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The DTS-200
is an automated in-line tinning system for a wide range of components
such as DIPs, SIPs, most configurations of SOICs and PLCCs, and
for power devices such as TO-220, TO-247, etc. Component grippers
are designed to handle devices in singulated form, but it is also
possible to specify conveyor set-ups that will handle a wide variety
of components in strips or lead frames.
It is also especially suited for soldering the terminals of Coils,
Bobbins, small Transformers and similar components, which require
simultaneous insulation stripping and soldering. The system may
be placed in-line with coil winding equipment and output to test
equipment, or set up to meet other interface requirements.
The optional
CF continuous feed conveyor is equipped with special grippers,
with multiple titanium blades, designed to handle components fed
continuously into the system, without the requirement for singulation
at the input. This system is suitable for high throughput processing
of a wide range of radial lead components, such as SIP, TO and
other power devices.
The system
is typically used to comply with the solderability and cleaning
requirements of MIL-STD 2000, MIL-PRF-19500, MIL-PRF-38534, and
MIL-PRF-38535.
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.
The DTS-200
is comprised of a central processing module and may be equipped
with several input and output handling options, depending on the
user's requirements. The system may be placed in-line with trim
& form, inspection, or other equipment to reduce or eliminate
handling.
In
the standard configuration the process is as follows:
- Load
- Flux
- Preheat
- Solder
- Unload
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
106" long by 34" wide by 77" high (2692 x 864 x 1955mm). It includes
a component conveyor, a wave fluxing module, a preheating module
and a wave soldering 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 covering 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). The standard conveyor
comes with 6 component carrying grippers per foot of conveyor
chain. This gives a typical throughput of 7,200 components per
hour (based on 6 grippers/ft and conveyor speed of 20 feet per
minute). Depending on the process requirements and the gripper
design, the system can be optionally equipped with 8 or 12 grippers
per foot, increasing the typical throughput to 9,600 - 14,400
components per hour. It is also possible to process components
in lead frame strips, giving throughput rates as high as 75,000
parts per hour, depending on component size.
The unique
design of the gripper assemblies with custom fingertips allows
them to hold the components by the body. This feature allows for
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 prevent corrosion by
flux fumes from the process. The snap-fit fingertips, designed
so they can be changed quickly, are made from titanium which has
good corrosion resistance and is non-wetting.
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.
Preheater
Module (Radiant): The preheating module utilizes radiant heating
elements in a stainless steel enclosure. The module has a digital
temperature controller with one thermocouple located at the midpoint
of its 18" (457mm) overall length.
Solder
Module: The solder module has a stainless steel solder pot.
The solder pot rolls in and out by means of a lead screw to facilitate
position adjustment and access for maintenance. A positive stop
ensures repeatability when returning to the operating position.
The pot has a thermally protected D.C. motor driven pump, which
provides precise wave height control in the solder nozzle, adjustable
via thumbwheel potentiometer. Standard or optional custom designed
wave nozzles are available.
The 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: The 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.
PROCESS
MODULE OPTIONS
NOTE:
Selection of optional process modules is limited by available
space in the central frame. They may also replace standard modules,
with appropriate price adjustment. Consult Corfin for details
and pricing of the process configuration best suited to your specific
requirements.
Auto Flux
Feed / Level Control: A flux reservoir bottle is housed in
the base of the machine, with a pump that feeds the fresh flux
to the main fluxer tank. A level sensor in the tank provides the
signal to the pump, ensuring that the flux is maintained at the
correct operating level. The bottle is easily accessed through
the doors in the base for quick and clean changeover.
Flux Density
Control System: The flux density control system automatically
adds the necessary amount of flux or thinner to maintain the specific
gravity setpoint, as well as the correct liquid level in the flux
tank. The fresh flux and thinner containers are housed in the
base of the machine, with pumps that feed flux or thinner to the
main fluxer tank, as directed by the flux density controller.
The FDC unit also has a built-in temperature sensor, with a compensation
feature to ensure correct density at different operating temperatures.
The flux density
controller incorporates the features of the Auto Flux Feed / Level
Control option.
Second
Fluxer Module: A second Wave Fluxing Module can be installed
for processes requiring a double pass, or two different flux types.
Preheaters:
The standard 18" radiant preheater may be supplemented with an
additional 12" or 18" radiant preheater, or with a 9" or 18" convection
preheater. The standard radiant preheater may also be replaced
by the 18" convection preheater. This provides a flexible arrangement
of preheating to meet a wide range of process requirements. It
should be noted that adding preheaters may necessitate the removal
of other process modules to create the required space
The convection
preheaters use 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.
Second
Solder Module: A second solder module can be installed for
processes requiring a double pass, or two different wave configurations.
The second solder module may be the same as the standard 9" wide
module, or a 12" wide module if longer dwell time in the solder
is required. The 12" module may also replace the standard 9" wide
module, with the appropriate pricing adjustment.
Solder
Module Auto Jacking System: The solder module is mounted on
a heavy-duty motorized jacking system, which raises and lowers
the module through a range of approximately 2.5 inches (65 mm).
