FINAL REPORT NO. 3137 LINEAR PHASOLVER DEVELOPMENT PROGRAM PHASE II

• Document Type: CREST
• Collection: NGA Records (Formerly NIMA)
• Document Number (FOIA) /ESDN (CREST): CIA-RDP78B04770A001800010052-6
• Release Decision: RIPPUB
• Original Classification: K
• Document Page Count: 76
• Document Creation Date: December 28, 2016
• Document Release Date: March 8, 2006
• Sequence Number: 52
• Publication Date: August 1, 1966
• Content Type: REPORT

STAT Approved For Release 2006/03/16 : CIA-RDP78604770A001800010052-6
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1 August 1966
FINAL REPORT NO. 3137
LINEAR PEASOLVER
DEVELOPMENT PROGRAM
PHASE II
Prepared for
United States Government
Washington, D. C.
Report No. 3137
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TABLE OF CONTENTS
Section
1 INTRODUCTION
Page
1-1
1.1 Scope 1-1
. 1. 2 Summary 1-1
2 PHASOLVER DESCRIPTION 2-1
2.1 Test Fixture
2.2 Physical Description
2.2.1 Phasolver Driver Patterns
2.2.2 Phasolver Coupler Patterns
2.3 Functional Description
2.3.1 Phasolver Operation
2.3.2 Electronics Operation,
2.3.3 Coarse Channel Operation
2-1
2-5
2-5
2-8
2-8
2-8
2-11
2-13
3 .PERFORMANCE TESTS 3-1
3.1 Intfoduction 3-1
3. 1. 1 System Resolution and Repeatability 3-3
3.1.2 System Long Term Stability 3-3
3. 1. 3 Scale Error Correction 3-4
3.2 Co/Cv Determination 3-5
3.3 Accuracy with Equal Amplitudes and Phase Quadrature
Drive Signals 378
3.3.1 Existing Phasolver Pattern 3-8
3.3.2 New Phasolver Pattern 3-14
3.4 Balance Accuracy and Test Repeatability 3-14
3.4.1 Existing Phasolver Pattern 3-14
3.4.2 New Phasolver Pattern 3-23
3.5 Humidity Test 3-30
3.6 Coarse Channel Test 3-33
4
CONCLUSIONS AND RECOMMENDATIONS
APPENDIX A - Linear Phasolver Development Program,
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LIST OF ILLUSTRATIONS
Figure
No.
Title J
Page
2-1
Linear Phasolver Test Fixture
2-2
2-2
Linear Phasolver Test Fixture, Closeup
2-3
2-3
Driver Patterns
2-7
2-4
Coupler Pattern
2-9
2-5
Vector Analysis of Phase Shift in a Phasolver
? 2-10
Dwg 1000-2942, Electronics Block Diagram
2-12
Dwg 700897A, Coarse Channel Electronics Schematic
2-15
3-1
Co/Cv Ratio versus Gap
3-6
3-2
Accuracy Data, Existing Phasolver Pattern, 2 Consecutive Runs
3-9
3-3
Accuracy Data Perfect Drive Signals, Existing Phasolver Pattern,
2 Consecutive Rt.ms
3-10
3-4
Existing Phasolver Pattern Error with Perfect Drive Signals
3-11
3-5
Existing Phasolver Pattern Error with Perfect Drive Signals
3-12
3-6
Existing Phasolver Pattern Error with Perfect Drive Signals
3-13
3-7
New Phasolver Pattern Error with Perfect Drive Signals
3-15
3-8
New Phasolver Pattern Error with Perfect Drive Signals
3-16
3-9
New Phasolver Pattern Error with Perfect Drive Signals
3-17
3-10
Best Accuracy Data, Existing Phasolver Pattern, Output
from Coupler
3-19
3-11
Best Accuracy Data, Existing Phasolver Pattern, Output
from Coupler
- 3-20
3-12
Best Accuracy Data, Existing Phasolver Pattern, Output
from Coupler
3-21
3-13
Best Accuracy Data, Existing Phasolver Pattern, Output
from Coupler
3-22
3-14
Best Accuracy Data, New Phasolver Pattern, Output
from Coupler
3-24
3-15
Best Accuracy Data, New Phasolver Pattern, Output
from Coupler
3-26
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Figure
No.
3-16
3-17
3-18
3-19
3-20
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LIST OF ILLUSTRATIONS (Continued)
Title
Accuracy Data, Perfect Drive Signals, New Phasolver Pattern,
Gage Blocks Run Together, Single Blocks Only
Best Accuracy Data., New Phasolver Pattern, Output from
Driver
Best Accuracy Data, New Phasolver Pattern, Output from
Driver
Accuracy versus Humidity,
Output from Driver
Accuracy versus Humidity,
Output from Driver
Existing Phasolver Pattern,
Existing Phasolver Pattern,
Page ?
3-27
3-28
.3-29
3-30
3-31
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SECTION 1
INTRODUCTION
1.1 SCOPE
This report describes the mechanization and test results achieved during Phase II of
the Applied Research Program for developing and demonstrating the feasibility of a
Linear Phasolver System for making measurements of linear motion with a resolution
and accuracy ?1 micron or better.
1.2 SUMMARY
During the period covered by this report, a Linear Phasolver test fixture was
designed and fabricated. This test fixture was designed to demonstrate the feasibility
of the Phasolver for making measurements of linear movement with a resolution and
accuracy of 1 micron or better. The electronics which was used during the Phase I
portion of this program was modified to provide for a resolution of 1/10 micron.
This electronics was built to provide the excitation signals for the transducer and to
process and digitize the transducer output. The coarse channel which was used in
the Phase I portion of the program was removed from the electronics at this time.
As originally planned, the Phase U portions of this program would have used only a
fine Phasolver pattern since the sole purpose of the program was to investigate the
behavior of the Linear Phasolver. It was later decided that a coarse channel would
be desirable, and a coarse channel was designed using a standard brush type shaft
encoder and a cable drive to couple the encoder to the driver plate.
The prime purpose of this program was to demonstrate the accuracy, resolution and
repeatability of the Linear Phasolver and to determine the sensitivity to variations in
gap, tilt, skew and humidity.
The results obtained were encouraging, but not completely successful. A resolution
of 1/10 micron was achieved quite easily. It is expected that a resolution better than
1/10 micron can be obtained by modifying the electroni cs to provide for a higher
counting rate. An accuracy of +1.2 microns within a single pole pair has been
1-1
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demonstrated. However, due to limitations in the design of the test fixture, this
accuracy could not be verified over the full length of the fixture. The system.
exhibited a large scale error which appeared to be a function of the connections to
the Phasolver plates. This scale error could be varied from +8.5 microns to -2
microns over the full length of 250 millimeters by changing the connections to the
coupler. The reason for this is unknown. In addition, the scale error is nonlinear.
Unfortunately, the tests for sensitivity to gap variations, tilt and skew could not
be performed due to severe pattern degradation. During the testing cycle, the
patterns were damaged by dust in the environment in which the tests were performed.
This dust severely scored the Phasolver patterns, requiring numerous touchups. In
addition, the Phasolver pattern itself became very porous in spots due to poor quality
control techniques by the vendor in applying the nickel coating used in the generation
of the Phasolver pattern. Prior to the performance of the gap, tilt and skew sensi-
tivity tests, the new experimental pattern, which had been specifically designed for
use on this program, became inoperable.
Humidity tests were performed using the remaining pattern to determine the
sensitivity of the Linear Phasolver to the relative humidity in the environment. This
test indicated a severe sensitivity to relative humidity. However, this pattern also
failed before repeatability of the data could be established and therefore the validity
of the data is unknown.
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SECTION 2
PHASOLVER DESCRIPTION
2.1 TEST FIXTURE
The Phasolver test fixture was designed to provide very accurate linear motion with
the capability for measuring this motion within 0.1 micron. The equipment used for
this program is illustrated in figure 2-1 and 2-2. To avoid the difficulties involved
in building (or the cost of buying) ways of jig-bores quality, no auxiliary guiding or
bearing surfaces were used except a glass guide. The driver slides with no lubri-
cation in the corner made by the guide and the coupler. The driver is set in position
approxi-rnately by hand and fine adjustments in linear motion are made with an 80 pitch
screw. In the fixture, the driver is set against gage blocks. The gage blocks in
turn are set against an anvil which is mounted by an elastic pantograph (parallel reed
assembly). The suspension of the anvil acts as a spring as well as pantograph.
Adjustable stops have been provided to protect both the leaf springs and the electronic
gage head. With the electronic gage head in place, it is possible to measure the force
at the null (arbitrary zero) position of the gage.
The test fixture consists of an aluminum frame which holds the two glass plates.
Since all tests were performed at a constant temperature, temperature stability was
not considered of major importance in the design.
The fixture was designed to allow easy dismantling of the four sides of the rectangular
box which houses the coupler plate of the Phasolver. This allows removal of the
coupler and guide plate when potted in the fixture. Provisions were also made for
the coupler and guide plate to be secured in the fixture without potting by two
rubber clutched adjust screws in front of the fixture and one at either end. This
method was chosen as more satisfactory than potting the coupler. By placing
ground surfaced glass spacers backed by rubber sheet spacers, the coupler and
guide plate can be secured by the adjust screws. Too much tension causes the
.rubber clutch feature of the screws to slip, preventing damage to either plate.
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The surfaces of these two plates were optically ground to within 0.0001 in. of flatness
over the entire length and were aligned in the fixture perpendicular within 0..0002
in, in breadth.
