ENGINEERING RESEARCH INSTITUTE THE UNIVERSITY OF MICHIGAN ANN ARBOR Progress Report No. > 7 SHOCK ON ELECTRICAL COMPONENTS IN TRACK-LAYING AND WHEELED VEHICLES Associate Professor~ t-i~rical Engineering. H lson Research Assistant Project 2145 DEPARTMENT OF THE ARMY DETROIT ARSENAL CONTRACT NO. DA-20-089-ORD-3654. May 1957

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FOREWORD This is the seventh semiannual progress report on a research program being carried on in the Department of Electrical Engineering of The University of Michigan. Most of the material reported here represents the endeavor of Harris Olson, who has devoted his full time to this program. The project has benefited from the counsel of Professor Jesse Ormondroyd of the Department of Engineering Mechanics. H. S. Bull Associate Professor of Electrical Engineering iii

TABLE OF CONTENTS Page LIST OF FIGURES v ABSTRACT vi OBJECTIVE vi CONCLUSIONS AND RECOMMENDATIONS vii Io BACKGROUND OF THE ROTARY-DRUM TESTER DEVELOPMENT 1 A. BASIS FOR DESIGN 1 B. CONCEPTION OF A SIMPLIFIED IMPACT TESTER 1 C. PILOT MODEL 2 II. DESCRIPTION OF THE ROTARY-DRUM TESTER 2 III. OPERATING INSTRUCTIONS FOR THE ROTARY-DRUM TESTER 5 A. INSTALLATION 5 B. MAINTENANCE OF THE ROTARY-DRUM TESTER 8 IVo ACCESSORIES FOR USE WITH TIHE ROTARY-DRUM TESTER 10 REFERENCES 11 APPENDIX 13 iv

LIST OF FIGURES Figure Page 1 Principal structural features of the first rotary-drum impact tester. 2 2 The modified rotary-drum impact tester with a rack of G-6 lamps mounted for testing. 3 3 The basic impact tester showing the drive mechanism, the frame, and the camn 4 4 The cam, partially disassembled, of the impact tester. 4 5 Method of lamp attachment on the rotary-drum tester. 5 6 Method used to loosen the clamping screws on the cam. 6 7 Suggested method of checking the offset and the periphery of the cam. 7 8 G-6 lamp rack attached to its loading fixture. 7 9 Bottom view of the G-6 lamp holder for the impact tester. 8 10 Correct method of spreading the spring clip for the insertion of a G-6 lamp. 9 11 The unit used by the project for the control and failure indication of impact tests. 10 12 The circuit used in the control unit for impact tests. 11

ABSTRACT This is the seventh semiannual progress report for this project. This report, with the approval of the project's contracting officer at the Detroit Tank Arsenal, does not cover an exact time period, but summarizes the development of the rotary-drum impact tester for miniature incandescent lamps. In addition to reviewing the background, the report contains a description of the tester and its principal accessories, and complete working drawings. OBJECTIVE The objectives of the research project are: 1. To design, study, and evaluate a new miniature lamp impact tester which may possibly supplant the impact testers now being used. 2. To study presently accepted methods of impacttesting vehicular lamps and to determine specifications for governing such tests. 50 To determine practicable means of increasing the operational life of incandescent lamps used in tactical military vehicles, particularly with reference to their resistance to mechanical shock and vibration. vi

CONCLUSIONS AND RECOMMENDATIONS 1. Experimental and theoretical evidence indicates the rotary-drum impact tester to be a simple, inexpensive, and reliable test instrument. 2. Working drawings are available for this rotary-drum tester to fabricate it for the impact testing of lamps having either an S-8 or G-6 bulb and a single contact bayonet candelabra base. 3. It is recommended that this machine be used for the impact testing or evaluation of miniature lamps in the two sizes for which lamp holders are now designed. vii

