SMT设备的操作与维护项目一 印刷设备操作与维护电子ppt课件.ppt

电子产品生产设备操作与维护课程教学资源建设,建设院校：,主要参与企业：,淮安信息职业技术学院,美国环球仪器公司德国埃莎亚太办事处无锡日联光电有限公司南京电子表面组装专业学会深圳日东电子科技有限公司 南京熊猫电子制造有限公司,学习情境介绍,从工作岗位到课程标准,1.应用电子技术专业人才培养方案介绍,学习情境介绍,从课程标准到学习领域,学习情境介绍,从学习领域到学习情境,学习情境介绍,2.教学模式简介,学习情境的组织形式-“车间教学”的组织形式,车间,班组（5-6人）,老师,车间主任,技术主管,班组长,班组（5-6人）,班组长,班组（5-6人）,班组长,约810组,生产组织日常考勤过程监控反馈处理,技术咨询故障处理技术反馈质量控制,3个身份,组织监控,组织监控,教学组织与实施教学资源,以学生为中心,学习情境介绍,学习情境介绍,学习情境介绍,构建“4T（true,即真实产品、真实设备、真实岗位、真实环境）”实训教学模式,学习过程现场2,学习情境介绍,通过虚拟仿真进一步提高教学效果,建立学习团队,表达能力,参考：德国哈勃,建立学习团队,教师团队介绍,建立学习团队,布置给班委会的艰巨任务：1、分组的方案如何确定？（成绩、爱好)2、每组的领导者、组织者如何选择？（责任心、纪律性),学习小组的组建,建立学习团队,学习小组或团队应考虑的问题,单元一 印刷设备操作与维护,本任务学习目标:,项目一 印刷机操作与维护,任务一 Suneast操作与维护,单元任务 印刷设备操作与维护,1、SMT生产线设备图,一、资讯,单元任务 印刷设备操作与维护,2、SMT制程工艺,3、SMT生产防静电,单元任务 印刷设备操作与维护,4、SMT设备维护工具,单元任务 印刷设备操作与维护,5、SMT印刷物料 5.1 锡膏 5.1.1锡膏组成 锡膏成份：合金粉和焊剂（活化剂、触变剂、基材树脂和溶剂）锡膏比例：合金通常占锡膏总重量的 8592%常见合金颗粒：300目625目,单元任务 印刷设备操作与维护,5、SMT印刷物料 5.1 锡膏 5.1.2 锡膏储存与使用 锡膏存储温度：210 回温时间：4小时 回温温度：25+/-3 回温技巧：倒装回温沿一种方向搅拌，能自行滑落 锡膏管理原则：先进先出 锡膏使用环境：25+/-3，50+/-10%RH,单元任务 印刷设备操作与维护,单元任务 印刷设备操作与维护,5、SMT印刷物料 5.2 模板,5、SMT印刷物料 5.3 刮刀,单元任务 印刷设备操作与维护,5、SMT印刷物料 5.4 印制电路板（PCB或基板）,单元任务 印刷设备操作与维护,1、印刷机操作编程 1.1 印刷机开机,单元任务 印刷设备操作与维护,二、任务实施,1、印刷机操作编程 1.2 印刷机首件编程,单元任务 印刷设备操作与维护,1、印刷机操作编程 1.2 印刷机首件编程,单元任务 印刷设备操作与维护,1、印刷机操作编程 1.2 印刷机首件编程,单元任务 印刷设备操作与维护,1、印刷机操作编程 1.3 印刷机试印刷与自动印刷,单元任务 印刷设备操作与维护,1、印刷机操作编程 1.4 印刷机关机,单元任务 印刷设备操作与维护,1）印刷结束剩余焊膏处理：印刷结束剩余焊膏用刮刀将其刮入空的焊膏瓶中，下次印刷取取新焊膏以1:1比例混合搅拌均匀再使用。2）退出并清洁钢网。3）清洁刮刀上焊膏。,2、印刷机点检维护保养 2.1 印刷机点检,单元任务 印刷设备操作与维护,2.1.1 设备点检制原则,定人：设立设备操作者兼职的和专职的点检员。定点：明确设备故障点，明确点检部位、项目和内容。定量：对劣化倾向的定量化测定。定周期：不同设备、不同设备故障点，给出不同点检周期。定标准：给出每个点检部位是否正常的依据，即判断标准。定点检计划表：又称作业卡，指导点检员沿着规定路线作业。定记录：包括作业记录、异常记录、故障记录及倾向记录。定点检业务流程：明确点检作业和点检结果的处理程序。,2、印刷机点检维护保养 2.1 印刷机点检 2.1.1 设备点检制表,单元任务 印刷设备操作与维护,2、印刷机点检维护保养 2.2 印刷机设备结构-外观,单元任务 印刷设备操作与维护,2、印刷机点检维护保养 2.2 印刷机设备结构-内部结构,单元任务 印刷设备操作与维护,2、印刷机点检维护保养 2.3 印刷机设备维护-主要器件,单元任务 印刷设备操作与维护,2、印刷机点检维护保养 2.3 印刷机设备维护,单元任务 印刷设备操作与维护,故障原因及对策1.机器摄像机进行了图像辨认，但未发现MARK故障(1)推定原因1)摄像机不在可捕捉记号的位置。2)记号与登录内容(形状/颜色/大小等)有不一致的地方。3)由于形状/浓淡/轮廓不鲜明，因此无法辨认记号。4)电路板未传送到所规定的位置。5)摄像机图像辨认装置发生故障(2)对策方案1)将摄像机移动到可辨认记号的位置。2)重新登录记号形状。3)调整摄像机照明等。4)电路板未传送到所定的位置时，取出搬入C/V,印刷台,搬出C/V上的电路板后重新操作。,单元一 印刷设备操作与维护,本任务学习目标:,项目一 印刷机操作与维护,任务二 DEK操作与维护,课程主题,安全说明机台概要载入基板档案载入钢板顶针刮刀更换载入锡膏执行生产钢板清洁器,印刷机台清洁印刷机台检查机台工作日志错误训息共通的印刷问题QC 计算极限2D 检查动作.,个人安全守则,Board Clamps 是锐利的煞车器是热的(Horizon只有Rising table)戴护目镜及手套用清洁溶剂时时时固定HEAD PROP(Horizon 没有)如有怀疑按紧急停止开关不要忽略安全.,OBJECTIVE 1,机台概要,个人安全护盖MMI(显示器,键盘,警示灯)印刷头刮刀组件钢板载入钢板调整轨道系统辨识系统盖升降台(RISING TABLE)目录架构.,OBJECTIVE 2,警示灯表示,光学点为蚀刻钢板一半,钢板,基板,FID.1,FID.2,FID 