BPM Microsystems, LP

1. BPM Microsystems, LP

2. TUBE STACKER FEEDER(Automated Tube Input) BP Microsystems Training Course # TUBF-001Rev. A

3. Teaching Method of the Course • Covers the fundamentals • More details in BPWin Help • 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 Feeder.

4. Tools Needed for the Course • Tube Stacker Feeder • Tubes of Devices • Feeder Tooling Kit to match Devices • SAE Hex Key Set (Allen wrenches)

5. Tube Stacker Feeder Training Chapters • Identification of parts • Installing and removing Feeder Tooling Kits • Loading Tubes in the Tube Feeder • Adjusting the Tube Feeder • Teaching the Tube Feeder • Clearing Jams • Tube Feeder Maintenance • Installing the Tube Feeder Option • Using BPWin Tube Stacker Control

6. Chapter 1Identification of Parts Training Seminar # TUBF-001 Revision A

7. Tube Stacker Feeder

8. Tube Stacker Feeder

9. Chapter 2Installing and Removing Feeder Tooling Kits Training Seminar # TUBF-001 Revision A

10. Install Feeder Tooling Kit • Remove/Replace the stop block. • Remove the pick point fiber optic cables from the guide rail(s) by pulling straight out. Do not damage the fiber optic cables by kinking or excessive flexing. • Remove the guide rail(s). Depending on the package, this could be two rails (left and right), or one wide rail with a single guide channel.) • Unlock an existing singulator by using the red T handle. • Disconnect the downstream plunger air line by pushing down on the connector and sliding the connector sleeve up. • Remove an existing singulator by lifting the nose up then sliding the assy down and out. • Install the new singulator by the reverse of step 6. • Make sure the singulator is seated correctly, then lock it into position with the red T handle. • Install the plunger air line by pushing the connector down onto the fitting until it locks. • Install the new rails with screws provided. Note that the shortest two screws are used at the front of the guide rails nearest the stop block. • Insert the fiber optic cables into the holes on either side of the guide rails. Gently push in until they stop.

11. Typical Feeder Tooling Kit

12. Standard Tooling Kits (Other kits available as Special Order)

13. Chapter 3Adjusting the Tube Feeder Training Seminar # TUBF-001 Revision A

14. There are four required adjustments to the Tube Stacker Feeder after changing tooling kits: • Adjust the Front Tube Guides for tube width. • Adjust the Rear Tube Guide Wings for tube width. • Adjust the Rear Tube Guide Assembly for tube length. • Adjust the Tube Spear for proper height.

15. 1. Adjust the Front Tube Guides for tube width. • Loosen the four (4) thumb screws on the front tube guides. • Place an empty tube between the front tube guides. (the tube is used as a gauge) • Center the tube on the singulator channel. • Slide the front tube guides to either side of the tube so that the lower end of the guides have 1mm gap between guide and tube, and the upper ends have a 2mm gap. See diagram on the next slide. • Tighten the thumb screws to lock the guides in position.

16. 1. Adjust the Front Tube Guides for tube width.

17. 1. Adjust the Front Tube Guides for tube width.

18. 1. Adjust the Front Tube Guides for tube width.

19. 1. Adjust the Front Tube Guides for tube width.

20. 2. Adjust the Rear Tube Guide Wings for tube width. • Note: The rear tube width guide wings are a friction • fit. You should be able to swing them into position • by hand. • Center the rear of the tube on the holding block in the rear tube guide assy. • Swing the rear tube width guide wings to each side of the tube leaving about 1mm gap on each side of the tube.

21. 2. Adjust the Rear Tube Guide Wings for tube width.

22. 2. Adjust the Rear Tube Guide Wings for tube width. Correct rear tube width adjustment.

23. 2. Adjust the Rear Tube Guide Wings for tube width.

24. 2. Adjust the Rear Tube Guide Wings for tube width.

25. 3. Adjust the Rear Tube Guide Assy for tube length. • Loosen either of the two thumb screws to release the connecting rod. • The rear tube guide assy with tube release mechanism can now slide along the main side rails. • Hold an empty tube in position, with the front end positioned correctly at the singulator. • Slide the rear tube guide assy to the tube so that there is about 2mm clearance between the rear end of the tube and the Ridge inside the guide wings. Refer to Fig A. • Position the connecting rod so that it does not interfere with the tube eject mechanism. • Tighten the thumb screw(s).

26. 3. Adjust the Rear Tube Guide Assy for tube length.