Io BACKGROUND OF THE ROTARY-DRUM TESTER DEVELOPMENT A. BASIS FOR DESIGN Several types of impact machines have been designed and built for lamp testing purposes by industrial concerns and test agencies. The one developed by Chrysler for testing miniature lamps, which has been described in previous reports under the heading of the Arsenal lamp impact-test machine, is one of the better known and widely used devices for impact testing. The erratic and inconsistent behavior initially observed in this tester has been largely eliminated by several modifications in the structure and in the operating specifications which resulted from studies carried out under this research project.1 With these modifications it has become a fairly reliable testing device, as shown by the results of two series of correlation tests conducted by several cooperating agencies.2 There are still a number of basic disadvantages; the replacement cost is high (estimated as high as $7000), it has a high noise level when operating, a large size and weight, and a need for frequent careful lubrication, cleaning, and routine maintenance. The noise is so disturbing that the majority of the installations are in sound-insulated cubicles. One further disadvantage this machine will have for some time is a lack of confidence in the test results by the operators. The modified machines will have to be operated for some time, and careful records kept, to build and maintain this confidence. B.o CONCEPTION OF A SIMPLIFIED IMPACT TESTER It was pointed out in the theoretical analysis of the Arsenal tester that the necessary acceleration of the lamp filament could be attained by a simpler method than that employed in this machine; for example, dropping the bulbs themselves through a distance of 1/32 inch and letting them bounce would apply as much stress to the filament as was attained by the operation of the heavy tester 3 The analysis also indicated that the considerable mass of the machine's moving parts served as an elastic cushion between the anvil and the lamp filament. Consequently the strident fury of the machine led to a gentle result. The logical step in a new approach to an impact device involved the reduction of this cushioning to a minimum It seemed likely that an arrangement could be made whereby the lamp would be dropped onto a relatively inelastic surface to excite the filament. This belief was confirmed by comrparing relative vibrating amplitudes for a filament excited first on an Arsenal-type Tester and then by releasing the lamp from a distance 1

above a masonite surface equal to the drop.4 The free drop gave consistently greater amplitude of vibration. C. PILOT MODEL A device was constructed to embody these ideas. This pilot model consisted of a cylindrical wooden drum turned by a motor and a lamp-holding device which supported the lamp envelope in a horizontal position on the upper surface of the drum. The drum had four uniformly spaced steps or offsets cut parallel to the axis of rotation. As the drum was rotated, the lamp was raised and dropped 3/32 inch as it encountered each step. The excitation of the lamp filament produced by this model proved to be more than ample for practical testing purposes. Reduction of the offset tended to produce lamp failures consistent with expectations. II. DESCRIPTION OF THE ROTARY-DRUM TESTER The present form of the rotary-drum tester has evolved from the pilot model previously described. The first enlarged model to embody the essential features of this design is illustrated in Fig. 1.5 It could accommodate 10 B-12 lamps, but was also designed to test 20 G-6 lamps and proportionate numbers of other sizes. It is interesting to note that the only features of this tester which seemed to require any change after exhaustive tests were the lamp holders. Fig. 1. Principal structural features of the first rotary-drum impact tester. Figure 2 shows the rotary-drum tester in its present form with a rack of G-6 lamps mounted for testing. It is quite evident from this illustration that 2

Fig. 2. The modified rotary-drum impact tester with a rack of G-6 lamps mounted for testing. the tester components have only been changed slightly to take advantage of design improvements. The machine, which is 30 x 21 inches and weighs 80 pounds, can be easily handled and requires a relatively small bench space. The basic machine, of which the rear quarter-view is shown in Fig. 3, is composed of three assemblies: the drive mechanism, the frame, and the cam. The purposes of the unit and the frame are self-explanatory, but it should be noted that each is composed of materials and parts that can be readily obtained, and can be fabricated with simple basic tools. The dimensional tolerances that are specified for most of the parts are readily obtainable. The cam, partially disassembled and shown in Fig. 4, has 21-13/16 inches of test length and is unique in that the offset can be adjusted up to approximately 1/8 inch by a simple procedure to be explained later. The length of this cam is adequate to accommodate either 20 G-6 or S-8 lamps and proportionate numbers of larger lamps. The cam material is such that it can be operated in normal environments with little or no dimensional changes due to moisture or heat. The operating principle of the tester can be explained quite readily. As the cam is rotated, the lamps are raised and dropped onto a relatively inelastic surface. This impact loading excites the filaments in a two-noded mode of free vibration with a large enough amplitude to cause ultimate failure. The two factors of the cam that govern the lamp's velocity of impact, which is the most important factor in producing filament deflection, are the cam's offset and speed of rotation. The theoretical relation of these two factors to the total relative velocity of impact was derived in a previous report.6 This relationship is supported by experimental evidence, since it was found that by increasing the 3~cc

