untitled MACHINE OVERVIEW OVERVIEW CHAPTER 4 MACHINE OVERVIEW OVERVIEW There are two machine cover designs as follows • Sliding Glass Cover Machine (two variants SGC and SGC iX) • Metal Cover Machine.
MACHINE OVERVIEW OVERVIEW CHAPTER MACHINE OVERVIEW OVERVIEW There are two machine cover designs as follows: • Sliding Glass Cover Machine (two variants: SGC and SGC iX) • Metal Cover Machine View on Front - Left Quarter View on Rear - Right Quarter Figure 4-1 Sliding Glass Cover Item Chapter Issue Jul 10 Description Item Description Opening Printhead Cover Rear Panel Mains Isolator Switch Right Hand Safety Cover Front Panel Emergency Stop Button (E Stop) TCM Manifold Left Hand Safety Cover Technical Reference Manual 4.1 MACHINE OVERVIEW OVERVIEW View on Front - Left Quarter View on Rear - Right Quarter Figure 4-2 Sliding Glass Panel iX Covers Item 4.2 Description Item Description Right-hand Control Buttons Programmable Beacon ESD Connection Point Emergency Stop Button (E Stop) Mains Isolator Switch Left Hand Control Buttons Rear Printhead ‘Knock-out’ Panel Environmental Control Connection Point Technical Reference Manual Chapter Issue Jul 10 MACHINE OVERVIEW OVERVIEW View on Front - Left Quarter View on Rear - Right Quarter Figure 4-3 Metal Covers Item Description Item Description Front Printhead Cover Rear Panel Mains Isolator Switch Right Hand Safety Cover Front Panel Emergency Stop Button (E Stop) Rear Printhead Fixed Cover Left Hand Safety Cover This chapter describes the function and the purpose of each of the machine modules and the relationship and interaction between modules, if applicable For detailed information regarding each module refer to the relevant module chapter in this manual Chapter Issue Jul 10 Technical Reference Manual 4.3 MACHINE OVERVIEW MODULE OVERVIEWS MODULE OVERVIEWS Man Machine Interface (MMI) Module The MMI module enables communication and interaction between the user and the machine This is achieved by the use of the touchscreen or monitor, IR keyboard/mouse or standard keyboard/mouse, tricoloured beacon, USB connector(s) and the two button control system The IR keyboard/mouse or standard keyboard/mouse is also available for maintenance purposes Tricolour Beacon Control Switches Touchscreen Monitor IR Keyboard/ Mouse (stowed inside front cover) Mains Isolator Switch Figure 4-4 MMI Sliding Glass Cover Programmable Beacon Control Buttons Control Buttons Touch Screen Monitor Keyboard & Tracker Ball Mouse ESD Point Mains Isolator Switch E Stop Figure 4-5 MMI Sliding Glass Cover (iX) 4.4 Technical Reference Manual Chapter Issue Jul 10 MACHINE OVERVIEW MODULE OVERVIEWS Monitor Tricolour Beacon Right Jog Button Left Jog Button System Button E Stop USB Connector USB Connector Mains Isolator Switch Figure 4-6 MMI Metal Covers Chapter Issue Jul 10 Technical Reference Manual 4.5 MACHINE OVERVIEW MODULE OVERVIEWS Power Supply Module Machine Control Module The M37 power supply module fulfils the following functions: • Transform and rectify the mains voltage supply to the voltages required by the electrical systems throughout the machine • Electrical safety - achieved by the use of emergency stop safety circuits (E Stop) When an E Stop is activated, power is removed from selected areas of the machine The M36 machine control enclosure is the central hub controlling machine motion Machine control also consists of I/O Nodes throughout the machine connected to the machine control enclosure using a CAN Bus Machine control is an interface between the software and: Machine PC Module • Stepper Motors • Servo Motors • Linear Motors • Sensors • Switches • Solenoids • Lamps The machine PC enclosure is the master controller of the machine Issuing sequential control commands to slave systems via the machine control enclosure, the PC analyses the feedback signals and issues further commands to ensure the correct operation and safety of the machine Power Supply Module Machine Control Enclosure Machine PC Enclosure Figure 4-7 Power Supply - Machine Control - Machine IBus PC 4.6 Technical Reference Manual Chapter Issue Jul 10 MACHINE OVERVIEW MODULE OVERVIEWS Rising Table Module The rising table module fulfils the following functions: • Provide a