| a |
|
Recording Discs
(continued from page one)
Stereo Cutting Head
|
The stereo cutting head consists of a stylus mechanically connected
to two drive coils and two feedback coils, which are mounted in a permanent
magnetic field, and stylus heating coil wrapped around the tip of the stylus
(Fig. 12-10). When the signal is applied to the drive coils, the alternating
current flowing through them creates a changing magnetic field, which alternately
attracts and repels the permanent magnet.
Since
the position of the permanent magnet is fixed, the coil moves in proportion
to the strength of the field created and the attached stylus moves with it.
The drive coils are so wound and mounted so that energizing either one alone
causes the stylus to move in a plane 45 degrees to the left or right of vertical,
depending on which coil is energized. Feeding both coils an in-phase signal
causes the stylus to move in the lateral plane, while feeding the coils out-of-phase
signals causes stylus motion in the vertical plane.
The feedback coils
are attached to the shank of the stylus and are, therefore, moved whenever
the stylus moves. The motion of these coils in the permanent magnetic field
creates a current flow in them, which is an accurate representation of the
stylus motion. By mixing the outputs of these coils out of phase with the
input signal in a technique called “negative feedback”, several advantages
are achieved.
1. The need for heavy mechanical damping
materials to control stylus motion is eliminated because the stylus responds
more accurately to the drive signal. Without negative feedback, inertia can
cause the stylus to overswing if it is not well damped. The lack of mechanical
damping removes variations of damping characteristics due to age and heat
from a hot stylus, which are characteristic of nonnegative feedback heads.
In addition, negative feedback is more efficient because it controls the
drive power while mechanical damping materials absorb it and dissipate it
as heat.
2. Since the stylus follows the drive signal more closely, less distortion is produced.
3. The effect of irregularities in the
hardness of the lacquer surface of the recording blank is reduced because
negative feedback senses them and changes the drive signal to compensate
for them.
4. The signal-to-noise ratio of the disc
is improved by approximately 16 dB at 10 kHz for a 6-inch groove diameter,
producing an overall signal-to-noise ratio of about 70 dB when used in conjunction
with a hot stylus.
5. The frequency response of the cutting
head can be flattened or changed as desired by adding EQ to the negative
feedback signal. The frequency range over which negative feedback can be
used by the mechanical resonance of the cutter head which shifts the relative
phase of the input and feedback signals. This results in the feedback becoming
positive at the higher frequencies. If the amount of the feedback is not
restricted at these frequencies, oscillations occur.
|
The recording stylus (Fig.12-11) is made of sapphire
(also known as corundum) because this substance is hard and can be ground
to very accurate dimensions.
Although it is not as hard as diamonds, the lack of grain in sapphire
and its ruggedness make it superior for disc recording purposes. The sapphire
is mounted in an aluminum shank so that it can be attached to the cutting
head. The cutting face of the stylus is ground flat and oriented so that
the disc rotates into it. The tip of the point of the cutting face is ground
to a 90 degree angle to form the cutting edges. The tip of the point is slightly
rounded but must have a radius of less than 0.00025 inch. A burnishing facet
ground into the stylus directly behind the cutting edge polishes the groove
as it is cut, to reduce noise. The dimensions of this facet are carefully
controlled because excess width erases the high frequencies of the disc.
The stylus heating coil is a small coil of wire wrapped
around the stylus tip through which current is passed to heat the stylus.
Cutting with a hot stylus produces several improvements in performance. Since
the linear distance per revolution traveled by the stylus decreases as it
moves closer to the center of the disc, while the time required to complete
each revolution remains the same, the groove velocity decreases as the groove
diameter decreases. As illustrated in Fig.12-12, groove velocity equals path
length divided by the time needed to travel the path. The path length between
lines A and B is less as groove diameter D1 than at diameter D2. Since the
disc rotates at a constant angular velocity, the time it takes the stylus
to travel an arc with angle is independent of groove diameter. As
a result, the groove velocity at diameter D1 is lower than at diameter D2.
