Ultra Optics 44R Operation And Maintenance Manual
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Ultra Optics 44R Operation And Maintenance Manual

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Summary of Contents for Ultra Optics 44R

  • Page 1 www.ultraoptics.com...

  • Page 2: Thank You

    Thank You The employee-owners of Ultra Optics wish to thank you for your business. The 44R and the Ultra Care Program is Ultra Optics’ latest innovation in a rich history of designing and manufacturing the most accurate and robust lens coating machines available.

  • Page 3: Design Modification

    Additional Copies Additional copies of this manual are available by contacting Ultra Optics by phone at 763.488.6030. No part of this document may be reproduced or copied in any form, or by any means, without the prior written permission of Ultra Optics.

  • Page 4: Safety

    Safety SAFETY FIRST! The 44R is a complex piece of equipment that contains various safety hazards. Some of these hazards include, but are not limited to:  Ultra Violet light – UV-light is used to cure the coating on the lens. Exposure to this light can damage the eyes.

  • Page 5: Table Of Contents

    Table of Contents Introduction ..............................i Thank You ..............................i Symbols ..............................i Service ................................ i Design Modification ..........................ii Additional Copies ............................ii Safety ................................iii Required Utilities ............................1 System Overview ............................1 General Overview ............................. 1 Lens Conveyor ............................2 Lens Load/Unload .............................
  • Page 6 Robot Suction Cups ..........................35 Air Filter Packs ............................. 36 Replacing sensors ............................ 36 Prox Sensors Index, Spindle Clocking and Lamp Home and Extend ........... 36 Conveyor position proximity sensor ....................36 Coating sensor............................. 36 UV sensor ............................37 Conveyor blocked sensor ........................37 Water sensor ............................

  • Page 7: Required Utilities

    The incoming trays have a work ticket with a bar code that the 44R system will read. This barcode will dictate to the machine whether or not to coat the lens as well as making sure each lens is returned to its respective tray.

  • Page 8: Lens Conveyor

    The lenses are processed directly from the tray, while still mounted to the block. It is not necessary to de-block the lens prior to entry into the 44R machine. The lenses are picked and held by use of vacuum pressure at each of the suction cups.

  • Page 9: Wash Process

    Wash process The lens is washed with high pressure, heated deionized water. As shown in the schematic below, the deionized water passes through a water heater where it is heated to approximately 140°F. The hot water then flows through a manual ball valve and a solenoid valve into the pneumatically driven pump.

  • Page 10: Coating Application

    PLC. This process is shown schematically in the following diagram. Cure process The 44R is designed to cure Ultra Optics’ line of UV-based coatings. After the lens has completed the coating application cycle, the lift cylinder will raise the arm assembly, which will then rotate 90°...
  • Page 11 The radiation energy from this lamp is used to effectively cure the coating to the lens with the proper characteristics of adhesion, hardness, etc. The PLC monitors the intensity of the lamp and the timing of the curing process based on the known performance and requirements of Ultra Optics’ coatings. www.ultraoptics.com page 5...

  • Page 12: System Operation

    System Operation Start-up Procedure The following procedure should be followed after the 44R has been shut-down, but not completely powered down. An example of this situation would be when the machine has been shut-down at the end of the day. This procedure does not apply to the first time the machine is powered-up.

  • Page 13: Communication With Lab Management System

    Lab Management System (LMS). Each job tray will have a work ticket containing a barcode. As the tray enters the 44R, the barcode on the ticket will be scanned. Once the bar code is scanned, the 44R controller will communicate with the LMS software to determine how the job should be processed.

  • Page 14: Work Feed Into The Machine

    It is necessary for the Lab Manager to ensure the CPID field is being populated for all jobs running through the 44R. If there is not a code in this field, the 44R will not be able to process the job.

  • Page 15: Loading Re-Work

    The conveyor on the front of the 44R will pull trays into the machine as space permits. The system controller will monitor the presence of trays and allow them to move forward by actuating stop pins located on the bottom of the conveyor.

  • Page 16: Recovery From Alarm Fault

    Recovery from Alarm Fault The following procedure should be followed if the system experiences an alarm condition that causes the machine to stop processing lenses: 1. Press Reset Alarm 2. If lens is still on the robot, open door and grab the lens. 3.
  • Page 17 6. Return the lens to its correct tray position as shown on the recovery screen. 7. If there is a lens over the Cure position, close the door and press the Spindle Down button. www.ultraoptics.com page 11...
  • Page 18 8. Once spindle is down, press the Lamp Cycle button. This will cure the coating on this lens. 9. When the lamp cycle button turns from green to red, the cycle is complete. 10. Press the Spindle Down button again and this will return the spindles to the up position. www.ultraoptics.com page 12...
  • Page 19 11. If there is no lens in the load/unload position, press the Index 90 degree until there is a lens in the load/unload position. 12. Open the door and grab the lens in the load/unload position, then press Release Lens button.
  • Page 20 16. Press Diagnostics tab. 17. Press Manual Controls on/off button to turn on manual controls. www.ultraoptics.com page 14...
  • Page 21 18. Press Manual Controls screen button. 19. Turn Conv. Sol. 1,2,3, and 4 buttons on. www.ultraoptics.com page 15...
  • Page 22 20. Press Conveyor button to turn on conveyer. This will clear all trays from the machine. 21. Press Conveyer button again to turn off conveyer once all trays are out. 22. Reload trays that have uncoated lenses to the infeed conveyor of the machine. 23.
  • Page 23 24. Press Manual Controls on/off button to turn off manual controls. 25. Press Auto Mode tab. www.ultraoptics.com page 17...
  • Page 24 26. Press Auto Cycle button to start production. www.ultraoptics.com page 18...

