through the base for fabrication

purposes.

Fig. 4.21 Extrusion of right paper stack rest

Fig. 4.22 Extension of right paper stack rest

41
Fig. 4.23 Hole through the paper tray

42
4.4.2 Assembly

4.4.2.1 Assembly of components

Fig. 4.24 Isometric view of assembly of components

43
 4.4.2.2 Exploded view of assembly of components

Fig. 4.25 Exploded view of assembly of components

Part No. Component Quantity

1 Modified Lexmark 35S2501 Paper Tray 1

2 Linear cam slot 1

3 Roller 1

4 Gear 1

5 Left side paper edge guide restraint 1

6 Right side paper edge guide restraint integrated with roller axle slot 1

7 Rear paper edge guide restraint integrated with roller axle slot 1

44
4.5 Fabrication

4.5.1 Materials

4.5.1.1 Acrylonitrile butadiene styrene plastic molded - Acrylonitrile butadiene styrene

is a common thermoplastic polymer. It is the type of plastic to be used as the only

material for all parts.

Fig 4.26 ABS plastic molded

4.5.1.2 Flat phillips M3x16 screw - A screw is a type of fastener with a helical thread. It

is to be used for fastening the roller, axle and axle cap.

Fig 4.27 Flat screw head

45
4.5.1.3 Paper size sticker guide - A sticker guide that indicates the length and width

dimensions of the paper.

Fig 4.28 Paper size sticker guide (Courtesy of Lexmark International Inc.)

4.5.1.4 Super glue - A super glue is a fast-acting and strong adhesive. It is to be used for

attaching the linear cam slot to the paper tray.

Fig. 4.29 Super glue

46
4.5.2 Equipment

4.5.2.1 Phillips screwdriver - Is to be used for screwing or fastening the philips screw.

Fig 4.30 Phillips screwdriver

4.5.2.2 Computer Numerical Control Milling Machine or CNC Milling Machine - A

computerized machine tool used for shaping of solid materiald. The CNC Milling

Machine is to be used for forming all parts of the mechanism.

Fig 4.31 CNC Milling Machine

47
4.5.3 Fabrication Procedure

Each part file is to be converted to step file and a drawing file of each part is to be

created. All files are to be submitted to the Machine Room at Lexmark for fabrication. All

parts are to be fabricated by the CNC Milling Machine available at Lexmark. Fabricated

parts arts are to be acquired at most 2 weeks after submission.

4.5.4 Assembly Procedure

1. Attach linear cam slot to paper tray using super glue.

2. Screw roller to axle with flat philips screw and screwdriver.

3. Place the roller and axle on the slot of the linear cam plate.

4. Insert rear link to the axle of the roller and assemble the rear paper edge guide

restraint to the paper tray

5. Insert side link to the axle of the roller and assemble the side paper edge guide

restraint to the paper tray.

6. Assemble opposite side paper edge guide restraint to the paper tray.

7. Assemble and mate pinion with the two racks of the side paper edge guide restraint at

the bottom of the paper tray. Screw pinion to the paper tray.

8. Set paper edge guide restraints to A5 position for alignment of hole on the paper

tray and the philips screw at the bottom of the roller. Using a screw driver, hold the

roller in place to prevent rotation of roller and axle. Simultaneously, screw the axle

cap to the axle using flat philips screw and philips screwdriver.

48
 9. Stick the paper size sticker guide on the path of the rear and side paper edge guide

restraints.

4.6 Testing

4.6.1 Materials

4.6.1.1 Stack of paper of different sizes (A5, B5, Executive, Letter, A4,and Legal) -

A 500-sheet stack of paper is to be used at each paper size adjustment and reload

testing.

Fig 4.32 Stack of paper

4.6.2 Equipment

4.6.2.1 Force Gauge - A force gauge is a measuring instrument used to measure push or

pull force. It is to be used for measuring the force needed to actuate the paper edge guide

restraint.

49
 Fig 4.33 Force gauge

4.6.2.2 Spring clamp- A spring clamp is a type of fastener used to hold objects

temporarily. A spring clamp is to be used to keep the paper edge guide restraint

unlocked.

Fig 4.34 Spring clamp

50
4.6.3 Testing Procedure

4.6.3.1 Adjustment and Paper Load Test

In this test, the working mechanism designed and fabricated is to be tested. It is to

be checked if both side and rear paper edge guide restraints adjust simultaneously and

accurately at each paper size position. It is required that the rear and side paper edge

guide restraint size indicators align with the markers on the sticker at each specific

position and that the 550-sheet stack of paper loaded fit within the paper edge guide

restraints.

The rear paper edge guide restraint is to be adjusted to each paper size catered by

the design. At each paper size position where the rear paper edge guide restraint is

adjusted to, the side paper edge guide restraint is to be checked if it matches with the

paper size position of the rear paper edge guide restraint. Moreover, the size indicator

of each paper edge guide restraint should align with the markers on the sticker and the

550-sheet stack of paper loaded at each size should fit within the bias fingers of the

paper edge guide restraint.

One trial is to be done for each paper size position since there is no numerical data

expected and the adjustment and movement of the paper edge guide restraints do not

change at each trial. The result at each paper size position will either be pass or fail and

is to be tabulated on the table below:

51
Table 4.2 Adjustment and paper load test results

Paper Size Result

A5

B5

Executive

Letter

A4

Legal

4.6.3.2 Force Test

In this test, the mechanism is to be checked if it is compliant with the requirement

of Section 508 of the Rehabilitation Act of 1973. Each force needed to actuate the paper

edge guide restraint from a specific size to its adjacent paper size position/s is to be

determined. It is required that the actuation will be no more than 5lb-force (22.24N).

The result of each actuation will either be pass or fail.

A spring clamp is to be used to pinch the rear paper edge guide restraint to keep it

unlocked. Starting at specific paper size position, a force gauge is to be used to push or

pull the paper edge guide restraint to its adjacent paper size positions and at the same

time measure the force applied.

52
 Fig. 4.35 Experimental set-up

Three trials are to be done per adjustment. The results of the three trials are to be

averaged. The average is to be compared to the 5lb-force (22.24N) requirement of

Section 508 of the Rehabilitation Act of 1973. If the average force is greater than 5lb-

force (22.24N), the result will be “fail” and if the average force is lesser than or equal to

5lb-force (22.24N), the result will be “pass”. The results are to be tabulated on the table

below:

53
Table 4.3 Force test results (A5-Legal adjustment)

TRIAL
Paper Size Adjustment Average Result
1 2 3

A5-B5

B5-Executive

Executive-Letter

Letter-A4

A4-Legal

Table 4.4 Force test results (Legal-A5 adjustment)

TRIAL
Paper Size Adjustment Average Result
1 2 3

Legal-A4

A4-Letter

Letter-Executive

Executive-B5

54
B5-A5

55
4.7 Expected Output

At the end of this study, it is expected that the following are accomplished:

A. The mechanism simultaneously adjusts both rear and side paper edge guide restraints during

paper reloading.

