I'm posting a diary of the major repair experience that we had this weekend. I'll follow up with a shorter post that sort of summarizes a few things.
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The service guys showed up at our facility about 8:30 Sat 28 Jul to work on the Radial 5 Inserter machine purchased used earlier.
The company that did the service work sent two guys who only spoke Spanish and a team lead that could translate. Although this is not particularly significant, I mentioned it because that was the reality of the job.
To start, they confirmed that the machine was up and running OK in their El Paso facility before it was sold to us. ------------------------------------------------------ On initially seeing the machine, one of the service guys cocked his head and observed that the chain was mis-aligned and they immediately started working on this.
(The machine was originally set up to have 60 part-feeders hooked up to place parts on the chain, but to save space, we took the option of using only one of the feeder modules for a total of 20 feeders.)
The insert head was not properly installed, so everything was completely removed, disassembled, and reassembled.
It was noted that the CnC (Clinch and Cut) head will need replacing about every three months during normal use.
Also, this machine will need some service at least once every month to keep it running properly.
[09:30] Took the inserter head over to a granite level and performed some measurements/adjustments to make sure of the alignment.
Adjusted pneumatic mechanism that powers the insert head.
[11:00] Took apart the button assembly and rebuilt the switches that are used to start the jobs on the machine. During install, it was merely noted that the [Start] button did not work properly.
The table where the PCB sits to receive parts was not rotating CCW as it is designed to do. To fix this, the PCB boards were checked for proper jumper configuration. Missing jumpers were the problem.
Explained how the MISSING PART button and RECOVER button works to prevent gaps in the job due to mis-insertion of parts both on the chain and on the board surface.
[11:30] Started a run, but the LEDs were leaning over as they approached the insert head. It was discovered that the 'bad part reject mechanism' was not attached and was merely sitting in the machine on the path of the chain. The mechanism was hitting components and knocking them over as they fed into the insert mechanism.
Found a new problem where clinching was only happening on one of the two leads. Adjusted and repaired.
[11:40] Inserter head still has problems so removed again and made more adjustments.
[12:05] Found out that the push tip we were using is wrong.
Fortunately, one of the three new ones that the vendor sent is the right one. There is a push tip that is designed to accommodate components with round (domed) tops like those of the LEDs we are working with. The one we had was a square-shaped tip that can cause insert errors.
[12:15] Cutter head that trims off the tape from the leads of components was not working properly. This problem took a long time to work and was not completed for an hour.
Lunch
[14:00-15:00] Some fine-tuning is happening, but basically, the machine is running fine at this time.
Re-programmed the big 256LED board and ran off a few examples making sure that the CnC works in all positions.
Provided some training to operators who are likely to be using the equipment.
Talked a little about performing mechanical work on the part-dispensing stations.
Agreed to come back Sunday and perform some programming training. ----------- Other notes: ----------- IMPORTANT: Recommended getting separate WBH (Work Board Holder) for each size of PCB that we will be running. Currently, the board needs to be latched and unlatched for each run to insert parts. The hardware on the current WBH is ***NOT*** going to be reliable enough to prevent misalignment which will cause false starts and wasted time.
We sent the service people back to El Paso with one sample of each of the four boards that we will be running to have someone look at and give an estimate for separate WBH rigs for each of the four board sizes that we have to run as of today. - - - - - - - - - - - - - - - - - - - - - - - - - - - - Air pressure drop is happening when inserting that is causing intermittent problems with part dispensing and cutting.
This is likely to be an operational issue at our facility when the Pick and Place machines, and other air-consuming equipment is on line and drawing down the pressure.
It is recommended that a hard pipe air line is brought down as close to the Rad 5 as is possible before connecting (as short as possible flexible air lines ) to the machine.
Currently, we run air from a 1.5" pipe that is about 200 ft from the compressor and is tapped in about five or six places upstream of and downstream of where the Rad 5 taps in using two 50-ft hoses. - - - - - - - - - - - - - - - - - - - - - - - - - - - - Repair lead recommended sending people to Universal's Binghamton, New York facility for some training after we have gotten a feel for the machine.
Universal uses something called Magna-Lube for parts requiring grease, but SMT grease used by us will work just fine.
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