27. 4. Adjust the Tube Spear for proper height. • The purpose of the spear is to allow only the bottom empty tube to fall into the net. This is accomplished by adjusting the spear so that it will engage the second tube from the bottom when the tube eject mechanism activates. See figure A • NOTE: If a spear block is included in any tooling kit, use that spear block. • To access the adjustment screw, it is usually easier to remove the rear guide wing assembly. See figure B.

28. 4. Adjust the Tube Spear for proper height. Figure A

29. 4. Adjust the Tube Spear for proper height. Figure B

30. Chapter 4Loading Tubes in the Tube Feeder Training Seminar # TUBF-001 Revision A

31. Loading Tubes in the Tube Feeder • Remove the front tube stopper. • Place a finger over the open end of the tube. • Position the open end of the tube at the top of the front plate. • Remove your finger and slide the tube down between the front tube width guides. • Remove the rear stopper. Slide the tube down between the rear tube guides. • Devices should slide smoothly into the singulator. • Note that all tube stoppers are to be removed from all tubes loaded into the tube stacker feeder.

32. Chapter 5Teaching a Tube Feeder Training Seminar # TUBF-001 Revision A

33. Start BPWin software and allow the handler to initialize. In the Workflow window, locate the “Sources” box. Give the tape feeder teach a valid name. NOTE: The teach name must begin with TUBEEXPIN.

34. Go to the main window, menu selection AUTOHANDLER/ TEACH. Select the “TUBEEXPIN” name to bring up the Adjust Nozzle Position window.

35. Enter the number of devices per tube.

36. 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.

37. Chapter 6Clearing Jams Training Seminar # TUBF-001 Revision A

38. The majority of jams occur at the mouth of the singulator channel. The cause is poorly adjusted front tube width guides. Usually they are not centered on the channel or spaced too far apart to allow the tubes to become off-center. Readjust as necessary. • The result of a jam is that the stacker will drop a full or partial tube into the net.

39. Chapter 7Tube Feeder Maintenance Training Seminar # TUBF-001 Revision A

40. Tube Feeders require very little maintenance. • There are very few user serviceable parts • inside. BP Recommends: • Periodically clean the channel of the singulator. Disassemble the two halves of the singulator and polish the channel with a soft cloth. • Inspect the conveyor belt for cuts and excessive wear. • Defective tube feeders will need to be sent to • BPM Microsystems, LP for repair. Call technical • support for Assistance.

41. Training Seminar # TUBF-001 Revision A Chapter 8Installing the Tube Stacker Feeder Option

42. Important: Power the system down and observe ESD precautions when handling electronic circuit boards.

43. List of installation parts for Tube Feeder Option CTUBEFEEDERCEXP, Tube stacker feeder WAIRCNCT-UNIV, Universal air connection kit WSERIALTUBEFEED, SP Card, mounted CPLATUBEFEEDER, Mounting plate CCAB7FTPHONEBLK, Communication cable

45. Installation Procedure • Bolt the feeder mounting plate (CPLATUBEFEEDER) 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 feeder pick point for teaching. • Bolt the feeder to the mounting plate. • Feed the communication cables and air line to the nearest access hole on the table top. • Mount the serial peripheral board assembly (WSERIALTUBEFEED) to a secure location inside the machine. • Connect the feeder cables to the SP card. They only install one way. • Connect one end of the Telephone cable (CCAB7FTPHONEBLK) to J1 on the SP card, and the other end to any unused port on the Interface board (4x00) or backplane (3x00). • Use the contents of the air connector kit (WAIRCONECTCEFDR) to splice into a regulated compressed air line and tee in the air line from the feeder. • NOTE: Installation on a 4x00 system may require a different plexiglass safety panel (rear or side depending on location).

46. Chapter 9Using the BPWin Tube Stacker Control Training Seminar # TUBF-001 Revision A

47. Tube Stacker Diagnostics Window Usage Go to main menu Autohandler/Diagnostics/Tube Stacker Control. Select the Feeder button. This window will allow manual manipulation of the feeder. It will also monitor the state of the two sensors on the feeder. The use of this window is self explanatory.

48. Tube Stacker Diagnostics Window

49. Review Questions • What parts are included in a typical feeder tooling kit? • What is a valid name for a tube stacker feeder teach? • What is the purpose of the “spear”? • What is the most common cause of a feeder jam? Chapter 5: Turning On and Off

50. Review Answers • What parts are included in a typical feeder tooling kit? Singulator Assy, Guide Rails, Stop Block, Spear Block. • What is a valid name for a tube stacker feeder teach? TUBEEXPIN…. • What is the purpose of the “spear”? To keep all of the tubes from dropping at the same time. • What is the most common cause of a feeder jam? Front tube width guides not centering the tube on the channel.