Fig. 3. The basic impact tester showing the drive mechanism, the frame, and the cam. Fig. 4. The cam, partially disassembled, of the impact tester. cam offset and/or the cam speed the velocity of impact was increased, the mortality rate increased, and the filaments tended to fail by plastic deformation instead of by f atigue. The borderline between these two types of f ailure is apparently at or near 8 inches per second. The present type of lamp holder, shown with G-6 bulbs in Fig. 5, has evolved from the original model in which the lamps were soldered onto a pivoted brass arm.7 The holders have been modified to permit quicker installation of lamps with either aluminum or brass bases into a spring clip unit, and a bulbinsertion tool that can be used for the G-6 or S-8 lamps simplifies the insertion or removal of lamps from the spring clips. Electrical contact is obtained through the steel clip on the base and a spring contact at the rear. Each lampholder unit can be removed from the tester frame quickly and easily, which also i k Hi~~~~~~~~~~~~~~~~~~1.. A E.F.i. -,,E......

permits the mounting of different lamp types. Fig. 5. Method of lamp attachment on the rotary-drum tester. It was previously pointed out that the velocity of impact is the most important factor in producing filament deflection. The lamp holder,. considered as a pendulum, which rotates around the pivot, also affects this velocity of impact. By experimental evidence and calculation it has been determined that the linear velocit is from 7.27 to 7.8 inches per second for a lamp holder of the type now used. Each lamp type has a holder designed for it according to its physical size, i.e., the impact point on the envelope is always maintained at 2 inches from the pivot center. III. OPERATING INSTRUCTIONS FOR THE ROTARY-DRUM TESTER The rotary-drum impact tester for miniature lamps was designed to be a simple, inexpensive, and reliable testing device. The proper procedure for its installation and maintenance will now be discussed. A. INSTALLATION The rotary-drum tester can be installed in almost any environment. The ambient temperature must always be kept below 150~F, and the machine must be mounted on a fairly stable base that is reasonably level. This base could easily be a bench top or a movable laboratory table that has a reasonable degree of stability. It would be desirable to have a protected storage space nearly for lamp holders not in use, and a small work area for loading and unloading the test racks. It will be assumed that the necessary power and control units are nearby. Adjustment of the cam's offset is effected by "cracking" or slightly.,~~~~~~~~~

loosening the eight clamping screws (RD 3-16) with a hexagonal Wrench through the frame as shown in Fig. 6. Once the cam plates are loosened, the four cam quarters may be moved by gently tapping with the palm of the hand or some other resilient material. The cam should be offset for counter-clockwise rotation when viewed from the driven end. As the offset is changed, it may be roughly checked with feeler gauges; final checks should be made with a dial indicator mounted on the frame in a manner similar to that shown in Fig. 7. Caution should be used to keep the periphery of the cam assembly true in addition to setting the offset accurately. When the adjustment is completed at one end, its cam plate is locked by the four screws and the procedure is repeated at the other end. The first end should be rechecked upon completing the setting at the second end, and the offset and risc for each quarter should be recorded for future reference and rechecks. Fig. 6. Method used to loosen the clamping screws on the cam. The driving unit consists of the motor, two belts, assorted pulleys, and a jack shaft. The tension of the belt from the drum to the jack shaft can be adjusted by moving either the tester frame and/or the jack shaft forward or backward to obtain about 1/4 inch deflection of the V-belt when moderately depressed at the midpoint. The second belt should be similarly adjusted for tension by moving the motor either forward or backward when the correct drum speed is obtained by adjusting the variable sheave on the motor shaft. Included with the present design are lamp holders for the G-6 lamp (shown in Fig. 8) and for the S-8 lamp. Both lamp holders are basically the same except for the spring clips which position the lamp to locate the point of impact a prescribed distance from the pivot. Before initial use of the lamp holder, the necessary fuses (RD 5-35) 6

Fig. 7. Suggested method of checking the offset and the periphery of the cam. Fig. 8. G-6 lamp rack attached to its loading fixture. should be installed underneath the plate, and the control cable (RD 5-23) connected to the terminals as shown in Fig. 9. Half of the connecting cables (RD 5-19) can be attached by soldering to the spring contact while the unit is in the inverted position. The remaining cables can be soldered to the clips in a similar manner when the holder is righted and attached to the mounting jig (RD 5-50 or RD 6-50).

