FLUIDMOVE forWindows™ Installation & User Guide (For versions 2.7 or higher.
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Manual Conventions Labels Dispensing system buttons, labels, switches or connections appear in this text style. Buttons Fluidmove for Windows (FMW) buttons and dialog boxes appear in this text style. Menu Selections All menu selections within FMW appear in this text style. Commands Fluidmove for DOS (FMDOS) windows, menu selections, and commands appear in this text style. Glossary Terms The first occurrence of a glossary term appears underlined. The definition of the term occurs in the Glossary.
TABLE OF CONTENTS 1 GETTING STARTED....................................................................1-1 2 INSTALLATION.............................................................................2-1 The FMW Installation Package.......................................................2-1 Setting up the Dispensing System for FMW Installation ................2-2 Installation Procedure .....................................................................2-3 3 TOUR OF FLUIDMOVE.................................
Area Fill Encapsulation .................................................................. 8-21 Placing Patterns............................................................................. 8-23 9 ADVANCED PROGRAMMING.................................................. 9-1 Overview ........................................................................................ 9-1 Programming Tips ......................................................................... 9-1 Underfill Patterns........................
Table of Tables Table 6-1 Passwords and Operator Level.......................................6-4 Table 7 -1 Fiducial Ratings...........................................................
1 Getting Started Welcome to Fluidmove for Windows (FMW). FMW is a true Windows™ software package for automated fluid dispensing. In most cases, FMW should arrive already installed and configured for your dispensing system. If you should need to re-install FMW refer to the Installation section of this manual. The tutorials are designed to teach you specific programming techniques. The first lessons teach basic elements used to build more complex patterns.
2 Installation In most cases, FMW arrives already installed on and configured for your dispensing system from the Asymtek factory. The installation process is a typical Windows installation with user prompts. ? NOTE Refer to this section for a first time installation only. Upgraded versions of FMW include their own installation instructions. The FMW Installation Package The FMW Installation Kit contains, at a minimum, the following components. Please check that you have all of them.
Setting up the Dispensing System for FMW Installation Before you begin the installation procedure, make certain that your dispensing system is operational by following the checks below. Reference the dispensing system Operations Manual for the location of indicated components or options. 1. Make certain that the dispensing system is ON by looking for the following indications. > If a beacon is present, it should be ON and yellow or green.
Installation Procedure Most of the standard installation process is automated. You will be prompted to insert disks, approve file locations and accept defaults. Automatic backups are made for some files during installation. Since FMW is a true Windows software package, installing FMW follows standard Windows 3.X installation procedures. This procedure also includes installation instructions for FMWTools.
3 Tour of Fluidmove Overview This chapter tells you what tools and supplies you will need and guides you through basic dispensing system setup procedures. This chapter also provides a tour of the unique Windows Graphic User Interface (GUI) of FMW. Each window will be visited and explained in detail, along with all icons, toolbars and message areas. After reading this chapter, you will be ready to start the programming exercises.
Simplified Setup/Configuration Routines Dispensing systems are complex and must be calibrated with the process you are performing. In addition, process programmers require a different setup procedure than a production operator. FMW allows you to set up programming options and preferences such as measurement, workpiece alignment, fluid setup, operator and access levels from the Main Window.
User Interface You will find that the FMW user interface was designed to utilize the simplicity and intuitiveness of Windows-based software. Upon installation, FMW creates two program groups: FMW and CognexTM Vision Processor. Depending on the options installed on your dispensing system, one or two additional program groups are also created: one Video BlasterTM or two MatroxTM.
If your system configuration includes a Matrox card, the following additional program groups are created: Figure 3-3 The FMW program group, as shown in Figure 3-1, contains the FMW application, the Heater Control for Windows (HCW) application, the Dispense Out debugging application, a DOS Prompt icon and a ReadMe file. • HCW controls the heaters and cooling devices on equipped systems. • Dispense.Out opens a text file where all debugging information is recorded.
FMW Windows and Menus Tour Use the mouse or trackball to explore FMW while being guided on this tour of the menus. There are five major windows in FMW: • Main Window • Programming Window • Run Window • Production Window • Tools Window A secondary window called the Teach Window, which displays the camera image from the vision system, is accessed from the Programming Window. Submenus and options are in drop-down menus below main buttons in all windows.
è The first window shown is the Main Window described below. Main Window The Main Window buttons, Run a Program, Teach a Program, and Tools give access to those windows. Configuration activates the drop-down Configuration menu and cascading dialog boxes. SECS/GEM opens the SECS/GEM Setup Window if your FMW includes the SECS/GEM Interface option. Help accesses the On-line Help. Off-line Programming is a feature to be implemented in a future release. FMW is designed for use on a dedicated PC.
Configuration Menu è Click on Configuration in the Main Window to access the drop-down Configuration menu shown in Figure 3-5. This menu is used to configure program preferences, setup fluids, service stations, and system components prior to starting a programming session. Needle Setup, Setup Conveyor and Setup Dispenser have cascading menus as indicated by the [ ä]. All menu selections bring up other dialog boxes when you select the configuration options.
The Setup Parameters dialog box shown in Figure 3-6 opens. This dialog box allows you to identify and calibrate the Vision System, and set specific preferences for fiducial searches. Figure 3-6 è 3-8 Choose Cancel to exit the Setup Parameters dialog box.
Tools Window è In the Main Window, click on Tools. The Tools Window shown in Figure 3-7 has buttons that allow direct communication with the major components of the dispensing system, the Dispenser, the Conveyor, the Scale and the Heaters. Figure 3-7 è Tour of Fluidmove Click on Terminal to display the drop-down buttons shown in Figure 3-8.
Figure 3-8 Clicking on Dispenser, Conveyor or Scale will bring up a Terminal Mode window. In the Terminal Mode Window, you can type commands for the device. The Dispenser and Conveyor use Automove Control Language (ACL) commands and the Scale uses its own command language. For information on ACL or Scale commands, contact Asymtek Application Engineering. Heater accesses Heater Control for Windows. 3-10 è Click on Conveyor to see an example of the Terminal Mode window.
Figure 3-9 Dispenser and Conveyor, shown in Figure 3-9, are used to access the I/O Test dialog box. è Click on Dispenser to see the I/O Test dialog box. è Choose Cancel and return to the Tools Window. è Click on Main to return to the Main Window.
Programming Window The Programming Window is where all programming is performed. It has a large menu structure and many icons to simplify keystrokes. è To view the Programming Window, click on Teach a Program. Menu Bar Process Toolbar Program Name Text Box Pattern Name Text Box Dispensing Program Command Insertion Point Program Commands Toolbar Units Selected in Configuration Figure 3-10 There are two toolbars in the Programming Window. The icons and commands are identified below.
Process Toolbar The commands associated with each icon in the Process Toolbar are identified below. However, you will notice that FMW toolbars have Tool Tips. As you scroll the cursor over a button, a “tip” appears below the button, explaining the function. If a button appears greyedout, that means that the command is not available at this point in the programming session. The Wet/Dry Mode and Camera On/Off buttons are toggled to change between the two modes.
Program Commands Toolbar The commands associated with each icon in the Program Commands Toolbar are identified below.
Dispensing Element Toolbar An additional toolbar is available in the Teach Window. It is shown below. è To view this Toolbar, click on Dispensing Elements to open the Teach Window.
Programming Window Menu Bar The menu commands on the menu bar activate drop-down menus. Some drop-down menu selections go to dialog boxes. Menu selections and an explanation of the basic category of command are shown below. è Dispensing Program File Manipulation Commands Use the mouse or trackball and select one of the menu commands to see the drop-down menu.