B. The mechanism is compliant with the requirement of Section 508 of the Rehabilitation Act of

1973

Fig 4.35 Isometric view of Two-Axis Paper Edge Guide Restraint

56
4.8 GANTT CHART

4.8.1 Thesis I: Proposal

SEP OCT NOV DEC
ACTIVITIES
1234123412341234
1. Meeting with Lexmark
1.1 Meeting with Lexmark Mechanical Department Manager and HR
1.2 Introduction to Lexmark printers
1.3 Presentation of possible thesis topics
2. Brainstorming
2.1 Selection of thesis topic
2.2 Establishment of thesis objectives
2.3 Conception of possible design solutions
3. Making of Chapter 1
4. Concept Selection
4.1 Reading of Related Literature
4.2 Identification of design criteria
4.3 Presentation of design concepts
4.4 Selection of design concept
5. Making of Chapter 2
6. Design Calculation
6.1 Acquisition of necessary dimensions of paper tray
6.2 Calculation of design parameters
7. Parts Modelling
7.1 Acquisition of design file of paper tray
7.2 Modelling of mechanism
8. Fabrication and testing procedures
8.1 Identification of necessary materials and equipment
8.2 Establishment of fabrication and testing procedures
9. Making of Chapter 3

57
 SEP OCT NOV DEC
ACTIVITIES
1234123412341234
10. Review of proposal draft
11. Mock defense at Lexmark
12. Submission of final proposal
13. Presentation and defense
14. Revision of proposal

- General Activity
- Specific Activity

58
 4.8.2 Thesis II: Proposal

JAN FEB MARCH APRIL MAY

ACTIVITIES
1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4
1. Fabrication Phase
1.1 Acquisition of materials and equipment
1.2 Submission of design to Lexmark
Machine Shop
1.3 Fabrication of mechanism
1.4 Acquisition of fabricated parts
1.5 Assembly of mechanism
2. Testing Phase
2.1 Acquisition of materials and equipment
2.2 Testing of mechanism `
2.3 Data gathering
3. Evaluation and Analysis of Data
4. Modification
4.1 Recalculation of design parameters
4.2 Fabrication of redesigned mechanism
4.3 Testing of redesigned mechanism
4.4 Data gathering
4.5 Evaluation and analysis of data
5. Revision of Chapter 4
6. Making of Chapter 5
7. Assembly of Complete Thesis Paper
8. Submission of Complete Thesis Paper

9. Presentation and defense at Lexmark

International Inc.
10. Presentation and defense at USC

59
 JAN FEB MAR APR MAY
ACTIVITIES
1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4
11. Revision of Thesis Paper

- General Activity
- Specific Activity

60
 APPENDIX

Appendix A - Tables

A.1 Table of standard paper sizes (Courtesy of Lexmark International Inc.)

Size Width (mm) Length (mm)

Legal 215.9 355.6

Foolscap folio 216.0 330.0

A4 210.0 297.0

Letter 215.9 279.4

Executive 184.2 266.7

B5 182.0 257.0

Statement 139.7 215.9

A5 148.0 210.0

A6 105.0 148.0

61
A.2 Table of mechanical properties of Acrylonitrile Butadiene Styrene (ABS) Plastic Molded

(Source: www.matweb.com and www.researchgate.net)

Mechanical Properties Metric Value (Average)

Hardness, Rockwell R 107

Tensile Strength, Ultimate 38.8MPa

Compressive Strength, Yield 65MPa

Tensile Strength, Yield 44.1MPa

Flexural Strength, Yield 74MPa

Shearing Strength 0.28 MPa

Modulus of Elasticity 2.81MPa

Static Friction 0.21

Kinetic Friction 0.38

A.3 Table of comparison of slopes between center feed and reference edge paper tray

Slope for center feed Slope for reference edge

Paper Adjustment
paper tray paper tray

A5-B5/B5-A5 0.361702 0.723404

B5-Executive/Executive-B5 0.113402 0.226804

Executive-Letter/Letter-Executive 1.248031 2.496063

Letter-A4/A4-Letter 0.167614 0.335227

A4-Legal/Legal-A4 0.05034 0.100683

62
A.4 Table of angle between adjacent paper size adjustments

Paper size adjustment Angle Result (<68.513)

A5-B5/B5-A5 19.890 Pass

B5-Executive/Executive-B5 6.470 Pass

Executive-Letter/Letter-Executive 51.300 Pass

Letter-A4/A4-Letter 30.740 Pass

A4-Legal/Legal-A4 2.880 Pass

A.5 Table of moment arm of side paper edge guide restraint (Measured from Solidworks file)

Paper size adjustment Length (mm)

A5-B5/B5-A5 67.82

B5-Executive/Executive-B5 78.97

Executive-Letter/Letter-Executive 91.24

Letter-A4/A4-Letter 109.33

A4-Legal/Legal-A4 168.26

63
A.6 Table of contact stresses at each adjacent paper size adjustment

Position Contact stress, MPa Result (<65 Mpa)

A5 TO B5 29.382 Pass

B5 TO EXEC 17.488 Pass

EXEC TO LTR 44.0 Pass

LTR TO A4 35.790 Pass

A4 TO LGL 12.356 Pass

A.7 Table of moment at each position of adjacent paper size adjustment

Position Moment. N-m

A5 TO B5 0.407

B5 TO EXEC 0.185

EXEC TO LTR 0.496

LTR TO A4 0.805

A4 TO LGL 0.181

64
A.8 Table of theoretical force applied to actuate

Position FApp, N

A5 TO B5 0.233444

B5 TO EXEC 0.191982

EXEC TO LTR 0.429191

LTR TO A4 0.276811

A4 TO LGL 0.182151

A.9 Table of rise and run of each paper size with A5 as reference

Paper size adjustment Rise (mm) Run (mm)

A5 0 0

B5 17 47

Executive 18.1 56.7

Letter 33.95 69.4

A4 31 87

Legal 33.95 145.6

65
Appendix B - Data gathered

B.1 Table of mass of paper edge guide restraints (Courtesy of Lexmark International Inc.)

