Features & Benefits of Universal’s Axial Insertion machine — VCD/Sequencer 8

Feature

Benefit

High performance Positive Axis Control servo-drive system

Dynamic motion control for smoother,  faster,  more precise motion, yielding precise component insertion and clinching with less mechanical wear and noise.  PAC provides very high repeatability.

Insertion Head

The insertion head is direct servo-driven, with a robust and highly reliable rack-and-pinion drive. 

The rack and pinion coupled with the direct drive provide long life and precise positional accuracy, resulting in high cycle rates, greater insertion process control, and lower PPM, with less noise and wear.

Minimized manual set-ups and adjustments

Elimination of manual set-ups reduces downtime.  To ensure consistency, set-ups are now performed through IM UPS Diagnostics software.  

Insertion Tooling

Newly designed tooling has a significantly longer life –up to five times longer than the previous model.

Tooling has to be replaced less often, reducing down time, tooling inventory and cost.

Tooling uses carbide inserts and titanium nitride coating.

This extends the tooling life.

The new design better handles bent input component leads.

The robust design reduces machine interruptions & down time caused by bent input component leads.

Four tooling options are available:

5mm: insertion spans from 5mm (0.197”) to 21.59mm 

( 0.85”)

5.5mm: insertion spans from 5.5mm(0.217”) to 24.13mm (0.95”)

Standard: Insertion spans from 7.62mm (0.3”) to 24.13mm (0.95”)

Large Lead: insertion spans from 7.62mm (0.3”) to 23.88mm (0.94”)

These options satisfy most applications.  If you are unsure which tooling to choose, contact the Product Team

Centering System

New cam-actuated component centering system is driven by the insertion head motor

The new design significantly increases reliability.

The centering door has been eliminated.

Better visibility and accessibility to the insertion area.

Adjustments have been reduced by 50%.

Only five simple adjustments are required on the centering system, reducing maintenance time.

The new centering system is a simple design, with 50% part reduction over the previous model.

The design provides increased reliability and extended life, with significantly less maintenance.

The centering fingers have replaceable carbide inserts

The inserts keep costs down and reduce maintenance cost and time. 

Servo-Driven Cut and Clinch

The clinch is operated with a servo-driven rocker/slide mechanism.

This mechanism provides quiet and repeatable up/down operation, increasing reliability and reducing maintenance.

The servo-driven anvil mechanism operates in a two-step motion.  The lower position is used for table rotation and board transfer, while the mid-position to full up-position is used for cutting and clinching component leads.  

The two step motion reduces motion cycle time and increases operating life.

Right and left anvils are coupled.

The coupled anvils assure synchronous operation and simplify set-ups. 

Anvil height set-up is performed via IM diagnostics software.

Guesswork is eliminated.  The anvil height is consistently set to program dimensions through the software, for greater accuracy and precision.

All mechanical adjustments are in the front and on the top of the clinch base.

The adjustments are in easy-to-reach locations, making them quicker and easier to perform.

The clinch assembly is pinned to the frame.

Head alignment after clinch removal and replacement is eliminated.

The clinch cutters use the proven Universal pneumatic actuators.

The actuators assure a full range of operation on leads from 0.38mm (0.015”) to 0.81mm (0.032”).

Positioning System

The positioning system operates by new X-Y motors with tachometer feedback and more responsive servo amplifiers.

7.62mm (0.30”) table moves are possible with no effect on machine cycle rate.

The table motion is smoother and more controlled.

Improved table motion increases the life of mechanical parts.

Insertion Span Axis

The insertion span axis uses a direct drive system with a brushless DC servo motor.

This drive eliminates belts, external motors, and limit switches, for greater reliability and less maintenance, while providing more precise positioning.

Chain-to-Chain Transfer

The new scrap remover is mechanical.

The design is a passive mechanical device that is quiet, clean and reliable.

The sequencer chain drive is operated by a new brushless servo motor.

