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The DTS-300
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.
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-300
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
- Cool
- Wash, Rinse
and Dry
- 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 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, a wave soldering
module, a cooling module, a multi-stage 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 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
Also
incorporated as a standard feature is a finger cleaner, located
directly above the post-cleaning module. It uses tap water to
completely rinse the conveyor chain, gripper assemblies and fingers,
eliminating flux residue build-up and reducing maintenance. 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.
Flux Density Control System:
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.
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.
Cooling
Module: Following the soldering module is a cooling module
that uses compressed air to reduce the temperature of the device.
This eliminates the possibility of thermal shock when the components
enter the post-cleaning section.
Post-Cleaner
Module: A two stage stainless steel cleaning module
is supplied with all DTS-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 the 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
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.
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.
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.
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.
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.
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 module 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.
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