Part Mass, kg

Rear paper edge guide restraint 0.07

Right side paper edge guide restraint 0.04

Left side paper edge guide restraint 0.03

Appendix C - Calculations

C.1 Forces on the rear paper edge guide restraint

∑ 𝐹𝑦 = 0 (𝑛𝑜 𝑣𝑒𝑟𝑡𝑖𝑐𝑎𝑙 𝑚𝑜𝑡𝑖𝑜𝑛)

∑𝐹𝑦 = 𝐹𝑁 − 𝐹𝑔 = 0

𝐹𝑁 − 𝐹𝑔 = 0

𝐹𝑁 = 𝐹𝑔

𝐹𝑁 = 𝑚𝑎

𝑚
𝐹𝑁 = (0.07 𝑘𝑔)(9.81𝑠2 ) (m- mass of rear paper edge guide restraint)

𝐹𝑁 = 0.6867 𝑁

∑𝐹𝑥 = 𝐹𝑁𝐸𝑇𝑅𝐸𝐴𝑅 = 𝐹𝑎𝑝𝑝 − 𝐹𝑓

∑𝐹𝑥 = 𝐹𝑁𝐸𝑇𝑅𝐸𝐴𝑅 = 𝐹𝑎𝑝𝑝 − 𝜇𝑘 𝐹𝑁

66
𝐹𝑁𝐸𝑇𝑅𝐸𝐴𝑅 = 𝐹𝑎𝑝𝑝 − 𝜇𝑘 𝐹𝑁

𝐹𝑁𝐸𝑇𝑅𝐸𝐴𝑅 = 22.2411𝑁 − (0.38)(0.6867𝑁)

𝐹𝑁𝐸𝑇𝑅𝐸𝐴𝑅 = 21.980154 𝑁

C.2 Maximum angle constraint

∑ 𝐹𝑥 = 𝐹𝑁𝐸𝑇𝑅𝐸𝐴𝑅 − 𝐹𝑁 sin 𝜃 − 0.38𝐹𝑁 cos 𝜃 = 0

21.980154 𝑁
𝐹𝑁 =
(sin 𝜃 + 0.38cos 𝜃)

∑ 𝐹𝑦 = 𝐹𝑁 cos 𝜃 − 0.260956 N − 0.38𝐹𝑁 sin 𝜃 = 0

0.260956 𝑁
𝐹𝑁 =
(cos 𝜃 − 0.38sin 𝜃)

21.980154 𝑁 0.260956 𝑁
𝐹𝑁 = = (cos 𝜃−0.38sin 𝜃)
(sin 𝜃+0.38cos 𝜃)

𝜃 = 68.513°

67
C.3 Frictional force of side paper edge guide restraints

Fig. A.1 Force body diagram on side paper edge guide restraint

Right side paper edge guide restraint

∑ 𝐹𝑦 = 0

∑ 𝐹𝑦 = 𝐹𝑁 − 𝐹𝑔

𝐹𝑁 − 𝐹𝑔 = 0

𝐹𝑁 = 𝐹𝑔

𝐹𝑔 = 𝑚𝑎

𝑚
𝐹𝑔 = (0.03 𝑘𝑔)(9.81 )
𝑠2

𝑚
𝐹𝑔 = (0.03 𝑘𝑔)(9.81 )
𝑠2

68
𝐹𝑔 = 0.2943 𝑁

𝐹𝑔 = 𝐹𝑁 = 0.2943 𝑁

Since 𝐹𝑓 = 𝜇𝑘 𝐹𝑁 ,

𝐹𝑓 = 0.38(0.2943 𝑁)

𝐹𝑓 = 0.111834 𝑁

Left side paper edge guide restraint

∑ 𝐹𝑦 = 0

∑ 𝐹𝑦 = 𝐹𝑁 − 𝐹𝑔

𝐹𝑁 − 𝐹𝑔 = 0

𝐹𝑁 = 𝐹𝑔

𝐹𝑔 = 𝑚𝑎

𝑚
𝐹𝑔 = (0.04 𝑘𝑔)(9.81 )
𝑠2

𝑚
𝐹𝑔 = (0.04 𝑘𝑔)(9.81 )
𝑠2

𝐹𝑔 = 0.3924 𝑁

𝐹𝑔 = 𝐹𝑁 = 0.3924 𝑁

Since 𝐹𝑓 = 𝜇𝑘 𝐹𝑁 ,

𝐹𝑓 = 0.38(0.3924 𝑁)
69
𝐹𝑓 = 0.149112 𝑁

Calculate 𝐹𝑓𝑆𝑅

𝐹𝑓𝑆𝑅 is the summation of friction forces on the right and left side paper edge guide restraint

𝐹𝑓𝑆𝑅 = ∑ 𝐹𝑓 𝑎𝑡 𝑒𝑎𝑐ℎ 𝑠𝑖𝑑𝑒 𝑔𝑢𝑖𝑑𝑒

𝐹𝑓𝑆𝑅 = 0.111834 𝑁 + 0.149112 𝑁

𝐹𝑓𝑆𝑅 = 0.260946 𝑁 (𝑘𝑖𝑛𝑒𝑡𝑖𝑐)

𝐹𝑓𝑆𝑅 = 0.144207 𝑁 (𝑠𝑡𝑎𝑡𝑖𝑐)

C.4 Dimensions of the rear paper edge guide restraint roller axle slot

∑𝐹𝑦 = 𝐹𝑁𝐸𝑇𝑅𝐸𝐴𝑅 − 𝐹𝑅 = 0

𝐹𝑁𝐸𝑇𝑅𝐸𝐴𝑅 − 𝐹𝑅 = 0

𝐹𝑁𝐸𝑇𝑅𝐸𝐴𝑅 = 𝐹𝑅

𝑀𝑦 𝑀 𝑀
𝜎= = =
𝐼 𝐼 𝑆
𝑐

𝑀
𝜎=
𝑏2ℎ
6

6𝑀
𝜎=
𝑏2ℎ

70
 6(0.076𝑚)(21.980154𝑁)
74 𝑀𝑃𝑎 = 𝑏 2 (0.004 𝑚)

𝑏 = 0.005819 𝑚

C.5 Forces and stresses on the roller

A5-B5:

∑ 𝐹𝑥 = 𝐹𝑁𝐸𝑇𝑅𝐸𝐴𝑅 − 𝐹𝑓 cos(𝜃) − 𝐹𝑁 sin(𝜃)

∑ 𝐹𝑥 = 𝐹𝑁𝐸𝑇𝑅𝐸𝐴𝑅 − 𝐹𝑓 cos(19.89) − 𝐹𝑁 sin(19.89)

∑ 𝐹𝑥 = 𝐹𝑁𝐸𝑇𝑅𝐸𝐴𝑅 − 𝜇𝑘 𝐹𝑁 cos(19.89) − 𝐹𝑁 sin(19.89)

∑ 𝐹𝑥 = 21.980154 𝑁 − 0.38𝐹𝑁 cos(19.89) − 𝐹𝑁 sin(19.89) (Eq. A)

∑ 𝐹𝑦 = 𝐹𝑁 cos(19.89) − 𝐹𝑓 sin(19.89) − 𝐹𝑓𝑆𝑅

∑ 𝐹𝑦 = 𝐹𝑁 cos(19.89) − 𝜇𝑘 𝐹𝑁 sin(19.89) − 0.260956 N

∑ 𝐹𝑦 = 𝐹𝑁 cos(19.89) − 0.38𝐹𝑁 sin(19.89) − 0.260956 N (Eq. B)