As the groove velocity decreases, more program material
must be recorded per revolution and more information must be crowded on inner
grooves of the disc. The effect of this crowding is that high frequency response
gradually decreases as the stylus moves from the outer to the inner grooves.
Prior to the introduction of cutting with a hot stylus the high frequencies
had to be boosted in gradually increasing amounts as the disc was cut in
order to compensate for the loss. This diameter equalization was achieved
by connecting the equalizer control to the lathe sled via pulleys, so that
the EQ varied as a function of the diameter of the groove being cut. While
compensating for the losses, this boosting also added to the noise and distortion
content of the inner grooves.
Heating the stylus has virtually eliminated the need for
diameter EQ because discs cut with a hot stylus exhibit losses of only 2
dB at 8 kHz on the inner grooves. This is a small loss as opposed to the
6 or 8 dB loss at the same frequency and groove diameter with a cold stylus,
without diameter EQ. Some cutting rooms still use diameter EQ even with hot
stylus cutting in order to recover the last 2dB of high frequencies otherwise
lost on the inner grooves.
The smoothing effect of the hot stylus produces a signal-to-noise
ratio that improves as the groove diameter decreases. The signal-to-noise
ratio of a disc cut with a cold stylus, on the other hand, worsens with decreasing
groove diameter. Discs cut with a hot stylus are 2 dB quieter on the inner
grooves. In addition, the smoothing action virtually eliminates groove modulation
noise (similar to the tape modulation mentioned earlier). A hot stylus cuts
through the lacquer coating of the recording disc much easier than a cold
stylus, facilitating the cutting of lacquered discs that have hardened due
to age. A cold stylus would produce inferior grooves called dry cuts on a
hard disc. The stylus heat also eliminates the horns caused by the elasticity
of the lacquer (Fig. 12-13). Horns are raised edges on the sides of a groove
that are easily broken and can cause the groove wall to break or crack when
the finished record is removed from the press, resulting in increased surface
noise. If horns occur on a disc, they are removed by polishing the molds
used on the presses. Since horns limit the level that can be cut on a disc,
higher levels can be cut with a hot stylus.
Stylus heat must be carefully set because too much heat
can cause horns to form and the wrong amount can reduce signal-to-noise ratio.
Heater current is set by listening to the cutting head feedback outputs and
adjusting the current for the minimum sputtering noise. Since groove velocity
is constantly decreasing as the disc is cut, the heat applied per unit area
progressively increases. As a result, lowest noise occurs only at the groove
diameter at which the current was set. Ideally, heater current should decrease
as the disc is cut. The signal-to-noise ratio of a lacquer master made with
a hot stylus and a negative feedback cutting head is about 70 dB, but the
plating process used in manufacturing of the finished records degrades this
figure by adding ticks and pops to the signal.
The material removed from the lacquer disc by the stylus
is called the “chip”. A tube aimed at the stylus and connected to the lathe
vacuum system removes the chip as the groove is cut; this prevents the chip
from blocking the oath of the stylus. The suction is always started first,
and stylus heat is then applied as the cutting head is lowered onto the disc.
If this is not done, the chip which becomes very limp when stylus heat is
used, may collect underneath the stylus before the suction can begin to act.
|
Since the playback stylus tracking angle has been standardized
at 15 degrees from vertical with the stylus pointing into the disc rotation,
the cutting head must be angled so that it produces a groove that is oriented
in the same way. This is complicated by the fact that the lacquer springs
back somewhat after being cut. As a result, cutting heads are operated at
a greater angle of about 18 degrees in order to produce a 15- degree groove.
This standardization of reproducer tracking angles is necessary because the
nature of the recording stylus assembly causes vertical information to be
cut in an arc, rather than strictly vertical. As the stylus moves in this
arc, the groove angle becomes wider than 90- degrees. If the playback stylus
tracking angle is not set to compensate for this increased groove angle,
second-harmonic distortion would be introduced into the program.
