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Ishino lab Sansui historical notes

bolero

Super Member
Ishino labs is gone, along with their website. Hirano has passed away & although you can google translate the archived site it's not very convenient.

RIP

I thought it would be easier to post the translated logs here in a thread, as long as no one objects?

I won't post any photos as Hirano didnt want them posted anywhere. But there is a lot of amazing Sansui history in there, as Hirano was an engineer who started out designing speakers, then moved on to amplifiers around 1976? And was key in developing the 707/717, 907/917, X1, superfeedforward, X balanced amps & eventual Alpha designs. Although I think he left Sansui right before the X balanced got renamed to Alpha.
 
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The concept of the AU-X1

Since the time when we were involved with the AU-607/707, Sansui had wanted to release a separate amplifier and present it to the world. Before that, there was a high-end separate series called the CA-3000, BA-3000, and BA-5000, but the BA-5000 with an autoformer modeled after McIntosh was well-received for its tough and solid sound, but it didn't sell well because of its weight.

We thought that if we could somehow establish a track record with the three pre-main models of the Diamond differential circuit, the next step would be a separate amplifier, but we felt that we still lacked the skills, know-how, etc. to get to that stage.

So we decided to release an integrated amplifier that was unlike anything else. Fortunately, there were no objections. The first model was going to be called AU-DI, but because it looked similar to the Audi car, it was decided to call it the AU-X1.

The commercialization plan was as follows:

A top-class, high-power, large integrated amplifier.

The functions would be designed so that it could also be used as a separate amplifier.

The tone control would be omitted, with sound quality taking priority.

Specifications:

Maximum output: 170W + 170W (8Ω)

Size: No particular restrictions.

Weight: No particular restrictions.

Circuit configuration:

Power amplifier: Diamond differential circuit

Flat amplifier: DC amplifier configuration

Phono equalizer: Diamond differential circuit

MC head amplifier: FET complementary configuration

This was the rough outline of the plan. In response to this plan, the technical and mechanical design team said, "If we're going to do the front panel, we want to use die-casting." Even now, the front panel of an amplifier is made by making a mold of the cross section of the panel, extruding aluminum, cutting it to the length of the panel, drilling holes for volume and other parts, processing it, and then anodizing it (a type of plating) to give it a color such as silver, champagne gold, or black. Die casting is used to make the entire front panel mold and make the front panel at once. It is suitable for precision machines such as cameras, but I was told that it was not suitable for audio amplifiers, and above all, the cost of the mold alone would easily exceed 20 million yen. I still don't understand why we went in that direction. Was it because the vertical dimension of the aluminum extrusion mold exceeded the limit?

As expected, when the mold cost became so high, the management did not immediately give the OK.

The concept of the TU-X1

Sansui's tuners did not gain much popularity compared to Trio (now Kenwood) at the time. In fact, the sales of the TU-707, which was designed to match the integrated amplifier, were only about 20% of the integrated amplifier. Up until that time, Sansui's only masterpiece was the TU-9900. Even the TU-9500, which was paired with the AU-9500, was said to be so open inside that it could be used for sports days.

At that time, Sansui was researching the AM stereo broadcasting system. Various systems were proposed, but in the end, the American system was adopted and the Sansui system was defeated. After all, if you want to move the industry, you need a company with that much influence, like Dolby, otherwise the business of adopting the system will not be successful.

So, Sansui used the technology of the AM stereo system to develop a technology that can receive AM broadcasts in high quality using a synchronous detection system. It was announced at EIAJ, but there was not much of a reaction. Audio Journal did not particularly take it up either. That's understandable. At that time, there was a lot of talk about multi-channel FM, and there was no interest in AM broadcasts at that time.

When I listened to the prototype, I could hear AM broadcasts with good sound. However, the world was in the stereo era, and high-quality mono was not profitable. Nevertheless, the development department was enthusiastic about somehow commercializing it, and they decided to commercialize an AM/FM tuner equipped with this method. So, it was finally decided to release it as a pair with the AU-X1 mentioned above. However, there was no prediction that it would be profitable. The only excuse was to make it an MKII and diligently amortize the die-casting mold costs as a long-life product.

Finally, permission was given to develop the high-end, ultimate, high-power integrated amplifier AU-X1.

Because of the high power mentioned above, there was no heat sink that could withstand 170W power. Even the AU-D907 was realized by combining two heat sinks that had been made up to that point. The mechanical design team was aiming for the ultimate, so they were adamant about making a dedicated heat sink mold for the heat sink. I still don't know why I was so bold back then. I don't think there were any other integrated processors that went this far. Of course, we predicted demand in advance, but we were lucky to get 3,000 units. However, for some reason, we made the molds for this model and developed it. If anyone is to blame, it may be because I was abnormally obsessed with it at the time.

I still have the large heat sink made from the die-cast mold, and it is huge and impressive. As with the AU-D907, we decided to use 3 pairs of non-magnetic LAPT transistors connected in parallel to output 170W. Of course, we guaranteed a 4Ω load, so with a 4Ω load, we could get nearly 300W of power.

The power transformer was large capacity, and of course an EI type transformer could not be housed in the case, so we had no choice but to use a toroidal transformer. The disadvantage of a toroidal transformer is that when high power is output, in the so-called dynamic state, there is a relatively large leakage flux. A transformer manufacturer analyzed this for us. Therefore, in such a case, it is more advantageous in terms of sound quality to use a separate transformer to supply power to the predrive stage, flat amplifier, and phono equalizer stage. Therefore, we decided to use a 70VA EI transformer for this power supply, just like the AU-D907. Naturally, the power supply section became very large and heavy.

Also, block capacitors, which are related to sound quality, were important. The choice of manufacturer was also due to the material policy, and we decided to use ELNA. The ELNA technical team was also very enthusiastic in cooperating with the development. (I still have a relationship with the technical people from that time.) Since parallel connection of capacitors reduces internal resistance and is advantageous in terms of sound quality, we decided to use parallel connection. We ended up with eight block capacitors lined up next to a huge heat sink, four on the left side and four on the right side.

When we were wondering what to do about the master volume of the AU-X1, the Panasonic Components Division introduced us to a volume control using CP (conductive plastic) resistors. Speaking of CP volumes, they were high-end products used in professional faders. As expected from Panasonic, I thought. I immediately decided to adopt them. The cost was also not high considering the contents. However, as a follow-up, it seems that there was a large variation in the rotational torque during mass production, and when a complaint was made, supply and production were immediately halted. I think they probably switched to Alps after about two lots.

So, since I wanted the main concept to be that it could be used as a power amplifier and preamplifier, I thought about what to name the mode switch. The words "POWER AMP OPERATION" suddenly came to mind, so I suggested this, and It was adopted. The balance volume was also used as the L/R gain volume of the power amplifier, which became a niche feature. This was later adopted in NEC's A-10, and recently in the West River amplifier "WRI-βZERO".

The preamplifier section was a flat amplifier and a DC amplifier, but the excessive emphasis on sound quality here caused problems later, as I will explain later. The MC head amplifier was adopted with six FETs connected in parallel, but I was disappointed when I listened to the prototype of the head amplifier alone. However, it was unavoidable because it is not possible to do anything better than this at the moment. I strongly felt that future models would have to be compatible with MC cartridges in a different way. At the very least, FETs did not match the MC cartridges because of their vague sound quality.

In the meantime, the prototype was completed. It was a huge amplifier with a width of 480 mm, a panel height of 180 mm, a depth of 450 mm, and a weight of 28 kg. I thought that it would be a great amplifier. However, I felt that not many people would be able to put such a huge amplifier in their listening room.

A prototype of the unique tuner TU-X1 has also been completed. This was huge because it used the same chassis. What's unique about it is that it has two separate dials for AM and FM, so even if we can't expect it to sell well, it's sure to be a unique tuner. Also, a friend who does live recording introduced me to a Yagi antenna, so since it's a high-performance AM tuner, we decided to develop and commercialize an antenna specifically for AM. This was commercialized in a short period of time. It was probably the first and last AM antenna accessory in the hi-fi component industry.
 
21st installment: AU-X1 troubles

Release date draws near

It was so big and heavy that it was extremely difficult to design, prototype, consider, adjust sound quality, and check. I thought that such a large and heavy integrated amplifier was the limit.

However, I was surprised to see that other manufacturers released large integrated amplifiers after this. The late Mr. Nagaoka wrote in an audio magazine, "Japanese companies will not do it unless other companies do it, and if they do it and are successful, they will follow suit." Government agencies are probably even worse. They will not do it unless there is a precedent. After all, the best way to protect yourself is to avoid trouble.

The AU-X1 was gradually completed, despite the difficulties. We asked critic SO to listen to the sound quality test of the mass-produced prototype. He said, "It's better than the D907! It's amazing! There's nothing else to say, but if I had to say one thing, it's too loud." I was very happy and went back to the office in ecstasy. In order to further improve the sound quality, we pushed it to the limit of stability. At a quality meeting, the reliability department said, "There are some stability problems," but it passed.

Major problems in the early stages

There were no particular problems with the first mass-produced lot. I breathed a sigh of relief. However, about three weeks after the release, reports of amplifiers breaking down started coming in one after another from the service department. The symptom was that no sound would come out even when the power switch was turned on! The problem occurred in the Kansai region, and not at a retailer, but at a user's home.

I felt a great sense of responsibility. However, thinking about it calmly, the power supply conditions in the 60Hz region were better than in the home of an audio store (audio stores have poor power regulation due to octopus-like wiring). This means that in a 60Hz power frequency, the performance of the power transformer is actually 20% better than in a 50Hz region. This means that rush current is more likely to flow when the power is turned on.

In general, when electrical equipment is turned on, it suddenly goes into full operation like an airplane taking off, so this is the most dangerous moment for an amplifier.

It seems that the hypothesis that the cause was oscillation when the power was turned on was correct. At that time, there were no digital oscilloscopes like those available today that can capture momentary dynamic behavior, so it was extremely difficult to analyze the cause. Just when I was in trouble, TD, one of the developers of the diamond differential circuit, offered to help me. The R&D department to which TD belongs has the latest measuring equipment, a waveform memory analyzer by Nikole (an overseas measuring device) that is the prototype of today's digital oscilloscopes.

When I measured it, I found that a slight oscillation was observed in the line amplifier in front of the power amplifier only at the moment the power was turned on. This concern reminded me of the fact that I had made the phase compensation capacitor as small as possible when examining the sound quality. A fellow engineer advised me to be careful, but I left it as it was because there were no problems in the quality assurance test. However, thinking back, the test at that time was done with a 50Hz power supply and was not checked with such a state-of-the-art, high-performance measuring device.

I thought that this was my responsibility. To deal with the problem, I immediately changed the capacitor to a value that would make it stable. However, there is no other way to fix something that has already been made and sold. The service department was supposed to clean up such defects, and I felt bad about making them clean up after it. Since I was close with YS from the service department, we went on a business trip together to Osaka, where many cases of this kind occur. We visited the customer's home, apologized, took the device back, and worked on repairing it at the repair bench in the office. The diamond differential circuit has a strong driving capacity, so once an abnormal signal is input, current flows rapidly in a short time, and everything after the Darlington stage is destroyed.

We also found that a multi-emitter type TR with a high Ft is prone to destruction when a large transient current flows, as current concentration occurs somewhere in the multi-emitter. Furthermore, the higher the power supply voltage of a transistor, the lower the current capacity, so it becomes even more prone to destruction. If you connect these parts in a bridge connection, you can lower the power supply voltage even with the same output, and it becomes more resistant to large currents. This may have been one of the hints for the development of X-balance in later years (four years later).

Well, instead of worrying about repairs, all you need to do is replace the differential push-pull and all three Darlington stages, and it will be fixed. However, the AU-X1 was big and heavy, so I had to remove the hood, take out the heat sink, and replace the semiconductors. Fortunately, the serviceability was good, so I was saved. I stayed at the Osaka sales office for a week and worked day and night on repairs. The local serviceman, unable to bear to see me working on a business trip from Tokyo, also helped me out as best he could. Somehow, I was able to put an end to the commotion in the Kansai region. Problems were also starting to appear in the Kanto region, so I spent about 30 days helping to repair the AU-X1 that had been brought over to the service department. When I helped with the work of other departments, I felt the pain and difficulty of the work, and it was a reward for me to learn this with my own body. At that time, the thought crossed my mind that it would be bad if an amplifier using a diamond differential circuit did not have a light current limiting circuit. This became decisive when I worked on a professional amplifier, which I will describe later.

In the end, sound quality is very important for an audio amplifier, but if it breaks or has an accident, there is nothing you can do. I learned first-hand that the manufacturer's responsibility is to prevent breakdowns and accidents. First of all, they occur in unspecified numbers and in unexpected usage environments. Whenever I see recent accidents involving Paloma gas, Panasonic warm air heaters, and rechargeable batteries, I am reminded of the seriousness of this issue. Since WR amplifiers and my brand of amplifiers cannot be subjected to rigorous reliability tests like manufacturers can, I use my past experience and track record to ensure that I do not do anything dangerous, and I also try to understand the state of the people who purchase them. That is why I cannot be proactive in selling through retailers. The only one who sells them is Sound Heights, but I always check with the buyer and make sure I am available to follow up at any time.
The importance of safety and its drawbacks

The audio industry has been lackluster in recent years. Some say, "It's not profitable, so we can't do it!" However, there have not been many new technologies that are interesting or topical lately. The reason for this is the incident that I introduced this time, which is a lesson in the past. Once a problem occurs, the damage will be great, such as recalls, free repairs, and factory line stoppages. The responsibility falls on the development and design department. In some companies, the responsible department bears the accounting burden of the damage costs. This is unbearable for the head of the department. He ends up telling his subordinates not to cause trouble. Designers who are already busy (especially in recent years) lose the motivation to realize new things and new ideas.

This is because new technology always has side effects. In recent years, it is sometimes difficult to change not only the circuit method but even the circuit constants. This is because if you change it, you are forced to prove whether it is okay.

This will make design work a 3K job, and there is a risk that engineering talent will gradually disappear. In fact, there are not many mass production engineers in the United States. Will this job be done by China in the future? It is a sad thing.

In this series, I will write about more painful experiences. Even now, it is a bittersweet memory.

Posted on December 17, 2006
 
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Part 22: Commercialization of the Limited Edition D907

Things Left to Do with the D907

The AU-X1 troubles were somehow resolved. It was heavy, big, and difficult. It was a high-priced pre-main, and it had just been released, so it was a relief that there were only a few units. There were surprisingly few problems at the dealer. The dealer had an octopus-like wiring, so it was fortunate that the power regulation was not good.

Meanwhile, 1979 was over, and the D907 was in its second year since its release. It's nothing special now, but at the time, audio was so hot that new products were released every year.

