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Hot Water Fiber Bending Procedure (view source)
Revision as of 18:24, 22 May 2014
, 18:24, 22 May 2014no edit summary
[[File:JK First Bending Collar.JPG|thumb|center|After the fibers have been properly aligned in the bundling tool and the tool has been rotated a collar is placed on the fibers to secure them in their positions.]]
[[File:JK First Bending Collar.JPG|thumb|center|After the fibers have been properly aligned in the bundling tool and the tool has been rotated a collar is placed on the fibers to secure them in their positions.]]
===Setting Up The Plates===
{|style="margin: 0 auto;"
|[[File:JK Bending Plate.JPG|thumb|upright|The bending plate with metal rods inserted.]]
|[[File:JK Unistrut Clamped to Plate.JPG|thumb|upright|The unistrut support clamped to the bending plate.]]
|[[File:JK Dummy Plate 1.JPG|thumb|upright|Dummy chimney plate 1.]]
|[[File:JK Dummy Plate 2.JPG|thumb|upright|Dummy chimney plate 2.]]
|}
==Bending Procedure==
==Bending Procedure==
====Securing the Orientation====
====Securing the Orientation====
For bending, it's important make sure the scintillating end of the fibers are square and flush. This process usually requires 2 technicians.
For bending, it's important make sure the scintillating end of the fibers are square and flush. This process usually requires 2 technicians.
{|style="margin: 0 auto;"
|[[File:JK Flush Fibers.JPG|thumb|upright|One technician holds the collar and flat block while the other pushes on individual fibers to make them flush.]]
|[[File:JK Fibers on Bending Plate.JPG|thumb|upright|A wider view of the bending plate with fibers secured in the first collar after being made flush.]]
|}
*Start by placing a flat block in front of the bundle and secure the collar onto the bending unit. Have one technician hold the flat block in place (or clamp the block to the table.)
*Start by placing a flat block in front of the bundle and secure the collar onto the bending unit. Have one technician hold the flat block in place (or clamp the block to the table.)
**Loosen the collar around the bundle enough to allow the fibers to slide but not change orientation.
**Loosen the collar around the bundle enough to allow the fibers to slide but not change orientation.
**'''Note:''' Be sure not to strain any of the fibers during this process!
**'''Note:''' Be sure not to strain any of the fibers during this process!
**When you are certain that the fibers are flush against the block, carefully tighten the chimney around the bundle so that the fibers neither slide nor change orientation. If you see that any fibers are offset by more than ~.5mm, repeat this process.
**When you are certain that the fibers are flush against the block, carefully tighten the chimney around the bundle so that the fibers neither slide nor change orientation. If you see that any fibers are offset by more than ~.5mm, repeat this process.
====Offsetting the Fibers====
====Offsetting the Fibers====
The next step involves offsetting the SciFi end past the bending unit. This will compensate for the length of fiber required to produce the S-bend.
The next step involves offsetting the SciFi end past the bending unit. This will compensate for the length of fiber required to produce the S-bend.
*Tighten the second collar so that the fibers do not slide.
*Tighten the second collar so that the fibers do not slide.
*Loosen the first collar so it may slide along the fibers. Move it to the "start" position as labelled on the bending plate and then tighten it again so the fibers do not slide or change orientation.
*Loosen the first collar so it may slide along the fibers. Move it to the "start" position as labelled on the bending plate and then tighten it again so the fibers do not slide or change orientation.
[[File:JK Start Line.JPG|thumb|center|The start line, here highlighted red.]]
*Loosen the second collar and move the first collar to the "finish position". This moves the fibers one inch past the bending unit plate to compensate for the length of fiber needed to produce the S-bend. This is also the final horizontal position of the fibers for the entirety of the bending process.
*Loosen the second collar and move the first collar to the "finish position". This moves the fibers one inch past the bending unit plate to compensate for the length of fiber needed to produce the S-bend. This is also the final horizontal position of the fibers for the entirety of the bending process.
