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The
LRT-2000 is a fully programmable 5 axis robotic lead finish
system. This system is designed to solder coat the leads on a
large variety of electronic components, with specific emphasis
on fine pitch devices. It provides a defect-free, cost-effective
process for solder coating QFPs, SOICs, PGAs, PLCCs, ceramic LCCs
as well as TAB devices, conformal coated parts and multi-chip
modules.
The
ability to accept a wide variety of robot tooling and the ease
of programming makes the system adaptable to a wide range of different
processes and products, for example handling wafers, fusible links
and connectors. Minimal transition time is required when changing
from one component to another. With the appropriate tooling option,
the LRT-2000 can process multiple components at a time, to meet
higher throughput requirements. Even fine pitch devices can be
accurately processed up to twelve components at a time with consistency
and reliability.
The
LRT-2000 is typically configured with the load/unload function
at one end, allowing the system to be operated by a single technician.
Placing this system in-line requires only a programming change
to load at the left end and unload at the right end, or vice versa.
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.
CENTRAL
PROCESSING MODULE
Standard
Features:
Main Frame / Enclosure:
The central processing module is totally enclosed, with
sliding tempered glass panels at the front and rear of the system,
enabling easy access and allowing for the process to be viewed
and monitored. The process chamber is ventilated
via exhaust stacks located at top of the enclosure; one or two
stacks can be used, depending on the process requirements. The
standard system footprint is 84" long by 34" wide by
74" high (2134mm x 864mm x 1880mm), excluding the exhaust
stacks. The standard system incorporates the robotic processing
head, wave fluxing module, hot air preheating module, wave soldering
module with an inert gas enclosure, post-clean/dryer module, and
the main control system.
Door and Window Interlocks:
Window interlocks are installed on all sliding windows
covering the main processing module to prevent operators from
accessing the interior of the system during processing. Interlocks
also protect the doors on electrical power enclosures. Should
a door or window be opened, the system will immediately stop.
Four
Axis Robotic Head: The four axis robotic head is operated
by a stepper motor drive system that permits accurate location
of the head. The head can be programmed for movement in the X-axis,
Y-axis, tilt, and rotate modes, either independently or simultaneously.
The X-axis can move at traverse speeds up to 10 inches (250 mm)
per second; the Y-axis up to 1 inches (25 mm) per second maximum.
If selected, the optional carrier indexing table operates as the fifth robot axis.
Single
Rotating Vacuum Gripper: A single vacuum gripper is
supplied which is suitable for holding one device. The spindle
can be rotated through 360 degrees for processing multi-sided
components. The single gripper can be easily removed and interchanged
with other optional or custom tools.
Wave Fluxing Module:
The fluxing module is constructed of PVC. The height of
the flux wave is controlled by a variable speed DC motor driven
pump. Fine adjustment of the wave is made at the module location
using a thumbwheel potentiometer. Two air knives are used to remove
excess flux. A drain is provided for quick clean-up at the end
of the work schedule, or for rapid changeover if more than one
type of flux is being used. This module can accommodate all standard
flux types.
Hot Air Preheating Module:
The preheating module is constructed of stainless steel
and uses compressed air passing through in-line heaters as the
heating medium. The module has a digital temperature controller
with a thermocouple located in the hot air stream at the nozzle.
The controller has high / low alarm band. Use of the preheating
module allows for evaporation of excess flux and volatiles, activation
of the flux, and warming of the package body to eliminate thermal
shock during the soldering process.
Solder
Module: The soldering module
consists of a stainless steel solder pot with 250 lbs (114 kg)
capacity. Corfin's dual chamber pot is designed to draw solder
from the base of the pot, minimizing the possibility of recirculating
dross through the wave. The pot has a thermally protected D.C.
motor driven pump, which provides precise wave height control;
fine adjustment of the wave is made using a thumbwheel potentiometer.
The standard nozzle is 4" x 8" (102 x 203mm), enlarged
to provide a greater solder surface when processing multiple devices.
A
digital temperature controller with high and low temperature alarms
(audible and visual) is provided. A low solder level alarm is
also provided as standard. Two plate heaters mount directly against
the walls of the solder pot, providing for excellent
heat transfer. Because the heaters are in contact covering the
full height of the solder, there is no danger of an eruption during
the warm-up phase. The solder module is mounted on a lead screw, which allows it to be
moved back to facilitate draining the solder and servicing the
solder module.
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.
Post-Clean Rinse/Dry Module:
The post-cleaning module is constructed of PVC. It has
an aqueous whirlpool for cleaning the components designed for
minimal use of tap or DI water. A specially designed air dryer
is located above the cleaner that uses quiet compressed air nozzles
to remove all traces of moisture before the components are returned
to their original pick-up position.