I thought about whether there was anything that could be talked about, anything left to do with the D907. It was possible to some extent to assume that it would be better to make the chassis non-ferrous, both electrically and in terms of sound quality, in terms of the flow of dirty components such as ripples into the ground line and electromagnetic noise. Some American-made professional amplifiers use aluminum chassis. The sound quality of the aluminum chassis amplifiers is similar to that of aluminum (sorry for being abstract), and I was not satisfied with this either. So I had them make a prototype using copper. This is natural and very good. I immediately consulted with YH, the leader of the mechanical design team, about using copper. He immediately said, "What a stupid thing to say! You have no cost consciousness at all!" However, YH changed his mind and said, "We can copper-plate the chassis!" Copper is always used as a base when plating because of its tendency to ionize. I asked them to make a prototype of a copper-plated chassis.

After a while, the copper-plated chassis of the D907 was completed. The exterior was easily stained by fingerprints and other stains, and it seemed unlikely that it could be commercialized as it was. Anyway, I had the factory assemble the D907 using this chassis.

When I listened to it, it certainly sounded powerful but also very smooth, and I felt that it had an elegance that had not been said much about the D907.

We had the people involved listen to it. It was very well received. It would be a waste to leave it at that stage! The D907 has only been on the market for a short time. After much deliberation, we decided to release a limited edition version. What exactly does "limited" mean? Some people in the company asked. We decided to limit the number of units produced.

Just as we were pondering what to do about the exterior and cosmetics, TM-san, who had just returned from a distributor in Belgium, joined our team. He gave us his opinion, "From now on, it's wood cabinets! They blend in with the room, and if you do that with the Macintosh, it adds value!" I see, the D907 has a shielded case inside to shield each part, so there was no need to worry about the bonnet being made of wood.

Mr. O, the designer who has worked on the 607/707, immediately drew a design. This was quite cute. He showed it to his superiors and got an excellent evaluation. We decided to make a prototype bonnet right away.

What should the model name be? The appearance of the AU-D907 Limited

The model name was decided without anyone's help. Then, we had a meeting with the PR department to decide how to introduce it to the market. In conclusion, the PR department proposed to make something like a newspaper for the D907 Limited and distribute it to dealers and to put copies of it in audio magazines. However, even audiophiles would get bored with a hardware approach, so we wanted to approach it from a human perspective. MT, who was the PR manager, said, "Let's hire a celebrity!" We didn't have much of a budget, and we were worried about who to hire, but we decided to hire Tadao Takashima.

MT and I went to Tadao Takashima's house together. Of course, we brought the amplifier with us. We were shown into the reception room, and his wife, Kayo Sumiko, made us coffee. Their sons, who are now independent, were still slightly overweight boys in elementary school. His wife said, "I was worried that my sons were getting a little overweight." Tadao Takashima was a former drummer turned actor, so he knew a lot about music and responded to my questions about audio. I asked him to give me a variety of comments, and somehow I was able to get enough comments to fill out the advertising paper. When the interview was over, Tadao Takashima said, "Japan Thermal Engineering Co., Ltd., the company I appeared in a commercial for, went bankrupt, but your company is fine, right?" I thought that was disappointing. However, 20 years later, Sansui stopped selling in Japan, and its stock price is hovering around a rock bottom of 25 to 26 yen. Tadao Takashima's words became reality 25 years later.

The selling point was the clean Grand Line. It was easy to get people to understand because the copper-plated chassis was visible.
Response after release

The electrical specifications of this limited edition were the same as the AU-D907, 100W + 100W (8Ω). The list price was 175,000 yen, 33,000 yen higher than the D907's 142,000 yen.

The response after release was amazing. I remember that the first batch was about 1,000 units, but they sold out in an instant, and the next batch was rushed.

Other manufacturers also seemed to be convinced by the copper plating concept, and one after another, models were adopted. You can still see amplifiers and CD players with copper-plated chassis.

The copper plating on the prototype was poor, but the plating and chassis makers worked together to prevent dust from sticking, and the final process was a beautiful clear lacquer coating. I wanted one too, but I couldn't afford to buy one.

We sold out 3,000 units in six months, and the question arose of what to do about an encore. If we made too many limited edition models and they piled up, they would lose their value. We felt bad for our users and should have stopped production at the right time. In the end, we stopped production at 5,000 units. The stores sold out all the display models, and there was no stock left on the market. Naturally, the next model was guaranteed to continue with the copper-plated chassis.

Are you all aware of Sansui's development and release of professional amplifiers for the US market?

I will write about that story in the 23rd installment. It ended in a tragic outcome. My self-satisfaction and carelessness were to blame.
 
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23rd installment: Development of professional amplifiers for the US and their failures - Part 1

Longing for the professional audio industry

When I was developing 4ch stereo, I frequented recording studios, where I made friends with mixers, wrote papers for the American AES (Professional Audio Society), and participated in the American AES convention, so I was completely drawn to the professional audio industry.

I also thought that the true power of an audio amplifier is valued in being recognized as a professional amplifier. At that time, and even now, apart from amplifiers for SR, Japanese-made amplifiers are hardly used in recording studios. As NHK is obligated to use Japanese-made products as a rule, Japanese-made adjustment consoles (e.g. Tamura), power amplifiers (e.g. Accuphase), speakers (always Diatone, and recently FOSTEX as a result of blind tests) are made in Japan, but recording studios were mainly foreign brands, and I think that is still the case today. This is because Western music is a white culture, so the people involved (musicians, mixers) are not satisfied unless the hardware that plays it is their brand. This may sound like I'm saying that it's the fault of people who are obsessed with imported products. In fact, in the past, more than half of the products were not as good as imported products in terms of overall quality. (It's hard to say now, though...)
Overseas research for a strategy to enter the professional audio division

We have meetings with the overseas sales department twice a year within the company, where we discuss product strategies. With my boss's permission, I proposed to enter the professional audio division of Sansui amplifiers at the meeting. At first, they didn't take me seriously. At the second meeting, they said, "If you say so much, we can do a local survey first."

So we decided on a good area to survey, and as expected, LA was the top of the recording business at the time.

During the 4ch stereo era, MY, a senior employee who was stationed in LA on the west coast of the United States and had connections with record companies and FM companies, accompanied me on my investigation.

I set off for LA with MY right away. MY told me that the road under the Beverly Hills sign, which is often seen on TV, is called Studio Street, and there are more than 10 recording studios lined up there.

MY made an appointment for me at a famous recording studio in LA.

First, we visited A&M Studios, which became a main label overnight with Burt Bacharach and Carpenter. A&M Studios was originally a recording studio built by Charlie Chaplin, and the main studio is very spacious and has a high ceiling. It had a rich resonance, and I thought that this was the source of A&M's bright, clear sound. It used a 38cm woofer modified from an Altec unit made by Mastering Ring Lab, and a 39cm coaxial unit. He was kind enough to play a tape he had just recorded and let me listen to it. The sound was clear, but the bass rumbled when it should have. This may have been due to the dry air of LA, but I had to say that the sense was different from that in Japan. (Later, he recorded the charity CD of "We are the world" in this studio, produced by Quincy Jones.)

At the end of the 1970s, while Japan was still using 16-channel multi-track recording, 24-channel multi-track recording was already widespread in America. There were almost no digital effects. At that time, there was a lot of interest in analog records, so I could sense that he took plenty of time to record and made the work until he was satisfied. For example, he said that he rented out the studio for more than 60 days to record Weather Report's albums.

As for the recording equipment, the speakers were not JBL. They had created the Mastering Lab's twin system and their own multi-way speaker system. None of the studios had the JBL 4343, which had sold explosively in Japan. It was estimated that over 90% of the speakers were for Japan. The Mastering Lab and Westlake Studios had built speaker systems to suit their studios. As expected, they placed the greatest importance on reproducing the low frequencies, especially the mid-low frequencies that are the base of music. The speaker system was a 2π space type that was embedded in the wall of the studio. There was no place where it was installed away from the wall.

As for the power amplifiers that we were interested in, McIntosh, which is familiar in Japan, was for consumer use and was not used at all. Crown (Amcron in Japan due to trademark issues) was the most commonly used, and while Crown's amplifier circuit was a bridge configuration, its selling point was a special circuit that would not break even if one side of the output was earthed. Next were the now-defunct BGW brand and phase linear.

I asked people at the studio about sound quality, and they emphasized that it should not break, and that if it does break, they can be serviced immediately, which increases the uptime of the studio. I then asked how much power they wanted, and they said, "Maybe over 300W?" They were concerned that the speaker would work without problems even if the impedance was 2Ω or less. Indeed, even if the woofer had a spec of 8Ω, the minimum impedance was about 3Ω, and there were some units that were powerful because of this.

Apart from the power amplifier, a parametric equalizer and a compressor were always installed as processors. There was also an EMT iron plate echo and an AKG spring reverb. I thought that Sansui could make a parametric equalizer. The parametric equalizer was a 4-band device that could perform variable frequency peaking and shelving. It was later commercialized for consumer use in Japan, but it never became as popular as the graphic equalizer and disappeared. I still think that it is really convenient when you use it, but... I visited the mastering room and cutting room of a record company (I think it was Motown Records) to see if there was a need for phono equalizers in the professional industry. They were using equalization during cutting. This explained why there was a difference between Japanese and overseas versions. At the time, master recorders were mainly AMPEX and Scully, and STUDER was hardly seen.

Therefore, the need for phono equalizers was limited to monitoring test-cut lacquer records, and there were not many of them. Rather, there was no other way than to hope that they would be adopted by record companies and that Japanese audiophiles would buy them because of their reputation.

I visited FM and AM stations in LA to see if there was anything for broadcasting stations. Broadcasting stations did not need large monitor speakers, the adjustment desks were small, and the record output equipment was inexpensive. A JBL 4311 was quietly playing on the broadcast output monitor.

I also visited Westlake Studios (which became well known for its speakers). The maintenance manager was Japanese, so I asked him a few questions. He said, "I tried using the equipment Yamaha sent for professional use, but it broke down a lot and was a problem." Yamaha took complaints like this into consideration, and in later years Yamaha power amplifiers came to dominate the Japanese SR (PA) market. I think this kind of activity bore fruit. I felt that you can't succeed in the professional market if you don't make a firm decision, if you don't enter it carelessly.

During my three-week business trip to LA, my product strategy was solidifying. When I got back to the office, I reported on the trip. As a result, the company took action. But it didn't end well.

So, please read on next time.
 
24th installment: Development of professional amplifiers for the US and their failures - Part 2
Model planning and development of the B-1, P-1, and E-1

Finally, the company decided to enter the professional amplifier genre in the US market.

The US branch hired personnel from the professional industry to be in charge of sales engineering work. So the decision of what kind of model to develop was left mostly to the local sales engineers and me, who went on a business trip to the US.

First of all, power amplifiers were the most likely. At that time, recording studios were large systems that were built by hand, and most were channel amplifier systems. Three power amplifiers were sold for the monitor system. They were required to have power of 300W or more, and to be tough enough to withstand a 4Ω load. This made it difficult for the amplifier to dissipate heat, but forced air cooling with a cooling fan was allowed. (This was not allowed for home use because people were concerned about the noise of the fan. McIntosh power amplifiers are equipped with fans, but I have never seen or heard of the fan running for home use.)

In today's studios, it seems that they monitor quietly with a small Yamaha NS-10M speaker, but in American studios at that time, they monitored and played back at a thunderous volume. Also, since the impedance of the speaker unit varies depending on the frequency, it was required that the protection circuit would not operate even if the music source was 2 ohms.

Previously, Sansui had a 300W amplifier with an autoformer called the BA-5000, which was modeled after the McIntosh power amplifier. It was tough and had a good sound quality, but it was too big and heavy, and McIntosh amplifiers were treated as home amplifiers in the United States, so this method could not be adopted.

Therefore, a diamond differential circuit was adopted, and the power stage was configured with three parallel large transistors with a collector loss of 200W.

The problem was in the protection circuit. In a demo of Crown Amplifier, a top brand of professional power amplifier, they put out maximum power and shorted both ends of the output with a hammer, and the amplifier still did not break. This is called a short test, and even today, audio manufacturers short the output at about 10V output, and it is fine if the amplifier's protection circuit works and does not break.

If the output is shorted at 300W/8Ω, it means shorting an AC voltage of about 50V. A tremendous current flows inside the amplifier for a moment.

We postponed such issues and started designing a professional power amplifier that would output 300W. Of course, the input was balanced. This professional power amplifier was named the B-1.

The next model was an effector, and we decided to commercialize a parametric equalizer. We decided to start designing it with a four-band band, modeled on the products of the ORBAN PARASAUND brand, which was popular at the time.

The internal parts, especially the volume, were not made in Japan, but were custom-made by Allen Bradley, ordered from the US and installed, so all the parts we wanted were OK. The Canon terminals were also made by Switchcraft, an American company.

A small module was developed for the unit amplifier, a key part, and it was designed to operate with a power supply voltage of ±30V or more, and output was able to be +30dBm or more without distortion. This model was named P-1. Naturally, the input and output were balanced transmission.

The next model was a phono equalizer for professional use, but although there was no chance of it selling well in the US pro industry, the calculation was that if it was well-received in the US as a professional product, Japanese enthusiasts would buy it. It was a mask similar to EMT's new product, a professional phono equalizer, to be released in 2007, which was compatible with three phono circuits and was operated with an illuminated push switch, just like professional products. This was named E-1. The output was a balanced OUT. The arrival of a key person and the collapse of the project

Three models of professional amplifiers were to be commercialized, and the design progressed smoothly. When it came to the mass production prototype stage, a sales engineer from the United States came to Japan to check them together. His first name was Kevin.

He was also going to be active as a sales manager, so he seemed full of expectations. He had no particular objections to the E-1 and P-1, and said that there were no problems, but that sales would not increase that much. As predicted, he planned to increase the reputation in the United States and have Japanese enthusiasts buy them.

The main target was the power amplifier. He was convinced by the electrical characteristics and sound (sound quality). Finally, when the maximum power was produced, he said he wanted to do a short test. This was not a big concern because it was shorted at 10V output, which is the company standard, and the mute relay was activated to protect the amplifier.

He played the JBL speaker loudly with the tape he brought with him, and when the volume reached a deafening level, he shorted the end of a thick speaker cable. At that moment, smoke rose from the power amplifier. The protective relay tripped. What was that?!

When I checked, I found that the power transistor was broken.

When I tried a similar test with an old BA-5000, the matching transformer limited the current and the front-stage drive capability (slew rate) was also decent, so it didn't break.

However, in the case of the B-1, the diamond differential circuit in the drive stage had an extremely high slew rate, so I found that it was driven too hard before it destroyed the power transistor. The protective relay's operation time was about 1 ms (1/1000 seconds), so it was too late. I concluded that it had somehow held up in the conventional short test. To deal with this situation, it would have been effective to add a current limiting circuit to prevent the power transistor from being destroyed, but a normal current limiting circuit would sacrifice sound quality, so we just couldn't bring ourselves to take such measures.

Kevin insisted that a power amplifier that would break due to a short circuit at full power would not sell, and the Japanese side tried to speed up the response speed of the relay, but he was still not satisfied. After returning to Japan, he quit Sansui's American branch.

