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  • Users: DAlbertson
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  1. DAlbertson

    Problem of air pressure regulator with enormous turn-down

    I'm building a test jig that needs an air pressure regulator with a very large turn-down: Inlet pressure range = 80 to 120 psig Discharge pressure range = 1 to 130 inches of water (0.036 to 4.7 psig) Discharge flow rate demand = 0 to 150 CFM, with the maximum d(flow)/dt = 800 CFM/s I've sent...
  2. DAlbertson

    Viton O-ring deformation model for simple partially-restrained axial seal

    I have a 5/8" orifice solenoid valve controlling room air with a differential pressure varying between 0.1 psi and 5.0 psi. Attached to this post is a sketch of the valve: Open, Closed, section Closed, and detail of o-ring Closed. Even though the pressures are very low and the resultant force...
  3. DAlbertson

    Production welding aluminum parts with flash-butt or resistance-butt

    My company is designing a production line for a new product. Two of the parts are aluminum near-mirror images of each other, and were to be assembled with adhesive. The customer change-ordered the fabrication to be welded instead. Sketches of one of the two parts is shown below. The...
  4. DAlbertson

    Bond overcoats on magnetic wire - electrical heat sealing?

    I'm winding a set of coils from 37 AWG magnet wire with a single-thickness polyurethane/nylon combination insulation (NEMA MW29-C) and a bonding overcoat of Polyvinyl Butyral. The bond overcoat can be made liquid with either Isopropyl Alcohol or heat. If heating, then a temperature of 110 C to...
  5. DAlbertson

    Damping collision of low-mass actuator

    I have a 22 gram mass steel actuator hollow rod that slides on a rail. At the end-point of its travel, it collides with a solidly mounted steel plate. Just before the collision, the actuator rod is travelling at between 2.3 to 3.3 meters/sec, depending on other factors, so it posesses kinetic...
  6. DAlbertson

    Galvanic corrosion in new product

    I've started a small design company, and I have 3 corrosion questions on my first product. It is a mechanism about 1/2 the volume of a can of Coke. The parts are made of the following materials: 1) 260 Brass 2) 410 Stainless, powdered metal, 85% density 3) several different polymers 4)...
  7. DAlbertson

    Scaling BH curves for non-fully-dense powdered metals

    I'm designing several small parts in 410 or 416 stainless, to be manufactured in powdered metal. It is common to specify the density of a part to be 80% to 85% of theoretical (solid) density. Higher densities, essentially to 100%, are achievable, but all these are much higher cost: initial...
  8. DAlbertson

    Using a vacuum to improve varnish impregnation of a coil

    I need to improve the varnish impregnation of a coil wound onto a bobbin (Ticona Vectra C130) with 30 layers of AWG 40 single-build insulation, around a solid core 1.5 inches long and 0.4 inches in diameter. I'd like to have the varnishing process be scalable to a desktop-sized tank...
  9. DAlbertson

    Radially-oriented magnetization of Ring Magnets

    Engineers, I'm building a set of small (12mm stroke, 20mm diameter) linear actuators for an after-hours toy. This is only my 2nd magnetics project, so I need to ask for your tolerance. The DC actuators are based on Lorentz Forces with a small spring return. The coil is wrapped on a steel...
  10. DAlbertson

    Calculating the approximate inductance of a coil

    Engineers, I need to design several coils for electromagnetic actuators for small nitrogen valves. One is a iron-core electromagnet, another is an air coil for a moving-magnet style "voice coil motor". Both are two-position, bang-bang actuators operating on DC current (100mA @ 10VDC). The...

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