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The ATS-300
is an automated in-line tinning system for axial leaded components.
This system is typically used to comply with the solderability
and cleanliness requirements of MIL-STD 2000, MIL-PRF-19500, MIL-PRF-38534,
and MIL-PRF-38535.
The system
is comprised of a central processing module and may be equipped
with several input and output handling options.
The ATS-300 may be placed in-line with inspection or other equipment
to eliminate handling. The ATS-300 system is designed for flexibility,
to allow the processing of a wide range of axial components, with
varying body lengths. The flux and solder modules have adjustable
positions to allow the operator to control the space between each
wave for different body lengths.
The system
may be specified to run lead-free alloys with little or no equipment
modification. To convert existing machines to lead-free requires
only a change in solder module to avoid contamination. In the
standard configuration the process is as follows:
- apply flux
to both leads
- preheat
component
- apply solder
to the first lead
- apply solder
to the second lead
- post-clean
and dry the complete component
CENTRAL
PROCESSING MODULE
Standard
Features:
Main Frame
/ Enclosure: The central processing module is a completely
enclosed welded tubular steel structure. Sliding glass panels
are provided in the front and rear of the system so the process
may be easily viewed and monitored. Vent stacks are located along
the top of the system. The standard system has a footprint of
146" long by 34" wide by 77" high (3708 x 864 x 1955mm).It
includes: a component conveyor, a wave fluxing module, a preheating
module, two soldering modules with inerting, a post-cleaning module,
a compressed air drying module, and hot air drying module.
The system
is equipped with explosion-proof interior lighting, giving good
visibility in the process area. Spill trays with drains under
each module facilitate clean-up and maintenance.
Operator controls
are located above the process modules on the upper panel. These
include Emergency Stop buttons at each end of the system and Alarm
Reset switches. Controls and indicators for Service Utilities,
Conveyor Control, Alarm Status and specific module control settings
are also located on these panels.
Door and Window
interlocks prevent operators from accessing the interior of the
system during processing. The standard door interlock package
provides interlocks on all doors covering electrical power cabinets.
The standard window interlock package provides interlocks on all
sliding windows in the main processing module.
Component
Conveyor: The variable speed component conveyor has a range
of 0 to 30 feet per minute (0 - 9.1 m/min). There are 12 grippers
per foot on the conveyor chain, thereby providing a typical throughput
of 14,400 components per hour (based on 12 grippers / foot and
speed of 20 feet per minute; 2/3 of maximum).
The gripper
assemblies are fitted with fingertips, custom designed to hold
the axial components by the body. This feature allows in-line
processing of the components and ensures part to part repeatability.
The conveyor chain and cam-actuated gripper assemblies are all
constructed of stainless steel to withstand the process environment.
The snap-fit fingertips, designed so they can be changed quickly,
are made from titanium which prevents solder from adhering to
them during processing.
Also incorporated
as a standard feature is a finger cleaner. The finger cleaner
is located directly above the post-cleaning module. It uses feed
water to completely rinse the conveyor chain and gripper/finger
assemblies, eliminating any flux residue build-up and greatly
reducing maintenance requirements. Sheet metal safety guards with
clear acrylic windows are provided to enclose the conveyor and
fingers at each end of the system.
Wave Fluxing
Module: The fluxing module has a wave flux pot constructed
of PVC. The height of the flux wave is adjusted by a thumb wheel
potentiometer, which controls a variable-speed D.C. motor pump.
Air knives are used to remove excess flux, thereby eliminating
solder splash and solder balls during the soldering process. A
drain is provided, as is overflow protection. This allows for
speedy clean-up at the end of the work schedule, or rapid changeover
if more than one type of flux is being used. This module can accommodate
all standard flux types.
Convection
Preheater: The 18" long convection preheater module uses compressed
air feeding through in-line heaters into a stainless steel enclosure
that directs the hot air stream through slot nozzles on either
side of the component. The thermocouplke sensor is in the hot
air stream and feeds back actual air temperature to a digital
controller with high and low limit alarms.