There was no one at the American branch who was familiar with the professional industry, so there was nothing they could do. The Japanese side didn't know either, so they didn't scold us, but I once again regretted my lack of understanding of the professional industry. The other P-1 and E-1 were commercialized without any problems. However, since we couldn't sell them, the product was left in limbo. We had no choice but to quietly sell only the first lot in Japan and then stop selling the rest.

As a product, the P-1 in particular was excellent, with amazing performance and sound quality. I felt sorry for everyone, from the materials department that had spared no effort in importing parts from overseas to the service department that had produced the troublesome service manual.

After a while, the three electrical designers for the B-1, P-1, and E-1 announced that they were leaving the company. There was no way to stop them, and it was a huge loss for both the company and me, especially for K.K. (who is still in contact with me today), who was in charge of the design of the P-1.

This project, which lasted for about two years, ended miserably. I still have the circuit diagrams for these three models safely stored in my files.

Since then, Japanese-made professional amplifiers have never made it into the American studio market. I think it was very admirable that RAMSA (Panasonic) was used for the stadium PA at the Los Angeles Olympics.

Even in Japan, foreign-made products are becoming more common for studio use, and Yamaha, RAMSA, and TOA are becoming more common for SR/PA. In this field in particular, lightweight, high power, and low price are required, and sound quality is secondary. With the rise of digital (D-class) amplifiers, 1kW power is not uncommon these days.

In the meantime, it's time to bring out a new approach to integrated amplifiers.

Please look forward to the next article.

Published February 17, 2007

Correction May 15, 2007... The person in charge on the American side during the development of the professional amplifiers was Kevin, not David. I remembered this when Mr. Susumu Takahashi pointed it out. We apologize for the mistake and will correct it.
 
8th installment: The beginning of the development of unique speakers and efforts towards amplifiers

Development of the unique speaker system
Around 1974, when the development of 4ch stereo was starting to die down, a veteran speaker developer and designer told me the following story. "Why don't speakers for hi-fi produce lively sound?" I immediately replied, "Is there such thing as lively sound?" in a half-denial tone. "Listen to the sound on TV and radio! The sound is natural and comes out effortlessly!" This person also played musical instruments and was an engineer who was always conscious of problems. If you listen to the sound of TV and radio in this way, it certainly feels like it comes out effortlessly. In particular, when listening to the voice of an announcer on a hi-fi speaker at that time, it often sounded like a deep voice, as critic Okihiko Kanno often said. The TV and radio speakers were not expensive, and their placement was not particularly considered. However, they were rear-opening. With this type of speaker, the sound comes from the back of the speaker (in opposite phase), so low sounds cancel each other out at the front and back, causing attenuation.

I recently reconfirmed that when listening to vocals with small, flat speakers that use felt to secure the speaker unit (previously introduced in Radio Technology, and the results are in the February issue!), you get a thrilling sense of realism, and the vocal positioning sounds like a live voice singing on stage! This is probably because the sound from the back reflects into the room and blends well with the sound in front. I think that flat baffled condenser speakers are highly rated for this reason.

There are many types of speaker system radiation systems depending on the purpose, claim, and preference, and it is not possible to say that one is better than the other. Each has its pros and cons.

For example, at one time, many recording studios had systems that were embedded in the walls. This is intended to radiate in 2π space, and there is no diffraction phenomenon of the speaker cabinet. However, the sound radiation becomes narrower. The tone-zoile type used for professional use limits the directivity, so within a certain angle, the sound jump (reach) is better. McIntosh SP is famous for the high end. Back-loaded horn systems increase efficiency, but there are cases where the back and front sides mix and the area around the switching frequency is annoying, and the size of the horn becomes very large when trying to reproduce low frequencies, so there were TANNOY's Autograph and Clipush that used the wall of the room.

The bass reflex method also has some of these problems. So, is a sealed method that surrounds the sound from the back with a cabinet good, but in many cases the sound becomes trapped and does not sound generous. That said, users of this method are very few in number, so it is not decided on omnidirectional speakers. There are also methods such as Bose SP that place many SP units on the back and use the reflection in the room.

It has problems with speakers and greatly affects the character of the audio system.

With these thoughts in mind, I decided to consider the proposed content. The gist of the proposal was that they wanted to improve the high-frequency dispersion. They said that the high-frequency unit was planned to be a cone type (also called a direct radiator) that has a large degree of design freedom. Since the frequency of a high-frequency speaker unit is high, even if it is covered with the back of the cone paper, it will only take up a small volume, and it is 100% designed that way. Since the diameter of the cone paper is small, the dispersion is quite good when measured, but it becomes narrower as the frequency increases. As a speaker engineer, this is natural, and it is not normal to have problems. That may be why the progress of speakers is slow. The Bose rear-radiating system was commercialized and introduced to Japan around this time, but speaker systems with dedicated equalizers had not yet been accepted in Japan.

Now, I was instructed to look for technical and acoustic benefits in preparation for commercialization, so I began to consider it. I was told to achieve this in about six months with my trio, a young mechanical engineer from the mathematics department and myself.

First, I opened the back of the cone tweeter, attached a baffle plate, and measured the dispersion in an anechoic chamber as an open-back type. As you know, it draws a figure-of-eight characteristic. It certainly became the characteristic that was just as in the textbook. However, it is not interesting to just place the speaker on a rotating table and rotate it to measure the directional characteristics. So I placed two of these tweeters in a stereo listening arrangement, bought a mannequin and attached a high-performance microphone to the ear part. I played a sine wave with frequency as a parameter to the tweeter, and stood 1.5m away from it to measure the sound pressure at both ears and the phase difference between the two ears. My experience in researching 4ch stereo was useful here.

Since there is no reflection in the anechoic chamber, the difference in the spread of the direct sound could be measured well. I also measured it in the vertical direction, and obtained a reasonable figure-of-eight characteristic. Since it is difficult to commercialize a simple open-back type due to the space in the cabinet, I decided to guide the sound from the back of the tweeter in three directions and back-load it on the left, right, and upper three sides. A young member of the team, who is a mathematician, quickly did the horn calculations for this unit. When we measured the spread of this unit again with a dummy head, the directional characteristics spread nicely, and the maximum sound pressure did not occur directly behind the unit as with a flat baffle. In actual listening, the unit produced a comfortable live feeling that could not be obtained with conventional closed tweeters. When I played it for my boss, he asked, "What about in an ordinary home?" At the time, Sansui was renting a vacant house with furniture in Karasuyama, so we brought it there, compared the sound, and were convinced.

So, a planning meeting was held to decide what the selling point of the product should be when it was commercialized. We reported on the progress of our investigation and insisted that the selling point should be excellent dispersion. Two years ago, JBL released a series named "Aquarius" that sold the spread of sound, but it did not sell at all. Jazz is probably twice as impressive if the sound does not spread too much and comes out crisp. So we decided to look for a vertical (audio) point.

From then on, when we think of jazz, we think of crispness! So we decided to study transient response. We added a tone burst signal to the speaker, picked up the sound with a microphone, and finally achieved an outstanding rise characteristic by combining the shape of the horn and the vibration system of the speaker unit. We named this method the Linear Motion method and made it the LM series. However, even if we can make a tweeter, it is not a complete system without a woofer. From now on, the veteran engineer mentioned above took charge and the product was released as a 16 cm, 2-way and 20 cm, 2-way speaker system. It was 1975 (s50). The theoretical background was written in an AES paper and published in the United States. In this way, it is inevitable to a certain extent that it will be a strong support in Japan, where white worship is strong, because it is a tool of Western music. The woofer had a fixed wave edge like Altec, so it was crisp. This product became a hit product that year. I still have the unit in my hands as new.

Our research team was unexpectedly recognized at the end of the year and received a prize. I remember that I didn't have money at that time either, and I used it to buy a coat. There was internal conflict in the company, and this LM speaker system ended after a year and a half, and no successor was released. After that, Sansui speakers tried various things such as sealed, bass reflex, and new materials, but they could not catch up with Diatone, Pioneer, Onkyo, etc. The atmosphere in the company that JBL was enough for speakers was also a negative. Because it was the time when JBL's 4343 was selling like crazy.

The beginning of amplifier development

In 1976, the 4ch stereo development department was officially disbanded. I was interested in amplifiers and was doing it on my own, so I decided to move on to amplifier development and planning director. At that time, Sansui amplifiers were sold as integrated amplifiers such as the AU-9900, 7900, and 6900, and I think they were on the serious path of audio, with 3-band tone control, decibel linear volume, etc. However, sales had been declining compared to the AU9500 era. At the time, Columbia (now Denon) pre-main amplifiers were highly rated and sold well. Pioneer's SA8800 series was also selling well, but this amplifier had an outstanding cost-performance ratio due to the way materials were spent, which left other companies in a lurch. There was also a rumor that the parts were made cheaply with cash, not with bills. Trio (now Kenwood) sold reasonably well with the catchphrase that two transformers sound good.

Anyway, going back to Columbia, there was information that Mr. U, the second bassist of the Jazz Big Four (Hachidai Nakamura, George Kawaguchi, Hidehiko Matsumoto, Mitsuru Ono), was involved in deciding the sound. When I bought a Columbia amplifier and listened to it, it certainly sounded good with jazz. At that time, there were still great jazz musicians alive in the United States. Records such as Blue Note Records were gaining popularity.

At that time, the speakers for the listening test at Sansui were Tannoy III LZ, which had a good reputation for classical music. And I was examining the sound quality mainly with classical music sources. Sansui was the import agent for JBL, and there were many JBL users in the company. Critics also wrote in audio magazines that Sansui amplifiers should be suitable for jazz.

So, how will they recover? Please look forward to the next article.

Published on April 16, 2006
 
No. 9: Development and commercialization of DC amplifiers

In the spring of 1975, while I was taking over the commercialization plan from my predecessor, I noticed that the next generation of integrated amplifiers had tentative model names, AU-607 and AU-707.

The font was well balanced, and it sounded fresh when I read them.

I thought this model name would work.

The problem was the content of the amplifier.

At that time, the first stage of the circuit was a differential configuration, but the second stage was a normal bootstrap amplifier, and the summing point where the NFB returned to the other side of the differential circuit had a resistor with a series capacitor attached, so the NFB became deeper as the frequency went down, and the low frequencies dropped, making it a so-called AC amplifier.

Meanwhile, amateur audio magazines such as MJ were starting to publish prototypes of DC amplifiers.

Manufacturer engineers generally looked down on amateurs, either ignoring them or treating them with contempt.
(The background to this is that at one time, a magazine company asked me to measure an amplifier made by an amateur, and when they measured it, it was oscillating and unstable, and it was not suitable for use as an audio amplifier. I was ingrained with the idea that I could not deal with manufacturers' engineers!)
So, what about the passion, motivation, and awareness of audio among the engineers who joined manufacturers? At any company, about one in ten engineers were enthusiastic?
(Now that audio has become a minority, I think people who like it are in charge, but veterans have retired, and in terms of analog technology, the results are that points that cannot be expressed by measurement cannot be passed on.)
This is true, because it is what I felt after leaving Sansui and being involved in design for various audio companies.

Now, looking overseas, the Face Linear 700A was sold as a professional amplifier, and the Ampzilla brand was sold as a DC amplifier configuration for high-end use.
The Ampzilla power amplifier was exhibited at the AES Convention (LA) venue, and I had a hard time obtaining something that looked like a circuit diagram.
Although it worked as expected, there seemed to be a problem with DC stability in actual use.
In fact, Ampzilla had many breakdowns, and importers had a hard time with it.
The JBL SA600 integrated amplifier had a completely unique and simple circuit configuration, but it was troublesome for manufacturers to increase the power supply of the three-stage Darlington by 0.6V each as expected, so no one adopted it.
All manufacturers adopted the T-circuit that connects the emitter resistor of the Darlington stage directly to the Nch-Pch without passing through the midpoint.
In addition, this amplifier was an inverting amplifier, which Japanese manufacturers did not like.
The polarity of JBL speakers is opposite to the others, so if you use this amplifier, if you use the same + as the others, the cone paper will come forward.
I tried to make a prototype using the JBL amplifier circuit 20 years later, and it produced a unique sound and was stable.
This JBL circuit was also called an inverting DC amplifier.
In the fall of 1976, the big task was to bring a new amplifier to the market and make up for lost ground to Sansui's amplifiers.

There wasn't much time to spare.

I believed that the true value of an amplifier lay in its circuit configuration, the components that make it up, and the structure (layout) that it takes, so I first struggled to decide what the circuit configuration should be.

While talking about various things with my boss, even though he didn't know much about amplifiers, he suddenly muttered, "Let's go for a DC amplifier!"

I thought this was a message from heaven, even though there were various issues with putting it into practice.

With conventional amplifiers, the amount of NFB increases as the frequency goes down, and the amplifier gain decreases, and eventually the gain almost disappears at around 1 to 2 Hz, and in the DC range the gain becomes zero, and no DC components are emitted from the amplifier's output.

(CD offset is a separate issue) A DC amplifier configuration means that the amplifier amplifies even in the DC region, so if the semiconductor elements that make up the amplifier drift in the DC region, DC (direct current) will come out of the amplifier and the center position of the connected speaker will shift.

In severe cases, the speaker's cone paper will move forward or backward.

This is harmful.

It is possible to reduce DC by increasing the amount of NFB and suppressing the amplifier output, but this will also reduce the amplification level, so there is a limit to how much you can do.

Theoretically, most of the amplifier's DC fluctuations are determined by the first stage of the amplifier, so if the operation of the first stage is stable, the problem will be solved.

In that case, the first stage device is important.

Transistors that are prone to drift due to fluctuations in the amplifier power supply and temperature changes have been problematic.

In that respect, FETs can be made quite stable by designing the drain current at the crosspoint (when set to a certain drain current, drift is significantly reduced in response to voltage and temperature changes).
Incidentally, in the WR amplifier, a stabilized power supply is installed to prevent power supply fluctuation drift.
At that time, there was nothing that could be used for the dual FET, and we were in trouble, but when we consulted Sony, they said they would make something somehow, but semiconductors cannot be made so quickly.
So, since the FET called 2SK43 was excellent, we decided to make it into a dual type.
Somehow, we managed to make it in time for the release, but the prototype was made by gluing two 2SK43s together with glue.
The completed dual FET was a 2SK97, and it is still sold at a high price at Wakamatsu Tsusho in Akihabara (about 1,800 yen!).
Of course, similar development was also done for transistors, and Mitsubishi was enthusiastic.
In particular, Mr. Y (currently the head of the semiconductor development sales department at Renesas) visited Sansui many times, listened to the transistors repeatedly, and created a transistor with good sound.
The masterpiece among them is the dual transistor 2SC1581, which is used in the first stage of the WR amplifier.
I didn't know that much at the time, but Kawanishi had selected a good device.

At that time, DC amplifiers meant direct coupling, and FETs, which eliminated the need for input capacitors, became a selling point.

(This is where the times change, so I have mixed feelings about business.)

Two years later, I listened to a huge Mark Levinson 25W A-class amplifier in Segawa Fuyuki's listening room and thought it was amazing!

I looked through the circuit diagram and found that the first stage was made up of transistors.