RD5-23':7 RDS- 35. RD5 - 19 Fig. 9. Bottom view of the G-6 lamp holder for the impact tester. Lamps are installed in the clips by the following procedure: 1. With the gauge RD 5-40, check the spring clip RD 5-17 or RD 6-17 to determine that the opening has not been sprung or become set beyond 9/32 inch. Replace the clip if needed. 2. Clean the spring contact if dirty or corroded. 3. Open the spring clip with the bulb-insertion tool as shown in Fig, 10, and slide the lamp into the clip from the front. Under no circumstances should the lamp be forced into the clip from the bottom. The lamp can now be adjusted for filament orientation, and moved forward in the clip until the envelope just strikes the front plate of the mounting jig. Repeat for each station. Mounting the lamp holder on the tester is a simple and quick operation. After removal from the loading jig the lamp holder is placed on the tester frame and secured with the two screws (RD 5-25). All the connecting cables should then be arranged in neat order as shown in Fig. 2. After the electrical connections are established the machine is ready for operation. B. MAINTENANCE OF THE ROTARY-DRUM TESTER Maintenance of the rotary-drum tester is held to a minimum because of its simplicity. The maintenance that is required should be done faithfully as test results can be altered by some of these factors. The requirements for the drive mechanism, the lamp holders, and the cam will be discussed in that order.

Fig. 10. Correct method of spreading the spring clip for the insertion of a G-6 lamp. The drive mechanism has two sets of bearings that will need periodic attention. The Sealmaster flange units (RD 2-15) should be greased at a 6 to 12month interval with a material that conforms to NLGI No. 2 consistency. The grease should be added slowly, with the shaft revolving, until a slight bead appears between the seals. Excess grease should be wiped away. The bearings (RD 1-12) on the jack shaft should be oiled at periodic intervals consistent for a sleeve-type bearing. The operator should be cautioned not to use an excess amount of oil, since it will merely be sloughed off onto adjacent parts. Felt pads can be secured under the bearings to catch excess oil and to facilitate the cleaning around the bearing. The oil requirements for the motor are stated on its name plate. It has been noted the driving unit has a tendency to become oily and dirty unless a minimum amount of lubrication is used and surrounding areas are wiped periodically. Several items on the lamp holders (e.g., the connecting cables, bearings, spring clips, and spring contacts) will require some attention. The connecting cables (RD 5-19, etc.) will need to be replaced when the individual strands of the cable start to break between the insulation and the tinned portion. These cables should serve many tests, but the handling of the lamp holder does seem to cause breaks. Group replacement is the most satisfactory method of maintaining the cables. If the machine is operated in a humid area, the pivot rod (RD 5-20, etc.) has a tendency to rust, especially if any dirt is allowed to accumulate on the rod. 9

A very light film of oil rubbed onto the rod will eliminate this danger. The bearing (RD 5-157-and 16) occasionally will get a slight amount of dirt imbedded in the shaft h.le which will retard the free movement of the pivoted unit. This can be corrected by running a No. 29 drill through the hole to enlarge it to the specified size. The spring clips (RD 5-17 or RD 6-17) need little or no maintenance except for the removal of any rust which might occur on the base contact surfaces. The rust can be removed with a light abrasive material. If, for any reason, the clip needs replacement, it is suggested that the clip, bearing, contact spring, and connecting cables be replaced as a unit because of the close relationship of these components. The contact spring becomes corroded after use, and needs cleaning at periodic intervals. It is suggested that a typewriter eraser or some other mild abrasive be used for this cleaning. The cam needs no attention, since the surface seems to wear well. If the edge of a cam quarter should become chipped or broken, it seems likely that the entire drum could be turned down to a smaller diameter. No information is available as to the effect of this operation, but the amount removed should be kept to a minimum, and careful checks made of the subsequent mortality rate. IV. ACCESSORIES FOR USE WITH THE ROTARY-DRUM TESTER One accessory that might easily prove its worth is an assembly of relays and neon glow lamps which can be arranged to give indication of lamp failures occurring during the "cold" or off portion of each testing cycle, as well as to time the cycling operation and shut down the tester at the conclusion of a predetermined testing period. Figure 11 shows one such device which has been in use by the project for an extended period. The circuit is shown in Fig. 12. Fig. 11. The unit used by the project for the control and failure indication of impact tests. 10

