untitled BOARD SUPPORT TOOLING MODULE INTRODUCTION CHAPTER 26 BOARD SUPPORT TOOLING MODULE INTRODUCTION The board support tooling module includes the following • Manual Tooling Plate • Tooling Options.
BOARD SUPPORT TOOLING MODULE INTRODUCTION CHAPTER 26 BOARD SUPPORT TOOLING MODULE INTRODUCTION The board support tooling module includes the following: Manual Tooling Plate • Manual Tooling Plate • Tooling Options The manual tooling plate is the basic tooling module fitted to the machine rising table There are various tooling options which attach to the manual tooling plate either by dowel pins or magnetically Locating Dowel Holes Manual Tooling Plate Rising Table View on Front Right Corner Figure 26-1 Manual Tooling Plate Tooling Options NOTE Do not leave unused tooling on the rising table in the area behind the rear rail If any object is left on the rising table outside the board printing area, it could collide with the camera carriage as the rising table moves to print height The following table shows how the tooling options are fitted to the tooling plate: Tooling Chapter Issue Jul 10 Fixing Magnetic Support Pillars Magnetic Vacuum Box Tooling Dowel Pins MultiFlex Tooling Dowel Pins Dedicated Tooling Plate Dowel Pins and Magnetic ProFlow Stencil Support Magnetic Grid-Lok Tooling Magnetic Technical Reference Manual 26.1 BOARD SUPPORT TOOLING MODULE MAGNETIC SUPPORT PILLARS MAGNETIC SUPPORT PILLARS The magnetic support pillars are positioned on the manual tooling plate by the operator These pillars can be positioned anywhere under the board to provide board support There are two types of support pillars available: • Flat-top pillars (19mm) for supporting boards which are not populated on the underside • Pin-top pillars (4mm) for supporting boards which are populated on the underside The pins are positioned so that they fit between the components on the underside of the board They are low profile, 15mm to the shoulder with a 4mm pin dimension Flat-top Pillars Unpopulated Board Populated Board Pin-top Pillars Tooling Plate Flat-top Pillars used on Unpopulated Board Pin-top Pillars used on Populated Board 19mm Dia 19mm 81mm (nominal) 81mm (nominal) Flat-top Pillar Dimensions 15mm 4mm Dia Pin-top Pillars Dimensions Board Magnetic Pillars Tooling Plate Fitment of Magnetic Pillars to Table Figure 26-2 Magnetic Support Pillars 26.2 Technical Reference Manual Chapter Issue Jul 10 BOARD SUPPORT TOOLING MODULE VACUUM BOX TOOLING VACUUM BOX TOOLING The vacuum box is manufactured to the same height as the magnetic pins, ie 81mm, irrespective of the thickness of the board being printed The vacuum boxes can be constructed without top or bottom plates to allow for additional pin support of the board Provision for machining of top plates to accommodate underside components is available The box is located on the table by means of dowels which locate in the two holes on the manual tooling plate The minimum length of the vacuum box is 90mm which is dictated by the locating dowels Where the board length is less than the vacuum box length, top plates either side of the board must be used to achieve vacuum The following graphic details the dimensional information on the vacuum box tooling for use on the rising table: Nominal Board Length -4mm (2mm overhang of board, each end) Minimum 90mm Maximum 508mm NOTE For Dual Lane machines Right to Left and Left to Right a 12mm elbow and a machined adaptor ring is fitted Insert Magnetic Pins as Required Nominal Board Width -12mm (6mm overhang of board, each end) 36mm Vacuum Hole Plan View of Vacuum Box NOTE Front Dowel Pins (3mm diameter) 81mm +0.00mm -0.05mm 80mm Front View of Vacuum Box NOTE View showing board positioned on Vacuum Box 2.5mm Left Hand Side View of Vacuum Box Figure 26-3 Vacuum Box Tooling NOTE For RTC or Dual Lane machines the vacuum box dimensions, as shown above, must not be used Contact DEK Customer support for details of the correct dimensions to be used Chapter Issue Jul 10 Technical Reference Manual 26.3 BOARD SUPPORT TOOLING MODULE VACUUM BOX TOOLING Nominal Board Length -4mm (2mm overhang of board, each end) Minimum 290mm Maximum 375mm NOTE A 12mm elbow and a machined adaptor ring is fitted Insert Magnetic Pins as Required