INS-IP3PPC-01E

FIP-IIIPlacing Pressure Controller Instruction ManualINS-IP3PPC-01EFuji Machine ManufacturingNotice1.All rights regarding this manual are reserved by Fuji Machine Manufacturing Co., Ltd. Thismanual may not, in whole or in part, be reproduced by any means (electronic, mechanical or otherwise), or reused in any way, without the prior written permission of Fuji MachineManufacturing Co., Ltd.2.Fuji Machine Manufacturing Co., Ltd. accepts no responsibility for any situations that may arise asa result of the use of this manual.3.Fuji Machine Manufacturing Co., Ltd. reserves the right to change the content of this manualwithout notice.4.Every effort has been made to ensure that this manual is correct in every detail. However, pleasecontact Fuji in the unlikely event that errors or omissions are detected.Copyright ©1999 by Fuji Machine Manufacturing Co., Ltd.All Rights Reserved.Fuji Machine Manufacturing Co., Ltd. serves its customers from the following locations: Fuji Machine Manufacturing Co., Ltd.19 Chausuyama YamamachiChiryu, Aichi Prefecture, 472-8686Tel :0566-81-2111Japan Fax :0566-83-1140Fuji America Corporation171 Corporate Woods ParkwayVernon Hills, IL. 60061Tel :847-913-0162USA Fax :847-913-0186Fuji Machine Mfg (Europe) GmbHPeter-Sander-Str. 43D-55252 Mainz-Kastel Tel :06134-202120Germany Fax :06134-202200Fuji Singapore OfficeC/O Mecomb Singapore LimitedSime Darby Centre896 Dunearn Road #04-03A, Tel :4675952Singapore 589472Fax :4693758Fuji Malaysia OfficeC/O Mecomb Malaysia Sdn Bhd2487, Jalan Sultan Azlan Shah Tel :604-656-400211700 Penang, Malaysia Fax :604-656-2941Fuji do Brasil Maquinas Industriais Ltda.Rua Joao Cachoeira, 128Itaim Bibi, Sao Paulo, SP04535-000Tel :11-3064-7650Brazil Fax :11-852-6833IntroductionIntroductionPlacing Parts with the Placing-pressure ControllerThere have been cases where parts were damaged or the leads bent because of the placing pressure applied when placing parts (the pressure applied to pressa part on the board down 0.3 mm) on the FIP-III. On the contrary, parts in thefuture may require much more placing pressure. The purpose of the placingpressure unit is to make it possible to place these parts.Using this manualThis manual lists the machine commands and maintenance necessary to “Place parts with the Placing-pressure Controller.” Read this manual before using this function.This manual supplements the Placing-pressure Control section in the following manuals.•FIP-III Maintenance Manual•FIP-III Proper Measurement Manual•FIP-III Operation ManualTable of Contents1.Maintenance...................................................................................1-11.1Details and Adjustments for each Part......................................................1-11.1.1Nozzle Attachment Unit..................................................................1-11.1.2Positioning the Measurement Unit.................................................1-31.2Replacing Parts.........................................................................................1-51.2.1Replacing the parts in the nozzle unit............................................1-51.3Daily inspection, cleaning and lubrication..................................................1-81.3.1Cleaning the inside of the nozzle (weekly or when findinga problem)......................................................................................1-81.3.2Calibrating the Placing Pressure control nozzle (weekly)..............1-92.Proper data.....................................................................................2-12.1Proper data List.........................................................................................2-12.2Proper data Measurements............................................................2-22.2.1Proper data (PPC_Calibrate Pos.X, Y)..........................................2-22.2.2Proper data (Pressure_Control_No.).............................................2-42.2.3Proper data (Nozzle_Spring_Constant).........................................2-42.2.4Proper data (Nozzle_Initial_Pressure)...........................................2-53.Operation........................................................................................3-13.1Automatic Operation..................................................................................3-13.2Commands................................................................................................3-23.2.1Command Hierarchy List................................................................3-23.2.2Command Page List.......................................................................3-33.2.3Command