[[File:JK Finish Line.JPG|thumb|center|The finish line, here highlighted red.]]
* Tighten the third through seventh collar. Loosen the first collar, and re-attach it to the bending unit plate and then tighten it.
* Tighten the third through seventh collar. Loosen the first collar, and re-attach it to the bending unit plate and then tighten it.
**At this point, all seven collars should be tight around the bundle, and attached to the bending unit.
**At this point, all seven collars should be tight around the bundle, and attached to the bending unit.
**Do not push or force any fiber into a chimney slot, as this will cause damage to the fiber!
**Do not push or force any fiber into a chimney slot, as this will cause damage to the fiber!
***If a fiber does not fit into a chimney slot, use a small file to widen the slot. Make sure it is large enough such that the fiber seeds into the chimney slot with no resistance.
***If a fiber does not fit into a chimney slot, use a small file to widen the slot. Make sure it is large enough such that the fiber seeds into the chimney slot with no resistance.
{|style="margin: 0 auto;"
|[[File:JK Chimney Placement 1.JPG|thumb|upright|The fibers placed in the chimney with a chimney top used to keep them in place.]]
|[[File:JK Chimney Placement 2.JPG|thumb|upright|All of the fibers properly aligned in dummy chimney plate 2.]]
|}
*Make sure that the lightguide fibers reach the very end of the chimney on plate #2. If they do not, move the plates and the bar until the lightguides reach the end of the chimney AND the bar (and its blocks) are able to fit between the metal tubes on the plates.
*Make sure that the lightguide fibers reach the very end of the chimney on plate #2. If they do not, move the plates and the bar until the lightguides reach the end of the chimney AND the bar (and its blocks) are able to fit between the metal tubes on the plates.
**This step is important, as it sets the distance the plates will remain from each other as well as the bend in the fibers.
**This step is important, as it sets the distance the plates will remain from each other as well as the bend in the fibers.
*Record the orientation and fiber name of each slot in the chimney in the Bundle Names Google doc. Here you may check that you have not altered the orientation of the fiber matrix.
*Record the orientation and fiber name of each slot in the chimney in the Bundle Names Google doc. Here you may check that you have not altered the orientation of the fiber matrix.
*With extreme care, cut off the main portion of the fiber tag with scissors. Afterwards, remove the rest of the fiber tag with your hands and remove the remaining adhesive glue with a dry lint-free cloth.
*With extreme care, cut off the main portion of the fiber tag with scissors. Afterwards, remove the rest of the fiber tag with your hands and remove the remaining adhesive glue with a dry lint-free cloth.
[[File:JK Removing Labels.JPG|thumb|center|Cut the majority of the labels off carefully with scissors, then remove the remaining portion by hand.]]
*Secure the rest of the chimney clamps on the rest of the chimneys of Bundle Plate #2. Do not screw them down so tight that they damage the fibers, but do secure them enough so that no fibers can slide out of their slots.
*Secure the rest of the chimney clamps on the rest of the chimneys of Bundle Plate #2. Do not screw them down so tight that they damage the fibers, but do secure them enough so that no fibers can slide out of their slots.
*Secure both plates to the bar with clamps.
*Secure both plates to the bar with clamps.
*Repeat the process for placing fibers in the chimney slots. Again starting with the right-most column, and the bottom fiber going into the right-most slot. Repeat the chimney and tag-removing process.
*Repeat the process for placing fibers in the chimney slots. Again starting with the right-most column, and the bottom fiber going into the right-most slot. Repeat the chimney and tag-removing process.
[[File:JK Finished Chimney Clamps.JPG|thumb|center|The fibers in both the chimney plates with the chimney clamps securely attached.]]
===Placement into Popsicle Stick===
===Placement into Popsicle Stick===
*Remove the collar tops of the first and second collars nearest the popsicle stick.
