BPM Microsystems, LP
TUBE STACKER LOADER
(Automated Tube Output)
BP Microsystems Training Course
# TUBL-001
Rev. A
Teaching Method of the Course
• Covers the fundamentals
– More details in the 3000 and 4000 Users Guides
• Step by Step
– Broken down to steps
– Start with Installation
– Continue through complete operation
• Examples
– Photos
– Diagrams
• Self taught or a taught course.
• When complete, trainee should be able to install and
operate the Tube Stacker Loader.
Tools Needed for the Course
•
•
•
•
Tube Stacker Loader
Tubes of Devices
Loader Tooling Kit to match Devices
SAE Hex Keys (Allen wrenches)
Tube Stacker Loader Training
Chapters
1.
2.
3.
4.
5.
6.
7.
8.
9.
Identification of parts
Installing and removing Loader Tooling Kits
Loading Empty Tubes in the Tube Loader
Adjusting the Tube Loader
Teaching the Tube Loader
Clearing Jams
Tube Loader Maintenance
Installing the Tube Loader Option
Using BPWin Tube Stacker Control
Chapter 1
Identification of Parts
Training Seminar # TUBF-001
Revision A
Tube Stacker Loader
A.
B.
C.
D.
E.
Tooling Channel
Tooling bed
Shutter
Air Tube
Channel landing area
F.
G.
H.
I.
J.
Air Valve Cover
Part Count Sensor
Tooling Clamp T handle
Air Tube Airflow Regulator
Air Tube Height Adjuster
A.
B.
C.
Tube Weight with Chain
Front Tube Width Guides
Tube Width Rails
D. Tube Width Rail Adj Knob
E. Count Sensor Fiber optic
F. Front Tube Support Assy
with Micro Switch
A.
B.
C.
D.
Tooling Channel
Count Sensor Through Hole
Micro Switch Assy
Front Tube Support Block Assy.
E. Support Block Height Adj
F. Height Adj Red T Handle
G. Micro Switch safety hinge
(shown open for identification)
A.
B.
C.
D.
E.
Rear Tube Width Guides
Hopper Attachment Knobs
Rear Vertical Plate
Tube Pusher Assy.
Rear Tube Support Plungers
F.
G.
H.
I.
J.
Blade Plunger Assy.
Blade Height Adj Knobs
Height Adj Brass Locknuts
Tube Width Adj Belt
Tube Length Sliders
A.
B.
C.
Locking handle for Tube Width
and Tube Length Adjustment
Full Tube Hopper
Tube Pusher Plunger
D. Tube Pusher Plunger Force
Regulator
E. Rear Tube Width Lead Screw
Pulley
Chapter 2
Installing and Removing Loader Tooling Kits
Training Seminar # TUBL-001
Revision A
Install Loader Tooling Kit
1.
2.
3.
Unlock the tooling by using the red T handle.
Remove the existing curved tooling channel if present.
If the new tooling kit contains a special air tube, then install it at this time.
Loosen the set screw that secures the air tube and switch them.
4. Install the new tooling channel by fitting the rear channel slot into the rear pin on
the loader tooling bed.
5. Press the front of the tooling down into the front pin, using care to prevent
damaging the copper air tube.
6. Check that the tooling channel is installed flat to the tooling bed, then lock the
channel in place with the red T handle.
7. Check the air tube position. It should just peek over the front of the tooling
channel. This tube aims air at the placed device to blow it down the channel and
into the tube.
8. If the new tooling kit contains a special shutter, replace it at this time by
loosening the two set screws that hold the shutter on the rotator shaft.
9. Adjust the shutter height so that it swings over the tooling without rubbing
excessively or leaving air gaps when closed.
10. Adjust the shutter rotation so that the shutter completely covers the channel top
when closed.
Typical Loader Tooling Kit
Top view of a tooling channel. Note the placement
landing on the left end.
Bottom view of a tooling channel. Note the alignment
Hole and slot on the left side, and the air tube clearance
Slot on the right end.
Standard Loader Tooling Kits
(Other kits available as Special Order)
FLDRKITSOIC150M
Loader Tooling, SOIC 8-16, 150Mil wide
FLDRKITSOIC08S2
Loader Tooling, SOIC 8, 200Mil wide
FLDRKITSOIC300M
Loader Tooling, SOIC All 300Mil wide
FLDRKITSOIC330M
Loader Tooling, SOIC 44, 330Mil wide
FLDRKIT1428SSOP
Loader Tooling, SSOP 14-28
FLDRKITTSSOPV2
Loader Tooling, TSSOP ? (.280 wide Channel)