Nominal Board Width -13.5mm (overhang 6mm rear and 7.5mm front) 36mm Vacuum Hole Plan View of Vacuum Box NOTE Front Dowel Pins (4mm diameter) 81mm +0.00mm -0.05mm 280mm Front View of Vacuum Box NOTE View showing board positioned on Vacuum Box 29.5mm Left Hand Side View of Vacuum Box Figure 26-4 Vacuum Box Tooling Rapid Transit Conveyor 26.4 Technical Reference Manual Chapter Issue Jul 10 BOARD SUPPORT TOOLING MODULE MULTIFLEX TOOLING MULTIFLEX TOOLING The MultiFlex tooling plate hardware consists of a hollow box constructed from four adjustable side plates The side plates are secured to the MultiFlex tooling plate using magnets The tooling plate is located on the tooling table by means of dowels Board support is provided by double ended steel pins on a 5mm matrix One end is 3mm tapering down to 1mm to allow for support of densely populated boards Vacuum (option) is achieved using the Venturi effect on the mains air supply The vacuum is variable by adjustment of the speed controller A gauge on the Venturi vacuum pump indicates the amount of vacuum The speed controller, solenoid and Venturi vacuum pump are mounted inside the main frame at the front of the machine The MultiFlex tooling plate is 14 inches x 10 inches The tooling height is the same as a standard magnetic tooling pin, ie 81mm The 3mm diameter tooling pins are placed on the 5mm pitch matrix according to the particular board configuration, to support the board, and yet miss any components, or features present Figure 26-5 MultiFlex Tooling Chapter Issue Jul 10 Technical Reference Manual 26.5 BOARD SUPPORT TOOLING MODULE DEDICATED TOOLING SYSTEM DEDICATED TOOLING SYSTEM The dedicated tooling system is a 3-piece construction comprising a plate assembly which locates on a tooling tower and magnetic support pins that provide support under the plate assembly when accommodating wide boards The system is manufactured to provide board support at the standard tooling height of 81mm The plate assembly can be specifically machined to accommodate underside components on customers products The tooling tower has dowel pin registration and is held in position on the manual tooling plate by two magnetic clamps located in the vacuum chamber of the tooling tower Additional board support can be utilized with the optional vacuum facility Figure 26-6 Dedicated Tooling System Item 26.6 Description Plate Assembly Tooling Tower Magnetic Tooling Pins Technical Reference Manual Chapter Issue Jul 10 BOARD SUPPORT TOOLING MODULE PROFLOW STENCIL SUPPORT PROFLOW STENCIL SUPPORT The ProFlow Stencil Support unit provides stencil support when printing with ProFlow and helps to avoid smearing paste onto the top of the stencil These are used mainly when printing boards that are narrower than the ProFlow transfer head (300mm minimum) The ProFlow Stencil Support is compatible with all tooling options The standard height (when the adjustable tooling top is in the closed position) is 81mm Magnetic Support (2 positions) Changeable Gauge Plate Tooling Bottom Adjustable Tooling Top Magnetic Feet Adjustable Tooling Top Stencil Support Height (81mm + PCB Thickness) Board Board Figure 26-7 ProFlow Stencil Support Changeable Gauge Plate The Changeable Gauge Plate, standard thickness 3/16" (4.77mm), may be changed in order to support larger stencil areas These are easily removed and held in position by fixed magnetic supports Tooling Bottom The Tooling Bottom is the fixed base for the stencil support with magnetic feet attached for easy position on the tooling table Adjustable Tooling Top The Adjustable Tooling Top can be moved by releasing the 7mm hexagonal nut securing it to the tooling bottom The unit can be slid upwards, raising the height of the support unit, to the desired height Chapter Issue Jul 10 Technical Reference Manual 26.7 BOARD SUPPORT TOOLING MODULE GRID-LOK TOOLING GRID-LOK TOOLING Overview Operator Interface Manifold Tooling Modules Grid-Lok Control Unit Grid-Lok tooling is a fully automated tooling facility that conforms to any given board profile, fully supporting the underside of a populated board and the stencil There are two types of Grid-Lok tooling modules: • Standard - Single row of tooling pins with a 25.4mm spacing • High