Operation Gyan-Vigyan

H7
U-PIN
&STEM
MAKING.
 Operation Gyan-Vigyan

U-PIN MAKING

U-pin making is a process in which the molybdenum wire of diameter 0.5mm mounted on
spool is passed through number of rollers in such a way that the rollers straighten the wire.
The straightened wire is bent into U-Shape over a desired surface.

COMPONENTS:
1. Molybdenumwire

Why Molybdenum wire is used: -Molybdenum is used in halogen lamps due to

following properties-

• Molybdenum wire has ability to resist high temperature without expanding or

softening property makes it useful in high temperature and high pressure.

• Good electrical conductivity

 Operation Gyan-Vigyan

• Good stiffness and molybdenum is not very reactive as it is resistant to air and
water at normal temperature.

• High melting point (2600˚C)

• High tensile strength

(It is the ability of the material to resist breakage under tension.)

SPECIFICATIONS:
1. Wire Diameter: 0.5mm

2. U-Pin Length (A)-17.6±0.1 mm

3. U-Pin Width (B) - 4.5±0.2 mm

Figure 1- position of cutter Figure2-Position of stopper

DEFECTS IN U-PIN
A value out-
1. It occurs due to stopper forward /backward (Disturb) from original position.
 Stopper should be adjusted to attain proper wire length.
2. It Occurs due to position out of cutter & nozzle.
 Operation Gyan-Vigyan

 Cutter should be adjusted to attain proper wire length.

B Value Out-
1. It occurs due to the tool damage.
WIRE BURR-0.05 max.
 It occurs due to bluntness of cutter and nozzle.
 Rotate/change the cutter & Nozzle to obtain sharp edge.
WIRE BEND-0.2 max.
 It occurs due to bend in molywire.
 The wire should pass through the rollers and after passing
through roller ensure that wire is straightened or not. If
not, then adjust the position of rollers.
 Operation Gyan-Vigyan

U Pin Machine -

OK Bin

Rej. Bin

Power Start Switch Reset Switch Loading On/Off

Off Emergency Switch
Switch Switch Stop Switch

Auto/Manual
Switch

MACHINE START/ SHUTDOWN PROTOCOL

 Operation Gyan-Vigyan

a) MACHINE START
 Clean the base part of the machine with air
pressure or cloth.
 Check the sharpness of the cutter.
 Open the air valve and check the desired pressure.
 Switch ON the power supply of the machine.

b) MACHINE STOP
 Clean the machine with air gun.
 Close the air valve.
 Switch OFF the main power supply.
 Operation Gyan-Vigyan

STEMMAKING

Stem making is a process in which two molybdenum wires of different shape&

size are held together with the help of quartz rod. The quartz rod is made to
stick on either side of molybdenum wires with the help of heat treatment. The
Vycorrods are melted through LPG and oxygen. The final product thus obtained
is known as bridge or stem.

Components:
1. Molybdenum wire (L1)
2. Molybdenum wire (L2)
 Operation Gyan-Vigyan

3. Quartz Rod

Specifications, problems and their countermeasures.

1. A Value -4.4±1 mm
 V-groove damage in wire holding jaw.
 It damages due to continuous usage. It should be replaced after
every 3 months.In jaw the angle between two v-groves is the
most important factor to attain proper A value.
 Upper wire holding jaw loose.
 Loose holding of wire in Jaw due to spring loose. Spring has to be
replaced.
 Wire bending tool damage.
 Due to continuous usage tool should be damaged. The bending
tool as per drawing with proper angle for L1 & L2 Bending.

Head Centering Gauge

2. B Value
 Operation Gyan-Vigyan

 Head out in inward-outward direction.

 Head centering with gauge.
3. C Value
Improper wire length, bending tool damage.
 Stopper should be adjusted to attain proper wire length.
 Bending tool should be as per drawing
4. D Value
 Stopper out.
 Improper bending tool angle.
 Stopper should be adjusted to attain proper wire length
 Bending tool should be as per drawing.
5. E Value
 Improper bending tool.
 It depends upon the angle of L1 & L2 wire given by bending tool
so bending tool should be as per drawing.

6. F Value (Quartz rod crack)

 Poor melting.
 Flame to melt upper quartz rod & lower Quartz rod should be that
both piece melts to the same extent. If both piece melts
differently then adust the injector knob by seeing the color of
flame it should be blue not yellowish because blue flame gave a
temperature of 1900˚c
7. G Value
 Stopper out.
 It depends upon the wire length and wire length is adjusted by
stopper.
8. H Value
 Pincher bit height variation.
 It occurs due to upper/lower pincher bit height variation. It can be
adjusted by setting lower /upper pincher bit with the help of
height gauge
 Operation Gyan-Vigyan

 Main turret head height variation.