FLDRKIT20PLCC
Loader Tooling, PLCC 20
FLDRKIT2832PLCC
Loader Tooling, PLCC 28/32
FLDRKIT44PLCC
Loader Tooling, PLCC 44
FLDRKIT52PLCC
Loader Tooling, PLCC 52
FLDRKIT68PLCC
Loader Tooling, PLCC 68
FLDRKIT84PLCC
Loader Tooling, PLCC 84
FLDRKITDIP3M
Loader Tooling, DIP 300Mil, 18-28
FLDRKITDIP6M28
Loader Tooling, DIP 600Mil, 24-28
FLDRKITDIP6M4X
Loader Tooling, DIP 600Mil, 32-48
Chapter 3
Adjusting the Tube Loader
Training Seminar # TUBL-001
Revision A
Tooling Adjustments
1. The tooling channel requires no adjustment.
2. Depending on the package, the airflow from the air tube may need
adjustment. Use the airflow regulator needle valve to increase or
decrease airflow. Closing the air flap by hand will activate the air
flow.
3. If a special air tube was included in the tooling kit, it may need to
be adjusted for height. Use the thumbscrew to make the
adjustment.
4. Usually the shutter requires no adjustment if installed correctly.
However it may be necessary to adjust either the shutter open
speed or shutter close speed. Use the needle valve regulators on
the rotator to make the adjustments. Use the Tube Stacker
Control to assist in the adjustments by manually opening and
closing the shutter during adjustment.
5. The Tube Pusher has a plunger force regulator. This rarely
requires adjustment.
Tooling Adjustments
A.
B.
C.
Air Tube Height Adj
Airflow Needle Valve
Shutter Close Regulator
D.
E.
Shutter Open Regulator
Valve Bank with manual
override buttons (orange)
The four required adjustments to the
Tube Stacker Loader after changing
tooling kits:
1.
2.
3.
4.
Adjust for tube width.
Adjust for tube length.
Adjust for Rear tube height.
Adjust for Front tube height.
1. Adjust for correct tube width.
a) Unlock the rail clamp using the red handle underneath the
loader. This allows the adjustment of both the tube width and
tube length.
b) Turn the black knob to adjust the rails for tube width. The belt
drives two lead screws which can either widen or narrow the
tube guides.
c) Place one tube in the loader.
d) Correct adjustment allows the tube approximately 1 mm sideto-side play. If the play is excessive, parts could jam at the
mouth of the tube due to horizontal misalignment.
e) Lock the rails in position using the red handle.
2. Adjust for tube length.
a) Unlock the rail clamp using the red handle underneath the loader.
This allows the adjustment of both the tube width and tube length.
b) Use one tube as a gauge for setting the length. The tube should
have one stopper in the rear position.
c) Setting tube length correctly is tricky because the tube pusher is
involved. Normally the tube pusher is extended while a job is
running. However, when the machine is idle the tube pusher is
retracted. The length adjustment should be made with the tube
pushed extended. Refer to Chapter 9 Tube Stacker Control to
extend the tube pusher.
d) With the tube pusher extended, slide the rear vertical plate into
position so that the tube has only 1mm of front/rear play. This
adjustment is critical.
e) Lock the rear plate into position with the red handle.
2. Adjust for tube length.
Make tube length adjustment with the Tube Pusher extended.
Also note that the stopper tab is pointing up.
3. Adjust for rear tube height.
a) Place a tube in the loader resting on the rear
support blocks.
b) Unlock the rear height adjusters using the brass
Lock nuts.
c) Adjust the height of the blades using the black
plastic knobs. The blades should just slip
across the top of the tube. When a full tube is
ejected, the blades should slip between the two
bottom tubes allowing only the bottom tube to
drop. Extend the blades by hand when making
this adjustment. (Pinch them together)
d) When adjusted, lock the height adjusters in
place with the brass lock nuts.
3. Adjust for rear tube height.
4. Adjust for Front Tube Height.
a) Place a tube in the loader. Make sure the micro switch
hinge is closed.
b) Use the red T Allen handle to adjust the height of the
front tube support block assy. Turning the T handle will
raise or lower the front tube platform.
c) Align the mouth of the tube to the tooling channel. This
will allow the device to slide smoothly into the tube
without jamming at the mouth of the tube.
d) Manually load devices into the tube to test the
alignment if necessary.
4. Adjust for Front Tube Height.
Note that the micro switch hinge is in the closed
position. The hinge should ALWAYS be closed to
prevent damage to the micro switch.
4. Adjust for Front Tube Height.
Chapter 4
Loading Empty Tubes in the Tube Loader
Training Seminar # TUBL-001
Revision A
Loading Tubes in the Tube Loader
Note: The empty tubes must have the rear stopper
installed. If the stopper has a tab, the tab must be
pointing upward.
•
•
•
•
Remove the tube weight by sliding up and out.