Density (HD) - Double row of tooling pins with a 12mm spacing The standard and HD tooling modules are available in two sizes: Tooling Module Size Pins Modules Supplied Standard 12 inch (305mm) 12 Standard 18 inch (457mm) 18 High Density (HD) 12 inch (305mm) 46 High Density (HD) 18 inch (457mm) 72 The Grid-Lok tooling modules are held magnetically to the manual tooling plate 26.8 Technical Reference Manual Chapter Issue Jul 10 BOARD SUPPORT TOOLING MODULE GRID-LOK TOOLING The Grid-Lok tooling system can be configured to handle the following board sizes: • Minimum board size - 38mm x 50mm • Maximum board size - 254mm x 508mm • Board thickness - 0.4mm - 5.0mm With the board loaded and raised to print height, all the Grid-Lok pins are extended using pneumatic pressure until they meet the underside of the board, stencil or component After a set period of time, the locking mechanisms of the tooling modules are activated and the pins remain in this position until the system is reset The Grid-Lok system incorporates two modes of operation, manual or automatic In manual mode, the tooling pins conform to the board profile and remain in that position until the reset button is pressed In automatic mode, the tooling pins conform to each board before it is printed Chapter Issue Jul 10 Technical Reference Manual 26.9 26.10 Technical Reference Manual Power Supply Input (M37 Power Supply Module) Machine Software Input (Node Board 2) Power Switch Grid-Lok Control Unit Solenoid (Lock Tooling Pins) Board Clamp Switch Programmable Interrupt Controller (PIC) Board Solenoid (Raise Tooling Pins) Selector Switch Operator Interface BOARD SUPPORT TOOLING MODULE GRID-LOK TOOLING Electrical Schematic Chapter Issue Jul 10 Chapter Issue Jul 10 Mains Air In At 4.5 Bar Minimum Filter/Reg Assy Technical Reference Manual Pressure Sense P Mains Air to Machine Grid-Lok Control Unit B Pneumatic Manifold (part of) 5/2 Pos A Board Clamps Grid-Lok Manifold Tooling Modules BOARD SUPPORT TOOLING MODULE GRID-LOK TOOLING Pneumatic Schematic 26.11 BOARD SUPPORT TOOLING MODULE GRID-LOK TOOLING Adjustments and Settings WARNING BOARD CLAMPS EXTREME CARE MUST BE EXERCISED WHEN WORKING IN THE TOOLING AREA OF THE MACHINE TO AVOID INJURY THE FOILS ON THE FRONT AND REAR BOARD CLAMPS ARE VERY SHARP Setting the Control Unit Function Switch The Grid-Lok control unit is located behind the rear panel and is mounted on the pneumatic manifold plate The control unit incorporates all the pneumatic and electrical control systems required to raise and lower the Grid-Lok tooling pins Function Switch Location Pointer at position Grid-Lok Control Unit An access hole on the right side panel is used to gain access to the function switch The switch sets the delay of the tooling pins being raised after the board leaves vision height, in automatic mode For Grid-Lok to operate correctly on a DEK printer, the selector switch must be set to 26.12 Technical Reference Manual Chapter Issue Jul 10 BOARD SUPPORT TOOLING MODULE GRID-LOK TOOLING Air Control Regulator The air control regulator is fitted to the top input of the Grid-Lok manifold and is used to adjust the air flow to the raise pins input of the tooling modules Figure 26-8 Air Control Regulator To adjust the air control regulator, use the following procedure: Ensure the operator interface is switched to Manual Release the locking nut on the air control regulator Adjust the air control regulator fully clockwise cutting off the air supply to the tooling modules Adjust the air control regulator one turn anti-clockwise Press the Set button on the operator interface If all the pins on the tooling modules not raise fully, press the Reset button on the operator interface and repeat Steps and If all the pins on the tooling modules raise fully, turn the air control regulator a further half turn anti-clockwise and secure the locking nut Press the Reset button on the operator interface NOTE Adjustment of the air control regulator must be performed when changing the amount of tooling modules used Chapter Issue Jul 10 Technical Reference Manual 26.13 BOARD SUPPORT TOOLING MODULE GRID-LOK TOOLING Replacement Procedures Fitting Grid-Lok Tooling WARNING BOARD CLAMPS EXTREME CARE MUST BE EXERCISED