I still think that TRs tend to produce clear sounds, while FETs tend to produce spatial expressions that express a sense of depth.

Published on April 16, 2006
 
Part 10: Searching for commercialization of the AU-607

What were the manufacturers doing at that time? Trio (now Kenwood) had just released the KA-9900 DC integrated amplifier with a three-stage differential amplifier circuit. There were none in the ¥59,800 price range, which was said to be a fierce battleground.

Sansui had fallen behind in this price range, so they wanted to catch up at all costs.

As usual, Pioneer's SA-8800II was selling well. In 1976, there were more than 2,000 audio retailers nationwide. Department stores' electronics sections and supermarkets' electronics sections (especially Daiei's audio section had huge sales). It was a time when an integrated amplifier could sell for about ¥3,000 per month if it was a hit. By the way, the audio market has shrunk to about 300 units per month these days.

I wanted to make something that I was satisfied with, and since I was a professional, I couldn't do anything if it didn't sell. If I made a good product but it didn't sell, I would only be satisfied and would end up not receiving a salary.

When I calculated the cost, I found that 59,800 yen was too difficult and would result in a loss. There was also a strategy to take a share of the market even if it meant a loss, calling it a strategic model, but this would not last long. The company's strength is already being drained by the price war for DVD recorders. Is this just how the electronics industry is?

So I decided to set a new price of 69,800 yen and compete in this price zone.

Now, going back to the development of the amplifier, the big problem was what to do with the entire circuit. This was because no one at Sansui had ever worked on a DC amplifier. The boss decided that Mr. T, who had been the chief engineer for the development of 4ch QS stereo, would take charge of it.

Mr. T had never worked on commercial audio amplifier design, and had been involved in development work since joining the company, so there were concerns within the company about developing a prototype circuit for a power amplifier to be used in mass production design.

However, Mr. T steadily continued his development, and by the beginning of 1976 (S51), he had created a prototype power amplifier. This circuit configuration was unique, a three-stage amplification configuration that combined a differential push-pull circuit with two stages of differential amplification. There was opposition to this circuit configuration from the company's technical department. Generally, with one stage of circuit, the phase shifts up to 90 degrees at the end of the frequency. With a two-stage amplification circuit, the shift is up to 180 degrees. With a three-stage amplification circuit, the shift is up to 270 degrees.

Oscillation in an amplifier occurs when the phase exceeds 180 degrees and the gain at that time is zero or greater. Therefore, it was common knowledge that a more stable amplifier can be made with fewer amplification stages. There was opposition to the idea that a three-stage amplifier is prone to unstable operation. However, Mr. T thought that there would be no problem if the constants were determined so that the phase and gain in the band would be stable for a stable amplifier. I was sitting next to Mr. T and we worked together on 4ch QS stereo, and I believed in his cleverness, so I supported him and asked him various questions, which I used as a learning experience for myself. Until now, Mr. T had believed that a certain amount of NFB, at least within the audible frequency band, would lead to uniform sound quality in the audible frequency band, based on the theory of a two-pole phase compensation circuit used in the field of automatic control. In other words, he thought that an amplifier that maintains stability by attenuating at 6dB/oct from around 100Hz, like an IC OP amplifier, was not desirable. I called this new method wide-range NFB. This basic method involves setting the first cutoff point near the upper limit of the audible frequency range in the calculation of the amplifier's open-loop gain and phase characteristics. This is called the first pole. If it is left as it is, the frequency characteristic will drop by 6 dB/oct, so the degree of drop will be insufficient and the stability will be insufficient, so somewhere it will be further dropped, that is, the drop characteristic will be 12 dB/oct, and this is the method of making it the second pole. Above that frequency, the phase delay will become too large, which will also deteriorate the stability, so the phase will be advanced from that frequency onwards. In this way, the gain and phase are controlled up to the high frequency range where the gain becomes zero, and the stability (margin) when NFB is applied is sufficiently secured.

At that time, scientific calculators had just become popular, so the stability constants were decided by cutting and trying prototype amplifiers.

The prototype machine that was prototyped according to the calculation results was stable. I still have the study materials. Normally, it was common knowledge that the distortion data of an amplifier deteriorates at high frequencies such as 10 kHz, but the results showed that the distortion at 1 kHz and 10 kHz was almost the same.

The next important point is where to set the amplification standard. For amateurs, it is often set at the power supply midpoint. Manufacturers vary, with Company A setting it at the amplifier's SPOUT point, Company B setting it at the input point, and Company C setting it at the power supply midpoint, with various ideologies. Starting with this model, since it is an NFB amplifier, the amplification standard is set at the first stage differential point where the NFB returns from the output and is compared with the input to produce the NFB effect. This point is called the summing point. Even if the electrical characteristics are the same, the sound quality changes considerably depending on this point, as I actually tried it out.

The output stage has to be low impedance, so a three-stage Darlington SEPP system was used. Kawanishi emphasizes that the instability of the SEPP circuit is the most important thing.

I don't know when Sansui started doing this, but they did put a small-capacity capacitor between the Darlington C and B, which other companies don't use. The recommended value was 33 pf.

In the AU607, a CR-based phase-advance circuit was placed in the first stage of the Darlington stage, and a resistor was placed between the E and B of the second and third stages to prevent instability. I don't think anyone paid that much attention at the time. Kawanishi also placed a small-capacity capacitor between the C and B of the first stage differential, but we had no idea about this at the time.

With this, the framework of the power amplifier section was complete. I listened to the prototype and was surprised by its fresh sound. For the monitor speakers, I used the JBL4320 without hesitation. I also wanted the JBL4320 personally. With my low salary, I couldn't buy a new one, so I got a used 4320 from the son of my mother's classmate, and I still use it, replacing the cone paper.

Now, it was up to us to commercialize it from now on. The important point for the amplifier was what to do about the power supply. At that time, Trio (now Kenwood) introduced the two-transformer system and was well-received, and the Sansui AU9500 also had a good reputation for its two-power supply system. The AU607 followed the Trio and used a two-transformer system. Using two transformers had the advantage of being less susceptible to influences from one channel, but the power supply fluctuation rate was relatively worse than with the single-transformer system, and I had experienced that the sound quality tended to be lighter. However, at this price range, if the technology did not materialize, it would be difficult to sell, so I was forced to adopt this system. Secretly, I had begun to think that if this model became a hit, the next higher-end model would have an even better power supply. However, when it comes to work, if it doesn't sell, my demands won't be heard, and before that, amplifiers were my livelihood.

Please look forward to the rest of this article, which will explain the process of making amplifiers at a manufacturer.

Posted on April 30, 2006
 
11th installment: How did manufacturer-made integrated amplifiers become products?

As soon as I started working on amplifiers, I realized that the quality of an amplifier, including its sound quality, comes down to the circuit, parts, and structure. It is essential to combine these elements well.

The basic power amplifier circuit and power supply method for the AU-607/707 were completed, so the next step was to design the chassis (mechanism). Before designing the chassis, the panel design must be decided. Until then, the image of Sansui amplifiers had always been a black panel with a metallic sheen, with the AU-111, AU777, and AU9500, giving it a rather rugged feel. I had decided to use a black panel this time as well, but the 9900 series was in a dire situation, so I wanted to do something about it. So I decided to have an external designer and a young designer who had just joined the company the previous year compete to create a design, evaluate it, and then decide. Of course, we decided on the functions to be attached to the panel and had them start the design. The external designer was excellent and created a design mockup with an extremely gutsy look. The work of young designer O-kun was extremely smooth, calm and elegant, something never seen before in Sansui. In particular, the sense of adding red lines to the knobs felt elegant and sexy. My boss praised young designer O-kun's design highly. I agreed, but the use of lever-type switches felt like an extremely three-dimensional accent. Even now, 30 years later, I think this design is the best we've ever done. The other day, I had a chance to call O-kun (now middle-aged), and when I told him about this, he said that he thought the same thing.

The work was then handed over to the person in charge of mass production design. In terms of structure, it is necessary to coordinate with the electrical design to determine how to lay out the audio signal lines from input to output, how to supply power, and how to communicate as much as possible between parts that generate electromagnetic waves, such as power transformers, and small signals to prevent interference and jumping.

Furthermore, it is important that the process flows smoothly on the assembly line. The way manufacturers do it is to have the board units prepared by installing parts outside the line or by subcontractors, pouring solder into a bath, and checking the operation of the units. The assembly line starts from the chassis frame. In terms of a car, this is like a monocoque body, and it is assembled, and then the amplifier unit, transformer, etc. are attached to it, and it becomes movable. Then, a functional test is performed, and if it is OK, the front panel is attached, the knobs are attached, and a functional test is performed again, and various functions are checked while listening to music, and the package is completed. The mechanical designer must design while imagining this. Serviceability is also important. If it cannot be disassembled smoothly for repair, it will be difficult to repair. In the factory, the production section checks and advises on serviceability, and the service section checks and advises on serviceability. It is common knowledge that an assembly line should be completed within 40 minutes at most. Incidentally, JBL amplifiers were the worst in terms of serviceability, and repairs were a nightmare. I even considered withdrawing from the amplifier business because of this.

By the way, the chassis had been made of unichrome or chromate-plated steel, but the AU-607 and 707 were boldly painted black. This is effective in preventing the chassis from rusting even after long use. Naturally, there were objections as this would increase the cost, but the policy was followed. In addition, the transformer was given a Sansui logo sticker, and a shield plate was applied inside to ensure complete electromagnetic shielding.

By the way, the flat amplifier of the preamplifier did not use SEPP in the output stage, but instead used a simple collector output circuit (the first differential stage has a constant current circuit), and there was no B-C capacitor in the first stage, but this was in very good agreement with the idea of the WR amplifier. Although the idea of negative resistance advocated by Kawanishi was not there, the instability of the SEPP circuit at ultra-high frequencies was keenly felt.

The phono equalizer circuit was an inverted Darlington circuit with seven transistors, which was innovative at the time.

The heat sink was a chimney type, which had just been developed at the time, because the weight of aluminum would have increased the cost. A chimney was placed inside the heat sink and made as long as possible. This was said to improve the cooling effect considerably. The power transformer was a two-transformer type, so the regulation was not very good, and this is probably what showed the sound quality tendency of the AU-607 and 707. The power capacitor was a total of four 12,000μ/63V capacitors, making it quite powerful. The AU-707 had a configuration of 15,000 x 4 capacitors.

Thus, the shape gradually took shape, and the first prototype was completed around June 1976. The appearance was calm, and above all, it felt elegant and sexy. It was quite different from the gutsy black face amplifiers that had come before. The sound that came out also matched the atmosphere, and I felt that it was not very suitable for powerful, ear-bleeding jazz sound reproduction. Rather, it felt like it had a mellow vocal, depth and clarity that was perfect for classical music. Still, I was surprised at how fresh the DC amplifier was. The release was to be held off until October, so the mass production prototype was approaching in August. We made improvements based on the results of the mass production prototype, and planned to conduct field tests outside. The field test was to have audio critics listen to it, or to visit the homes of customers to check for defects, whether the sound was as imagined, and how the critics felt about it.

Next time, I will write about the audio journals and reactions of audio stores at the time. Unlike today, there was an amazing amount of energy and enthusiasm. That's how much of a business it became.

Published on May 7, 2006
 
Part 12: AU-607/707 Release Approaching

Things are getting hectic. SONY's newly developed DUAL-FET, 2SK97, has somehow managed to make it in time for mass production. The power transistors are NEC's TO-3 type 2SC1403A and 2SA745A single pp, and mass production arrangements have also been made.

About 10 mass production prototypes of each have been completed. Two were for reliability testing, one for factory analysis, two for design review, and the remaining four were allocated for catalog/advertising photos and sales promotion.

We were allowed to use three of each as we liked. For the first time, we were taking them out of the company. At that time, every audio manufacturer had a public relations officer who was active in the audio journals and critics. The public relations officer was a very active person, a hard worker who loved JBL and jazz.

Let me tell you about the state of audio journals at that time. The more technical ones were "Radio Technology," "Radio and Experiments," and "Radio Science (out of print)," the more domestic audio ones were "Stereo" and "Stereo Art (out of print)," the more fanzine-like "Audio People (out of print)," the more imported audio ones were "Stereo Sound," and at the time FM magazines such as "Weekly FM (out of print)," "FM Fan (out of print)," and "FM Recopal (out of print)" also had a considerable influence. For the industry, "Audio Senka" developed into "Audio Accessories," and Dempa Shimbunsha also put effort into its audio pages. There were magazines specializing in decks such as "Tape Sound" (out of print), and more music-oriented magazines such as "Record Geijutsu" and "Swing Journal", and they were all really popular. Naturally, there was a shortage of writers, and many people quickly became audio critics.

After fine-tuning the idle and DC adjustments of the mass-produced prototype and checking the listening performance with the in-house JBL 4320, we finally took it to the home of critic Mr. S (still the leading expert in Japan). Mr. S was a JBL fan and had a favorable opinion of Sansui, which was a JBL distributor. At the time, there was still the McIntosh XR Before the release of the T-20, he used a JBL 4320 for the listening test. While smoking his pipe, Mr. S connected an AU-607 to the 4320 and started to play. I think the cartridge he used was Goldbug's Mr. Briar, which uses pipe material for the shell. The first was Beethoven's Piano Concerto backed by the Nagoya Philharmonic, recorded by Mr. S. After listening to four or five pieces, including a jazz combo recorded by Mr. S, he began to comment. I realized that I was getting thirsty and nervous. "It's completely different from the sound of previous Sansui amps! I can feel the bounce of high-quality rubber and the sound is clear! The wildness of the amp has disappeared and it's elegant! He even said, "This might be a hit." As I found out later, Mr. S was not one to give lip service. It is true that the sense of bounce was due to the moderate fluctuations in the power supply, which I think worked in its favor. If it had been a high-end integrated amplifier with over 100W, it would have been a disadvantage. Anyway, the first external test produced good results.

My boss, Mr. T, who was in charge of the basic design of the power amp circuit, and the sales and promotion staff, who had been a little skeptical, all seemed to feel a bit more confident about sales. Encouraged by this, I next visited the home of Mr. SF, who is still talked about today for his passionate audio reviews, and who passed away at the young age of 46. At that time, he was still living in a housing complex, and his small room was taken over by his audio equipment. I thought to myself, "That must be hard for your wife!" as I went to visit his own home. I thought of this as I was comparing the two situations. His record player was mainly the extra-large EMT927, with a Mark Levinson LP2 preamplifier. The speakers were the 4341 (later to be developed into the 4343), which had not yet been released in Japan, and he also had a KEF BBC monitor set up. The hearing cartridge was an EMT/TSD-15, which was stepped up by a transformer and sent to the phono terminal of the amplifier. I remember playing the chanson "Barbara". He also played a few classical records, and listened to both the AU-607 and 707 amplifiers. SF was also an industrial designer, so first of all he praised the design highly. "The harshness of Sansui and the somewhat rustic flashiness have gone, it's refined and elegant! " he said. I was enthralled when I heard the sound of the JBL 4341 for the first time. The 4341 was rarely sold in Japan, and was a smaller four-way speaker than the 4343. Despite its compact size, it had a good bass and produced a very well-rounded sound. SF also liked the sound quality very much, but it seemed he preferred the 707. Later, in an evaluation test by Stereo Sound magazine, the 707 came out as the recommended model.