8'ON'9MG _____ _I, s I _ER I. _ I A ______________________ /WO_______ K 2 TO REMAINIV6 i_ _ ______ _7 — 0 TD RIEWMA/,NINV LAWMPS 7, /4,28 V(OLTS ENGINEERING RESEARCH INSTITUTE DAla.B D ".T C UNIVERSITY OF MICHIGAN CHECKD. YAT / ANN ARBOR MICHIGAN TITLi PROJECT CIRCUIT FOtR INCANDESCENT _ _ 2/1,45 LAMP IMPACT TESrFVNC I_ SUE CLASSIFICATION Dwd. O BFig. 12o The circuit used in the control unit for impact tests. REFERENCES 1. Shock on Electrical Components in Track-Laying and Wheeled Vehicles, The University of Michigan Engineering Research Institute Semiannual Progress Report No. 3 (Jan. 1, 1955, to June 30, 1955), pp. 4-9. 2. Semiannual Progress Report No. 5 (Dec. 2, 1955, to May 31, 1956), pp. 1-24. 3. Semiannual Progress Report No. 2 (July 1, 1954, to December 31, 1954), p. 25. 4. Tbid., pp. 37-38. 5. Semiannual Progress Report No. 3 (Jan. 1, 1955, to June 30, 1955), pp. 18-21. 6. Semiannual Progress Report No. 5 (Dec. 2, 1955, to May 31, 1956), p. 33. 7. Semiannual Progress Report No. 4 (July 1, 1955, to Dec. 1, 1955), pp. 10-14. 8. Ibid., p.o 16. 11

I I I I I I I I I

APPENDIX The tabulation which follows gives the part numbers, part titles, DTA drawing numbers, and the interchangeability of components for the following rotary-drum assemblies: RD 1-10, RD 2-10, RD 3-10, RD 5-10, RD 5-50, RD 5-60, RD 6-10, and RD 6-50. It should be noted that no parts, even though designated by a part number, that can be counted as a hardware item, are listed. The drawings for each assembly and component follow the tabulation in a numerical order of their part or assembly numbero Part No. or Part Title DTA Drawing Part Interchangeable With Assembly Noo No. RD 1-10 Driver assembly, rotary- 17700 none drum impact tester RD 1-13 Shaft 17701 none RD 1-18 Base 17702 none RD 2-10 Frame assembly 17703 none RD 2-11 End plate 17704 RD 2-12 right end mirror opposite RD 2-13 Frame base plate 17705 none RD 2-14 Frame back plate 17706 none RD 2-15 Bearing modification 17707 none RD 3-10 Cam assembly 17708 none RD 3-11 Cam quarter 17709 none RD 3-12 Shaft right end 17710 none RD 3-13 Cam plate 17711 none RD 3-14 Shaft left end 17712 none RD 5-10 G-6 lamp-holder assembly 17713 none RD 5-11 Plate 17714 RD 6-11 RD 5-12 Clamp, upper 17715 RD 6-12 RD 5-13 Clamp, lower 17716 none RD 5-14 Bracket 17717 none RD 5-15 Bearing, pivot 17718 RD 6-15 RD 5-16 Bearing, pivot center 17719 RD 6-16 RD 5-17 Clip, pivot arm 17720 none RD 5-17A Clip, pivot arm 17721 RD 6-17 RD 5-18 Spring contact 17722 none RD 5-19 Cable, connecting 17723 RD 6-19 RD 5-20 Rod, pivot 17724 RD 6-20 RD 5-21 Cable holder 17725 RD 6-21 RD 5-22 Ground strip 17726 RD 6-22 RD 5-23 Cable assembly 17727 RD 6-23 RD 5-40 Gage RD 5-17 17749 Use also on clip RD 6-17 13

