Radial 5 Enhancements

 

There are three (3) enhancements that distinguish the Radial 5 from the Radial IIIXQ:

Auto Recovery
Increased Cycle Rate to 9,200 Cycles/Per Hour
New Machine Cover Package

Auto Recovery:

Auto recovery was introduced to aid our customers in their continuous pursuit of high quality electronics manufacturing. By having the machine repair misinsertions automatically, you greatly reduce the opportunity for operator error, and consequently increase the quality of your product.

First, we will briefly describe auto recovery and then follow with a discussion of some of the common questions customers might have about auto recovery. To initiate auto recovery, there is a set command in the software “auto R” that must be set to 1. If this set command is set to 0, the machine will perform repairs the ame as previous level machines did, with the operator placing a component in the board and pressing the repair button to activate the cut and clinch.

If auto R is set to 1 and the machine experiences a misinsertion, the misinserted component should be cleared from the board by the operator. Once the component has been cleared, the operator presses the repair button, then the start button. At this point, the operator can leave the machine and continue doing what they were before the misinsertion occurred. The chain will sequence the carrier clip back to the dispensing head that the misinserted component came from, and the dispensing head will then place a component in that carrier clip. That carrier clip then travels back to the insertion area and the component is inserted into the printed circuit board. The machine then continues automatically with the remaining insertions of the pattern program.

Some questions that customers may ask are listed below:

1. Question: Is auto recovery an option that I need to buy?
Answer: No. It comes standard with the machine software. Also, the price
of the Radial 5 is the same as the Radial IIIXQ.
2. Question: How long does it take the machine to perform auto recovery?
Answer: The time required to perform auto recovery is based on the length
and configuration of the sequencer module. We have not tested all
sequencer configurations, but we believe the time for auto recovery
will be between 29 seconds (20 station straight back) and 90
seconds (80 station in-line). The other configurations that have
been tested are 40 station straight back (50 seconds) and 60 station
straight back (62 seconds).

3. Question: Do I have to repair misinsertions through auto recovery?
Answer: No. You can repair misinsertions manually also.

As noted earlier, the customer can choose the operate the machine in auto recovery mode or they can perform repairs in the traditional manner, they simply enter a 1 or 0 in the auto R set command.

4. Question: If I have a older Radial machine, can I retrofit auto recovery
onto it?
Answer: Auto recovery will be available as a purchased retrofit for
Radial IIIXQ machines only, and is available in the near future.

5. Question: Since auto recovery takes longer to repair a misinsertion than an
operator does, why would I want to use it?
Answer: Operators make mistakes and put polarized components
(electrolytic capacitors, diodes, transistors, etc.) in the board
backwards which causes test failures after wave solder. This
causes the PCB line throughput to decrease along with possible
component damage. Auto recovery will not put a component in
backwards, and in combination with the Expanded Range Verifier
(ERV) will verify the component before inserting it again.

The auto recovery function should be presented as a repair alternative. Not all customers will use auto recovery because of the time required, especially on larger machines, but the option is there for customers who believe from a manufacturing quality standpoint that misinsertions need to be repaired automatically. From a competitive standpoint, Panasonic through the use of its shuttle can perform auto recovery faster than the Radial 5 users can use auto recovery and still maintain greater throughput vs. Panasonic. When in competition with TDK, it is important to note that we give the customer a choice in terms of auto recovery (see competitive matrix). TDK does not offer auto recovery at all.

 

Machine Speed Increase:

Once again, as we introduce a new machine, we also have been able to increase the machine speed. The Radial II had a machine speed of up to 7,300 cycles per hour, the Radial III, 8,700 cycles per hour, the Radial IIIXQ, 9,000 cycles per hour, and now the Radial 5, with 9,200 cycles per hour. This slight speed increase was attained by some subtle changes to the machine and the manufacturing processes. The speed of 9,200 cycles per hour allows us to retain our position as the fastest Radial Inserter on the machine, (TDK’s VC7 with a speed of .39 sec/component–9,230 will not be introduced until the third quarter of 1994). By increasing our speed and maintaining our current pricing, we continue to position ourselves as the best price/performance Radial machine on the market. (Price/performance analysis using your customers data is available through the product teams.)

New Machine Cover Package:

When we looked at redesigning the machine cover package, we wanted to accomplish three things. We wanted a cover package with lines that appealed aesthetically, a consistent “look” with the VCD/Sequencer 3, and to aid the manufacturability of the machine.

