SMT設(shè)備的操作與維護8.2.1-1項目一 印刷設(shè)備操作與維護-電子課件

《電子產(chǎn)品生產(chǎn)設(shè)備操作與維護》課程教學(xué)資源建設(shè)建設(shè)院校：主要參與企業(yè)：淮安信息職業(yè)技術(shù)學(xué)院美國環(huán)球儀器公司德國埃莎亞太辦事處無錫日聯(lián)光電有限公司南京電子表面組裝專業(yè)學(xué)會深圳日東電子科技有限公司南京熊貓電子制造有限公司學(xué)習(xí)情境介紹從工作崗位到課程標準1.應(yīng)用電子技術(shù)專業(yè)人才培養(yǎng)方案介紹學(xué)習(xí)情境介紹從課程標準到學(xué)習(xí)領(lǐng)域?qū)W習(xí)情境介紹從學(xué)習(xí)領(lǐng)域到學(xué)習(xí)情境學(xué)習(xí)情境介紹2.教學(xué)模式簡介學(xué)習(xí)情境的組織形式----“車間教學(xué)”的組織形式車間班組（5-6人）老師

車間主任

技術(shù)主管

班組長

班組（5-6人）班組長

班組（5-6人）班組長

約8－10組生產(chǎn)組織日常考勤過程監(jiān)控反饋處理

技術(shù)咨詢故障處理技術(shù)反饋質(zhì)量控制

3個身份

組織監(jiān)控

組織監(jiān)控

讓學(xué)生以“員工”體會職業(yè)環(huán)境和工作過程強化學(xué)生的自我管理能力和組織能力

鍛煉學(xué)生的合作、溝通能力和責(zé)任心

班組的自評和互評成為個人評價的主要信息

教學(xué)組織與實施－教學(xué)資源

以學(xué)生為中心

學(xué)習(xí)情境授課說明

項目引導(dǎo)文

學(xué)習(xí)資料

工藝文件

練習(xí)題

評價表

反饋表

檢查單

學(xué)習(xí)情境介紹學(xué)習(xí)情境介紹學(xué)習(xí)過程現(xiàn)場1上板架調(diào)整焊膏攪拌印刷機編程印刷檢測貼片上料貼片編程爐前檢測SMT設(shè)備維護1SMT設(shè)備維護2

物料稽核學(xué)習(xí)情境介紹

構(gòu)建“4T（true,即真實產(chǎn)品、真實設(shè)備、真實崗位、真實環(huán)境）”實訓(xùn)教學(xué)模式學(xué)習(xí)過程現(xiàn)場2學(xué)習(xí)情境介紹虛擬視頻教學(xué)系統(tǒng)虛擬設(shè)備操作視頻虛擬動畫虛擬編程軟件通過虛擬仿真進一步提高教學(xué)效果建立學(xué)習(xí)團隊表達能力參考：德國哈勃建立學(xué)習(xí)團隊教師團隊介紹校內(nèi)專任教師：具備中級以上職稱、雙師型教師企業(yè)兼職教師：

具備三年以上工作經(jīng)驗、有教學(xué)經(jīng)歷建立學(xué)習(xí)團隊布置給班委會的艱巨任務(wù)：

1、分組的方案如何確定？（成績、愛好……)

2、每組的領(lǐng)導(dǎo)者、組織者如何選擇？（責(zé)任心、紀律性……)

學(xué)習(xí)小組的組建建立學(xué)習(xí)團隊學(xué)習(xí)小組或團隊?wèi)?yīng)考慮的問題

學(xué)習(xí)什么？學(xué)習(xí)到什么程度？怎樣學(xué)習(xí)？什么時候、在哪里、用什么學(xué)習(xí)？針對學(xué)習(xí)媒體的問題針對時間順序的問題針對學(xué)習(xí)方法和學(xué)習(xí)組織方式的問題針對學(xué)習(xí)目標和學(xué)習(xí)意圖的問題針對學(xué)習(xí)內(nèi)容和專業(yè)技術(shù)人員資格要求的問題單元一印刷設(shè)備操作與維護本任務(wù)學(xué)習(xí)目標:熟悉SMT印刷工藝1認知SMT印刷物料2

知道Suneast印刷機操作編程方法3

理解Suneast印刷機點檢維護保養(yǎng)方法4項目一印刷機操作與維護任務(wù)一Suneast操作與維護單元任務(wù)印刷設(shè)備操作與維護1、SMT生產(chǎn)線設(shè)備圖印刷機貼片機

上料機接駁臺回流焊下料機接駁臺一、資訊單元任務(wù)印刷設(shè)備操作與維護2、SMT制程工藝3、SMT生產(chǎn)防靜電單元任務(wù)印刷設(shè)備操作與維護離子風(fēng)機防靜電桌墊防靜電工作臺屏蔽袋防靜電地板或漆