stable base and positioning for the board support tooling • Positioning the transport rails at various heights during the print cycle Board Support Tooling Module The role of the board support tooling is to support the board during the print stroke, to prevent print distortion caused by flexing of the board as a result of the downward pressure of the squeegees/ProFlow Several different types of board support tooling are available to suit a variety of surface mount process requirements Transport Rails Module The transport rail system is a programmable width conveyor system, utilized to transport the board through the machine and to secure the board during the print stroke The rail system height is positioned by the rising table, during the print cycle Two sytems are currently available, the RS or rail system and the MTR or modular transport rail; the latter has a modular centre section which can give support to a variety of clamping arrangements Rising Table Board Support Tooling Transport Rails Figure 4-8 Rising Table - Board Support Tooling - Transport Rails (RS) Chapter Issue Jul 10 Technical Reference Manual 4.7 MACHINE OVERVIEW MODULE OVERVIEWS End Rail Mid Rail Centre Section - Over theTop Snuggers (OTS) Board Transport Belts MODULAR TRANSPORT RIALS Figure 4-9 Transprort System (MTR) 4.8 Technical Reference Manual Chapter Issue Jul 10 MACHINE OVERVIEW MODULE OVERVIEWS High Throughput The high throughput conveyor (HTC) module is an optional programmable width conveyor system The function of the HTC is to transport up to three boards Conveyor through the machine at one time using belts The rail system height is Module positioned by the rising table, during the print cycle Two systems are currently available, the standard HTC systemand the MHTC MHTC is a modular transport rail system for the HTC It has a modular centre section, which can give support to a variety of clamping arrangements M27 HTC Controller Enclosure HTC Module Figure 4-10 High Throughput Conveyor (HTC) Dual Lane Chapter Issue Jul 10 The dual lane machine consists of two sets of transport rails, one being a print lane and the other being a pass through lane The machines are a dedicated build and available as a front print or rear print machine Dual lane is not an option that can be fitted to a standard machine Technical Reference Manual 4.9 MACHINE OVERVIEW MODULE OVERVIEWS M40 Dual Lane Controller Dual Lane Module Figure 4-11 Dual Lane 4.10 Technical Reference Manual Chapter Issue Jul 10 MACHINE OVERVIEW MODULE OVERVIEWS Camera System Module The function of the camera system is to supply a visual indication of screen to board alignment and board/screen inspection data to the machine PC enclosure The captured information supplied to the PC enclosure enables the processor to: • Align the screen to the product board • Provide visual information for the user on the MMI monitor The camera assembly traverses horizontally in the X and Y axis and is driven by either: • Rotary Servo Motors • Linear Servo Motors The camera carriage is also used to transport the board stop and the underscreen cleaner Camera System Figure 4-12 Camera System Chapter Issue Jul 10 Technical Reference Manual 4.11 MACHINE OVERVIEW MODULE OVERVIEWS Underscreen Cleaner The underscreen cleaner module automatically cleans the underside of the screen so reducing the build up of paste.The underscreen cleaner is driven across the underside of the screen by the camera carriage There are three types of underscreen cleaner available: • Blue Underscreen Cleaner • Cyclone Underscreen Cleaner • Vortex Underscreen Cleaner The underscreen cleaner module provides the facility to store solvent for wet cleaning cycles Solvent is stored in one of the following: • External Solvent Tank • Solvent Bottle (metal covers machine only) The external solvent tank may be mounted on either side or the rear of the machine and is secured to the machine frame The vacuum filtration unit removes excess paste from the screen and solvent/ print material fumes There are three types of vacuum filtration units: • VF35i Vacuum Filtration Unit • VF25 Vacuum Filtration Unit • VF10 Venturi Vacuum Filtration Unit Underscreen Cleaner External Solvent Tank