∑ 𝐹𝑦
tan (19.89) = ∑ 𝐹𝑥
(Eq. C)

Substitute Eq. A and Eq. B to Eq. C

𝐹𝑁 cos(19.89)−0.38𝐹𝑁 sin(19.89)−0.260956 N
tan (19.89) = (Eq. D)
21.980154 𝑁−0.38𝐹𝑁 cos(19.89)−𝐹𝑁 sin(19.89)

𝐹𝑁 = 7.723436259 𝑁
71
Contact width:

32𝐹(1 − 𝑣 2 )𝑟
𝑤= √
𝜋𝑡𝐸

32𝐹𝑁 (1 − 𝑣 2 )𝑟
𝑤= √
𝜋𝑡𝐸

32(7.723436259 𝑁)(1 − 0.352 )(0.0075𝑚)

𝑤= √
𝜋(0.006𝑚)(2.81𝑥109 𝑃𝑎)

𝑤 = 1.752389916𝑥10−4 𝑚

Contact stress:

4𝐹𝑁
𝜎𝑐 =
𝑤𝑡

4(7.723436259 𝑁)
𝜎𝑐 =
(1.752389916𝑥10−4 𝑚 )(0.006 𝑚)

𝜎𝑐 = 29382487.66 Pa or 29.382 MPa

B5 - Executive:

∑ 𝐹𝑥 = 𝐹𝑁𝐸𝑇𝑅𝐸𝐴𝑅 − 𝐹𝑓 cos(6.47) − 𝐹𝑁 sin(6.47)

∑ 𝐹𝑥 = 𝐹𝑁𝐸𝑇𝑅𝐸𝐴𝑅 − 𝜇𝑘 𝐹𝑁 cos(6.47) − 𝐹𝑁 sin(6.47)

∑ 𝐹𝑥 = 21.980154 𝑁 − 0.38𝐹𝑁 cos(6.47) − 𝐹𝑁 sin(6.47)

72
∑ 𝐹𝑦 = 𝐹𝑁 cos(6.47) − 𝐹𝑓 sin(6.47) − 𝐹𝑓𝑆𝑅

∑ 𝐹𝑦 = 𝐹𝑁 cos(6.47) − 𝜇𝑘 𝐹𝑁 sin(6.47) − 0.260956 N

∑ 𝐹𝑦 = 𝐹𝑁 cos(6.47) − 0.38𝐹𝑁 sin(6.47) − 0.260956 N

∑ 𝐹𝑦
tan (6.47) = ∑ 𝐹𝑥

𝐹𝑁 cos(6.47)−0.38𝐹𝑁 sin(6.47)−0.260956 N
tan (6.47) = 21.980154 𝑁−0.38𝐹𝑁 cos(6.47)−𝐹𝑁 sin(6.47)

𝐹𝑁 = 2.736082899 𝑁

Contact width:

32𝐹(1 − 𝑣 2 )𝑟
𝑤= √
𝜋𝑡𝐸

32𝐹𝑁 (1 − 𝑣 2 )𝑟
𝑤= √
𝜋𝑡𝐸

32(2.736082899 𝑁)(1 − 0.352 )(0.0075𝑚)

𝑤= √
𝜋(0.006𝑚)(2.81𝑥109 𝑃𝑎)

𝑤 = 1.04301388𝑥10−4 𝑚

Contact stress:

73
 4𝐹𝑁
𝜎𝑐 =
𝑤𝑡

4(2.736082899 𝑁)
𝜎𝑐 =
(1.04301388𝑥10−4 𝑚 )(0.006 𝑚)

𝜎𝑐 = 17488312.49 Pa or 17.488 MPa

Executive - Letter:

∑ 𝐹𝑥 = 𝐹𝑁𝐸𝑇𝑅𝐸𝐴𝑅 − 𝐹𝑓 cos(51.30) − 𝐹𝑁 sin(51.30)

∑ 𝐹𝑥 = 𝐹𝑁𝐸𝑇𝑅𝐸𝐴𝑅 − 𝜇𝑘 𝐹𝑁 cos(51.30) − 𝐹𝑁 sin(51.30)

∑ 𝐹𝑥 = 21.980154 𝑁 − 0.38𝐹𝑁 cos(51.30) − 𝐹𝑁 sin(51.30)

∑ 𝐹𝑦 = 𝐹𝑁 cos(51.30) − 𝐹𝑓 sin(51.30) − 𝐹𝑓𝑆𝑅

∑ 𝐹𝑦 = 𝐹𝑁 cos(51.30) − 𝜇𝑘 𝐹𝑁 sin(51.30) − 0.260956 N

∑ 𝐹𝑦 = 𝐹𝑁 cos(51.30) − 0.38𝐹𝑁 sin(51.30) − 0.260956 N

∑ 𝐹𝑦
tan (51.30) = ∑ 𝐹𝑥

𝐹𝑁 cos(51.30)−0.38𝐹𝑁 sin(51.30)−0.260956 N
tan (51.30) = 21.980154 𝑁−0.38𝐹𝑁 cos(51.30)−𝐹𝑁 sin(51.30)

𝐹𝑁 = 17.31714136 𝑁

74
Contact width:

32𝐹(1 − 𝑣 2 )𝑟
𝑤= √
𝜋𝑡𝐸

32𝐹𝑁 (1 − 𝑣 2 )𝑟
𝑤= √
𝜋𝑡𝐸

32(17.31714136 𝑁)(1 − 0.352 )(0.0075𝑚)

𝑤= √
𝜋(0.006𝑚)(2.81𝑥109 𝑃𝑎)

𝑤 = 2.623998382𝑥10−4 𝑚

Contact stress:

4𝐹𝑁
𝜎𝑐 =
𝑤𝑡

4(17.31714136 𝑁)
𝜎𝑐 =
(2.623998382𝑥10−4 𝑚 )(0.006 𝑚)

𝜎𝑐 = 43996829.36 Pa or 44.0 MPa

Letter - A4:

∑ 𝐹𝑥 = 𝐹𝑁𝐸𝑇𝑅𝐸𝐴𝑅 − 𝐹𝑓 cos(30.74) − 𝐹𝑁 sin(30.74)

∑ 𝐹𝑥 = 𝐹𝑁𝐸𝑇𝑅𝐸𝐴𝑅 − 𝜇𝑘 𝐹𝑁 cos(30.74) − 𝐹𝑁 sin(30.74)

∑ 𝐹𝑥 = 21.980154 𝑁 − 0.38𝐹𝑁 cos(30.74) − 𝐹𝑁 sin(30.74)