The new cover package features rounded edges and corners, along with an integrated pushbutton panel for a smoother, more modern look. The new VCD/Sequencer 3 and the Radial 5, now have the same cover package. This allows us to have a consistent look for our machines, especially when they are sitting side by side in a manufacturing line.

 

 
Radial IIIXQ Enhancements

 

I. – 70% fewer setup adjustments.
– 56% fewer piece parts.
– Larger component body diameters.
– Increased reliability of component transfer from chain to chain
to insertion head.
– Clip locating at all component transfer points.

Component Transfer Assembly:

The component transfer assembly (CTA) on the Radial IIIXQ replaces the loader used on the Radial II and III machines. The CTA provides the same function as the loader did, namely moving components from the chain clip into the insertion head, but does so without the use of loader blades. The elimination of the loader blades and their associated setup and adjustment reduces the wearable tooling and the required adjustments in the loader area. (See Component Transfer Assembly (Drawing 1))
Drawing here.

Besides reduced setup and adjustment, the new CTA along with a redesigned guide jaw allows the Radial IIIXQ to insert components with 13mm body diameters and a height of 38.5mm as measured from center of tape feedhole to the top of the component. The new CTA also allows for rotation of 10 pin resistor networks by the insert head in 90 degree right, 0, or 90 degree left orientations, with the old loader there were rotational limitations.

The Component Transfer Assembly also features clip locating similar to the clip locating found on the dispensing head. The clip locating combined with the smooth cam action (see drawing 2) of the CTA helps to ensure reliable component transfer from the carrier clip into the insert head.

II. – 13mm Body Diameter Capability
– Ability to run wider range of components.

As mentioned earlier, there have been some changes to the insert head. The footprint of the insertion jaw was slightly elongated in the back to allow for 13mm body diameter capability. The 10.5mm insert head is still offered for those customers who have 10.5mm body diameter as their largest component, and required the smaller footprint for board density issues. For customers who only insert 5mm span components and require yet a smaller footprint, we still offer high density tooling, but the maximum body diameter is 9.0mm.

Along with the modifications that were done to be able to run 13mm body diameter components, further modifications were done to the insertion jaw for all insertion heads to allow for more reliable insertion of a wider range of components. The area of the insertion jaw where the component leads are grasped has been polished at a 8 micro inch finish; any sharp corners/edges have been rounded. This, combined with the CTA transferring components into the head at a higher point allows us to run a wider range of components in terms of different standoffs on the bottom of the component and on the leads (such as box capacitors).

III. – Superior clinch scrap lead removal.
– Easier access to machine assemblies.

Another area of the machine that has been enhanced is the clinch scrap lead removal system. This system clears lead scrap out of the cutter head. This new system features improved air flow through the cutter head due to an in-line vacuum transducer that is able to allow scrap material to pass through it. This allows for the transducer to be located closer to the clinch for superior air flow and scrap clearing characteristics.

To further air in scrap removal, a hole has been added to the cutter head (see drawing 3). This hole allows for greater air flow through the clinch which aides in clearing scrap from the clinch.
Drawing here.

Along with the enhancements done to improve air flow through the cut and clinch, the scrap bowl was relocated to the back side of the cover door for easier access and the bowl was enlarged to allow for longer run times between bowl emptyings. With the scrap bowl mounted on the access panel door, a window was added (see drawing 4) so that the scrap level could be checked without removing any cover panels. Along with the scrap bowl being relocated, the cut and clinch valve pack was relocated; this was done to allow easier access to the clinch base.

Drawing here.

IV. – European Code Enhancements
– Enhanced Tape Scrap Removal System
– Enhanced Documentation

The Radial IIIXQ also addresses the unique code issues of our European customers with a new “E” stop redundant interlock circuit on the inserter and sequencer covers. This new redundant interlock circuit features European code approved componentry including failsafe mechanical relays. A new light curtain cover package was also developed for European customers ordering non pass-thru machines. A new power disconnect lockout and main power circuit breaker was added to the machine (see drawing 4). Other enhancements were also done to the electronics of the machine that were not related to European code issues. Examples include new servo amplifier, new power supply, and the addition of a power conditioner.

The tape scrap removal system and machine documentation were enhanced. The tape scrap removal system was designed with anti-static consideration in mind, such as different tubing material and a grounded scrap bin (see drawing 5). The machine documentation has added icons for clarification and has replaced some text with tables that are easier to use and understand (see attachment 1 and 2).

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