警示標志防靜電工作椅接地線手腕帶4、SMT設(shè)備維護工具單元任務(wù)印刷設(shè)備操作與維護5、SMT印刷物料

5.1錫膏

5.1.1錫膏組成錫膏成份：合金粉和焊劑（活化劑、觸變劑、基材樹脂和溶劑）錫膏比例：合金通常占錫膏總重量的

85~92%

常見合金顆粒：300目~625目單元任務(wù)印刷設(shè)備操作與維護無鉛有鉛5、SMT印刷物料

5.1錫膏

5.1.2錫膏儲存與使用錫膏存儲溫度：2~10℃

回溫時間：≥4小時回溫溫度：25+/-3℃

回溫技巧：倒裝回溫沿一種方向攪拌，能自行滑落錫膏管理原則：先進先出錫膏使用環(huán)境：25+/-3℃，50+/-10%RH單元任務(wù)印刷設(shè)備操作與維護單元任務(wù)印刷設(shè)備操作與維護5、SMT印刷物料

5.2模板5、SMT印刷物料

5.3刮刀單元任務(wù)印刷設(shè)備操作與維護5、SMT印刷物料

5.4印制電路板（PCB或基板）單元任務(wù)印刷設(shè)備操作與維護1、印刷機操作編程

1.1印刷機開機單元任務(wù)印刷設(shè)備操作與維護二、任務(wù)實施1、印刷機操作編程

1.2印刷機首件編程單元任務(wù)印刷設(shè)備操作與維護1、印刷機操作編程

1.2印刷機首件編程單元任務(wù)印刷設(shè)備操作與維護1、印刷機操作編程

1.2印刷機首件編程單元任務(wù)印刷設(shè)備操作與維護1、印刷機操作編程

1.3印刷機試印刷與自動印刷單元任務(wù)印刷設(shè)備操作與維護1、印刷機操作編程

1.4印刷機關(guān)機單元任務(wù)印刷設(shè)備操作與維護1）印刷結(jié)束剩余焊膏處理：印刷結(jié)束剩余焊膏用刮刀將其刮入空的焊膏瓶中，下次印刷取取新焊膏以1:1比例混合攪拌均勻再使用。2）退出并清潔鋼網(wǎng)。3）清潔刮刀上焊膏。2、印刷機點檢維護保養(yǎng)

2.1印刷機點檢單元任務(wù)印刷設(shè)備操作與維護2.1.1設(shè)備點檢制原則定人：設(shè)立設(shè)備操作者兼職的和專職的點檢員。定點：明確設(shè)備故障點，明確點檢部位、項目和內(nèi)容。定量：對劣化傾向的定量化測定。定周期：不同設(shè)備、不同設(shè)備故障點，給出不同點檢周期。定標準：給出每個點檢部位是否正常的依據(jù)，即判斷標準。定點檢計劃表：又稱作業(yè)卡，指導(dǎo)點檢員沿著規(guī)定路線作業(yè)。定記錄：包括作業(yè)記錄、異常記錄、故障記錄及傾向記錄。定點檢業(yè)務(wù)流程：明確點檢作業(yè)和點檢結(jié)果的處理程序。2、印刷機點檢維護保養(yǎng)

2.1印刷機點檢

2.1.1設(shè)備點檢制表單元任務(wù)印刷設(shè)備操作與維護2、印刷機點檢維護保養(yǎng)

2.2印刷機設(shè)備結(jié)構(gòu)-外觀單元任務(wù)印刷設(shè)備操作與維護2、印刷機點檢維護保養(yǎng)

2.2印刷機設(shè)備結(jié)構(gòu)-內(nèi)部結(jié)構(gòu)單元任務(wù)印刷設(shè)備操作與維護2、印刷機點檢維護保養(yǎng)

2.3印刷機設(shè)備維護-主要器件單元任務(wù)印刷設(shè)備操作與維護2、印刷機點檢維護保養(yǎng)

2.3印刷機設(shè)備維護單元任務(wù)印刷設(shè)備操作與維護故障原因及對策1.機器攝像機進行了圖像辨認，但未發(fā)現(xiàn)MARK故障(1)推定原因1)攝像機不在可捕捉記號的位置。2)記號與登錄內(nèi)容(形狀/顏色/大小等)有不一致的地方。3)由于形狀/濃淡/輪廓不鮮明，因此無法辨認記號。4)電路板未傳送到所規(guī)定的位置。5)攝像機／圖像辨認裝置發(fā)生故障?(2)對策方案1)將攝像機移動到可辨認記號的位置。2)重新登錄記號形狀。3)調(diào)整攝像機照明等。4)電路板未傳送到所定的位置時，取出搬入C/V,印刷臺,搬出C/V上的電路板后重新操作。單元一印刷設(shè)備操作與維護本任務(wù)學(xué)習(xí)目標:項目一印刷機操作與維護任務(wù)二DEK操作與維護熟悉DEK印刷機操作1

熟悉DEK印刷機編程2

4熟悉DEK印刷機運行維護3課程主題安全說明機臺概要載入基板檔案載入鋼板頂針刮刀更換載入錫膏執(zhí)行生產(chǎn)鋼板清潔器印刷機臺清潔印刷機臺檢查機臺工作日志錯誤訓(xùn)息共通的印刷問題QC計算極限2D檢查動作...個人安全守則BoardClamps是銳利的煞車器是熱的