75
∑ 𝐹𝑦 = 𝐹𝑁 cos(30.74) − 𝐹𝑓 sin(30.74) − 𝐹𝑓𝑆𝑅

∑ 𝐹𝑦 = 𝐹𝑁 cos(30.74) − 𝜇𝑘 𝐹𝑁 sin(30.74) − 0.260956 N

∑ 𝐹𝑦 = 𝐹𝑁 cos(30.74) − 0.38𝐹𝑁 sin(30.74) − 0.260956 N

∑ 𝐹𝑦
tan (30.74) = ∑ 𝐹𝑥

𝐹𝑁 cos(30.74)−0.38𝐹𝑁 sin(30.74)−0.260956 N
tan (30.74) = 21.980154 𝑁−0.38𝐹𝑁 cos(30.74)−𝐹𝑁 sin(30.74)

𝐹𝑁 = 11.45929424 𝑁

Contact width:

32𝐹(1 − 𝑣 2 )𝑟
𝑤= √
𝜋𝑡𝐸

32𝐹𝑁 (1 − 𝑣 2 )𝑟
𝑤= √
𝜋𝑡𝐸

32(11.45929424 𝑁)(1 − 0.352 )(0.0075𝑚)

𝑤= √
𝜋(0.006𝑚)(2.81𝑥109 𝑃𝑎)

𝑤 = 2.13454049𝑥10−4 𝑚

Contact stress:

4𝐹𝑁
𝜎𝑐 =
𝑤𝑡
76
 4(9.976135344 𝑁)
𝜎𝑐 =
(1.991620685𝑥10−4 𝑚 )(0.006 𝑚)

𝜎𝑐 = 35790036.79 Pa or 35.790 MPa

A4 - Legal:

∑ 𝐹𝑥 = 𝐹𝑁𝐸𝑇𝑅𝐸𝐴𝑅 − 𝐹𝑓 cos(2.881911002) − 𝐹𝑁 sin(2.881911002)

∑ 𝐹𝑥 = 𝐹𝑁𝐸𝑇𝑅𝐸𝐴𝑅 − 𝜇𝑘 𝐹𝑁 cos(2.881911002) − 𝐹𝑁 sin(2.881911002)

∑ 𝐹𝑥 = 21.980154 𝑁 − 0.38𝐹𝑁 cos(2.881911002) − 𝐹𝑁 sin(2.881911002)

∑ 𝐹𝑦 = 𝐹𝑁 cos(2.881911002) − 𝐹𝑓 sin(2.881911002) − 𝐹𝑓𝑆𝑅

∑ 𝐹𝑦 = 𝐹𝑁 cos(2.881911002) − 𝜇𝑘 𝐹𝑁 sin(2.881911002) − 0.260956 N

∑ 𝐹𝑦 = 𝐹𝑁 cos(2.881911002) − 0.38𝐹𝑁 sin(2.881911002) − 0.260956 N

∑ 𝐹𝑦
tan (2.881911002) = ∑ 𝐹𝑥

𝐹𝑁 cos(2.881911002)−0.38𝐹𝑁 sin(2.881911002)−0.260956 N
tan (2.881911002) = 21.980154 𝑁−0.38𝐹𝑁 cos(2.881911002)−𝐹𝑁 sin(2.881911002)

𝐹𝑁 = 1.365735999 𝑁

Contact width:

32𝐹(1 − 𝑣 2 )𝑟
𝑤= √
𝜋𝑡𝐸

77
 32𝐹𝑁 (1 − 𝑣 2 )𝑟
𝑤= √
𝜋𝑡𝐸

32(1.365735999 𝑁)(1 − 0.352 )(0.0075𝑚)

𝑤= √
𝜋(0.006𝑚)(2.81𝑥109 𝑃𝑎)

𝑤 = 7.36900481𝑥10−5 𝑚

Contact stress:

4𝐹𝑁
𝜎𝑐 =
𝑤𝑡

4(1.365735999 𝑁)
𝜎𝑐 =
(7.36900481𝑥10−5 𝑚 )(0.006 𝑚)

𝜎𝑐 = 12355680.16 Pa or 12.356 MPa

C.6 Moment at each adjacent paper size adjustment

A5-B5:

∑ 𝐹𝑥 = 𝐹𝑁𝐸𝑇𝑅𝐸𝐴𝑅 − 𝐹𝑓 cos(19.89) − 𝐹𝑁 sin(19.89)

∑ 𝐹𝑥 = 𝐹𝑁𝐸𝑇𝑅𝐸𝐴𝑅 − 𝜇𝑘 𝐹𝑁 cos(19.89) − 𝐹𝑁 sin(19.89)

∑ 𝐹𝑥 = 21.980154 𝑁 − 0.38𝐹𝑁 cos(19.89) − 𝐹𝑁 sin(19.89)

∑ 𝐹𝑦 = 𝐹𝑁 cos(19.89) − 𝐹𝑓 sin(19.89) − 𝐹𝑓𝑆𝑅

∑ 𝐹𝑦 = 𝐹𝑁 cos(19.89) − 𝜇𝑘 𝐹𝑁 sin(19.89) − 0.260956 N

78
∑ 𝐹𝑦 = 𝐹𝑁 cos(19.89) − 0.38𝐹𝑁 sin(19.89) − 0.260956 N

∑ 𝐹𝑦
tan (19.89) = ∑ 𝐹𝑥

𝐹𝑁 cos(19.89)−0.38𝐹𝑁 sin(19.89)−0.260956 N
tan (19.89) = 21.980154 𝑁−0.38𝐹𝑁 cos(19.89)−𝐹𝑁 sin(19.89)

𝐹𝑁 = 7.723436259 𝑁

Calculate Fx and Fy using the value of FN

∑ 𝐹𝑥 = 16.59269041 𝑁

∑ 𝐹𝑦 = 6.003194825 𝑁

∑ 𝐹𝑦 = 𝐹𝑦𝑅𝑂𝐿𝐿𝐸𝑅 = 6.003194825 𝑁

𝐿 = 0.06782 𝑚

Moment @ A

𝑀 = (𝐿)𝐹𝑦𝑅𝑂𝐿𝐿𝐸𝑅

𝑀 = (0.06782 𝑚)(6.003194825 𝑁)

79
𝑀 = 0.407 𝑁 − 𝑚

B5 - Executive:

∑ 𝐹𝑥 = 𝐹𝑁𝐸𝑇𝑅𝐸𝐴𝑅 − 𝐹𝑓 cos(6.47) − 𝐹𝑁 sin(6.47)

∑ 𝐹𝑥 = 𝐹𝑁𝐸𝑇𝑅𝐸𝐴𝑅 − 𝜇𝑘 𝐹𝑁 cos(6.47) − 𝐹𝑁 sin(6.47)