Access to On-line Help and Program Information Commands for Viewing the Log File Displaying Preferences Run Commands for Doing a Sample Run of a Program Setup Commands for the Dispensing System and Control of Components Figure 3-15 Tour of Fluidmove 3-17
è Click Dispensing Elements on the Program Commands Toolbar to open a Teach Window. Teach Window The Teach Window includes a message area with instructions for the user, a camera video display of the dispensing area, teach command buttons for teaching locations, X-Y-Z Position Controls for moving the dispensing head, and a dialog box section that changes depending on the selected dispensing command. The appearance of the Teach Window varies depending on the task you are performing.
Instructions to the User Teach Command Buttons Dispensing Elements Toolbar Video Display X-Y-Z Position Controls Dialog Box Area Varies with Commands Target Box for “click and move” Position Control Figure 3-17 You can use the X-Y-Z Position Controls in the Teach Window, as shown in Figure 3-17, using a mouse or trackball, or you can use the Position Controls on the Dispenser Control Panel to move the dispensing head around the dispensing area.
è Now, click on a location in the Target Box. The crosshairs and the dispensing head move to the new location. The dispensing head will move to the new location. è To exit the Teach Window, click Cancel. è To exit the Programming Window and return to the Main Window, click the menu bar. è In the Main Window, click on Run a Program. on Production Window The Production Window is primarily used by production operators during daily production runs.
Fluidmove Files are FileName.fmw Figure 3-19 When you write a program in FMW, the file is stored as a .fmw file on the hard drive of the computer or to a specified network drive. The last file saved is automatically loaded upon FMW startup. Alternatively, a new file is selected from the list as shown in Figure 3-19. Fluid files, used to define the dispensing fluid characteristics, are attached to the program you choose to run.
Setup Routine with on-screen prompts for each item that needs to be setup prior to a production run Options for setting up individual items prior to a run. Options vary depending on Operator Level. Figure 3-20 Most of the time the operator will choose Prompted Setup to run a program. On-screen prompts cue the user for setup steps such as changing the needle or syringe. Customized, scripted Prompted Setup routines can also be created. This will be demonstrated in a tutorial later in this manual.
Starts the Run and Goes to the Run Window Controlled Run Commands Figure 3-21 è Tour of Fluidmove Click on Run Production to access the Run Window.
Run Window This window contains system controls for starting, stopping or pausing the run and access to the SECS/GEM interface control. All fluid information entered from the Setup Fluid dialog box from the Configuration menu is shown in this window along with real-time fluid statistics such as a running timer of the pot life and thaw time since the beginning of the run. The Run Window shows the run statistics such as number of boards, run-time and failure counts.
SECS/GEM Interface If you have the SECS/GEM Interface Option, refer to Chapter 5 – SECS/GEM Interface to tour the windows of the SECS/GEM Interface. For SECS/GEM Interface programming information, refer to the SECS/GEM Interface Option Reference Manual.
4 Heater Control for Windows Heater Control for Windows (HCW) is an accessory application that allows the user to directly control dispensing system heaters, needle heaters, fluid cooling and temperature sensing devices. This chapter explores the user interface of HCW and teaches you how to set up the configurable options. Most settings are set at the Asymtek factory at the time of shipment and usually do not need to be changed.
This window is used as a quick-check for viewing Set Points and Present Value. Later in this chapter, you will learn how to set these options. This dialog box shows the model number of the controller and the version of the firmware. These lists show the Mode, Set Point (SP) temperature, Present Value (PV), Units and status of each available loop. These buttons are used to upload and download heater files, save current settings and start the Alarm Acknowledgements.
Each loop has a dialog box which shows its settings under the Main tab. Figure 4-2 shows the Main tab dialog box and the tabs to access more dialog boxes. In the Main dialog box, you set the temperature with Set Point. The Output Value is the percentage of the heater’s total capacity that is being used to achieve or maintain the Set Point. Auto Mode regulates the loop temperature automatically.
Figure 4-3 The Run Time dialog box shown in Figure 4-3 shows the parameters for configuring heater behavior during production runs. The heaters can be turned off or turned down during fiducial searches. Heater temperature can also be verified before dispensing begins. • 4-4 From the Run Time tab, select the Heat Control tab.
Figure 4-4 The Heat Control dialog box shown in Figure 4-4 shows control parameters that are used to define the heating process for your specific system. All values in this dialog box should be set at the Asymtek factory prior to shipping and should not be changed by the user. For more information, consult the Anafaze User’s Guide. • Next, select the Input tab.
Figure 4-5 The Input dialog box in Figure 4-5 is used to define the input types for each loop. Unused loops which do not have heaters attached are defined as “skipped”. Also, any process offsets to make up for signal inaccuracy are set here. All settings in this dialog box are set for each loop in your system at the Asymtek factory prior to shipping. Input Reading Offset can be used to make up for a calibration offset.
Figure 4-6 Figure 4-6 shows the Output dialog box which is used to define the type of output the controller uses for the heating process and specific parameters for the output type. All settings in this dialog box are set for each loop in your system at the Asymtek factory prior to shipping. The Type of output mostly used for the dispensing system heaters is Time Proportioning (TP). In this Type, the percent output is converted to a percent duty cycle on the programmed cycle time.
Figure 4-7 The Alarm dialog box shown in Figure 4-7 is used to setup the process alarms. The alarms can be set for each loop. The alarms identify and notify the user of changes and deviations from the temperature Set Point. Process alarms can be set to notify the operator and/or control the output in the event of deviations from the Set Point. Figure 4-8 shows the activation and deactivation points. There are four alarm types: High Process, Low Process, High Deviation and Low Deviation.
Heater Control for Windows 4-9
High process alarm on High process alarm off High alarm limit } Deadband High deviation alarm on SP + Deviation } Deadband High deviation alarm off Setpoint Low deviation alarm off } Deadband SP - Deviation Low deviation alarm on } Deadband Low alarm limit Low process alarm on Low process alarm off Figure 4-8 4-10 Heater Control for Windows
5 SECS/GEM Interface FMW can be configured to interface with a GEM system. This is a factory-set option. Your version of FMW might not have a SECS/GEM interface option. If it does not, your SECS/GEM interface button on the Main Screen will be grayed and disabled. Below is a description and tour of the user interface for the SECS/GEM option. It is intended as an Operator Guide.
2. Click on the Terminal tab and refer to Figure 5 -2. Figure 5 -2 > 3. This tab is used to acknowledge and send messages to and from the host. Click on the Setup Tab and refer to Figure 5 -3. > This tab is used to setup the default Communication State, Control State, message and communication handling.
4. Click on the Communication Tab and refer to Figure 5 -4. > This tab is used to establish addresses for the host and the device. > Changes in this dialog box require exiting and restarting FMW in order for the changes to take effect. Figure 5 -4 5. Click on Cancel to return to the Main Window. 6. In the FMW Main Window, click on Run a Program. 7. In the Production Window, click on Run. 8. Click on Run Production to go the Run Window. 9. Click on the SECS/GEM Tab and refer to Figure 5 -5.
Figure 5 -5 10. Click on Return to return to the Production Window. 11. Click on Main to return to the Main Window. This concludes the tour of the SECS/GEM interface user interface.
6 Setup and Configuration This chapter guides you through basic configuration and setup routines. There are six types of configuration and setup routines in FMW: System Configuration, Preferences, Initial Setup, Programming Setup, Prompted Setup and Manual Setup. System Configuration is done outside of FMW using FMWTools, a utility software included in the FMW software kit. Preferences can be changed at any time within FMW.