A precision ground bar extends the full length of the fixture supporting a thumbscrew
released carriage containing the 80 pitch driver plate adjustment screw. A steel
plate is provided at the right end of the fixture, and a magnet is attached to the 80
pitch screw carrier. It can be raised only at the right end position and is held in
this raised position by the magnet.
The parallel-read assembly consists of an anvil that is cantilevered from the
mounting base by four spring steel bands forming a pantograph. Provisions are
incorporated on the parallel-read assembly to adjust and stop its motion by means
of adjust screws.
The parallel reed assembly and millionth indicator probe are attached to a single
bracket which holds those items in pOsitive position and is attached with adhesive
on the bottom to the coupler plate and in the back to the guide plate.
-
A hemisphere is bonded to the end of the driver which contacts with the gage block.
Another spherical surface is mounted to the anvil. These hemispheres are necessary
to minimize the error of incorrect alignment of the gage blocks. Initially, it had
been intencled that the anvil and pantograph mechanism would be used to align the
gage blocks. This turned out to be unsatisfactory. Any gage blocks longer than
8 millimeters became unwieldy. The errors introduced using the anvil surface with
large gage blocks is considerably greater than that possible with a spherical surface.
The alignment of the gage blocks has always been a severe problem in this program.
Most of the errors in repeatability can be blamed on the inability of the operator to
adjust the gage blocks parallel with the direction of motion. Glass guides were
fabricated to help the operator align the gage blocks parallel with the direction of
motion. These guides were very helpful with the long, blocks, but turned out to be
ineffective with the small blocks.
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2.2 PHYSICAL DESCRIPTION
The Phasolver consists of two glass plates, one of which is shorter than the other by
the amount of desired motion. Parallel bands of nickel are applied to both plates and
processed to provide the patterns which enable the Phasolver to perform its function.
The patterns on the two plates are of different configurations and perform different
functions. The patterns on one plate are utilized as the signal-drive element in the
electrostatic coupling process and are designated as drive patterns. The patterns
on the second plate are utilized as the coupling element in the electrostatic process
and are designated as the coupler patterns.
The moving plate is the shorter of the two and has been chosen to be the driver.
Provided that there is no difference in scale between the two patterns that exceeds
one cycle (pole pair) over the length of the driver, and further provided that the
driver ends symmetrically, the driver theoretically behaves like a single line at
Its midpoint. Therefore, the scale of the device should be controlled by the coupler.
Interchanging the position of the coupler or the selection of which shall be the moving
element should not affect the results.
The longer of the two patterns controls the scale accuracy of the device. Because it
is easier to generate a coupler accurately and also easier to measure the results,
the coupler was made the longer of the two patterns. In the fixture, the coupler is
mounted as part of the fixed assembly and the driver slides on the coupler.
The driver slides on three adjustable delrin feet which straddle the coupler pattern.
These feet can be adjusted to produce a gap from 0.0005 inch to 0.014 inch. The
normal operating gap was 0.002 inch. Electrical connections were made to the driver
pattern by soldering wire to thin copper shim stock and connecting the shim to the
diverging lead lines of nickel from the pattern with conductive silver paint. A
similar procedure was followed in making connections to the coupler plate.
2.2.1 Phasolver Driver Patterns
Two Phasolver patterns were generated in the lofting of the master. A new
symmetrical pattern was developed from theoretical analyses performed which
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indicated that this pattern should be significantly less sensitive to skew, gap
variations and tilt than a pattern with a configuration similar to the patterns used
in the rotary Phasolver.
A second pattern was lofted which is very similar to the pattern used in the rotary
Phasolver systems. This pattern is not symmetrical and skew tests were not
planned for this pattern.
In addition to the two Phasolver patterns, a coupling area was provided to couple
the output signal from the coupler back to the driver to test the feasibility of
placing all electrical connections on the driver plate. The driver patterns are
illustrated in figure 2-3.
The new driver pattern consists of two identical patterns - one of which is a mirror
Image of the other. These patterns each consist of four sinusoidal areas phase
displaced by 90 degrees. Between each sinusoidal area is a thin conductor which
is electrically grounded during use and acts as a guard band to confine the
electrostatic fringe fields and control their effect.
The existing phasolver driver pattern consists of two bands of conjugate sinusoidal
patterns which are physically phase displaced by 90 degrees. Therefore, all four
conductor areas are phase displaced by 90 degrees. In addition, guard bands
separate the two conjugate patterns. This basic configuration is used on all rotary
Phasolverse
The total area of the sinusoidal portions of both patterns is approximately equal.
The length of each cycle (pole pair) is exactly 1 millimeter. Each pattern consists
of 254 pole pairs.
The driver pattern was generated by lofting a single, greatly enlarged, sine wave;
photographically reducing the sine wave; compositing this sine wave with other
sine waves in a small mask; and by a step and repeat process, photographically
producing the final master pattern. This master pattern was then used to generate
a photographic plate which was used in the manufacture of the actual driver pattern.
The driver pattern was manufactured by vacuum depositing a thin film of nickel on the
plate and photo-etching the unwanted nickel off the plate, leaving the Phasolver pattern.
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^v^v^v^v
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NEW PHASOLVER DRIVER PATTERN
COUPLING AREA
Wv",^v"v"VVVVv^v"4/4. Wv,v^,^4/Vs,
VVVVVVVVVVV?v^ v^v^41-v^v^ "4/`, v
?vvvvvw\AAANwvvvvvv^?wvyklA44..WwW/VVVstvvvv",/v?AA,A,
v^,^4A/v/W41^v",^4/v/WWW,WWv^ v v v
?VVVVVVV`V^,AvVv/WAW,VVVV,^,^41=A^,Ww",^AVVVVvr^v^,^4,"
^V",./WW,WW,WWWWW=IWAIVVVVVVVVVV,
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Arv^v^v^v","\ANWV,./WvWv v^v^v v^v^v", v v
v",^v"v^.A.A./VVVVVW?v^v^v",^,^v",^v*,^v"v^v^v"v^v",:Wv","v",^VVVV`v^v"V`v^v"v^v"," \e",^v^,i'V'v^v"V`
EXISTING PHASOLVER DRIVER PATTERN
A A A A A A A
V V s' V 4 4 r v r r V r rf V V V '4 V V, V 4, \V V V 4, 4, V4 r4 v VVVVV v' v 4 V 4, V 4 V V 'V 4VVVrv
8
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FIGURE 2-3 DRIVER PATTERNS
(2X SIZE)
2-7
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2.2.2 Phasolver Coupler Patterns
The coupler patterns used with each driver pattern are very nearly identical. Only
the width is different to accommodate the different widths of the driver patterns.
Each coupler pattern consists of a series of bars separated by the glass substrate.
The width of each bar is 1/4 mm (1/4 the length of the corresponding pole pair on
the driver pattern). The bars are exactly 1 mm apart. Therefore,. each bar is
aligned identically with each cycle of the driver pattern. The coupler pattern is
illustrated in figure 2-4.
?
The coupler pattern was generated by a moving machine (ruling engine) which can
very accurately generate the rectangular straight line shapes required of the
coupler pattern. The coupler pattern was manufactured by coating the coupler plate
with wax and cutting the desired pattern out of the wax with ,the ruling engine. The
plate was then vacuum deposited with nickel, and the wax removed. The areas
where the wax had been removed by the ruling engine were covered with nickel, and
those which had been untouched by the ruling engine were bare.
2.3 FUNCTIONAL DESCRIPTION
2.3.1 Phasolver Operation
The four clrive patterns are each excited by one of the four sinusoidal quadrature
drive signals. The frequencies are the same but are displaced from each other by
a 90-degree phase difference.
The driver and coupler plates are mounted so that the two patterns face each other,
closely spaced. The relative amplitude of the drive signal which is coupled from
each driver pattern is a function of the area of the driver pattern encompassed by
the coupler-pattern bar. The output provided by the coupler pattern at any position
is the vector sum of the coupled drive signals.
The generation of phase-shift information in response to a change in the relative
position of the driver with respect to the coupler is illustrated in figure 2-5. This
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0 DEGREES
90 DEGREES
180 DEGREES
270 DEGREES
COUPLER
BAR
ONE PATTERN
PAIR
START
COUPLER BAR
IS MOVED ACROSS
, 1/8 OF A PATTERN
PAIR
COUPLER BAR
IS MOVED ACROSS
1/4 OF A PATTERN
PAIR
1 COUPLER BAR
IS MOVED ACROSS
1/2 OF A PATTERN
PAIR
COUPLER
I BAR IS
I MOVED
ACROSS
3/4 OF
A PATTERN
PAIR
D I
D-CzO
B-A
D-C
B-A
PHASE
SHIFT
D-C
THE MOVING Of THE COUPLER BAR ACROSS
ONE PATTERN PAIR PRODUCES 360? Of
ELECTRICAL PHASE SHIFT IN THE OUTPUT SIGNAL
PHASE
SHIFT
B-A
D-CIO
PHASE
SHIFT
PHASE
SHIFT
RESULTANT VECTOR
SHOWN BY
HEAVY ARROW
B-A
GENERATION Of PHASE
SHIFT IN THE RESOLVER
D-C=0
D-C
RESULTANT SHOWN
BY HEAVY LI NE
OUTPUT FROM t
? COUPLER BAR
Figure 2-5.. Vector Analysis of Phase Shift in a l="hasolver
1
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illustration shows only one sinusoidal segment (pole-pair) and follows the motion of
the coupler-pattern bar over this pole-pair. At each progressive position of the
coupler bar corresponding diagrams are shown for the vector summation of the
output signal.
