1、Micron AdvancedTraining Modules.Tools List (Hidden Slide)See notes pageCopyright StatementThe content of this presentation is confidential and the copyright of Dek. It is intended for the exclusive use of the recipient.The content may not be copied in whole or part without the prior written permissi

2、on of an authorised officer of Dek.Course GoalsUpon completion of the Advanced Maintenance training program you will be able to :Understand theory of operation of all major components and sub-assembliesPerform sub-assembly replacement proceduresPerform machine critical settings and calibrationsUse I

3、SCAN HealthcheckUse dek and Knowledge base to assist fault finding Recover from complex machine faultsPerform machine SPC benchmarking testsCourse Content Machine Installation Software Installation Electrical systems theory & replacement procedures ISCAN Healthcheck All sub-assembly modules:* Electr

4、ical and mechanical theory of operation Adjustments and settings Replacement procedures Calibrations SPC benchmark test SPC diagnostics Advanced troubleshooting Use DEK Website, Knowledge Base and Escalation procedures.* Print Carriage, Squeegee mechanism, ProFlow, Paste Dispenser, ASM, Screen Align

5、ment, Rails, Camera assembly (Linear and Rotary), Blue USC, Cyclone, Rising TableCourtesy and safetyWear PERSONAL PROTECTIVE EQUIPMENT with paste and solvent based products If in doubt press the E STOP.Personal Safety MOVING MACHINE PARTS MAY CAUSE INJURY DURING THIS COURSE WE WILL OPERATE THE MACHI

6、NE WITH CERTAIN COVERS REMOVED ALWAYS ENSURE SYSTEM POWER IS REMOVED PRIOR TO UNDERTAKING ANY WORK ON THE MACHINE .WARNING!Classroom SafetySafety for Linear motorsObjective 1: Locate the hazardous areas of the machineImpact of Lead FreeInstallation.InstallationFit and remove all transit bracketsPerf

7、orm levelling procedure (4 and/or 5 leg levelling)Perform a check disk on drives C: D: & E:i.e. chkdsk c: /r /fRun SPC testReview on-site customer training requirementsReview installation manual - any questions?Objective 2 - Perform machine installation proceduresSoftware InstallationThe “software c

8、onsists of:the appropriate system disk for the PCa DEK software diska disk containing the latest stdfeat file, the machine key and any specific keys for the machineWhen the system disk is loaded, it creates 3 partitions:C: Windows XPTM operating systemD: DEK softwareUpdated by new build issues or se

9、rvice packsE: DataCalibrations files, product files, features key etc.Should be backed up regularlySubsequent “ghosts overwrite C and D only, leaving the data drive undisturbedSoftware InstallationObjective 3 - Perform machine software installationVersion 9 SoftwarePerform software installation of V

10、9Review V9 training moduleInstall V9 Desktop Demo onto your laptopSoftware InstallationSoftware InstallationSoftware InstallationElectrical theory.PCPower Supply M37Control Enclosure M36USBUSBControl SystemThe Core system has 3 main electrical enclosuresPower Supply:All DC unit accepting mains input

11、 voltages 115 to 230V AC +/-10%.No transformer tapping.No line conditioners needed for poor factory mains supplies.Control Enclosure:Small, simple unit.All internal interconnection by PCB, no internal wiring.PC:I-Bus(newer machines)orAdvantech(older machines)PCPower Supply M37Control Enclosure M36US

12、BUSBSystem communicationUSB HubKeyboardMouseTouchscreenFlash diskThe flash disk is bolted to the printer frame (at the rear on latest machines). Now combined with the DK2 dongle.It stores machine type, serial number, number of prints made etc.The touch screen is a resistive type.The keyboard is an I

13、R or wired type with integral trackball.USBORCAN System* This configuration is correct for the Dunker motor but the newer Berger Lahr motor with integral Node will have the same line in line out as the other nodesPower supply M37PSU 242V / 48V DC SMPSUPSU 1Multi-Rail SMPSU42V or 48V DC switched24VDC

14、 Un-switched12V DC Un-switched5V DC Un-switched-12V DC Un-switchedPower supply monitorSafety circuitE- StopInterlocks2 Hand controlSystem switchUSBMains I/PCircuit breakers24VDC switchedContactors115 230V ACM37 Block DiagramVacuum PumpPC MainsPower supply M37Objective 4: Complete diagram in workbook

15、Power supply M37E-stop circuit (simplified)Task: Complete diagram in workbookE-stop circuit (simplified)E-stop CCT LED indicationsTask: Complete diagram in workbookE-stop CCT LED indicationsE-stop circuitMonitor card measures 64 DC voltages in the M37 power supply and reports them to the PC via USB.