To configure the dispensing system: 1. Close all open programs, including FMW. 2. In the FMW program group, locate the FMWTools icon . 3. Open FMWTools by double clicking on the icon. > FMWTools has three levels of operation, Service Mode, Diagnostic Mode, and Production Mode. To fully configure the dispensing system, you must have access to the Service Mode. Contact Asymtek Technical Support for more information. 4. In the FMWTools Main Window, click on Configuration Wizard. 5.
Preferences User Preferences for FMW are located on the Configuration menu in the FMW Main Window. The list below identifies the customizable preferences available. You may change these preferences at any time. Use (inches, mm or machine units) All measurements in FMW will be displayed in your choice of units. Change Operator Level FMW limits access to menus by use of this option. This option works in conjunction with Setup Password.
Default passwords for each level are shown in Table 6-1 below. To setup passwords: 1. In the FMW Main Window, click on Configuration. 2. Select Setup Password from the Configuration menu. 3. Enable the Service option, and type in an old password (if previously password protected) and type in a new password in the appropriate text boxes. TIP 4. Passwords must be selected for the service and System levels of operation. Passwords can be up to 8 characters long.
Event Logging It is a good idea to enable Event Logging so that you can check how your programs have executed. Event Logging is a useful tool for troubleshooting. An Event Log file is stored by date in c:\fmw\log\.log. To read the current file, select View from the Programming Window menu and then select Log File. ? NOTE You must remember to “clean out” the Event Log directory regularly, otherwise it will fill up the hard disk. Use File Manager to remove old files. To setup Event Logging 1.
Initial Setup Your system is initially configured and setup by an Asymtek representative. However, it may be necessary or desirable to repeat some of the configuration routines to insure programming accuracy. ? NOTE Initial Setup is not equivalent to a complete system re-installation configuration and setup procedure. If your system requires re-installation, please call Asymtek for assistance.
Vision System Setup If the Vision System has not been calibrated since FMW was initially installed, you will receive a notice when FMW starts, indicating that the Vision System has not been calibrated. If the camera or any part of the vision system has been changed or upgraded, the Vision System will need to be re-calibrated. It is also a good troubleshooting routine to perform if you are having trouble identifying fiducials, corners or see an accuracy problem. To start Camera Calibration: 1.
5. 6. Click on Next. > FMW checks the fiducial location by offsetting the camera in all four directions along the X and Y axis, and relocating the fiducial. This ensures that the number of pixels moved within the video display window is properly calibrated to the number of mils the X and Y motors must move to find the same location in the dispensing area. > When this process is complete, an X,Y value is displayed in the Instructions area at the top of the Teach Window.
Figure 6-4 9. Click on Help for complete details on the reticles option. 10. Click on Done when complete. This concludes the tutorial on Vision Setup.
Height Sensor The Height Sensor Configuration window allows the operator to establish parameters such as speed and distance for raising and lowering the dispensing head. The window is divided into two sections: Mode and Parameters. Mode If your dispensing system is equipped with a Height Sensor, you will have two options in this dialogue box: Height sense always and Height sense on command.
Parameters Down Speed The rate in inches per second that the dispensing head descends to the point where dispensing begins. Up Speed The rate in inches per second that the dispensing head will go up after each dispense. Acceleration The rate at which the dispensing head goes from being stopped to reaching either the designated Down Speed or Up Speed. Max. Search Distance substrate Establishes a maximum distance that the dispensing head descends from absolute zero when searching for the surface.
7. Lower the dispensing head until the needle is at the desired dispensing height. > All subsequent dispensing operations will be performed at this height, including dot and line parameter settings, except for ZFast dots. 8. Click on Next. 9. Follow the on-screen prompts for adjusting the probe height. 10. Click on Next. 11. Click on Done. To perform Setup for No Height sense Mode (all three options): 1. Load a board or part into the dispensing area, if one is not already present. ? NOTE 2.
Calculate Master Offsets This screen-prompted routine identifies and records a Safe-Z Height for dispensing head travel, the XYZ locations of the Purge Station and Weigh Station, Needle and the substrate height. It also calibrates the camera-to-needle and probe-to-needle offsets. This routine is performed when the dispensing system is initially installed and configured. Those values and settings are recorded.
To perform a Calculate Master Offsets procedure: Follow all on-screen prompts. 1. In the Main Window, click on Configuration. 2. Click on Needle Setup, and select Setup Parameters. > The Needle Setup Parameters dialog box opens. See Figure 6-5. Figure 6-5 3. Select Calculate Master Offsets in the Machine Setup Process section of the dialog box.
> 6. A Teach Window opens asking you to clear the work area. Make sure that the work area is clear and free of any obstacles so the dispensing head does not collide with anything when it moves. The dispensing head will move after your response. 7. Click on Next. > 8. Check to make sure that the Height Sensor probe tip is lower than the needle tip as shown in the on-screen prompt. > 9. If you are not using a Height Sensor, skip to Step 9.
21. Use the Position Controls to move the dispensing head to the Purge Station location. 22. Activate the Z-axis controls and lower the dispensing head until the needle tip is flush with the Purge Station boot. 23. Click on Teach. The dispensing head will move after your response. 24. Do one of the following, depending on the type of Needle Sensor installed on your system: a.
29. Click on Next. 30. Select a dot style in the box below the video display. > Consult the on-line help for assistance, if necessary. 31. Click on Next. 32. Answer “Yes” if you are asked if you want to re-teach the reference dots. 33. Use the Position Controls to center the needle tip over the first simulation dot as shown in the on-screen prompt. 34. Click on Teach. 35. Repeat the previous 2 steps for the other three dots.
Valve Offsets This screen-prompted routine identifies and records a Safe-Z Height for dispensing head travel, the XYZ locations of the Purge Station and Weigh Station, Needle and the substrate height. It also calibrates the camera-to-needle and needle-to-probe offsets. This routine is performed when the dispensing system is initially installed and configured. Those values and settings are recorded. You can run this routine again at any time to insure dispensing accuracy or reflect hardware or changes.
To perform a Valve Offsets procedure: 1. In the FMW Main Window, click on Configuration. 2. Click on Needle Setup, and select Setup Parameters. 3. In the Setup Parameters dialog box, shown in Figure 6-5, select Valve Offsets in the Machine Setup Process section of the dialog box. 4. Click on OK. ? NOTE If you are changing from Calculate Master Offsets to Valve Offsets, it is recommended that you exit FMW and restart FMW before continuing this procedure. 5.
6. Click on Run next to 1. Teach Purge Location. The dispensing head will move after your response. > The dispensing head Finds Home, then moves to the Purge Station location. A Teach Window opens. 7. Use the Position Controls to align the needle tip to the purge boot opening at the Purge Station. 8. Activate the Z-axis controls and lower the needle tip into the purge boot. 9. Click on Teach. 10. Click on Done. > The Teach Window closes and you return to the Setup dialog box.
> For dual pumps without Height Sensor (Calculate Valve2 to Valve1 Z Offset), perform the following procedure. a. Click on Run next to 3. Calculate Valve2 to Valve1 Z Offset. Don’t worry about selecting Valve1 or Valve2 in the radio box. Either pump can function as the basis for the calculation. A Teach window opens. b. Activate the Z-axis controls. c. Lower the dispensing head until the needle tip on Valve1 just touches the white circle on the dispensing surface. d. Click on Teach. A Teach window opens.
22. Use the Position Controls to align the needle tip with the same circle or with the Load Cell, depending on your type of Needle Sensor. > For NSZ Series Needle Sensor, DO NOT TOUCH THE LOAD CELL with the needle tip. Center the needle tip over the Load Cell. > For NS Series Needle Sensor, TOUCH THE NEEDLE TIP TO THE SUBSTRATE. 23. Click on Teach. The dispensing head will move after your response. > The dispensing head automatically performs a height sense. 24. Click on Done to accept the results.