∑ 𝐹𝑥 = 21.980154 𝑁 − 0.38𝐹𝑁 cos(6.47) − 𝐹𝑁 sin(6.47)

∑ 𝐹𝑦 = 𝐹𝑁 cos(6.47) − 𝐹𝑓 sin(6.47) − 𝐹𝑓𝑆𝑅

∑ 𝐹𝑦 = 𝐹𝑁 cos(6.47) − 𝜇𝑘 𝐹𝑁 sin(6.47) − 0.260956 N

∑ 𝐹𝑦 = 𝐹𝑁 cos(6.47) − 0.38𝐹𝑁 sin(6.47) − 0.260956 N

∑ 𝐹𝑦
tan (6.47) = ∑ 𝐹𝑥

𝐹𝑁 cos(6.47)−0.38𝐹𝑁 sin(6.47)−0.260956 N
tan (6.47) = 21.980154 𝑁−0.38𝐹𝑁 cos(6.47)−𝐹𝑁 sin(6.47)

𝐹𝑁 = 2.736082899 𝑁

Calculate Fx and Fy using the value of FN

∑ 𝐹𝑥 = 20.63875449 𝑁

80
∑ 𝐹𝑦 = 2.340542992 𝑁

∑ 𝐹𝑦 = 𝐹𝑦𝑅𝑂𝐿𝐿𝐸𝑅 = 2.340542992 𝑁

𝐿 = 0.07897 𝑚

Moment @ A

𝑀 = (𝐿)𝐹𝑦𝑅𝑂𝐿𝐿𝐸𝑅

𝑀 = (0.07897 𝑚)(2.340542992𝑁)

𝑀 = 0.185 𝑁 − 𝑚

Executive - Letter:

∑ 𝐹𝑦 = 𝐹𝑁 cos(51.30) − 𝐹𝑓 sin(51.30) − 𝐹𝑓𝑆𝑅

∑ 𝐹𝑦 = 𝐹𝑁 cos(51.30) − 𝜇𝑘 𝐹𝑁 sin(51.30) − 0.260956 N

∑ 𝐹𝑦 = 𝐹𝑁 cos(51.30) − 0.38𝐹𝑁 sin(51.30) − 0.260956 N

∑ 𝐹𝑦
tan (54.31) = ∑ 𝐹𝑥

81
 𝐹𝑁 cos(51.30)−0.38𝐹𝑁 sin(51.30)−0.260956 N
tan (51.30) = 21.980154 𝑁−0.38𝐹𝑁 cos(51.30)−𝐹𝑁 sin(51.30)

𝐹𝑁 = 17.31714136 𝑁

Calculate Fx and Fy using the value of FN

∑ 𝐹𝑥 = 4.350912436 𝑁

∑ 𝐹𝑦 = 5.430826464 𝑁

∑𝐹𝑦 = 𝐹𝑦𝑅𝑂𝐿𝐿𝐸𝑅 − 𝐹𝑅𝑆𝐼𝐷𝐸 = 0

𝐹𝑦𝑅𝑂𝐿𝐿𝐸𝑅 − 𝐹𝑅𝑆𝐼𝐷𝐸 = 0

𝐹𝑦𝑅𝑂𝐿𝐿𝐸𝑅 = 𝐹𝑅𝑆𝐼𝐷𝐸 = 5.430826464 𝑁

L = 0.09124 m

Moment @ A

𝑀 = (𝐿)𝐹𝑦𝑅𝑂𝐿𝐿𝐸𝑅

𝑀 = (0.09124 𝑚)(5.430826464 𝑁)

𝑀 = 0.496 𝑁 − 𝑚

Letter - A4:
82
∑ 𝐹𝑥 = 𝐹𝑁𝐸𝑇𝑅𝐸𝐴𝑅 − 𝐹𝑓 cos(30.74) − 𝐹𝑁 sin(30.74)

∑ 𝐹𝑥 = 𝐹𝑁𝐸𝑇𝑅𝐸𝐴𝑅 − 𝜇𝑘 𝐹𝑁 cos(30.74) − 𝐹𝑁 sin(30.74)

∑ 𝐹𝑥 = 21.980154 𝑁 − 0.38𝐹𝑁 cos(30.74) − 𝐹𝑁 sin(30.74)

∑ 𝐹𝑦 = 𝐹𝑁 cos(30.74) − 𝐹𝑓 sin(30.74) − 𝐹𝑓𝑆𝑅

∑ 𝐹𝑦 = 𝐹𝑁 cos(30.74) − 𝜇𝑘 𝐹𝑁 sin(30.74) − 0.260956 N

∑ 𝐹𝑦 = 𝐹𝑁 cos(30.74) − 0.38𝐹𝑁 sin(30.74) − 0.260956 N

∑ 𝐹𝑦
tan (30.74) = ∑ 𝐹𝑥

𝐹𝑁 cos(30.74)−0.38𝐹𝑁 sin(30.74)−0.260956 N
tan (30.74) = 21.980154 𝑁−0.38𝐹𝑁 cos(30.74)−𝐹𝑁 sin(30.74)

𝐹𝑁 = 11.45929424 𝑁

Calculate Fx and Fy using the value of FN

∑ 𝐹𝑥 = 12.38011392 𝑁

∑ 𝐹𝑦 = 7.362468572 𝑁

83
∑𝐹𝑦 = 𝐹𝑦𝑅𝑂𝐿𝐿𝐸𝑅 − 𝐹𝑅𝑆𝐼𝐷𝐸 = 0

𝐹𝑦𝑅𝑂𝐿𝐿𝐸𝑅 − 𝐹𝑅𝑆𝐼𝐷𝐸 = 0

𝐹𝑦𝑅𝑂𝐿𝐿𝐸𝑅 = 𝐹𝑅𝑆𝐼𝐷𝐸 = 7.362468572 𝑁

𝐿 = 0.10933 𝑚

Moment @ A

𝑀 = (𝐿)𝐹𝑦𝑅𝑂𝐿𝐿𝐸𝑅

𝑀 = (0.10933 𝑚)(7.362468572 𝑁)

𝑀 = 0.805 𝑁 − 𝑚

A4 - Legal:

∑ 𝐹𝑥 = 𝐹𝑁𝐸𝑇𝑅𝐸𝐴𝑅 − 𝐹𝑓 cos(2.881911002) − 𝐹𝑁 sin(2.881911002)

∑ 𝐹𝑥 = 𝐹𝑁𝐸𝑇𝑅𝐸𝐴𝑅 − 𝜇𝑘 𝐹𝑁 cos(2.881911002) − 𝐹𝑁 sin(2.881911002)

∑ 𝐹𝑥 = 21.980154 𝑁 − 0.38𝐹𝑁 cos(2.881911002) − 𝐹𝑁 sin(2.881911002)

