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Report on Lakeport Tooling Cylinder After 1M Cycles Burn-in. Last Update : 6 th December 2005. Objectives. Study the condition of the cylinder pistons after 1M cycles burn-in under heavy contamination. Compare the response of the cylinder pistons before and after clean up and re-assembling.
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Report on Lakeport Tooling Cylinder After 1M Cycles Burn-in Last Update : 6th December 2005
Objectives • Study the condition of the cylinder pistons after 1M cycles burn-in under heavy contamination. • Compare the response of the cylinder pistons before and after clean up and re-assembling. • Compare the clamping repeatability of the clamping set before and after clean up and re-assembling.
Support base with compress air supply Lakeport package Fiber Tilting sensor Clamp set Solder balls Testing Setup Foreign materials on cylinders added purposely Testing Conditions Clean test cylinder
Set A Set B 0.1 clearance (clean) 0.1 clearance (clean) 0.1 clearance (clean) 0.1 clearance (with fiber and solder ball) C4 C5 C3 0.1 clearance (clean) 0.1 clearance (with fiber and solder ball) 0.2 clearance (clean) 0.1 clearance (clean) 0.1 clearance (with fiber only) 0.1 clearance (with fiber only) C1 C2 0.1 clearance (clean) 0.1 clearance (clean) 0.2 clearance (with fiber and solder ball) 0.1 clearance (with fiber and solder ball) 0.2 clearance (with fiber only) 0.1 clearance (with fiber only) Cylinders C1, C2 and C3 are those cleaned after burn-in test. Cylinders C4 and C5 are those originally clean cylinders. Cylinder Cleaned Up
Small scratch marks were observed on the cylinder piston No obvious difference was found in performance Cylinder after test 0.2mm Clearance Reference Clamp Cylinder After Test
Bottom of seal ring Top of seal ring No damage was observed on the seal ring Side of seal ring Seal Ring of 0.2mm Clearance Reference Clamp Cylinder After Test
Stroke Time of 0.2mm Clearance Reference Clamp Cylinder After TestDuring Burn-in The heavily contaminated cylinder (C1) of 0.2mm clearance maintained a stroke time of 0.7s at 7LPM flow rate (2turns) though out the 1M cycles burn-in, with a safety margin of 62%.
Small scratch marks were observed on the cylinder piston No obvious difference was found in performance Cylinder after test 0.1mm Clearance Reference Clamp Cylinder After Test
Bottom of seal ring Top of seal ring No damage was observed on the seal ring Side of seal ring Seal Ring of 0.1mm Clearance Reference Clamp Cylinder After Test
Stroke Time of 0.1mm Clearance Reference Clamp Cylinder After TestDuring Burn-in The heavily contaminated cylinder (C2) of 0.1mm clearance maintained a stroke time of 0.7s at 7LPM flow rate (2turns) though out the 1M cycles burn-in, with a safety margin of 62%.
Small scratch marks were observed on the cylinder piston No obvious difference was found in performance Cylinder after test 0.1mm Clearance Moving Clamp Cylinder After Test
Bottom of seal ring Top of seal ring No damage was observed on the seal ring Side of seal ring Seal Ring of 0.1mm Clearance Moving Clamp Cylinder After Test
Stroke Time of 0.1mm Clearance Moving Clamp Cylinder After TestDuring Burn-in The heavily contaminated cylinder (C3) of 0.1mm clearance maintained a stroke time of 0.6s at 7LPM flow rate (2turns) though out the 1M cycles burn-in, with a safety margin of 68%.
No damage was observed on the cylinder piston No obvious difference was found in performance Cylinder after test 0.1mm Clearance Uncontaminated (normal) Reference Clamp Cylinder After Test
Bottom of seal ring Top of seal ring No damage was observed on the seal ring Side of seal ring Seal Ring of 0.1mm Clearance Uncontaminated (normal) Reference Clamp Cylinder After Test
Stroke Time of 0.1mm Clearance Uncontaminated (normal) Reference Clamp Cylinder After TestDuring Burn-in The clean cylinder (C4) of 0.1mm clearance maintained a stroke time of 0.6s at 7LPM flow rate (2turns) though out the 1M cycles burn-in, with a safety margin of 68%.