Descriptions..................................................................3-43.3Proper data................................................................................................3-63.3.1Proper data List..............................................................................3-63.3.2Error Displays and Remedies........................................................3-6About This ManualThis manual is made up of parts, and within each part chapters. Because thechapter numbers start from 1 in each part, the same chapter numbers arerepeated throughout the manual.The version number starts at Version 1.0 for a newly published manual. When minor corrections are made for misprints and omissions, the decimal part of the version number increases. When the actual content of the manual is revised, the integer part of the version number increases.Because the version number on each page is changed only if that page isrevised, it should be clear which pages have been altered from the previousmanual.Example:Version 1.0 (A new manual)Version 1.1 (Minor correction of misprints and omissions)Version 2.0 (Major revision of contents)Note:The above described version numbers are not related to the software version numbers.1.Maintenance1.1Details and adjustments of each part1.1.1Nozzle Attachment UnitThere is a reference-position check flag inside the ball-spline axis.Parts are picked up by the Placement-pressure Control functionwhen the Reference-position Sensor detects this flag.The Reference-position Sensor is positioned to go on when thenozzle is compressed a certain amount. Use the Z-axis servo countof this position as the standard position.•Adjustment(1)Remove the rotary joint cover.(2)Adjust the Reference-position Sensor location. Set a gap of 0.1mm between the sensor and the flag, and tighten set screw 1.(3)Inch the nozzle down until it touches the upper-surface of theboard.(4)Adjust the height of sensor so that it goes on 0.4 mm (200[pulse]) below the surface of the board. Make the heightadjustment by loosening the three set screws (at 2 ), fixing the main body of the rotary joint by hand, and spinning the sleeve with a spanner.(5)Lift the tip of the nozzle with a finger to ensure that there is alittle leeway in the stroke. Lower the nozzle 2.5 mm from the position in item (4), and ensure that the nozzle has a advance stroke.1.1.2 Measurement Unit Positioning•Adjustment of attachment height(1)Adjust the upper-surface height of the bracket on theMeasurement Unit to be 215 mm from the surface of the base.Use the adjustment bolt for the fine adjustment.(2)Set the Float surface on the Measurement Unit to the height ofProper data Z0. Lower the Z-axis to the Z0 position aftertemporarily attaching the Measurement Unit (including loadcell). The Z0 height refers to the servo pulse displayed on themonitor.surface on the measurement unit to the Z0 height (0 ~ 0.2 mm).• Level Adjustment(1)Remove the nozzle assembly.(2)Set dial gauge to the sensor holder. This is set to location A inthe following illustration.(3)Move the XY-table in each direction with the inching keys andadjust the four adjustment bolts so that that the range theneedle on the dial gauge is within 0.02 mm.(4)Set dial gauge to locations B, C, and D, and make theadjustments as in step (3).1.2Parts Replacement1.2.1Replacing the spring in the nozzleA special jig is necessary when replacing the spring.(AQPJ1120: Spring attachment jig)It is advisable to clean and lubricate the nozzle unit when replacingthe nozzle. Refer to “1.3 Daily Inspections, Cleaning, andLubrication.”•Spring Removal(1) Insert the jig into the nozzle as shown in the followingillustration. Insert it in as far as it will go while turning itslowly to the right.(2) Pull the jig out. Ensure that the spring is in the jig, and slowlyremove the spring.(Caution) The spring and collar may be lost if they are removed forcefully.(Danger) The pipe end of the jig is made of thin metal. Be careful no tocut your fingers when handling the jig.AQPJ1120 Spring attachment jig•Spring Attachment(1) Insert the spring and the collar into the jig. Firmly insert the jigas far as it will go.Note:The P4 spring on the next page does not fit completely into the jig. (Danger) The pipe end of jig is made of thin metal. Be careful no to cut your fingers when handling the jig.(2)Insert the jig into the nozzle. Insert it in as far as it will gowhile turning it slowly to left.