A minute change in the relative position of the driver with respect to the coupler
varies the relative amplitude of the quadrature signals coupled from the driver to
the coupler pattern. This results in a change in the vector summation and causes
a change continuously from 0 to 360 degrees as the moving element moves a distance
equal to one sinusoidal driver pattern. Because of the symmetry in arrangement of
the pattern-pairs and coupler bars of the patterns, an average output of all pattern
pole-pairs is obtained. This averaging effect results in minimizing errors intro-
duced because of nonlinear pattern pole-pair spacing and random pattern distortions.
2.3.2 Electronics Operation
A block diagram is shown in drawing 1000-2942. The energizing frequencies for the
Phasolver are derived from a countdown chain which has as its clock a Hewlett
Packard Model 101A 1 megacycle oscillator which is also used to run a Hew/Jett
Packard Model 5275A 100 megacycle time interval counter. The 1 megacycle.
oscillator frequency is divided by 100 to provide the 10KC energizing frequency for
the Phasolver. The 1 megacycle oscillator is multiplied by 100 in the time interval
counter to provide the 100 megacycle clock counter. In addition, the 10KC signal
is further divided to provide a 5 cycle reset signal for the counter.
The 10KC squarewave output from the timing chain is filtered to provide the basic
10KC sinusoidal drive signal. Operational amplifiers are used to provide the phase
displacements which create the four quadrature drive signals.
The output of the Phasolver is a sinusoidal signal which is displaced in time from the
Input signal by an increment which is a function of the linear movement to be
measured. The output signal is processed through a preamplifier and another 10KC
filter and then applied to a zero crossing detector and pulse shaper circuit which
generates a pulse at the zero crossing of the output signal. The time interval between
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Drawing 1000-2942
(furnislied in separate folder)
2-12
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the output stop pulse and a start pulse, which is derived from the countdown chain,
Is measured by the counter. This time interval is a measurement of the physical dis-
placement of the Phasolver. Since the counter uses a 100-megacycle clock frequency
and the Phasolver is energized with a 10KC frequency, the counter can resolve one
part in 10,000 of the Phasolver motion. The Phasolver output rotates through 360
electrical degrees for 1 millimeter of linear motion. This provides an electrical
resolution of 1/10,000 of 1 millimeter, .or 1/10 of a micron.
2.3.3 Coarse Channel Operation
The coarse channel consists of a shaft encoder, a gear train, a cable drive to
couple the shaft encoder to the driver plate, and a separate electronics chassis.
The encoder used is a standard brush type encoder with a binary coded decimal
output. The encoder is geared such that the least significant bit is equivalent to
1/10 of a millimeter of plate driver motion. The encoder is geared in this ratio
so that the proper carry from the Phasolver electronics to the encoder electronics
can be made.
This encoder is designed with a self-selecting "U" scan internal brush selection
logic. In the normal operation of the encoder, the least significant bit brush
controls the selection of the leading or lagging brushes on each track of the
encoder. For the Phasolver system to propagate the carry properly into the coarse
encoder, it must control the brush selection logic. This means the Phasolver
system electronics must generate a signal which has the same weight as the least
significant bit brush of the shaft encoder, but which switches with the accuracy of
the Phasolver system. By replacing the output of this least significant bit brush
with the output from the Phasolver system which has the same binary weight, the
coarse encoder brush selection logic will then switch with the accuracy of the Phasolver
system.
The brush selection logic of this encoder is so designed that all decades must
be aligned with the least significant bit brush of the encoder. Otherwise, it is
possible to switch brushes at the wrong point and obtain false results. This last
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restraint imposes a severe mechanical limitation on this system. Since the least
significant bit signal is replaced by the Phasolver system, the alignment between
the Phasolver driver and the coarse encoder must be maintained within 1/2 the
linear distance corresponding to the bit or 0. 002 inch of linear travel. This includes
all errors in the gear train, stretch in the cable, and slippage on the cable drive
pulley.
This tight mechanical tolerance is required only because of the design of the
particular encoder used. Presently, the least significant decade of the encoder is
used only for alignment purposes. With simple modifications to the brush block
assembly and the code disc, this decade could be used. This would reduce the speed
of the encoder by a factor of 10 and therefore loosen the required tolerance by a
factor of 10 to 1/2 millimeter. The high cost and long delivery time associated
?with modifying this encoder has precluded its use on this program.
Since the encoder has a BCD code, the signal used to replace the least significant
bit must have a decimal weight of The only suitable digit which has this weight
is the least significant bit of the most significant decade of the Phasolver word. In
order to match this weight with that of the encoder, the encoder must be run at 10
times the speed. This constraint imposes the severe mechanical tolerances on the
encoder drive system.
The coarse channel electronics is assembled in a chassis separate from the main
electronics unit. It provides a three-digit decimal display and is designed to act
as a go-between between the commercial counter, coarse channel, and a Hewlett/ '-
Packard Model 562-A digital recorder. The coarse channel electronics, in
addition to decoding the coarse encoder, also assembles the entire linear Phasolver
word, four digits from the Phasolver counter and three digits from the coarse
encoder. The three digits from the coarse encoder are displayed on the digital
readout. In addition, all seven digits are sent to the printer and printed out as a
single word. A schematic of this unit (drawing 700897A) is included with this
report.
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Draiving 700897A
garnished in separate folder)
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Approved For Release 2006/03/16 : CIA-RDP78604770A001800010052-6
SECTION 3
PERFORMANCE TESTS
3.1 INTRODUCTION
Linear Phasolver accuracy tests were performed following the Linear Phasolver
Development Program Phase II Test Procedure. Portions of this procedure could
not be performed due to pattern damage caused by dust particles scratching the
pattern and by deterioration of the nickel coating which makes up the pattern itself.
In addition, difficulties in using the gage blocks prevented measurements at all of
the positions called for in the procedure. A modified procedure to incorporate these
limitations is included as Appendix A.
All of the accuracy tests were performed in a special room in which the temperature
could be maintained at 680 F +1/20F, the nominal temperature at which the gage
blocks were calibrated. The relative humidity in the room was maintained at 50
percent for all tests. The room, unfortunately, was not equipped to control the
amount of dust in the air and this became a severe problem.
The pattern was damaged when dust particles lying on the coupler plate became
wedged between the plates as the driver plate was moved across the coupler plate.
The configuration of the driver pattern is such that a single dust particle can cut a
single conductive area into over 100 parts which requires extensive repair work.
With a gap of 0.002 inch, it is easy to understand how this situation could occur.
After the damage was repaired, the Linear Phasolver fixture was placed in a special
dust free chamber which was installed inside the controlled temperature room. This
significantly reduced the amount of further pattern damage due to dust scratches.
This chamber was also used to perform the humidity tests.
Deterioration of the Phasolver pattern was caused by poor vacuum deposition of the
nickel coating prior to the application of the Phasolver pattern. If proper controls
on the nickel deposition process are not maintained, large pinholes appear in the
nickel which after some period of time increase in size due to lack of adhesive
quality around the perimeter of the hole. This is a critical process In the manufac-
ture of Phasolver discs and receives considerable attention by STAT
personnel during the normal manufacturing, process. Unfortunately, the
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Approved For Release 2006/03/16 : CIA-RDP78604770A001800010052-6
generation of the coupler plate was beyond the capabilities of our present vendor and
both the coupler and driver plates were fabricated by another company,
source inspection was not available since the new vendor was riot a local concern.
When the damage was found, repairs were attempted using conductive silver paint
of the type that was used to make connections on the coupler and driver plates. Not
all of the repair work was successful. In, some places, the area to be repaired was
a cut in the pattern possibly only 2 to 3 thousandths of an inch long. The area of the
cut usually was not significant, but in many cases the cut separated a significantly
large portion of the pattern. In most cases, only a tiny spot of conductive paint was
applied to bridge together the two portions of the pattern that had been damaged. In
the areas where the pattern had deteriorated, the paint was again used solely to
regain connections to areas which had become disconnected.
?A large amount of difficulty N,vas encountered in obtaining repeatability, using the
test fixture as it was originally designed. A minimum number of gage blocks were
bought for use with the fixture. It had been planned that these blocks would be rung
together to obtain the different lengths that were wanted. This approach was taken
because of the large expense entailed in the purchase of these blocks. It had been
planned that with a total quantity purchase of 14 blocks, different combinations of
blocks could be made which would completely define the operation over the full
length of the pattern. Shortly after the tests started, however, it became obvious
that, using this approach, the heat input to the blocks from the operator's hands and
the, friction generated during the ringing operation made it impossible to obtain
repeatable results Gloves and tongs were used to isolate the operator's body heat
from the blocks. This technique helped, but was not sufficient to eliminate the
uncertainty. This severely limited the testing that could be performed with the
blocks on hand. The original plans called for measurements within the pole-pair at
three points on the patterns: at 7 millimeters, 132 millimeters and 257 millimeters.
This had to be dropped and all measurements within the pole pair were made at 7
millimeters. In addition, measurements were planned every 15 millimeters over
the length of the pattern. This plan also had to be dropped. The data that was
obtained, therefore, is not complete. However, the data shows very definitely the
capabilities of the Phasolver system, as far as resolution and accuracy over small
distances. The lack of ability in using the gage blocks as originally intended reduces
3-2
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'
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the amount of data that is available for accuracy over long distances. However,
the goal of determining the operation of the Phasolver has definitely been met.
