How to maintain and maintain CCD contraposition suction and pasting machine?

The maintenance of CCD alignment suction machine directly affects its accuracy, stability and service life. It needs to be systematically managed from mechanical, visual and electrical dimensions by combining daily inspection, regular maintenance and preventive maintenance. The following are the specific maintenance points:

I. Daily maintenance (daily/shift)

1. Cleaning and dust removal

Mechanical parts:

Wipe the moving parts such as guide rail, lead screw and linear module with dust-free cloth to remove dust, debris and residual lubricant, so as to prevent particles from wearing the track.

Clean the surface of suction nozzle and fixture, remove residual adhesive or stains from components, and prevent the suction nozzle from being blocked (alcohol or ultrasonic cleaning machine can be used).

Visual system:

Wipe the surface of the camera lens and light source gently with lens paper or cotton swab dipped in anhydrous ethanol to avoid fingerprints or dust affecting the imaging quality.

Check whether the light source is loose or offset, and adjust the angle in time to ensure uniform illumination.

Equipment surface:

Wipe the fuselage shell and operation panel, keep the equipment clean and tidy, and prevent liquids or sundries from entering the electric control cabinet.

2. Check the running status

Mechanical movement:

Manually operate each axis to observe whether there is jamming, abnormal sound or vibration, and whether the lubrication state of the guide rail is good (the oil film is even without drying up).

Check the vacuum degree of the suction nozzle (monitored by the pressure gauge, the normal range is-60kPa to-80kPa). If the vacuum is insufficient, check the air passage leakage or the suction nozzle blockage.

Visual system:

Check whether the camera imaging is clear, whether there is noise or color cast; Whether the brightness of light source is stable (the light intensity value can be monitored by software).

Randomly select products to verify whether the alignment accuracy is within the tolerance range (such as x/y ≤ 0.02 mm, θ≤ 0.1).

Electrical system:

Check whether the power indicator and barometer are normal, and whether the buttons and emergency stop switches are sensitive.

Observe whether the fan in the electric control cabinet runs normally, so as to avoid the aging of components caused by poor heat dissipation.

Second, regular maintenance (weekly/monthly)

1. Mechanical system maintenance

Lubrication maintenance:

Grease (such as lithium base grease) or lubricating oil (such as ISO VG 32) shall be added to the moving parts such as guide rail, lead screw, bearing, etc. according to the instructions, and attention shall be paid to avoid pollution caused by excessive lubrication.

For the gear transmission mechanism, check the tooth surface wear, remove the debris and apply grease to ensure smooth transmission.

Fastener inspection:

Use a torque wrench to check the torque of motor mounting screws and guide rail fixing screws of each shaft (according to the original factory standard) to prevent looseness caused by long-term vibration.

Check the fixity of fixture and suction nozzle mounting base to avoid looseness affecting the mounting accuracy.

Gas path maintenance:

Clean or replace the filter element of the air filter, drain the condensed water in the oil-water separator and ensure that the air source is dry and clean (once a week is recommended).

Check whether the trachea joint leaks, and replace the aged trachea in time (rubber tube is recommended to be replaced every year, and PU tube can be extended to 2-3 years).

2. Vision system maintenance

Camera and light source calibration:

Use calibration board to recalibrate the visual coordinate system every month to compensate the accuracy deviation caused by mechanical wear or environmental change.

Test the attenuation of light source. If the brightness drops by more than 20%, replace the light source (the life of LED light source is usually 50,000 hours, and the service time should be recorded).

Image processing optimization:

Clean up the visual software cache, delete outdated template files, and ensure that the software runs smoothly.

According to product batch differences, template matching parameters (such as gray threshold and feature point priority) are updated or optimized to improve alignment stability.

3. Electrical and software maintenance

Line inspection:

Check the power cord and signal cord for damage, aging or poor contact, and focus on the cables near the moving parts (such as cables in the towing chain) to avoid wear and short circuit.

Fasten the terminal strip and contactor contacts in the electric control cabinet, remove dust and foreign objects, and prevent electrical failure.