34. Use the Position Controls to center the Height Sensor over the first dot location. 35. Click on Teach. 36. Answer “Yes” if you are asked if you want to re-teach the reference dots. > Notice the Enable Verification Step in the bottom of the Teach Window. Enabling this feature activates a distance tolerance for later testing the needleto-camera offset. Refer to the on-line help for more information. 37.
49. Click on Done to accept the results. > The Teach Window closes and you return to the Setup dialog box. Notice that the box next to number 6 now has an X in it to indicate that Step 6 has been completed. ? NOTE If your dispensing system is equipped with a dual action dispensing head, you must also perform a complete Valve Offsets for the second valve. 50. Click on Done. This concludes the tutorial on Valve Offsets.
Programming Setup Before you begin programming sessions, it is recommended that you perform a Prompted Setup procedure in addition to the Calculate Master Offsets or Valve Offsets procedure. Also, before creating a dispensing program, you should visit the Configuration menu to setup your workpiece and fluid file, which is used to keep track of fluid characteristics and statistics. Fluid Files Fluid files record information about the dispensing fluids used in your programs.
To setup a fluid file: 1. In the FMW Main Window, click on Configuration. 2. Select Setup Fluid Manager. > The Fluid Manager dialog box, shown in Figure 6-7, opens. Figure 6-7 3. Consult the On-line Help for detailed instructions. This concludes the tutorial on fluid files.
Sample Programming Setup The following exercise will take you through a recommended programming setup. As you become more familiar with your system, you may want to modify this routine. This routine includes: • Loading a board • Creating a new file • Attaching a fluid file • Teaching Workpiece alignment • Teaching Workpiece fiducials ? NOTE You will need to have the Tutorial Board handy for this part of the exercise.
y-axis Dispensing System Workpiece y-axis Defined pojnts along Workpiece x-axis Workpiece x-axis Dispensing System Origin of Workpiece (0,0) Workpiece Angle Dispensing System Home Position Workpiece x-axis Figure 6-8 5. Click on Configuration. 6. From the Configuration menu, select Setup Fluid Manager to open the Fluid Manager dialog box, shown in Figure 6-7. 7. Enter the information on the fluid you will be using for this tutorial (Hysol 4510 or equivalent). 8.
13. Place the Tutorial Board as follows, depending on the type of dispensing system you have: A. For systems equipped with a conveyor, set the Tutorial Board (Side 1) at the mouth of the conveyor. Use the dispensing system Conveyor Controls to set the proper width. Choose Manual Load Board from the Run menu. The board is loaded into the dispensing area. The clamps should push the board up to the bottom of the rail slot. > B.
24. Select Model Finder. 25. Click on Next. > Teach the first fiducial in the same location where you taught the origin. > If the dot does not fit entirely inside of the square overlay in the video display, you will need to adjust the size of the Model Window. Notice the Model Size Width and Height text boxes in the area below the video display. 26. Click on the up arrows next to the Width and Height text boxes to adjust the size of the Model Window until the square is larger than the dot. 27.
Prompted Setup Prompted Setup is generally the most frequently used setup procedure. It should be performed prior to all production runs, after changing the needle or valve, and if you are experiencing inaccurate dispensing. ? NOTE If you have a DP-2000 Dispensing Pump installed on your system, you will need to use FMWTools to configure your dispensing system for the DP-2000 before running a Prompted Setup. Please contact Asymtek Technical Support for more information.
Figure 6-9 3. Select Non-Scripted Prompted Setup. > Scripted Prompted Setup is described below in the next section. 4. Click on OK. 5. In the Main Window, click on Run a Program. 6. From the Production Window, click on Setup, then click on Prompted Setup. > A Teach Window opens. 7. Make sure that the dispensing area is clear of obstacles. 8. Click on Next to continue. The dispensing head will move after your response. > The dispensing head Finds Home and moves to an area behind the service stations.
> If no suction is detected, contact Asymtek Technical Support. 17. Click on Next. > The Operator Name dialog box opens. 18. Type in your name. 19. Click on Next. > A dialog box opens asking if you intend to install a new syringe. If you answer “Yes”, proceed to the next step. If you answer “No”, skip to Step 27. 20. Fill in all of the requested fluid information. > Consult the documentation that is packaged with the fluid for Thaw Time and Lot Number information. 21.
Scripted Prompted Setup Prompted Setup can be tailored into a Scripted Prompted Setup to meet your specific setup requirements. FMW includes several pre-programmed valve-specific scripted setup procedures that can be used for production run setup, or you can create your own script. ? NOTE For information on creating your own scripted prompted setup, refer to the On-line Help. To perform a scripted Prompted Setup: 1. In the FMW Main Window, click on Configuration. 2.
Figure 6-10 8. Follow the on-screen prompts. Consult the On-line Help for assistance, if necessary. > Each step must be performed in the order that it is listed. > Scripted Prompted Setup allows you to run each step of the procedure one step at a time, or from start to finish. > Scripted Prompted Setup is also capable of running customized script files. Consult the On-line Help for more information.
Manual Setup There are several manual operations that you can perform at any time. These are listed in Manual Setup. To view the Manual Setup options: 1. From the Main Window, click on Run a Program. 2. Click on Setup. 3. Note the setup options listed in the drop-down menu. > Any of the setup options can be performed individually by double clicking on the option name. This concludes the tutorial on Manual Setup.
7 Programming Basics Overview This chapter introduces the fundamentals of developing dispensing programs in FMW. These skills prepare you for more complex programming in the next two chapters. It is essential to be familiar with the tools you will use to program, such as the Vision System software. This chapter explains the use of Model Fiducial Finder and Corner Finder in the Vision System. You will be taught basic tips on how to define and recognize good fiducials and how to set up for edge detection.
For example, the first level of a multipass underfill program might look like this in FMW: The first line of the program is a Purge command. The dispensing head will move to the Purge Station and purge the vale for two seconds. The second command and the 11th command form a multipass loop, which means that commands 3-10 will execute in order a defined number of times, in this case twice, as defined in line 2.
Building a Program in FMW It is important to learn how to build programs in FMW. Complex multipass dispensing programs are built by first defining patterns, then adding those patterns to the whole workpiece. When building programs, it is important to keep in mind that you want to develop the fastest method of dispensing in order to maximize production throughput. You gain this efficiency by constructing the patterns and adding them to the program in the most time-effective manner.
Look at the following program instructions in Figure 7 -1. Specific pattern program lines are displayed separately. Only the instructions for the currently selected pattern are displayed in the programming screen. As shown, the currently selected pattern is Workpiece. The instructions for Workpiece shown in the programming screen are function calls to a sub-pattern called Chip 1. To display the instructions for Chip 1, you would select Chip 1 from the Pattern Name Text Box.
The Vision System An essential component of the programming and production process of fluid dispensing is the Vision System. The Vision System hardware consists of a camera, light source, Cognex Vision Processor and video board. The software portion includes Fluidmove for Windows (FMW) which controls all programming and dispensing functions and uses the Asymtek Vision for Windows (AVW) library in conjunction with Cognex software to perform fiducial location and edge detection functions.
Figure 7 -2 7-6 Programming Basics
Fiducial Detection The Vision System has three tools or methods to find fiducials as described below. The exercises that follow will teach you how to use these tools. The first exercise will use the Model Finder method to define Workpiece fiducials. The second exercise will use the Corner Finder method to define a pattern fiducial. Defining Workpiece and pattern fiducials are the crucial first steps to creating any dispensing program.
