Why are devices being placed at an angle when using an Automated Programming System(APS)?

Why are devices being placed at an angle when using an Automated Programming System(APS)?

Summary

Procedure to evaluate and troubleshoot why devices are placed at an angle.

Details

The angular placement can be any angle, 5 degree , 30 degree, 45 degree, 90 degree, etc. This angular placement can be seen in the sockets, tray, laser nozzles or anywhere else.
The problem can be random, intermittent, occasional, or constant and can be seen during teach or production.


Check Points

1. Is the Z bellows loose?
If loose, tighten.
2. Is the Z bellow straight? 
Check nozzle runout is within specification, replace bellows if required.
3. Is there a strong vacuum on the nozzle?
Devices can slip on the nozzle if the vacuum is too weak.
Attached a vacuum gauge to the installed nozzle and turn on the vacuum to see what pressure you are getting.  If too low, investigate the cause further.
4. Check the Theta drive system for correct operation.
There could be a problem with either the Theta motor or the Theta motor driver.
In 4X systems, the Theta motor driver board can be swapped with the Z-axis motor driver board, provided the correct DIP switches are set. Depending on the BPWin version you are running, then there is a W (Theta) axis drift check.  This will require the use of a special nozzle, part number CPICNOZTESTJIG, which is included in the standard nozzle kit since 2011
To access this test, go to Main Menu/
Autohandler
/Diagnostics/Pick and Place Motion. Select the W Axis Drift Test from the
pull down
menu and follow the instructions on
screen
.
If the test fails, make sure that the CPICNOZTESTJIG is a snug fit on the Z bellows.
If the fit is too loose, the test will fail.
If the fit is tight and the test fails, replace first the theta motor, then if the rotational problems still exist, replace the theta driver. The theta motor is a 2 phase stepper motor, so each of the motor's two internal windings can be checked for integrity by measuring the resistance of each winding (pin 1 & 2 vs pin 3 & 4).  The resistance values should match exactly. The actual value is not that important. If the resistance values do not match exactly, replace the motor. It is possible, but extremely rare, that the CyberOptic system is the cause. Check the CyberOptic system by running the Main Menu/Autohandler/Diagnostics/Cyberview utility. Click the Capture button and get a screenshot of the results. This is a good indicator of the CyberOptic system, to check that it is working normally. More information on using Cyberview diagnostics is available in BPWin Help. Also see CyberOptic test interpretation document below:

Machine specific considerations:

3x00 - First check that the break-away coupler that connects the theta motor shaft to the Z bellows is not rubbing on the underside of the motor body. There should be a tiny gap so that rubbing does not occur. Loosen the set screw and slide the coupler down a little.

Breakaway coupler clearance.PNG

It is possible that the W axis drift test passes but the theta motor is still defective. The 3x00 theta motor part number is D04336PD. It should be noted that the theta motor cable, along with the laser pointer and vacuum switch cables should be tie wrapped to the laser pointer housing to prevent cable flexing, which will quickly break the theta motor conductors where they exit the motor.

Secured Theta Harness.PNG

The theta driver on a 3x00 is not swappable with any other driver in the E-Box. It is completely different. The theta driver part number is D04152AD. The chain cables have a high flex rating and they seldom fail.

4x00 - The theta motor is usually stable. However, you may check the set screw on the theta motor flex coupler, located underneath the motor, attached to the motor shaft. The replacement theta motor is part number WPICMOT04.

The theta driver board can be swapped with the Z driver. The DIP switches on the drivers must be reset to their respective axes.

4XDriverDIPs.PNG

The replacement theta driver part number is WPICBRD04-T. 4x00s with the old style e-chain ribbon cables should consider replacing these cables (upper and/or lower) only if replacing both the motor and driver do not solve the rotational problem. Upper ribbon cable part number: CPICCAB02, Lower ribbon cable part number: CPICCAB01.

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