(Horizon只有Risingtable)戴護目鏡及手套用清潔溶劑時時時固定HEADPROP

(Horizon沒有)如有懷疑按緊急停止開關(guān)不要忽略安全...OBJECTIVE1機臺概要個人安全護蓋MMI(顯示器,鍵盤,警示燈)印刷頭刮刀組件鋼板載入鋼板調(diào)整軌道系統(tǒng)辨識系統(tǒng)蓋升降臺(RISINGTABLE)目錄架構(gòu)...OBJECTIVE2系統(tǒng)電源未開錯誤停止機臺初始化機臺在設(shè)定狀態(tài)維修錫膏筒錫膏不足清潔紙不足清潔溶濟不足機臺正常運轉(zhuǎn)在等待狀態(tài)下警示燈表示光學(xué)點為蝕刻鋼板一半鋼板基板FID.1FID.2FID2X-OFFSETFID1X-OFFSETFID2Y-OFFSETFID1Y-OFFSET調(diào)整Y-actuatorY-actuatorXRXRXFXF目錄架構(gòu)RUNHEAD*PASTELOADCLEANSCREENADJUSTSETUPMONITORHEAD*TOGGLECLAMPPRIMEPAPERPRIMESOLVENTAUTODISPENSEMANUALLOADLOADCARTRIDGEPRINTDIRECTIONEXITNEXTPREVIOUSINCRDECREXITMODELOADDATAEDITDATASETUPSQUEEGEECHANGESCREENCHANGETOOLINGCHANGELANGUAGEEXITLOGONCLEARBATCHBATCHLIMITPERFORMDISPLAYEVENTDISPLAYSYSTEMDISABLEEXIT*'OPENCOVER'onHorizon載入基板檔案加載生產(chǎn)檔案(使用功能鍵)加載生產(chǎn)檔案(使用條形碼讀取器)...OBJECTIVE3,4MODELOADDATAEDITDATASETUPSQUEEGEECHANGESCREENCHANGETOOLINGCHANGELANGUAGEEXITRUNHEAD*PASTELOADCLEANSCREENADJUSTSETUPMONITOR*打開前蓋'onHorizon刮刀更換選擇刮刀類型選擇刮刀長度高度校正確認壓力...OBJECTIVE6,7,8.CALIBRATEHEIGHTSCHANGESQUEEGEEEXITMODELOADDATAEDITDATASETUPSQUEEGEECHANGESCREENCHANGETOOLINGCHANGELANGUAGEEXITRUNHEADPASTELOADCLEANSCREENADJUSTSETUPMONITOR載入鋼板先載入生產(chǎn)檔案更換鋼板...OBJECTIVE5MODELOADDATAEDITDATASETUPSQUEEGEECHANGESCREENCHANGETOOLINGCHANGELANGUAGEEXITRUNHEAD*PASTELOADCLEANSCREENADJUSTSETUPMONITOR*打開前蓋'onHorizon頂針一般頂針(MAGNETICTOOLING)DEDICATEDTOOLINGPLATESAUTOFLEXTOOLING真空頂針(VACUUMTOOLING)MANUFLEX...OBJECTIVE6HEADADJUSTHOMESTOPBOARDSTOPFULLWIDTHLOADWIDTHBOARDWIDTHEXITMODELOADDATAEDITDATASETUPSQUEEGEECHANGESCREENCHANGETOOLINGCHANGELANGUAGEEXITRUNHEADPASTELOADCLEANSCREENADJUSTSETUPMONITOR刮刀

金屬VS塑料(聚氨酯)刮刀長度的影響載入錫膏手動載入錫膏自動加載錫膏...OBJECTIVE10AUTODISPENSEMANUALLOADLOADCARTRIDGEPRINTDIRECTIONEXITRUNHEAD*PASTELOADCLEANSCREENADJUSTSETUPMONITOR*打開前蓋onHorizon生產(chǎn)準備登入/注銷清除批量數(shù)/設(shè)定批量數(shù)...OBJECTIVE13,14.LOGONCLEARBATCHBATCHLIMITPERFORMDISPLAYEVENTDISPLAYSYSTEMDISABLEEXITRUNHEADPASTELOADCLEANSCREENADJUSTSETUPMONITOR執(zhí)行生產(chǎn)開始攪拌錫膏..OBJECTIVE15ENDRUNSTOPCYCLEPASTELOADCLEANSCREENADJUSTPASTEKNEADRUNHEADPASTELOADCLEANSCREENADJUSTSETUPMONITOR執(zhí)行生產(chǎn)調(diào)整...ENDRUNSTOPCYCLEPASTELOADCLEANSCREENADJUSTPASTEKNEADRUNHEADPASTELOADCLEANSCREENADJUSTSETUPMONITOR調(diào)整印刷速度鋪錫速度前印刷界限后印刷界限前刮刀壓力后括刀壓力鋪錫高度印刷間隙脫膜速度脫膜間距鋼板清潔周期1鋼板清潔周期2前向X補償值前向Y補償值前向THETA補償值后向X補償值后向Y補償值后向THETA補償清潔鋼板錫膏的處理手動擦拭清潔USC清潔鋼板清洗...OBJECTIVE16ENDRUNSTOPCYCLEPASTELOADCLEANSCREENADJUSTPASTEKNEADRUNHEADPASTELOADCLEANSCREENADJUSTSETUPMONITORUSC清潔紙II清潔紙卷動位置清潔刮片紙張供料方向擦拭過臟紙卷動位置機臺前方位置清潔溶劑供給棒('BLUE'TYPE)印刷機臺清潔升降臺區(qū)域頂針基板夾板器(BOARDCLAMPS)刮刀托盤防錫膏滴下托盤...OBJECTIVE17印刷機臺檢查PRINTCARRIAGE滑軌刮刀機械部位CAMERACARRIAGE滑軌BOARDCLAMPS是否有損壞...檢查印刷機臺是否有錫膏或清潔劑位置:OBJECTIVE18機臺工作日志印刷時的任何突發(fā)狀態(tài)與異常機臺的任何問題機臺維修所做的維修紀錄...紀錄機臺狀態(tài)在工作日志簿:OBJECTIVE19錯誤訊息未找到光學(xué)測試點