Table 7 -1 Shape Fiducial Ratings Characteristics £ donut Excellent. Immune to rotation. Inner and outer diameters allow for further definition. # pound Good. Uniqueness maintained under rotations. l circle Good. Immune to rotations. m hole/gap Poor. Requires machining accuracy to match definition. Not repeatable between different workpieces. : cross Poor. Single axis identification does not allow for poor quality printing of the shape.
Metal Dot Fiducial Search Window Outer Contrast Ring Model Window Metal Dot Fiducial on Dark Background Donut Fiducial with High Contrast Background Shaped Fiducial Pattern Figure 7 -3 Programming Basics 7-9
To teach a model fiducial: 1. In the FMW Main Window, click on Teach a Program. 2. Load the Tutorial Board (Side 1) as follows, depending on the type of material handling option your system has: A. For systems equipped with conveyors, set the Tutorial Board (Side 1) at the mouth of the conveyor. Use the dispensing system Conveyor Controls to set the proper width. Choose Manual Load Board from the Setup menu or click on the Load Board icon. > The board will be loaded into the dispensing area.
> Notice the choices for fiducial finding offered below the video display window. 15. Select the Model Finder method. 16. Click on Next. > Notice the white-lined box in the video display window. This is the Model Window, the area which will be defined as the fiducial. > For our first fiducial, we are going to use the same dot we used to define the workpiece origin. 17. Using the Position Controls, align the camera crosshairs with the center of the dot. 18.
> 7-12 “Check for location tolerances” means that FMW will check the found location of the fiducial and compare it to the location where it expected to find it. If the difference between the two locations is greater than the Location Tolerance, FMW will consider the fiducial to be “Not Found.” This ensures that an incorrect fiducial is not considered to be a correct fiducial, and prevents dispensing on parts that are too far away from their expected locations.
22. Click on the Image tab. > Read the TIP section on “Gain” below. TIP Gain The Gain controls the way digital values are assigned to the analog signal from the camera. Lower Gain values will increase the contrast of the image and may help to differentiate the fiducial from the background. However, a low Gain value may also amplify “noise” in the image. Therefore, it is recommended that you first adjust the light level, then adjust the Gain only if necessary. The default value of the Gain is 255. 23.
Corner Fiducials Corner Finder is an alternate method provided by the Asymtek Vision System to identify fiducials that are part edges or lines or edge pairs, such as the edge of a die. In some cases accuracy is greatly improved by identifying the part to be dispensed on as a fiducial. The position of parts can be slightly rotated by automatic placement systems, or the parts can be dislodged during the solder reflow process.
Read the TIP section “Light Level” below. TIP Light Level The Light Level controls brightness of the LED or fiber optic lights directly. The vision system can have one or two light sources. For finding the corner of a die on a board, one light source may be better at casting the proper shadow onto the board and producing the high contrast which is most easily recognized by the Vision System. Light Level can be varied from 0 - 15.
When using a single fiducial with Orthogonality Tolerance, FMW calculates the angle of the corner defined by the calipers. If the corner is within the Orthogonality Tolerance, the part is considered square and dispensing on the part will be performed. For example, if the Orthogonality Tolerance is set at 5, and the corner fiducial is determined to be 85-95 degrees, FMW considers the part to be square.
? NOTE You should first perform the preceding tutorial on Model Fiducials before performing the following exercise. To use Corner Finder to locate an edge: 1. In the Programming Window, click on Pattern on the Program Commands toolbar. 2. Select Create Pattern. > The Create Pattern dialog box opens. 3. Type Sample in the text box and choose One fiducial. 4. Click on OK. > A Teach Window opens asking you to define the pattern origin. 5.
TIP Caliper Sizing The Search Length should be optimized so that it contains only one gray value transition (light to dark, dark to light). A longer Caliper increases the range for finding the corner, but also increases the chances for finding the wrong corner. Projection Length controls the averaging for the transition amplification. A wider Caliper is better for rough edges or eliminating noise caused by traces on the board. Thinner calipers are more immune to rotated parts.
Editing Fiducials You can edit fiducials defined for your workpiece at any time. You may want to edit fiducials if the system fails to find too many of them during production runs. The procedure below is a reference procedure. Do not perform it now. To edit fiducials: Using Model Finder 1. Load the workpiece board. 2. In the Programming Window, make sure that the name of the pattern containing the fiducials you wish to edit appears in the Pattern Name text box. 3.
8 Beginning Programming Overview This chapter introduces you to the fundamental dispensing commands and patterns that form the foundation of all dispensing applications. You will learn how to create basic dispensing patterns. Later in this chapter, you will learn how to place those patterns at multiple locations on the same workpiece. It is essential for you to develop the basic programming skills in this chapter. These skills will be further developed in the next chapter, “Advanced Programming”.
Lines Lines are a common dispensing element for flip chip underfill applications. Weight control lines, which are lines whose fluid weight can be user-defined, are often used in that application. In this exercise, you will learn how to program and dispense simple lines. Afterwards you will learn how to edit the lines. Weight control lines are treated separately in the next section. Estimated time to complete: 45 minutes.
> 9. A Teach Window opens. Choose Line from the Dispensing Elements toolbar in the Teach Window. 10. Use the Position Controls to move the crosshairs to the starting point of the first line in the ULHC on the Tutorial Board. 11. Click on Teach. 12. Use the Position Controls to move the crosshairs across the line to the endpoint. 13. Click on Teach. 14. Click on Done. > In the Program Window, you should see the following: X1,Y1 Coordinates of Line 1 Start Point 1 Line 1, Start: (12.264, 10.
16. In the Programming Window, click on Run and select Dry Run. The dispensing head will move after your response. > Watch the video display as the dispensing head performs the programmed commands. The camera will act as the needle and follow the lines, but no dispensing will be performed. If the lines were “dry dispensed” at an incorrect angle, you may need to reprogram the origin of the board and workpiece angle. Unfortunately, this means you will need to start over defining this program. 17.
Editing the Lines If you were not satisfied with the lines dispensed, you can simply edit them. This exercise will teach you how to edit existing lines in a program. For this exercise, you will shift the lines over and shorten them. To edit the lines (shift them over and shorten): 1. From the Edit menu in the Programming Window, select Edit Pattern. 2. Click on Workpiece. The dispensing head will move after your response. 3. Place the cursor on 1 LINE in the program and double-click.
Weight Control Lines Most lines for flip chip underfill applications are weight control lines. These are lines where the programmer has greater control over specific characteristics of the line. A defined amount (weight) of fluid is dispensed over a defined length of line or pattern. Estimated time to complete: 45 minutes. To view the customizable parameters for weight control lines: 1. In the Programming Window, click on Edit and select Edit Line Parameters. > 2.
Pre-Move Delay Factor Some fluids have a high viscosity which means that they do not dispense as quickly as lower viscosity fluids. The Pre-Move Delay Factor increases the time that the dispensing head is parked with the valve ON, prior to a programmed move. The delay at the beginning position insures that a full line is dispensed. The units are seconds. Typically, 50 ms (0.050 sec) is sufficient for most underfill fluids.
Backtrack Length This is the horizontal distance that the dispensing head moves back over the dispensed line after raising up the Backtrack Gap distance. This encourages congealed fluids to detach and distributes any excess fluid back across the line. The units are inches. Typically, 30 - 40 mils (0.030 - 0.040 in) is sufficient. Backtrack Speed This is the speed that the dispensing head travels when moving along the Backtrack Length. The units are inches/second. Typically, 2 in/sec is sufficient.
To program weight control lines: 1. 2. Perform the Programming Setup in Chapter 6 - Setup and Configuration. > Load Side 1 of the Tutorial Board. > When you create the Workpiece, define the Workpiece Alignment. > Choose No Fiducials. Click on Dispensing Elements on the Program Commands toolbar. > 3. A Teach Window opens. Click on Weight Control Lines. > Notice, as shown in Figure 8-3, that the Teach Window has additional text boxes below the video display specifically for weight control lines.