Software upgrade and backup:

Back up equipment programs and parameters regularly (once a month is recommended) and store them in external hard disk or cloud to prevent data loss.

According to the patch or upgrade package issued by the manufacturer, update the control system software, fix loopholes or improve functions.

Third, quarterly/annual in-depth maintenance

1. Mechanical system overhaul

Accuracy calibration:

Use laser interferometer or club instrument to detect the positioning accuracy and repeatability of each axis. If it is out of tolerance, it is necessary to adjust the parallelism of the guide rail, the pitch error of the lead screw or replace the worn parts.

Calibrate the verticality of the Z axis of the suction nozzle (deviation ≤0.01mm), ensure that it is pressed vertically during mounting, and avoid tilting of components.

Component loss assessment:

Check the wear of guide rail and lead screw (such as surface roughness of guide rail and pitch error of lead screw), and replace it in time if it is seriously worn (such as obvious dent or gap).

Test the cylinder stroke and pressure, and replace the aging sealing ring or piston to ensure accurate pneumatic action.

2. Deep maintenance of vision system

Camera performance test:

Use the resolution test card to check whether the resolution of the camera is up to standard, and replace the camera sensor or the whole machine if the pixel offset or bad spots increase.

Check the lens distortion coefficient, and compensate or replace the low distortion lens (such as industrial telecentric lens) through software algorithm.

Light source system upgrade:

Evaluate the uniformity of the light source (the illuminance difference at each point of the light spot is less than or equal to 5% measured by a luminometer). If the uniformity decreases, it is necessary to adjust the light source structure or replace the light guide plate.

For the equipment using halogen lamps and other heating light sources, it is recommended to upgrade to LED light sources to reduce heating and prolong service life.

3. Comprehensive detection of electrical system

Insulation and grounding test:

Use the insulation resistance tester to measure the insulation resistance (≥2MΩ) of the power line and the grounding resistance (≤4Ω) to ensure that it meets the safety standards.

Check the status of UPS battery (such as voltage and internal resistance), and the aging battery needs to be replaced as a whole (usually once every 3-5 years).

Lightning protection and anti-interference:

Check the lightning protection grounding device of the equipment before the rainy season, and test whether the function of surge protector (SPD) is normal, so as to avoid lightning damage to the precision circuit.

Optimize electromagnetic compatibility (EMC), separate power lines from signal lines, and increase shielding measures (such as metal trunking and magnetic ring filtering) to reduce external interference.

Fourth, special scene maintenance

1. Long-term downtime maintenance

Before stopping, clean the equipment and turn off the power supply. Apply antirust oil on the metal surfaces such as guide rails and lead screws, and cover them with dust-proof cloth to prevent dust from invading.

Power on once a week (more than 30 minutes) to drive away moisture and avoid electronic components from being damaged by moisture.

Before restarting the machine, check the status of all components, test the motion axis and vacuum system, and then put into production after confirming that there is no abnormality.

2. Strengthening measures for high dust/wet environment

Improve the sealing performance of the equipment, install a high-efficiency filter (such as HEPA filter element) at the air inlet and replace it regularly (adjust the cycle according to the dust concentration, such as once every two weeks).

Put moisture-proof agent in the electric control cabinet, install temperature and humidity monitoring module, and automatically start heating and dehumidification when the humidity exceeds 70%.

V. Maintenance records and management

Establish a maintenance account:

Record the time, content, replacement parts model and parameter adjustment of each maintenance, and form traceable maintenance files.

Count the replacement cycle of wearing parts (such as suction nozzle, sealing ring and light source), and reserve spare parts in advance to avoid downtime.

Personnel training and assessment:

Regularly provide technical training for operators and maintenance personnel (such as new product debugging and new fault handling), and they can only take up their posts after passing the examination.

Encourage employees to record equipment anomalies (such as occasional alarms and precision fluctuations) and predict potential failures through big data analysis.

Six, common faults and prevention

Possible causes of fault phenomena and preventive measures