Instrumentation and tools

INSTRUMENTATION

Every instrument solves specific need. Here you will see how prototypes of instrumentation, jigs, holders and other tools are born.

The process will be shown in a very specific way - Main concept solved on the paper and then finished prototype.

I will skip details such as 3d modeling and production processes. Only start and finish.

The goal here is to solve the need in most elegant and production friendly way for a prototype or one off kind of tool.

°°° Materials which are used they are in most of the cases for prototype building phase only.
  • Year: 2020
  • Project: Tools and sketches

TWO lOCKABLE CARRIAGE SLIDER TOOL
This tool is is a base part of a bigger setup - Adjustable rig for vacuum tube maker.
Base part should be a slider with two lockable carriages. This slider will be attached later to arm with many degrees of freedom. Carriages should lock tightly and have a large mating surface to be able to hold forces and loads from various tools which will be attached to the carriages.
Tools from sketches series by Coillights. Slider tool sketch - bar slider.
First thoughts were about making carriage moving on two steel bars and have a lock plate. Later this idea was abandoned.
Tools from sketches series by Coillights. Slider tool sketch - final assembly sketch
Final sketch before going to production. Two carriages with nine threaded holes each for the attachements and tools. Plate lock.
Tools from sketches by Coillights. 
Completed slider and two carriages. Dissasembled
Dissasembled slider and carriages.Two top surfaces were leveled to same height.
Tools from sketches by Coillights. 
Completed slider and two carriages.
Two lockable carriages and slider finished

VACUUM CHAMBER SIGNAL WIRE HOLDER
This holder is made from materials which have a very little outgassing in vacuum — aluminum and PTFE (Teflon) and stainless steel screws. Two plates are connected together with a Teflon rod which has grooves and holes for wires. Vacuum venting holes are made in end of each inner thread.
Vacuum chamber signal wire holder sketch. by Coillights.com
This is a very simple part with two plates, two screws and rod.
Vacuum chamber signal wire holder parts by Coillights
Parts are ready and prepared for work under vacuum - they should be squeaky clean. Removing oils, then several ultrasonic washes with special detergents and solvents.
Vacuum chamber signal wire holder by Coillights
Vacuum chamber wire holder is ready

GLASS TO METAL SEAL TOOL
This is a prototype of a hand/glass lathe tool for making glass to metal wire seal. Tool holds two parallel wires with glass beads which will be melted in fire and then formed with special tool, the length of the wires is adjustable (by sliding a long part on bars).
Glass to metal seal tool production sketch by Coillights
Process of thinking about this tool was pretty quick so here you see finished holder production drawing.
Tools from sketches by Coillights. 
Completed slider and two carriages. Dissasembled
Glass-metal tool is ready for work

INNER GLASS TUBE SEAL INSTRUMENT
This is a glass lathe tool which holds small part on the end. This jig allows to make a controllable height seal inside big diameter glass tube (the long part of the tool is inserted into the tube)
Adjustable inner glass seal instrument drawing by Coillights
Side and perspective drawing of the tool
Adjustable inner glass seal instrument by Coillights
Tool prototype in extended position
Adjustable inner glass seal instrument by Coillights
Tool is in closed position.
Adjustable inner glass seal instrument by Coillights
Tip of the tool - sliced spring steel holder for a glass part

VACUUM TUBE PART
I make research on electrovacuum instrumentation and vacuum tubes. This piece is an electrode mounted on a 4 wire slider. When you need to attach a light part with certain degree of freedom in vacuum, this is an easiest way to do it.
Tools from sketches by Coillights. 
Completed slider and two carriages. Dissasembled
In this drawing electrode and attachment system being developed.
Tools from sketches by Coillights. 
Completed slider and two carriages. Dissasembled
Electrode is produced and attached to the slider which mounted on two glass metal wire seals
Tools from sketches by Coillights. 
Completed slider and two carriages. Dissasembled
Closeup on 4 wire sliders. Wires are spot welded.

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