5. Move the camera crosshairs to the beginning of the top weight control line on Side 1 of the Tutorial Board. 6. Click on Teach. 7. Move the camera crosshairs to the end of the line. 8. Click on Teach. 9. Click on Done. > A message box opens, indicating the calculated line speed for the newly created weight control line. 10. Click on OK. > The Workpiece Pattern program should look like this: Weight of Line 1 WEIGHT CONTROL: 20.000, 1,... 2 END Line Style 11.
24. Click on OK. 25. In the Programming Window, select Edit Line Parameters from the Edit menu to open the Line Parameters dialog box. 26. Set the Line Parameters for Line Type 1 to: Pre-Move Delay Factor: 0.1 Shut-off Distance: 0.010 Dispense Gap: 0.015 Speed: (not used for weight control lines) Dwell: 0.0 Retract Distance: 0.100 Backtrack Gap: 0.050 Backtrack Length: 0.040 Backtrack Speed: 2 Down Speed: 2 Down Acceleration: 300 Retract Speed: 2 Retract Acceleration: 300 Suckback: 0.000 27. Click on Save.
Dots FMW can dispense precision dots as well as lines. Dots are used in surface mount adhesive (SMA) applications. For this exercise, use the valve conditioning fluid. The conditioning fluid simulates the characteristics of SMA fluids. The size of the dots and characteristics of the dispensing are controlled by Dot Parameters in the Edit Dot Parameters. You will learn how to program and dispense dots on the workpiece. Next, you will learn how to alter the size of the dots and re-perform the dispense.
Mid-Move 1 and Mid-Move 2 These parameters are advanced dot parameters used for special applications and testing. For more information, contact Asymtek Application Engineering. Down Speed The Down Speed is how fast the dispensing head lowers to dispense. Low viscosity fluids tend to drip and you may want to set this parameter to a high value. The higher the value, the faster the dispensing head will move. Height sense accuracy is dependent on Down Speed and Down Acceleration.
Retract Acceleration This is the parameter that controls how fast the dispensing head comes up to the Retract Speed. You may need to set this high for small dispensing moves. The units are inches/second squared. Typically, 300 in/sec2 is sufficient. Retract Distance This is a vertical distance that the dispensing head moves after dispensing. The Retract Distance must be within the Safe-Z Height defined in Initial Setup. The Retract Distance can be reduced to increase dispensing speed.
To program dots: 1. Perform the Programming Setup in Chapter 6 - Setup and Configuration. > Load Side 1 of the Tutorial Board. > When you create the Workpiece, define the Workpiece Alignment. > Choose No Fiducials. 2. Click on Dispensing Elements from the Program Commands toolbar. 3. Select Dot from the Dispensing Elements toolbar. 4. Use the Position Controls to move the crosshairs to the center of the dot in the ULHC of the first Dots Square on the Tutorial Board. 5. Click on Teach. 6.
12. Select Edit Dot Parameters from the Edit menu. 13. For an approximate 30 mil dot, set the Dot Parameters for Type 1 to: Valve-On Time: Dwell Time: Dispense Gap: Down Speed: Down Acceleration: Settling Time: Number of Shots: Retract Speed: Retract Acceleration: Retract Distance: Suckback: PostDwell 0.070 sec 0.030 sec 0.015 in 2 in/sec 300 in/sec2 0 1 3 in/sec 300 in/sec2 0.250 in 0.000 0.00 14. Move the cursor to Type 2 in the Dot Parameters dialog box. 15. Set the Dot Parameter Valve-On Time to 0.
ZFast Mode ZFast is an option that allows fluid to begin flowing through the pump as soon as the dispensing head begins moving to the dispensing location within the Z-axis. Once the dispensing head reaches the dispense height, the pump remains on until the dot is completed. This feature is applicable only to dots and is not functional in Height Sense Always mode. To activate the ZFast mode: 1. In the Programming window, place the cursor on the command before which the ZFast command should appear. 2.
Arcs There are two available methods for teaching an arc, Start, Middle, End (SME) and Center. Refer to Figure 8-4 below. The SME method asks you to teach a starting point for your arc, a middle point, and an end point. The three points are treated like a part of a circle and the arc will be dispensed along the three points accordingly. The Center method asks you to teach a starting point on the arc followed by a center point.
To program arcs: 1. Perform the Programming Setup in Chapter 6 - Setup and Configuration. > Load Side 1 of the Tutorial Board. > When you create the Workpiece, define the Workpiece Alignment. > Choose No Fiducials. 2. Click on Dispensing Elements from the Program Commands toolbar. 3. Click on Arc on the Dispensing Elements toolbar. 4. Select the method (SME or Center) for teaching the arc. 5. Use the Position Controls to move the dispensing head to the arc start point. 6. Click on Teach. 7.
Circles There are two available methods for teaching a circle, Start, Middle, End (SME) and Center. The SME method asks you to teach a starting point for your circle, a middle point, and an end point. The three points are treated like points along the circumference of the circle and the circle will be dispensed along the three points accordingly. The Start and End points may be the same point, but it is not necessary to program the circle in that manner.
9. Use the Position Controls to move the dispensing head to the circle end point. 10. Click on Teach. 11. Click on Done. 12. In the Programming Window, select Dry Run from the Run menu. > Watch to see the camera trace the path of the circle. The dispensing head will move after your response. 13. Select Wet Run from the Run menu. > Watch as the circle is dispensed. > Examine the board for quality and accuracy. This concludes the tutorial on Arcs.
Area Fill Encapsulation Area Fill dispensing is used to encapsulate a part on a board. It is important for the fluid to cover the part completely without voids. The process by which the fluid is dispensed should be fine-tuned for best results. Area Fills can also be dispensed using Weight Control. In that case, a defined weight of fluid is dispensed in the Area Fill. If Weight Control is not used, the Line Parameters for the selected Line Type are used.
9. Click on Done. 10. Select Dry Run from the Run menu. > Watch to see the camera move across the rectangular pattern. The dispensing head will move after your response. If you get an error message that the speed is too slow, re-check your dot parameters and try again. 11. Select Wet Run from the Run menu. > Watch as the Area Fill dispenses. > Examine the board for quality and accuracy.
Placing Patterns Patterns, as explained in “Building a Program” earlier in this chapter, are essential building blocks of complex dispensing processes for workpieces. In this exercise you will learn how to create a simple dispensing pattern and place it on a workpiece at multiple locations. For this exercise, you will create a simple L-shaped underfill pattern and place it on the workpiece Tutorial Board. You will perform a wet dispense.
5. Click on OK. > 6. A Teach Window opens asking you to teach the pattern origin. Use the Position Controls to center the camera crosshairs on the ULHC of Flip Chip 1 on the Tutorial Board. > This will be the Origin of the pattern. 7. Click on Teach. 8. Click on Done. > 9. The Teach Window changes asking you to select a method for defining a fiducial. Select Corner Finder and click on Next.
18. Click on OK. The dispensing head will move after your response. 19. Select Edit Line Parameters from the Edit menu and check to make sure that the Line Parameters for Style 1 match those values established earlier in the tutorial for Weight Control lines. 20. Click on Dispensing Elements in the Program Commands toolbar. 21. Click on Weight-Control Line. 22. Enter 20 mg in the weight text box and choose Style 1. 23. Use the Position Controls to center the crosshairs on the ULHC of Flip Chip 1. 24.
