Công nghệ SMT máy DEK hệ thống camera system module

Công nghệ SMT máy DEK hệ thống camera system module CAMERA SYSTEM MODULE OVERVIEW ELECTRICAL SCHEMATIC ADJUSTMENTS AND SETTINGS REPLACEMENT PROCEDURES CALIBRATIONS AND CHECKS APPENDIX A VISION SYSTEM SET UP

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Chapter Issue 5 Dec 10 Technical Reference Manual 22.1

CHAPTER 22 CAMERA SYSTEM MODULE

OVERVIEW

Figure 22-1 Camera Overview Rotary Drive

4 Y Axis Right Hand Linear Bearing

(mounted on bottom of right hand printhead) 12 Camera Mounted Board Stop & Board Stop Extended Sensor

(shown transparent for clarity)

8 Y Axis Left Hand Linear Bearing

(mounted on bottom of left hand printhead)

1

4

2

3 5

6 7

14

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Figure 22-2 Camera Overview Linear Drive

Board Stop Extended Sensor

1

4 2

5 6

7 8

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The camera assembly traverses horizontally in the X and Y axis to position the camera to carry out the following functions:

• Board Stop

• Fiducial Capture - for screen to board alignment

• Site Capture - pre and post printing for 2Di inspectionPositioning of the camera assembly is carried out by the X and Y drive mechanisms There are two types of drive system, linear servo motor systems and rotary servo motor systems

The camera contains an optical unit for image focusing and a lighting unit for board and screen illumination during fiducial and 2D camera capture opera-tions

The camera carriage also contains the following:

• Camera Board Stop

• Board at Stop sensor

• Board Stop Extended SensorThe camera board stop is a pneumatically driven unit which is lowered to stop the board in position ready for clamping and vision alignment to take place The board at stop diffuse background suppressed opto detects the board when

it reaches the board stop This starts a timer which when elapsed stops the belts and clamps the board

The board stop extended sensor is fitted to ensure that the board stop is raised before any camera carriage movement is demanded

The camera positions are referenced from the home position Each camera axis only homes during initialisation, which can be from power-up or exiting diagnostics

The camera system also provides the drive mechanism for the under screen cleaner

The camera system contains one of the following cameras dependant on the specification of the machine and what options are fitted:

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Figure 22-4 Linear Drive Schematic

NOTE 1 The breaks in the CAN Bus chain reflect that additional I/O Nodes may be fitted, refer to Machine Control chapter for the complete CAN Bus chain 2 HawkEye encoder edge connector is fitted to

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ADJUSTMENTS AND SETTINGS

WARNING STRONG MAGNET FIELD A STRONG MAGNETIC FIELD EXISTS IN THE VICINITY OF THE LINEAR MOTORS THIS MAY PRESENT A HAZARD TO PERSONNEL OR EQUIPMENT.

PROHIBITION STRONG MAGNETIC FIELD A STRONG MAGNETIC FIELD EXISTS IN THE VICINITY OF THE LINEAR MOTORS THIS MAY REPRESENT A SERIOUS HAZARD TO PERSONNEL FITTED WITH A PACEMAKER.

PROHIBITION STRONG MAGNETIC FIELD A STRONG MAGNETIC FIELD EXISTS IN THE VICINITY OF THE LINEAR MOTORS THAT REPRESENT A SERIOUS HAZARD TO PEOPLE FITTED WITH METALLIC IMPLANTS.

PROHIBITION STRONG MAGNETIC FIELD A STRONG MAGNETIC FIELD EXISTS IN THE VICINITY OF THE LINEAR MOTORS THAT MAY ACT UPON FERROUS OBJECTS WHOSE MOVEMENTS COULD LEAD TO PERSONAL INJURY AND/OR DAMAGE

TO THE MACHINE.

NOTE The X axis parallelism is factory set and shouldn’t normally need to be adjusted.

1 Select Open Cover Commands.

2 Select Carriage To Rear.

3 Select Unload Screen.

4 Open the front printhead cover

5 Remove the screen from the machine

6 Close the front printhead cover

7 Press the System button.

8 Select Back.

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9 Select Maintenance.