16、It measures both sides of every circuit breaker. Shows power GOOD/BAD and breaker IN/OUT for all DC power circuits.PC display shows average, max and min voltage values.Power good shown GREEN, fault condition shown RED.Updates every 2 sec.Power supply monitorObjective 5: Monitor DC voltages using pow

17、er monitor softwareControl enclosure M36Control EnclosureRotarymotorsLinear motorsControl Enclosure card layoutX1X2X3X4X5X6X7Objective 6: Complete diagram in workbookControl Enclosure card layoutX1X2X3X4X5X6X7DualStepperXf actuatorXr actuatorDualStepperFront Sq.Rear Sq.DualStepperY actuatorMovingRai

18、l RTC VaneNext MoveESInterfaceNext MoveESMotionControllerEuroFlexDriveCamera XAxis 0(Linear only)EuroFlexDriveCamera YAxis 1(Linear only)Nextmove interface cardTask: Check voltage tolerances using knowledge dbaseNextmove ES card (Node 1)Dual stepperX1, X2, X3Cards are interchangeableSo long as the b

19、it switches are configured appropriately i.e for RTC or Micro Step motorsElectrical system QuizWhich configurations and settings must be completed if the Nextmove ES card is changed?Name 3 locations where +24v can be monitored?Which cards are interchangeable for troubleshooting purposes?Task: Comple

20、te the answers in your workbookElectrical enclosuresWith Advantech PCWith I-Bus PCI-bus PC (Digital Camera)I-Bus PC - Digital cameraI-Bus PC layoutObjective 7: Complete diagram in workbookI-Bus PC layoutPC System motherboardFirewire Card (IEEE 4)I-Bus PC - Analogue cameraI-Bus PC - Analogue cameraVi

21、sion cardVision adaptor cardAdvantech PC analogue camerasAdvantech PC- Green CameraAdvantech PC- Gold CameraAdvantech PC card layoutNetwork card*Vision cardVision card(gold camera only)Sound card*Wireless bridge breakout*Vision adaptor cardSingle board computer4 Port USB hubPeripheral connectors* Re

22、quired only for Interactive software optionAdvantech - Single board computerVision cardVision adaptor cardPC TasksCheck the PC BIOS settingsAlways check the technical reference manualNEVER restore BIOS defaults!Use PC Health Status in BIOS to monitor internal voltages and temperatures.Remove the PC

23、and disassemble parts.TroubleshootingHidden slide see notes pageSensors and switchesObjective 8: Identify and test sensors and switchesSensor & Switch SchematicsSolid State Sensors:Through-beam optoLong-throw optoCapacitive proximity SensorsSwitches:Reed switchSafety SwitchMicro-switchPressure Switc

24、hSensors tasksMonitor the signal output of the camera Y home sensor using the diagnostics software Measure the supply voltage at the camera Y home sensorMeasure the signal voltage output from the sensor in both on and off statesRepeat the tasks above for the rail lifted right sensorIs there a differ

25、ence? If yes why?Task: Complete the details in your workbookSingle unit includes servo motor, drive electronics, encoder, processor and CANopen interfaceUnits are connected via CAN busCamera X (Rotary machines)Camera Y (Rotary machines)Print CarriageServo MotorDrive electronicsProcessorCANopen inter

26、faceCAN BusDC PowerGearboxCANopen servo motorServo motor block diagramMOTOR_CANSERVO MOTOR MODULEV = Objective 9: Complete the diagram in your workbookV = Servo PowerPSU _Logic SupplyPSU _Print Carriage_ _ _ _Servo motor block diagramPrint CarriageNode 7MOTORHOMEENCODERCANbusCANSERVO MOTOR MODULE42

27、- 48V DCPrint Carriage24V DCLogic SupplyPSU 1NextmoveESServo PowerPSU 2CanOpen StepperStepper motor with CAN bus interfacePaste Dispenser (shown)RTC moving rail homeSTEPPERStepper motorRequires step / directionNo positional feedbackFront SqueegeeRear SqueegeeRail WidthXf, Xr, Y actuatorsStepper Moto

28、r theoryThis is a bi-polar 2- phase stepper drive configuration as used in:SqueegeesActuatorsMoving RailStep and Direction signals into the Dual stepper drive card are converted to switching signals for the H bridge circuits (Q1-Q8)Stepper motor block diagram MOTORHome Strain Gauge _X _PSU _ _FrontS

29、queegeeObjective 10: Complete the diagram in your workbookStepper motor block diagram Home Strain Gauge PSU 1 NextmoveESDual step driveX2NextmoveInterfacePrint Carriage Node 3CAN BusFrontSqueegeeMOTORMicro Step.New developmentMicro-step uses existing hardwareActuator resolutionCurrent = 3.41 microns

30、Micro-step = 0.4 micronsMicro-step uses 1/8th step card configurationWill introduce a jiggle effect I.e. every alignment movement (even 0 microns) will have a backwards and forwards move into positionNo effect on cycle timeSimple dc motorSimple ConstructionUSC paper feedCyclone scrub motorDC MOTORDC