> This will be where you will place your pattern. 37. Click on Teach. 38. Use the Position Controls to center the camera crosshairs on the ULHC of the adjacent Flip Chip 2. > The pattern will also be placed at this location. 39. Click on Teach. 40. Click on Done. > Your program should look like this: 1 DO: FCLine1 at (0.348, 0.429) Function call to dispense the line FCLine1 at this x,y location 2 DO: FCLine at (0.546, 0.356) 3 END > Your location numbers may vary from this example. 41.
9 Advanced Programming Overview This chapter discusses and demonstrates some of the more advanced techniques for perfecting your dispensing programs. You will perform two underfill tutorials, one L-shaped pattern and one U-shaped pattern. You will learn how to increase throughput by using timers and skip marks and reusing fiducials and height sense information. ? NOTE You should complete the preceding chapter, “Beginning Programming” before attempting the tutorials in this chapter.
Re-using Fiducials and Height Sense Information If your workpiece contains many parts, and the pattern to be dispensed is a two or three part pattern such as the L-shaped and U-shaped patterns, checking fiducials and the substrate height during every pass can be time consuming. In many cases, it is unnecessary since the likelihood that the parts could move before the timers expire is very low.
Chip Offset Chip Offset is the distance between the edge of the part (usually a die) and the edge of the dispensing needle. It is defined to ensure that the needle does not chip the die edge during a dispense. The Chip Offset is used in the X-axis and Y-axis as shown in Figure 9-1. A formula is used to calculate the Chip Offset: ½dn + 7 mil = Chip Offset where dn is the outer diameter of the needle. Reticles can also be used to perform the same function as Chip Offset.
Underfill Patterns There are several types of line patterns used for underfill applications. Two common types are L-shaped and U-shaped patterns as shown in Figure 9-2. Variations of these types of underfill patterns are used as well. These patterns and processes are designed to assure complete underfilling without excess and to prevent voids in the underfill.
Advanced Underfill Workpiece In these exercises, you will learn to program an entire underfill workpiece. The first exercise will be the L-shaped pattern. The second exercise will be the U-shaped multipass pattern. You will learn when to insert timer commands, height sense commands, flow rate measurements, use skip marks and re-use fiducials. Estimated time to complete: 60 minutes For the exercise below, you will use Side 2 of the Tutorial Board.
To program the workpiece with L-shaped underfill patterns: 1. Perform a Programming Setup. (See Chapter 6 - Setup and Configuration for assistance.) > Load the Tutorial Board to Side 2 with the multiple underfill patterns. > For Setup Workpiece Alignment, choose Two Fiducials, and Learn Workpiece Angle first. > For your fiducials, use the Model Finder method and program Fid 1 as the fiducial in the LLHC and Fid 2 as the fiducial in the URHC on Side 2 of the Tutorial Board. 2.
> A Teach Window opens asking you to select the method for teaching your skip mark. 19. Select Model Finder. 20. Click on Next. 21. Use the Position Controls to center the camera crosshairs on the dot slightly above and to the left of where you taught the origin and fiducial. 22. Click on Teach. 23. Test the skip mark or click on Next. > The Teach Window closes and you return to the Edit Pattern Skip Info dialog box. 24. Click on OK to close the box.
4 END PASS: 5 END 32. Place the cursor on the first END PASS. 33. From the Program Commands toolbar, click on Dispensing Elements. > A Teach Window opens. 34. From the Dispensing Elements toolbar, click on Find Substrate Height. 35. Use the Position controls to move the dispensing head to a location near the flip chip model. > When you have actual parts placed on a workpiece, you do not want to teach the height of the parts, but rather the height of substrate onto which you will dispense.
> This will start the timer after the first line is dispensed. 48. Place the cursor on the second END PASS and click on Time in the Program Commands toolbar. 49. Select Await Multipass Timer. > The Await Multipass Timer instruction dialog box opens.
50. Type in 30 seconds. > The system will wait for 30 seconds before beginning the next run. > Set the timer according to how long your fluid takes to underfill the flip chip model. 51. Click on OK. 52. From the Program Commands toolbar, click on Dispensing Element. 53. Select Weight-Control Lines. 54. Enter 30 mg in the Total Weight text box and select Line Style 1. 55. Use the Position Controls to move the dispensing head to the ULHC of the first flip chip in the ULHC of Pattern 1.
63. From the File menu, select Save and type in undrfil.fmw to save your program as undrfil.fmw. > The program will find a substrate height at this XY location This is the Lshaped line in the first pass Your program should look like this: START PASS: FOR PASS 1 2 FIND SUBSTRATE HEIGHT: (x, y) 3 WEIGHT CONTROL: 50.
76. In the Teach Window, select Lfill in the Available Patterns text box. 77. Use the Position Controls to move the dispensing head to the ULHC of the first flip chip in the ULHC of Pattern 1. 78. Click on Teach. 79. Click on Done. > You program will look like this: 1 MEASURE FLOW RATE 2 LOOP PASS: FROM 1 TO 2 3 DO MULTIPASS: Lfill AT (x1, y1) 4 NEXT LOOP: 5 END: 80. Place the cursor on NEXT LOOP. 81. Click on Pattern on the Dispensing Process toolbar. 82. Select Place Multipass Pattern. 83.
> The Edit Pattern Skip Info dialog box opens. 91. Select Check Children If Mark Not Found. > This means that the if the Workpiece skip mark is not found, the Lfill skip marks will be checked. 92. Click on Teach Skip Mark. > A Teach Window opens asking you to select the method for teaching the skip mark. 93. Select Model Finder. 94. Click on Next. 95. Use the Position Controls to center the camera crosshairs on the dot in the ULHC of the Tutorial Board. > This will be the Workpiece skip mark. 96.
111. From the Run menu, select Wet Run. > Watch to make sure that the program, performs the following: • Finds two corner fiducials on the workpiece. • Finds the Workpiece skip mark. • Finds the fiducials at each flip chip model location for the Lfill pattern. • Finds the Lfill skip marks. ? NOTE The skip mark for Pattern 3 should not be found and the pattern should be skipped. • Performs a Flow Rate measurement. (Only performed on Wet Run.) • Performs a Substrate Height Measurement.
To program a U-shaped multipass: 1. Perform a Programming Setup. (See Chapter 6 - Setup and Configuration.) > Load the Tutorial Board to Side 2 with the multiple underfill patterns. > For the Configure Workpiece, choose Two Fiducials, and Learn Workpiece Angle first. > When prompted to Teach your fiducials, program Fid 1 as the fiducial in the ULHC and Fid 2 as the fiducial in the LRHC of Side 2 of the Tutorial Board. 2. From the Main Window, click on Teach a Program. 3.
18. Click on Done. > A message box opens indicating that the dispensing head is about to move to the “Workpiece” origin. The dispensing head will move after your response. 19. Click on OK. 20. Select U-pass from the Pattern Name text box. > A message box opens indicating that the dispensing head is about to move to the “U-pass” origin. The dispensing head will move after your response. 21. Click on OK. 22. From the Program Commands toolbar, click on Pattern and select Pass Block.
> The program should look like this: 1 START PASS: FOR PASS 1 2 FIND SUBSTRATE HEIGHT: (x, y) 3 END PASS: 4 START PASS: FOR PASS 2 5 END PASS: 6 START PASS: FOR PASS 3 7 END PASS: 6 END 29. From the Program Commands toolbar, click on Dispensing Elements. 30. Click on Weight Control Lines. 31. Enter 30 mg in the Total Weight text box and select Line Style 1. 32.
> Use Chip Offset or reticles. 47. Click on Teach. 48. Use the Position Controls to move the dispensing head to the URHC of the same flip chip model. > Use Chip Offset or reticles. 49. Click on Teach. 50. Click on Done. 51. From the Program Commands toolbar, click on Time. 52. Select Reset Multipass Timer. > This will start a new timer. 53. Place the cursor on the last END PASS (for Pass 3) and click on Time in the Program Commands toolbar. 54. Select Await Multipass Timer. 55.