As shown in Fig. 12-14A, with no vertical information,
the recording stylus is in position 1, and a 90-degree groove angle is cut.
When the cutter receives vertical information, the stylus cuts deeper into
the disc. It does not move straight down, rather the support arm pivots as
shown by stylus position 2. This produces a groove angle greater than
90-degrees. Fig. 12-14B shows that since the playback stylus cutting angle
is set to a (greater than 15 degree angle to compensate for spring back)
so that the groove walls will present a 90-degree angle to the playback stylus.
Fig.12-14C shows the vertical tracking angle error with the stylus perpendicular
to the disc. Peaks of the stylus motion occur before the peaks of the groove
motion, and dips in the stylus motion occur after dips in the groove.
Other potential sources of signal degradation such as
tracing distortion, the pinch effect, reaching the groove excursion limit
and mis- tracking can also occur during playback of the finished record.
Tracing distortion results from the difference in the shape of the recording
and the playback styli. The recording stylus cutting edge comes to a sharp
point while the playback stylus has a rounded point. Because of this, the
playback stylus point of contact with the groove varies depending on the
instantaneous amplitude of the groove modulation., and the path traced in
playback is not the same as that recorded (Fig. 12-15). The point of groove
wall contact for the play stylus wanders as the modulation is traced, producing
an output corresponding to the dotted path rather than the modulation. The
distortion increases as the signal level increases and as the wavelength
of the recorded signal decreases and approaches the dimensions of the stylus
tip. Thus, tracing distortion increases as the signal frequency increases
and as groove diameter decreases, because both of these factors cause the
wavelength of a signal to decrease (wavelength equals groove velocity divided
by signal frequency, and groove velocity decreases as groove diameter decreases).
Tracing distortion refers to the inability of the playback
stylus to follow groove modulations in the vertical plane. A similar problem
in the lateral plane is called pinch effect. Due to the triangular shape
of the cutting stylus, the width of the groove measured perpendicular to
the line cut by the stylus tip does not remain constant (Fig. 12-16A). The
playback stylus is pinched where the groove narrows, and therefore it rides
higher in the groove, As the groove widens, the stylus rides lower in the
groove (Fig. 12-16B). This motion adds a vertical component to the signal
output that was not present in the input signal. The pinch effect is greater
for high level and high frequency signals, for these cause abrupt changes
in groove direction and therefore causes the width of the groove to become
narrower.
The groove excursion limit is reached when the radius
of curvature of the groove modulation is equal to the tip radius of the playback
stylus, preventing it from following all of the modulation. As shown in Fig.
12-17, the radius of curvature of the groove modulation is equal to the stylus
tip radius, producing 50% second-harmonic distortion. Since the radius of
curvature decreases both with increase in level as well as with increase
in frequency, a limit exists on the level of high frequency information that
can be accurately reproduced.
All three of these types of distortion would be reduced
if the playback stylus point were very small. Distortion would be eliminated
altogether if the playback stylus was shaped like a recording stylus. A stylus
with a small tip radius, however, would ride on the bottom of the groove,
producing noise and other types of distortion. However, a cutter shaped stylus
would tend to cut into the disc and erase high frequency information.
A compromise solution is the use of bi-radial elliptical
stylus rather than the standard conical stylus. The conical stylus has a
round tip with a radius of 0.6 mil. The elliptical stylus has an edge radius
of 0.2 mil and a radius at right angles to the groove of 0.7 mil. The small
edge radius follows groove excursions more accurately than the conical stylus,
while the larger radius prevents the stylus from hitting the bottom of the
groove. Distortion is reduced somewhat, at the cost of increased wear on
the disc.
The Shibata stylus, designed for playing discrete quadraphonic
discs, reduces wear by contacting the groove walls in a line rather than
at only two points as do the conical and elliptical styli. The edge of the
Shibata stylus is narrower than the elliptical stylus and therefore traces
even higher recorded velocities. Fig.12-18 shows the cross sectional areas
of the conical, elliptical and Shibata styli.