2 X-OFFSET,FID 1 X-OFFSET,FID 2 Y-OFFSET,FID 1 Y-OFFSET,调整,Y-actuator,Y-actuator,XR,XR,XF,XF,目录架构,载入基板档案,加载生产档案(使用功能键)加载生产档案(使用条形码读取器).,OBJECTIVE 3,4,MODE,LOADDATA,EDITDATA,SETUPSQUEEGEE,CHANGESCREEN,CHANGETOOLING,CHANGELANGUAGE,EXIT,RUN,HEAD*,PASTELOAD,CLEANSCREEN,ADJUST,SETUP,MONITOR,*打开前盖 on Horizon,刮刀更换,选择刮刀类型选择刮刀长度高度校正确认压力.,OBJECTIVE 6,7,8.,CALIBRATEHEIGHTS,CHANGESQUEEGEE,EXIT,MODE,LOADDATA,EDITDATA,SETUPSQUEEGEE,CHANGESCREEN,CHANGETOOLING,CHANGELANGUAGE,EXIT,RUN,HEAD,PASTELOAD,CLEANSCREEN,ADJUST,SETUP,MONITOR,载入钢板,先载入生产档案更换钢板.,OBJECTIVE 5,MODE,LOADDATA,EDITDATA,SETUPSQUEEGEE,CHANGESCREEN,CHANGETOOLING,CHANGELANGUAGE,EXIT,RUN,HEAD*,PASTELOAD,CLEANSCREEN,ADJUST,SETUP,MONITOR,*打開前蓋 on Horizon,顶针,一般顶针(MAGNETIC TOOLING)DEDICATED TOOLING PLATESAUTOFLEX TOOLING真空顶针(VACUUM TOOLING)MANUFLEX.,OBJECTIVE 6,HEAD,ADJUST,HOMESTOP,BOARDSTOP,FULLWIDTH,LOADWIDTH,BOARDWIDTH,EXIT,MODE,LOADDATA,EDITDATA,SETUPSQUEEGEE,CHANGESCREEN,CHANGETOOLING,CHANGELANGUAGE,EXIT,RUN,HEAD,PASTELOAD,CLEANSCREEN,ADJUST,SETUP,MONITOR,刮刀 金属 VS 塑料(聚氨酯),刮刀长度的影响,载入锡膏,手动载入锡膏自动加载锡膏.,OBJECTIVE 10,AUTODISPENSE,MANUALLOAD,LOADCARTRIDGE,PRINTDIRECTION,EXIT,RUN,HEAD*,PASTELOAD,CLEANSCREEN,ADJUST,SETUP,MONITOR,*打开前盖on Horizon,生产准备,登入/注销清除批量数/设定批量数.,OBJECTIVE 13,14.,LOG ON,CLEARBATCH,BATCHLIMIT,PERFORMDISPLAY,EVENTDISPLAY,SYSTEMDISABLE,EXIT,RUN,HEAD,PASTELOAD,CLEANSCREEN,ADJUST,SETUP,MONITOR,执行生产,开始搅拌锡膏.,OBJECTIVE 15,ENDRUN,STOPCYCLE,PASTELOAD,CLEANSCREEN,ADJUST,PASTEKNEAD,RUN,HEAD,PASTELOAD,CLEANSCREEN,ADJUST,SETUP,MONITOR,执行生产,调整.,ENDRUN,STOPCYCLE,PASTELOAD,CLEANSCREEN,ADJUST,PASTEKNEAD,RUN,HEAD,PASTELOAD,CLEANSCREEN,ADJUST,SETUP,MONITOR,调整,印刷速度铺锡速度前印刷界限后印刷界限前刮刀压力后括刀压力铺锡高度印刷间隙脱膜速度脱膜间距,钢板清洁周期1钢板清洁周期2前向X补偿值前向Y补偿值前向THETA补偿值后向X补偿值后向Y补偿值后向THETA补偿,清洁钢板,锡膏的处理手动擦拭清洁USC清洁钢板清洗.,OBJECTIVE 16,ENDRUN,STOPCYCLE,PASTELOAD,CLEANSCREEN,ADJUST,PASTEKNEAD,RUN,HEAD,PASTELOAD,CLEANSCREEN,ADJUST,SETUP,MONITOR,USC清洁纸,I I,清洁纸卷动位置,清洁刮片,纸张供料方向,擦拭过脏纸卷动位置,机台前方位置,清洁溶剂供给棒,(BLUE TYPE),印刷机台清洁,升降台区域顶针基板夹板器(BOARD CLAMPS)刮刀托盘防锡膏滴下托盘.,OBJECTIVE 17,印刷机台检查,PRINT CARRIAGE 滑轨刮刀机械部位CAMERA CARRIAGE 滑轨BOARD CLAMPS是否有损坏.,检查印刷机台是否有锡膏或清洁剂位置:,OBJECTIVE 18,机台工作日志,印刷时的任何突发状态与异常机台的任何问题机台维修所做的维修纪录.,纪录机台状态在工作日志簿:,OBJECTIVE 19,错误讯息,未找到光学测试点(FIDUCIAL NOT FOUND)钢板清洁器位置不对(SCREEN CLEANER OUT OF POSITION)轨道升上错误(RAIL LIFT ERROR)刮刀压力错误(SQUEEGEE PRESSURE ERROR)系统电源未启动(SYSTEM POWER DOWN.),OBJECTIVE 20,印刷问题“桥接(Bridging)”,OBJECTIVE 21,桥接的原因,钢板损坏印刷区域热或锡膏黏刮刀钝刮刀压力太高印刷偏移印刷间隙(PRINT GAP),OBJECTIVE 21,印刷问题“印刷高度过高(锡尖)”,OBJECTIVE 21,印刷高度过高(锡尖)原因,钢板损坏印刷区域热或锡膏黏刮刀钝刮刀压力太低刮刀片损坏基板不良印刷间隙,OBJECTIVE 21,印刷问题“锡凹(Scooping)”,OBJECTIVE 21,锡凹(Scooping)原因,印刷区域热或锡膏黏刮刀压力太高基板不良,OBJECTIVE 21,印刷问题“不完整的印刷(Incomplete print)”,OBJECTIVE 21,Is the paste too high in viscosity?