31、 motor block diagram_V = V = PSU _ _MOTORUSCPaper feed_V = Objective 11: Complete the diagram in your workbookNextmove ESUnder Screen CleanerNODE 4MOTORCANbusPSU 1 USCPaper feed12V DC24V DC24VDC motor block diagramSpeed control by adjusting potentiometer on driveHigh torque available for high speed

32、and heavy board applications.Require enable, direction and start/stop (with dynamic braking).DC conveyor motorsConveyor motor block diagram_MOTORPSU _ V = _FrontTransport BeltV = Task: Complete the diagram in your workbookNEXTMOVENEXTMOVEINTERFACEMOTORPSU 1 24v DCEnableDirectionFrontTransport Belt24

33、V DCConveyor motor block diagramMotor Type UsageObjective 12: Identify motor types used on the machineMotor Type Features Application CAN ServoExcellent positional accuracy (due to encoder). High speed and high torqueIncludes CAN encoder/decoder and integrated drive electronics ?StepperGood position

34、al accuracy but not used for high speed or high torque applications ?DC Conveyor MotorSpeed controllable, high torque. ?Simple DC Motor Simple design, unsuitable for precision speed control or positional accuracy ?Motor Homing sequenceForwardReverseStopHomeSensorMotorDriveAll motors except the Risin

35、g Table Rising Table Homing sequenceForwardReverseStopHomeSensorMotorDriveObjective 13: Describe the homing sequence of each motor typeControl Area Network(CAN Bus).Why CAN ?Reduced wiringFuture proof ease of adding optionsCAN Open specification allows multiple manufactures to be sourcedShort reacti

36、on times for priority commandsFault analysis built into architecture ability to recoverSimplicity of interface (mechanical and electrical)CAN FeaturesUses Line topology partcipants are connected parallel via bus(DEK)Data transmission speed of 500 Kbit/sec (DEK)Data exchange:Each device (Node) may se

37、nd data if bus is not occupiedCOBs are read by all Nodes but any action is only performed by the addressed Node(s)A COB-ID (COB identifier) determines the receiving Nodes address and the priority of the messageCAN DevicesCAN bus components:I/O NodesServo NodesCAN Transceiver (on board Nextmove ES)CA

38、N bus theoryController Area NetworkCANDEK CAN architecture CANNextmove ESTxRxTransceiverCAN HighCAN Low0V+24VNodeElectronicsFor the node to read the bus level correctly it is important that signal reflections are avoided. This is done by terminating the line with a resistor at both ends of the bus.N

39、odeElectronics+24VLogicSupply+24VLogicSupply120120From BG9010 (Dunker motor)OrBerger Lahr motor assemblyObjective 14: Complete details in workbookNodesFront of Machine(Plan View)RisingTable motor (Dunker)Node 6MainMachineNode 2ScreenCleanerNode 4PrintCarriage I/ONode 3PasteDispenseNode 10Camera Y(on

40、 motor)Node 9Print Carriage(on motor)Node 7Camera X(on motor)Node 8Print CarriageNextMove ES CardNode 1 - CAN MasterRisingTable motor (Berger Lahr)Node 6Communicates via CAN busMultiple sensor inputsMultiple outputs including solenoid drivesMain machine I/O node 2Power & CAN Bus activity LEDsCheck K

41、nowledge base for issue status and related articlesCommunicates via CAN busMultiple sensor inputsMultiple outputsMounted on Print CarriageSupport for all Print Carriage functionality including Temp/Hum, Print Pressure (includes amplifier), Paste Roll Height Monitoring, ProFlow, Paste dispensing.Prin

42、t carriage I/O Node 3Check Knowledge base for issue status and related articlesCommunicates via CAN busMultiple sensor inputsMultiple outputsSolvent pump drive circuitSupport for all under screen cleaner functionality including paper & vortex, pumped or pressurised solvent.Screen cleaner I/O Node 4C

43、heck Knowledge base for issue status and related articlesServo / Stepper Motor nodes* Either separate BG9010 or integral node depending on motor typeServo node 6 Rising Table*Servo node 7 Print CarriageServo node 8 - Camera X (rotary only)Servo node 9 - Camera Y (rotary only)Stepper node 10 Paste di

44、spense (option)Servo Node 11 Board stop node (RTC)Stepper Node 12 Moving Rail (RTC)Servo Node 13 Paste Management for Big RedNodesObjective 15: Complete details in workbookList the nodes in the order they appear in the CAN bus chain Node _Nextmove ESNode _Node _Node _Node _Node _Main Machine I/O Nod