Solvent Bottle VF10 Venturi Vacuum Filtration Unit VF25 Vacuum Filtration Unit VF35i Vacuum Filtration Unit Figure 4-13 Underscreen Cleaner Components 4.12 Technical Reference Manual Chapter Issue Jul 10 MACHINE OVERVIEW MODULE OVERVIEWS Adjustable Screen Mount (ASM) The ASM is the receptacle for the screen during printing operations The ASM is fully adjustable to accommodate the most popular of screen sizes The print screen is clamped into place by the ASM during the print cycle The ASM is a machine option replacing the C Chase There are two methods used for achieving correct position of the screen within the chase assembly: • Screen Depth Adjuster • Screen Change Mechanism The screen depth adjuster is set (Distance to Image) by the operator prior to loading the screen The screen is loaded into the chase until it reaches the stop at the end of the screen depth adjuster The screen change mechanism places the screen in the correct position calculated by the software Screen Alignment Module The screen alignment module enables adjustment of the ASM to achieve optimum screen to board alignment prior to the print stroke Actuators move the print screen in the X, Y and theta planes to nullify the misalignment error signal from the vision system Screen Alignment (actuators) Screen Alignment (chase clamp) Screen Change Mechanism Screen Depth Adjuster Screen Alignment (chase clamp) Adjustable Screen Mount (ASM) Figure 4-14 Adjustable Screen Mount (ASM) - Screen Alignment Chapter Issue Jul 10 Technical Reference Manual 4.13 MACHINE OVERVIEW MODULE OVERVIEWS Cast C Chase Module The cast C chase is the receptacle for the screen during printing operations The cast C chase accommodates the standard 29” by 29” screen size A universal adapter is available to accommodate smaller screens The print screen is clamped into place by the cast C chase during the print cycle The cast C chase is a machine option replacing the ASM There are two methods used for achieving correct position of the screen within the chase assembly: • Screen Depth Adjuster • Screen Change Mechanism The screen depth adjuster is set (Distance to Image) by the operator prior to loading the screen The screen is loaded into the chase until it reaches the stop at the end of the screen depth adjuster The screen change mechanism places the screen in the correct position calculated by the software Screen Alignment Module The screen alignment module enables adjustment of the C chase to achieve optimum screen to board alignment prior to the print stroke Actuators move the print screen in the X, Y and theta planes to nullify the misalignment error signal from the vision system Screen Alignment (actuators) Screen Alignment (chase clamp) Screen Change Mechanism Screen Depth Adjuster Screen Alignment (chase clamp) Cast C Chase Figure 4-15 Cast C Chase - Screen Alignment 4.14 Technical Reference Manual Chapter Issue Jul 10 MACHINE OVERVIEW MODULE OVERVIEWS Machined C Chase The machined C chase is the receptacle for the screen during printing operations The machined C chase accommodates the standard 29” by 29” screen size A stencil frame adapter is available to accommodate smaller screens The print screen is clamped into place by the machined C chase during the print cycle The machined C chase is only fitted to the metal covers machines There are two image scales used for achieving correct position of the screen within the chase assembly: Screen Alignment Module • Centre Justified Image Scale • Front Justified Image Scale The screen alignment module enables adjustment of the machined chase to achieve optimum screen to board alignment prior to the print stroke Actuators move the print screen in the X, Y and theta planes to nullify the misalignment error signal from the vision system Screen Alignment (actuators) Screen Alignment (chase clamp) Machined C Chase Screen Alignment (chase clamp) Figure 4-16 Machined C Chase - Screen Alignment Chapter Issue Jul 10 Technical Reference Manual 4.15 MACHINE OVERVIEW MODULE OVERVIEWS Print Carriage Module Paste Dispenser Module The print carriage module is the vehicle that transports the following: • Squeegee/ProFlow Module • Paste Dispenser Module • Screen Change Module The