Model: TCM45A Work Cell

Transcription

1 CONFORMAL COATING SYSTEMS Model: TCM45A Work Cell Bubble-free & energy saving systems specializes in the application of conformal coating of components on the printed circuit board assemblies for Automotive, Aerospace, Military, Medical, Industrial, Telecommunication industry sectors, both full board and select. TCM45A Coating Work Cell the fully automated and programmable coating system backed by ECM_XP control, integrates a five(5) axis precise robot with advanced coating applicators to provide consistent coatings, substantially reduce masking and minimize rework. Using automation from TTns you can expect the material utilization to be improved by 40-60% compared to conventional spraying or dipping processes. The range of conformal coating materials currently applicable comprises acrylics, rubber, urethane, epoxy, silicone and water based coatings. TTnS conformal coating systems can provide edge-defined transparent film-build in a continuous production thanks to the techniques of non-atomized film patterning and tri-mode spiral dispensing. In addition to a patented curing oven EC099-d 150ºC and modular single board or magazine conveyor hardware, a complete working process can be supplied. Presently PCB manufacturers have been continually challenged by the need to balance throughput, materials and labour investments in addition to addressing the environmental concerns relating to the conformal coating processes. As a result, potential customers who need conformal coatings, more and more, realize the importance of cost effective and environment friendly solutions. TTnS patented, bubble-free and energy saving ovens for curing, provides remarkable benefits for those, value analyzing investors, and specially high degree of coating performances, at every level of batch to inline production. TCM45A coating work cell which in combination with ECO99C curing oven, and adjoining conveyors offer a total solution which guarantees fast payback.

2 CONFORMAL COATING SYSTEMS Coating Work Cell Features and Benefits 1) Precision five(5) axis robot, Selective conformal coating system virtually eliminates extensive masking and coating reworks whilst maximizing the throughput and repeatability. 2) Equipped with Easy Coating Manager ECM_XP which is TTnS exclusive coating program and compatible with Windows-XP. All operators can handle it with ease. This exclusive software is capable of performing various coating patterns as follows. Line Coating Film and Spiral gun Area Coating (beyond-area coat) Film and Spiral gun Intermittent Coating (mid-on/off coat) Film gun only Spot Coating Film and Spiral gun Tilt Coating Film gun only adopts, Four-sides coating 30 angle Duplicate Program Coating programming assistant Pulse-spray Coating 1/1000 sec control, Spiral gun only Step and repeat 3) A leading conformal coating system TCM45A, backed by intermittent coating technique, has been completed by the integration of TTnS film dispensing CAF-gun that performs non-atomized film pattern with 100% TE, precision fluid/pneumatic controls, and advanced knowledge & experiences in robotics. CAF FILM PATTERN (SIDE VIEW) CAF FILM PATTERN (FRONT VIEW) CAF FILM NOZZLE & CAF FILM GUN

3 CONFORMAL COATING SYSTEMS 4) TTnS Versatile spiral dispensing CAS-gun, eligible for various coating applications, performs trimode of coatings bead, spiral-bead, and spiral-spraying in good penetration and materials TE. And a milliseconds controllable Pulse-Time Controller TPC999 improves the system reliability. SPIRAL SPRAYING PATTERN CAS SPRIRAL GUN PULSE TIME CONTROLLER MILLISECOND, 4 CHANNEL PULSE S6CN SPIRAL NOZZLE & CAS SPIRAL GUN 5) System safety features, While the system is running, all safety interlocks have to be active. TCM45A detects any fault then displays the error message and appropriate troubleshooting on the system windows along with buzzer and control tower illumination. Pre/After Purge interlock Gun Trigger Pressure Low interlock Atomizing Air Pressure Low interlock Syringe Pressure Low interlock (spare) Accidental Door Open interlock X-Y-Z Robot Overrunning interlock 30º Tilting-angle Outrange interlock VOC Vent Fail interlock Conveyor Jamming/Timeout interlock Fluid Level Low interlock (optional) 6) Build quality, the underbody of the platform a singlepiece robust welded structure all surfaces are powder coated. The workcell assembly provides four(4) wide access doors front and back for easy operation and maintenance Three Stage Conveyor WORK CELL. EASY ACCESS & AMPLE ROOM Robust Structure

