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Recording Discs
(continued from page one)

S
tereo 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.

Fig.12-10

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.


  Recording  Stylus

     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.

Fig. 12-11

 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.

Fig. 12-12

    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.

Fig. 12-13

    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.


Distortion

    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.

Fig.12-14

    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).

Fig. 12-15
   
     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.

Fig. 12-16

    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.

Fig. 12-17

    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.

Fig. 12-18
   
    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.

   Fig. 12-19
   
     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
coming soon
Stamping The Records
coming soon

 
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