XG-4000 自动卧式联体机操作说明书 l Preface l This" operates the operation instruction" Enclose one at random, please keep this manual, in order to consult at any time l Please must read a manual carefully conscientiously in front of operating this apparatus l Because the renewal of technology and special requirement for the products, some material objects of product may be different to some extent with the manual, please subject to products material object, we will supplement and add as much as possible to prove l When the apparatus uses normally, please keep certain space in front and at the back of this apparatus, as operating and maintaining the necessary space In addition, please don't make and hinder heat from discharging the arrangement of the space to this apparatus l The environment for use of the apparatus: The temperature is: 5- 25 C, the relative humidity is: 20- 95%, is not penetrated directly by the sunshine, will not form the dew and will not spatter the place that water, oil, chemistry are liquid l The technical staff who operates and maintains this machine must know and use the computer l The computer that disposes on this machine can only be used for this machine, forbids using as it, forbid inserting other movement memories which carries the virus in this machine, so as not to destroy the control system l Tight and anti-virus excellent one disposed at random is invaded, forbid using on other computers at will l Consider on the basis of the personal security, the apparatus is during operation, the movable door before and after please don't open in case of not taking any safety measure, in and the entering limbs machine what or got limbs near the machine can move the position, otherwise, will bring the unnecessary bodily injury l The power of repeated switch, will become one of the reasons why the apparatus produce the trouble In the power OFF ' Cut off) And then, please carry on the power ON (open) again through more than 20 seconds l Don't let the apparatus struck strong vibrations, otherwise may cause the trouble l While cutting off the apparatus power, please carry on systematic withdrawal / shut-down course in following order, if does not carry out this course but cut off or restart, will make the data unable to get intact save the power directly, may cause the damage of the hard disk at the same time Withdrawal / shut-down course: Withdraw from the application program and withdraw from Windows and cut off the 东莞市新泽谷机械有限公司 -1www.sciencgo.com XG-4000 自动卧式联体机操作说明书 power If delay using this apparatus, please keep the apparatus in the following places: The ambient temperature is to 40 C, the relative humidity is 20- 95% , Not penetrated directly by the sunshine, will not form the dew and will not spatter the place that water, oil, chemistry are liquid l For being dustproof, can consider taking and hiding the measure (such as wrapping the cover) ,But dampproof Please contact us in the place not understood, cut the affair to operate blindly Note: Please pay attention to the above-mentioned items! Chapter one Summary XG-4000 series apparatus to arrange, lead the component different kind ' Electrolyze components such as a slice of electric capacity of electric capacity, porcelain,etc.) Arrange material, in at unique W -shaped material insert, pass on one more to, get the intersection of roller chain and material insert and send to the plug-in package head and jump the line on the circuit board (PCB) through the intersection of station and head On if you can't automatically insert by various, last line,and last pieces of products professional that be measured plug-in package bad plug-in package status display at display and plug-in package, it is a kind of high-accuracy automation equipment with high capacity and efficiency 一、A prominent characteristic of this machine is: Can jump tube-shape directly the line is not graded again and directness is inserted in PCB, can save jumping the line of 1/3 Until software that develop by oneself cooperate, this machine incorporates three kinds of functions into an organic whole: Not only can insert and jump the line insert the horizontal electronic element alone alone, but also can, can also jump the lines to mix and insert with the horizontal component A machine, only need a person to operate, the ones that can finish 40 people's manual plug-in package can 东莞市新泽谷机械有限公司 -2- www.sciencgo.com XG-4000 自动卧式联体机操作说明书 produce Machine specification parameter: Specification parameter Project Theory speed 24000 o'clock /hour Insert the bad rate Smaller than 300PPM Meddle in the direction Parallel degrees, 90 degrees, 270 degrees for 180 degrees Span of component From 5.0mm-20mm pairs of hole Size of the base plate Minimum 50mm *50mm, biggest 450mm *450mm Thickness of the base plate Component kind 0.79-2.36mm Condenser, transistor, diode, resistance, fusing silks,etc are horizontal to arrange and take one to feed The component lead wire cuts the foot 1.2-2.2mm is (adjustable) length The component lead wire curves the angle 0-35 degrees are (adjustable) of foot Quantity of material 60 stations (push away and store use to stand and station count) ,Available ' 10-100 stations) Machine size (long * It is wide and * high) Host computer size 1700mm * 1300mm* 1600mm Material stand size (long * It is wide and * 510mm * 1000mm * 1410mm (10 stations) high) The host computer thinking highly of 700KG amount Pair of machine weight 750KG (40 stations) Use the power 220V, AC is (single-phase) 50/60HZ, 2.0KVA; The system protects Use the power 东莞市新泽谷机械有限公司 Incessant power (UPS) Dispose, can run for 15 minutes after cutting out 1.6KW is (energy-efficient) -3- www.sciencgo.com XG-4000 自动卧式联体机操作说明书 Use the atmospheric pressure Gas consumption 0.6 0.8MPA 0.3 cube / minute Second, mechanical part: 1,Framework The framework structure passes scientific calculation, adopt square iron pipe and iron plate to weld, and then deal with through prescroption, rigidity is good, are stabilized The intersection of four corners and installation in framework have, resist shock foundation, the height of the foundation can be adjusted, level degree used for adjusting the machine 2,X, Y working bench organization This machine is to move by the workbench which puts PCB, realizes that carries on the plug-in package to PCB each area Each working bench organization is done the orbit by two pieces of hard steel axle, install a ball vice and servo motor of guide screw as driving in the middle, guide screw nut and platform board are fixedly connected, two axles of the guide screw are fixed in end, the motor links up with it through taking synchronously The motor drives the guide screw to rotate, the guide screw drives guide screw nut and platform to rectilinear motion X, Y install straight the intersection of negative pole and limit, moderate with zero measuring the photoelectric switch each at the the intersection of working bench and organization Organization's sports go beyond the first terminal motor and moderate, go beyond the second terminal motor to stop after moderating, avoid producing the destructive impact to the servo system Zero measure photoelectric switch, determine the intersection of workbench and the intersection of organization and position when shutting down X working bench organization installs on a platform of host computer, Y working bench mechanism installed on X working bench organization, working bench platform adopt, import the aluminium material while being good, realize light quantization Having set up the revolving stage organization on Y working bench organization, this revolving stage is for letting PCB that is fixed thereto make 90 degrees and ¡À 180 degrees of ¡À of ¡À to rotate from all angles, the electronic element regarding meeting as different directions and is distributed is inserted Organization of this revolving stage sets up a round rotary table in the platform of working bench Y, the round rotary table is held up 东莞市新泽谷机械有限公司 -4- www.sciencgo.com XG-4000 自动卧式联体机操作说明书 by four bearings of horizontal installation, restricted the location to it all around by four bearings installed vertically Each install a localization card seat with Model V mouth correspondingly around the disc, under the normality, localization organization installed on the platform " The tongue " Stretch out, contact with which orientate the intersection of Carlos and flat the intersection of Model V and mouth closely, make a reservation to the disc Orienting the organization is mainly applied the air cylinder, a scalable one by two forms " The tongue " And the retainer plate,etc make up When the revolving stage needs rotating, the air cylinder stretches out, " tongue " Contract, and move out of contact with card seat Rotation of disc drive by motor by revolving stage, the intersection of revolving stage and through bring with first scalable round rounds of organization linking synchronously motor Install an air cylinder on round organizations, when the disc needs rotating, this air cylinder stretches out, the round wheel keeps in touch with the edge of the disc closely, the rotation of the motor is to drive the rotation of the disc 3,Plug-in package head and base organization Plug-in package head is mainly from encoder, motor, rack, bearing, wheels synchronous,etc fittings make up Head organization installs the plug-in package on the square tube of 100*150*6 Install having, motor, rack, bearing, synchronous wheel, one set and take a photograph of high precision such as device, stabilize the fittings of good performance on it, The movements of the plug-in package head are to control to send material part and plug-in package part to realize by the servo motor of Panasonic Note: The plug-in package head noumenonn movement step is as follows: It give it is in material part it last component to plug-in package head since pairs of roller chain of high precision then it last accurate one to in organization component to in, and then send to the head lower side of the plug-in package, the main shaft of the plug-in package (H) at this moment the roller chain The axle of the gear of China is rotated under the drive of the servo motor, thus drive the downward sports of the rack, cut the downward sports of the knife, cut off the lead wire of the component, shape thereupon downward sport too once, convert the lead wire of component both ends into curved, the the Eight Character converting the whole component into otherly type; Pushing the knife continues downward sports again, will roll over the curved component to insert in PCB At this