(FIDUCIALNOTFOUND)鋼板清潔器位置不對

(SCREENCLEANEROUTOFPOSITION)軌道升上錯誤

(RAILLIFTERROR)刮刀壓力錯誤

(SQUEEGEEPRESSUREERROR)系統(tǒng)電源未啟動

(SYSTEMPOWERDOWN...)OBJECTIVE20印刷問題“橋接(Bridging)”O(jiān)BJECTIVE21橋接的原因鋼板損壞印刷區(qū)域熱或錫膏黏刮刀鈍刮刀壓力太高印刷偏移印刷間隙(PRINTGAP)OBJECTIVE21印刷問題

“印刷高度過高(錫尖)”O(jiān)BJECTIVE21印刷高度過高(錫尖)原因鋼板損壞印刷區(qū)域熱或錫膏黏刮刀鈍刮刀壓力太低刮刀片損壞基板不良印刷間隙OBJECTIVE21印刷問題

“錫凹(Scooping)”O(jiān)BJECTIVE21錫凹(Scooping)原因印刷區(qū)域熱或錫膏黏刮刀壓力太高基板不良OBJECTIVE21印刷問題

“不完整的印刷(Incompleteprint)”O(jiān)BJECTIVE21Isthepastetoohighinviscosity?(i.e.greaterthansome92Pa.sor92%metalloading).不完整的印刷(Incompleteprint)原因鋼板錫膏塞孔鋼板損壞舊的或過干的錫膏刮刀損壞或鈍掉刮刀壓力過低刮刀壓力過高及錫膏有異物基板不良印刷偏移OBJECTIVE21印刷問題

“印刷偏移(Misalignment)”O(jiān)BJECTIVE21印刷偏移(Misalignment)原因光學(xué)測試點設(shè)定粗劣基板拉伸機臺毀壞–逐步的OBJECTIVE21干凈的邊緣頂端平坦印刷高度=鋼板厚度正確的印刷位置無助焊劑流出...完美的印刷COURSEAIMIdentifyallmajorcomponentsandsub-assembliesUnderstandbasicprogrammingtohelpdifferentiatebetweenmachineandprocessfaultsRecoverfrommachineelectricalandsoftwarefaultsPerformmachinecriticalsettingsandassociatedcalibrationsPerformpreventivemaintenanceroutinesTestmachineaccuracyandreturntofactorystandardCOURTESYANDSAFETYPERSONALSAFETYWearPERSONALPROTECTIVEEQUIPMENTwithpasteandsolventbasedproductsIfindoubtpresstheESTOP...

