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UP3000 ULTRAFLEX

UP3000 ULTRAFLEX. THE INDUSTRY CHOICE FOR SPEED, ACCURACY AND FLEXIBILITY. HIGH END PRINTER MARKET. Introduced in 1995 - Only true High-End printer in market 800 + installs worldwide 80 % of sales are repeat customers Design concept: High-End Printer,

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UP3000 ULTRAFLEX

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  1. UP3000 ULTRAFLEX THE INDUSTRY CHOICE FOR SPEED, ACCURACY AND FLEXIBILITY

  2. HIGH END PRINTER MARKET • Introduced in 1995 - Only true High-End printer in market • 800 + installs worldwide • 80 % of sales are repeat customers • Design concept: High-End Printer, with advanced features and options for advanced high speed applications • Focus on High Speed, Accuracy and Reliability while providing Ultra-Flexibility. • Design fits Double-sided, High-changeover environments with a large variety of board sizes.

  3. UP3000 ULTRAFLEXFrame Design New frame design that is Dynamically tuned • Centernest strengthened to handle new design • Cross member added for increased strength • Three fold increase in Stiffness

  4. UP3000 ULTRAFLEXFrame Design UP3000 Frame Design UP3000 Ultraflex Frame Design

  5. UP3000 ULTRAFLEXDRIVER POD(outside)

  6. UP3000 ULTRAFLEXDRIVER POD(inside)

  7. New Pentium Computer Change in MUX card #3 New mechanical pod and I/O track cover locks. UP3000 ULTRAFLEXCOMPUTER POD

  8. Solid State Relays The addition of the Safety Relay New Breakers UP3000 ULTRAFLEXAC POD

  9. UP3000 ULTRAFLEXNew “Print Engine”

  10. SUB-FRAME Casting design Four point mounting system Dynamically tuned to handle new axis design UP3000 ULTRAFLEXSUB-FRAME

  11. Parallelism achieved though castings Stepper motor control ( small distance movement) Accuracy 2000 micro-steps per revolution = 16 mm UP3000 ULTRAFLEXX-Y AXIS

  12. Direct Drive Servo Motor Increased resolution 12,800 micro-steps per Revolution Increased Speed Possible UP3000 ULTRAFLEXTHETA-AXIS

  13. Z - AXIS Servo Motor Design New Linear Bearing Design UP3000 ULTRAFLEXZ-AXIS

  14. Z - AXIS Hollow Core Servo Motor Direct Drive Lead Screw Maximum resolution and stiffness during movement for improved Snap-Off UP3000 ULTRAFLEXZ-AXIS

  15. Both the Z and Theta use Resolver feedback. Both Servos need Step and Direction signals to work. The Theta motor needs a Positive signal to enable and the Z motor needs a Negative signal to enable. The servos have a digital display letting you know the condition of the servo: 1. On the Z motor servo a dash (-) indicates that it is OK. 2. On the Theta motor servo a Zero (0) and a period (.) indicates that it is OK. Direction signal for the theta axis only is a differential signal. For this reason Motion Multiplex (mux) #3 is different from the others and no longer interchangeable with the other mux cards. UP3000 ULTRAFLEXZ+Theta SERVO MOTORS

  16. UP3000 ULTRAFLEXCenternest • Snugger system uses two pistons at ends of bar • Results in more flexible and repeatable board handling • Snugger Height - Four Inter-Dependent Fine Pitch Motors(the eccentrics are no longer used for snugger height) • New Flipper Design • Handles difficult boards

  17. UP3000 ULTRAFLEXCenternest

  18. UP3000 ULTRAFLEXVacuum Shut off • Immediately shuts off vacuum for better stencil release. • Results in more flexible and repeatable board handling

  19. UP3000 ULTRAFLEXSnugger and Flipper Enhancements

  20. New Flipper Design Previous Flipper Design 1 2 3 UP3000 ULTRAFLEXNew Flipper Design Movement

  21. UP3000 ULTRAFLEX Flipper Enhancements 1. They ride on a four bar linkage. 2. Can be changed to a thinner flipper, 0.005 (5mil) so you can print with the flippers on. (Not available at this time) 3. There are 2 pistons for extending and one for retracting (retract piston is spring loaded). 4. Pistons have a Lip seal that go into the piston block. Note: Prior to disassembly Shut down the air, if done with the air on, pistons will go flying.