3.1.1 System Resolution and Repeatability
From the very beginning, the Phasolver easily met the requirement of 1/10 micron
resolution. This resolution appears to be limited only by the electronics and not
by the Phasolver. The electronics as designed is not capable of measuring to a
finer resolution. This feature was demonstrated by comparing the Phasolver to the
millionths indicator and showing that the system could easily resolve the 1/10 micron.
As mentioned earlier, considerable difficulty was encountered while trying to obtain
reasonable repeatability due to the problem of expansion of the gage blocks. Using
single gage blocks, however, repeatability in the order of 0.1 micron has been
achieved.
3.1.2 System Long Term Stability
A constant and unresolvable problem,has been linear instability. Either the
millionths indicator or the Phasolver or both appear to drift with time. Overnight,
the millionths indicator moved off scale (typically greater than 2-1/3 microns)
while the Phasolver moved less than 1 micron. When the Phasolver was then moved
until the millionths indicator again read 0, the Phasolver count exhibited a
significant change from the previous zero reading. Differences of 3 to 4 microns
were common. Some differences were as large as 9 microns. Tests on the millionths
indicator have shown no significant drift when installed in a special test fixture to
measure this drift. The unit was also replaced with no effect. During the humidity
test, the millionths indicator reading was changing while the Phasolver reading
remained constant. It is important to note that when these tests were being made,
the Phasolver was being pressed against the pantograph mechanism spring and the
indicator was acting as a force gage to measure the force upon the indicator probe
so that the same force could be maintained at all times. In the condition just
described, the Phasolver driver is significantly more massive than the indicator
probe tip, and it seems unlikely that the Phasolver could be moving as much as the
Indicator probe indicated, and in such a manner that the Phasolver count did not
move.
During accuracy tests on the new pattern, it was observed that the Phasolver count
changed with the indicator remaining constant. This situation, however, was
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Approved For Release 2006/03/16 : CIA-RDP78B04770A001800010052-6
accompanied by other instabilities which indicated that the instability was due to the
Phasolver pattern itself. The situation is believed caused by the severe degradation
of the new pattern at the time. This particular instability was not present with the
existing pattern.
On occasion, for short periods of time, an instability would be noted where the
Phasolver zero reading would not repeat to the same point. On comparing the
balance prior to and after this happened, no difference was found in the condition
Of the balance. All of this data indicates that there is a mechanical instability
somewhere in the test fixture rather than the Phasolver, which severely limits the
creditability of any long term data.
3. 1. 3 Scale Error Correction
Errors in the scale of the coupler pattern due to lofting errors or temperature changes
are a primary source of large errors. Early in the program, a method of correcting
?
this error was devised which, it was, thought, would enable this error to be
eliminated electrically. Circuitry?to test this technique was built and the scheme
was evaluated. It was found to be unsatisfactory.
The technique was based on changing the scale relationship between the least
significant bit of the Phasolver word and the length of the Phasolver pole pair. An
error in the scale of the device will stretch or shrink all of the pole-pairs alike.
If the Phasolver counter clock is used to generate the energizing signals for the
Phasolver, the modulus (the total count corresponding to a pole-pair) is fixed regard-
less of how the clock frequency varies. If, however, the counter clock is different
from that used to generate the energizing signals, it is possible to vary the modulus
and cause each count to have a slightly different scale value.
For this purpose, a 1 mc variable oscillator was used to change the energizing fre-
quency of the Phasolver signals. A separate 1 mc crystal controlled oscillator was
used as the counter clock.
In a single pole-pair, this technique did indeed vary the scale. However, the
Phasolver output phase shift recycles to zero at the beginning of each pole-pair. This
forces the Phasolver counter to zero. If the modulus is such that it does not recycle
to zero synchronously with the pole-pair output (as would be the case if the modulus
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Approved For Release 2006/03/16-: CIA-ADP78B04770A001800010052-6
were to be changed), the readout produces false data. For example, if the modulus is
adjusted to be smaller than normal (as if the pattern were shrunk), the Phasolver
.? _
counter will recycle to zero before the register is full thereby eliminating some
combinations of numbers. If, on the other hand, the modulus is adjusted to be
larger than normal, the Phasolver counter will recycle once when the register is
full and again when the Phasolver phase shift recycles to zero. This allows some
numbers to be repeated in the same pole-pair. Since the counter recycles as a
function of the Phasolver pole-pair length, the scale correction is only valid for
small distances within a single pole-pair.
3.2 Co/Cv DETERMINATION
The Co/Cv ratio is the ratio of the fixed capacity to the variable capacity of each of
the sinusoidal areas which make up the Phasolver pattern. It is analogous to the
signal to noise ratio in other systems. In a theoretical Phasolver, the effects of
Co cancel, leaving only the effect of Cv in the output. Theoretically, the Co/Cv
ratio can have a value no less than 2. On existing Phasolvers, this value ranges
anywhere from 5 to 14 and is strongly dependent upon the gap between the plates. As
the Co/Cv ratio increases, the allowable tolerances on drive amplifier drift and gap
variations become tighter since the fixed capacity errors become more significant.
Figure 3-1 illustrates the Co/Cv ratio of each of the Linear Phasolver patterns as a
function of gap. It is obvious from this graph that the existing pattern has a
significantly better ratio than the new pattern. Examination of the new pattern also
shows that the Co/Cv ratio of conductive areas 10 and 25 is significantly higher than
that of the remainder of the areas in the new pattern. The effect of this discrepancy
Is to seriously effect the accuracy of this pattern with perfect drive signals. As
shown in figure 2-3, the Linear Phasolver Driver pattern, areas 10 and 25 have the
same phase relationship. The effect of this discrepancy is that the static portion,
Co, of this pattern will have a disproportionate effect on the output and the Co's will
not effectively cancel. This seriously disturbs and reduces the accuracy of this
pattern.
A number of tests were performed to determine the nature and cause of this discrep-
ancy.. As yet, no satisfactory hypothesis has been generated that can be easily proved.
The areas of the patterns were measured on a Mann Mono-Comparator, Model 422-C.
The results were run through a Packard-Bell PB-250 computer, and were found to be
3-5
Approved For Release 2006/03/16 : CIA-RDP78604770A001800010052-6
NO. 340-MP DIETZGEN GRAPH PAPER
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Approved For Release 2006/03/16 : CIA-RDP781304770A001800010052-6
almost identical. Any differences between patterns were much smaller than the
discrepancies indicated by the variation in this ratio. One hypothesis that appears
to have merit is the following:
Each of the driver areas of this pattern is surrounded on both sides by a grounded
guard band. The nickel pattern on this plate is very thin and consequently the
electrical resistance is quite high. This is especially true of the guard bands since
they are only 0.005 inch wide. Electridal contact was made to these patterns on ,
only one end. Therefore, it is possible for the guard band to pick up some of the
signal that is impressed on the drive area and re-radiate this to the coupler. The
drive signals have been observed with an oscilloscope on the guard bands?at the far
end from their connections. Guard bands 9 and 26 have a pattern on only one side.
Therefore, they are more likely to pick up signals from areas 9 and 25 than guard
band 24, which, during this test, had the area on one side grounded while the
pattern on the other side was energized. Unfortunately this hypothesis cannot be
proven without generating another pattern. The effect of this unbalance, however,
has been seen during the test on this pattern with perfect quadrature signals.
A second hypothesis which takes into account information gathered on later tests is
as follows:
The Co/Cv ratio is the ratio of the fixed capacity to the variable capacity, or in
other terms, the ratio of the fixed area to the variable area. Any increase in the
fixed capdcity would cause this ratio to be increased. The fixed capacity could be
increased by an increase in a non-sinusoidal portion of the pattern. It could also be
increased by uncontrolled coupling of the drive signal to the coupler external to the
pattern. The method by which the electrical connections were made to the pattern is
significantly different on this system than has been used on any other Phasolver
system. In this system, the connections are made by connecting the drive wires to
the side of the driver plate opposite to the pattern and running conductive material
around one end of the driver plate and making connections to the pattern. The spacing
of the connection lines running along the plate could not be made symmetrical to the
pattern because of space limitations. During the accuracy tests on the new pattern,
with the output signal coupled to the driver, it was noted that a sizeable output
signal existed on the coupling area with the driver plate lifted completely off the
coupler plate. Tests showed that the energy from the drive lines and the conductive
3-7
Approved For Release 2006/03/16 : CIA-RDP78604770A001800010052-6
?
Approved For Release 2006/03/16 : CIA-RDP78604770A001800010052-6
material along the end were coupling directly to the coupling area. By moving the
wires slightly, the magnitude of the output signal could be dramatically changed. It
is possible that some of the energy in these conductors was unevenly coupled to the
coupler bar due to this non-symmetry. Again, this hypothesis cannot be proven
without modifying the driver plate to accept connections on the end of the plate close
to the driver pattern and supplying the input to the driver with shielded drive lines.