I also visited the homes of more than 10 critics to listen to the speakers, and rather than their evaluations, I remembered their comments about whether they were okay in various combinations, listening rooms, and with various program sources, and whether certain combinations were particularly good. One interesting experience was when I visited the home of Mr. K, who has a background in electrical engineering. At the time, Mr. K seemed to be researching the correlation between capacitors and sound quality.

Immediately, I noticed a Panasonic 1μ film capacitor that was in parallel with the block capacitor. We were concerned about the impedance rising electrically at ultra-high frequencies, which would cause instability when used as a power source for the amplifier. Mr. K suggested adding another capacitor, and attaching it in the opposite direction to the winding of the film capacitor. It was not something I could understand, but I didn't think it was that important. Mr. K must have sensed the look on my face. He asked me to test it with the AU-607 I had brought with me, and so we conducted an on-the-spot hearing test. Mr. K was a huge classical music fan, and said he never missed an annual Bayreuth Festival, was a regular member of the NHK Symphony Orchestra, and attended nearly 100 concerts a year. I think the program source was Dieskau's "Winterreise." And finally, When he tried it, the vocals certainly sounded smoother.

After that, Mr. K got involved in the development of sound quality components, and various high quality parts would appear later.

Now, implementing this in mass production would be stressful. Increasing the cost of materials by adding a total of four more units! And instructing the factory to install them in the opposite direction! They would probably say that's not possible. He returned to the company and immediately made a request to the relevant departments. There was a lot of opposition, but he pushed through, saying, "It'll be a hit!" He was grateful for the support from his superiors, but he was prepared to take responsibility and step down from any involvement in the commercialization of the amplifier if it wasn't a hit.

The sales department also took on the challenge with a great deal of resolve. They invited sales managers from major retailers across the country to the company to hold a meeting to explain the new amplifier. A total of 50 people came, I think it was a good idea. So I spent most of the day promoting the amplifier in a seminar format. During the final Q&A session, a dealer in Shikoku asked me to play some Mori Shinichi. After listening to it, he said that Mori Shinichi's unique low-mid range was lacking. I was so angry that I thought, "I can't be judged by pop songs!" I calmed down and realized that he was trying to say that music has no appeal as audio if it doesn't have a solid low-mid range. This is probably an important point, especially when listening to music at a dealer. I immediately started looking into improving the sound quality in that area.

Look forward to the results of this study and the sales battle with rival models.

Published on May 10, 2006
 
Part 13: The Eve of the Release of the Integrated Amplifier and Afterwards

Let me mention the integrated amplifiers that competed with the AU-607/707 around 1976. The leading models were the Pioneer SA-8800II (¥59,800), SA-8900II (¥79,800), Technics 80A (¥88,000), Trio (now Kenwood) (¥78,000), KA7700D (¥110,000), YAMAHA CA-800II (¥95,000), CA-1000III (¥128,000), and Marantz MODEL 1150MKII (¥129,000). Of course, there was no consumption tax at that time, and instead a 15% commodity tax was applied to the manufacturer's price, so in effect, the tax was about 7-10%, which was higher than the 5% consumption tax.

Finally, September arrived and we had to decide on the list price. We had increased costs in various ways to improve the product's appeal, and when we calculated the cost, it was impossible to sell the AU-607 for 69,800 yen. 79,800 yen was more reasonable from a business perspective. We wanted to make a comeback with this model, so we couldn't compromise on 69,800 yen. After much debate in an internal meeting, we decided on 69,800 yen. The AU-707 was also difficult in terms of cost, but we decided on 93,800 yen to somehow secure the minimum standard for profit.

Continuing from the previous article, we thought about how to make the reproduction of the mid-low range more realistic. From my experience in speaker design, if the lowest impedance point of the woofer unit (i.e., the frequency where only DC resistance exists is often the mid-low range of 100Hz to 200Hz) is designed as low as possible, the transistor amplifier will be able to receive more power and become richer. It seems that the woofer unit of the past JBL deliberately lowered it to about 4Ω even though it was marked as 8Ω at this frequency. The JBL 4320 does not produce deep bass, but it produces a sufficient mid-low range, so I did not notice this so much. I think everyone has experienced that the mid-low range sounds richer when listening through a preamplifier than when listening directly through a power amplifier. Therefore, the constant of the coupling capacitor of the line amplifier of the preamplifier section and the strengthening of the ground pattern on the printed circuit board (low DCR by back wiring) were significantly improved. Finally, I asked the factory and the inspection department to set the idling current of the power amplifier to a slightly larger 40-50mA. (The manufacturer adjusts the idling current to minimize distortion by outputting 10 kHz. For a 0.22 Ω emitter resistor, this is about 20 mA.) The distortion specifications were more than adequate.
Unexpected pitfalls

For mass production, the amplifier must pass a drop test in its packaged state. It must be dropped from a height of 90 cm onto a concrete surface at six points, including the face, edge, and corner, and must not be damaged or deformed. The chassis of manufacturer-made amplifiers is a monocoque structure like a car, so the transformer and heat sink are attached to it to give it strength. The AU-607 had a shielding case added from the beginning, which made it heavy. The power transformer had sunk about 10 mm. We immediately added a support bracket between the back panel and the chassis and the problem was resolved.
Weaknesses of the AU-607

Due to its structure, it was difficult to remove the power rectification and protection board unit, and repairing this part was time-consuming. Last year, I actually had a hard time getting a repair request for an AU-607. I was worried that complaining would be a waste of time.

Next, I made the master volume step-type for a professional look. At the time, Alps could only adjust the volume to -60dB, and there were complaints that the volume was too loud for rear-field listening in the middle of the night. The AU-707 had a -20dB mute switch, so there was no problem. From the next D series, other competitors followed suit, making the volume continuously variable down to -80dB, so in a short time, the step-type volume disappeared from standalone component amplifiers.

What should we do about our advertising strategy?

The advertising department asked me for advice on how to advertise in catalogs and audio magazines. What kind of slogan should we use to sell this amplifier? The people involved gathered and held a meeting, but no good phrases came to mind. I wanted to propose "wide-range NFB," but ordinary people don't understand what that means. Even an amplifier designer needs to think carefully before it makes sense. I wanted to say that unlike amplifiers where the amount of NFB starts to drop at around 100Hz, which is far below the audible range, the audible range has the same amount of NFB applied correctly. In conclusion, since it covers the frequency characteristics from the DC range to 200KHz, the catchphrase was decided to be "Wide Range DC! Amplifier".

I had been writing articles about audio production since my student days, so writing for audio magazines was not a hard task. I had to rewrite the copy of the PR staff a lot, and they were annoyed, but now it's a fond memory for both of us. The catalog also had more space than usual, with a 6-page spread.

The first lot of production finally starts

In October, the first lot of production finally started. Many of you may know that the production factory was a lattice-patterned factory along the national highway in Saitama. It has now become a supermarket, and there is no trace of it.

Two of my colleagues who joined the company at the same time (and still work together today) were the factory line leaders and the inspection department leaders. All three of us were audiophiles and had a lot in common. We wanted to somehow deliver a stable product, and to use it as a means of expanding sales within the company, especially to the sales department, so we decided to do a hearing check of the first batch of amplifiers, something that had never been done before. Normally, amplifier manufacturers would take out about five units and have the designer check the characteristics and usage (are the knobs loose, can the amplifier be used normally, etc.), and check the appearance, etc., but we decided to do a hearing check of about 400 units out of the first batch of 2,000 units. The factory was full of energy at the time, and the factory manager was my senior at school, so he gave us permission. We carried the completed amplifiers one after another to the factory listening room, turned them on, warmed them up, and listened to music. Of course, we wore white gloves because we couldn't get any dirt on the amplifiers. At first, we listened to each one for about 10 minutes, but as we got used to it, we were able to listen to it for about 2 minutes. The finished product was very similar to the prototype and was good. We were able to separate them into three types: soft, hard, and medium. This task took five days, but there was an unexpected by-product. The young inspector who was helping us became interested, and as he got used to it, he was able to distinguish the sound quality almost at our level. After this, he was in charge of managing the sound quality of new products, and if there was even the slightest change in sound quality, he would immediately contact us. We were able to find the cause of the change without fail. In this way, the products that we were confident in were delivered to retailers nationwide in late October.
Retailer's Situation

It's still the same today, but when introducing a new product to a store, it's hard to sell it unless it's displayed in the store. Therefore, display products are sold at a lower price than usual. When the product reaches the end of its life, the retailer sells it at a lower price as a display clearance. At that time, there were more than 2,000 stores, so more than 2,000 units were sold just for display products. On top of that, customers came to buy them, so we planned to produce 6,000 AU-607s and 5,000 AU-707s by the end of 1976, and we were making them one after another, so the sales department had to secure display space, sell them, and get customers to sell them. At that time, at the end of the year, during the bonus period in July, each manufacturer would send out sales helpers to support the dealers.

There were sales helpers from companies A, B, and C in the store, and they were competing with each other in the store. Each company also temporarily brought in staff from the administrative department other than the sales department to compete for sales. Anyway, we had to do our best and wait for the sales results in January of the following year. At that time, manufacturers who were members of EIAJ (Electronic Industries Association of Japan) honestly reported their monthly sales and announced the total number of units per month by price range, so if you used that as the denominator and your own number as the numerator, you could find out your market share. Also, the industry-oriented audio magazine "Audio Senka" at the time conducted sales surveys at major retailers every month and published the results in the paper, so we had some idea of what was selling at each store.

So, how did it get off to a good start?

Published on May 12, 2006
 
Part 14: Results and Reputation after Release, Next Strategy

The sales department informed me that stores were steadily buying the product. However, since audio was at its peak at the time, I think rival models were also doing quite well. Just at that time, Stereo Sound released a special edition of "Sansui" to see if they could give some support. The AU-607/707 was the focus of the magazine, so I think it had an effect of informing audio fans. This special edition was released at the same time as special editions on brands such as Lux, Victor, and Marantz. Many articles introducing FM magazines began to appear, and I also placed a fair amount of advertisements in audio magazines. I spent November and December helping with such promotional activities. Although it was not my main job, I wanted to know the situation outside the company and get some hints for my own future direction, corrections, etc.

The end of 1976 came and New Year's Day came. After another flurry of activity, the sales statistics from the Electronic Industries Association of Japan (EIAJ) came in after the 15th. The results were promising, and although Shar doesn't remember exactly, the results for November and December were at or near the top. At the morning meeting, the boss said, "Customers have a lot of trust in Sansui Amplifiers," and did not praise anyone involved. However, if they acted as if they had worked hard, the resentment and jealousy within the company would only grow stronger. This is especially true in the Japanese salaryman society. The boss was considerate of other departments, saying that it would be easier to work with them in the future if they acted humbly. In fact, even when making a product, it is accomplished through the combined strength of the company, and this was something that he came to truly understand and feel much later, when he spun out, founded a company, and made the product himself. In particular, if a manufacturer neglects departments that are not visible in the public eye, such as quality assurance and production technology, it will eventually be in danger. Meeting Akihiko Kaneda

Amateurs were quicker to realize DC amplifiers. Through the mediation of the editors of MJ magazine, I was able to meet Akihiko Kaneda (who was also a professor at Akita University at the time) who had a track record with DC amplifiers (Kaneda amplifiers). I remember him giving a strict explanation of the basics of DC amplifiers. For example, I think he said that in the power supply circuit, the decoupling circuit in the front stage should also have no time delay until the DC region. At the time, I wasn't very impressed, but many years have passed since then, and Kaneda has demonstrated sufficient achievements in MJ magazine, and I bought a book that summarized them. When I read the preface, which talks about music and his love of it, I thought once again what a wonderful person he was. It took more than 20 years for me to think this way.
Introducing it to the American audio world

Since it was a hit in Japan, I thought it was time to compete with these amplifiers overseas. The overseas sales department knew that receivers were common overseas, especially in the US, and that full-scale systems were separate (separate preamplifier and power amplifier), and that integrated amplifiers were not familiar in the US. (Even now there are few integrated amplifiers made in the US. I think the JBL integrated SA-600 sold better in Japan than in the US.)

Still, they decided to try to sell it in the US somehow. To sell it in the US, it had to obtain a safety standard called UL (stricter than PSE), so the cost of obtaining this was about 500,000 yen per model at the time, since samples and main parts had to be sent to the US (now a Japanese company does this on our behalf). After obtaining this, it was decided that only the AU-707 would be sold overseas, and the model name became AU-717. I was able to go on a business trip to the US just in time for the new product launch in the US. After the announcement at CES in Chicago, Sansui held preview events in major cities such as NY, SF, and LA, inviting local Sansui representatives and major retailers to hotels.

After all, America is a receiver market, and even though the AU-717 had a good reputation, it seemed that there was little hope for actual sales. However, TY, the local LA manager (who later became the founder of Avex), also recognized the good design and promoted it strongly. Although the planned number was fully sold, I still think that the profit was less than expected. Looking at rival brands, there were no integrated amplifiers at CES, and most were receivers or systems that combined a receiver with speakers, a record player, and a cassette deck (called a one-brand system). Only Fisher was competing with Japanese products, and long-established companies such as Scott and Sherwood were weakened by the offensive of Japanese brands. During this period, there were no industrial products exported to America from Korea or China.

Since the shipping costs for speakers for a single brand are high, many of them were cheap and assembled locally in the United States. Why were they so cheap? Because they used black and Hispanic workers, so the labor costs were low. American society is still a society of inequality and discrimination. Different races and ethnicities never live in the same area, they live separately. The exchange rate at that time was 1 dollar = 308 yen. After that, the yen became stronger, around 240 yen.

Next Strategy

Even though they got off to a good start with the AU-607/707, they were only making up for it with their mid-range model. They were still content with lower-class models like the former AU-9500. "Next is the AU-907!" What should they do? They can't continue on this path, in other words, even if they make a higher-class model from a lower-class model, their image won't improve.

First of all, from the circuit point of view, it is undoubtedly an advanced DC amplifier, but the first stage is fine, and the third stage differential push-pull circuit is not bad either, so the second stage differential circuit is ordinary, and the way to lead the signal to the negative side is to use a level shift circuit to lead it to the negative side differential push-pull, which is not smart or elegant, and it seems to be an obstacle to the rise (slew rate) characteristics. By the way, the slew rate of the AU-607/707 is 60V/μs, which is quite high.

While I was feeling confused, I asked Mr. T, the original circuit developer, for advice. "The second stage is not clear, so after all, a two-stage amplifier circuit would be better!" I said provocatively. I knew that a certain part of the technical department had evaluated Yamaha's two-stage differential circuit. "Anyway, can't you make a circuit that does not need a level shift circuit?" I got it! Let's try it. I'll assign Mr. TT, who joined the company at the same time as you, to circuit development. Mr. T had become head of the R&D department, so he couldn't work on circuit development full-time, but he said he would cooperate. My colleague TT (who I still keep in touch with) was young, clever and hardworking. He had come to the development department from the service department and was full of enthusiasm.