4 CONFORMAL COATING SYSTEMS 7) Fluid management and delivery. The Coating workcell is equipped with the precision & multipurpose fluids delivery circuit as standard, for appropriate responding to various coating materials and applications. On the basis of this standard fluids circuit, customers can extend the use of the work cell for film coating, spiral coating and needle dispensing by the integration of additional coating applicators as necessary. The optional material changeover can be useful in material change and/or line cleaning with no risks of exposure to harmful VOC. 8) Patented curing oven concept, guarantees bubble-free transparent coating layers in the continuous production. You can expect minimal 50% of energy saving and maximal 25% of working space saving thanks to the unique selective curing technique using standard PCB magazines Primary power for curing oven ECO99C / Entire Oven Length : 10(Kwh) / 2,400(mm). Through put up to 3 PCB s / Minute

5 CONFORMAL COATING SYSTEMS Model: TCM45A Conformal Coating Work Cell Specifications System Configuration Easy Maintenance & Robust Platform CE Certified Five-axes (X-Y-Z, Rotate, Tilt by 30 ), Gantry Robot System VOC Ventilation Management System Material Handling System (Three Independent Transfer-Conveyors) Fluid Delivery System, Non-circulation, with Coating Applicator Film dispensing NCAF-gun, Spiral spraying NCAS-gun available depending on application Electric Control System with Safety Interlocks Easy Coating Manager (TTnS, exclusive coating program, ECM_XP) Available JPG image background, Grid/Snap coordinating in aid of coating programming Standard Features PCA size : Min. 60(W)x60(D)mm Max. 380(W)x350(D)mm, larger capability optional PCA thickness : 0.8(mm) 5.0(mm) allowable PCA Edge Clearance : More than 3.5(mm) both sides PCA Transfer-conveyor running speed : Max. 200(mm/sec) Electric Control System : PC-basis, Windows-XP Pro (DSP) Motorized, Transfer-conveyor Width Adjustment Transfer-conveyor, Left to Right Running Transfer-conveyor, Front-rail Fixed Compatible with SMEMA Interface, Spec 1.2 Options CAD File Conversion Local Ventilation Unit Low Fluid Detection & Alarm Dispensing Volume Detection & Monitoring with Alarm Coating Materials/Solvent Changeover Unit Dispensing Applicators Dispensing Nozzles Fluid Pressure Vessel - Useful in making an actual coating program - Vent Cabinet : 650(W)x500(D)x860(H)mm *noise proof design Vent Volume : 15(CMM)x50(mmAQ)x0.4(Kwh)x4(P) direct - Level detection by weighing the remaining material and interface - Detection liquid material flow rate by Flow-Meter and monitoring Flow rate: 2~100(L/HR), Minimum ml/30(ms) - Quickly material change for cleaning the fluids tube and dispensing applicator/nozzle tip after completion of a daily work - Film Gun Ass y(ncaf), Spiral Gun Ass y(ncas) available - Film Nozzle(FCN25/50/60), Spiral Nozzle(S6CN30/40/50) available - STS304, PV-5 (5 litres ) & PV-10 (10 litres ) available