3.3 ACCURACY WITH EQUAL AMPLITUDES AND PHASE QUADRATURE
DRIVE SIGNALS
3.3.1 Existing Pha solver Pattern
The accuracy data of the existing Pha.solver pattern with perfect drive signals is
shown in figures 3-2, 3-3, 3-4, 3-5 and 3-6. The data in figures 3-4, 3-5, and 3-6
was taken prior to the pattern damage as noted earlier in this report. The linear
distances indicated on the graphs were obtained by ringing together appropriate gage
blocks to obtain the desired distances. Figure 3-4 wa.s obtained by ringing together
the 15 millimeter block first with the 7 millimeter block and then with the 7 1/8 mm
block, the 7 1/4 nam block, etc. Figure 3-5 was obtained by ringing together in the
same manner the 7 mm, 7 1/8 mm, etc. blocks with the 125 millimeter block.
Correspondingly, in figure 3-6; the 7 mm block was run consecutively together with
the 250 mm block. Figures 3-4, 3-5, and 3-6 were each composed of four
consecutive runs. The vertical lines at each data. point indicate the spread of the data
of the four runs. As is evident from these curves, as the distances became larger,
the uncertainties at each point became larger. For example, the worst case
uncertainty in figure 3-4 is 1 micron. In figure 3-5, the worst case uncertainty is
4 1/2 microns at one point. In figure 3-6, the uncertainty is 5 microns at every
point.
The increased non-repeatability as the distance increased indicated that measurements
taken over long distances by ringing blocks together was not a satisfactory arrange-
ment. Accordingly, after the patterns were repaired, the data Was again repeated
using single blocks by themselves. This data is shown in figures 3-2 and 3-3 and
shows a significant difference in the data. However, the drive signals had been
adjusted since the first runs were made and the starting point in the pole pair had
been changed to correspond electrically with the reference drive signals. Figure
3-2 also shows one other interesting facet - 2 runs were made, one following the
3-8
Approved For Release 2006/03/16 : CIA-RDP78604770A001800010052-6
ERROR
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other almost immediately. A negative shift occurred between the two runs, yet the
balance data looks almost identical. The repeatability of each point was measured
during each run and found to be less than 0.4 micron. Figure 3-3 shows the scale
error of these two runs. It appears that in the area from 7 mm to 60 mm, only the-
zero point has changed. The slopes are all constant.
3.3.2 New Phasolver Pattern
Figures 3-7, 3-8 and 3-9 show the accuracy of the new Phasolver pattern as a
function of perfect drive signals. This data was taken in the same manner as the
data on the existing Phasolver pattern and shows a. similar type of error. This data
could not be repeated after the patterns were repaired since sufficient pattern
damage had occurred that it was not possible to obtain a phase shift from the new
pattern after repairs. A comparison of the error curves of both patterns shows that
the nature of the error is a. single cycle of approximately 45 microns peak-to-peak
with the new pattern and 50 microns peak-to-peak with the existing pattern. This is
considerably in excess of that predicted for the new Phasolver pattern based upon the
analysis which was used to generate the new pattern. However, the large Co/Cv
discrepancy which was measured earlier may explain this large error. The existing
Phasolver pattern shows, the same type of error and even larger magnitude than the
new pattern and yet has no significant Co/Cv unbalance. This indicates that the
existing Phasolver pattern configuration has some serious drawbacks which are not
evident in the new pattern. ?
3.4 EALANCE ACCURACY AND TEST REPEATABILITY
3.4.1 Existing Phasolver Pattern
The existing Phasolver pattern was phase balanced with the output signal taken from
the coupler. Balancing is defined as the adjustment of the drive signals to obtain a
linear phase relationship to mechanical motion. Balancing is performed to compen-
sate for pattern irregularities, systematic pattern errors, and uncontrolled
coupling.from the drive signals to the Phasolver output. Two types of balancing
techniques are used.
a. Phase Balance
b. Amplitude Balance
3-14
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257.25mm. 257.50mm
LINEAR DISTANCE
257..75mm
258
Approved For Release 2006/03/16 : CIA-RDP78604770A001800010052-6
The phase balance procedure calibrates the phase shift output of the Phasolver
against a known standard. The drive signals are adjusted so that, at the eight
intercardinal points in the pole pair, the error is minimized.
The amplitude balance procedure adjusts the drive signals so that the output of the
Phasolver has a constant amplitude as is predicted by the Phasolver theory. There
is a very close correlation between amplitude balance and accuracy. However, for
the most accurate measurements, the phase balance is preferred.
Figure 3-10 shows the interpole-pair accuracy data within the pole pair from 7. milli-
meters to 8 millimeters. After balancing, the output signals were taken from the
coupler in a number of different positions in an effort to determine the mechanism of
the large scale error which had been noted earlier. Cables were attached to both
ends of the coupler pattern and connected to a switch. The output of the switch went
to the electronics unit. In addition, the center of the coupler pattern was connected
to the large coupling area on the coupler plate with conductive paint and another lead
was taken from the coupling area to the switch. By changing the switch position, it
was possible to connect the various parts of the coupler together and connect any
point or combinations of points.of the coupler to the electronics. Figure 3711 shows
the scale error over the length of the driver motion (250 millimeters).
A very strange and interesting phenomenon is that when the output cable is connected
to the left hand side of the coupler, the scale error has a positive slope and when it
is connected to the right hand side, the scale error has a much larger negative slope.
Combinations of these two, when connected to the center, all appear about the same.
However, the fact that the slope passes through zero when picking off the coupler at
a single point from the right hand side to the left hand side indicates that there
probably is some point on the coupler where the output could be connected at which
the scale error should be zero.
In figure 3-10 it should be noted that the balance error varies insignificantly as a
function of coupler connection. This indicates that, assuming the proper point on
the coupler were located, it would not in any significant way affect the balance
accuracy within the pole pair.
Figures 3-12 and 3-13 show the accuracy of the Phasolver pattern with the output
taken from the driver. The error within the pole pair is somewhat larger on this
3-18'
Approved For Release 2006/03/16 : CIA-RDP78604770A001800010052-6
INN NIB. IMO MINI N ANS P Ella EN 11111111,H Pan 1.111 11111m allt mail 11111 ME Ill.
ApprovdtILFIMERelease 2006/03/16 CIA-RDP78B047E78A004800010052-6
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graph. The nature of this error indicates that the error could probably not be
eliminated by rebalancing. The error has a value of + 1. 5 microns.
Figure 3-13 shows the scale error of this pattern with the output taken from the
driver. This output signal was routed to the driver in the following manner:
The coupler pattern on the stationary plate was connected to the large coupling area
in the center of the coupler plate between the two coupler patterns. A conductive
strip of silver paint made a connection from the center of the coupler to the coupling
area and wires were connected to the end of the coupler pattern and the ends of the
coupling area on the coupler plate. These wires went to switches so that.as in the
previous graph we would be able to switch connections between the coupler and the
coupling area on the coupler to obtain all possible combinations. Unfortunately, it
was not possible to disconnect the center connection at will in this configuration as
It was in the previous data when the signal was taken from the coupler.
The output signal from the coupler which is connected to the coupling area is
capacitively coupled to the coupling area on the driver plate from which it is con-
nected to the electronics. The area of the coupling area is considerably larger than
the area of the pattern and therefore presents a significantly lower impedance to the
signal than thb driver pattern itself.
The data shows two very interesting items. (1) All four curves are very similar to
one another in value. The differences between the curves, regardless of coupler
connections, are within 1 micron of each other, worst case. (2) The curves are
nonlinear. The scale error from 0 to 125 millimeters is considerably more than the
scale error from 125 millimeters to 250 millimeters. The error from 0 to 125 milli-
meters is approximately 5.5 microns while the error from 125 millimeters to 250
millimeters is less than 1 micron.
3.4.2 New Phasolver Pattern
The .new Phasolver pattern was phase balanced in the same manner that the existing
Phasolver pattern was balanced. Figure 3-14 shows the interpole accuracy data with
the output signal taken from the coupler. This shows an error within the pole pair of
approximately 1 1/4 microns; of which 3/4 micron appears to be the result of non-
closure in the pole pair.
3-23
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Figure 3-15 shows the scale error of this pattern over the full length of movement.
The slope of the scale error around 7 millimeters where the system was balanced
is approximately 1 micron per millimeter. This explains the nonclosure of the above
pole pair data. If the scale error could be eliminated, the accuracy within the pole
pair would appear to be about 1/2 micron. This data shows a very interesting
correlation with the previous scale error curves. The curve with the largest negative
slope is a curve taken from the right hand side of the coupler. The curve with the
least negative slope is the curve taken from the left hand side of the coupler. The
remaining connection combinations all appear to have the same error with no
significant differences.
The nonlinear characteristic of the scale error exhibited in this curve appears to be
quite similar to the curve in figure 3-16. Figure 3-16 was taken with the right cable
only on this pattern but with perfect drive signals. A comparison of the slopes in the
two curves shows that the slopes between the points where both are measured in
common are very close together. This indicates that the scale error is not a function
of balance. This was already evident since the balance was not affected when the
scale error was changed by moving the output coupler connection (figure 3-14).
Figures 3-17 and 3-18 show the best balanced accuracy data for the new Phasolver
pattern with the output signal taken from the driver. Figure 3-17 shows the accuracy
within the pole pair. This curve was taken at a time when the new Phasolver pattern
appeared to be rapidly deteriorating. This balance could be significantly improved
over what is shown here. However, before the pattern could be rebalanced, all work
stopped on this pattern for a lack of repeatability. The data shown here is the best
data that was obtained from the pattern. No estimate of the ultimate accuracy that
can be obtained from this pattern configuration can be made from the available data.