function of the paste dispenser module option is to apply a precise amount of solder paste onto the print screen, the frequency is fully programmable in software Paste Dispenser Print Carriage Figure 4-17 Print Carriage - Paste Dispenser - Screen Change 4.16 Technical Reference Manual Chapter Issue Jul 10 MACHINE OVERVIEW MODULE OVERVIEWS Pneumatics Module The function of the pneumatics module is to supply regulated air pressure to the pneumatic devices throughout the machine The air supply is routed to the required pneumatic device via an electrically operated solenoid valve controlled by the machine control system There are two banks of pneumatic solenoids, one located on the rear frame of the machine and the other located on the print carriage Squeegee Module The function of the squeegee module is to apply the print material through the screen image onto the board in a controlled manner Squeegee height and downward pressure is monitored during the print stroke to optimize the print quality ProFlow Module The ProFlow module is an optional self contained paste transfer unit, employed to apply print material directly to a screen, alleviating the need for squeegees and the paste dispenser Squeegees ProFlow Pneumatics Figure 4-18 Pneumatics - Squeegee - ProFlow Chapter Issue Jul 10 Technical Reference Manual 4.17 MACHINE OVERVIEW MODULE OVERVIEWS Foreign Machine Interface (FMI) Module The FMI provides a communications link between upline/downline machines and the DEK machine The FMI pod, fitted to the rear of the machine, is used to communicate with upline/downline machines using SMEMA, Fuji or Panasonic interfaces The Multi-Interface Unit (MIU), fitted inside the front cover of the machine, is used to communicate with upline/downline machines using all other protocols DEK Interactiv™ Module The DEK Interactiv™ module provides an engineer with a wireless real time link between the DEK machine and the DEK call centre, via the internet, for fault diagnosis DEK Interactiv M1SK1 UPLINE MIU 191114 PROTOCOL UP LINE Foreign Machine Interface M1SK2 DOWNLINE SELECTION +12V DOWN LINE POWER +24V +24V SW SEND UPLINE I/P'S SEND DOWNLINE IN CONTROL READY UPLINE READY DOWNLINE OUT CONTROL M1PL3 DEK M/C O/P'S M1SK4 DEK USB DEK Interactiv Figure 4-19 Foreign Machine Interface - DEK Interactiv 4.18 Technical Reference Manual Chapter Issue Jul 10 MACHINE OVERVIEW MACHINE PRINT CYCLE MACHINE PRINT CYCLE The following, is a typical machine print cycle (RS transport rail system), with camera mounted board stop and squeegees/paste dispenser used as the paste applicator system: Print is selected, the printhead cover lock is engaged and the rising table carries out a rail lifted check The camera positions itself at the board stop co-ordinates The print carriage moves to the start of the print stroke and both squeegees drive to their set dwell height The chase clamps are applied clamping the chase in position The board is transported into the machine stopping at the board stop The transport belts stop running as soon as the board stop sensor detects the board The board clamp mechanism operates, clamping the board in position and the board stop retracts The camera carriage drives to the position determined by Fiducial X & Y co-ordinates The print carriage is driven to its enhanced start position and the appropriate squeegee is driven down to start height The rising table carries out a rail lift check and drives up to vision height 10 The vision data window displays the board fiducial on the left and the stencil fiducial on the right of the split display 11 The fiducials are located and a small blue cross with the fiducial outline appears in the centre of each fiducial on the split display indicating successful location 12 While the camera drives to Fiducial X and Y coordinates, the location of the Fiducial board and stencil fiducials are copied to the align data structure 13 Fiducial board and stencil fiducials are located 14 The chase clamps are de-energised and the screen actuators carry out a rough alignment on the screen The chase clamps are re-applied securing the screen 15 The camera relocates Fiducial and On completion, the camera carriage drives to its home position 16 