In the event of a machine stoppage, which would normally result
in the main conveyor beam lifting clear of the process modules,
the solder module will instead jack down so that the solder wave
is below the component leads. Other process modules such as flux
wave, etc will switch off. The system can then resume operation,
without requiring manual intervention to clear components from
the input and output areas. The raise/lower function of the main
conveyor is still available, but is selected only when required
by the operator.
High Temperature
Solder Module: 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.
Solder
Exhaust Module: The supplementary solder exhaust module is
located directly at the solder wave area and extracts fumes as
soon as components touch the solder. This minimizes the spread
of fumes through the interior of the machine and is recommended
when solder coating large surface areas, which may generate excessive
flux fumes.
Exiting
Cam Over Solder Pot: A cam over the solder pot increases the
exit angle thereby guaranteeing uniformity of solder coverage
and no bridging on horizontal leads.
Note: The
exiting cam cannot be used with the CF conveyor option.
Automatic
Solder Wire 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.
Post-Cleaner
Module: This is a two stage stainless steel cleaning module.
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.
The following
two modules, Blow-Off / Dryer and Hot Air Dryer, are included
with the Post-Cleaner Module.
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
air 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.
HANDLING
OPTIONS
CF Continuous
Feed Conveyor: The CF continuous feed conveyor is equipped
with special grippers, with multiple titanium blades, designed
to handle components continuously fed into the system, without
the requirement for singulation at the input. This system is suitable
for high throughput processing of a wide range of radial lead
components, such as SIP, TO and other power devices.
The variable
speed component conveyor has a range of 0 to 30 feet per minute
(0 - 9.1 m/min). The stainless steel and titanium gripper assemblies
link together through the process to form a continuous carrier
that ensures accurate and reliable pick-up of components. Depending
on the process requirements and the component size, throughputs
in excess of 45,000 parts per hour are possible.
Note:
The solder jacking option is recommended for machines equipped
with the CF conveyor
Input /
Output Handling: A range of manual and automatic handling
equipment allows the user to choose the degree of automation that
best suits the application. The input / transfer module accumulates
and singulates the components for pick-up by the conveyor. This
may be fed manually or interfaced with the automatic or semi-automatic
handling options offered by Corfin, or with other third party
handling equipment. Similarly, at the output end, the transfer
discharge module can be interfaced with different handling options.
The input and output can be set up to automatically load/unload
using tubes, trays, bulk, etc, or any combination required. Request
further information from the Corfin. Some of the options offered
by Corfin are as follows:
Input /
Transfer: Accumulator and Singulator: The input module is
designed to accumulate components received from the loading module.
It then singulates these components as they move onto the transfer
conveyor. This transfer conveyor is synchronized with the finger
assemblies on the component conveyor. This method of device transfer
allows us to handle a number of different length components with
no changeover required. Input modules are designed and available
for most standard device types and widths. Transfers will vary
according to component types and widths.
Note:
With the optional CF continuous feed conveyor, singulation of
the devices is not required.
Output
/ Transfer: Transfer and Discharge Assembly: The Output Module
receives the devices from the component conveyor and transfers
them to the unload module. It also counts the devices to ensure
an accurate number is loaded into each tube or tray. Output modules
are available for most standard device types and widths.
Semi-Automatic
Load / Unload:
Load-End
Tube Handler: 2 Position Star Index: This option provides
semi-automatic feeding into the input/transfer of the DTS system.
The operator places two full tubes into the star-index loader.
The loader is then moved in line with the feeding slide to the
tinning system and the tube empties. When the first tube is empty
the operator manually moves the star indexer to position 2, and
while this tube empties replaces the first tube with a full one.
This operation is repeated as each tube empties.
Unload-End
Tube Handler: 2 Position Shuttle: The shuttle is interfaced
with the output/transfer to provide semi-automatic loading of
the processed parts back into tubes. When one tube is filled,
the operator switches the shuttle to an empty tube. While the
second tube is filling, the first is removed and replaced with
an empty tube, and the process repeated.
Additional
Insert Sets: The star index loader and unload shuttle come
equipped with a set of inserts (4), dedicated to a tube/component
type. To change over to a different tube/component type requires
only changing the inserts, supplied as a set of four.
Automatic
Tube Handler: The handler takes tubes from the magazine and
automatically advances them into the loading position. Tubes are
then indexed to the emptying position, and the components slide
out of the tube into the input/transfer of the machine. When the
sensors indicate that the tube is empty, it is ejected and a new
tube is brought into position. At the output end, a similar operation
takes place with empty tubes being retrieved from the magazine,
and filled with processed parts delivered from the output/transfer.
The handler is customized to accommodate the user's tube and component
type(s), and is controlled via the machine's PLC. This system
provides for continuous operation at high throughput rates.
Automatic
Tray Loader / Unloader: The 15 tray automatic loader consists
of two magazines, each with a 15 tray capacity. Full trays are
loaded into the one magazine; after the components have been offloaded
for processing, the empty trays are transferred into the second
magazine. A tilting table, located between the two magazines,
aligns the tray with the input/transfer. As the tray is indexed,
each row empties its components into the transfer slide. At the
output end, the system can be equipped to feed the processed parts
automatically back into trays, or may be equipped with tube, or
other handling equipment depending on customer requirements.
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 DTS systems and are clearly outlined in the
system's 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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