10 Select Diagnostics.

11 Use Next or Previous to highlight Rail System.

12 Select Select Module.

13 Ensure that Home Rail Width is highlighted.

14 Select Run Diagnost.

15 Select Exit.

16 Use Next or Previous to highlight Rising Table.

18 Use Next or Previous to highlight Raise Table to Vision Height.

20 Select Exit.

21 Use Next or Previous to highlight Rail System.

22 Select Select Module The board clamps are released.

24 Remove any tooling from the manual tooling plate

25 Remove the board clamp from the front transport rail, Board Clamp Replacement - Replacement Procedures section of the Transport Rails Module chapter refers

26 There are two versions of the rail setting jig (DEK Part No 191156) and they are labelled:

• Standard Rails (round belts)

• Heavy Board Rails (flat belts)

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27 Confirm which type of rails are fitted to the machine and select the ate rail setting jig.

appropri-28 Place the jig on the manual tooling plate ensuring that the location pins on the underside of the jig abut the front face of the manual tooling plate Check

there is no gap using a 0.05mm feeler gauge.

29 Secure the jig to the front rail using the two jig to rail thumbscrews

30 Secure the jig to the rising table using the two jig to table thumbscrews

31 Check that the location pins are up against the front edge of the manual

tooling plate using a 0.05mm feeler gauge, as in Step 28.

View on Left Hand Side

Rail Setting Jig

View on Rear of Transport Rails

Jig to Table Thumbscrews

Jig to Rail Thumbscrew Jig to Rail Thumbscrew

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32 Using feeler gauges check that the gap between both alignment pads and

the belt support plate of the front rail is 0.25mm ±0.05mm.

33 If adjustment is necessary refer to the Transport Rails Module chapter - Adjustments and Settings - Front Rail Parallelism

34 Bring the camera carriage X axis support platform into contact with the camera alignment pins

Feeler Gauge Alignment

Pad

Belt Support Plate

View on Rear of Transport Rails

View on Arrow A (Camera Y Axis Removed)

Camera Alignment Pins (2 positions) Alignment Jig

0.25 mm

Camera Parallelism Check

Camera Alignment Pins (2 positions)

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35 Look for a gap between the camera alignment pins and the linear bearing

on the front edge of the camera X axis support platform, if no gap exists adjustment is unnecessary Continue from Step 48

36 If a gap exists, carefully attempt to insert a 0.25mm shim between the

alignment pin and the linear bearing on the front edge of the camera X axis

support platform If the shim cannot be fitted the gap is less than 0.25mm

and adjustment is unnecessary Continue from Step 48

37 If a gap exists which is greater than 0.25mm adjustment is necessary.

38 For machines with rotary motors continue with Step 39 For machines with linear motors go to Step 44

39 Loosen the three securing screws

40 Using a soft headed mallet gently tap the edge of the camera X axis support platform to close the gap on the camera alignment pins

NOTE The camera can be severely damaged if excessive force is used to position the camera axis.

41 Tighten the three securing screws taking care not to allow the position to slip

42 Check for parallelism again

43 Go to Step 48

View From Beneath Camera Carriage

Securing Screws

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44 Loosen the two securing screws at each end of the camera X axis support platform

45 Using a soft headed mallet gently tap the edge of the camera X axis support platform to close the gap on the camera alignment pins

NOTE The camera can be severely damaged if excessive force is used to position the camera axis.

46 Tighten the two securing screws at each end of the camera X axis support platform, taking care not to allow the position to slip

47 Check for parallelism again

48 Remove the location jig from the rising table

49 Fit the board clamp to the front rail

50 Refit the screen

53 Select Exit.

54 Select Exit.

55 Select Back.

Y Axis Parallelism The Y axis parallelism for both rotary and linear motor machines is factory set

and is not adjustable

View on Arrow A

A

Securing Screws Securing Screws

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Magnet Track and Forcer Assembly Settings (Linear Servo Motor Systems Only)

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.

TO THE MACHINE.

Setting the Forcer

Air Gap

CAUTION STRONG MAGNETIC FIELD The X and Y Magnet tracks exhibit strong magnetic fields, care should be taken when working with ferrous or magnetic implements and tools All tools used should be non-ferrous or anti-magnetic.

The forcer unit comprises electrical windings encapsulated in an epoxy tion If the unit is offset it may rub against the side wall of the magnet track To prevent this an air gap of 0.5mm on both sides of the forcer unit should be maintained

insula-1 Select Maintenance.