6 Complete process line Technical Data Conveyor#1 ENTRY SECTION Conveyor#2 COATING SECTION & Conveyor#3 EXIT SECTION Coating Robot System Cartesian Robot Pass-line Height Rail Fixing PCA Size Components PCA Flow Conveyor Running Speed Conveyor Type Driving Motor PCA Stopping Width Adjust Pass-line Height Rail Fixing PCA Size Components PCA Flow Conveyor Running speed 900±30(mm) normal Front-rail Fixed standard 60x60(mm) - 380x350(mm) workable +60(mm) above, -30(mm) below the PCA workable standard Left to Right standard Adjustable Flat-belt Type (6mm/1.0T) AC Motor (6W x 1ea per each Conveyor) Detection and stopping by Air Cylinder By Stepping Motor of Conveyor#2 900±30(mm) normal Front-rail fixed standard 60x60(mm) - 380x350(mm) workable +60(mm) above, -30(mm) below the PCA workable standard Left to Right standard Adjustable One step of very SLOW speed available Conveyor Type RS-chain Type (STS304 #25) Driving Motor PCA Stopping Width Adjust PCA Clamping AC motor (6W x 2ea) Detection and stopping by Air Cylinder By Stepping Motor (M569, TM Screw) Backup plate for supporting Housing; by DASA, Controls & Motors; by Panasonic Position Accuracy; +/-50(um), - Max. Speed; X,Y=500(mm/sec), Z=100(mm/sec) Acceleration; 3,000(mm/sec2) normal, - Max. payload; 6.5Kgf at 0.4G Coating program; Easy Coating Manager, ECM_XP Exclusive use for conformal coatings X-axis Drive X-axis Actuator Y-axis Drive Y-axis Actuator Z-axis Drive Z-axis Actuator Tilting unit Angle adjustment Servo motor (200W) Air purge balance Ball screw & LM-guide Servo motor (400W) Air purge balance Ball screw & LM-guide Servo motor (100W with brake) Air purge Ball screw & LM-guide A Pivot joint by an aid of air cylinder Tilting unit Angle(XY-direction) 0 / 30 / -30 available Rotating Z-axis 0 / 90 / 180 available (motorized)

7 Technical Data Select all or one item out of below two options depending on the application 1. Film Coating Applicator : - One NCAF dispensing gun along with Three FCN different size nozzles Recommended at low viscosity of materials where below 100(Cps) Fluid Delivery System Easy Coating Program ECM-XP / Coating Pattern Available VOC Ventilation System Overall System Dimension & Weight System Interlocks for Safety 2. Spiral Spray / Linear-bead / Spiral-bead Coating Applicator : - One NCAS dispensing gun along with Three S6CN different size nozzles Recommended at various range of viscosity materials where 100 to 3,000(Cps) Option with material changeover kit for fluid circuit/applicator cleaning - STS304, one set of PV-5 (5 litres) vessel with ball valves for switching Pneumatic control box integrated in order for switching the coating mode from Film dispensing to Spiral spraying or reversely LINE COAT: Available in Film dispensing, Bead/Spiral dispensing, Spiral spraying AREA COAT: Available in Film dispensing, Bead/Spiral dispensing, Spiral spraying BEYOND-AREA COAT: Available in all kinds of Coating Programming DUPLICATE COAT: Available in all kinds of Coating Programming MID ON/OFF (Intermittent) COAT: Available in Film dispensing only SPOT COAT: Available in Film dispensing, Bead/Spiral dispensing TILT COAT: Available in Film, Bead/Spiral dispensing, Spiral spraying. Tilt all sides by 30 PULSE DISPENSING COAT: Conditionally available in Spiral ventilation (To use existing central venting duct is normal) - Ventilation volume : 15(CMM) at 30(mmAQ) VENT-FAIL interlock while in working - Exhaust duct with damper: Ø6 port Dimension; Width 1,180(mm), Depth 1,200(mm), Height 1,540(mm) Weight; Approx. 550(Kg) The system can move by an aid of own casters - Pre/After Purge, Interlock - Spiral coating applicator NCAS, Atomizing air pressure fault, Interlock - Film/Spiral coating applicators (NCAF/NCAS), Operating pressure fault, Interlock - Syringe pressure fault, Interlock (For spare purpose) - Door open, Interlock - Robot beam sensor (detecting overrun), Interlock - Fume ventilation fail, Interlock - Fluid low level, Interlock (option), Material flow rate inconsistent, Interlock (option)

8 CONFORMAL COATING SYSTEMS Model: TCM45A Work Cell Primary Utilities Electric Power Supply Pneumatic Air, Primary VOC Ventilation 1Ø x 220(VAC), 50/60(Hz), Max. 1.5(KVA) It requires Max. 3(KVA) where the site of central venting is unavailable 6-7(bars) x Ø10 Air-hose, port Exhaust Duct : Ø6 (146mm) x port

