Công nghệ SMT máy DEK chức năng proflow ATX

Công nghệ SMT máy DEK chức năng proflow ATX Electrical Schematic PNEUMATIC Schematic Adjustments Settings Replacement Procedures CALIBRATIONS MAINTENANCE .......................... ..........................

PROFLOW ATX OVERVIEW CHAPTER 13 PROFLOW ATX OVERVIEW The ProFlow® ATx system attaches to the print carriage and is used to print various high viscosity materials which display non-Newtonian characteristics The system can accommodate two different sized cartridges of print medium (6 fl oz and 12 fl oz) As the print carriage drives the system across the stencil, the constant system pressure and the enclosed design of the transfer head ensures minimum wastage and maximum environmental protection of the print medium The detachable transfer head is available in both 300mm or 400mm configurations; this provides effective coverage for different sized substrates, as well as optimal print medium application Figure 13-1 ProFlow Evolution ATx System Components Item Chapter Issue December 10 Description ProFlow ATx System Mount Technical Reference Manual Item Description ProFlow ATx Transfer Head Unit 13.1 PROFLOW ATX OVERVIEW ProFlow ATx Mount 10 Viewed from Front Figure 13-2 ProFlow ATx System: Mount Components Item Description Item Description Z-axis Motor Vertical Transfer Head Pin Mount Archimedes Screw Motor Print Medium Cartridge Transfer Head Mount Bracket (2 positions) Conditioning Grid Drive Cog Archimedes Screw Drive Cog Conditioning Grid Drive Mount Thumbscrew (2 positions) 10 Conditioning Grid Motor The ProFlow ATx mount assembly attaches to the machine’s print carriage It features a pneumatically driven print medium delivery system, two adjustable transfer head mount brackets, and the vertical transfer head pin mount The adjustable transfer head mount brackets incorporate the transfer head drive mechanisms; the left mount bracket features the conditioning grid drive system, and the right mount bracket has the Archimedes screw drive system A Z-axis stepper motor drives the ProFlow system up and down, delivering the transfer head to the print contact height 13.2 Technical Reference Manual Chapter Issue December 10 PROFLOW ATX OVERVIEW Transfer Head Unit 2 A View On Front with Cut-away to Archimedes Screw 13 12 10 11 10 View On A Figure 13-3 Transfer Head Unit Components Item Description Item Description Vertical Mount Pin Conditioning Drive Gear Print Medium Pneumatic Cylinder (2 positions) Front Wiper Blade Print Medium Delivery Tube 10 Side Ski (2 positions) Print Medium Level Indicator Pin (2 positions) 11 Rear Wiper Blade Archimedes Screw Drive Gear 12 Conditioning Grid Locator Dowel (2 positions) 13 Print Medium Type Indicator Archimedes Screw (internal component) Chapter Issue December 10 Technical Reference Manual 13.3 PROFLOW ATX OVERVIEW View on Rear with Cut-away Showing Crosshead Piston and Conditioning Grid Figure 13-4 Transfer Head Unit Internal Components Item Description Crosshead Piston Seal Conditioning Grid Item Description Crosshead Piston The transfer head is a detachable assembly with a sealed twin chamber configuration which protects the print medium from the environment after it has been pneumatically driven out of the paste cartridge An Archimedes screw mechanism distributes the print medium along the length of the unit The print medium fills the conditioning chamber and a crosshead piston pushes down on it, providing a pressurised environment which, along with the rotating conditioning grid, mechanically prepares the print medium for printing As the transfer head moves across the stencil, the print medium is forced through the apertures in the stencil by a combination of the system pressure, the print medium pressure, and the rolling action of the conditioning grid As the trailing wiper moves across the stencil, a shearing action collects the print medium 13.4 Technical Reference Manual Chapter Issue December 10 PROFLOW ATX OVERVIEW System Pressure The System Pressure is a programmable parameter that controls the contact pressure of the transfer head against the stencil As the transfer head moves across the surface of the stencil, it must have enough downwards pressure to: • Ensure that the side skis and wipers provide the enclosed environment which prevents any