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The
DTS-400 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-400 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
- Pre-clean
- Rinse
and dry
- 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 186" long
by 34" wide by 74" high (4725 x 864 x 1880mm). It includes
a component conveyor, a pre-cleaning module, 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.
Precleaning Module:
The precleaning module is designed to remove severe oxidation
from component leads prior to the tinning process. 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.
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-400 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
NOTE: Selection of optional process modules is limited by available space
in the central frame and may necessitate the removal of other
process modules to create the required space 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 air stream and feeds back actual
air temperature to a digital controller with high and low alarm
limits.
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 system
is recommended for machine 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
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 accomodate 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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