Solder
Modules: The two individual solder modules have stainless
steel solder pots. These solder pots roll in and out by means
of lead screws to facilitate position adjustment and access for
maintenance. A positive stop ensures repeatability when returning
to the operating position. The wave of the first solder pot in
line tins one of the axial leads of the component; the wave on
the second pot is adjusted, depending on the length of the component
body, to tin the opposite lead. Each pot has its own thermally
protected D.C. motor driven pump, which provides precise wave
height control in the solder nozzle, adjustable via thumbwheel
potentiometer.
Each module
is equipped with a digital temperature controller with high and
low temperature alarms (audible and visual). A low solder level
alarm is also standard. The system uses two non-contact heaters,
which uniformly heat the walls of the pot, thereby minimizing
the danger of an eruption during the warm-up phase. Corfin's dual
chamber pot is designed to draw solder from the base of the pot,
eliminating dross recirculation through the wave
Inerting
System: Each solder pot is equipped with an inert gas enclosure
around the solder wave, with stainless steel gas diffusers that
provide a non-turbulent protective gas cover over the wave. The
controlled atmosphere reduces dross formation on the solder wave,
promotes wetting and ensures uniform solder coverage of the component
leads. The process of solder coating component leads is greatly
enhanced by the inerting process, with the virtual elimination
of icicles and flags. A stainless steel shroud that covers the
rear of the solder pot, including the pump area, is injected with
inert gas to reduce the formation of dross and black powder from
the pump shaft. Consumption of solder and maintenance times are
greatly reduced by the inerting system.
Post-Cleaner
Module: A two stage stainless steel cleaning module is supplied
with all ATS-300 systems. The standard configuration for aqueous
cleaning has a turbulent wave wash section with recirculating
pump, followed by a spray rinse section. Hot feed water is supplied
to the rinse section, ensuring that the components are rinsed
clean before exiting the module. The rinse water then cascades
to wash section and is recirculated by pump through the turbulent
wave nozzle. An immersion heater located in the wash section maintains
the water at the set temperature.
Overflow from
the wash section goes to drain, or may be recycled through an
existing or optional recovery/treatment system. The post-cleaning
module may be supplied with tap, reverse osmosis, or deionized
water depending on customer process requirements. Flow rate for
the cleaning module is adjustable via a flow meter; generally
1.5 - 2.5 gpm (5.7 - 9.5 litres/min) provides good cleaning results.
Post-Clean
Blow-Off / Dryer: At the exit end of the cleaning module there
are two air blow-off nozzles that remove the large droplets of
water. Devices then enter the drying module where specially designed
nozzles remove residual water.
Hot Air
Dryer Module: A hot air dryer is installed just prior to the
discharge of the components, thus assuring that all moisture is
removed prior to repackaging. It uses compressed air feeding through
in-line heaters into a stainless steel enclosure that directs
the hot air stream through slot nozzles on either side of the
component. The thermocouple sensor is in the hot air stream and
feeds back actual air temperature to a digital controller with
high and low limit alarms.
PROCESS
MODULE OPTIONS
Precleaning
Module: The precleaning module is designed to remove severe
oxidation from component leads prior to the tinning process. To
accommodate the preclean module requires an extended frame for
the machine; the frame is extended by one section, adding 40"
(1 m) to the overall length of the machine. The module is comprised
of three stages.
The first
stage is the deoxidizer tank, which is completely enclosed and
has its own venting system. It utilizes a variable speed D.C.
motor driven recirculation pump to provide a turbulent bi-directional
wave for effective removal of oxides from the component leads.
CPVC construction makes it compatible with most commercial pre-cleaning
solutions. A Teflon coated immersion heater is provided to heat
the pre-cleaning liquid and a digital temperature controller maintains
the set temperature. The immersion heater is protected by a compressed
air purge and flow switch. A separate pump is provided to feed
pre-clean solution from a container housed in the base of the
machine in order to maintain the correct liquid level in the tank.
This auto liquid feeder provides level control with a high and
low limit.
The second
stage is an aqueous spray rinse with fresh hot water feed. This
removes residual precleaning solution from the components and
prevents contamination of the flux. A set of compressed air blow-off
nozzles follows the spray rinse.
The third
stage is a compressed air blow-off module which removes residual
rinse water from the devices.
Flux Density
Controller: The flux density controller is designed to control
the specific gravity of the flux. Once the operator has set the
recommended specific gravity, the controller will automatically
add the necessary amount of flux or thinner to maintain the setting
and the proper level in the flux pot. The FDC unit has a built-in
temperature compensation feature.