We also wanted to get the distortion characteristics below 0.01%, not 0.03%. At 20kHz, the transistor characteristics were a bottleneck, and this was an obstacle.

If we pushed it too hard, the oscillation stability would deteriorate, we would receive more complaints in the market, and we would lose credibility. The expected specs for the AU-907 were as follows:
Power amplifier section
Maximum output 100W+100W (8Ω)
Minimum load 4Ω
Distortion 0.0081% or less (20-20KHz/8Ω/100W/2ch simultaneous operation)
Frequency characteristics 10-100KHz (within -3dB, 1W/8Ω/2ch simultaneous operation)
Input sensitivity 1V/47KΩ
Through rate 100V/μs or more
Appearance of improved new devices

The performance limits of bipolar transistors are becoming apparent. Semiconductor companies have been trying to improve the drawback of switching distortion caused by the accumulation effect of minority carriers. Specifically, Fujitsu's ring emitter transistor was the first. The emitter was shaped like a ring to improve the above drawback. Sanken also improved it by making it a multi-emitter structure, calling it a linear amplifier transistor (LAPT). These improved devices certainly had better characteristics, but they seemed to be weak against large currents. It was not very flexible and was easily destroyed if used in an unreasonable way. I intend to delve a little deeper into this topic next time.

What is the correlation between chemical capacitors and sound quality?

Until around 1975, most manufacturers did not pay much attention to the sound quality tendencies of components. Electrical characteristics are related to safety and reliability, so knowledge was available with a fair degree of accuracy. For example, high-frequency characteristics of capacitors, leakage current, capacitance error, temperature characteristics, etc. From my experience in speaker design, I also thought that the speaker was the dominant factor in sound quality tendencies. It is true that speakers still determine the tendencies of reproduced sound, but when it comes to the details of sound quality, the components control the sound quality tendencies. I first confirmed that block chemical capacitors had sound quality tendencies. At that time, price and delivery time were given priority over the chemical capacitor brand and specifications.

The capacitance of a chemical capacitor can be increased by increasing the surface area of <200b><200b>the aluminum foil. First, to make it smaller, an oxide film is created on the aluminum foil, and then a process called etching is used to make the surface uneven and widen it. Compared to back then, the capacity is about three times larger, which contributes to miniaturization. I think Japan (Nichi-Kemi and Nichi-Con) is the best in the world in terms of the quality and technical level of chemical capacitors. As a result, Sprague was temporarily under the umbrella of Nikkei (now the France Bichet Group), and Mallory, although the brand remains, has been absorbed by Cornell Tabler. Mr. K, a critic mentioned in the 13th issue, was the first to point out the unique sound quality of chemical capacitors. Companies have been actively developing block chemical capacitors for audio. Various prototypes arrive one after another from each company, and one of them invited me to visit the chemical capacitor factory and see the production site, so I visited the Toyoshina factory of Nichi-Con. I see, it turns out that making chemical capacitors is an industry that uses a lot of electricity and water. Small capacitors were already being made in huge quantities using automatic machines back then. Block chemical capacitors were still partially wrapped by hand with aluminum foil.

I speculate that the factors related to the sound quality of block chemical capacitors are as follows.

Etching ratio
Number and width of electrode extraction tabs
Aluminum foil winding tension
Interlayer paper
Electrolyte
Terminal material
Filling amount and material
(Aluminum) Outer box

A chemi-con expert would probably say there are more!

Aluminum foil with zero etching is called plain foil. I still have chemi-con made with this foil, but with current technology, it would be 50V/3300μ, but with plain foil, it can only take 50V/15μ. The sound quality is certainly clean and pure. Chemi-con manufacturers stopped production soon because there was little demand. Increasing the number of electrode extraction tabs would take more effort, but the resistance would decrease and the sound quality would improve, but there was also a trade-off with the cost. The winding tension is now done by an automatic machine, so once it is set, it is uniform. Since the prototype was hand-wound, the sound quality sometimes differed from that of mass production. The interlayer paper is apparently a matter of expertise, and there are many different types, including Manila hemp, Japanese paper, bamboo fiber, and carbon paper (black gate). The electrolyte is a liquid similar to the sauce used in grilled eel, and is extremely conductive; if even a small amount is spilled and an electric potential is applied, electricity will flow. There have been very rare cases of electrolyte leaking and shorting out the area, resulting in accidents (apparently this still happens with Chinese-made products).

The electrolyte hardens and gasifies over time, and when there is only a small amount left, its lifespan ends, but rather than what the manufacturer says, this lifespan is long when it comes to audio equipment. I learned this after repairing it. It is still going strong even after 30 years. (However, gasification may occur.)Ichijirushiku, fukuran deru mono wa kōkan jikidearu. ) Onshitsu to no kanren wa kakusha nōhau ga atte, imademo kōkai dekinaidearouga, tōji no kemikon kaisha wa shichō-shitsu o tsukutte, JBL 4343 o sonaete ita. Soshite, sokode kiite mite, ōdiomēkā ni sanpuru o jisan shite, hyōka shite morau. Sōshite, saiyō o pusshu suru eigyōdeatta. Onshitsu ni totte yo-sa-sōna koto wa, etchingu bairitsu wa hikui hō ga yo-sa-sōdearu. Zenjutsu no purēn haku no kemikon wa ishinorabo demo hanbai shite irunode, sono onshitsu o tashikameru koto mo dekiru. Hikide tabu wa futoku (tsūjō wa 6 mm kurai) suru to, kore mo yo-sa-sōdearushi, hikide tabu-sū ga ōito yoi hōkōdearu. Mata, kemikon wa seiryū-ji, mata ōdio shingō de henchō kake rarete shindō suru. Chōshinki de kikeba, ongaku ga kikoeru hazudearu. Shitagatte, kemikon'yunitto o kotei suru jūten-zai wa ippai tsumeta hō ga yoi hōkōdeatta. Sarani, sotogawa no kēsu wa enchūdearuga, Firippusu wa kono kēsu ni ōkina ōtotsu o tsuketa kemikon o ima demo tsukutte iru hazudearu. Kō suruto, kyōdo ga mashite, kemikon no shindō yokusei ni yūkō to no kotodearu. Firippusu no patentodearurashī. Sate, AU − 907 (kashō) ni tōsai suru burokkukemikon wa dō shiyou ka to shian shite ita koro ni yunīkuna keijō no kemikon o teian shite kita mēkā ga atta. Jikai o otanoshimini. Tōji no Amerika sansui no kōdaina honsha tōji no Amerika sansui no kōdaina honsha sōko (NJ-shū ni atta. ) (Tokubetsu ni sansui OB saito shihainin-sama ni keisai kyoka o itadakimashita. ) 2006-Nen 5 tsuki 23-nichi keisai purinta-yō gamen kono kiji no 1-gyō-me ni tobu mae dai 13-kai purimein'anpu hatsubai zen'ya to sonogo kategorītoppu dai 1-dan Nihon ōdio-shi-ji dai 15-kai jiki moderu no kaihatsu kopīraito © 2003 - 2023 ISHINO LAB. © 2003 - 2023 MASTERS All rights reserved. Bariddo XHTML 1. 0 Transitional bariddo CSS! Makurosofuto intānettoekusupurōrā gūguru chrome makurosofuto Edge
929 / 5,000
Anything that is noticeably swollen is time to replace it.)

Each company has their own know-how regarding sound quality, and even now they probably can't disclose it, but at that time, chemical capacitor companies built listening rooms and equipped them with JBL4343s. They would listen to the capacitors there and bring samples to audio manufacturers for evaluation. This was the sales method that pushed for their adoption.

It seems that a lower etching ratio is better for sound quality. Ishino Lab also sells the plain foil chemical capacitors mentioned above, so you can check their sound quality. Making the pull-out tabs thicker (usually about 6 mm) also seems to be good, and having more pull-out tabs is also a good direction. Also, the chemical capacitor vibrates when rectified and when it is modulated by the audio signal. If you listen with a stethoscope, you should be able to hear the music.

Therefore, it was better to fill the filler that holds the chemical capacitor unit in place as much as possible. Furthermore, the outer case is cylindrical, and I believe Philips still makes capacitors with large bumps on the case. This increases the strength and is said to be effective in suppressing vibration of the capacitor. It is apparently a Philips patent.

Anyway, when I was pondering what kind of block capacitor to install in the AU-907 (tentative name), a manufacturer proposed a capacitor with a unique shape. Please look forward to the next article.
 
Part 15: Development of the Next Model

The other day, I was listening to a program called Sunday Cafe on NHK FM, and a sociologist said that it would be better to write down past events in order to convey them. Recently, some people have been self-publishing what they call "autobiographies." He criticized that most of them are "bragging histories," which he said is a problem. It is true that human memory is designed to forget unpleasant things. If we don't do this, we will become depressed due to stress. Things that we can't forget will become traumatic, which is also not good. I intend to write objectively, but there is also self-assertion in it, and I intend to continue the series in the future, being careful not to make it selfish.

Evaluation of a new prototype chemical capacitor and its handling

The JC development department is enthusiastic about research into block-type chemical capacitors, and has submitted an oval-type chemical capacitor as a prototype. The inside is made up of two parallel-connected chemi-con units, and there are more pull-out tabs than in conventional products. Overall, there is less loss over high frequencies, and the ion conduction speed is said to be faster by considering the interlayer paper, electrolyte, and etching rate. When attached to the power supply of the prototype, it is true that there is no sluggishness that is felt with chemi-con units, and it has a clean, instantaneous power. Naturally, the cost is high, and it seems that it will be difficult to use anything other than the AU-907 class for the next amplifier. If four of these are used in a two-power supply configuration, the cost will be significantly affected. However, there was something fresh about this sound. I was determined to use it at all costs. I made a reservation with Nichicon and asked them not to sell it to anyone else.
Development of a new circuit

The development started as described in the 14th installment. In order to eliminate the negative side level shift circuit and connect it directly to the negative side third stage differential push-pull, the negative side output of the second stage must be close to the negative power supply voltage. So TT wondered if it would be possible to put two differential circuits, one above the other, in a complementary form? That would create a DC potential that could be directly connected to the third stage. How would the bias for the second stage be created? A voltage of at least 0.6V x 3 = 1.8V or more must be created somewhere. TT thought that a direct-connect circuit could be realized by putting three diodes in series with an additional resistor on the drain side of the first stage differential circuit. When he tried it, it worked well. Moreover, the upper and lower complementary differential circuits were extremely stable in terms of DC. It was also discovered that the gain of the second stage was about 4 times (12 dB), and it was more stable if it was not too high. In this circuit, when the input becomes large and the voltage between B and E becomes large and approaches clipping, both the upper and lower differential circuits are turned on, and the ± power supply voltage is fully applied. This means that it has an extremely high slew rate and drives the following circuits with all its might. If it goes too far, it will exceed the ASO (Area of Safe Operation) of the Darlington transistor and power transistor. In other words, in such a situation, there is a risk that all subsequent semiconductors will break. In the ASO area, the current value becomes smaller as the power supply voltage increases, so the higher the power amplifier, the more dangerous the circuit is. In addition, since the first stage flows up to the FET crosspoint, there is no need to limit the slew rate. The third stage operates in the same way as the second stage, so it has become clear that the rise of this new circuit is extremely high and fast. Compared to the AU-607 circuit, phase compensation can be performed according to theory, it is simple, and there is no need to apply a partial feedback circuit. In addition, the DC stability against power supply fluctuations is excellent.

With this circuit, TT made a 100W stereo power amplifier as a handmade sample. He assembled it with ordinary parts without considering sound quality components. We decided to listen to it immediately, so the relevant parties gathered together and conducted a hearing test. It was a fresh and sharp sound that I had never heard before. The sound was scary in a good way. This amplifier was sealed as the prototype amplifier.

The slew rate of the prototype amplifier with the new circuit easily exceeded 200V/μs. The distortion was also less than 0.005% at 20KHz. I was secretly convinced that this new circuit had great potential for future development. This would develop three years later.

Needless to say, a patent application was immediately filed, with TT at the center, and was granted. Now that time has passed, the patent has of course expired.

What should we name the circuit?

With the success of the new circuit, the relevant departments gathered together (that's how companies are). Various meetings were held with the development department, technology department, planning department, advertising department, and patent management department, but it didn't take long to decide.

If we were to forcefully describe this circuit, it would be called a complementary dual differential circuit, but that's not very interesting. Looking at the circuit, the complementary joints form a cross shape with four circuits coming together. It can be said that cross → cross → diamond. We decided to make it a diamond differential circuit (we still see typos like this today, but it can't be helped), but the patent management department advised us that diamond might be a similar trademark to Mitsubishi Diatone. We decided to go with diamond differential circuit, which is closer to the English pronunciation. During this time, Sansui registered VINTAGE as a trademark based on the idea of VOLTAGE. This was when Shiseido's VINTAGE was selling well. Trademark registrations are approved and registered even if the classification is different, even if the product is the same. VINTAGE served as a catchphrase for the AU-X1, which will be described later.

Speaking of names, Colombia is the name of the country, and Columbia is Nippon Columbia.

Posted on June 4, 2006
 
Part 16: What was happening in the early days of D-class amplifiers

The concept and basic structure of D-class amplifiers have been described for quite some time. However, when people tried to make them, they didn't work, and everyone was at a loss.

In the late 1970s, I received a proposal of marriage from South Africa. He said he had succeeded in prototyping a D-class power amplifier. The engineer was Atwood. Speaking of highly efficient amplifiers, Bob Carver, who founded Phase Linear at the time, announced a newly developed highly efficient amplifier. This new type of amplifier modulated the power supply with an audio signal, and its efficiency was close to 80%. As you know, analog amplifiers are theoretically as high as 78.5% at maximum output, but when you add up the power supply voltage distribution loss, device loss, circuit loss, etc., the efficiency was at most about 40%. In particular, at normal listening levels, the efficiency is about 10%, and if you subtract the heater power, even a transistor amplifier will not be that small and lightweight. In fact, vacuum tube amplifiers are likely to be lighter because they do not require a heat sink as a power device.

The Carver brand amplifiers mentioned above sold quite well in the United States, and at one time they were quite popular as racers, power amplifiers, and commercial power amplifiers. At the time, Carver commercial amplifiers were imported by Sanyo Trading and began sales activities in Japan. Even high-power amplifiers such as 400W + 400W were extremely light, weighing only 10.8 kg. Even in the Japanese audio industry, which is weak to imported products, it seems that the sound quality did not lead to widespread use.

