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mLine 1:
Line 1: − '''Overview'''+ − + − '''Procedures''' − *Note: the fiber straightening procedure will require 2 technicians.+ − + + + − + − + − + − ** aluminum bar Line 22:
Line 22: − + − * If the aluminum bar has just been removed from the heat treating pipe, it will still have a bundle of straightened fibers on it. In this case you may not need extra collars and screws. − *Unscrew the collars and remove the straightened bundle. − *Before putting a new bundle on the aluminum bar, clean the straightened bundle with a damp lint-free rag and put it, labeled, in the intermediate storage box. − + − + + + Line 44:
Line 43: + Line 61:
Line 61: − + − + + + + + + + + + + + + + + + − * Fill the pipe:+ − ** The valve for the air inlet hose should be closed.+ − ** Oven valves 1, 3, and 6. Close valves 2, 4, and 5.+ − ** Turn on the cold water filtered water, and turn the water inlet valve 90 degrees. + − ** When the water starts coming out into the fish tank, open all the valves intermittently to bleed air out. + − ** After the air is expelled from the pipes, close all of the valves except for three and two. − + − − − + − * Again, put on clean gloves.+ − + − + +
Hot Water Straightening Light Guides Procedure (view source)
Revision as of 16:47, 29 January 2016
, 16:47, 29 January 2016Jonesrt moved page Straightening Light Guides Procedure to Hot Water Straightening Light Guides Procedure: make it clear which generation of procedures this refers to
==Overview==
The optical fibers received from Saint Gobain Crystals are shipped via large diameter cardboard spools. As a result the optical fibers, when unspooled, tend to have an intrinsic curvature to them. It is very difficult to manipulate thirty 5+ foot curved fibers during bundle construction. For this reason the fibers are first straightened using a heat treating process. This process helps to alleviate stresses within the fibers due to the manufacturing process. By minimizing the internal stress of the fibers we can reduce the risk of crazing or fracture that otherwise might occur during the bundle manufacturing process.
The optical fibers received from Saint Gobain Crystals are shipped via large diameter cardboard spools. As a result the optical fibers, when unspooled, tend to have an intrinsic curvature to them. It is very difficult to manipulate thirty 5+ foot curved fibers during bundle construction. For this reason the fibers are first straightened using a heat treating process. This process helps to alleviate stresses within the fibers due to the manufacturing process. By minimizing the internal stress of the fibers we can reduce the risk of crazing or fracture that otherwise might occur during the bundle manufacturing process.
==Procedure==
* Make room at a table for the aluminum U bar.
This procedure will require 2 technicians.
* Make room at a table for the unistrut straightening bar.
[[File:full setup.JPG|thumb|center|Full straightening setup.]]
[[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 collars have been removed, set out:
** 6 or 7 light guide collars
** 7 fiber collars
** 12 or 14 half inch 440 screws.
** 14 half inch 4-40 screws
** Bundling tool
** Bundling tool
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* Don a clean pair of gloves
* Don a clean pair of gloves.
* Move 30 rough cut light guides from the intermediate storage box to the table where you will bundle the fibers.
* Move 30 rough cut light guides from the intermediate storage box to the table where you will bundle the fibers.
* Bundle the light guides into the anchoring collar at one end of the aluminum bar where there are no springs between the collar and the end of the bar.
* Bundle the light guides into the anchoring collar at one end of the aluminum bar where there are no springs between the collar and the end of the bar.
** 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.
** 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.
**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 through the collar.
** Use the flat face of a piece of aluminum to align the ends of the fibers flush 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.
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* 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.
** These springs will ensure that the fibers have enough tension to be pulled straight rather than just lessen the bow between collars.
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* Insert the aluminum bar into the heat treating pipe.
* Insert the straightening bar into the empty PVC straightening pipe.
** One worker should tilt the pipe, and the other should remove the top cap and set it aside. While the one worker holds the pipe tilted, the other inserts the bar. Be careful not to knock the bundle against bars or pipes below the ceiling. Also, do not let the bar fall into the straightening unit. Set it carefully at the bottom of the pipe.
** One worker should tilt the pipe, and the other should remove the top cap and set it aside.
**While the one worker holds the pipe tilted, the other inserts the bar. Be careful not to knock the bundle against bars or pipes below the ceiling. Also, do not let the bar fall into the straightening unit. Set it carefully at the bottom of the pipe.
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| [[File:JK Straightening Pipe 1.JPG|thumb|upright|The heat treating pipe in its vertical position.]]
| [[File:JK Straightening Pipe Bottom.JPG|thumb|upright|The bottom of the heat treating pipe showing the inlet for the thermistor used to measure the temperature in the pipe.]]
| [[File:JK Straightening Pipe Top.JPG|thumb|upright|The top cap of the heat treating pipe unscrewed with valves 7 and 8 labeled.]]
| [[File:JK Straightening Pipe 2.JPG|thumb|upright|The heat treating pipe tilted sufficiently for the aluminum bar holding the fibers to be inserted.]]
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* Screw the cap back onto the pipe, making sure to hand tighten it.
* Screw the cap back onto the pipe, making sure to hand tighten it.
* Fill the pipe:
** The valve for the air inlet hose (7) should be closed.
** Open valves 1, 3, and 6. Close valves 2, 4, and 5.
** Turn on the cold filtered water, and turn the water inlet valve 90 degrees.
** When the water starts coming out into the tank, open all the valves intermittently to bleed air out.
** After the air is expelled from the pipes, close all of the valves except for three and two.
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| [[File:JK Fish Tank.JPG|thumb|upright|The "fish tank" bending unit.]]
| [[File:JK Fishtank Valves.JPG|thumb|upright|Valves one through six in the bending unit.]]
| [[File:JK Fish Tank Valves 2.JPG|thumb|upright|Valves 9 and 10 in the bending unit.]]
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* Run the LabVIEW program to heat the water.
* Run the LabVIEW program to heat the water.
* After the water has reached its maximum temperature it should cool for 12 hours before the straightening bar is removed from the pipe.
* After the water has reached its maximum temperature it should cool for 12 hours before the aluminum bar is removed from the pipe.
* After 12 hours or more, drain the pipe by opening all of the valves, including the one for the air inlet.
* After 12 hours or more, drain the pipe by opening all of the valves, including the one for the air inlet.
* One worker should tilt the pipe, and the other should remove the cap and take the bar out of the pipe.
* Replace the cap and raise the pipe to its vertical position.
* Set the bar on the bundling table.
* One worker should tilt the pipe, and the other should remove the cap and take the bar out of the pipe. Replace the cap and raise the pope to its vertical position. Set the bar on the bundling table. Unscrew the collars and remove the straightened bundle. Before putting a new bundle on the aluminum straightening bar, clean the straightened bundle with a damp lint-free cloth, label it, and put it in the intermediate storage box.
* Unscrew all collars and remove the straightened bundle.
* Before putting a new bundle on the aluminum straightening bar, clean the straightened bundle with a damp lint-free cloth, label it, and put it in the intermediate storage box.