MOVINGMACHINEPARTSMAYCAUSEINJURYDURINGTHISCOURSEWEWILLOPERATETHEMACHINEWITHCERTAINCOVERSREMOVED

ALWAYS

ENSURESYSTEMPOWERISREMOVEDPRIORTOUNDERTAKINGANYWORKONTHEMACHINE...WARNING!!!!!!!CLASSROOMSAFETYSAFETYFORLINEARMOTORSWarning!TheDEKprintercontainsElectro-StaticSensitiveDevicesDonottouchanyelectroniccomponentorPCBunlesswearingacorrectlygroundedwriststrapSTATICHAZARD!ESDHAZARDImpactofLeadFreeMACHINEOVERVIEWFrontandrearcoversObservelocationofcamsafeswitchMonitorassemblySystembuttonandjogbuttonsTri-colourbeaconChaseassemblyPrintcarriageSqueegeeassembly/ProFlowPastedispenser...Removefront,sideandrearcovers!MACHINEOVERVIEW(CONT)ScreenloadScreenalignmentactuatorsRailsystemCamerasystemRisingtableMainsisolatorswitchServicepanel/circuitbreakersUnderscreencleanerVacuumunit...BEACONINDICATIONSINITIALISATIONSET-UPMAINTENANCEPASTECARTRIDGELOWPAPEREMPTYSOLVENTEMPTYOPERATIONALWAITINGINREADYSTATESYSTEMPOWEROFFHALTEDBYERROROperatormanualInstallationmanualOnboardtutorialsFasttrackguidesTechnicalReferencemanualElectricaldrawingsWebbasedmechanicalinformationCDRomNAVIGATINGTHEMANUALS&SOURCESOFINFORMATIONWorkbooktaskA2MaintenanceMachineOverviewINITIALISATIONSEQUENCEObservethemachineasitinitialises:WorkbooktaskMO1STATEMONITORAREASWorkbooktaskMO2CREATEAPRODUCTFILECreateanewproductfilebasedonthedefaultfileMeasureboarddimensionsaccurately…WorkbooktaskMO3UsesyntheticfiducialswheneveravailableDiagonallyopposite...SETUPSYNTHETICFIDUCIALSWorkbooktaskMO4UniqueimageStrongContrastReferencetocenterStronghorizontal&verticallinesUsediffiducialspoorordamagedandforSPCfaultisolationtechniquesSETUPVIDEOMODELWorkbooktaskMO5PRINTCYCLESEQUENCEPressrunObservemachineoperationduringtheprintcycle…WorkbooktaskMO6COMMONERRORMESSAGESFiducialNotFoundScreenCleanerOutofPositionRailLiftErrorActuatorClosetoLimitsSqueegeePressureErrorSystemPowerDown...WorkbooktaskMO7MaintenanceElectricalTheoryandTroubleshootingDIAGNOSTICSMODULESWorkbooktaskET1ELECTRICALENCLOSURESWithAdvantechPCWithI-BusFirewirePCPCPowerSupplyM37ControlEnclosureM36USBUSBSCALEABLECONTROLSYSTEMTheCoresystemhas3mainelectricalenclosuresPowerSupply:AllDCunitacceptingmainsinputvoltagesfrom85>264VAC.Notransformertapping.Nolineconditionersneededforpoorfactorymainssupplies.PC:Powersupplyacceptinginputvoltagesfrom90>264VAC.ControlEnclosure:Small,simpleunit.AllinternalinterconnectionbyPCB,nointernalwiring.SYSTEMCOMMUNICATIONPCPowerSupplyM37ControlEnclosureM36USBUSBUSBHubKeyboardMouseTouchscreenFlashdiskTheflashdiskisboltedtotheprinterframe.Itstoresmachinetype,serialnumber,numberofprintsmadeetc.Thetouchscreenisaresistivetype.ThekeyboardisanIRtypewithintegraltrackball.USBPCUSBHubBarcodeScannerADSLModemFlatbedScannerOptionalperipheralsalsouseUSBUsingWindowsXPallowsperipheralstobeaddedsimplyby‘plugandplay’.BluetoothAdapterAddoptionsAddnewfunctionalityLinePrinterPERIPHERALCONNECTIONS(OPTIONS)ELECTRICALDIAGRAMPOWERSUPPLYM3740VDCSMPSUMulti-RailSMPSU40VDCswitched24VDCUn-switched12VDCUn-switched5VDCUn-switched-12VDCUn-switchedPowersupplymonitorSafetycircuitE-StopInterlocks2HandcontrolSystemswitchUSBMainsI/PCircuitbreakers24VDCswitchedContactors85–264VACPOWERSUPPLYM37–BLOCKDIAGRAME-STOPCIRCUITPOWERSUPPLYM37WorkbooktaskET2Monitorcardmeasures64DCvoltagesintheM37powersupplyandreportsthemtothePCviaUSB.Itmeasuresbothsidesofeverycircuitbreaker.ShowspowerGOOD/BADandbreakerIN/OUTforallDCpowercircuits.PCdisplayshowsaverage,maxandminvoltagevalues.PowergoodshownGREEN,faultconditionshownRED.Updatesevery2sec.POWERSUPPLYMONITORWorkbooktaskET3PCCONFIGURATIONSUMMARYWhichConfigurationdoyouhave…..?WorkbooktaskET4ADVANTECHPC(ANALOGUECAMERA)PC–BLOCKDIAGRAM-GREENCAMERAPC–BLOCKDIAGRAM–GOLDCAMERAPC-CARDLAYOUTNetworkcard*VisioncardVisioncard(goldcameraonly)Soundcard*Wirelessbridgebreakout*VisionadaptorcardSingleboardcomputer4PortUSBhubPeripheralconnectors*RequiredonlyforInteractivesoftwareoptionSINGLEBOARDCOMPUTERNETWORKCARDVISIONCARDVISIONADAPTORCARDSOUNDCARDI-BUSPCWITHFIREWIRECARDI-BUSPCWITHDIGITALCAMERAI-BUSPC-CARDLAYOUTFireWireCardI-BUSPCWITHANALOGUECAMERAI-BUSPC-CARDLAYOUTVISIONCARDVISIONADAPTORCARDCONTROLENCLOSUREM36CONTROLENCLOSURE–BLOCKDGMRotarymotorsLinearmotorsCONTROLENCLOSURE-CARDLAYOUTX1X2X3X4X5X6X7DualStepperXfactuatorXractuatorDualStepperFrontSq.RearSq.DualStepperYactuatorMovingRailNextMoveESInterfaceNextMoveESMotionControllerEuroFlexDriveCameraXAxis0(Linearonly)EuroFlexDriveCameraYAxis1(Linearonly)NEXTMOVEESCARDNEXTMOVEINTERFACECARDDUALSTEPPERX1,X2,X3CardsareinterchangeableNODESFrontofMachine(PlanView)RisingTableNode6MainMachineNode2ScreenCleanerNode4PrintCarriageI/ONode3PasteDispenseNode10Camera‘Y’(onmotor)Node9PrintCarriage(onmotor)Node7Camera‘X’(onmotor)Node8PrintCarriageCommunicatesviaCANbusMultiplesensorinputsMultipleoutputsincludingsolenoiddrivesMountedatrearofprinterMAINMACHINEI/ONODE2CommunicatesviaCANbusMultiplesensorinputsMultipleoutputsMountedonPrintCarriageSupportforallPrintCarriagefunctionalityincludingTemp/Hum,PrintPressure,PasteMonitoring,Pro-Flow,Pastedispensing.PRINTCARRIAGEI/ONODE3CommunicatesviaCANbusMultiplesensorinputsMultipleoutputsSolventpumpdrivecircuitMountedatrearofprinterSupportforallunderscreencleanerfunctionalityincludingPaper&Vortex,pumpedorpressurisedsolvent.SCREENCLEANERI/ONODE4Bynowyoushouldbeableto…..IdentifyBoardsinEnclosuresRemoveandreplacePCB’sIdentifyconfigurationrequirementsENCLOSURESANDPCB’SSUMMARYWorkbooktaskET5WhichconfigurationsandsettingsmustbecompletediftheNextmovecardischanged?Name3locationswhere+24vcanbemonitored?Whichcardsareinterchangeablefortroubleshootingpurposes?QUIZWorkbooktaskET5SENSORSANDSWITCHESWorkbooktaskET6LinearMotorsGalaxyMachineOnlyLINEARMOTORSCAMERAX&YForcerPermanentMagnetTrackReadHeadCameraWorkbooktaskET7EncoderstripHomesensor‘index’Sensorusedonearlymachines.Nolongerfitted.LINEARMOTORCONTROLHOMEAxis=………?V=___PSU__HALLEFFECTFORCERM37M36MOTORWorkbooktaskET7LinearEncoderLINEARMOTORCONTROLREADHEADHOMENEXTMOVEINTERFACEV=48VNEXTMOVEESEUROFLEXPSU2HALLEFFECTFORCERM37M36MOTORAxis=CameraXCameraYLinearEncoderAEuroFlexcardsuppliespowersequentiallytothethreephasewindingsintheForcer.Thewindingsarephysically120degreesoutofphase.Themagneticfieldcreatedinthewindingreactswiththepermanentmagnetsinthetracktocreatemotion.TheHallEffectswitchesareusedduringstartup.Theyproducesixpulsesthatprovidetheinitialcommutation.Oncespeedanddirectionisestablishedmotiondetectionpassesovertotheencoder.LINEARMOTORSTHEORYLINEARENCODERTHEORYTheopticalreadheadmeasurespositionalinformationfromtheencoderstriprunningthelengthofthepermanentmagnettrackLINEARENCODER(READHEAD)Read-headLEDconditions:-GreenReaderset-upcorrectly,encodercleanandallpulsescanberead.AmberTheReader/EncoderStripmayneedcleaning,orthegapbetweentheReadheadandEncoderstripisgreaterthan0.8mm.RedReaderhasfailedtoreadencoderpulses,servopowerisdisabledifthisoccurs.WorkbooktaskET8EUROFLEXCARDS(LINEARMOTORS)X6,X7CardsareinterchangeableWorkbooktaskET9LINEARMOTORHOMINGSEQUENCEForwardReverseStopHomeSensorLinearMotorWorkbooktaskET10PRACTICALEXERCISEMeasureXforcerresistanceMeasureYforcerresistanceMonitorReadHeadLEDstateduringhomingsequenceWorkbooktaskET11LINEARMOTORMAINTENANCEThelinearmotormagnetsrequirenospecialmaintenanceunlesstheybecomecontaminated.Intheeventofcontamination,carryoutthefollowingprocedure:Wrapaplasticspatulawithstickytape,stickysideout.UsethespatulatoremoveanydebristhatisattachedtotheXandYcameralinearmotormagnets.Toremoveprintmaterialfromthemagnets,usealcoholonalintfreecloth.TheCameraXandYlinearmotorencoderstripsrequirenomaintenanceunlesstheybecomecontaminated.Intheeventofcontamination,useadrylintfreeclothtowipetheencoderstrip.StandardRotaryMotorsAllMachinesSingleunitincludesservomotor,driveelectronics,encoder,processorandCANopeninterfaceUnitsareconnectedviaCANbusCamera‘X’(Rotarymachines)Camera‘Y’(Rotarymachines)PrintCarriageServoMotorDriveelectronicsProcessorCANopeninterfaceCANBusDCPowerGearboxCANOPENSERVOMOTORSTEPPERSTEPPERMOTORRequiresstep/directionNopositionalfeedbackFrontSqueegeeRearSqueegeeRailWidthXf,Xr,YactuatorsSIMPLEDCMOTORSimpleConstructionUSCpaperfeedDCMOTORSpeedcontrolbyadjustingpotentiometerondriveHightorqueavailableforhighspeedandheavyboardapplications.Requireonly2inputs:Directionandstart/stop(withdynamicbraking).DCCONVEYORMOTORSWorkbooktaskET12MOTORDCMOTORCONTROLMOTOR_____V=V=Axis=…..?Axis=…..?WorkbooktaskET13USCPaperfeedNEXTMOVENEXTMOVEINTERFACEMOTORDCMOTORCONTROLBeltMotorFrontBeltMotorRearNEXTMOVEI/ONODEMOTORCANbusPSU1PSU124vDC24vDCENABLEDIRECTIONMOTORSTEPPERMOTORCONTROLV=Axis=…..?WorkbooktaskET14PSU1NEXTMOVEDUALSTEPDRIVEMOTORHOMESTEPPERMOTORCONTROLNEXTMOVEINTERFACEFront/RearSqueegeesMovingRailXFront,XRear,YActuators(Nohomesensors)24vdcMOTORCANSERVOMOTORCONTROL______CANSERVOMOTORMODULEV=V=Axis=…..?WorkbooktaskET15NEXTMOVESERVONODEMOTORHOMEENCODERCANSERVOMOTORCONTROLCANbusPSU2CameraXCameraYPrintCarriageCANSERVOMOTORMODULE48VDCNEXTMOVESERVONODEMOTORHOMEENCODERCANSERVOMOTORCONTROLCANbusPSU2RisingTable48VDCSENSORHOMINGSEQUENCEControl(I/ONodeorNMI/Fcard)SENSORControl(I/ONodeorNMI/Fcard)HOMINGSEQUENCESENSORControl(I/ONodeorNMI/Fcard)HOMINGSEQUENCESENSORControl(I/ONodeorNMI/Fcard)HOMINGSEQUENCESENSORControl(I/ONodeorNMI/Fcard)HOMINGSEQUENCEHomevanestopsjustoutsidesensorformostmotoraxis…SENSORControl(I/ONodeorNMI/Fcard)HOMINGSEQUENCE(RisingTableonly)TheRisingTablehomevaneonlyreturnstosensorandstaysthere.WorkbooktaskET16ThesimplestwaytorecoverfromanyWINDOWSorsoftwarerelatedfaultsistocarryoutacompletere-installationofthesoftware.ThisiscarriedoutusingtheDEKsoftwareCD_ROM.Importantto“BackUp”ConfigandProductfilesSOFTWARERECOVERYSOFTWAREINSTALLATIONThe“software”consistsof:theappropriatesystemdiskforthePCaDEKsoftwarediskafloppydiskcontainingthelateststdfeatfile,themachinekeyandanyspecifickeysforthemachineMaintenanceSettingsandCalibrationsBACKUPCRITICALFILESCopycriticalmachinefilesfromtheE:\driveWorkbooktaskSC1MACHINESETUPMENUSIdentifytheparameterswithintheMachinesettingsmenusI.e.TransportmodeForeignmachineinterfaceToolingtypeetc.WorkbooktaskSC2HOMEPOSITIONSCheckthehomepositionsinyourworkbookAdjustifrequiredandrecordthedetailsinyourworkbookFollowinstructionsinTechnicalReferenceManualWorkbooktaskSC3Inspectboardclampsfordamage&replace...BOARDCLAMPSWorkbooktaskSC4Transferrail“O”ringsupportBoardclampInspectbeltsfortension,damage&wear...CONVEYORBELTSWorkbooktaskSC5RAILTOTABLEHEIGHTRailtotableheightCheckAdjustifrequiredFollowinstructionsinTechnicalReferenceManualWorkbooktaskSC6VisionHeightSetindiagnosticsSavedtoconfigurationfile(config.cfg)Risingtablepositiontoallowcameratocaptureboardfiducials...HomepositionVisionheightCALIBRATIONSWorkbooktaskSC7BoardstopXoffsetcalibration.CarriedoutindiagnosticsEnteredinSetPrefersSavedtoconfigurationfile(config.cfg)CarriedoutwhenacameraisreplacedDistancemeasuredfromcentreofopticstoboardstopassembly...CALIBRATIONSWorkbooktaskSC8ReferenceprintheightHomepositionPrintheightSetindiagnosticsSavedtoconfigurationfile(config.cfg)Risingtablepositiontoplaceboardincontactwithstencilforprinting.Note:Setwithoutboard,thenwhenprinting,boardthicknessistakenintoaccount….CALIBRATIONSWorkbooktaskSC9CameraReferenceSetindiagnosticsSavedtoconfigurationfile(config.cfg)Pointfromwhichallcamerapositionsaremeasured...CALIBRATIONSWorkbooktaskSC10Offsetcalibration2mm2mmVisioncalibrationVision&OffsetCalib.CarriedoutinMaintenance/CalibrateVisionSavedtoconfigurationfile(config.cfg)Calculatesscalingfactor,centreofrotationofstencil,fiducialcaptureand‘x’and‘y’offsetsofcamerasystem...CALIBRATIONSPOSITION1VisionsystemlocatesandRemembersposition1InxandyVISIONCALIBRATION2mmPOSITION2VisionsystemlocatesandRemembersposition2InxandyVISIONCALIBRATIONPOSITION32mmVisionsystemlocatesandRemembersposition3InxandyVISIONCALIBRATIONThenumberofpixelsmovedThesizeofapixelinvideounitsThemovementinywhenxismovedThemovementinxwhenyismovedThesizeofthegraphictobedisplayedonthesetupscreenTHEFOLLOWINGISCALCULATEDVISIONCALIBRATIONItisimportantthatthefiducialsareset-upaccuratelybeforethe‘thetacalibration’and‘fiducialcapture’arecarriedoutVISIONCALIBRATIONWorkbooktaskSC11VisionsystemlocatesandremembersScreenfiducialpositioninxandySTEP1CENTROIDOFFSETCALIBRATIONSTEP2