(i.e.greater than some 92 Pa.s or 92%,metal loading).,不完整的印刷(Incomplete print)原因,钢板锡膏塞孔钢板损坏旧的或过干的锡膏刮刀损坏或钝掉刮刀压力过低刮刀压力过高及锡膏有异物基板不良印刷偏移,OBJECTIVE 21,印刷问题“印刷偏移(Misalignment)”,OBJECTIVE 21,印刷偏移(Misalignment)原因,光学测试点设定粗劣基板拉伸机台毁坏逐步的,OBJECTIVE 21,干净的边缘顶端平坦印刷高度=钢板厚度正确的印刷位置无助焊剂流出.,完美的印刷,COURSE AIM,Identify all major components and sub-assembliesUnderstand basic programming to help differentiate between machine and process faultsRecover from machine electrical and software faultsPerform machine critical settings and associated calibrationsPerform preventive maintenance routinesTest machine accuracy and return to factory standard,COURTESY AND SAFETY,PERSONAL SAFETY,Wear PERSONAL PROTECTIVE EQUIPMENT with paste and solvent based products If in doubt press the E STOP.,MOVING MACHINE PARTS MAY CAUSE INJURY DURING THIS COURSE WE WILL OPERATE THE MACHINE WITH CERTAIN COVERS REMOVED ALWAYS ENSURE SYSTEM POWER IS REMOVED PRIOR TO UNDERTAKING ANY WORK ON THE MACHINE.,WARNING!,CLASSROOM SAFETY,SAFETY FOR LINEAR MOTORS,Warning!The DEK printer contains Electro-Static SensitiveDevices,Do not touch any electroniccomponent or PCB unlesswearing a correctly groundedwrist strap,ESD HAZARD,Impact of Lead Free,MACHINE OVERVIEW,Front and rear coversObserve location of cam safe switchMonitor assemblySystem button and jog buttonsTri-colour beaconChase assemblyPrint carriageSqueegee assembly/ProFlowPaste dispenser.,Remove front,side and rear covers!,MACHINE OVERVIEW(CONT),Screen loadScreen alignment actuatorsRail systemCamera systemRising tableMains isolator switchService panel/circuit breakersUnder screen cleanerVacuum unit.,BEACON INDICATIONS,INITIALISATIONSET-UPMAINTENANCE,PASTE CARTRIDGE LOWPAPER EMPTYSOLVENT EMPTY,OPERATIONALWAITING IN READY STATE,SYSTEM POWER OFFHALTED BY ERROR,Operator manualInstallation manualOn board tutorialsFast track guides,Technical Reference manualElectrical drawingsWeb based mechanical information,CD Rom,NAVIGATING THE MANUALS&SOURCES OF INFORMATION,Workbook task A2,Maintenance,Machine Overview,INITIALISATION SEQUENCE,Observe the machine as it initialises:,Workbook task MO1,STATE MONITOR AREAS,Workbook task MO2,CREATE A PRODUCT FILE,Create a new product file based on the default fileMeasure board dimensions accurately,Workbook task MO3,Use synthetic fiducials whenever availableDiagonally