Anyway, back to the story, Atwood came to us around 1978 with a prototype. The R&D staff immediately took over and showed us his circuit. We also measured and listened to the prototype. It seemed to be quite impressive. So, based on his circuit, the R&D department decided to make a prototype and check the performance and sound quality. I think the prototype was assembled in about three days. However, the NFB did not work well. Therefore, the characteristics did not improve. His prototype worked well. The event did not bear fruit, and the cause was unknown. After nearly 30 years, I think that the carrier accumulation effect in bipolar transistors prevented carriers from being pulled out properly, and switching, which is the basis of D-class, did not work well. As expected, the emergence of MOSFETs that operate with a large number of carriers, and the so-called high-current MOSFETs, which have significantly improved switching characteristics, reduced internal resistance, and can handle large currents, helped to put D-class amplifiers into practical use. High-current MOSFETs were originally developed for switching power supplies and inverters, so they cannot be used unless they have good switching characteristics.

From around 1998, D-class amplifiers began to be used as amplifiers for high-power subwoofers. In addition, its high efficiency has led to its use increasingly as an audio amplifier for TVs. I think it has progressed to the point where it can be listened to as a high-end audio amplifier. However, it still has a long way to go before it can achieve the best sound quality. However, as the device has progressed significantly, it will only be a matter of time before it is improved and improved. Lightweight, compact, and highly efficient do not necessarily align with taste, but we cannot say that for sure.

Atwood, mentioned above, currently lives in the United States and is still active and active as a pioneer and authority on D-class amplifiers.

Advances in measuring instruments and catalog data and their meanings

Even as the leading role changed from vacuum tube amplifiers to semiconductor amplifiers, engineers were motivated to design amplifiers with low distortion. In the old days, there was a vacuum tube amplifier called Point One with a leaky sound, which was a monumental amplifier that was the first to have a distortion rate of less than 0.1%. In 1970, the distortion rate meter was the HP331A, and the data was reliable up to a full scale of 0.1%, or about 0.03% in actuality. For a while, this was the top-grade distortion rate meter. In 1976, HP's automatic distortion rate meter, called the 4343 (there was a theory that it was named after the JBL 4343), was introduced to various companies. This had a full scale of 0.01%, and the secret was in the last range. This range had a high-pass filter of 100KHz, which cut out ultra-high frequency noise, so the data was better. After this meter appeared, the catalog data for distortion began to fall below 0.01%. After that, metering devices that provided data that was more favorable to amplifiers appeared one after another. Please do not misunderstand that if the distortion components of a 0.1% amplifier are mostly harmonic distortion, the above measuring device will show the same value.

Recently, even digital amplifiers are written about as boasting excellent distortion data, but I think that data such as 0.001% measured by measuring distortion at 1KHz, sharply dropping the high pass filter of the measuring device from 20KHz, and measuring it is not very meaningful. Since digital amplifiers switch at high frequencies, if you measure it with a distortion meter with a low pass filter of about 500KHz, the distortion (including noise → noise distortion) data will be full of distortion.

If possible, you should measure it with a low pass filter of about 50KHz. The standard for noise distortion measurement of normal analog amplifiers is around 100KHz.

In the late 1970s, the HP 4343 was the standard distortion meter for each company, and this was the basis for comparison and examination. In the 1980s, HP released the 8903B digital distortion meter (called an audio analyzer; I bought one second-hand), which made it possible to measure distortion even lower than the 4343. Influenced by this, Meguro Denpa, Shiba Sok, and Panasonic released a series of low-distortion measuring instruments in Japan. Panasonic in particular made one that could measure distortion one order of magnitude lower than the HP8903B. This measuring instrument was a bit sensitive and prone to failure if handled incorrectly.

These measuring instruments have now been released by manufacturers and are being sold as second-hand goods, but there are only a few left. I believe that you should measure first and then listen to it without being influenced by the results. This is because there are some unfortunate cases where you hear something great without measuring it, and then measure it and it oscillates.

Nowadays, an analyzer called AudioPresion (abbreviated as Ap) is the most prestigious, and when I show this data to people, they seem to be convinced. This measuring device is linked to a computer, and all the measurement conditions are set on the computer. It is said that the set costs about 2 million yen. It seems that manufacturers that are still involved in audio are purchasing it. Many older engineers find it troublesome to measure with a computer every time. On the other hand, I hear that young engineers are not opposed to it, but they often do not fully understand the meaning of the data because they do not have enough experience.

"So, what's the point of measuring distortion?", "Audio is all about listening!", "Amplifiers should not be slaves to measuring devices!", etc. I think it is deplorable that measurement is not valued in the current situation. First of all, I think it is necessary to measure with a continuous signal and recognize the static operation of the amplifier. In the 1970s, there was a race to reduce distortion. Is the backlash from that still continuing?

The correlation between distortion and hearing sensation for continuous sine waves is high, at least for vacuum tube single amplifiers that produce clean second harmonics.

When it gets below 0.1%, I have experience that if you remove the noise components and perform a spectrum analysis, you can get a correlation with the sense of hearing to some extent. In any case, it is not affected by the results of distortion, but you want to keep it to a minimum. Going to the doctor and being diagnosed with a stethoscope and looking at your complexion is similar to judging an amplifier with just a tester. If you think you should at least get an X-ray and a blood test, you should at least do a distortion analysis.

However, when it comes to the truly important dynamic state, the measurement conditions are multidimensional and out of hand, so the Acoustical Society has given up. The current trend is to enjoy each individual tone. Is this okay? However, since it's a hobby, I think it's fine...

Matti Otala and TIM Distortion

At the height of audio, Nordic audio researcher Matti Otala presented a research paper on what an audio amplifier should be, which became a hot topic for a while. He came to Japan around 1977 and visited audio manufacturers to explain his theory. According to his research, audio amplifiers that use NFB without any consideration will momentarily lose power when a transient signal is input, resulting in extremely poor sound quality. He named this distortion Transient Intermodulation Distortion (TIM distortion). At the time, there was a race to produce low distortion, but it was also beginning to be pointed out that low distortion does not necessarily mean good sound quality, so TIM distortion was accepted by the audio world.

His proposal for a solution to this problem was that since NFB requires the amplifier to supply a larger current during music playback, the amplifier itself should have a circuit and power supply with excellent instantaneous current supply capacity. If this is not possible, he also said that a high-cut filter should be installed to prevent high frequencies from being input into the amplifier, making it a narrow-band amplifier. Since a vacuum tube amplifier with a transformer input is narrow-band, TIM distortion is unlikely to occur. Also, an amplifier that uses an OPAMP with a low slew rate will have a large TIM distortion, so the sound quality will be poor. This was convincing. If this is true, I still think that the diamond differential circuit was perfect against TIM distortion.

Published on July 2, 2006
 
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Part 17: Creating the Next Model
Consideration of Design, Internal Structure, and Layout

The power amplifier circuit has been decided, so what should the overall appearance be?

At least, I was confident from the beginning that the industrial design would follow the 607/707. Even now, in 2006, more than 30 years later, I still think it's the best design. The calmness of the matte black, the knobs with red lines, and the lever switches with just the right amount of unevenness - I felt that since around 1980, push switches have become mainstream and the faces of amplifiers have become flat and unattractive. The manufacturer is going to discontinue lever switches. I couldn't help but sigh, "They don't get it!" The name of the next model was decided to be AU-D907, the initial letter D of the diamond differential circuit. This was decided by a meeting of the people involved, and no one disagreed.

Now, the mechanical design is large at 100W x 2, so the depth of the 607 has been extended. The power supply configuration is the oval chemi-con mentioned in the previous article, the power transformer is a two-power supply configuration with a large toroidal transformer for the power stage, and the power block capacitors are four custom oval capacitors made by Nichicon. The pre-drive stage and preamp section are equipped with sub-transformers using EI transformers. The power supply section is heavy, large, and takes up a lot of space.

The chimney type heat sink used in the 607/707 alone cannot dissipate heat, so a fin-type heat sink is added to it to create a composite structure. The chassis is painted black, just like the 607. An internal shield case is used for all blocks. This direction is also popular for amplifiers from other manufacturers.

Adoption of new power devices

At that time, using iron was considered to be bad because it caused distortion. This led to the release of an analyzer that could measure distortion extremely well, and this measuring device was used to measure various materials. This measuring device can detect distortion down to -140dB (0.00001%). When current flows through iron, distortion can be detected at this minute level. Also, articles about iron being bad began to appear in audio magazines. During this time, Sanken Electric developed a multi-emitter type power device with low distortion called LAPT (Linear Amplifier Power Transistor), and asked us to adopt it. Indeed, when we listened to it, we could hear a smooth and powerful sound. It also seemed to match well with the diamond differential circuit. Meanwhile, Sanken Electric made a device called NM-LAPT. Of course, it was a TO-3 type at the time. NM stands for non-magnetic, and it is said that non-magnetic materials were used for the base and cover of the power transistor. It is true that even if a magnet is brought close to it, it does not stick to it. However, because of this, the strength of the base and emitter terminals is not as strong as iron, and they bend when force is applied, which makes it difficult to work with. However, when I immediately attached this sample to the prototype amplifier and listened to it, it seemed to have even more transparency and resolution. Since the AU-D907 was 100W, single PP was not possible in terms of current, so a parallel push-pull configuration was used. The disadvantage of this device was that it increased costs, but the materials department negotiated with us, saying, "Sansui's use will have an advertising effect, so you can give us a discount!" and the cost increase was kept to a minimum.

For the first stage, Sony's 2SK97 is not bad, but a dual FET called μPA68H (NEC) was released that is said to have even better pair characteristics, and this was the one we decided to use. For the Darlington stage, we found Fujitsu's 2SA898 and 2SC1903, which had excellent linearity, so we used this. After Fujitsu stopped manufacturing transistors for this device, there were no mid-sized transistors that could beat it. With this, the device to be used for the power amplifier was decided.
Phono equalizer circuit competition

At the time, the best sound source was the sound from records, and we relied on this to examine the sound quality of power amplifiers. We had not yet decided what to do with the phono equalizer circuit that was the basis of this. The phono equalizer circuits of the 607/707 were excellent, but even now, the grade of the power amplifier prevailed and the balance was somewhat poor.

Naturally, we were still worried about what to do at the time. After consulting with the design and research departments, we decided to prototype all possible circuits, measure and listen to them, and make a decision.

We prototyped about nine types of circuits in total, and conducted a review (explanation session) based on the circuit diagram, explaining the circuit operation, and then had a hearing evaluation. Several people were involved in this project, and worked hard overtime despite their busy schedules. Even now, more than 25 years later, we have not discarded this report, and I still have the board unit of the circuit that was well evaluated.

Well, after listening to the manufacturers with bated breath, the top choice was a phono equalizer that used a diamond differential circuit from a power amplifier. It conveyed the energy of music well.

There were other circuits with very beautiful sound quality, but from the perspective of sales, there was a risk that their merits would not be understood at the store. Brand image is a scary thing, and if Sansui produced a beautiful sound, it was easy to predict that it would be perceived as gay. (A beautiful sound would have been fine for Yamaha, but I think Sansui needed guts and energy to do it. I felt that especially during the period when we were a JBL distributor.)

The contest ended with the above conclusion, but it seems that the engineers in charge of the circuits that were not adopted were left with some resentment. I will write about what happened after that around the 20th contest.

Application to MC cartridges

The evaluation of MC cartridges has been increasing, perhaps due to the influence of an article by Takagi-san, an opinion leader at the time. A trend emerged that cartridges were not cartridges if they were not MC. Now, how should they be handled in an integrated amplifier? There was the MC transformer, but installing it inside the amplifier was thought to attract hum noise, so instead, it became popular to incorporate an MC head amplifier. We were forced to deal with this issue with the AU-D907, so we decided to make a head amplifier by connecting FETs in parallel and incorporate it. We didn't care much about the sound quality of this head amplifier. It didn't end up being of great quality, and we didn't have much time to consider it. Even when we visited critics' homes, it was normal to receive the output from a high-end MC transformer and do a listening test. In short, the head amplifier of the integrated amplifier was just a bonus.
Sound quality consideration begins now

Now, with the circuit and structure of the AU-D907 decided, the design work progressed smoothly, and a mass production prototype was completed around August 1978.

Now we will begin considering the sound quality that will put the soul into the amplifier. The release was scheduled for October, so we didn't have much time to spend on it.

Sound quality considerations include the components to be used, wiring, ground circuit processing, detailed circuit constants, etc. Look forward to the next article to find out more!

Mail from Mr. Susumu Takahashi

In an email from Mr. Susumu Takahashi, whom I respect, there was a more detailed description of the circumstances surrounding the development of the diamond differential circuit. (From now on, for ease of writing, I will refer to Mr. Susumu Takahashi as Mr. T.)

Mr. T listened sincerely to my proposals in the development of the X-balanced circuit that followed the diamond differential circuit, and was a great contributor to its concrete circuitization.

Now, let's post the text of Mr. T's email.

First of all, around the same time as the transistor appeared, the Massachusetts Institute of Technology (MIT) invented a circuit named the diamond circuit. This circuit is an emitter-follower circuit, but it is unique in that it uses the fact that the potential difference between the base and emitter is the opposite potential for NPN and PNP to cancel out the base current. I had already thought (even before the days of DC amplifiers) that I could make a differential amplifier based on this idea, but there was no point in using four transistors in a differential circuit that could originally be made with two, so the idea remained for many years without even making a prototype.

The reason is that the MIT diamond circuit is extremely significant in that it cancels the base current when building a high impedance input. But in a differential amplifier, no one is happy just because the base current is canceled. So, although it was a circuit that only existed in my head, as I was making DC amplifiers, I came to think, "An amplifier with a high slew rate is good! It doesn't produce TIM distortion!" " I thought, why not try making a differential amplifier like the MIT diamond circuit? Until then, I had only thought about the benefits of having a zero base current, but I predicted that by making it differential, it would be possible to make a circuit that would allow an unlimited amount of current to flow from NPN to PNP, and that it would be possible to make a circuit with a high slew rate even though it was a differential circuit.

However, I was unsure whether it would work as expected, so I wrote a circuit diagram and handed it to TT. Then, I was surprised when TT immediately (I don't think it was even a day) said to me, "Takahashi, this is an amplifier with a really high slew rate." Although it was my idea, I asked him to become a co-inventor to praise his dexterity in finishing it into a reliable amplifier.

Anyway, this is how the diamond differential circuit was created.

This is a vivid description of the birth of the diamond differential circuit in more detail. I also knew about the diamond circuit. The crossed circuit diagram and the name "diamond" had been strangely intriguing to me.

I mentioned TIM in the 16th issue, but it will be an important point when releasing AU-D907 to the market. Mr. T is also a key person who appears in the case of Mr. Black, the inventor of NFB. I spoke to Mr. Takahashi by phone for the first time in three years, and he is a charming person who I hope will work on a project together again if we are both young and in good health.
 
18th installment: Sound quality review of the AU-D907
Start of sound quality review of the AU-D907

Long ago, there was something called a sound quality evaluation committee within the company, and if the product did not pass the committee, it could not be put into production or sold. This system was abolished after the AU-607.

In the case of the AU-D907, it was the top model at Sansui at the time, so it was clear that sales would be tough unless the sound quality was highly evaluated. .