However, this data shows some very interesting properties. A comparison with the
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1 micron oh both patterns. Aside from this change, the shape of the patterns is
untouched.
Figure 3-18 shows the scale error of this pattern. This curve shows the same
characteristic as that of the corresponding curve on the existing Phasolver pattern.
The scale error is unaffected by connections to the coupler. Again, in this pattern,
the worst case sensitivity to changes of connections is 1 micron,,
3-25
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Approved For Release 2006/03/16 : CIA-RDP78B04770A0018000100521,-6
3.5 HUMIDITY TEST
The purpose of this test was to determine the sensitivity of the Phasolver to the
relative humidity of the air in the vicinity of the Phasolver plates.
For the purposes of this test, the dust free chamber in which the test fixture was
mounted was sealed as well as possible from the outside environment with mylar
tape. Bottled dry nitrogen was fed into the chamber and also into an air washing
bottle in which the nitrogen was bubbled through a water bath. The output of the
washing bottle was fed into the chamber. By mixing the dry nitrogen and wet nitrogen
coming from the washing bottle, it was possible to adjust the relative humidity of the
air in the chamber without seriously disturbing the temperature. Although undoUbtedly
some cooling of the gas occurred when the nitrogen absorbed the water vapor from the
water bath (as occurs in an evaporative cooler), no change was noted in the tempera-
ture of the air inside the chamber itself. Simple absorption type relative humidity
indicators, which had previously been calibrated, were used to monitor the relative
humidity.
Three test runs were made using the existing Phasolver pattern. The first run WaS
made at 31 percent relative humidity. With 100 percent dry nitrogen, the humidity
could not be brought down below 20 percent. Presumably moisture trapped in the
materials inside the chamber, such as the cables and gaskets surrounding the test
fixture, outgassed and maintained the moisture content at a relatively high level for
a long period of time. The system was balanced roughly by an amplitude balance
method at?this relative humidity. The humidity was then raised slightly to 44 percent
and allowed to stabilize for about 4 hours. A run was made and the humidity was then
increased to the maximum relative humidity that could be obtained using only the
washing bottle. The humidity stabilized from this technique at 58 percent relative
humidity. In order to obtain a higher relative humidity we would have had to heat the
water in the air washing bottle. This would have caused a temperature change in the
chamber.
The data obtained in this test is shown in figures 3-19 and 3-20. Figure 3-19 shows .
the accuracy within the pole pair from 7 millimeters. to 8 millimeters. Figure 3-20
shows the scale accuracy over the full length of linear motion. Figure 3-19 shows a
considerable degradation in accuracy as a function of humidity. The accuracy goes
from 5 microns peak-to-peak to 28 microns peak-to-peak as the relative humidity
3-30
Approved For Release 2006/03/16 : CIA-RDP78604770A001800010052-6
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Approved For Release 2006/03/16 : CIA-RDP78604770A001800010052-6
rises from 31 percent to 58 percent. The validity of this data is in question,
however, since the pattern failed during the final repeat run at 30 percent relative
humidity. The purpose of this run was to determine the validity of the test.
Figure 3-20 shows a significant bit of information. The 0 degree and 180 degree drive
signals were interchanged on the existing pattern to change the direction of motion for
Increasing count. In other words, on all other tests, as the driver plate moved from
left to right, the Phasolver count decreased. In this test, the Phasolver count
Increased as the driver plate moved from left to right. figure 3-20 shows a scale
error which has inverse properties of the scale error of all other graphs. The slope
is very positive from 0 to 60 millimeters and while remaining positive, becomes
much smaller as the motion approaches 250 millimeters. This eliminates the
hypothesis that the scale error is electrical in nature, since any electrical error
would behave the same regardless of the way the Phasolver was connected. As an
example, any variable phase shift in the coupler circuit due to a variable resistance
In the coupler pattern, as the driver moved over the pattern, would always cause a
variable lag in the output signal. IjoWever, the fact that this error is reversed from
the previous tests indicates that the scale error has indeed some other source.
3.6 COARSE CHANNEL TEST
The Linear Phasolver test fixture and the coarse channel encoder were installed
together. A cable loop drive was used from the driver plate to the pulley which turns
the coarse encoder. The encoder is geared up by a 4 to 1 gear ratio. This ratio in
combination with the size of the pulley wheel controls the encoder scale. This was
set at 10 counts per millimeter as was explained earlier in the text.
Difficulties were encountered in obtaining repeatable operation because of slippages of
the drive cable over the coarse encoder pulley. The torque of the coarse encoder
when multiplied by the 4 to 1 gear ratio is sufficient to cause some slippage in the
drive cable over the pulley. Operation of the coarse channel over the full length was
obtained, however, and demonstrated that the coarse channel did indeed function
properly. In order to eliminate the slippage of the drive cables, it would have been
necessary to replace the drive pulley with a special spiral groove pulley. This was
not done because of schedule and funding limitations.
3-33
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Approved For Release 2006/03/16 : CIA-RDP78604770A001800010052-6
SECTION 4
CONCLUSIONS AND RECOMMENDATIONS
From the data obtained in this program and included in this report, it is clear that
Linear Phasolver has fulfilled the basic requirements for which it was intended.
The resolution, repeatability and accuracy of the unit either exceeds or very closely
approaches the design goals. The scale error over the length of the pattern is,.
nnfortunately, significant. However, it is repeatable and can easily be eliminated
digitally elsewhere in the system, if necessary. The linear instability which has
caused a great deal of difficulty is believed to be caused by something in the system
other than the Phasolver. The fact that the Phasolver reading remained constant
while the millionths indicator, which was used as a reference point, varied,
indicates that some other portion of the fixture was changing. This could have been
an uncontrolled movement of any item in series with the indicator and Phasolver.
The humidity data indicates a more serious problem area. The Phasolver
require a supply of dry air in the environment of the Phasolver plates to maintain
any stability. This is not a difficult requirement to cope with.
This system has shown such promise that the development of a working model should
be continued. It is recommended that the test fixture be redesigned to allow overhead
ways to support the gage blocks, eliminating any interference with the patterns. Also,
It is advisable to provide a positive guide to secure the driver against the guide block
during travel. This would allow the measurement takeoff to be placed in the. center of
the driver on top. Any; expansion of the driver would then be symmetrical fore and
aft of a theoretical center and would cancel out any errors.
Redesign of the driver would allow direct contact to the driver patterns similar to
the method used on the existing Phasolver. The use Of shielded cables would
eliminate coupling of any energy from the drive lines directly to the coupling areas
and prevent uncontrolled coupling of the drive signals to the output. The driver
patterns could be put on the plates with the techniques used in the fabrication of
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Approved For Release 2006/03/16 : CIA-RDP78604770A001800010052-6
the existing Phasolvers
better patterns since
on this process:
since there is now a photo-master.
This would result in
has considerable in-house technical knowledge
It is also suggested that more gage blocks be used, encompassing all of the measure-
ments to be made.
With these modifications, it is believed that the source of some of the problems and
their solutions could be found and that the testing program could be pursued to a
satisfactory conclusion.
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Approved For Release 2006/03/16 : CIA-RDP78604770A001800010052-6
'APPENDIX A
LINEAR PHASOLVER DEVELOPMENT PROGRAM
PHASE II SYSTEM TEST PROCEDURE
General Test Conditions and Special Instructions
1. Ambient Temperature: 68?F +1?F
2. Ambient Relative Humidity: Within the range 30 - 50 percent, but controlled
to +5 percent at set point.
3. The system shall be soaked at constant temperature for several hours prior
to any tests.
4. The number of heat sources in the room should be kept to a minimum:
a. One test operator (two operators during balance).
b. One electronics subsystem including the 100 mc counter and crystal
oscillator.
5. Precautions should be taken to prevent hands_or other parts of body from
touching the fixture during the test period to minimize thermal changes.
6. Gloves or tongs are to be used when handling gage blocks. Do not touch
blocks with bare 'hands.
Pattern Identification (Figure 2-3)
1. The existing Phasolver pattern hereafter will be referred to as Pattern I.
2. Areas 9 through 17 and Areas 18 through 26 of the new Plaasolver pattern .
will be referred to as ,Patterns HA and IIB respectively.
_
3. The new Phasolver pattern- which is HA and Tril connected in parallel, will
be referred to as Pattern HI.
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Approved For Release 2006/03/16 : CIA-RDP78604770A001800010052-6
TEST 1 Co/Cv Determination
1.1 Test Conditions
1.1.1 Gap + 0.0015 inch nominal. Record measured value (height of feet
with respect to surface of driver plate).
1.1.2 Set up plates for minimum skew. Record all pertinent set-up
dimensions.
1.2 Measure Co, Cv, and compute Co/Cv for Patterns I, IIA, RB and DI with the
outputs taken from the coupler patterns.
1.3 Measure Co, Cv, and compute Co/Cv for Patterns I, IIA, IIB and III with the
outputs taken from the driver patterns.
1.4 Repeat 1.2 for 0.004, 0.003 and 0.002 inch nominal gap.
1.5 Review results.
1.6 Set Gap at best compromise of Co/Cv ratio and mechanical clearance
?
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ci
1 ?
2.2.3 Repeat 2.2.2 once. This is to be accomplished directly upon
completion of 2.2.2 without interruption.
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TEST 2 Accuracy, Resolution, Test Repeatability
2.1 Test Conditions and Procedures
2.1.1 Gap = 0.0025 inch nominal. Record measured value (height of feet
with respect to surface of driver plate).