High Temperature
Solder Modules: For certain alloys and processes, higher than
normal operating temperatures are required. A specially treated
stainless steel solder pot, pump and nozzle assembly are available
for operating temperatures in excess of 650oF (343oC). This option
is also required if lead-free alloys are used in the process.
Automatic
Solder Feeder: This unit draws solder wire from a 44 lb (20
kg) spool. When a signal is received from a fixed probe at the
surface of the solder, the DC motor/wire feeder drives the required
quantity of solder wire through a guide tube into the solder pot.
The probe is positioned to maintain a constant pre-set solder
level. The unit is self-contained and functions automatically.
INPUT OPTIONS
Detaping
Device: A detaping device may be used for processing taped
axial components. This device mechanically removes the tape from
the ends of the leads, then singulates and presents the components
to the conveyor fingers for processing.
Bulk Feed:
A "Jacobs Ladder" is used to sort and singulate loose components
and load them on a transfer wheel which presents them to the conveyor
fingers for processing. The bulk feed requires that the components
have straight leads.
Lead Straightener:
This device is designed to straighten component leads prior
to off-loading them to the bulk feed.
Polarity
Indexer: This device is designed to index the components in
the same polarity direction. This device is mounted at the exit
end of the lead straightener.
Vibratory
Bowl Feeder System: To fully automate the processing of feeding
loose axial components a vibratory bowl may be added. This bowl
can be adjusted to handle virtually any size of axial component.
Components with badly bent leads will be automatically rejected
by the bowl.
OUTPUT
OPTIONS
Taping
Device: The taping device accepts parts from the discharge
of the central processing module. This device requires that the
component leads be straight. It can be easily and quickly changed
over to accommodate a wide variety of parts. Component spacing
on the tape is selectable at .200", .400", or .600" centre to
centre distance. This device may also be used as a stand-alone
system for taping loose axial components.
MISCELLANEOUS
OPTIONS
Computer
Control Package: The Computer Control and Data Acquisition
Package consists of a customized version of Wonderware's Intouch.
Intouch process control software allows users to monitor, control,
generate alarms, store data, and graphically display archived
data. Corfin has used Intouch and its many powerful features to
produce a data acquisition package designed specifically for your
tinning system.
Intouch runs
on a personal computer supplied as part of this option package
and interfaces with the Programmable Logic Controller (PLC) on
the tinning system. The program is easy to install and easy to
use. A printer (not supplied) is recommended if hard copy printouts
are desired. The printer must utilize the parallel printer port.
Upper Panel
Covers and Locks: Transparent acrylic panels can be installed
with locks to restrict access to any of the process controls on
the overhead panels. Strategic cut-outs in the panel can permit
operator access to customer specified controls.
Additional
Set of Instruction Manuals: The hard-copy operating manual
for the system is normally supplied in two 3-ring binders; one
with the operating and maintenance instructions; one with a full
set of bills, assembly drawings, and electrical schematics. This
option provides a full duplicate set of binders.
CD-ROM
Electronic Manual: The operating manual, with full system
bills of materials, assembly drawings, and electrical schematics
are supplied on CD-ROM allowing loading to standard PC. The electronic
manual has internal "links" for ease of access. Any part of the
manual, including drawings, can then be printed out if a duplicate
copy is required.
Spare Parts
Kit: The spares kit is recommended to ensure that first line
spare parts are available at customer location. The 5% of system
cost guideline is normally sufficient to ensure a comprehensive
range of essential spares.
SAFETY
FEATURES
Safety features
are built into the ATS-300 and are clearly outlined in the systems
complete operating manual.
Audio and
visual alarms are standard on the system to monitor the levels
and temperature in each module and report any fault conditions.
The operator may stop the audible alarm using the alarm reset
button, however the visual alarm will continue until the fault
condition is corrected.
If the conveyor
is stopped for any reason while processing components, the entire
conveyor assembly automatically lifts clear of the process modules,
eliminating the potential for thermal or chemical damage to any
components that are in process.
An exhaust
system with interlock ensures that all process fumes are evacuated
from the machine. Where appropriate, local venting at the process
modules supplements the overall evacuation of the process chamber.
Door and window
interlocks protect the operator from electrical hazards and from
moving parts in the process chamber.
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