print medium leakage • Allow the trailing wiper to remove the excess print medium from the surface of the stencil during printing The system pressure is maintained by a Z-axis stepper motor which lowers and raises the ProFlow ATx system Based on a preset parameter, the motor turns a leadscrew that precisely positions the transfer head’s wipers and skis against the stencil NOTE It is important for the transfer head to be aligned correctly as the system pressure is directed down through the centre of the transfer head Z-Axis System Pressure Down Through Centre of Transfer Head Unit Z Axis Motor ATx Movement (Y Axis) Z Axis Screw Transfer Head Unit Print Medium Board Stencil View on Left Side Wiper (2 Positions) Figure 13-5 ProFlow ATx System Pressure Chapter Issue December 10 Technical Reference Manual 13.5 PROFLOW ATX OVERVIEW Print Medium Pressure Two pneumatically driven print medium pressure pistons are located on top of the transfer head; during conditioning and printing these pistons exert an even downwards force on the crosshead piston As it presses down on the print medium, the seal on the crosshead printer flares out creating a pressurised environment within the conditioning chamber This flaring prevents any print medium from leaking past the seal Paste Pressure Causes Flare on Crosshead Piston Seal Paste Pressure Piston Crosshead Piston Direction of Print Carriage Archimedes Screw Conditioning Grid Print Medium Cross Section on Left Hand Side of Transfer Head Figure 13-6 Print Medium Pressure Inside the Transfer Head 13.6 Technical Reference Manual Chapter Issue December 10 PROFLOW ATX OVERVIEW Print Medium Charging/ Recharging At the end of a print stroke, if the crosshead piston level sensor detects that the print medium level is low, the ProFlow ATx system charges, or recharges, the conditioning chamber in the transfer head Crosshead Piston Level Sensor View on Left Hand Side of Transfer Head Figure 13-7 Transfer Head Crosshead Piston Level Sensor During the procedure, the print rails remain raised to support the transfer head, and system pressure is applied to the ProFlow ATx system to prevent any leakage The print medium pressure is reversed, which raises the crosshead piston and creates a void in the conditioning chamber Pneumatic pressure is applied to the print medium cartridge to drive print medium to the head of the Archimedes screw which rotates for the preprogrammed amount of revolutions These actions deliver the print medium into the conditioning chamber, and the rotating conditioning grid prepares and distributes the print medium ready for application Chapter Issue December 10 Technical Reference Manual 13.7 PROFLOW ATX OVERVIEW System Pressure Paste Pressure Piston Crosshead Piston Print Medium Archimedes Screw Conditioning Grid Inlet Port Cross Section on Left Hand Side of Transfer Head Figure 13-8 Transfer Head Unit Status During Charging Action Next, the Archimedes screw and conditioning grid stop rotating, the system pressure is relaxed, and print medium idle pressure is applied The system is now ready to resume the print cycle NOTE Charging and recharging the transfer head is an automatic process and requires no intervention from the machine operator 13.8 Technical Reference Manual Chapter Issue December 10 PROFLOW ATX OVERVIEW Rolling Conditioning During charging/recharging, conditioning, or when the ProFlow ATx system moves across the stencil during printing, the conditioning grid rotates This action keeps the print medium in the optimum condition required for successful printing During the print process the rotation of the conditioning grid, working together with the print medium pressure, forces print medium into the apertures of the stencil Direction of Print Carriage Conditioning Grid Print Medium Cross Section on Left Hand Side of Transfer Head Figure 13-9 Print Medium Flow During Rolling Conditioning Chapter Issue December 10 Technical Reference Manual 13.9 PROFLOW ATX OVERVIEW Transfer Head Covers The ProFlow ATx system ships with two cover options for the transfer head: • Base Cover - Protects the wiper blades, skis and print medium during prolonged storage (more than one hour) • Protective Cover - Provides protection to the wiper blades, skis and the operator during short-term operations, including