  22. UP3000 ULTRAFLEXNew Flipper Design Movement

  23. UP3000 ULTRAFLEXBOARD THICKNESS AXIS

  24. UP3000 ULTRAFLEXBOARD THICKNESS AXIS Left front Board thickness Stepper motor Screw Housing BD_THICK Screw BD_THICK Sensor Striker Plate

  25. UP3000 ULTRAFLEXBOARD THICKNESS AXIS MOTOR 3 MOTOR 4 MOTOR 1 MOTOR 2 DRIVER

  26. UP3000 ULTRAFLEXCalibrating Snugger Height 1) Calibrating the BD_THICK sensor. **This sensor is used as a mid type sensor. During reset the BD_THICK Screw comes out of the screw housing until the sensor is turned on then it travels inward.(Negative) -0.270 inches--- This is the Negative software limit. If the sensor is set incorrectly it will bind at this point. Then when it steps off to its default value the motor screw will move off at different setting depending on how much it was bound up during over-travel. 1. In axis base settings with the Z-axis at board transport height Jog the BD_THICK axis negative until the motor stops turning. 2. Slowly jog the axis positive ( Move Upward ) until the knob on top of the motor just starts to move about 1/8 to 1/4 of a turn. 3. Hit exit on the mouse then select "RESET AXIS" on the axis base setting screen. This will reset the counter on the BD_THICK axis. 4. Jog the BD_THICK axis to 0.280 and set the BD_THICK Sensor to "Just off". 5. Next jog the axis positive to 0.290 the SENSOR should turn on before it gets to 0.290 6. Finally slowly jog the z axis up and verify that the striker plate will not contact the BD_THICK SENSOR. If it does the sensor will have to be reset (redo procedure) NOTE: After calibrating the BD_THICK sensor the motors will have to be retimed and snugger height will have to be redone. Also after calibrating snugger height the machine MUST be powered down before verify

  27. UP3000 ULTRAFLEXCalibrating Snugger Height 2) Timing the board thickness motors. 1. Always check snugger height with the table at vision height. At snugger height eccentrics may be touching. The newest software allows the snugger height to be checked at snugger height but it is best to verify at vision height. 2. Turn off Stepper Power 2 through the I/O screen. 3. Measurement should be with Z-track on. Make your measurement at the end of the rails. 4. Your reference will be on the left front adjustment (This is your reference adjustment, DO NOT TOUCH.) The three other points where you’ve made adjustments should be within 0.001 mil. 7. Of the three adjustments, two have the thumbscrew adjustments on top, the right rear the adjustment is on the bottom. 8. Turn Stepper Power 2 back on and Reset the machine. 3) Perform the Calibrate Snugger Height through Base Settings screen. 1. Verify the correct board thickness is entered in Setup Page 1. 2. Follow instructions on the screen. Then after completion power down. 3. Power up, reset and verify snugger height.

  28. UP3000 ULTRAFLEXE-STOPS / POD Interlocks Safety Relay (K2)

  29. UP3000 ULTRAFLEXDOS Software Changes • The .100 file extension. (used for Ultraflex only) • Version 8.1+ will need a jumper on LRDB J21 (it should already be there) • Gem screen access. • The Key pad accessory. • New axis BD_THICK.100

  30. UP3000 ULTRAFLEXDOS Software Changes

  31. UP3000 ULTRAFLEXSlow Snap-Off Hardware • Z- axis redesigned with slow snap-off in mind • Enhanced Resolution of Servomotors • Increments of movement - 0.0003” • Controlled harmonics

  32. UP3000 ULTRAFLEXSlow Snap-Off Software • Release profile now programmable with up to 5 separate sections • Up/ Down - breaks bond of paste and stencil • Continuous - vibration free release • Stepped - introduce controlled harmonics

  33. UP3000 ULTRAFLEXSlow Snap-Off Software Four Snap-Off Profiles for Flexibility • Speed - Cycle time and definition • Standard - For majority of Applications • Fine Pitch - Leading edge Applications • Custom - User defined parameters

  34. UP3000 ULTRAFLEXSlow Snap-Off Software

  35. UP3000 ULTRAFLEXNT Software • DOS standard with Ultraflex release - 8.1 • Windows NT available Q4 - year 2000 • Icon-Based User Interface • Designed with operator in mind • Multi-tasking capability • New wiper profile • SPC Trend analysis display

  36. UP3000 ULTRAFLEXNT Software Main Screen Concept

  37. UP3000 ULTRAFLEXReliability The simpler the manufacturing process the more reliable the machine • Manufacturing methods built into design • Modular manufacturing design. • Pre-tested sub-assemblies. • Meets present UL and CE requirements

  38. UP3000 ULTRAFLEXRepeatability

  39. UP3000 ULTRAFLEXConclusion • True High-End Printer • Advanced design, features and options • Ability to handle technology for today and tomorrow • First Customer Ship June 2000

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