The drive gives more precise dynamic position control for improved component transfer, lowering PPM.

Board Error Correction (BEC) and “Teach”

BEC is a four quadrant electro-optical sensor, used to measure expected programmed PCB hole locations.  It provides feedback to the control processor to compensate for PCB hole misalignment, which drives the X-Y table to the desired hole location.

BEC adjusts a given pattern to a given board, significantly lowering PPM.  BEC compensate for circuit board construction variations between tooling holes and related patterns, improving insertion reliability.

“Teach”uses BEC to custom fit a pattern to a board.

“Teach”greatly improves pattern accuracy and lowers PPM. 

Add – On Sequencer Modules

The sequencer is available with up to 220 stations (in 20-station add-on modules).

The add-on modules provide flexibility in meeting a variety of applications.

Improved “Low Part’warning is displayed on the machine monitor, which indicates the module and level of the “low part”condition.

“Low Part”warning is more visible to the operator, defining the location better.  The warning is recorded, for better process control.

The dispense head guides and bearings are newly designed.

The new design improves reliability and ease of use.

The pneumatic valves are DC.

DC valve provide improved response for more consistent dispense head actuation.

Refire

Optical refire senses missing parts in the component input tape.

Refire reduces “Part Missing”errors by actuating the dispense head if a part is not sensed in the component input tape.

Easy-to-see LEDs show dispense head refire status.

The LED’s simplify input component loading by visibly displaying refire status and input component sensing in the dispense head.

Refire information is fed back to the machine controller

The feedback provides better information for machine performance analysis.

Jumper Wire Dispense System

Up to two jumper wire dispensers may be used in the machine.  Jumper wire dispensers may be placed on stations 3 and 23.   

Even the most “jumper wire intense”applications can be satisfied with no effect to machine cycle speed.

Jumper wire dispenser design improvements:

Improved wire feeder alignment

New drive bearing

The new design gives better cut length accuracy and increased wire dispense reliability, longer bearing life.

System Software

The VCD/Sequencer 8 utilizes IM-Universal Platform Software (IM-UPS)

This is the same Windows-based software used in Universal’s other through hole Series 8 machines and surface mount equipment, reducing the learning curve for operation, maintenance, and programming.

Graphical user interface with “pop-up”error screens

Easy to understand and use, especially for non-English speakers.

Advanced Product Editor (APE) offers a component library, graphical display of PC board, and insertion path.

APE makes programming quick, accurate, and easy.

Optimization feature

Optimization improves programs by ordering steps in the fastest insertion path.

Management data is generated & stored in a database

Machine performance can be tracked and graphed to provide a quick aid for decision making and reporting. 

Machine event messages are displayed and logged.

Machine activity can be traced, greatly aiding analysis.

Diagnostics are provided on-line

The diagnostics through software provide point-and-click simplicity for set-up and sub-system troubleshooting.

On-line manuals and user help is provided

Eliminates the need to keep manuals near the machine

Product trainer

Available in English, Spanish, and Chinese, Product Trainer provides operating and maintenance instructions through a CD.  This tool increases workforce competency and productivity  

Repair

The operator clears any misinserted component, and places a new component in the repair location.  If the ERV option is present, the machine verifies the correct part, inserts it, and clinches it automatically.

The “repair”mode enables outgoing board quality to reach 0 PPM.

Expanded Range Verifier (ERV) –Option

ERV provides on-line verification of component values and polarity.

ERV reduces the possibility of inserting defective, out-of-sequence, or incorrectly oriented components in the pattern location.

Other Features

Uninterruptable Power Supply

In the event of a blackout or brown out, the UPS provides up to 10 minutes of power.  This allows the operator to save patterns and end the current cycle.

Audible alarm

The audible alarm is programmable to alert operators of machine conditions. 

About SMThelp

We design and manufacture Odd Form component auto insertion machine,SMT equipment, and providing spare parts service. Worldwide Installation and on site support and training.

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