CENTROIDVisionsystemlocatesandremembersBoardfiducialpositioninxandyOFFSETCALIBRATIONVisionsystemcalculatesxandyoffsetBetweenscreenandboardfiducialsSTEP3YOFFSETXOFFSETOFFSETCALIBRATION

Camerareplacement Visionheightadjustment(Risingtable) Railtotableheightadjustment ActuatorreplacementVISIONCALIBRATION---WHEN?WorkbooktaskSC11PrintheightHomepositionSqueegeereferenceheightSqueegeeReferenceHeights.Carriedoutineithermaintenance/calibratesqueegeeorSet-up/Set-upSqueegee.Savedtoconfigurationfile(config.cfg)Calculatesdistanceinstepsfromhomepositiontorailandpressurefactor(steps/kg)….CALIBRATIONSWorkbooktaskSC13MachineadjustmentAssociatedcalibrationsRisingTableHomePositionVisionHeightPrintHeightVisionCalibrationOffsetCalibrationSqueegeeReferenceHeightsRailToTableHeightVisionHeightPrintHeightVisionCalibrationOffsetCalibrationSqueegeeReferenceHeightsVisionHeightVisionCalibrationOffsetCalibrationPrintHeightPressureCalibration(Heights)CALBRATIONSUMMARYTHEPERFECTPRINTRisingtable,rails,boardclamps,chaseallflatandlevelChaseclamps,boardclamps,rollerbearingsadjustedcorrectlyMachinefullycalibratedPreventivemaintenanceperformedMachinecleanandfreefromdamagePRINTDEFECTSBridgingIncompleteMisalignmentExcessWorkbooktaskSC14MaintenancePreventiveMaintenanceCLEANLUBRICATEUsingtheTechnicalReferenceManualasaguide,performtheMonthlyPreventiveMaintenanceproceduresonthemachine.PREVENTIVEMAINTENANCEWorkbooktaskPM1UNDERSCREENCLEANEROptimisetheUSCsettingsusingtheproceduresinyourworkbookCalibratetheSolventTimeToGoCalibratethePaperTimeToGoWorkbooktaskPM2MaintenanceBenchmarkTestSTENCILBOARDSTENCILSTENCILBOARDBOARDALIGNMENTTHEORYSCREENALIGNMENTScreenImageBoardBoardScreenImageXrXrXfXfYYPARAMETERSMEASUREDEditoutputsinproductfileEditlimitsinproductfileSPCDataAlignmentErrorXALIGNERRORYALIGNERRORXALIGNERRORYALIGNERRORFIDUCIAL1FIDUCIAL2NOTE:THISINFORMATIONFORSPCISOUTPUTJUSTBEFORETHEPRINTSTROKEBUTAFTERTHEALIGNMENTPROCESSS,AND/ORJUSTAFTERTHEPRINTSTROKESPCDataBoardStretchStencil(mm)-Board(mm)=BoardStretchStencil(mm)Board(mm)Fid2Fid1Fid2‘x’Error(PreorPost)Fid1‘x’Error(PreorPost)Fid2Fid1SPCDataCycleTimeL-RorR-LBoardReceivedbyMachine=CycleTimestartsBoardExitsMachine=CycleTimestopsCYCLETIMESPCDataCycleTimeR-RorL-LBoardReceivedatBoardStop(1)=CycleTime1startsBoardReceivedatBoardStop(2)=CycleTime1stopsandCycleTime2startsCYCLETIMEBoardstopCYCLE1CYCLE2SqueegeePressureAveragepressureacrossprintstrokeSPCoutputProgrammedPressure+feedback5KgStroke1Stroke2Stroke3Stroke4etc.BENCHMARKTESTUSINGQC-CALCQC-CalcbyProlinkCorporationPre-installedonallMicronmachinesAccessedviaDUIordesktopCanberuninrealtimealongwithDeksoftwareBENCHMARKTESTPROCEDURELoad265TEST1productfileSetuptoolingandfitsqueegeesCalibratesqueegeereferenceheightLoadcalibrationstencilApplylubricationtostencil/squeegees continued...BENCHMARKTESTCONT.ClearbatchandsetbatchlimitCopySPCdatatofloppydisc