9 CONVECTION CURING OVEN Model: ECO99C TTnS Inc. have resolved the long-troubled bubble issue in conformal coatings for printed circuit board with successful transparent film application at no sacrifice to actual throughput (UPH). ECO99C, TTnS patented (PAT ) The fully automated convection curing oven is capable of the bubble-free and transparent coating films in the inline mass production. Specifically, the ideas of selective convection curing achieves saving in heating energy and reduced working-space requirements. Existing magazine and PCBA handlers can be used throughout the coating and curing process Mode of operation. The system runs PCB s in magazines throughout the oven. Applications include the curing of solvent based materials such acrylic, epoxy, urethane resin and rubber. Under the unique selective heating, precise SCR-control and wide-vision of advanced Touch program, ECO99C has accomplished a bubble-free curing solution, minimal 50% energy & working space savings in a fully automated continuous coating process. Selective Convection Heating The ECO99C is fully automated, electric-powered convection, selective heating oven which controls the temperature precisely with a range of +/-2.5. The recycling hot air flow of 20CMM makes three equally divided hot-air-turbulent-streams at 100 or 150ºC temperature maximum rating and cycles 8 times per minute. The system gives heat precisely to the loaded magazines which reduces energy consumption by more than 50% and substantially improves solvent flash-off

10 CONVECTION CURING OVEN Basic operation According to a central control signal, the magazine fully stacked with coating PCB s moves into the curing oven and makes cyclic pitch movements on RS40 chain conveyor by aid of an encoder. The next magazine stacks the next batch of coated PCB s one by one until it is filled then repeats the movement in the same way. This mechanism actually effects a continuous production as well as securing solvent flash interval while the magazine completes stacking prior to oven. This dwell significantly reduces trapped bubbles in the film. ECO99C has been developed focusing on, 1. Easy operation/maintenance, 2. Compact designed for low power consumption 3. High performance in the system self-diagnosis for safety issue The system operator can direct the oven running by an aid of wide-vision touch-screen. The system can monitor and display all the operational status real time by an aid of self diagnosis. More than 50% energy & working space savings with a bubble-free solution Dust/VOC eliminating carbon filter keeps the cycling air clean and reduced VOC. Selective hot air curing ensures high performance of solvent flash and homogeneous temperature.

11 CONVECTION CURING OVEN Typical Curing Profile Free Knocked-down Structures with Advanced Insulation-panel The entire skeleton of ECO99C is fabricated with knockeddown aluminium profiles and very slim 45(mm) thick ceramic insulation panels that TTnS exclusive designed. This panel guarantees minimal heat transfer loss despite being 50% thinner than conventional insulation

12 CONVECTION CURING OVEN Safety Interlock of the System ECO99C Convection curing oven has been developed with the philosophy of the system safety as a top priority. While the system is running, the faults detecting for safety has to be in full scale action accordingly all the time. Once a system error occurs or unexpected accident, ECO99C displays the error message and appropriate troubleshooting simultaneously on the system windows along with buzzer and control tower blinking. System overheating preventive Error System temperature control Error System temperature display Error System conveyor-run Error System conveyor-display Error System circulation fan-run Error System VOC ventilation Error System carbon-filter pressure Error Air-seal fan-run Error Magazine positioning Error Turntable communication Error System runtime Error System primary e-power Error

13 Intergration The coating cell TCM45A and magazine curing oven ECO99C can be fully integrated and automated by adding: Danutek KFT Angol utca Budapest Hungary Multi Magazine Loader Intermediate magazine stacker and 90º turn unit (between coating and curing cells Multi Magazine Un-loader Tel Fax Altus Group Ltd Block 5, Unit 1 Muirhead Mitchelston Industrial Estate Kirkcaldy, Fife KY1 3PB UK Example of integration of single sided coating. Kia automotive electronics production. Tel. +44 (0) Fax. +44 (0) sales@danutek.com Spares: spares@danutek.com