Part Noo or DTA Drawing Part Title Part Interchangeable With Assembly No......No. RD 5-50 Loading fixture assembly 17728 none G-6 lamp holder RD 5-51 Base 17729 RD 6-51 RD 5-52 Block 17730 RD 6-52 RD 5-53 Stop 17731 RD 6-53 RD 5-54 Spacer 17732 RD 6-54 RD 5-55 Support 17733 RD 6-55 RD 5-56 Plate 17734 none RD 5-60 Lamp insertion tool 17735 Use on any lamp held by a assembly clip similar to RD 5-17 RD 5-61 Arm 17736 none RD 5-62 Pivot bar 17737 none RD 5-63 Disk 17738 none RD 5-64 Rod 17739 none RD 5-65 Spring, compression 17740 none RD 5-66 Spring, torsion 17741 none RD 6-10 S-8 lamp holder assembly 17742 none RD 6-1i Plate 17714 RD 5-11 RD 6-12 Clamp, upper 17715 RD 5-12 RD 6-13 Clamp, lower 17743 none RD 6-14 Bracket 17744 none RD 6-15 Bearing, pivot 17718 RD 5-15 RD 6-16 Bearing, pivot center 17719 RD 5-16 RD 6-17 Clip, pivot arm 17745 none RD 6-17A Clip, pivot arm 17721 RD 5-17A RD 6-18 Spring contact 17746 none RD 6-19 Cable connecting 17723 RD 5-19 RD 6-20 Rod, pivot 17724 RD 5-20 RD 6-21 Cable holder 17725 RD 5-21 RD 6-22 Ground strip 17726 RD 5-22 RD 6-23 Cable assembly 17727 RD 5-23 RD 6-50 Loading fixture assembly, 17747 none S-8 lamp holder RD 6-51 Base 17729 RD 5-51 RD 6-52 Block 17730 RD 5-52 RD 6-53 Stop 17731 RD 5-53 RD 6-54 Spacer 17732 RD 6-54 RD 6-55 Support 17733 RD 6-55 RD 6-56 Plate 17748 none 14

SOURCES OF SUPPLIES AND MATERIALS FOR THE ROTARY-DRUM TESTER A limited number of the components of this tester are made of materials and supplies that are not necessarily readily available. To aid in the duplication of future machines the sources of these materials are enumerated. Part Component of Part Title Assembly Part Description Source RD 2-15 Bearing RD 2-10 Sealmaster SF-8 Michigan Bearing Co. 1/2-in.-shaft dia. 85 Oakman Boulevard Detroit 3, Michigan RD 3-11 Cam quarter RD 3-10 Masonite die stock Masonite Corporation 111 West Washington Street Chicago 2, Illinois (The local distributor's name may be secured from this office.) RD 3-17 Insert RD 3-10 Ros'an R106 SB-8 Ros'an, Inc. 2901 West Coast HighRD 3-18 Lock Ring RD 3-10 Ros'an RL28 SB-8 way Newport Beach, Calif. RD 5-17 Clip, pivot arm RD 5-10 Barnes, Gibson, and Raymond RD 5-18 Spring contact RD 5-10 Plymouth, Michigan RD 6-17 Clip, pivot arm RD 6-10 RD 6-18 Spring contact RD 6-10 RD 5-19 Cable, connecting RD 5-10 4/16/002 stranded Gavitt Wire and Cable Co. RD 6-19 Cable, connecting RD 6-10 Wire type 26 R Brookfield, Mass. RD 5-32 Binding post RD 5-10 Eby No 60 M Eby Sales Company 130 Layfayette St. RD 6-32 Binding post RD 6-10 New York 13, N. Y. 15

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-ON M.mam mem. -. e". Az LETTERIN6 CENTERED __________________________ CS(K 5 2 LD. I3z AC t. 27 (/44)DlRI/L 4 HOLES ~~t —--- -~ ~- - - 4- -- FOR S — Lh4PS ONLY _ __L~- _ -_..-. __ -1.,. ~~~~/ / 4-3G TAP fDEEP a HOLES RDF6- PLAT I I LINE BAP(ELIAE 1t 5 "x L j:ART, AM, / IR.Q'o. MA TL r SIZE DIMENS/iONAL TOLERANCE FRACTIOMAL ~ ENGINEERING RESEARCH INSTITUTEm I. UNIVERSITY OF MICHIGAN cc -2 - 5? ANN AREOR MICHIGAN TITL PRCOJCT 2145 PL A T A loan ~ I ATKCLASIFICATIONWN. B

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