Robot Vision Guided Laser Solder Cell Product

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Robot Vision Guided Laser Solder Cell,Product Specification. Document Number DS 0005,Model Number PRO6TL,Work cell Overview. The soldering cell has been developed to provide autonomous non contact soldering when used. in an in line conveyorized production line Pallets are automatically transferred into and out of the. cell using an edge type roller chain conveyor, A single four axis robot is used to selectively solder circuits using a non contact diode laser fiber. coupled heat source and a stepper motor driven automatic solder wire feeder Vision guidance. along with a Cartesian robots is employed to position the focusing lens and solder feeder Vision. guidance is used to assure that the location of the product to be soldered is accurately known. with minimal reliance on mechanical positioning repeatability of the product to be soldered. All components are first quality industrial duty and the design meets NFPA 79 guidelines as well. as applicable safety standards, While more detail on the system is provided later a brief overview of the system specifications is. detailed below,Overall Dimensions 76 Wide X 59 Deep X 77 Tall.
Conveyor Height Adjustable from 35 to 37 additional details below. Conveyor Width Adjustable from 3 to 14 additional details below. Guarding Sheet metal safety enclosure interlocked per applicable safety standards. Work cell Robot An Adept AWC060 MV10 robot controller is used to control position of the two Cartesian. Controller robots provide vision capability and control the work cell The controller provides 28 tasks. and abundant I O for real time work cell control and allows unparalleled processing power. and flexibility Motion is highly coordinated and optimized for speed An industrial flat panel. touch screen is used for operator interface to the controller. Operator Interface The operator interface is provided via an industrial flat monitor Simple to use GUI based. process control menus allow real time modification of process parameters Comprehensive. help screens operator messaging and ease of use are major features of this platform. Manual Teach Industrial quality Adept teach pendant for manually moving the robot within the work space. Pendant The pendent displays robot coordinates incorporates safety features to meet RIA safety. standards and allows the axis coordinates to be displayed and controlled in a variety of. Industrial I O Ruggedized Adept I O technology and Bechoff DeviceNet IO are used to provide bulletproof. optically isolated digital and analog I O options for the work cell DeviceNet connectivity is. supplied standard on the cell for ease of expansion. Position Process CAD data for the circuit pad locations and reference fiducials is used to define soldering. Table locations for the robots Actual product orientation is vision generated before moving to. locations on circuit defined by CAD data Databases containing vision setup and process. data are stored in the controller memory Separate process parameters for each solder. location are stored in memory also Multiple process setups part numbers can easily be. selected via menu, Datalogging A process log is recorded to the hard drive. Program Language System programmed in Adept V Adept AIM Visual Basic PC front end only with optional. Adept Windows not included, Vision Guidance The system is supplied with Adept s fully integrated EVI vision motion guidance and. inspection system Ease of use flexibility and high performance are the hallmarks of this. system System setup is GUI based and requires minimal training Two vision cameras. Page 2 of 13,Robot Vision Guided Laser Solder Cell. Product Specification,Document Number DS 0005,Model Number PRO6TL. and associated lighting are used to find the orientation of the product to be processed. Motion Axes X axes 400 mm Adept H Module,Y axes 350 mm Adept M Module.
Z axes 130 mm Sz Module,Theta Axes Adept Servo motor bearing set. XY Axes Repeatability 0 0004, XY Working Area X 11 Y 13 77 Y axis is parallel to conveyor. Heat Source Spectra Physics 60 Watt Non Contact Diode Laser System. Beam Delivery multi fiber optic with focusing lens. Minimum Beam Diameter 0 7 mm,Maximum Beam Diameter 2 4 mm. Adjustable Power Range 1 60 Watts, Power Adjustment Controlled real time per process database. Intregra MP Diode Laser system 960nm,Diode Life 12000 hours.