*Remove the collar tops of the first and second collars nearest the popsicle stick.
*Secure a chimney clamp onto the bending plate and rest the SciFi ends of the fibers against it so you may attach the popsicle stick to the bending plate without having to hold the fibers.
*Secure a chimney clamp onto the bending plate and rest the SciFi ends of the fibers against it so you may attach the popsicle stick to the bending plate without having to hold the fibers.
[[File:JK Popsicle Stick Displacement.JPG|thumb|center|A clamp is attached to the bending plate to gently bend the fibers out of the way of the area where the popsicle stick will be attached.]]
*Have one technician tilt the entire bending unit (bending bar, bending plate, and chimney plates) with both hands so that a second technician can attach the popsicle stick to the bending plate. Place a large washer between the popsicle stick and the bending plate. This is so the fibers do not have to bend.
*Have one technician tilt the entire bending unit (bending bar, bending plate, and chimney plates) with both hands so that a second technician can attach the popsicle stick to the bending plate. Place a large washer between the popsicle stick and the bending plate. This is so the fibers do not have to bend.
*While holding the fibers in the proper oriented matrix, place the fibers gently into the popsicle stick. They will jut out of the end because of the extra length.
*While holding the fibers in the proper oriented matrix, place the fibers gently into the popsicle stick. They will jut out of the end because of the extra length.
[[File:JK Fiber in Popsicle Stick.JPG|thumb|center|The fibers being placed in the popsicle stick.]]
*Gently place the popsicle stick top onto the fibers without stressing them, and put the two rods through the popsicle stick. The rods are different, so if they are not properly aligning with the threaded rods, switch their positions. Secure the bolts onto the threaded rods a few turns so that the popsicle stick top doesn't move.
*Gently place the popsicle stick top onto the fibers without stressing them, and put the two rods through the popsicle stick. The rods are different, so if they are not properly aligning with the threaded rods, switch their positions. Secure the bolts onto the threaded rods a few turns so that the popsicle stick top doesn't move.
{{File:JK Popsicle Stick Top.JPG|thumb|center|The popsicle stick top placed on top of the fibers with both of the rods secured through it.]]
===Filling and Siphoning the Tank===
===Filling and Siphoning the Tank===
**Put the siphon completely underwater in the tank and pump it until no more air bubbles come out.
**Put the siphon completely underwater in the tank and pump it until no more air bubbles come out.
**Keeping the siphon underwater put the hose into the inlet of the left exclusion area and pump the siphon until no air comes out of the outlet of the left exclusion area.
**Keeping the siphon underwater put the hose into the inlet of the left exclusion area and pump the siphon until no air comes out of the outlet of the left exclusion area.
[[File:JK Siphon.JPG|thumb|center|The siphon hose in the inlet valve of the left exclusion area.]]
*After the water systems have been siphoned and there are no air bubbles, have two technicians place the bending unit and fibers into the room temperature water.
*After the water systems have been siphoned and there are no air bubbles, have two technicians place the bending unit and fibers into the room temperature water.
*Wear thick rubber gloves to protect your hands from the hot water.
*Wear thick rubber gloves to protect your hands from the hot water.
*Two technicians should remove the bending unit from the tank and place it upside down on the stools.
*Two technicians should remove the bending unit from the tank and place it upside down on the stools.
[[File:JK Bending Unit in Tank.JPG|thumb|center|The bending unit in the tank before being removed.]]
*All clamps should be removed from the bending unit. Be careful taking them off as now the chimney plates are no longer attached to the bending plate.
*All clamps should be removed from the bending unit. Be careful taking them off as now the chimney plates are no longer attached to the bending plate.
*With one technician holding the bending plate, and one technician bracing the chimney plates and bar, have the third technician take hold of the top bending plate and secure it on the first two threaded rods.
*With one technician holding the bending plate, and one technician bracing the chimney plates and bar, have the third technician take hold of the top bending plate and secure it on the first two threaded rods.