Fortunately, JBL speakers, especially the expensive 4343, were selling very well at that time, so even if the company's own products did not sell well, they managed to survive somehow. And sales overseas, PX (sales to US military bases) were still selling well even after the Vietnam War ended, and the company's profits were supported by this part. Sales of transformers ended, and there were efforts to revive it, but the audio craft industry was forgotten and it ended in failure.

At that time, Sansui amplifiers were gaining momentum with the AU-607/707, so expectations for the AU-D907 were high. They were hoping for a track record similar to that of the former popular model, the AU-9500.

In the first place, sound quality is a matter of sensibility, so is there any point in considering sound quality? What is sound quality that sells? If we start discussing such things, it is a strange thing about audio that we still don't reach a conclusion. Especially since audio amplifiers are electronic products, it is strange to include issues of hearing, but since audio amplifiers drive speakers, it can be said that the world is all about "listening!". I had to consider sound quality with such vague feelings.

In fact, what is important in hearing is probably a matter of each person's thoughts and preferences. I got involved in audio because my grandfather was a concert piano tuner, and my parents also loved music, and our house was surrounded by my grandfather's mementos, a violin and a mandolin, and two phonographs that my father bought. I wanted to be a musician, but realized that I didn't have the talent to be a performer, so I got into audio from the perspective of a listener, so I wasn't a radio boy like my generation, but rather a boy who loved music. When I was a student, I used to go to Mr. Kawanishi's house at WR, and we would stay overnight and listen to classical records, go to cheap concerts together, and hold rotating record concerts with six friends who liked music, and sing masses by Bach and others in the glee club at my alma mater. Therefore, when it came to music, I was completely into classical music until I got a job.

I've digressed a little. I had a powerful experience during a business trip to the United States that showed me how I was able to reconcile such musical knowledge with my position as an employee of an audio manufacturer.

I was taken to the Village Vanguard in NY, which is considered a holy place for jazz fans, and listened to authentic jazz. In Japan, I had heard the skills and sounds of professional musicians at live recording and recording studios. They're so good! I thought they were truly professionals. However, the music in the real world is beyond good, it's amazing! That's all I could say. Especially the jazz of black people has a freedom and unrestrainedness, like the Tsugaru shamisen, which is a Japanese music.

I felt that Japanese jazz musicians don't go beyond "good!" Even if Japanese jazz musicians go to the real world, there may be union issues, but the basics are different. Isn't this the same as when an American comes to Japan and plays the Tsugaru shamisen or shakuhachi, and says that he's good for a foreigner?

Next, I listened to a rock band in LA. It was so powerful! Music that they have completely made their own blows away sheet music and such.

Therefore, I was convinced that Sansui's audio amplifiers would fully bring out the energy of the music, and that this should be the case with JBL speakers, for which Sansui is the import agent. Fortunately, both A and TS agreed on this important point.

Also, the person who understood me the most was my boss. I heard that my boss grew up in a blessed environment, with his father being a guitarist and his brother a composer, and that he joined Sansui because he loved audio.

My boss felt that the in-house staff alone were not objective enough, so he invited an outside expert to join him in the discussion. Unfortunately, that person has already passed away. Let's call him Mr. A. Mr. A had a track record that could be called professional in examining the sound quality of speaker systems and taking and summarizing the sound balance. However, he honestly told us that it was his first time with an audio amplifier.

Setting up the hearing system


The sound quality examination was conducted in the first listening room, which was about 30 tatami mats in size, out of the three audio rooms newly built in the Mitaka office. We decided to continue using the JBL 4320 speaker system. The JBL 4343 has been selling very well and has been used more and more in hearing tests by various audio magazines. The JBL 4343 was originally developed as a playback monitor for studio use, with the aim of allowing the people involved to listen to the finished sound source comfortably, and was not very suitable for sound production. The 4320 was a simple 2-way with clear positioning, smooth band connection, and above all, the woofer vibration system was lighter than the 4343, so it had instantaneous power. (I still can't let go of the 4320. Also, I used four 4320s and two power amplifiers BA-5000 (300W + 300W) for the sound reinforcement of the "Nagisa Yuko Recital" at the Shinjuku Welfare Pension Hall, and it was a fun memory that we were able to provide the best sound thanks to the skill of the famous mixer Mr. Namekata.)

Now, around this time, the importance of speaker cables began to be pointed out, but I decided to avoid having a special sound quality tendency and use a shielded cable type, 2 square, about 5m long speaker cable. Since there were no CDs at that time, analog records were the program source. I decided to use a Technics SP10MKII turntable, a Victor tonearm, and an Empire 4000DIII cartridge.

So, what program source should I use? I thought it would be best to use something with a wide range of instruments and vocals, which I'm most familiar with.

So, when I was designing the speakers, I listened to "Close to you" by the Carpenters hundreds of times. JBL also goes well with jazz, so I used "We get Request" to consider sound quality. I also often used the album of Hiromi Iwasaki, who had just debuted at the time, for consideration.

When I asked Mr. A what he would use as the main program source next time, he said that he would mainly use "Introduction to the Orchestra on Themes by Purcell," composed by Britten, conducted and narrated by Andre Previn, on side A, and "Peter and the Wolf, composed by Prokofiev" on side B. The label was EMI/Angel.

I see, I was impressed that they chose a program source that met the above conditions.

Start of the hearing review

We started, but Mr. A was not in good condition during the day, and his sensitivity did not become sharp until dark/late at night. Since we were salaried workers, we could not do our normal work unless we came to work at the regular time the next morning. The sound quality review staff was me, TS, and the model designer. The designer could not work until late due to internal circumstances, so the three of us decided on the items to be considered to a certain extent, and it was almost 9 o'clock, so TS and I were waiting for Mr. A.

I'm sorry to jump around a bit, but in the case of a manufacturer, even if you get a sound that you like, it does not become a product as it is. First of all, there are various problems that arise, such as whether there are any problems in terms of quality and reliability, if special parts are used, how reliable are those parts, can they be purchased, and how to adjust the company if the cost increases.

Specifically, there was a problem with the transient response waveform. I was able to judge the hearing of this area by the sound of the moment the cartridge is lowered onto the record surface, the beginning of the narration, the way the consonants are cut off, etc. When the circuit is refined in this way, the electrical response changes depending on the sound quality considerations such as the amount of NFB and phase margin. Specifically, a 10kHz square wave response with a resistive load resulted in 2.5 waves of ringing. An audio engineer would strive to create a response without ringing. We tried to do so, but it resulted in a lifeless, dull sound no matter how many times we tested it. As a speaker engineer, I acknowledged such efforts with a resistive load, but since it was not a speaker load, I insisted that hearing should take priority.

In terms of frequency characteristics, it was confirmed that a slight peak occurred around 250kHz. If this did not cause oscillation under severe conditions for the amplifier, such as the capacity load of the amplifier, there would be no problem with reliability, and the amplifier's outstanding instantaneous power could be maintained.

By the time the discussion with Mr. A was over, it was past 1am, and I would borrow a company car to go home late at night, then leave home at 5:30am the next morning to go to work.

Thank you for reading this disorganized article. In the next issue, I will continue with the sound quality discussion and talk about field tests at critics' homes.

Published on September 23, 2006
 
19th installment: Sound quality review and its evaluation

What does sound quality review involve? Is its evaluation meaningful?

Audio amplifiers are electronic products, so if they perform well, they can still be used as products. I have previously mentioned that the sound quality of an amplifier is determined mostly by three elements: circuit, parts, and structure (including layout).

In the previous installment, the circuit was solidified, and now it's time to move on to parts. If the parts are ideal, there is no need to spend time selecting them. However, there are no ideal parts, and various factors come into play, especially in the high frequency range. If it is not an NFB amplifier, the frequency band it handles will be much narrower, so the relationship between parts and sound quality will be weaker. Since NFB can be applied deeply in a direct-coupled transistor amplifier, it is necessary to consider the response up to a higher frequency range.

From my perspective, I think that if you select active parts such as vacuum tubes well, the impact of passive parts is small for a non-feedback vacuum tube amplifier. With a non-feedback vacuum tube amplifier, if you pay attention to residual noise, you can enjoy the vacuum tube sound of your choice, and I think it's an interesting hobby.

Now, from the outside, examining the parts and sound quality looks like a repetition of listening, replacing parts, listening again, and replacing parts, and I've often been told by thoughtless people that this job is not for engineers, that it's for change-makers. It's certainly not something for people with little DNA or experience (emotions) that love music. Audio companies are concerned about this, and it has become commonplace for engineers who design amplifiers not to have the power to decide on sound quality. Of course, this is limited to models where sound quality is a concern. Specifically, they would send the person in charge of sound quality to concerts, and at one company, they would have a famous jazz bassist who was also interested in audio at the time attend the concert, and they would give him a lot of decision-making power. Also, at another company, there was a person in charge of sound quality, and that person would be given the power to decide on sound quality.

In the case of the AU-D907, first of all, we used Taiyo resistors, whose resistor bases are made of brass instead of iron. After listening to the previous resistors and the amplifier made with this resistor, we immediately decided to use this resistor. It was smooth and fresh. Its weakness is that it is a little soft, but this was fully covered by the circuit. The power block chemical capacitor was decided in advance, so it was only necessary to check the mass-produced prototype. However, in the high-frequency range, the chemical capacitor alone brings in components other than the capacitor, so it was necessary to attach a film capacitor with excellent high-frequency characteristics in parallel. In the AU-607, we attached two Panasonic film capacitors, but this time we were not satisfied with them. Around that time, various parts that had achieved results in improving the sound quality of capacitors appeared. Specifically, we decided to attach a total of four 2.2μ film capacitors called V-con. This increased the cost by more than 500 yen.

At that time, interest was finally beginning to be paid to the relationship between the sound quality and characteristics of capacitors. We also received information that AUREX (Toshiba's audio brand at the time) had patented a utility model that connects two or more types of film capacitors in parallel to a chemical capacitor. The purpose of this utility model was to get closer to the ideal capacitor by attaching a capacitor that matches each band. In the end, it seems that no audio manufacturer paid any attention to this when designing.

In addition, we found that reinforcing the ground pattern in the printed circuit board with jumper wires made the sound quality more and more solid. We also found that a different method of handling the current flowing through the chassis could be used to improve the situation, but this could not be adopted in this model, so we will discuss this in the next model. We also found that it is better to use a thicker cable for the ground line, but not if it is too thick. In the AU-D907, two AWG20 cables were used in parallel at key points.

In this way, the summer of 1978 came to an end, and the sound quality gradually came together. We decided to conduct field (outside the company) tests in time for the new product announcement schedule in late October. At that time, there were more than 20 critics, and everyone was very busy with work. The test with the late Nagaoka Tetsuo was very impressive. First, he asked about the weight. I remember him muttering something like, "It's quite heavy! This produces a good sound!" He played some very pulsating records and blared them out through his homemade back-loaded horn speakers. To my ears, the sound was incomparably more powerful than the AU-607/707. I thought the AU-607/707's strong point was its freshness. Now in 2006, when I listen to the repaired sound after repairing my AU607, I still get the same impression. It still has the same appeal, and I'm reminded once again that it has a more attractive sound than the current product.

That aside, I remember visiting about 10 places and finding out that it was better to slightly increase the current of the first stage FET of the power amplifier and to make the idling current nearly twice as much as usual, and making the necessary changes. Overall, it was very well received. I think this positive reception was not only because the AU-D907 certainly had an excellent sound, but also because it was a song of encouragement to regain the top reputation that the AU-9500 had in the past.


Now, we had to decide how to sell this amplifier, so we first had to decide on a concept for advertising and promotion. The advertising department took the lead in coming up with ideas, but nothing seemed to work. This one also had an excellent slew rate, so how about an ultra-high speed amplifier? We also suggested this, but this didn't work either. At one of the several meetings, the developer Takahashi, who participated as a special guest, suggested that the catchphrase be "no TIM." Indeed, Matti Otala, the proponent of TIM, had said that increasing the slew rate was effective in preventing TIM from occurring. Thus, the copy "Challenge to Zero TIM" was born, which was ahead of other companies. It was decided that this copy would be used for all audio magazine advertisements and catalog copy. Looking back now, I think it was a good copy. September 1978 passed, and October came, and it was time to start production of the first lot. The production took place in the Saitama factory, a unique building with a latticework exterior that no longer exists. The first lot was 1,000 units, which would be astonishing today.

Next time, I would like to talk about that first lot and subsequent developments. Once again, I would like to thank you for reading my poor writing.

Published on November 8, 2006
 
Part 20: Release of the D series and development of the AU-X1
Release of the D (Diamond Differential) series

The AU-D907 was released in late October 1978. At that time, audio manufacturers were selling a lot of components, so they held new product launches in major cities across the country. The venue was a first-class hotel. It was held in Tokyo, Osaka, Nagoya, Fukuoka, Sendai, and Sapporo, and it was "unbelievable!", something that is unthinkable today.

At the presentation venue, critics, audio magazine editors, retailers, and employees in charge of each were on hand to explain and entertain. I also went on business trips to six locations nationwide. Of course, other companies did the same. Sales were quite good, but overall, I don't think it was profitable. Sansui was still in a good position because they had a profitable product called JBL. The audio industry at that time was a thriving industry without profits. There were about 2,000 audio stores nationwide, so even if customers didn't buy the first batch, about 1,000 units would be sold in no time for display in stores.

In any case, the home appliance industry is still competing to lower the prices of digital home appliances, but this seems to be due to the fact that both manufacturers and retailers have a sales culture that only thinks about selling cheaply and increasing sales, and not about profits. But exports were booming at the time, so the company as a whole grew significantly.

The first batch of AU-D907s did not reach the mass-produced prototypes in terms of sound quality. I was a little worried. The sound quality was slightly dry. The momentum is scary, and perhaps because the reviews in audio magazines were almost rave reviews, sales were smooth and we immediately started production of the second batch. The staff, including myself, went to the factory and tried to improve the product, and the result was a product that was comparable to the mass-produced prototypes. Up until then, the feeling of "rubbery quality with the AU-607," which critic SO had said in a good way, was completely wiped away, and the expression of power, smoothness, and depth was also flawless. It also went well with JBL, and jazz sound sources sounded more comfortable than classical music.

It was only moderately compatible with MC cartridges, which left me a little dissatisfied. It seemed that many users were listening to MM type. The next model had to deal with the issue of how to support MC cartridges. Also, if possible, I would have liked to have been able to play classical music in a more mellow way.

The audio fair at that time was a huge success, with the entire Harumi fair hall being rented out. Audio-related men crowded around the female show models decorating each booth, taking photos. Of course, Sansui's booth had the AU-D907 as its main theme, and it was very exciting. Other companies probably sold similar products, which shows how hot audio was at the time.

Then, the lower-end models AU-D607 and AU-D707 were released, and in 1978, there were three integrated amplifiers that used diamond differential circuits. And so, 1978 came to an end.

Looking back at the audio articles that were released from the end of 1978 to the spring of 1979, I found that these three models, especially the AU-D907, were introduced in many cases. By the way, the high-end pre-main amplifier that had a good reputation at the time was the Yamaha CA-2000. These two models seemed to divide the high-end pre-main amplifier market in half.
 
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