3 Use Next or Previous to highlight Camera Axes.

5 Ensure that Home Camera X Axes is highlighted.

7 Use Next or Previous to highlight Home Camera Y Axes.

9 Select Exit.

10 Select Exit.

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11 Select Back.

12 Select Shut Down.

13 Select Continue.

14 Switch the mains isolator to OFF.

16 Remove the screen

X Axis 17 Remove the left side panel

18 Using a 0.5mm shim on the left hand end of the magnet track, ensure that

the air gap between the forcer and the magnet track is equal on both the left and right side of the forcer

Forcer to Magnet Track Air Gap (both sides)

0.5mm Min

Magnet Track Adjustment Screws (3mm)

Test both gaps on both ends of the forcer

Camera at Home

Magnet Track Adjustment Screws (5 off)

A

View on Arrow A Camera Mount

X Forcer

X Magnet Track

Y Linear Rail

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19 Manually move the camera to the right hand side of the machine and repeat Step 18 for the right hand end of the magnet track.

20 If the alignment is correct, go to Step 24

21 From the underside of the assembly locate the five magnet track adjustment screws Slacken the screws but do not remove Gently move the bracket

in the direction required for the 0.5mm shim to fit comfortably all around Tighten the screws to secure

22 Check the air gap again to ensure that the screws have all been tightened evenly without misaligned the forcer

23 Slide the camera assembly along the whole length of the X camera axis and ensure there are no points where the forcer contacts the magnet track side wall

24 Refit the left side panel

Y Axis 25 Remove the right side panel

26 Manually move the camera support beam to a central position where access

to the unit can be readily gained

27 Using a 0.5mm shim on the front end of the magnet track, ensure that the

air gap between the forcer and the magnet track is equal on both the left and right side of the forcer

28 Repeat Step 27 for the rear end of the magnet track

29 If the alignment is correct, go to Step 33

30 On the top surface of the Y Magnet Track locate the two magnet track adjustment screws Slacken the screws but do not remove Gently move

the bracket in the direction required for the 0.5mm shim to fit comfortably all

around Tighten the screws to secure

Test both gaps, on both ends of the forcer

Y Forcer And Magnet Track

(Support brackets and fixings removed for clarity)

Magnet Track Adjustment Screw (2)

Test bo both en

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31 Check the air gap again to ensure that the screws have been tightened evenly without misaligning the forcer

32 Slide the camera assembly along the whole length of the Y camera axis and ensure there are no points where the forcer contacts the magnet track side wall

33 Refit the right side panel

34 Refit the screen

36 Power up the machine

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Board at Stop Sensor

The sensitivity should be adjusted to see a board on the rails at transport height The distance between the top of the board and the top of the tooling can change, due to different board thicknesses, even if the same underside clearance parameter is used The optimum adjustment is achieved using the thinnest board, down to a minimum of 0.2mm thick If the sensor is adjusted and later

a thinner board is used in the machine, it is possible that the decreased distance between the sensor and the tooling may cause the sensor to be activated while

no board is present, due to tooling being positioned directly below the sensor

If a 0.2mm board is not available, extra care should be taken to ensure that the sensor is detecting only the top of the board used

Underside View Camera Assembly

Camera Mounted Board Stop Camera

Board at Stop Sensor

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To check and adjust the sensitivity of the board at stop sensor, carry out the following procedure

1 Ensure that the rail width is setup for the test board

2 Select Open Cover Commands.

6 Remove the screen

9 Select Back.

14 Use Next or Previous to highlight Drive to Board Stop Position.

16 Select Exit.

17 Use Next or Previous to highlight System.

19 Use Next or Previous to highlight Toggle Lid Bolt.

22 Position the test board (a 0.2mm board if available) on the rails below the sensor

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23 If the red LED on the sensor is illuminated, turn the sensitivity/focal length adjustment anti-clockwise using a plastic trimmer tool until the LED extin-guishes (or the LED is flickering).

24 Turn the sensitivity/focal length adjustment very slowly in a clockwise direction until the instant the LED is fully illuminated (the LED may flicker before fully illuminating)

25 Turn the control in a clockwise direction approximately 10 to 20 degrees beyond the point at which the LED illuminated

NOTE Turning the control more than 10 to 20 degrees beyond the point at which the LED first illuminated may cause the sensor to detect the tooling whilst printing using thin boards.