fitting and removal Base Cover View on Front with Base Cover Locking Clips Protective Cover View on Front with Protective Cover 13.10 Technical Reference Manual Chapter Issue December 10 PROFLOW ATX REPLACEMENT PROCEDURES 21 Remove the left hand side conditioning grid drive housing screws (2 positions), using a 4mm Allen key Conditioning Grid Drive Housing Screws Conditioning Grid Drive Housing Conditioning Grid Shaft Bearing View on Left Hand End of Transfer Head 22 Remove the conditioning grid drive housing (the conditioning grid shaft bearing remains embedded in the drive housing) 23 Inspect the conditioning grid drive shaft bearing for contamination from print medium If required, remove the conditioning grid shaft bearing and clean off any excess print medium Transfer Head Ski (2 Positions) Conditioning Grid Drive Housing Conditioning Grid Shaft Conditioning Grid Shaft bearing View on Transfer Head Left End 24 Remove the left hand ski 25 Remove the conditioning grid; this action releases the split hubs and carrier hub components from either end of the conditioning grid 13.50 Technical Reference Manual Chapter Issue December 10 PROFLOW ATX REPLACEMENT PROCEDURES 26 Dismantle the conditioning grid into its separate components: a Remove the carrier hub b Remove the conditioning grid from the centre shaft c Remove the two split hubs (they separate from the centre shaft as the conditioning grid is removed Carrier Hub Conditioning Grid Shaft Conditioning Grid Split Hubs Conditioning Grid Components 27 Remove the right hand ski from the transfer head 28 Fit new skis: a Fit the right hand ski to the transfer head b Fit the left hand ski to the conditioning grid drive housing 29 Reassemble the conditioning grid: a Fit the split hubs to the machined location at the left end of the conditioning grid shaft b Fit the conditioning grid to the shaft; the conditioning grid secures the split hubs in place Conditioning Grid Split Hub (2 Positions) Conditioning Grid Shaft View on Left End of Conditioning Grid Assembly Chapter Issue December 10 Technical Reference Manual 13.51 PROFLOW ATX REPLACEMENT PROCEDURES c Fit the carrier hub to the right end of the conditioning grid shaft Conditioning Grid Carrier Hub View on Right End 30 Fit the conditioning grid assembly to the transfer head NOTE Ensure the the conditioning grid drive shaft does not damage the right hand ski during fitting 31 Fit the conditioning grid drive housing to the transfer head; ensure the conditioning grid shaft is located through the bearing 32 Refit and tighten the two conditioning grid drive housing screws, using a 4mm Allen key 33 Fit the conditioning grid shaft bearing to the conditioning grid drive housing 34 Fit the small drive cog to the end of conditioning grid shaft; ensure the conditioning grid shaft is located through the bearing 35 Fit the conditioning grid drive transfer cog NOTE Ensure the large flange on the large cog is positioned against the body of the conditioning grid housing Failure to orientate the cog this way causes a failure of the conditioning grid drive mechanism Conditioning Grid Drive Transfer Cog View on Left Hand End of Transfer Head 13.52 Technical Reference Manual Chapter Issue December 10 PROFLOW ATX REPLACEMENT PROCEDURES 36 Refit the end plate 37 Refit and tighten the four end plate screws, using a 3mm Allen key 38 Refit the wiper blades 39 Refit the wiper blade retainers 40 Refit and tighten the wiper blade retainer screws, using a 2.5mm Allen key 41 Refit the archimedes screw assembly into the transfer head 42 Refit the front cover onto the transfer head 43 Refit the transfer head front cover screws, using a 3mm Allen key Replacing the Z-Axis Motor Drive Belt To replace the the Z-axis drive belt, carry out the following: Select Open Cover Commands Select Carriage to Front Select Back Select Shut Down Select Continue Switch the mains isolator to OFF Open the machine cover Remove the transfer head from the ProFlow ATx mount Remove the ProFlow ATx mount from the print carriage Belt Guard Z-Axis Drive Belt Z-Axis Motor Mount Plate Z-Axis Motor View on Rear of ProFlow ATx Mount Print Carriage Mount Plate 10 Remove the belt guard screws (2 positions), using a 3mm Allen key If required, lower the mount beam by manually turning the Z-Axis drive belt