Note the orientation of the weight. It should only
install one way.
Check that the hinged flap is closed.
Load empty tubes with the stopper toward the
tube pusher.
Re-install the tube weight.
Chapter 5
Teaching a Tube Loader
Training Seminar # TUBL-001
Revision A
In the Workflow window, locate the “Destinations” box.
Give the tape feeder teach a valid name. NOTE: The teach
name must begin with TUBEEXPOUT.
Go to the main window, menu selection
AUTOHANDLER/TEACH. Select the “TUBEEXPOUT”
name and click Teach.
When prompted, place a device in the loader tooling channel
about in the middle of the landing area and click OK.
The Adjust Nozzle Position window will appear. Select the
correct Pin 1 position according to the Figures (A or B). Use
the arrow buttons to position the downward camera or laser
pointer over the device, and press OK. Remove the device
when prompted.
Chapter 6
Clearing Jams
Training Seminar # TUBF-001
Revision A
If jams occur at the mouth of the tube:
1. The Device count sensor detects that a part is blocking the
sensor and gives an error.
2. Visually inspect the jam. If the tube is sitting too high or too
low, readjust the front tube support height setting.
3. If the height is OK, then the guide rails could be too far apart.
Readjust as necessary.
If tubes fail to drop when full:
1. Check that the tabs on the rear stoppers are pointing up
2. Check that the tabs are not interlocking.
3. Check that the tube blades are not binding the tube. Readjust
rear tube height as necessary.
4. Check that the tube pusher is not binding the tube. Readjust
tube length as necessary.
Chapter 7
Tube Loader Maintenance
Training Seminar # TUBL-001
Revision A
Tube Loaders require very little maintenance.
There are very few user serviceable parts
inside. BP Recommends:
1. Periodically clean the channel of the tooling.
Remove the metal cover and polish the
channel with a soft cloth.
2. Check the Air Mist Separator for water
and/or oil.
Defective tube Loaders will need to be sent to
BP Microsystems, LLP for repair. Call technical
support for Assistance.
Chapter 8
Installing the Tube Stacker Loader Option
Training Seminar # TUBL-001
Revision A
Important: Power the system down and
observe ESD precautions when handling
electronic circuit boards.
Installation Procedure
1.
Bolt the feeder mounting plate (CPLATUBELOADER) to the host machine
table top. This can be any location desired as long as the downward camera
(4x00) or laser pointer (3x00) can “see” the loader place point for teaching.
2. Bolt the loader to the mounting plate.
3. Feed the communication cables and air line to the nearest access hole on
the table top.
4. Mount the serial peripheral board assembly (WSERIALTUBELOAD) to a
secure location inside the machine.
5. Connect the loader cables to the SP card. They only install one way.
6. Connect one end of the Telephone cable (CCAB7FTPHONEBLK) to J1 on
the SP card, and the other end to J4 on the tube feeder SP card
(WSERIALTUBELOAD). This daisy chains the 2 SP cards.
7. Mount the Mist Separator/Super Mist Separator filter assy to the frame
inside the handler. Drilling and tapping mounting holes may be necessary.
8. Use the contents of the air connector kit (WAIRCONECTCEFDR) to splice
into a regulated compressed air line and tee in the air line to the filter assy.
9. Connect the loader and feeder air lines to the filter assy.
10. NOTE: Installation on a 4x00 system may require a different plexiglass
safety panel (rear or side depending on location).
Chapter 9
Using the BPWin Tube Stacker Control
Training Seminar # TUBL-001
Revision A
Tube Stacker Diagnostics Window Usage
Go to main menu Autohandler/Diagnostics/Tube Stacker
Control.
Tube Stacker Diagnostics Window Usage
Select the Loader button. This window will allow manual
manipulation of the loader. It will also monitor the state
of the three sensors on the loader. The use of this
window is self explanatory.
Tube Stacker Diagnostics Window
Review Questions
1.
2.
3.
4.
5.
What parts are included in a typical Loader tooling kit?
What is a valid name for a tube stacker loader teach?
What is the purpose of the air tube?
What is the purpose of the blades?
What is the most common cause of a loader jam?
Chapter 5: Turning On and Off
Review Answers
1. What parts are included in a typical Loader tooling kit?
Device channel.
2. What is a valid name for a tube stacker loader teach?
“TUBEEXPOUT”
3. What is the purpose of the air tube?
Air blows the part down the channel and into the tube.
4. What is the purpose of the blades?
To separate the bottom 2 tubes, allowing the bottom
tube to fall when ejected.
5. What is the most common cause of a loader jam?
Incorrect adjustment of the front tube height block.
This concludes the Tube Stacker
Loader Class
Training Seminar # TUBL-001
Revision A