opposite.,SETUP SYNTHETIC FIDUCIALS,Workbook task MO4,Unique imageStrong ContrastReference to centerStrong horizontal&vertical lines,Used if fiducials poor or damaged and for SPC fault isolation techniques,SETUP VIDEO MODEL,Workbook task MO5,PRINT CYCLE SEQUENCE,Press runObserve machine operation during the print cycle,Workbook task MO6,COMMON ERROR MESSAGES,Fiducial Not FoundScreen Cleaner Out of PositionRail Lift ErrorActuator Close to LimitsSqueegee Pressure ErrorSystem Power Down.,Workbook task MO7,Maintenance,Electrical Theory and Troubleshooting,DIAGNOSTICS MODULES,Workbook task ET1,ELECTRICAL ENCLOSURES,With Advantech PC,With I-Bus Firewire PC,PC,Power Supply M37,Control Enclosure M36,USB,USB,SCALEABLE CONTROL SYSTEM,The Core system has 3 main electrical enclosures,Power Supply:All DC unit accepting mains input voltages from 85 264 V AC.No transformer tapping.No line conditioners needed for poor factory mains supplies.,PC:Power supply accepting input voltages from 90 264 V AC.,Control Enclosure:Small,simple unit.All internal interconnection by PCB,no internal wiring.,SYSTEM COMMUNICATION,PC,USB Hub,BarcodeScanner,ADSLModem,FlatbedScanner,Optional peripherals also use USB,Using Windows XP allows peripherals to be added simply by plug and play.,BluetoothAdapter,Add optionsAdd new functionality,Line Printer,PERIPHERAL CONNECTIONS(OPTIONS),ELECTRICAL DIAGRAM,POWER SUPPLY M37,40V DC SMPSU,Multi-Rail SMPSU,40V DC switched,24VDC Un-switched,12V DC Un-switched,5V DC Un-switched,-12V DC Un-switched,Power supply monitor,Safety circuit,E-Stop,Interlocks,2 Hand control,System switch,USB,Mains I/P,Circuit breakers,24VDC switched,Contactors,85 264V AC,POWER SUPPLY M37 BLOCK DIAGRAM,E-STOP CIRCUIT,POWER SUPPLY M37,Workbook task ET2,Monitor card measures 64 DC voltages in the M37 power supply and reports them to the PC via USB.It measures both sides of every circuit breaker.Shows power GOOD/BAD and breaker IN/OUT for all DC power circuits.PC display shows average,max and min voltage values.Power good shown GREEN,fault condition shown RED.Updates every 2 sec.,POWER SUPPLY MONITOR,Workbook task ET3,PC CONFIGURATION SUMMARY,Which Configuration do you have.?,Workbook task ET4,ADVANTECH PC(ANALOGUE CAMERA),PC BLOCK DIAGRAM-GREEN CAMERA,PC BLOCK DIAGRAM GOLD CAMERA,PC-CARD LAYOUT,SINGLE BOARD COMPUTER,NETWORK CARD,VISION CARD,VISION ADAPTOR CARD,SOUND CARD,I-BUS PC WITH FIREWIRE CARD,I-BUS PC WITH DIGITAL CAMERA,I-BUS PC-CARD LAYOUT,Fire Wire Card,I-BUS PC WITH ANALOGUE CAMERA,I-BUS