moment, under cutting the intersection of foot and the intersection of organization and upper and lower drive of motor, two cut foot air cylinder stretch out, convert inserting the lead wire in PCB into curved, and cut off the surplus lead wire, the electronic element is fixed on PCB board Then, base drop, go back location, the 东莞市新泽谷机械有限公司 -5- www.sciencgo.com XG-4000 自动卧式联体机操作说明书 intersection of plug-in package and rapidly to last time location main shaft rapidly Until next arrival of order, and then repeat this movement 4,Jump the line organization This machine all right the light ' Jump the line) Grade without the order grading machine, and send to the head lower side of the plug-in package and insert directly Send the line motor to rotate, draw the light (jump the line) Move from left to right, the light alignment at the same time, and then send to the head lower side of the plug-in package, wait to insert (movements are the same with inserting the electronic element) 5,The electricity, air control the part Offer kinetic energy and control signal for machine The movement orders of all of this machines are to import and export through the computer The testing signal of the machine inputs the computer through I\O board, the order signal of movements is input into I\O board or server by the computer This machine uses 220 V AC, 24 volts and volts direct current Allocate UPS alternating current source Alternating current source have, leak electricity switch at the bus, consist of insurance in charge of at the every branched circuit; The direct current is offered by power of switch The earth connection system must be normal, reliable Every one exchanges the servo motor controlled by a server Various servo parameters can be read or adjusted in the screen of the server directly, can also read or adjust on the computer through the specialized software Can reveal the trouble code of the servo system, realize servo " diagnose by oneself " on the screen of the server Source of the gas of machine by angry to accuse of, make up, input into, send give corresponding air cylinder by from various places electromagnetic valve 6,The camera is constructed Use onlinely and insert the programming of coordinate and rectify a deviation to the circuit board automatically It is made up of camera and light source that the camera is constructed Camera install in the intersection of plug-in package and left side of head, lock in one piece about at the mounting bracket of the fine setting; The lens of the camera can regulate focus and thing distance; Install a light source in the camera lens lower side, is used for assisting and shooting 7,Servo control This machine shares the following picture of eight servo systems It is to realize control on sport torques permanent, speed ratios wide, at a high speed, high precision 东莞市新泽谷机械有限公司 -6- www.sciencgo.com XG-4000 自动卧式联体机操作说明书 Improve the strong assurance of whole performance of the machine Because the motor uses the alternating current, so extraordinary energy-conservation Every servo motor is controlled by a server Moderate, be terminal, insert and control the computer by encoder signal while being servo; Server in control board by movement, stand location drive Carlos and computer control Various servo parameters can be read or adjusted in the screen of the server directly, can also read or adjust on the computer through the specialized software Can reveal the trouble code of the servo system, realize servo " diagnose by oneself " on the screen of the server The ripe technology H axle C1 axle X axle Y axle C axle C2 axle B axle W axle Head Arrange X axle Y axle Span To hitting Base Jump the of servo software and hardware, make the fault rate of the servo system nearly zero Symbol Name the line material roller chain Power 1000W 750W 400W 400W 400W 400W 400W 100W Brand Taiwan Taiwan Panasonic Panasonic Panasonic Panasonic Panasonic Panasonic 东莞市新泽谷机械有限公司 -7- www.sciencgo.com XG-4000 自动卧式联体机操作说明书 reaches reaches 8,Electric This machine uses single-phasely and exchanges 220V, the power of the frequency 50HZ The electric energy consumption is 1600 watts The machine is furnished with UPS incessant power, in case that when the factory supply power to stop, the machine can work normally for about 15 minutes incessantly, will not waste and wait to make the component The electricity controls the circuit design scientifically The electric original paper selects suitable materials and strictly controls quality, the first-selected famous brand The machine is also supplied direct-flow +24V and +5V by the switch power that mixes at the same time besides using 220V alternating current 9,Apparatus / systematic earthing Have by one earthing lead wire end in apparatus, be can last apparatus / earthings systematiced, let's last apparatus /at the time of system, can hope user correct earthing, so can control large-scale electricity interfering with and differential electric potential of system effectively Note: According to international electric code and the relevant regional electric code, in order to confirm correct size and position of the earthing plug, please Earthing all these are connected as getting rid of the ground wire which bear the weight of every signal cable and including the additament (not the