(3)Push the shaft of the jig and remove it from the nozzle. (Caution)Calibrate the nozzle after changing the spring.Here are the spring types and classifications.The nozzle assembly number is determined by the nozzle size and the strength of the spring. The part numbers are shown in the following table.1.3Daily inspections, Cleaning, and Lubrication1.3.1Cleaning the inside of the nozzle (weekly or when finding aproblem)The dust and other partials in the atmosphere accumulate insidethe nozzle and may cause the nozzle to clog. The pick-up pressurewill decrease and part miss-picks will occur, resulting in a decreasein placement accuracy, if the clogs remain.Extra suction for parts pick-up will become neccesary if the dust inthe nozzle remains, and it will be imposssible to change nozzleswhen nozzle operation becomes bad. The placing-pressure controlnozzle in particular, will not get the necessary pressure.Clean the inside of the nozzle once a week and use a cotton swab tolubricate the inside of the nozzle with Biral T&D. Wipe the nozzlewith a clean rag to minimize further resistance and then grease thenozzle hook unit.It is also neccesary to clean and grease the nozzle hook unit on theZ-axis on a weekly basis along with the placing-pressure controlnozzle.Calibrate the nozzle after the cleaning and lubrication.1.3.2Calibrating the Placing-pressure Control Nozzle (weekly)Each of the placing-pressure control nozzles have placing-pressureProper data.This Proper data varies with the degree of internal resistance due to dirt build-up that occurs between the nozzle and the Z-axis.Do the calibrations weekly to maintain the stable applied pressure.It is necessary to clean and lubricate the inside of the nozzle andthe Z-axis before doing the calibration (Refer to 1.3.1).Refer to the command operations for the method of calibration.(Reference)Errors during the calibrationsAn error occurs when the deviation value sought from the Properdata measurement results of a certain nozzle exceeds the set value(Refer to 3.2.2 for information on operation).Clean and lubricate the inside of the nozzle and Z-axis again afterthe error occurs. Recalibrate the axis again after ensuring that there are no dirt or scratches.2.Proper data2.1Proper data listThe Proper data used is as follows:Proper data No.181. PPC_Calibrate Pos.X1=000000182. PPC_Calibrate Pos.Y1=000000183. PPC_Calibrate Pos.X2=000000184. PPC_Calibrate Pos.Y2=000000232. Pressure_Control_No. (0-30)=0247. Nozzle 1_1_Spring_Constant=0000248. Nozzle 1_1_Initial_Pressure=0000:=:638. Nozzle 2_12_Spring_Constant=0000639. Nozzle 2_12_Initial_Pressure=00002.2Measuring the Proper data2.2.1Definition of Proper Data (PPC_Calibrate Pos.XY)This definition pertains to the next four items.181. PPC_Calibrate Pos. X1182. PPC_Calibrate Pos. Y1183. PPC_Calibrate Pos. X2184. PPC_Calibrate Pos. Y2The PPC_Calibrate Pos. XY Proper data is specifically for theplacing-pressure control device. This Proper data is the servo countwhen each nozzle for heads 1 and 2 is at the center of theMeasurement Unit (load cell).181. PPC_Calibrate Pos. X1=X coordinate for Head 1182. PPC_Calibrate Pos. Y1=Y coordinate for Head 1183. PPC_Calibrate Pos. X2=X coordinate for Head 2184. PPC_Calibrate Pos. Y2=Y coordinate for Head 2 During the calibration, the machine refers to this value and movesthe nozzle above the load cell. The placing-pressure control willnot function correctly if an incorrect value is input. Transmit theProper data to the MCS after completing the measurements.Calibrating (PPC_Calibrate Pos. XY)Jigs used:Procedures:The following procedures are the same for both Heads 1 and 2. (1)Set the dial gauge to the Q-axis as shown in the followingillustration.Remove the nozzle assembly from the Q-axis before set thegauge.(2)Attach the XY Proper measurement jig to the sensor holder.Inch the targeted head close to the pressure application device.Press [SET] →[PROPER] →[PLACING PRESSURE] →[HEAD1 (or 2)] and [INCHING SPEED], decrease the inching speed,and align the head directly over the pressure application unit.(3)Look at the range of the dial gauge needle while turning the Q-axis by hand. Move the X-axis and Y-axis until the variancebecomes less than 0.02 mm.(4)Input the following commands.Press [POSITION] and [SET], then input the servo count as the PPC_Calibrate Pos. X1 (X2), Y1 (Y2)Proper data. (5)Receive the Proper at the MCS after performing themeasurements.2.2.2Definition of Proper data (Pressure_Control_No.)This definition pertains to232. Pressure_Control_No. (0-30).The machine communicates with the PPC (Placing-pressureController) during calibration. Set the 6-channel port number forthe connection. This value should normally be set to between 11and 30.2.2.3Definition of Proper data (Nozzle_Spring_Constant)This definition pertains to the following twenty-four data items:247. Nozzle 1_1_Spring_Constant ~638. Nozzle 2_12_Spring_Constan t.Nozzle_Spring_Constant sets the spring number for all nozzles used. This Proper data is set automatically during the calibration.The placing-pressure control will not function correctly if anincorrect value is input. Receive the Proper to the MCS afterperforming the measurement. The calibration operation is entirely automatic.