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Propeller Head Plaza Technical and scientific discussion of amps, cables and other topics. |
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Propeller Head Plaza Technical and scientific discussion of amps, cables and other topics. |
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In Reply to: OT Question... posted by geoffkait on March 5, 2004 at 05:52:43:
geoffkait: ""can you please identify the 11 directions/dimensions. After the first 6, I imagine the rest are rotational directions...Sure..
Most ask why more than three.
Axis: X, phi, Y, Z, Theta, delta, sigma, wirefeed, stylus force, gate force, ultrasonic power..
X. the physical distance along the tube..
Phi: The tube rotational axis
Z: The height of the wire above the rotation axis of the tube.
These three axis are all that is required to define a position in three dimensional space...but the process of ultrasonically bonding the superconductors to the tube is a directional one (among other things)
Y: The direction orthogonal to the tube axis and vertical..used for angle of attack, slide angle, stylus side angle, and for flat pattern running in a slot, or on a flat surface. I'll explain that need later..
Theta: Rotation of the wiring head. It points in the direction the wire is going.
Delta: Rotary axis, coaxial to theta, used to BEND the wire. The process requires the wire be where it is supposed to be, and tight bends of the wire fight the modulus of the wire, it wants to remain straight..
Sigma: a rotary axis, aligned like the banking of an airplane..used to tilt the wire feed mechanism to the right or left, for collision avoidance. The magnets we build typically have 1kpsi to 10kpsi forces on the structure, requiring lots of beefy metal very close to the force generating wire.
Wirefeed; the rotary axis used to pay out the wire.
Stylus force: the downward force exerted on the wire, to place it and couple the ultrasonic transducer to the wire for good ultrasonic energy transfer. The process is the ultrasonic energy goes through the wire, and is absorbed by the surface I am putting it on, a b stage epoxy.
Gate force: the force put against the wire at the wirefeed capstan. this, with the coefficient of friction of the wire against it's capstan, produce the axial force needed to push the wire. The capstan is physically designed to decouple when the wire is not moving at the feed capstan rate..It's the same principal as that used on a boat..they have a constant velocity capstan, and you wrap the rope around it a coupla times..if you pull on the rope, it's coefficient of friction amplifies your pull, and you can end up with a quarter million pounds force on the rope (dad used to be in the navy).
Ultrasonic power is just the signal to the ultrasonic generator for rms power. The generator has a VERY low B-dot current viewing resistor, and that value is multiplied by the voltage of the generator, to derive an exact measure of the delivered power to the ultrasonic welding head. The circuit subtracts reflected energy to give a delivered power entity. Ultrasonic power is velocity based, geared to provide relatively constant joules per linear inch.
Those are the physical axes'...I also have four pseudo-axis'...Angle of attack, slide angle, stylus side angle, and a five dimensional coordinated motion involving gate pressure, stylus pressure, ultrasonic power, delta axis and gate axis for bonding the turns (that's a tad too complex to describe here)..
Angle of attack is a modulation of phi, y, and z, to effect an angle between the stylus and the tube surface..It is used to remove dogboning of the tight inner turns of the pattern, as the wire tries to fight the epoxy before the heat capacity of the wire can absorb the energy. I think that motion is visible in the video clip on one of the web pages..
Slide angle is the same thing, but orthogonal to angle of attack..
Stylus side angle is used for collision avoidance..
All the pseudo's I created so that the physicists don't have to worry about the process...just create the magnetically correct point to point wiring file...which I limit to half a million points..for now.
I have two machines presently, one capable of three meter coils, one for two.
Both are visible on a few of the web pages I maintain for magnet division...
here's the links:
http://www.bnl.gov/magnets/BEPCII/Overview.asp
http://www.bnl.gov/magnets/Linear_Collider/Magnet_Construction.aspThe mechanical accuracy of the machine has to be good.. 300 millionths of an inch average placement accuracy over a three meter tube...Luckily it's not too tight a tolerance..:-)
Sorry to give such a simplified description..
Cheers, John
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Follow Ups
- Re: OT Question... - jneutron 07:37:12 03/05/04 (1)
- Re: OT Question... - geoffkait 09:27:37 03/05/04 (0)
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