26 Remove the test board from the machine

27 Refit the screen

Amber LED (Target Detected)

Background Suppressed Opto

Emitter/Receiver

A

NOTE The final set position can be at any angle.

Final Set Position LED Illuminated

LED Not Illuminated

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Vision Height for RS and MTR Rail Systems

NOTE Ensure the board file used has the correct board thickness value Check rail / camera X motor bracket clearance Remember that the vision height may be higher if a thinner board is used.

4 Place the board on the rails and slide to a central position

5 Refit the screen

8 Select Load Screen.

11 Use Next or Previous to highlight Rising Table.

13 Use Next or Previous to highlight Raise Table To Vision Height.

15 Remove the left hand safety cover

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16 For RS systems Using a suitable metric rule, measure the distance between the bottom of the screen to the top of the board Check that the

dimension is 78mm -0.0mm / +0.2mm, (ie the height cannot be less than 78.0mm).

NOTE For MTR transport rail systems, the vision height setting is set as above, but

the measurement is 79.5mm.

17 If the dimension is correct, go to Step 26

18 Use Next or Previous to highlight Drive Table Using Jog Buttons.

20 Using jog buttons drive the rising table to achieve a vision height of 78mm -0.0mm / +0.2mm, (ie the height cannot be less than 78.0mm)(For MTR systems 79.5mm).

CAUTION VISION HEIGHT The rising table must not be jogged up higher than the specified dimension, camera damage may occur.

NOTE The right jog button drives the rising table up, the left jog button drives the rising table down.

21 Use Next or Previous to highlight Set Reference Vision Height.

22 Select Run Diagnost The message ‘This Will Alter The Printer uration File - Please Confirm’ is displayed.

Config-23 Select Confirm.

24 Use Next or Previous to highlight Home Rising Table.

26 Refit the left hand safety cover

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Camera Focus The camera focus is factory set and sealed and should not need adjustment

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Camera Reference Position

5 Use Next or Previous to highlight Home Camera X Axis.

7 Use Next or Previous to highlight Home Camera Y Axis.

9 Use Next or Previous to highlight Initialise Vision System.

10 Select Run Diagnost

11 Select Drive to Reference Position.

12 Select Run Diagnost, a box and the white dot on the board clamp are visible

on the monitor

13 If the reference position is correct, go to Step 18

14 Using Move Camera X Axis Using Jog Buttons and Move Camera Y Axis Using Jog Buttons, position the box centrally inside the white dot, as

shown in the graphic in Step 12

15 Use Next or Previous to highlight Set Reference Position.

16 Select Run Diagnost The message ‘This Will Alter The Printer uration File - Please Confirm’ is displayed.

Board Clamp Box

White Dot

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REPLACEMENT PROCEDURES

Camera

TO THE MACHINE.

The following procedure is valid for all cameras

3 Select Back.

8 Remove the screen

9 To gain access to the camera for removal, move the camera forward and central over the table by manually moving the camera carriage

10 Remove the following connectors from the rear of the camera unit:

11 Loosen the two camera mount screws and lift the dovetail fixings to free the

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camera, lift the camera out of the camera mount.

Fitment 12 Slide the camera into position in the dovetail ensuring that the end of the

camera mount butts against the right hand side of the dovetail and secure camera mount screws (2)

13 Connect 10SK13 and 10SK17

14 Ensure that the cable-ties are secure and the cables are positioned to prevent any chaffing on the board clamps or transport rails

15 Refit the screen

17 Power up the machine

18 The following adjustments/calibrations must be carried out:

• Camera Reference Position Adjustment

• Board Stop X Offset Check Calibration

• Vision Calibration

• Calibrate Offset Calibration

Camera Mount with Camera Removed

Dovetail Fixings Remain in Place

Loosen Screws (2)

Remove Connectors

at Rear

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Camera X Axis Timing Belt (Rotary Servo Motor Systems Only)

3 Select Exit.

NOTE Exiting diagnostics initialises the machine, homing the camera axes.

4 Select Back.

10 Remove the left and right side panels

11 Slacken the idle pulley locknut at the left hand end of the camera carriage

12 Slide the pulley inwards to release tension on the timing belt

13 Slacken the four timing belt clamp securing screws sufficiently to remove the timing belt from the clamp

NOTE

View From Beneath Camera Carriage

Idle Pulley Securing Screws

(in 4 positions)

Locknut

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