Control
System: The system uses a personal computer
as its controller. The software is menu-driven and user friendly.
Programs for different part types can be generated very easily
and stored in memory. The following parameters are programmable:
(a) conveyor speed, (b) dwell times for fluxing, preheating and
solder immersion, (c) solder temperature, (d) immersion depths,
(e) immersion and withdrawal angles, (f) speed of immersion and
withdrawal.
A
printer is recommended (customer supplied) if hard copy print-outs
are desired. The printer must utilize the parallel printer port.
In
addition to the computer controlled functions, there is a control
console mounted above the operating chamber with on/off switches,
temperature controllers, pump speed controls and warning lights.
This console can be protected by the optional upper panel covers
and locks.
SYSTEM
OPTIONS
Joystick & Software:
The joystick can be used instead of the computer keyboard
to program mechanical movements of the robot. It allows the engineer
greater mobility and the opportunity to walk the length of the
system to facilitate setting the process parameters.
Carrier Indexing Table:
An indexing table that moves in the depth of the system
is available for the load/unload area. This table can be used
when processing parts that are presented in matrix trays or multi-device
carriers, and performs as a 5th axis for the robot
head.
90° Indexing Adaptor:
A 90° indexing adapter for the robot head permits the
tilt direction to be re-oriented. This allows front to rear tilting,
which is required in some applications for multi-component pick
up.
PROCESS
MODULE OPTIONS
Precleaning Module: A precleaning
module is available for the removal of severe oxidation from the
component leads. This module is constructed of CPVC with a capacity
of 3.8 gallons (14.6 litres). A variable speed DC motor pump controls
the height of the wave; fine adjustment of the wave is made using
a thumbwheel potentiometer. The module is fitted with quick drain
and overflow protection. The precleaning bath has it's own lip
vent connecting to the main exhaust duct. If required, the precleaning
operation can be followed by a rinse/dry step, using the post-clean
rinse/dry module.
Heater for Precleaning Module:
A Teflon coated immersion heater heats the precleaning
liquid to a preset temperature. The unit is equipped with a digital
temperature controller with high/low limit alarms. A level sensor
prevents the heater from switching on if the liquid level is too
low. To protect the heater from corrosion due to condensation,
the Teflon jacket is continuously purged with compressed air.
Auto Liquid Feeder with Level Detector for Preclean: This provides a separate pump to automatically feed
preclean 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.
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:
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.
Automatic Solder Wire Feeder: This
unit holds a 44 lb (20 kg) spool of solder which is released upon
a signal received from a fixed level probe at the surface of the
solder pot. The unit is self contained, driven by its DC motor
sending solder wire through a flexible Teflon tube into the solder
pot. The probe is positioned to maintain a constant preset solder
level. The function is fully automatic.
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.
ROBOT
TOOLING OPTIONS
Rotating Vacuum Grippers:
These grippers are available with from one to six rotating
spindles, so that a number of multi-sided devices can be processed
at the same time. The pitch of the spindles can be specified to
suit the specific device. A single device spindle is included
as standard with the machine.
Vacuum Gripper - Multiple Cup: Multiple
Cup Vacuum Grippers are available for customer specific applications
for processing multiple parts. Gripper may be ordered with up
to 12 cups (or more on special request), with cup spacing configured
to suit the specific application. The devices cannot be individually
rotated, but the entire gripper head rotates through 360 degrees.
Mechanical Gripper:
Mechanical grippers are available to handle from one to
a multiple of 5 devices. The device is held mechanically in titanium
fingers, custom-designed for the component. The devices cannot
be individually rotated, but the entire gripper head rotates through
360 degrees. Higher device count may be feasible, depending on
part size and configuration. Quotations will be supplied on request.
HANDLING OPTIONS
Tube to Tube Load / Unload (Option): For
components which are handled in tubes, an automatic feeder using
linear vibratory means is available for input and output. Single
lane or multiple lanes are available.
Matrix Tray Locator (Option):
A machined interface plate for mounting on the indexing
table to accept Jedec or other standard tray configurations, locate
precisely and lock in position.
Automatic Load/Unload (Option):
For the many package, tube, tray, etc., styles produced,
Corfin offers a large variety of tooling and handling options
developed to meet your requirements. The system can be configured
to handle special requirements in a fully automatic mode. Quotations
will be supplied on request.
MISCELLANEOUS
OPTIONS
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.
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 LRT-2000 and are clearly outlined
in the system operating manual.
Audible
and visual alarms are standard on the system to monitor the levels
and temperature in each module and report any faulty conditions.
The operator may stop the audible alarm using the computer keyboard,
but the visual alarm will continue until the faulty condition
is corrected.
An
exhaust system with interlock ensures that all process fumes are
evacuated from the machine. 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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