counter-clockwise 11 Remove the belt guard Chapter Issue December 10 Technical Reference Manual 13.53 PROFLOW ATX REPLACEMENT PROCEDURES 12 Loosen, but not fully unscrew, the four screws that secure the Z-axis motor to the support plate, using a 3mm Allen key Z-Axis Motor Mount Screws (4) View on Rear of ProFlow ATx Mount 13 Adjust the position of the motor to reduce the tension on the Z-axis drive belt 14 Remove the old drive belt 15 Fit the new drive belt 13.54 Technical Reference Manual Chapter Issue December 10 PROFLOW ATX REPLACEMENT PROCEDURES 16 Fit a cable tie, or similar, around the motor so that it can be securely pulled with a force meter, in the direction shown Force Meter 3Kg to 4Kg Tension Cable Tie View on Right Side of ProFlow ATx Mount 17 Pull the motor, with a force meter, to a tension of 3kgs to 4kgs 18 Tighten the motor screws, using a 3mm Allen key 19 Remove the cable tie 20 Fit the belt guard with the two screws removed earlier, using a 3mm Allen key 21 Fit the ProFlow ATx mount to the print carriage 22 Fit the transfer head to the mount Chapter Issue December 10 Technical Reference Manual 13.55 PROFLOW ATX REPLACEMENT PROCEDURES Replacing the Conditioning Grid Drive Belt To replace the conditioning grid drive belt, carry out the following: Select Open Cover Commands Select Carriage to Front Select Back Select Shut Down Select Continue Switch the mains isolator to OFF Open the machine cover Remove the transfer head from the ProFlow ATx mount Remove the ProFlow ATx mount from the print carriage and place it on a clean work area 10 Remove the conditioning grid drive assembly screws (five positions), using a 3mm Allen key 11 Remove the cover; the cover should slide downwards and away from the mount assembly Left Hand Side Transfer Head Mount Drive Belt Guide Conditioning Grid Motor Pulley Conditioning Grid Drive Belt Belt Tensioner Conditioning Grid Drive Pulley View on Left Side (Side Cover and Left Thumbscrew Assembly Removed) 12 Release the tension on the drive belt: a Fit a 17mm spanner to the nut on the rear of the belt tensioner b Hold the tensioner steady, using a flat-head screwdriver c Turn the spanner anti-clockwise to loosen the tensioner d Slide the tensioner up, away from the conditioning grid drive belt 13.56 Technical Reference Manual Chapter Issue December 10 PROFLOW ATX REPLACEMENT PROCEDURES 13 Remove the drive belt NOTE The tensioner may have to be removed to allow for the removal of the drive belt 14 Fit a new drive belt; ensure it follows the path shown in the graphic at Step 11 15 Fit the tensioner if it was removed at Step 13 16 Turn the tensioner clockwise to take up any slack in the new drive belt, using the flat-head screwdriver 17 Refit the cover of the conditioning grid drive belt assembly on the left hand side mounting bracket NOTE Ensure the electrical cabling and air feed pipes fit into the slot on the mounting block and are not damaged by the cover Transfer Head Cable and Air Feeds Secured Behind Conditioning Grid Drive Cover View on Left Side of ProFlow ATx Mount 18 Refit and tighten the five screws removed earlier, using a 3mm Allen key Chapter Issue December 10 Technical Reference Manual 13.57 PROFLOW ATX CALIBRATIONS CALIBRATIONS Adjusting the Home Sensor 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 Select Maintenance Select Diagnostics Select Print Carriage Select Select Module Select Home Print Carriage Select Run Diagnost Select Set Print Carriage Home Offset Select Run Diagnost Select Move 10 Open the machine cover 11 Measure the horizontal distance between the inside face of the front rail belt support plate, and the machined face of the print carriage (the squeegee/ ProFlow interface area); the correct setting is 612.0mm +/-2.0mm Right Hand Printhead 612mm +/- 2.0mm ProFlow ATx Home Sensor Vane Front Rail Machine Plan View 12 If the adjustment is correct, go to Step 17 If the further adjustment is required, continue to Step 13 13 Remove the measuring equipment, and close the machine cover 14 Press the System button The following window and menu bar is displayed: HOME OFFSET 13.58 10.0 Technical Reference Manual mm Chapter Issue December 10 PROFLOW ATX CALIBRATIONS 15 Enter a new value for the Home Offset; a positive value drives the print carriage towards the rear of