 It occurs due to head height variation. The height of the head can
be adjusted with the help of the gauge.

9. I Value
 More melting.
 Improper height of head.
 It can be adjusted by setting the head with height gauge.
10.L Value
 Due to Misalignment of pincher bit.

11. M Value
 L1,L2 wire bending tool damage.
12. N Value
 Bending tool damage
 Stopper out.
 Stopper should be adjusted to attain proper wire length.
13. O Value
 Poor vacuum.
 Picher bit Hole block/chock. It can be cleaned with the help of
brass brush.

Other Important Points & Process involved at bridge machine.

MELTING:To attach the Vycor rod the melting is provided to melt the Vycor rod
so that they can stick over the molybdenumwire. The melting is givenby LPG and
OXYGEN. The melting should be such that a proper shape should be formed.

CRIMPING:Crimping is provided in molybdenum wire so that the Vycor rod can

not slip off the wire. It is a process in which two or more pieces of metal or other
ductile material are joined by deforming the material to hold the other material
this deformity is called Crimp.
Operation Gyan-Vigyan
 Operation Gyan-Vigyan

MACHINE START/ SHUTDOWN PROTOCOL

c) MACHINE START
 Start chiller compressor and water pump.
 Clean burner and pincher bit from brass brush.
 Clean machine base and Quartz rod hopper.
 Switch on main power supply.
 Open air and gasses valves (1st LPG followed by Oxygen)
 Cut moly wire in manual mode to check cutter condition for wire
burr and wire bend.
 Check water flow in pincher bit.
 Check moly wire straightness.
 Check flame condition of burners.
 Switch ON the vision system.
 Put the machine in auto mode.
 Check moly wire oxidation, quartz rod transparency and crack
or scratch.
 Fill PPQC parameters.

d) MACHINE STOP

 Push stop button to stop machine.

 Close air and gasses valves.( Ist Oxygen followed by LPG)
 Stop chiller compressor and water pump.
 Clean machine base and other area.
 Operation Gyan-Vigyan

Process Parameter(CKD bridge)

Air Pressure 4 - 6 Kgf/cm2
Oxygen Pressure 1.5 - 2.0 Kgf/cm2
Nitrogen Pressure 0.7- 1.1 Kgf/cm2
Propane Pressure 0.7- 1.0 Kgf/cm2
Air Pressure < 4kgf/cm² : If Air pressure reduced from the range
then machine will automatically stop and all the relative function will not
operate.

Effect on next operation and end user:- When machine will

stop then no part produced and not effected to next operation and end user
also.

Oxygen Pressure 1.5- 2.0 Kgf/cm² reduced from the

range : when oxygen pressure gets reduced the desirable range
then improper combustion of propane results poor melting of
quartz rod.
 Operation Gyan-Vigyan

Effect on next operation and end user : Due to low melting

of quartz rod it gets crack during punching on moly wire.

Effect on end user it leads to lamp failure .

Oxygen Pressure 1.5- 2.0 Kgf/cm² increased from the

range : when oxygen pressure is increased from the desired range then
High melting of Vycor rod or Vycor rod over melted.

Effect on next operation and end user : Due to Over melting

of Vycor rod its visual appearance not good for end user.

Nitrogen Pressure 0.7-1.1 Kgf/cm² reduced the range:

when Nitrogen pressure is reduced from the desired range then
Oxidization take place on the moly wire .

Effect on next operation and end user : Due to oxidization

Wire will be black and the appearance is not good at visual inspection
station and the lamp gets milky at user end.

Nitrogen Pressure 0.7- 1.1 Kgf/cm² Increased the

range : When Nitrogen pressure is increasd from the desired range then
also oxidation take place

Effect on next operation and end user : Due to oxidization

Wire will be black and the appearance is not good at visual inspection
station and the lamp gets milky at user end.
 Operation Gyan-Vigyan

Propane Pressure 0.7- 1.0 Kgf/cm² is reduced from the

range : When Propane pressure gets reduced the desirable
range then the back fire take placed due to increase in oxygen.

Effect on next operation and end user : Once back fire is on

the machine then operation is stop till the back fire problem not resolved.
So no effect on next operation and end used also.

Propane Pressure 0.7- 1.0 Kgf/cm² is Increased from

the range : When Propane pressure is increased from the desired
range then High melting of Vycor rod or Vycor rod over melted.

Effect on next operation and end user : Due to Over melting

of Vycor rod its visual appearance not good for end user and its
consumption is also high and increased the cost of the operation.
Operation Gyan-Vigyan