Narration of a novel process

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Narration of a novel process 
A PowePoint presentation of a novel process for manufacturing tubular heating elements.

Script is 1044 words long and should should be about 7 minutes.
Please send your demos and rates as soon as possible. Thank you in advance for auditioning.
2007-09-24 08:14:42 GMT
2007-09-26 08:42:57 (GMT -05:00) Eastern Time (US & Canada) 
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Voice123 SmartCast is seeking 50 auditions and/or proposals for this project (approx.) Invitations sent by SmartCast have resulted in 27 audition(s) and/or proposal(s) so far.

Project Parameters

The Voice Actor should be located in:
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English - British AND English - USA and Canada
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Young Adult Female OR Young Adult Male OR Middle Age Female OR Middle Age Male
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There are no special pre-, post-, or production requirements for this project.
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Script Details





This presentation is intended to introduce a new development in the manufacture of tubular heating elements: The Impact Powder Filling Machine.

Tubular electrical heating elements are used for a wide range of purposes involving heat generation from domestic water heaters, washing machines and irons to industrial applications.

Heating elements come in a variety of shapes and sizes.

But most metal-sheathed tubular heating elements have the same basic components.

A coil of resistance wire, usually a nickel-chromium alloy, capable of withstanding high operating temperatures.
A sheath that is made of copper, aluminum, steel or stainless steel, depending on the intended application.
The void between the resistance wire and the sheath is filled with a refractory powder, usually magnesium oxide, known as magnesia, to provide electrical insulation and thermal conduction.

Stages of conventional manufacture.
The most commonly used method of manufacturing heating elements involves:

Filling the sheath-coil assembly with loose refractory powder to using specially-built filling machines.
But powder density is a critical factor, as thermal conductivity is a strong function of the packing density. For the refractory powder to perform as required, it needs to be highly consolidated to offer adequate thermal conduction.

Consolidating the powder is usually achieved by roll reduction, to a density of 3.1 to 3.2 grams per cubic centimeter.
In Roll Reduction, the filled tube is run through a series of 8-12 individually driven pairs of rolls made of hardened steel or sintered tungsten carbide.

However, roll reduction typically results not only in diameter reduction but also in tube elongation of up to 30% with considerable element-to-element variations. The tube elongation is a significant drawback. It complicates the process of controlling the final product length. Tube elongation requires the manufacturer to use another process of length trimming to rectify its effects.

Trimming to length is usually done through a further rolling process or through stretching.

The other main penalty introduced by the roll reduction process is the work hardening of the sheath metal tubes which prevents bending the tubes into the various required shapes.

This, in turn, brings the need for a capital-intensive process of annealing to soften the metal prior to bending.

These processes require expensive machinery in terms of cost, maintenance and energy expenditure.

The IPF Process
The new process of filling tubular heating elements, The Impact Powder Filling Process offers the potential of eliminating all these expensive processes of roll reduction, trimming and annealing.

This is now possible because powder compaction takes place during the filling process! The consolidation of the refractory powder is achieved at the same time as filling… one millimeter at a time!

As in conventional filling, powder flows down the filling tube that also acts as a ram. However, instead of being withdrawn at a constant speed, the filling tube is oscillated up and down to rest on the thin layer of powder deposited beneath it.
When the ram is lifted, a small amount of powder, approximately 1mm thick, is deposited below the ram head, which is then brought down to rest over the new layer.

That layer is then consolidated through the application of a large force. That force is supplied by a fast moving mass called the hammer and is transmitted to the ram via a specially designed “grip-release” mechanism.

Basic IPF Components:

The Filling Ram.
This is simply a strong tube that can slide freely inside the heater element sheath while the resistance coil passes through it. During operation, the ram is raised and lowered cyclically over a distance of a few millimeters at a rate of around 400 times a minute.

The upper end is supplied with powder from a hopper. The powder flows down under gravity and is agitated by the ram’s cyclic up-down movement.

The lower tip accommodates the ram head which consolidates powder. The Ram Head is composed of two small components.

The Grip-Release Mechanism.
This is a simple, robust mechanism of linked square-section steel bars constructed s that a blow on the strike pads …results in the mechanism gripping the filling ram strongly and therefore transmitting the blow to the material beneath it.
On the other hand, a small force applied to the ‘release surfaces’ loosens the grip and allows the mechanism to slide freely relative to the filling ram.
At the end of every cycle, the grip-release mechanism is shifted down by a small amount equal to the deposited layer of powder to always assume the same position at the beginning of every cycle. This is achieved by a very simple mechanism in the form of a tube attached to the drive that applies a small force to the release surfaces of the grip-release mechanism.

The Hammer.
The blow that consolidates that thin layer of powder is obtained from a relatively large mass, in the order of 2.5 kg for an 8mm heater tube, which is made to oscillate sinusoidally by a drive mechanism that travels a distance of around 40mm.
The hammer is separated from the drive by two sets of springs, above and below the hammer.

Those springs are sized to give the hammer a very high speed at the end of the cycle, where it strikes the strike surfaces of the grip-release mechanism.


The Drive Frame acts as an actuator of the main phases of the action and controls and synchronizes the various events.

This plot illustrates the movement of the three main components: the driving mechanism, the hammer and the ram during a single cycle.
The machine lends itself naturally to filling a bank of tubes simultaneously all modules fill tubes separately while being actuated by the same drive frame.

Concluding remarks:

A prototype machine was built by the inventor and used for the initial investigation. The concept was fully validated. Powder consolidation densities in excess of 2.95 grams per cubic centimeter were achieved. More development work is needed to determine the upper limits of compaction densities and heater tube lengths.

A second prototype was built at the Kathal Machinery AB premises in Hallsthammar, Sweden, but the company was sold by the parent, Sandvik Corporation, before the project was completed.

International patents were applied for.
In June, 2007, The European Patent Office decided to grant the patent. 

A prototype machine was built by the inventor and used for the initial investigation. The concept was fully validated. Powder consolidation densities in excess of 2.95 grams per cubic centimeter were achieved. More development work is needed to determine the upper limits of compaction densities and heater tube lengths. 
Please note that you should only use the script or your recording of it for auditioning purposes. The script is property, unless otherwise specified, of the voice seeker and it is protected by international copyright laws.

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