the machine, a negative value brings the print carriage to the front of the machine 16 To move, and test, the printhead at the new setting, repeat Steps to 12 17 Select Set 18 The status message This Will Over-write the Value in the Configuration File, Proceed? is displayed 19 Remove the measuring equipment and close the machine cover 20 Select Yes 21 Select Exit 22 Select Exit Configuring the Proflow ATx Contact Position Before printing with the ProFlow ATx system, it is necessary to calibrate the print contact height If the print contact height is set too high, the transfer head may not contact the stencil If the print contact height is set too low, the transfer head may contact the stencil with too much force, resulting in damage to the board clamps, stencil, or transfer head wiper blades NOTE The ProFlow ATx system hangs lower on its left hand side due to the weight of the conditioning grid drive motor assembly During calibration, manually raise the left hand side of the ProFlow ATx system slightly before testing with the shim To configure the print contact height position, carry out the following: Select Open Cover Commands If available, select Carriage to Front If the only option reads Carriage to Rear, continue Select Back Open the machine cover Load a calibration screen onto the chase Configure the ProFlow ATx mount brackets to accommodate the 200mm calibration jig 200mm Calibration Jig View on Front Fit the calibration jig to the ProFlow ATx mount Connect the calibration jig loom to 9SK06 on the left hand side mount Chapter Issue December 10 Technical Reference Manual 13.59 PROFLOW ATX CALIBRATIONS bracket to prevent it from becoming tangled during the calibration process Place a 0.1mm calibration shim on the calibration screen; position the shim so that it will be below the ProFlow ATx system when the print carriage is in the Ready position 10 Close the machine cover 11 Press the System button 12 Select Load Screen 13 Select Continue 14 Select Continue; the calibration stencil loads, and the print carriage stops in the Ready position 15 Select Maintenance 16 Select Calibrations 17 Select ProFlow 18 Select ProFlow Heights The following window and menu bar is displayed: ProFlow Calibrations 0.0 PFLOW CONTACT POS mm This PFLOW CONTACT POS parameter sets the height of the ProFlow transfer head Minimum Maximum Increment Default -10mm +10mm 0.1mm 0.0mm 19 Select Incr or Dec until the contact height reads 0.5mm 20 Select Move to Position The ProFlow ATx system is driven to the position set by the contact height parameter 21 Open the machine cover 22 Check the shim to see if it is evenly held in place by the calibration jig 23 If the contact height is correct, go to Step 27 If not, continue to Step 24 24 Close the machine cover 25 Press the System button 26 Repeat Steps 19 to 23 27 Close the machine cover 28 Select System 29 Select Exit 30 Select Exit 31 Select Exit 32 From the Maintenance screen, select Back 33 Select Unload Screen; the ProFlow ATx system performs a shake-off and the print carriage returns to the Home position 34 Select Continue 35 Select Open Cover Commands 36 Select Carriage to Front 13.60 Technical Reference Manual Chapter Issue December 10 PROFLOW ATX CALIBRATIONS 37 Select Continue 38 Select Back 39 Open the machine cover 40 Remove the calibration shim 41 Remove the calibration screen 42 Disconnect the calibration jig cable from 9SK06 43 Remove the calibration jig from the ProFlow ATx mount 44 Close the machine cover 45 Press the System button The print contact height calibration process is now complete Configuring the Print Medium Low Sensor On machines that not have the Time-To-Go (TTG) feature, the Print Medium Low state is triggered when the sensor reads a zero percent status (the print medium cartridge is completely empty) On machines fitted with the TTG feature, the machine triggers a Print Medium Low state when the volume of remaining print medium in the cartridge reaches 10% For the machine to gauge the 0% or 10% levels, it must first be calibrated using both a full cartridge (100%), and an empty cartridge (0%) To configure the print medium cartridge levels, carry out the following: Open the machine cover Load a calibration screen onto the chase Close the machine cover Press the System button Select