New Cable Bender


This is the second bending fixture for bending the extension cables.
The removable alignment block lets you keep the cable perpendicular to the bending jaws.
The new upper bending block (labeled 90° + 16°) is designed to overbend the cable by 16 degrees. However, tension in the cable counteracts the bend
You can see the (over)bend, and the opposite curves on either side.
These blocks can hold the cable at 74°.
These blocks can hold the cable at 74°.
After that, cables can be stored in this holder.
For bends that are too close to the ROC connector, here are special jigs for making these zigzags. The connector end fits snugly into the bottom piece. Notice there is a strong G10 edge, rounded on one side, that supports the first mm of the cable. There is a matching piece of G10 on top, so the cable is protected against sharp bend on the edge of the cable's backing plate.

For the big-cable version, the depth of the drop-off needs to be changed for each of the different stations. This is done by inserting one or more layers of white cardboard (or other sheet material) in the dropoff area.

Here are the ROC-end zigzag step heights for all cables: 

      cable    step(mm)       cable    step(mm)
      ---------------       -----------------
st.1  1A  3201  0.000   st.3  1A  3401  3.253
      2A  3202  1.003         2A  3402  4.003
      1B  3203  0.000         1B  3403  3.253
      2B  3204  1.239         2B  3404  4.003
                                        
st.2  1A  3301  1.752   st.4  1A  3501  5.959
      2A  3302  2.503         2A  3502 12.898
      1B  3303  1.753         1B  3503  5.959
      2B  3304  2.503         2B  3504 12.898


Below are the cable bending instructions I found on the offline Wiki:

  1. Check the connections on the controller box
  2. Turn on the controller box, and watch the unit do a self-test, and then report room temperature for top and bottom heaters.
  3. To start up software at the beginning of the day, log into HDItest account on bending jig laptop. Double-click CN7-A icon on desktop to open software. On main menu, click on 'Instrument Status' to make sure the software is communicating with the jig.
  4. Address 32 is the bottom thermocouple, address 33 the top thermocouple. Both thermocouples should have a setpoint of 10°C to start - something cooler than room temperature. The actual readout temperature will be close to room temperature.

    Click on 'Configure Instrument' Set 'Units' to 'Deg. C', change thermocouple 'Input Type' to 'Type E T/C'. Check the box for 'Allow Remote Changes via Communications (LOrE)'.

    For Address 32, check the current setpoint and limits by clicking on 'Read Configuration From an Instrument'. 'Setpoint 1 (SP1)' should be 10, 'Setpoint Low (SPL)' 0, and Setpoint High (SPH)' 135, where the values refer to °C. Repeat to check the limits for address 33.

    Plug in jig if not already plugged in. Red digital display on jig is bottom thermocouple, green is top thermocouple.

    Select frame depending on bend direction - tall frame is for upstream bends, short for downstream. Set the height of the lower heating bar to match the short or tall frame using the two pegs. With the top thermocouple raised, put the frame onto the jig with the wedge sandwiched in between, and screw the frame on with the 4 small screws. The top of the frame is the side with the rectangle cut out of it. Note that the wedge won't look perfectly straight. Push the HDI over the heating bar by hand and lower the top thermocouple so that the HDI is held in the bent position. (Note that thermocouples should be cool while you're doing this.)

    When you're ready to proceed with bending, to heat the thermocouples, change Setpoint 1 to 100°C for address 32, then click 'Send Configuration To an Instrument'. Repeat immediately for address 33 - don't wait for the first to finish warming up. Stay at 100°C for 5 minutes. Then set both channels back to 10°C to let them cool down.

    After ~10 min they should cool to ~30°C. A fan can be used to make them cool faster. At UNM, they took the wedge off the jig at 30 deg C, but may want to try revisiting this given the observed relaxation in the bend angle.