Power Consumption 250W, Solder Process A miniature solder process camera is utilized on each of the two robots to provide a real. Monitor and time highly magnified view of the soldering process The video image is displayed on an. Cameras LCD video monitor to aid in process development. Conveyor System Heavy duty chain drive edge roller conveyor. Edge Rollers on 1 0 centers, Edge Roller affixed to Heavy Duty 40 Extended Pin Roller Chain. Bodine Gear Motor,Speed range 1 20 FPM,Edge Clearance 0 25 Standard. Conductive Chain Bumper Guide Strips,ESD Protection. Conveyor Width Adjustable 3 14,Conveyor Height Adjustable 35 37.
Two Positions One queue position one work position. Auxiliary Auxiliary air and AC connections are provided included on front of machine SMEMA. Connections interface connections for in line conveyor operation are supplied standard. General Software Information, The controller for the system includes dual AWC 060 processors Adept Vision Guidance VXL. and utilizes AIM MotionWare VisionWare and V for the operating system. The Adept system includes V the basic operating system and AIM a windows like operating. system In addition several utility programs are included The software is briefly described. V Basic operating system for Adept robots This is included with the machine and the. machine always boots up in the V environment, AIM MotionWare Adept s version of windows This database centered programming. environment runs on top of V and uses V basic like subroutines as the basis of it s. extremely high level language The end user has the ability to make custom statements in. AIM using V routines to implement high level functions. VisionWare Adepts vision guidance package is seamlessly integrated with AIM MotionWare. and is provided in the work cell,Page 3 of 13,Robot Vision Guided Laser Solder Cell. Product Specification,Document Number DS 0005,Model Number PRO6TL. Utilities Adepts utilities disk is included in the directory C UTIL Some of the most helpful. programs are DISKCOPY SPEC etc See the Adept utilities manual for more information. Machine Control Application Most of the machine control is done in the AIM programming. environment AIM is basically a collection of V basic like routines used to create a higher. level language of simple to use commands Each AIM command has a corresponding V. program used to perform the required tasks While most functions are included with the base. AIM package some custom functions were implemented. Process Overview, The soldering work cell maintains precise control over all parameters during the solder process.
The parameters are independent for each pin and can be edited in real time while the machine is. running greatly reducing the solder parameter optimization process When multiple circuits are. processed the same process and location data are used for all circuits in the array of circuits to. be processed,Hardware Description, Most of the major hardware components used in the work cell are briefly described in the. following sections,Adept Cartesian Robots, Adept Cartesian robots are used to position the vision camera and soldering head at the each of. the two heated work positions located inside the work cell This robot controller is used to control. the motion axes as well as pneumatics and other peripherals in the system. Each robot uses the following axes to comprise a Cartesian robot with a rotational theta axis. Table 1 Adept Cartesian Axes components,Axis Adept P N Description Mechanical BOM Ref. X Axis 90400 10040 H Module 400mm 1,Y Axis 90400 20035 M Module 350mm 4. Z Axis 90402 40013 Sz Module 130mm 5, Theta Axis Motor 100W Sigma Servo Servo motor with encoder 42.
The theta axis is a custom designed axis that uses an Adept servo motor to control the. rotation of the solder, The controller for the system includes dual AWC 060 processors Adept Vision Guidance VXL. and utilizes AIM MotionWare VisionWare and V for the operating system. Page 4 of 13,Robot Vision Guided Laser Solder Cell. Product Specification,Document Number DS 0005,Model Number PRO6TL. Adept I O Boards, The inputs and outputs for the Adept robot controller are terminated on a breakout module The. location of the various I O is described below Refer to the documentation included in the. Appendix for more information on the interface module. 1 JDIO 1 Inputs 1033 to 1048,2 JDIO 2 Inputs 1049 to 1064.