Load Screen Select Continue Select Continue; the calibration stencil loads, and the print carriage stops in the Ready position Select Open Cover Commands Select Carriage to Front 10 Select Back 11 Load a full print medium cartridge into the ProFlow ATx system 12 Select Maintenance 13 Select Calibrations 14 Select ProFlow 15 Select Transfer Material Chapter Issue December 10 Technical Reference Manual 13.61 PROFLOW ATX CALIBRATIONS 16 Select Set Full The message Confirm: Transfer head is fitted and full? is displayed 17 Select Confirm The message ProFlow Transfer Material Level set to full: 100% is displayed 18 Remove the full print medium cartridge from the ProFlow ATx system 19 Fit an empty print medium cartridge to the ProFlow ATx system 20 Select Set Empty The message Confirm: Transfer head is fitted and empty? is displayed 21 Select Confirm The message ProFlow Transfer Material Level set to empty: 0% is displayed 22 Select Exit 23 Select Exit 24 Select Exit 25 Select Back 26 Remove the empty print medium cartridge from the ProFlow ATx mount 27 Install a new print medium cartridge into the ProFlow ATx mount The print medium cartridge’s full and empty calibration settings are now set 13.62 Technical Reference Manual Chapter Issue December 10 PROFLOW ATX MAINTENANCE MAINTENANCE To ensure effective operation of the ProFlow ATx system, maintenance tasks should be performed on both a daily, and an as required basis Daily Maintenance WARNING HARMFUL SUBSTANCES CLEANING WIPES AND CLEANING SOLUTIONS MAY CONTAIN SUBSTANCES HAZARDOUS TO HEALTH OBSERVE ALL MANUFACTURERS’ HEALTH AND SAFETY GUIDELINES ALWAYS WEAR APPROVED PROTECTIVE CLOTHING WHEN CLEANING THE MACHINE MANDATORY TOXIC CHEMICALS MAY BE PRESENT SAFETY GLOVES MUST BE WORN MANDATORY TOXIC CHEMICALS MAY BE PRESENT EYE PROTECTION MUST BE WORN Preparation Before performing daily maintenance on the transfer head, first remove it from ProFlow ATx mount NOTE Fit the protective cover to the transfer head before removing it from the ProFlow ATx mount for daily maintenance No Task Tools Clean transfer head wiper blades Completed Spatula, Wipes As Required Maintenance Perform as required maintenance to ensure optimal performance of the ProFlow ATx system Preparation Before performing as required maintenance it may be necessary to remove the transfer head from the ProFlow ATx mount, or the ProFlow ATx mount from the print carriage NOTE Fit the protective cover to the transfer head before removing it from the ProFlow ATx mount for maintenance Chapter Issue December 10 No Task Replace the print medium cartridge as indicated by the user interface alerts Clean the transfer head; occasionally strip down the transfer head and clean all the internal components Tools Completed Spatula IPA Impregnated Wipes 2.5mm Allen Key 3mm Allen Key Technical Reference Manual 13.63 PROFLOW ATX MAINTENANCE No Task Inspect the Z-axis stepper motor belt; if it is worn, replace the belt Tools Completed 3mm Allen Key NOTE Refer to Z-Axis Motor Drive Belt, earlier in the chapter Inspect the conditioning grid drive belt: a If the belt slips, tighten the drive belt tensioner b If worn, replace the drive belt 3mm Allen Key NOTE Refer to Conditioning Grid Belt, earlier in the chapter Inspect the skis for damage; if dam- Spatula age is detected, replace both skis IPA Impregnated Wipes 2.5mm Allen Key NOTE 3mm Allen Key Refer to Transfer Head Skis, earlier in the chapter Inspect the transfer head for paste leakage; look down the print medium level indicator holes in the top plate If paste is present, replace the crosshead piston seal Spatula IPA Impregnated Wipes 2.5mm Allen Key NOTE Refer to Crosshead Piston Seal, earlier in the chapter 13.64 Technical Reference Manual Chapter Issue December 10 .. .PROFLOW ATX OVERVIEW ProFlow ATx Mount 10 Viewed from Front Figure 13-2 ProFlow ATx System: Mount Components Item Description Item Description... Cover 13.10 Technical Reference Manual Chapter Issue December 10 PROFLOW ATX OVERVIEW ProFlow ATx Stencil Support The ProFlow ATx stencil support option provides extra support for the stencil... Issue December 10 PROFLOW ATX REPLACEMENT PROCEDURES Fitting the ProFlow ATx Mount Locate the four captive mount screws and two locator dowels on the rear mount plate of the ProFlow ATx mount assembly