2.1.2 Set up plates for minimum skew. Record all pertinent setup
dimensions.
2.1.3 Adjust preamplifier gain for 3 volts peak-to-peak signal amplitude
at CD input. This value is to be used for all tests and is to be:
,
checked prior to the start of any test.
2.1.4 Counter readings are to be recorded as the range of readings seen
for each plate position: Example:
Position (CM) Counter Reading (Microseconds)
10.000 100.00- 100.03
2:1:5 Output is to be taken from the coupler patterns.
2.2 Accuracy with Equal Amplitudes and Phase Quadrature Drive
Signals - Pattern I.
2. 2. 1
Adjust the amplitudes and phases of the drive signals such that the .
amplitudes are equal within +0.0001 wins and the phases are in
quadrature within +10 nanosecs.
2.2.2 Perform an accuracy run starting at 0 mm. The actual system
output shall be recorded for the following positions: 0, 7,
7.125, 7.250, 7.375, 7.500, 7.625,?7.750, 7.875, 8, 15, 30,
60, 125, 250 mm. Compute the system error (correct system
output minus actual system output).
?
. 2. 2. 4 Review the results of 2. 2. 2 and 2. 2. 3,
A-3
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2.3 Accuracy with Equal Amplitudes and Phase Quadrature Drive Signals
Patterns LEA, I IB, and. Ill.
2.3.1 Repeat 2.2 for each of the above patterns.
2.4 Balance, Accuracy, and Test Repeatability - Pattern I.
2.4.1 Perform a phase balance starting at 7 mm. Record final balance
readings. Compute system error. Use 8 intervals within a pole
pair (9 positions).
2.4.2 Perform an accuracy run for 250 mm travel. Record actual system
output; compute the system error (correct system output minus
actual system output). Use the following displacements in millimeters:
0, 7, 7.125, 7.250, 7.375, 7.500, 7.625, 7.750, 7.875, 8, 15, 30,
60, 125, 250.
2.4.3 Repeat 2.4.2 once. This is to be accomplished directly upon completion
of 2.4.2 without interuption.
2. 4. 4 Review the results of 2. 4. 2 and 2. 4. 3.
2.5 Balance, Accuracy, and Test Repeatability - Patterns HA, UB and M.
2.5.1 Repeat 2.4 for each of the above patterns.
A-4
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Approved For Release 2006/03/16 : CIA-RDP78604770A001800010052-6
TEST 3 Pattern Separation
3.1 Test Conditions
3.1.1 Gap = 0.0025 inch nominal. Record measured value (height of
feet with respect to surface of driver plate.
3.1.2 Set up plates for minimum skew. Record all pertinent setup
dimensions.
? 3.1.3 Adjust preamplifier gain for predetermined signal amplitude at
ZCD input. This value is to be used for all tests and is to be
checked prior to start of any test.
3.1.4 Counter readings are to be recorded as the range of readings
seen for each plate position. Example:
Position (CM)
Counter Reading (Microseconds)
10. 000 100.00 - 100.03
3.1.5 Output is to be taken from the coupler patterns.
3.1.6 Energize alternate sections of Patterns HA and JIB to represent
a Phasolver pattern with increased spacing of individual pattern
segments.
3.2 Accuracy with Equal Amplitudes and Phase Quadrature Drive Signals.
3.2.1 Adjust the amplitudes and phases of the drive signals such that
the amplitudes are equal within +0.0001 vrms and the phases are
in quadrature within +10 nanosecs.
3.2.2 Perform an accuracy run. The actual system output shall be
recorded for the following positions: 0, 7 mm, 7.125, 7.250, 7.375
7.500, 79625, 7.750, 7.875, 8, 15, 30, 60, 125, 250 mm. Compute
the system error; correct system output - actual system output.
3.2.3 Repeat 3.2.2 once. This is to be accomplished directly upon
completion of 3.2.2 without interruption.
A-5
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Approved For Release 2006/03/16 : CIA-RDP78B04770A001800010052-6
3.2.4 Review the results of 3.2.2 and 3.2.3.
3.3 Balance, Accuracy, and Test Repeatability
3.3.1 Perform a phase balance starting at 7 mm. Record final balance
readings. Compute system error. Use 8 intervals within a?
pole pair (9 positions).
3.3.2 Perform an accuracy run for 250 mm travel, Record actual
system output; compute the system error (correct system output
minus actual system output). Use the following displacements in
millimeters: 0, 7, 7.125, 7.250, 7.375, 7.500, 7.625 7.750,
7.875, 8, 15, 30, 60, 125, 250.
3.3.3 Repeat 3.3.2 once. This is to be accomplished directly upon
completion of 3.3.2 without interruption.
3,3.4 Review the results, of 3. 3. 2 and 3. 3. 3
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Approved For Release 2006/03/16 : CIA-RDP78604770A001800010052-6
TEST 4 Driver Coupled Output
4.1 Test Conditions
4.1.1 Gap = 0.0025 inch nominal. Record measured value (height of
feet with respect to surface of driver plate).
4.1.2 Set up plates for minimum skew. Record all pertinent setup
dimensions.
4.1.3 Adjust preamplifier gain for predetermined signal amplitude
at ZCD input. This value is to be used for all tests and is to
be checked prior to start of any test.
4.1.4 Counter readings are to be recorded as the range of readings seen
for each plate position. Example:
4.1.5
Position (CM) Counter Reading (Microseconds)
10.000 100.00 - 100.03
Output is to be taken from wide output band of the driver plate.
The coupler pattern should be connected to the wide band on the
coupler plate.
4.1.6 Use the pattern which produced the best accuracy results in
2.2, 2.3, 2.4 and 2.5.
4.2 Accuracy with Equal Amplitudes and Phase Quadrature Drive Signals.
4.2. 1 Adjust the amplitudes and phases of the drive signals such that
the amplitudes are equal within +0.0001 vrms and the phases are in
quadrature within + 10 nanosecs.
- 4. 2. 2
Perform an accuracy run over a pole pair span (one mm travel)
starting at 7 mm. The actual systemi output shall be recorded
for the following positions: 0, 7 mm, 7.125, 7.250, 7:375, 7.500,
7.625, 7.750, 7.875, 8 mm: Compute the system error; correct
system output-actual system output.
A-7
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Approved For Release 2006/03/16 : CIA-RDP78604770A001800010052-6
4.2.3 Repeat 4.2.2 once. This is to be accomplished directly upon
completion of 4.2,2 and 42,3.
4.3 Balance, Accuracy, and Test Repeatability
4.3.1 Perform a phase balance starting at 7 ram. Record final balance
readings. Compute system error. Use 8 intervals within a pole
pair (9 positions).
4:3.2 Perform an accuracy run for 250 mm travel. Record actual
system output; compute the system error (correct system output
minus actual system output). Use the following displacements in
millimeters: 0, 7, 7.125, 7.250, 7.375, 7.500, 7.625, 7.750,
7.875, 8, 15, 30, 60, 125, 250.
4.3.3 Repeat 4.3.2 once. This is to be accomplished directly upon
completion of 4.3.2 without interruption.
4. 3. 4 Review the results 'of 4. 3. 2 and 4. 3. 3.
A-8
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Approved For Release 2006/03/16 : CIA-RDP781304770A001800010052-6
TEST 5
5? 1 Test Conditions
Skew
5. 1. 1 Gap = 0.0025 inch nominal. Record measured value (height of feet
with respect to surface of driver plate).
5.1.2 Set up plates for minimum skew. Record all pertinent setup
dimensions.
5.1.3 Adjust preamplifier gain for predetermined signal amplitude at
ZCD input. This value is to be used for all tests and is to be
checked prior to start of any test.
5.1.4 Counter readings are to be recorded as the range of readings
seen for each plate position. Example:
Position (CM) Counter Reading (Microseconds)
?
10.000 100.00- 100.03
5.1.5 Output is to be taken from the coupler patterns.
5.2 Pattern I - Balance, Accuracy, and Test Repeatability.
5.2.1 Perform a phase balance starting at 7 mm, Record final balance
readings. Compute system error. Use 8 intervals within a pole
pair (9 positions).
5.2.2 Perform an accuracy run for 280 mm travel. Record actual system
output; compute the system error (correct system output minus
actual system output). Use the following displacements in
millimeters: 0, 7, 7.125, 7.250, 7.375, 7.500, 7.625, 7.750,
7.875, 8, 15, 30, 60, 125, 250.
5.2.3 Introduce 0.0002 inch/inch of driver bkew with respect to
the coupler pattern.
A-9
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Approved For Release 2006/03/16 : CIA-RDP78604770A001800010052-6
5.2.4 Perform an accuracy run for 250 mm travel. Record actual system
output; compute the system error (correct system output minus
actual system output). Use the following displacements in
millimeters: 0, 7, 7.125, 7.250, 7.375, 7.500 7.625, 7.750,
7.875, 8, 15, 30 60, 125, 250.
5.2.5 Rephase balance for minimum error within a pole pair span
starting at 7 ram..
5. 2. 6 Perform an accuracy run for 250 mm travel. Record actual
system output; compute the system error (correct system output
minus actual system output). Use the following displacements in
millimeters: 0, 7, 7.125, 7.250, 7.375, 7.500, 7.625, 7.750,
7.875, 8, 15, 30, 60, 125, 250.
5. 2. 7 Review results. _ ,
.?.
5.2.8 Introduce a second value of skew selected on the basis of results
obtained in 5.2.1 through 5.2.7.