45、e _Node _Node _Node _Node _NodesList the nodes in the order they appear in the CAN bus chain Node 1Nextmove ESNode 6Rising TableNode 10Paste Dispenser (optional)Node 3Print Carriage I/ONode 7Print Carriage MotorNode 2Main Machine I/O Node 11Board Load Motor (RTC, optional)Node 12Rail Width Stepper (

46、RTC, optional)Node 4Screen Clean I/O (optional)Node 9Camera Y Motor (710, optional)Node 8Camera X Motor (710, optional)Practical ExerciseMeasure CAN bus line resistance:With CAN cable connected to Nextmove ES card = 60 (2x 120 in parallel)With CAN cable disconnected from Nextmove ES card = 120Discon

47、nect +24V to a node and power on machineWhat message is displayed?Task: Complete the workbook tasksCAN bus troubleshootingCheck Power supplies using Power Monitor Look at the Event Log for cluesCheck CCT breakersDetermine which Node is causing the problem. This can be done using ISCAN*Test Can bus w

48、ires for continuity and resistanceCheck NextMove ES has initialised OKCheck voltages to Node(s)ISCAN Healthcheck softwareIntelligent Scaleable Control Area NetworkTests condition of each node on CAN busProvides diagnostic feedback regarding CAN bus errorsTests Firewire camera functionalityTests Serv

49、o motor performanceTests Linear motor encoder performanceMonitors Analogue and digital inputs and outputs on each nodeISCAN Healthcheck tasksDownload ISCAN Healthcheck to a memory deviceInstall ISCAN Healthcheck on machineDisconnect node and observe feedbackTest the camera functionalityTest Print Ca

50、rriage performanceTest Node inputs and outputsReference: ISCAN Healthcheck user and help notesObjective 16: Complete activities in your workbookEvent Log AnalysisA good troubleshooting toolCheck for error messagesCheck knowledge base for error code definitionsCheck what happened leading up to the pr

51、oblemObjective 17: Complete activities in your workbookTroubleshootingHidden slide see notes pagePneumaticsThe Pneumatic module consists of the following sub-assemblies:Solenoid bank at rearSolenoid bank on print carriageRegulatorsMains inputChase clampBoard clampPaste dispenserSnuggersMains pressur

52、e sensorSolenoid valvesValve type 5/2For double acting cylindersValve type 3/2For single acting cylindersPneumatics TasksAdjust mains input within toleranceReplace a solenoid valveManually test the functionality of all pneumatic solenoidsObjective 18: Complete activities in your workbookElectrical s

53、chematicPneumatic schematicMachine Modules.Print CarriageThe Print Carriage module consists of the following sub-assemblies:Print Carriage Motor (Node 7)Print carriage I/O Node 3Home SensorDrive BeltPrint Carriage TasksRemove and refit print carriage beltRemove and refit motorCheck print carriage ho

54、me positionObjective 19: Complete activities in your workbookPrint Carriage SchematicSqueegee ModuleThe squeegee module consists of the following sub-assemblies:2 x Squeegee stepper motors2 x Drive beltsDual stepper drive card (X2)Strain Gauge2x micro switch home sensorsSqueegee Module TasksTest the

55、 strain gauge linearity complete workbook taskRemove and strip down and re-build the squeegee headPerform a squeegee pressure calibration with pressure jigPerform squeegee height calibrationObjective 20: Complete activities in your workbookSqueegee Module SchematicProFlow ModuleThe ProFlow module co

56、nsists of the following sub-assemblies:Print-head mechanismPressure mechanism Transfer head1 x stepper motor1 x drive beltDual stepper drive card (X2)Home sensorCassette low sensor (digital) ORPaste level sensor (analogue) with amplifierSoftware Controlled Air pressure Regulator (SCAR)ProFlow Module

57、 TasksSwap from Squeegees to ProFlowAdjust ProFlow cassette low sensorSet ProFlow contact positionCalibrate paste empty and full and configure Time To GoObjective 21: Complete activities in your workbookProFlowPaste Dispenser ModuleThe paste dispenser module consists of the following sub-assemblies:

58、1 x CAN Open stepper motor (Node 10)1 x Drive beltTilt actuatorHome sensorsPaste level sensorDispenser up / down sensorsTilt up/down speed control pneumatic valvesPaste Dispenser TasksRemove paste dispenser belt and replaceRemove paste dispenser motor and replaceAdjust paste level sensorAdjust pneum

59、atic controls for smooth tilt up and down operationObjective 22: Complete activities in your workbookPaste DispenserThe ASM module consists of the following sub-assemblies:ChaseLeft and right chase rail assembliesPneumatic release valvesScreen change mechanismScreen at centre long throw optoScreen i

60、n position reflective optoScreen clampsDrip tray mechanismAdjustable Screen Mount (ASM)Remove Chase RailReplace ASM CableReplace chase rail and check chase to table levelAdjust screen load sensorSet screen change lever up and down sensor positionsASM TasksObjective 23: Complete activities in your wo