The chase clamps are de-energised and fine alignment on the screen is carried out On completion, the chase clamps are re-applied 17 The relevant squeegee is driven down to make contact with the screen with 0.5kg force 18 The rising table drives up to the print height 19 The appropriate squeegee is driven down to the calculated pressure setting, as set in the board parameter menu 20 The print carriage drives in the appropriate direction to perform a print stroke 21 The squeegee mechanism releases full pressure but keeps the squeegee Chapter Issue Jul 10 Technical Reference Manual 4.19 MACHINE OVERVIEW MACHINE PRINT CYCLE in contact with the stencil with 0.5kg force (hold height) 22 The rising table is lowered to separation distance at separation speed Once separation distance has been reached the rising table accelerates to its normal speed, lowering the table to transport height The board clamps are released and the relevant squeegee is raised to dwell height 23 The front and rear transport belts drive until the board is detected at the output sensor and the chase clamps are released 24 The board count, paste dispense and screen cleaner cycle counts are incremented If either the paste dispense or screen cleaner counts has reached the values set by the dispense rate or clean screen rate, the appropriate cycle is performed 4.20 Technical Reference Manual Chapter Issue Jul 10 Chapter Issue Jul 10 Technical Reference Manual USB USB USB O/Ps O/Ps Dual Stepper Card X3 M37 Power Supply Module Motherboard O/P I/Ps I/Os O/Ps Dual Stepper Card X2 PC O/Ps O/Ps I/Ps Aout Ain Dual Stepper Card X1 NextMove Interface I/Ps NextMove ES (I/O Node 1) Camera Y Linear Motor EuroFlex Card X7 System Switch Jog Buttons E Stop System Lamp Host Comms DEK Interactiv Camera System (vision) MMI Touchscreen IR Keyboard/Mouse USB Flash Drive Y Actuator Moving Rail Motor Front Squeegee Motor Rear Squeegee/ProFlow Motor X Forward Actuator X Rear Actuator Camera Trigger Transport Belt Motors FMI E Stop Power Squeegee Home Sensors Transport Rail Sensors Board Stop Sensors Jog Buttons (via M37) Cover Interlock FMI Power ‘ON’ Monitor Camera X Home (Linear Motor) Camera Y Home (Linear Motor) Temperature to ECM USC Solvent Level CAN Bus Camera X Linear Motor EuroFlex Card X6 M36 Machine Control Enclosure Servo Node (Camera X Rotary Motor) Servo Node (Camera Y Rotary Motor) I/O Node Board (Screen Cleaner) Stepper Node 15 (Pass Through Lane Rail Width Motor) I/O Node Board (Main Machine) Servo Node (OTS) Servo Node (Print Carriage Motor) I/O Node Board (Print Carriage) Stepper Node 10 (Paste Dispense Stepper Motor) Servo Node (Rising Table Motor) Camera X Home (Rotary Motor) Camera Y Home (Rotary Motor) USC Sensors USC Home Clamps USC Motors and Solvent Pump Vacuum Power Pass Through Rails Home Sensor Snug and Clamp Solenoids Snug and Clamp Regulators Board Stop Chase/Screen/Board Clamps Lid Bolt Tricolour Beacon USC Cleaner Squeegee Vacuum Tooling Power Air Pressure Sensor Lid Bolt Sensor Screen Sensor Vacuum Tooling Sensor Print Carriage Home Sensor Drip Tray Sensor Paste Cartridge Horizontal/Vertical Paste Level Sensor Paste Roll Low ProFlow Link - ProFlow SCAR Screen Cylinder Sensors Screen Position Sensor Squeegee Pressure Drip Tray Solenoid Paste Cartridge Tilt Solenoid Paste Dispense Solenoid Paste Height Laser ProFlow Paste Pressure ProFlow SCAR Screen Actuator Paste Carriage Home Sensor Rising Table Home Sensor Rising Table Motor MACHINE OVERVIEW ELECTRICAL SCHEMATIC ELECTRICAL SCHEMATIC 4.21 MACHINE OVERVIEW ELECTRICAL SCHEMATIC 4.22 Technical Reference Manual Chapter Issue Jul 10 ... M1PL3 DEK M/C O/P'S M1SK4 DEK USB DEK Interactiv Figure 4-19 Foreign Machine Interface - DEK Interactiv 4.18 Technical Reference Manual Chapter Issue Jul 10 MACHINE OVERVIEW MACHINE PRINT CYCLE MACHINE. .. Reference Manual 4.17 MACHINE OVERVIEW MODULE OVERVIEWS Foreign Machine Interface (FMI) Module The FMI provides a communications link between upline/downline machines and the DEK machine The FMI pod,... Manual Chapter Issue Jul 10 MACHINE OVERVIEW MODULE OVERVIEWS Machined C Chase The machined C chase is the receptacle for the screen during printing operations The machined C chase accommodates