A more effective means of reducing tracing, pinch effect
and groove excursion limit distortion is through the use of a “tracing simulator”
such as Neumann’s Model TS-66. All three of the discussed types of distortion
are predominately of the second harmonic variety. Pre-distorting the signal
to be cut on the disc in an inverse manner to the distortion generated by
the playback stylus (Fig.12-19) can reduce their effect. The tracing simulator
generates a voltage corresponding to the second harmonic of the program signal
and adds it to the program out of phase with the distortion created in playback.
This second harmonic component is cancelled by the tracing, pinch effect,
and groove excursion limit generated during playback, resulting in a disc
with substantially less distortion and greater high frequency level capability.
Since the amount of distortion
produced in the playback is a function of groove velocity, which is in turn
determined by the groove diameter for any particular turntable speed, a series
of micro-switches are connected in the lathe bed to sense the position of
the cutter head. The micro-switches enable the drive signal to be pre-distorted
the proper amount for that groove diameter.
The tracing simulator can only optimize distortion for
one tip radius at a time; it is usually adjusted for 0.6 mil that is the
international standard for the radius of a conical stylus. The elliptical
and Shibata styli with their narrow side radii would not completely cancel
the second-harmonic distortion added to the signal by the tracing simulator.
Therefore, these styli would not receive the full benefits of the distortion
reduction.
Mistracking results from loss of stylus contact with the
groove walls during playback, due to record velocities in excess of that
which the stylus can follow. The recorded velocity is measured in centimeters
per second (cm/sec) and is determined by computing the distance that the
playback stylus must move, laterally or vertically, per second from the unmodulated
groove position to accurately track the groove modulation. Since recorded
velocity is constantly changing, the value used is instantaneous peak velocity.
Mistracking often sounds like a buzz or crackling on heavily
modulated passages, or sibilance on vocals. Mistracking can cause instruments
which should have sharp, clear sounds, such as bells, to produce a dull thud
at the beginning of each note. Increasing the tracking force (pressure of
playback stylus on the groove) reduces mistracking. The maximum recorded
velocity, listed by frequency, which can be accurately tracked at a certain
tracking force is a function of its design and specifies the trackability
of a stylus/cartridge assembly. The better the trackability, the lower the
tracking force needed to prevent mistracking.
The pressure of the stylus results in some indention of
the groove modulations. As the radius of curvature of the recorded signal
increases, the stylus indents the record surfce more, resulting in less output.
This playback loss more severe as frequency rises and as groove diameter
decreases, because both of these increase the radius of curvature. Typical
finished records have playback losses of 3 to 4 dB at 15- kHz at minimum
diameter, relative to the master tapes. Stiffer record compounds are indented
less and therefore have lower losses.
Most phonograph cartridges are designed using either magnetic
or piezoelectric principles. The magnetic cartridge coverts stylus motion
into electrical current flow through use of a permanent magnets and coils.
Designs are available using fixed magnets with fixed coils in which the stylus
motion varies the magnetic coupling to the coils. In all cases, the coils
are angled 90 degrees apart from each other and are oriented so that signals
in the outer wall of the groove produce current flow in the left channel
coil. The coils are phased so that lateral stylus motion produces in-phase
outputs from both coils, while vertical stylus motion produces outputs that
are out of phase.
The piezoelectric or crystal phonograph cartridge generates
an output voltage proportional to the varying pressure applied to a crystal
by the stylus motion. Crystal cartridges are much less expensive to manufacture
than magnetic ones, they also produce higher outputs levels so that the extra
stage of pre-amplification required by magnetic cartridges is not needed.
The magnetic cartridge, however, is quieter and operates at lower tracking
forces, creating less wear on the grooves. Crystal cartridges are mainly
used on lower end record players.
|
|
Equalization
|
|
coming soon
|
|
The Mastering Console
|
|
coming soon
|
|
Mastering
|
|
|
|
Stamping The Records
|
|
coming soon
|
|
|
a |