PC-CARD LAYOUT,VISION CARD,VISION ADAPTOR CARD,CONTROL ENCLOSURE M36,CONTROL ENCLOSURE BLOCK DGM,Rotarymotors,Linear motors,CONTROL ENCLOSURE-CARD LAYOUT,X1,X2,X3,X4,X5,X6,X7,DualStepperXf actuatorXr actuator,DualStepperFront Sq.Rear Sq.,DualStepperY actuatorMovingRail,Next MoveESInterface,Next MoveESMotionController,EuroFlexDriveCamera XAxis 0(Linear only),EuroFlexDriveCamera YAxis 1(Linear only),NEXTMOVE ES CARD,NEXTMOVE INTERFACE CARD,DUAL STEPPER,X1,X2,X3Cards are interchangeable,NODES,Front of Machine(Plan View),RisingTableNode 6,MainMachineNode 2,ScreenCleanerNode 4,PrintCarriage I/ONode 3,PasteDispenseNode 10,Camera Y(on motor)Node 9,Print Carriage(on motor)Node 7,Camera X(on motor)Node 8,Print Carriage,Communicates via CAN busMultiple sensor inputsMultiple outputs including solenoid drivesMounted at rear of printer,MAIN MACHINE I/O NODE 2,Communicates via CAN busMultiple sensor inputsMultiple outputsMounted on Print CarriageSupport for all Print Carriage functionality including Temp/Hum,Print Pressure,Paste Monitoring,Pro-Flow,Paste dispensing.,PRINT CARRIAGE I/O NODE 3,Communicates via CAN busMultiple sensor inputsMultiple outputsSolvent pump drive circuitMounted at rear of printerSupport for all under screen cleaner functionality including Paper&Vortex,pumped or pressurised solvent.,SCREEN CLEANER I/O NODE 4,By now you should be able to.Identify Boards in EnclosuresRemove and replace PCBsIdentify configuration requirements,ENCLOSURES AND PCBS SUMMARY,Workbook task ET5,Which configurations and settings must be completed if the Nextmove card is changed?Name 3 locations where+24v can be monitored?Which cards are interchangeable for troubleshooting purposes?,QUIZ,Workbook task ET5,SENSORS AND SWITCHES,Workbook task ET6,Linear MotorsGalaxy Machine Only,LINEAR MOTORS CAMERA X&Y,Forcer,Permanent Magnet Track,Read Head,Camera,Workbook task ET7,Encoder strip,Home sensor,index Sensor used on early machines.No longer fitted.,LINEAR MOTOR CONTROL,HOME,Axis=?,V=_,PSU _,HALL EFFECT,FORCER,M37,M36,MOTOR,Workbook task ET7,Linear Encoder,LINEAR MOTOR CONTROL,READ HEAD,HOME,NEXTMOVEINTERFACE,V=48V,NEXTMOVEES,EUROFLEX,PSU 2,HALL EFFECT,FORCER,M37,M36,MOTOR,Axis=Camera XCamera Y,Linear Encoder,A EuroFlex card supplies power sequentially to the three phase windings in the Forcer.The windings are physically 120 degrees out of phase.The magnetic field created in the winding reacts with the permanent magnets in the track to create motion.The Hall Effect switches are used