No damage was observed on the cylinder piston No obvious difference was found in performance Cylinder after test 0.1mm Clearance Uncontaminated (normal) Moving Clamp Cylinder After Test
Bottom of seal ring Top of seal ring No damage was observed on the seal ring Side of seal ring Seal Ring of 0.1mm Clearance Uncontaminated (normal) Moving Clamp Cylinder After Test
Stroke Time of 0.1mm Clearance Uncontaminated (normal) Moving Clamp Cylinder After TestDuring Burn-in The clean cylinder (C5) of 0.1mm clearance maintained a stroke time of 0.6s at 7LPM flow rate (2turns) though out the 1M cycles burn-in, with a safety margin of 68%.
Stroke Time and Back Pressure of Cylinders Before and After Cleaning At 1LPM (1/2 turns) • The problem of air leakage reduced after cleaning of cylinders, as back pressure can maintain above 4.5bar with 5bar supply pressure. • The stroke time of the heavily contaminated cylinders after cleaning was close to the clean cylinders (smaller than 0.3s difference). • The slower stroke time for the clean cylinder before cleaning was due to the influence of the contaminated cylinders. This is because the reference clamps are connected to the same compress air supply.
Stroke Time and Back Pressure of Cylinders Before and After Cleaning At 7LPM (2 turns) • The back pressure of all cylinders can maintain at 5bar with 5bar supply pressure when the flow rate is at 7LPM (2 turns). • The difference in stroke time before and after cleaning is smaller than 0.1s, which is within the measurement errors, and the safety margin is maintained above 60%.
The Measurement Procedures of Clamping Set Repeatability • Use the clamping block to hold firmly a 34x34 package. • The position of the dowel pin on the clamping set is measured with reference to the reference corner. • The position of the 4 corners of the package is measured with reference to the reference corner. • 5 sets of measurement are made and the clamping block was opened-and-closed for 5 times between each measurement. • A total of 25 clamping cycles are preformed and 5 sets of data are measured. • The repeatability was found by comparing the 5 sets of measurement results, the position of the dowel pin hole in each measurement is used as the absolute reference in comparison.
The Repeatability of Clamping Set Before and After Disassembling with Absolute Reference • The package rotation was reduced by 0.005° for Set A and 0.002° for Set B. • The package centre repeatability was reduced by ±0.002mm for Set A and ±0.001mm for Set B. • The package corner repeatability was reduced by ±0.003mm for both Set A and Set B.
Effect On Measurement Errors • The GRR for both package measurement and dowel pin measurement are below 10%, which are acceptable. • Detail GRR report are attached in the appendix
Discussions • The heavily contaminated cylinders can maintain a stroke time of 0.7s for reference clamp and 0.6s for moving clamps through out the 1M cycles burn-in. • Although scratch marks are observed on the heavily contaminated cylinder pistons, the stroke time of the cylinders can still maintain 60% safety margin. • The deviation between the stroke time of the heavily contaminated cylinders after cleaning and an originally clean cylinder was smaller than 0.1s and the back pressure was maintained at 5bar at appropriate working conditions, which showed that the heavily contaminated cylinders after running one million cycles can perform as well as an originally clean cylinder. • The repeatability of the clamp sets after disassembling is closed to those before disassembling, and the difference in the measured results is smaller than the measurement errors in the GRR report. This induced that the variation in performance of the cylinders before and after disassembling is not significant.
Conclusions: • The burn-in test results showed that the cylinders can perform with good margins (>60%). • The heavily contaminated cylinders before cleaning can perform on par to originally clean cylinder. • The clamping set can maintain its repeatability after disassembling and reassembling during maintenance.
