This design project documents the design of two low cost, easily assembled, easily replaced charging devices useable in the electrophotographic process. The design process begins with the purpose of the chargers and a comparison to previous designs. Manufacturing processes and material selections are covered. Two plastic springs are designed and analyzed using classical equations and finite element analysis. Consideration is given to temperature and time effects on these springs. The major plastic structure (the housing) is analyzed for stress and deflection using finite element analysis with consideration given to thermal and creep effects. Datum selection is discussed. Tolerance analysis is performed on critical component interfaces. The previous charger design and the improved design are then analyzed and compared using the Boothroyd and Dewhurst Design for Assembly software. Snap fit insertion forces are determined using classical equations. Customer interfaces are reviewed and insertion forces quantified. A general approach to assembly system justification is provided. Manual assembly, flexible automation and hard automation are considered. Complete production drawings of all charger components are provided.

Library of Congress Subject Headings

Charge transfer devices (Electronics)--Design and construction; Electrophotography--Equipment and supplies

Publication Date


Document Type


Department, Program, or Center

Mechanical Engineering (KGCOE)


Names Illegible


Note: imported from RIT’s Digital Media Library running on DSpace to RIT Scholar Works. Physical copy available through RIT's The Wallace Library at: TK7871.99.C45 D434 1990


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