during start up.They produce six pulses that provide the initial commutation.Once speed and direction is established motion detection passes over to the encoder.,LINEAR MOTORS THEORY,LINEAR ENCODER THEORY,The optical read head measures positional information from the encoder strip running the length of the permanent magnet track,LINEAR ENCODER(READ HEAD),Read-head LED conditions:-GreenReader set-up correctly,encoder clean and all pulses can be read.AmberThe Reader/Encoder Strip may need cleaning,or the gap between the Read head and Encoder strip is greater than 0.8mm.RedReader has failed to read encoder pulses,servo power is disabled if this occurs.,Workbook task ET8,EUROFLEX CARDS(LINEAR MOTORS),X6,X7Cards are interchangeable,Workbook task ET9,LINEAR MOTOR HOMING SEQUENCE,Forward,Reverse,Stop,HomeSensor,LinearMotor,Workbook task ET10,PRACTICAL EXERCISE,Measure X forcer resistanceMeasure Y forcer resistanceMonitor Read Head LED state during homing sequence,Workbook task ET11,LINEAR MOTOR MAINTENANCE,The linear motor magnets require no special maintenance unless they become contaminated.In the event of contamination,carry out the following procedure:Wrap a plastic spatula with sticky tape,sticky side out.Use the spatula to remove any debris that is attached to the X and Y camera linear motor magnets.To remove print material from the magnets,use alcohol on a lint free cloth.The Camera X and Y linear motor encoder strips require no maintenance unless they become contaminated.In the event of contamination,use a dry lint free cloth to wipe the encoder strip.,Standard Rotary MotorsAll Machines,Single unit includes servo motor,drive electronics,encoder,processor and CANopen interfaceUnits are connected via CAN busCamera X(Rotary machines)Camera Y(Rotary machines)Print Carriage,Servo Motor,Drive electronics,Processor,CANopen interface,CAN Bus,DC Power,Gearbox,CANOPEN SERVO MOTOR,STEPPER,STEPPER MOTOR,Requires step/directionNo positional feedbackFront SqueegeeRear SqueegeeRail WidthXf,Xr,Y actuators,SIMPLE DC MOTOR,Simple ConstructionUSC paper feed,DC MOTOR,Speed control by adjusting potentiometer on driveHigh torque available for high speed and heavy board applications.Require only 2 inputs:Direction and start/stop(with dynamic braking).,DC CONVEYOR MOTORS,Workbook task ET12,MOTOR,DC MOTOR CONTROL,MOTOR,_,V=,V=,Axis=.?,Axis=.?,Workbook taskET13,USC Paper feed,NEXTMOVE,NEXTMOVEINTERFACE,MOTOR,DC MOTOR CONTROL,Belt Motor FrontBelt Motor Rear,NEXTMOVE,I/ONODE,MOTOR,CANbus