∑ 𝐹𝑦 = 𝐹𝑁 cos(2.881911002) − 𝐹𝑓 sin(2.881911002) − 𝐹𝑓𝑆𝑅

∑ 𝐹𝑦 = 𝐹𝑁 cos(2.881911002) − 𝜇𝑘 𝐹𝑁 sin(2.881911002) − 0.260956 N

∑ 𝐹𝑦 = 𝐹𝑁 cos(2.881911002) − 0.38𝐹𝑁 sin(2.881911002) − 0.260956 N

84
 ∑ 𝐹𝑦
tan (2.881911002) = ∑ 𝐹𝑥

𝐹𝑁 cos(2.881911002)−0.38𝐹𝑁 sin(2.881911002)−0.260956 N
tan (2.881911002) = 21.980154 𝑁−0.38𝐹𝑁 cos(2.881911002)−𝐹𝑁 sin(2.881911002)

𝐹𝑁 = 1.365735998 𝑁

Calculate Fx and Fy using the value of FN

∑ 𝐹𝑥 = 21.39316472 𝑁

∑ 𝐹𝑦 = 1.076959657 𝑁

∑𝐹𝑦 = 𝐹𝑦𝑅𝑂𝐿𝐿𝐸𝑅 − 𝐹𝑅𝑆𝐼𝐷𝐸 = 0

𝐹𝑦𝑅𝑂𝐿𝐿𝐸𝑅 − 𝐹𝑅𝑆𝐼𝐷𝐸 = 0

𝐹𝑦𝑅𝑂𝐿𝐿𝐸𝑅 = 𝐹𝑅𝑆𝐼𝐷𝐸 = 1.076959657 𝑁

𝐿 = 0.16826 𝑚

Moment @ A

𝑀 = (𝐿)𝐹𝑦𝑅𝑂𝐿𝐿𝐸𝑅

𝑀 = (0.16826 𝑚)(1.076959657 𝑁)

𝑀 = 0.181 𝑁 − 𝑚

85
C.7 Dimensions of the side paper edge guide restraint roller axle slot

𝑀 𝑀 𝑀
𝜎= = =
𝐼 𝐼 𝑆
𝑐

𝑀
𝜎=
𝑏2ℎ
6

6𝑀
𝜎=
𝑏2ℎ

6(0.805 𝑁−𝑚)
74 𝑀𝑃𝑎 = 𝑏 2 (0.004 𝑚)

𝑏 = 0.0039378619 m

C.8 Radius of the roller axle

𝑉
𝜏=
𝐴

𝑉
𝜏=
𝜋𝑑𝑎2
4

21.980154 𝑁
0.28 𝑀𝑃𝑎 =
𝜋𝑑𝑎2
4

𝑑𝑎 = 0.009975 𝑚

C.9 Linear cam slot

In making the linear cam or displacement diagram, paper size position A5 is to be made as

reference.
86
 Width papersize  148
Rise 
2

Run  Lengthpapersize  210

With the data from Table A.1, the rise is plotted as the ordinate and and the run is plotted as

the absissca. Each endpoint is connected starting from the reference point, A5, to Legal.

Fig. A.2 Linear cam or displacement diagram

In making the linear cam slot, circles with the radius of the roller, 7.5mm, is plotted on

the linear cam. The circles are then connected tangentially to form a slot.

87
 Fig. A.3 Linear cam slot

The thickness if the cam slot is equal to the thickness of the roller which is 0.006m.

Fig. A.4 Isometric view of the linear cam slot

88
C.10 Theoretical force applied to actuate

A5 - B5:

∑ 𝐹𝑥 = 0

∑ 𝐹𝑥 = 𝐹𝑁𝐸𝑇𝑅𝐸𝐴𝑅 − 𝐹𝑁 sin(19.89) − 𝐹𝑓 cos(19.89) = 0

∑ 𝐹𝑥 = 𝐹𝑁𝐸𝑇𝑅𝐸𝐴𝑅 − 𝐹𝑁 sin(19.89) − 𝜇𝑠 𝐹𝑁 cos(19.89) = 0

∑ 𝐹𝑥 = 𝐹𝑁𝐸𝑇𝑅𝐸𝐴𝑅 − 𝐹𝑁 sin(19.89) − 0.21𝑁 cos(19.89) = 0

𝐹𝑁𝐸𝑇𝑅𝐸𝐴𝑅 − 𝐹𝑁 sin(19.89) − 0.21𝑁 cos(19.89) = 0

∑ 𝐹𝑦 = 0

∑ 𝐹𝑦 = 𝐹𝑁 cos(19.89) − 𝜇𝑠 𝐹𝑁 sin(19.89) − 𝐹𝑓𝑆𝑅 = 0

∑ 𝐹𝑦 = 𝐹𝑁 cos(19.89) − 0.21𝐹𝑁 sin(19.89) − 0.144207 N = 0

𝐹𝑁 = 0.165965 𝑁

𝐹𝑁𝐸𝑇𝑅𝐸𝐴𝑅 − 0.165965 𝑁 sin(19.89) − 0.21(0.165965 𝑁) cos(19.89) = 0

𝐹𝑁𝐸𝑇𝑅𝐸𝐴𝑅 = 0.089237 𝑁

𝐹𝐴𝑃𝑃 = 𝐹𝑁𝐸𝑇𝑅𝐸𝐴𝑅 + 0.144207 𝑁

𝐹𝐴𝑃𝑃 = 0.089237 𝑁 + 0.144207 𝑁

89
𝐹𝐴𝑃𝑃 = 0.233444 𝑁

B5-Executive

∑ 𝐹𝑥 = 0

∑ 𝐹𝑥 = 𝐹𝑁𝐸𝑇𝑅𝐸𝐴𝑅 − 𝐹𝑁 sin(6.47) − 𝐹𝑓 cos(6.47) = 0

∑ 𝐹𝑥 = 𝐹𝑁𝐸𝑇𝑅𝐸𝐴𝑅 − 𝐹𝑁 sin(6.47) − 𝜇𝑠 𝐹𝑁 cos(6.47) = 0

∑ 𝐹𝑥 = 𝐹𝑁𝐸𝑇𝑅𝐸𝐴𝑅 − 𝐹𝑁 sin(6.47) − 0.21𝑁 cos(6.47) = 0

𝐹𝑁𝐸𝑇𝑅𝐸𝐴𝑅 − 𝐹𝑁 sin(6.47) − 0.21𝑁 cos(6.47) = 0

∑ 𝐹𝑦 = 0

∑ 𝐹𝑦 = 𝐹𝑁 cos(6.47) − 𝜇𝑠 𝐹𝑁 sin(6.47) − 𝐹𝑓𝑆𝑅

∑ 𝐹𝑦 = 𝐹𝑁 cos(6.47) − 0.21𝐹𝑁 sin(6.47) − 0.144207 N

𝐹𝑁 = 0.148672 𝑁

𝐹𝑁𝐸𝑇𝑅𝐸𝐴𝑅 − 0.148672 𝑁 sin(6.47) − 0.21(0.148672 𝑁) cos(6.47) = 0

𝐹𝑁𝐸𝑇𝑅𝐸𝐴𝑅 = 0.047775 𝑁

90
𝐹𝐴𝑃𝑃 = 𝐹𝑁𝐸𝑇𝑅𝐸𝐴𝑅 + 0.144207 𝑁

𝐹𝐴𝑃𝑃 = 0.047775 𝑁 + 0.144207 𝑁

𝐹𝐴𝑃𝑃 = 0.191982 𝑁

Executive - Letter:

