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Hot Water Straightening Light Guides Procedure (view source)
Revision as of 19:45, 13 January 2014
, 19:45, 13 January 2014no edit summary
* Make room at a table for the aluminum U bar.
* Make room at a table for the aluminum U bar.
[[File:full setup.JPG|thumb|center|Full straightening setup.]]
* If the Unistrut bar is not in the heat treating pipe, and if the collars have been removed, set out:
* If the Unistrut bar is not in the heat treating pipe, and if the collars have been removed, set out:
** Bundling tool
** Bundling tool
** aluminum bar
** aluminum bar
{|style="margin: 0 auto;"
| [[File:collars.JPG|thumb|upright|Collar components.]]
| [[File:aligner.JPG|thumb|upright|Fiber alignment guide.]]
|}
* Don a clean pair of gloves
* Don a clean pair of gloves
** Use the bundling tool to arrange the fibers into a 5x6 matrix. Rotate the bundle so that the fibers will fit in the anchoring collar. Screw the upper half of the collar to the lower half, but not too tightly. You want the fibers to be able to move lengthwise through the collar.
** Use the bundling tool to arrange the fibers into a 5x6 matrix. Rotate the bundle so that the fibers will fit in the anchoring collar. Screw the upper half of the collar to the lower half, but not too tightly. You want the fibers to be able to move lengthwise through the collar.
** Use the flat face of a piece of aluminum to align the ends of the fibers so they all project the same distance beyond the anchoring collar, about a half inch. One worker may hold the metal, while the other pushes the fibers against it. Tighten the anchoring collar around the bundle so it will not slip.
** Use the flat face of a piece of aluminum to align the ends of the fibers so they all project the same distance beyond the anchoring collar, about a half inch. One worker may hold the metal, while the other pushes the fibers against it. Tighten the anchoring collar around the bundle so it will not slip.
{|style="margin: 0 auto;"
| [[File:matrix.JPG|thumb|upright|5x6 matrix of fibers.]]
| [[File:tapped fibers.JPG|thumb|upright|Fibers tapped until they all protrude about 1/2 inch.]]
| [[File:final fastened end.JPG|thumb|upright|Final view. This end is fastened and does not move with springs during bending.]]
|}
* Run your gloved fingers along the fiber towards the next collar, keeping the fibers in the same position of the matrix. If constant pressure is kept on the top, bottom, and sides of the bundle with your hands, the bundle stays in a square matrix and is able to be placed in the next collar very easily.
* Run your gloved fingers along the fiber towards the next collar, keeping the fibers in the same position of the matrix. If constant pressure is kept on the top, bottom, and sides of the bundle with your hands, the bundle stays in a square matrix and is able to be placed in the next collar very easily.
* Slide all the collars as far as possible toward the aligned end of the bundle. Make sure the bundle is straight. Tighten the collars just enough so that they do not slip when the springs are attached in the the next step. You can test this by trying to move the collar along the slots in the aluminum. If the collar moves, push it back to its original position and tighten the collar a little bit more. If it moves, repeat the procedure above. If it will not move at all, the collar is now tight enough.
* Slide all the collars as far as possible toward the aligned end of the bundle. Make sure the bundle is straight. Tighten the collars just enough so that they do not slip when the springs are attached in the the next step. You can test this by trying to move the collar along the slots in the aluminum. If the collar moves, push it back to its original position and tighten the collar a little bit more. If it moves, repeat the procedure above. If it will not move at all, the collar is now tight enough.
[[File:sliding brackets.JPG|thumb|center|The collars are attached in sliding brackets but should sit toward the aligned end of the bundle to start.]]
* Fasten springs to the collars to put the fibers in tension. Use sections of wire to tie the springs to the collars.
* Fasten springs to the collars to put the fibers in tension. Use sections of wire to tie the springs to the collars.
{|style="margin: 0 auto;"
| [[File:spring anchor.JPG|thumb|upright|The anchored end of a spring is attached with a nut, screw and two washers as shown.]]
| [[File:spring floating.JPG|thumb|upright|The floating end of the spring pulls on the collar via a wire loop.]]
| [[File:spring knot.JPG|thumb|upright|The wire loop is tied through the collar in a double knot.]]
| [[File:spring final.JPG|thumb|upright|Final view. The collar is now applying tension to the fiber bundle.]]
|}
* The collar on the end opposite the anchor should be screwed down tight and fitted with two springs on the left and right, to ensure even tension.
{|style="margin: 0 auto;"
| [[File:end springs anchor.JPG|thumb|upright|The two springs on the end are anchored with a screw, nut and two washers as shown.]]
| [[File:end springs wires.JPG|thumb|upright|Each spring is attached to a wire loop through its side of the collar.]]
| [[File:end springs knots.JPG|thumb|upright|Each loop is tied in a knot on its respective side.]]
| [[File:final springs.JPG|thumb|upright|Final view. The last collar should now pull evenly on the bundle.]]
|}
* Insert the aluminum bar into the heat treating pipe.
* Insert the aluminum bar into the heat treating pipe.