67. Click on Done. 68. From the File menu, select Save As and type in multipas.fmw to save the file as multipas.fmw. > Your program should look like this: 1 START PASS: FOR PASS 1 2 FIND SUBSTRATE HEIGHT:(x, y) 3 WEIGHT CONTROL:30.00,1,([x1,y1],[x2,y2]) 4 RESET MULTIPASS TIMER: 5 END PASS: 6 START PASS: FOR PASS 2 7 AWAIT MULTIPASS TIMER: 20 seconds(s) 8 WEIGHT CONTROL:30.
77. In the Teach Window, select U-pass in the Available Patterns text box. 78. Use the Position Controls to center the camera crosshairs on the ULHC of the first flip chip model in Pattern 3 on the Tutorial Board workpiece. 79. Click on Teach. 80. Choose Done. > Your program will look like this: 1 MEASURE FLOW RATE 2 LOOP PASS: FROM 1 TO 3 3 DO MULTIPASS: U-pass AT (x1, y1) 4 NEXT LOOP: 5 END: 81. Place the cursor on NEXT LOOP. 82.
89. From the Run menu, select Dry Run. > Make certain that the program executes the following steps correctly: • Finds two corner fiducials on the workpiece. • Finds the fiducials at each flip chip model location for the U-pass pattern. • Perform a Flow Rate measurement. (Only performed on Wet Run.) • Performs a substrate height measurement. • Dry dispenses two lines around each of the four flip chip models.
10 Running Production After a program has been built and the dispensing process perfected, the program will be used in a Production Run. This chapter will guide the Operator through a System Set-up, Production Run and Shut Down. The exercises in this chapter assume that the dispensing system is in good working order as described in System Setup and Operation in Chapter 3 - Tour of Fluidmove.
4. Follow the on-screen prompts. 5. Once you have completed a Prompted Setup, click on Load in the Production Window. 6. Select multipas.fmw from the file list and click on OK. > A dialog box opens telling you that FMW is “Downloading …please wait.” 7. After the file has loaded, click on Run in the Production Window. 8. Click on Run Production. > The Run Window opens. See Figure 10-1. > A message box appears requesting you to “Clear the conveyor”. 9. Clear the conveyor. 10. Click on OK. 11.
Figure 10-1 Running Production 10-3
To Simulate a Production Run This exercise will teach you how to simulate a production run on conveyor dispensing systems. Follow the procedure below to simulate a production run. To simulate a production run: 1. Unload all boards. 2. Turn the Main Power Switch OFF. 3. Install the TS-01 as indicated below: a. Attach the TS-01 Upstream/Downstream cable adapter to the TS-01 box. b. Attach the TS-01 Upstream Cable to the upstream connector on the Interface Module at the rear of the dispensing system.
> A message box appears requesting you to “Clear the conveyor”. 13. Clear the conveyor. 14. Click on OK. 15. Click on Go. > The message “Waiting for a board” will appear. 16. Place a Tutorial Board at the mouth of the conveyor. 17. Press the #3 TS-01 button to move the board to the dispensing station. > Dispensing will be performed. > When dispensing is complete, the red LED #4 on the TS-01 turns ON. 18. Press the #5 TS-01 button.
Shutdown The Shutdown button in the Production Window does not shut down the dispensing system. It allows the operator to perform a valve cleaning procedure or unload a board. To shutdown a Production Run at any time, use the Run Control Buttons in the lower right corner of the Run Window. To shutdown the dispensing system, refer to the Start-up\Shutdown section of the Operation Manual.
Glossary area-fill: Dispensing lines of fluid within a geometric pattern to completely cover an area. auer boat: A metal material handling plate used to transport parts into automated systems. Automatic Fiducial Locating System: A vision system that finds fiducials and compensates for small changes on a workpiece during dispensing. Automove Control Language (ACL): An Asymtek proprietary motion control language consisting of commands that control all components of the dispensing system.
flip chip: A die with solder bumps which is placed die circuit side-down on a PCB. flip chip underfill: Dispensing lines of fluid around the perimeter of a flipchip so that the fluid flows underneath the chip. flow rate: The amount of fluid in milligrams per second that is flowing from the valve. gantry: A non-conveyorized dispensing area on a non-conveyorized dispensing system.
multipass pattern: A pattern that re-uses one set of fiducials to repeat the same pattern at one or more locations on the workpiece. needle sensor: An instrument used to locate the position of the dispensing tip in the X-Y-Z directions. needle sensor substrate: A ceramic pad placed on the needle sensor and dispensed on during needle location definition routines.
SECS/GEM Interface: SEMI Equipment Communication Standard (SECS)/SEMI Generic Equipment Model for Effective Factory Automation (GEM). SECS/GEM is the protocol used in cases where several factory equipment units are linking together via a Host Computer. The GEM standard defines useful conventions for designing the communications interface on a unit of factory equipment to improve operations with a Host Computer. SEMI: Semiconductor Equipment and Materials International.
vision system: Includes the camera, vision software and light source. X-axis: Left to right movement of the dispense head in the dispensing area. weigh station: A location on the dispensing system where fluid is dispensed into a cup and weighed for volume. X/Y-axis: Two axes at right angles to each other. weight-control line: A line whose thickness is determined by the amount of fluid weight it contains. workpiece: An object to be dispensed upon, such as a PCB, auer boat or leadframe.
Index –A– alarms, 4-8 Anafaze, 4-1 area fill, 8-21 Asymtek program group, 3-3 Asymtek Vision for Windows (AVW), 3-2 automatic back-ups, 2-3 Automove Control Language (ACL), 3-10 dispensing system setup, 3-1 dots parameters, 8-12 down acceleration, 8-13 down speed, 8-8, 8-13 dwell, 8-7, 8-12 –B– backtrack gap, 8-7 backtrack length, 8-8 –E– edge detection, 7-6, 7-12 encapsulation, 8-21 event log, 6-3, 6-5 –C– CAD Import, 9-21 calibration, 3-2 camera, 6-7 caliper tool, 7-13 calipers density, 7-16 sizing,
heaters controller, 4-2 heater control, 4-1 heater setup, 4-1 input offset, 4-6 loop names, 4-2, 4-3 manual mode, 4-3 needle heater, 4-1 output value, 4-3 set point, 4-3 temperature deviations, 4-8 thermocouple type, 4-6 time proportioning alarms, 4-8 height sensor, 3-2, 6-1, 6-10, 6-15, 9-5 height sensor micrometer, 6-12 –I– I/O, 3-11 initialization, 3-2 installation, 1-1, 6-1, 6-6, 6-10, 6-15 Installation Package Installation Guide, 2-1 Tutorial Board, 2-2 User Guide and Tutorial, 2-1 L light levels, 3-
dispensing system, 2-2, 3-7 heaters, 4-1 initial, 3-2, 6-1, 6-10, 6-15 Manual, 6-32 production, 3-2, 3-22, 6-1, 6-27, 10-4 programming, 6-21, 6-23 purge, 6-1 vision system, 6-6, 6-8 shutdown, 10-6 shut-off distance, 8-7 single fiducial, 7-12, 7-14 skew correction, 3-2 skip marks, 9-2 SMEMA, 10-1 software update, 6-10, 6-15 SPC data log, 6-5 spiral fill, 8-22 statistics, 3-2, 3-24 suckback, 8-8, 8-14 surface mount technology (SMT), 9-21 system configuration, 6-1, 6-2 system setup, 6-1 –T– temperature, 4-2 t
Index - 4