∑ 𝐹𝑥 = 0

∑ 𝐹𝑥 = 𝐹𝑁𝐸𝑇𝑅𝐸𝐴𝑅 − 𝐹𝑁 sin(51.30) − 𝐹𝑓 cos(51.30) = 0

∑ 𝐹𝑥 = 𝐹𝑁𝐸𝑇𝑅𝐸𝐴𝑅 − 𝐹𝑁 sin(51.30) − 𝜇𝑠 𝐹𝑁 cos(51.30) = 0

∑ 𝐹𝑥 = 𝐹𝑁𝐸𝑇𝑅𝐸𝐴𝑅 − 𝐹𝑁 sin(51.30) − 0.21𝑁 cos(51.30) = 0

𝐹𝑁𝐸𝑇𝑅𝐸𝐴𝑅 − 𝐹𝑁 sin(6.47) − 0.21𝑁 cos(6.47) = 0

∑ 𝐹𝑦 = 0

∑ 𝐹𝑦 = 𝐹𝑁 cos(51.30) − 𝜇𝑠 𝐹𝑁 sin(51.30) − 𝐹𝑓𝑆𝑅

∑ 𝐹𝑦 = 𝐹𝑁 cos(51.30) − 0.21𝐹𝑁 sin(51.30) − 0.144207 N

𝐹𝑁 = 0.312575 𝑁

𝐹𝑁𝐸𝑇𝑅𝐸𝐴𝑅 − 0.312575 𝑁 sin(51.30) − 0.21(0.312575 𝑁) cos(51.30) = 0

91
𝐹𝑁𝐸𝑇𝑅𝐸𝐴𝑅 = 0.284984 𝑁

𝐹𝐴𝑃𝑃 = 𝐹𝑁𝐸𝑇𝑅𝐸𝐴𝑅 + 0.144207 𝑁

𝐹𝐴𝑃𝑃 = 0.284984 𝑁 + 0.144207 𝑁

𝐹𝐴𝑃𝑃 = 0.429191 𝑁

Letter - A4:

∑ 𝐹𝑥 = 0

∑ 𝐹𝑥 = 𝐹𝑁𝐸𝑇𝑅𝐸𝐴𝑅 − 𝐹𝑁 sin(30.74) − 𝐹𝑓 cos(30.74) = 0

∑ 𝐹𝑥 = 𝐹𝑁𝐸𝑇𝑅𝐸𝐴𝑅 − 𝐹𝑁 sin(30.74) − 𝜇𝑠 𝐹𝑁 cos(30.74) = 0

∑ 𝐹𝑥 = 𝐹𝑁𝐸𝑇𝑅𝐸𝐴𝑅 − 𝐹𝑁 sin(30.74) − 0.21𝑁 cos(30.74) = 0

𝐹𝑁𝐸𝑇𝑅𝐸𝐴𝑅 − 𝐹𝑁 sin(30.74) − 0.21𝑁 cos(30.74) = 0

∑ 𝐹𝑦 = 0

∑ 𝐹𝑦 = 𝐹𝑁 cos(30.74) − 𝜇𝑠 𝐹𝑁 sin(30.74) − 𝐹𝑓𝑆𝑅

∑ 𝐹𝑦 = 𝐹𝑁 cos(30.74) − 0.21𝐹𝑁 sin(30.74) − 0.144207 N

𝐹𝑁 = 0.191725 𝑁

92
𝐹𝑁𝐸𝑇𝑅𝐸𝐴𝑅 − 0.191725 𝑁 sin(30.74) − 0.21(0.191725 𝑁) cos(30.74) = 0

𝐹𝑁𝐸𝑇𝑅𝐸𝐴𝑅 = 0.132604 𝑁

𝐹𝐴𝑃𝑃 = 𝐹𝑁𝐸𝑇𝑅𝐸𝐴𝑅 + 0.144207 𝑁

𝐹𝐴𝑃𝑃 = 0.132604 𝑁 + 0.144207 𝑁

𝐹𝐴𝑃𝑃 = 0.276811 𝑁

A4 - Legal:

∑ 𝐹𝑥 = 0

∑ 𝐹𝑥 = 𝐹𝑁𝐸𝑇𝑅𝐸𝐴𝑅 − 𝐹𝑁 sin(2.881911002) − 𝐹𝑓 cos(2.881911002) = 0

∑ 𝐹𝑥 = 𝐹𝑁𝐸𝑇𝑅𝐸𝐴𝑅 − 𝐹𝑁 sin(2.881911002) − 𝜇𝑠 𝐹𝑁 cos(2.881911002) = 0

∑ 𝐹𝑥 = 𝐹𝑁𝐸𝑇𝑅𝐸𝐴𝑅 − 𝐹𝑁 sin(2.881911002) − 0.21𝑁 cos(2.881911002) = 0

𝐹𝑁𝐸𝑇𝑅𝐸𝐴𝑅 − 𝐹𝑁 sin(2.881911002) − 0.21𝑁 cos(2.881911002) = 0

∑ 𝐹𝑦 = 0

∑ 𝐹𝑦 = 𝐹𝑁 cos(2.881911002) − 𝜇𝑠 𝐹𝑁 sin(2.881911002) − 𝐹𝑓𝑆𝑅

93
∑ 𝐹𝑦 = 𝐹𝑁 cos(2.881911002) − 0.21𝐹𝑁 sin(2.881911002) − 0.144207 N

𝐹𝑁 = 0.145932 𝑁

𝐹𝑁𝐸𝑇𝑅𝐸𝐴𝑅 − 0.145932 𝑁 sin(51.30) − 0.21(0.145932 𝑁) cos(51.30) = 0

𝐹𝑁𝐸𝑇𝑅𝐸𝐴𝑅 = 0.037944 𝑁

𝐹𝐴𝑃𝑃 = 𝐹𝑁𝐸𝑇𝑅𝐸𝐴𝑅 + 0.144207 𝑁

𝐹𝐴𝑃𝑃 = 0.037944 𝑁 + 0.144207 𝑁

𝐹𝐴𝑃𝑃 = 0.182151 𝑁

94
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