(1)Press [SET] →[PROPER] →[PRESSURE] →[HEAD] and[START](2)Press [RETURN] once the measurement is complete, to displaya message to save the results to the memory board in thecontrol box.Select “YES” to save the results.An error indicating inadequate placing-pressure will display ifthere are nozzles whose deviation results exceed 40 gf (in 3σ) in the measurements. It may be necessary to refer to "3.3.2 Error Displays and Remedies," or to clean and lubricate the inside of the nozzle ifthis error displays.2.2.4 Definition of Proper data (Nozzle_Initial_Pressure)The Proper explained here is the following twenty-four data items: 248. Nozzle 1_1_Initial_Pressure ~639. Nozzle 2_12_Initial_PressureSet the original pressure value for theNozzle_Initial_Pressure Proper data.This Proper data is set automatic during the calibration.The placing-pressure control will not function correctly if anincorrect value is input.Procedure:This value is set simultaneously with theNozzle_Spring_Constant measurement.Refer to the definition of Proper data 2.2.3.(Nozzle_Spring_Constant).3.Operation3.1Automatic OperationPlacing parts with placing-pressure controlPlacing-pressure controlled part placement is carried out based on thevarious data obtained from the calibrations. The machine however, willignore the Part data setting for the Carring_data item30: Placing_offset_Z.Part Placement with the placing-pressure control takes place through thefollowing steps.Operation(1)The machine processes the image of the part that is picked up.(2)The part is then moved to the placement coordinates.(3)From there, the part is lowered at the regular speed to 2 mm above theProper data Z0.(4)The nozzle is then lowered at 0.5 % of the maximum speed until thereference-position sensor goes on.(5)Once the reference-position sensor goes on, that location is thenconsidered the reference position.(6)Here, the machine checks the placing pressure set in the Part data, andthen continues to apply the placement pressure.(7)Nozzle processing (like turning off the vacuum) takes place when thenozzle reaches the lower-limit.(8)From there, the part is raised at the regular speed to 2 mm above theProper data Z0.(9)The nozzle is then raised at the normal speed to the parts transportheight.3.2Commands3.2.1Command Hierarchy3.2.2Command Page ListUse this list as a convenient reference to the commands. Only the first three digits of the command page will display on the screen. Command Name Description Command Page *Ready Page 000 SET This sets different machine settings Page 500 PROPER This sets the Proper data Page 530 ETC This sets other commands Page 535 ETC This sets other Proper data Page 535-5 PRESSURE This sets the placing pressure Page 535-5-1 [Head 1, 2]Use this to select head 1 or 2Page 535-5-2 POSITION Use this to shift to the next screen Page 535-5-33.2.3Command DescriptionsThis section only mentions the commands for the placing-pressure controller.•Action of the Function KeysPOSITION:Press this to move to the next page.START:Press the [START] button after selecting this command to begin the spring constant and initial pressure value calibrationmeasurements for the targeted nozzle.CHG UNIT:This changes the nozzle to be calibrated.SPEED:This changes the inching speed.RETURN:Press this to return to Page 535-5-1.After pressing [RETURN], the machine will ask if you want to save the measurement results to the Proper data.Select “YES” to save the results.•Action of the Function KeysSET:Press this to measure the PPC position.Press [SET] after inching the targeted nozzle above the placing-pressure measurement unit to set the X and Y coordinates.RETURN:Press this to return to Page 535-5-2.After pressing [RETURN], the machine will ask if you want to save the measurement results to the Proper data.Select “YES” to save the results.•Function Key MenuMeasuring Proper data POSITION3.3Proper data3.3.1Proper data listData Name Input Range181:PPC_Calibrate Pos.X1(-7000~0) [pulse]=000000 182:PPC_Calibrate Pos.Y1(0~260000) [pulse]=000000 183:PPC_Calibrate Pos.X2(0~700000) [pulse]=000000 184:PPC_Calibrate Pos.Y2(0~260000) [pulse]=000000 232:Pressure_Control_No.