5. 2. 9 'Repeat 5. 2. 1 through 5. 2. 7.
5. 3 Pattern UI - Repeat 5.2 for Pattern III.
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Approved For Release 2006/03/16 : CIA-RDP781304770A001800010052-6
TEST 6 Tilt
6.1 Test Conditions
6.1.1 Gap = 0.0035 inch nominal. Record measured value (height of feet
with respect to surface of driver plate).
6.1.2 Set up plates for minimum skew. 'Record all pertinent setup
dimensions.
. , .
6.1.3 Adjust reamplifier gain for predetermined signal amplitude at
ZCD input. This value is to be used for all tests and is to be
checked prior to start of any test.
6.1.4 Counter readings are to be recorded as the range of readings seen
for each plate position. Example:
Position (CM) Counter Readino? (Microseconds)
10. 000 100.00 - 100.03
6.1.5 Output is to be. taken from the coupler patterns.
6.2 Pattern I - Tilt Axis A (Defined in 6.2.2)
6.2.1 Perform a phase balance starting at 7 mm. Record final balance
' ? readings. Compute system error. Use 8 intervals within a pole
pair (9 positions).
6.2.2 Introduce 10 arc seconds of tilt with respect to rotation about an
axis which is perpendicular to an axis along the line Of travel..
6.2.3 Measure resultant error within a pole pair span starting at 7 mm.
6.2.4 Perform an accuracy run for 250 ram travel. Record actual
system output; compute the system error (correct system output
minus actual system output). Use the following displacements
in millimeters: 0, 7, 7.125, 7.250, 7.375, 7.500, 7.625, 7.750,
7.875, 8, 15, 30, 60, 125, 250.
A-11
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Approved For Release 2006/03/16 : CIA-RDP7813047.70A001800010052-6
- 6.2.5 Rephase balance for minimum error within a pole pair span starting
at 7 mm.
6.2.6 Perform an accuracy rim for 250 mm travel. Record actual system
output; compute the system error (correct system output minus
actual system output). Use the following displacements in milli-
meters: 0, 7, 7.125, 7.250, 7.375, 7.500, 7.625, 7.750, 7.875,
8, 15, 30, 60, 125, 250.
6. 2. 7 Review results.
6.2.8 Return to zero tilt.
6.2.9 Perform a phase balance starting at 7 mm. Record final balance
readings. Compute system error. Use 8 intervals within a pole
pair (9 position's).
6.2.10 Introduce a second value of tilt selected on the basis of the results
obtained in 6. 2. 3 through 6.2.7.
6.3 Pattern I - Tilt B (Defined in 6.3. 2)
6.3.1 Perform a phase balance starting at 7 mm. Record final balance
readings. Compute system error. Use 8 intervals within a pole
pair (9 positions).
6.3.2 Introduce 30 arc seconds of tilt with respect to rotation about an
axis along the line of travel.
6.3.3 Measure resultant error within a pole pair span starting at 7 mm.
6.3.4 Perform an accuracy run for 250 mm travel. Record actual
system output; compute the system error (correct system output
minus actual system output). Compute the normalized system
error (zero system error at 265 mm). Use the following displace-
ments in millimeters: 0, 7, 7.125, 7.250, 7.375, 7.590, 7.625, 7.750,
7.875, 8, 15, 30, 60, 125, 250.
A-12
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Approved For Release 2006/03/16 : CIA-RDP78604770A001800010052-6
6.3.5 Rephase balance for minimum error within a pole pair span
starting at 7 mm.
C
6.3.6 Perform an accuracy run for 250 mm travel. Record actual
system output; compute the system error (correct system output
minus actual system output). Use the following displacements in
millimeters: 0, 7, 7.125,,7.250, 7.375, 7.500, 7.625, 7.750,
7. 875, 8, 15, 30, 60, 125, 250.
6. 3. 7 Review results. :-
6.3.8 Return to zero tilt.
6.3.9 Perform a phase balance starting at 7 mm. Record final balance
readings. Compute system error. Use 8 intervals within a pole
pair (9 positions)
6.3.10 Introduce a second value of tilt selected on the basis of the
results obtained in 6.3.3 through 6.3.7.
6. 3. 11 Repeat 6. 3. 3 through 6. 3. 8.
6.4 Patterns IIA or UB, III and Separated Pattern
6.4.1 Repeat 6.2 and 6.3 for the above patterns.
A-13
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Approved For Release 2006/03/16 : CIA-RDP78604770A001800010052-6
TEST 7 Gap
7.1 Test Conditions
7.1.1 Gap = 0.0025 inch nominal. Record measured value (height of feet
with respect to surface of driver plate).
7.1.2 Set up plates for minimum skew. Record all pertinent setup
dimensions.
7.1.3 Adjust preamplifier gain for predetermined signal amplitude at
ZCD input. This value is to be used for all tests and is t6 be
checked prior to start of any test.
7.1.4 Counter readings are to be recorded as the range of readings seen
for each plate position. Example:
Position (CM) Counter Reading (Microseconds1
10.000 100.00 -100.03
7.1.5 Output is to be taken from the coupler patterns.
7.2 Pattern I
7.2.1 Perform a phase balance starting at 7 mm. Record final balance
readings. Compute system error. Use 8 intervals within a pole
pair (positions).
7.2.2 Set gap at 0.0035 inch. During the time interval that the gap change
Is made, the electronics shall remain on, with standard test
conditions maintained. The amplitude of the drive signals shall
be measured prior to removal and after reinstallation of the driver
plate.
7.2.3 Measure resultant error within a pole pair span starting at 7 ram.
A-14
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Approved For Release 2006/03/16 : CIA-RDP78604770A001800010052-6
7.2.4 Perform an accuracy run for 250 mm travel. Record actual system
output; compute the system error (correct system output minus actual
system output). Use the following displacements in millimeters:
0, 7, 7.125, 7.250, 7.375, 7.500, 7,625, 7.750, 7.875, 8, 15, 30,
60, 125, 250.
7.2.5 Rephase balance for minimum error within a pole pair span starting
at 7 ram.
7.2.6 Perform an accuracy run for 250 mm travel. Record actual system
output; compute the system error (correct system output minus
actual system output). Use the following displacement in millimeters:
0, 7, 7.125, 7.250, 7.375, 7.500, 7.625, 7.750, 7.875, 8, 15, 30,
60, 125, 250.
7.2.7 Review results
7. 3 Measure Co, Cv, and compute Co/Cv for Patterns I, IIA, IIB and 1:11 with the
output taken from the coupler pattern.
7.4 Measure Co, Cv, and compute Co/Cv for Patterns I, HA, JIB and III with the
output taken from the driver pattern.
7.5 Patterns IIA or IIB
7.5.1 Repeat 7.1 and 7.2 for Patterns HA or
7.6 Pattern III
7.6.1 Repeat 7.1 and 7.2 for Pattern III.
7.7 Separated Pattern
7.7.1 Repeat 7.1 and 7.2 for separated pattern used in Test 3.
7.8 Repeat 7.1 through 7.7 using a gap setting of 0. 007 inch in 7.2.3.
A-15
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Approved Release 2006/03/16 : CIA-RDP78B01ir001800010052-6
I. SUMMARY
1.1,
THIRTY-THIRD MONTHLY PROGRESS REPORT
MODEL 933 PHASOLVER SYSTEM
10 MAY 1966
?
The system accuracy testing is continuing. Since the
test fixture was placed in a "Sterishield" chamber we
have had little further pattern dmage. The accuracy
tests On the 915E-1 pattern (normal Phasolver pattern)
have been completed.
The data obtained to date is both interesting and
encouraging. The system exhibits a scale error which
is sensitive to the pickoff point on the coupler pattern.
This scale error varies from -8.5 microns to +2 microns.
in 250 millimeters as the pickoff point on the coupler
is moved from one end to the dther. See Figure I. This
error is independent of the balance condition. If the
coupler signal is capacitively coupled to the driver disk,
the scale error is independent of the pickoff point on
the coupler. See Figure II.
The error. within the pole pair with perfect guadrature
drive signals is approximately 32 microns peak to peak.
With balancing, the errbr has been reduced to 2.3 microns
peak to peak. See Figure III. The repeatability of this
measurement is less than 0.4 micron-; peak to peak.
Measurements on the new (bow-tie) pattern have begun. The
pattern has deteriorated sufficientl: ...-Ht.hc, output
,g -
does nc-L .)11.ase through 360 degrees with perfect
quadrature drive signals. However, with balancing the
output can be. made to shift phase linearly. No quantitative
figures on accuracy are available yet.
1.2 The coarse.channel fixtures have been fabricated and are
awaiting a convenient time to incorporate them into the
test fixture.
2. WORK PLANNED FOR NEXT REPORT PERIOD
2.1 Complete the accuracy testing.
2.2, Incorporate the coarse channel into the test fixture.
2.3 Complete the humidity testing.
2.4 Write the final report.
Approved For Release 2006/03/16 :CIA-RDP78B04770A001800010052-6
Microns
-
Microns
NO. 340-MP DIETZGEN GRAPH PAPER ELIGIN:
Approvedfloriletease 2006/03/1k: CIA-RDP78B047,70A001800010052-6
l?
Pattern_ 1, Output from Coupler
,,Sest 6 9Y mat
Pages 26,27 & 28
4/29/66
A
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NO. 340-MP DIETZGEN GRAPH PAPER ?UGE
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