replacement) of ground wire in the power cable ,The ground wire in the power cable should be grounded too, usually go on through mixing the conduit of the line system, there should not be power in this ground, but not only neutral, can't connect the power cable conduit as being only the place If possible, the systematic power board should be grounded too No matter which kind of the intersection of earthing and system does it use, should make, smaller than, also should interfere with the source isolate with electricity by 10 OHmS in DC-10mHZ to the intersection of ground and impedance, so as not to interfere with, spread into the apparatus / system systematically through earthing 10,Adjust the apparatus level After the apparatus moves the destination, can put down the foundation, utilize the level (the tool) Put in the platform, adjust competence; Reduce the machine to shake Adjust competence correctly, can make the apparatus run more smoothly, the noise is less, the life-span is longer a) Adjust the horizontal step of the machine as follows: 东莞市新泽谷机械有限公司 -8- www.sciencgo.com XG-4000 自动卧式联体机操作说明书 b) Four foundations of machine of the order are unsettled, move over the apparatus into the destination c) Adjust the level from side to side of the machine first: Because weight of machine in behind,adjust by two foundation of rear on machine d) The level in front and at the back of then adjust the machine: Only need to adjust a foundation ahead, because determine one side at three o'clock There are unsettled foundations that will be fastened and twisted more, the fixed nut of foundations will be locked altogether Attention: Three foundation go to the fields, come, it changes competence to be can swift effective 11,The file is introduced systematically In the main catalogue D: \In the plate, include the following important file: 1) File double-layered XG-4000: Keep the file that the application program XG-4000.exe used 2) The file is installed: Keep the file that has already registered our company AI apparatus, register the temporary data file produced 3) The new pool valley data of file: It is parameters such as apparatus parameter, component parameter, camera, origin testing, statistics, publishing the factory value of keeping application program kept with Excel job book form,etc 4) Apparatus parameter: Keep some parameters of AI apparatus, for instance parameters such as plug-in package head skew constant CX, plug-in package head skew constant CY, plug-in package head journey constant HL,etc 5) Component parameter: Keep parameters such as the type, diameter, pin interval of the component that the apparatus needs to insert,etc (this parameter can be added according to components needed to insert) Warn: The above-mentioned file can't random deletion or manual update, otherwise will cause the application program to be destroyed, can't run normally, make the apparatus be unable to run normally and even will cause destructive damage to the apparatus 12,The worker accuses of the installation of computer and software: 1) Turn on the host computer case, install the picture and gather card and sport control board Notes: Pay attention to defending the static measure Installation and arrangement of the control board of sports: (1)Guarantee your computer system stability is good valley registration of new pool 东莞市新泽谷机械有限公司 (2)Have guaranteed the computer already the (3)Guarantee the main board of the computer has -9- www.sciencgo.com XG-4000 自动卧式联体机操作说明书 more than three PCI slots (4)Operate D first: \Install this file of PISO_DIO_Win2k_V241 in Win2k_xp in the file, after REGIST2K that and then run in the board card operates REG2K accordingly, shut down, then move the intersection of control board and PISO-C64 insert in the intersection of PCI1 and slot, pairs of two pieces of the intersection of DMC1000 and (control board of sport) again then Insert in PCI2 and PCI3 slot separately ( 5) Turn on duplicate to D on the set computer new the intersection of pool and the intersection of valley and data and the intersection of XG-2000E and file, and then insert the encryption dog that attaches on USB interface ( 6) The computer has finished and hit my computer attribute in right since examining and entering and speaking the system Hardware There is a Leisai Controjjer (the control board of movement) in equipment control device Click to find DMC1000 right key attribute driver in plus sign ahead Upgrade the driver Search for the driver of the apparatus suitable for me The next step An appointed position The next step Browse through ' Find D: \Install \'s board card \ DMC1000) Open Fix It installs its drive well automatically if next; Yuan of installations the same too, but is having a look around (find D: \Install \'s board card \ REGISTER) Open Fix It can install the drive of card of this board automatically if next (7)Run to install PISO_DIO_Win2K_v241 in Win2K to install while installing P32-C32 sport control board (8)Open and operate XG-4000E.exe Ø 2) The computer main board BISO sets up attentive matters: Ø CPU configuration Hyper Threading Technology [Disabld ] < closes ultra thread technology> Onboard Devices Configuration Onboard AC' 97 Audio [Disabled ] Ø Drive A/B 1.44M, 3.5 in [None ] Ø USB Cinfiguration Legacy USB Support [Disabled ]