WHEN WORKING IN THE TOOLING AREA OF THE MACHINE TO AVOID INJURY THE FOILS ON THE FRONT AND REAR BOARD CLAMPS ARE VERY SHARP WARNING COMPRESSED AIR COMPRESSED AIR SHOULD NEVER IMPINGE UPON THE BODY PORTS, PIPES, ETC MUST NEVER BE BLOCKED BY HAND BEFORE CONNECTING OR DISCONNECTING ANY PNEUMATIC COMPONENTS, ENSURE THE COMPRESSED AIR SUPPLY HAS BEEN DISSIPATED AND DISCONNECTED FROM THE MACHINE Select Open Cover Commands Select Carriage To Rear Select Shut Down and switch the mains isolator to OFF Open the front printhead cover Remove the screen from the machine The tooling modules can be configured to suit the product to be printed The tooling modules can be staggered in the X axis and/or spread evenly in the Y axis to fully support the product to be printed (see figure below for examples) NOTE Tooling modules must never be placed underneath the front or rear rails 5 3 Plan View on Manual Tooling Plate Place the manifold on the rear of the tooling plate Connect the 6mm diameter pneumatic pipe marked to the top 6mm connector of the Grid-Lok manifold Connect the 6mm diameter pneumatic pipe marked to the bottom 6mm 26.14 Technical Reference Manual Chapter Issue Jul 10 BOARD SUPPORT TOOLING MODULE GRID-LOK TOOLING connector of the Grid-Lok manifold 10 Connect 4mm diameter pneumatic pipes from the manifold to all the tooling modules ensuring that the outputs marked red on the manifold connect to the inputs marked red of the tooling modules To Connector of the Grid-Lok Control Unit Grid-Lok Manifold To Connector of the Grid-Lok Control Unit Tooling Modules NOTE Only tooling modules and are connected for clarity Chapter Issue Jul 10 Technical Reference Manual 26.15 BOARD SUPPORT TOOLING MODULE GRID-LOK TOOLING 11 If vacuum tooling was used previously, open the rear cover and change the vacuum tooling connector to the Grid-Lok connector on N2SK9 - I/O Node Board MAIN I/O NODE 181436 ISSUE N2SK9 (Vacuum Tooling Sensor or Grid-Lok Tooling) View on Rear of Machine 12 Refit the screen 13 Power up the machine 14 Setting of the air control regulator must be carried out before running the machine, Air Control Regulator in the Adjustments and Settings section of this chapter refers 26.16 Technical Reference Manual Chapter Issue Jul 10 BOARD SUPPORT TOOLING MODULE GRID-LOK TOOLING Removing Grid-Lok Tooling WARNING BOARD CLAMPS EXTREME CARE MUST BE EXERCISED WHEN WORKING IN THE TOOLING AREA OF THE MACHINE TO AVOID INJURY THE FOILS ON THE FRONT AND REAR BOARD CLAMPS ARE VERY SHARP WARNING COMPRESSED AIR COMPRESSED AIR SHOULD NEVER IMPINGE UPON THE BODY PORTS, PIPES, ETC MUST NEVER BE BLOCKED BY HAND BEFORE CONNECTING OR DISCONNECTING ANY PNEUMATIC COMPONENTS, ENSURE THE COMPRESSED AIR SUPPLY HAS BEEN DISSIPATED AND DISCONNECTED FROM THE MACHINE Select Open Cover Commands Select Carriage To Rear Select Shut Down and switch the mains isolator to OFF Open the front printhead cover Remove the screen from the machine Disconnect and remove the 4mm pneumatic pipes from the manifold to the tooling modules Disconnect the two 6mm pneumatic pipes to the manifold Remove the manifold and the tooling modules from the manual tooling plate NOTE Ensure that the two 6mm pneumatic pipes remain flat on the tooling plate and not impinge on the movement of the rear rail or the screen (when the rising table is at print height) If vacuum tooling is to be used, open the rear cover and change the Grid-Lok connector to the vacuum tooling connector on N2SK9 - I/O Node Board Chapter Issue Jul 10 Technical Reference Manual 26.17 BOARD SUPPORT TOOLING MODULE GRID-LOK TOOLING 26.18 Technical Reference Manual Chapter Issue Jul 10 ... (part of) 5/2 Pos A Board Clamps Grid-Lok Manifold Tooling Modules BOARD SUPPORT TOOLING MODULE GRID-LOK TOOLING Pneumatic Schematic 26.11 BOARD SUPPORT TOOLING MODULE GRID-LOK TOOLING Adjustments... Grid-Lok tooling modules are held magnetically to the manual tooling plate 26.8 Technical Reference Manual Chapter Issue Jul 10 BOARD SUPPORT TOOLING MODULE GRID-LOK TOOLING The Grid-Lok tooling. .. amount of tooling modules used Chapter Issue Jul 10 Technical Reference Manual 26.13 BOARD SUPPORT TOOLING MODULE GRID-LOK TOOLING Replacement Procedures Fitting Grid-Lok Tooling WARNING BOARD CLAMPS