(0~260000) [pulse]=000000 247:Nozzle 1_1_Spring_Constant(0~30)=0248:Nozzle 1_1_Initial_Pressure(0~5000) [gf]=0000 ::638:Nozzle 2_12_Spring_Constant=0639:Nozzle 2_12_Initial_Pressure(0~5000) [gf]=00003.3.2Error Displays and Remedies(a)Errors that occur after pressing [AUTO]Code:None“PPC setting value out of valid range”Cause:The placing pressure value set in the Part data isincorrect.Remedy:Change the value in the placing-pressure setting.Another remedy would be to change to a nozzle that iswithin the effective range.Code:None“Nozzle name is not set in Part Data“Cause:The nozzle name is not set in the Part data.Remedy:Set the nozzle name in the Part data for the part thatrequires placing pressure control.Code:None“Spring constant and initial pressure are not set in Proper”Cause:The spring constant and/or initial placing pressure for the nozzle are not set in the Proper data.Remedy:Set the spring constant and/or initial placing pressure for the nozzle in the Proper data.(b) Errors that occur during calibrationCode:None“PPC_Calib Pos X and Y are not set in Proper”Cause:The position of the pressure measurement unit is not set in the Proper data. Another cause may be that theposition of the measuring unit has not been measuredwith the calibration command.Remedy:Set the pressure measurement unit position. Anotherremedy may be to measure the position before doingthe calibration.Code: 12020701“PPC Communication time-up”Cause: A communication timeout occurred at the digitalindicator.Remedy:Ensure that the communication cable for the digitalindicator is properly connected to the 6-channelcommunication board.Code: 12020702“PPC: Overflow”Cause:Various digital indicator errors (including an overflow) have occurred.Remedy:Reboot the machine and perform the measurementsagain.Ensure that there are no disconnection in the cablebetween the digital indicator and the load cell.Code: 12020703“PPC: Unstable measured value”Cause:The measurement value displaying on the digitalindicator is unstable.Remedy:Reboot the machine and perform the measurementsagain.It will be necessary to change the digital indicator if thiserror occurs frequently.Code: 12020704“PPC: Not in Hold mode”Cause:The digital indicator is not in Hold mode.Remedy:Use the I/O (PLAC PRES T/H, PLAC PRES H/M) to ensure that the digital indicator is in Hold mode.Another remedy would be to ensure that the digitalindicator Hold mode is set to “3” (interval-peak Holdmode).Code: 12020705“PPC: Zero Tracking...”Cause:The digital indicator is tracking the zero position.Remedy:Use the digital indicator to turn off the zero trackingfunction.Code: 12020706“PPC: Status reading error”Cause:An error occurred during the status reading on thedigital indicator.Remedy:Ensure that the communication cable for the digitalindicator is properly connected to the 6-channelcommunication board.Code: 12020707“PPC: Measured value reading error”Cause:An error occurred during the measurement reading on the digital indicator.Remedy:Ensure that the communication cable for the digitalindicator is properly connected to the 6-channelcommunication board.(c) Errors that occur during the placement of partsCode: 12056007“Error: PPC origin position sensor”Cause:The placing-pressure reference position sensor is notoperating correctly.Remedy:Ensure that the placing-pressure reference sensoroperates correctly. Another remedy would be to ensurethat the position of placing-pressure reference sensor ispositioned correctly.(d) Errors that occur during Proper data transmissionCode: 11022633(No display)Cause:The communication port setting (Pressure Control No.) used to communicate with the digital indicator isoverlapping another port setting. The port setting maynot between 11 and 30.Remedy:Change the port number setting.The FUJI InternetFuji Internet aims at providing information to our customers in the most efficient manner. This site makes a range of services available, from manual updates and FAQs, to online technical reports. Fuji hopes that this site will be used as a source of information in addition to the services provided by your agent. Fuji’s website is located at http://www.fuji.co.jp/Fuji Internet membership is required to access the Technical Information section of the site, contact your agent for details.Any comments or opinions regarding this manual can be sent to smtdocu@fuji.co.jpIP-III(E) PPC Instruction Manual1.0 Version November 9, 1995FUJI Machine Manufacturing Co., Ltd.SMT Equipment19 Chausuyama, Yamamachi, Chiryu,Aichi Prefecture, 472-8686 JapanCopyright ©1999 by Fuji Machine Manufacturing Co., Ltd.Printed in Japan。