3 JDIO 3 Outputs 33 to 48,4 JDIO 4 Outputs 49 to 64. 5 JUSER Emergency Stop circuitry, 6 JSIO Isolated I O Figure 1 Adept I O interface board. Device Net I O, In addition to the Device Net outputs incorporated in. the pneumatics manifold a block of Device Net I O is. incorporated into the back panel of the machine, Digital inputs and outputs are included on this block. as well as the analog outputs used to control the, Animatics Motors on the rotational axes of robot 1 and.
robot 2 Configuration of the Device Net I O is,discussed in the Appendix for your reference. Robot Signal Interface Boxes,Figure 2 Beckoff Device Net I O. The encoder and various interface connections for system. each of the Cartesian robots goes through a signal. interface box The interface boxes are located on the. back of the machine as shown in the accompanying,Spectra Physics Diode Laser. A 60 Watt Diode Laser soldering system is used by,each of the two Cartesian robots to heat the pins. during soldering The assembly consists of a lamp, house a fiber optic cable and a light beam focusing.
lens Figure 3 Robot signal interface boxes,The Laser system used was configured as follows. Twin 40 watt stacks for a true 60 Watt output with MP controller. Fiber optic cable,Focusing Lens, YB 10FF1 Panasonic Solder Feeder System 0 8mm solder diameter. The status of the Laser is monitored by the control program before and after each solder joint is. Page 5 of 13,Robot Vision Guided Laser Solder Cell. Product Specification,Document Number DS 0005,Model Number PRO6TL. The Laser system communicates with directly via Adept digital I 0 to control the soldering power. shutter control functions and monitor any error status. Panasonic Wire Feeder not included with TRW system. A step motor actuated solder feeder mechanism is, used to feed the solder to the pins being soldered.
for each of the robots end effectors This consists. of a wire feeder controller assembly and the actual. wire feed mechanism,The wire speed for the two wire feeders is. communicated via serial to parallel converter,modules connected to the two serial ports on the. leftmost AWC processor The feed solder control,bit is controlled directly off of Adept I O. The status of the wire feeder is monitored by the,control program before and after solder is fed If. an alarm condition exists a message will be,displayed to the operator.
Figure 4 Solder feeder controller and wire,feed mechanism. The printed circuit boards are transferred into the. machine using a roller chain edge type conveyor,system The speed of the conveyor is controlled. via a potentiometer located inside the control,cabinet on the back of the machine The. conveyor motor is turned off and on via a relay,controlled from the Adepts digital I O. Figure 5 Conveyor speed control,potentiometer,Page 6 of 13.
Robot Vision Guided Laser Solder Cell,Product Specification. Document Number DS 0005,Model Number PRO6TL,Pallet Sensors. A reflective fiber optic sensor is used to sense the presence of pallets at each work area The. sensitivity of the sensors are adjusted via an adjustment screw on the amplifier head The yellow. amplifiers are mounted inside the front door to the machine on the left hand side The sensors. should be adjusted so that they come on when a pallet is present and go off when the pallet is not. present For best results the heaters should be hot before adjusting the sensors gain If. problems are experienced with the sensors remove the stainless guard tube from the sensor fiber. and clean the sensor s face with alcohol to remove any dust or flux residue. Stainless Heat,Fiber Optic, Figure 6 Fiber optic pallet sensors left and fiber optic amplifiers right. Vacuum Pump and Sensors optional, A vacuum pump is used to provide vacuum on the parts to keep them from moving while they are. being soldered This may or may not be necessary depending on how much force the solder puts. into the PCB as it is being fed onto the pad being soldered. Vacuum can be enabled or disabled by opening the Robot 1 I O or Robot 2 I O menu from the. master control menu and selecting the vacuum enable icon. Vacuum sensors for each of the zones are located underneath the tabletop just inside the front. door on the machine The status of the vacuum sensors displayed using the Robot 1 I O for. heater block 3 sensors or Robot 2 I O for heater block 4 sensors closest to machine exit. Guard Bypass Switch, On the front of the machine just under the Adept control panel there is a keyed guard bypass.
Product Specification Document Number DS 0005 Model Number PRO6TL Page 1 of 13 Robot Vision Guided Laser Solder Cell Product Specification Document Number DS 0005 Model Number PRO6TL Page 2 of 13 Work cell Overview The soldering cell has been developed to provide autonomous non contact soldering when used in an in line conveyorized production line Pallets are automatically

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