  • Page 25: Maintenance

    The following table should be used as a guide for performing regular preventative maintenance on the 44R to maintain ultimate system efficiency and up-time. It is expected that the user of this machine is capable and performs the following maintenance items at the scheduled intervals.
  • Page 26  needle points to “change”  filters are moist/dirty  every six months Monthly Replace coating filter P/N 4404 Check capacitors Primary capacitor to read 20 µf Ensure positive air flow Hold tissues over openings and confirm the tissue blows out, away from the machine.

  • Page 27: Robot Pick And Place Point Calibration

    Robot Pick and Place Point Calibration Over time, as the robot moves and turns, the pick and place points may drift out of calibration. As a result, it is necessary to re-calibrate these points to ensure secure handling of the lenses through the system.
  • Page 28 3. Select the Control Panel tab on the Robot Manager window 4. Select the Motor On option 5. Click Yes to confirm www.ultraoptics.com page 22...
  • Page 29 6. Select the tab for Jog & Teach 7. Select the Execute Motion Tab 8. Select Point 01 (if machine operates left to right) or Point 23 (if machine operates right to left) from the Destination drop menu www.ultraoptics.com page 23...
  • Page 30 9. Select Execute 10. Select Yes to confirm 11. Move –Z Axis Until aligning pin is just above calibration tool www.ultraoptics.com page 24...
  • Page 31 12. If pick point needs calibration, go to Control Panel tab and turn Motor Off 13. With Motor Off selected, depress the white button next to Motor Indicator light 14. Move aligning pin into the hole in the calibration tool until it is at the mark 15.
  • Page 32 16. Select Jog & Teach tab, then select the Teach Points tab 17. Select the Teach option 18. Select Yes to Re-Teach Point 01 (if machine is left to right) or Point 23 (if machine is right to left). www.ultraoptics.com page 26...
  • Page 33 19. Select Point 00 (if machine is left to right) or Point 22 (if machine is right to left) from the Point drop down menu. 20. Select the Teach option 21. Select Yes to Re-Teach Point 00 (if machine is left to right) or Point 22 (if machine is right to left).
  • Page 34 22. Select the Points tab 23. Change the Z axis for AboveLens1A to –42.525 24. Select Save to save new value www.ultraoptics.com page 28...
  • Page 35 25. Select the tab for Jog & Teach 26. Select the Execute Motion Tab 27. Select Point 01 (if machine is left to right) or Point 23 (if machine is right to left) from the Destination drop menu. www.ultraoptics.com page 29...
  • Page 36 28. Select Execute 29. Select Yes to confirm 30. Select AboveLens1B from the Destination drop down menu www.ultraoptics.com page 30...

  • Page 37: Calibrating The Cognex Barcode Scanner

    31. After selecting Execute, Select Yes to confirm 32. Repeat steps 9-22 for Point 03 and Point 02 (if machine is left to right) or Point 25 and Point 24 (if machine is right to left). 33. Select AboveLens1A from the Destination drop menu 34.
  • Page 38 2. Double click on the DM60 device. 3. Click OK if this warning pops up. 4. Under File, select Restore Device www.ultraoptics.com page 32...
  • Page 39 5. Click on Quick Setup 6. Click on Live Display 7. With a barcode in front of the reader, click on Tune www.ultraoptics.com page 33...
  • Page 40 8. Click on Optimize Brightness 9. Under File, Select Save Configuration 10. Select Yes to save to non-volatile memory. 11. Close Software www.ultraoptics.com page 34...

  • Page 41: Replacing Consumable Parts

    Replacing Consumable Parts It is expected that the user be capable of changing out the following consumable parts. Hepa Pre-filter 1. Replace with new filters monthly Hepa Filter 1. Disconnect power cable from filter unit to the top of the machine 2.

  • Page 42: Air Filter Packs

    8. Close water side door 9. Press “home” button 10. Press “Rbt. Motor” button Air Filter Packs 1. Turn air to the machine off 2. Press up on the bottom of the air filter canister and turn clockwise 3. Unscrew plastic retainer at the base of filter and remove old filter 4.

  • Page 43: Uv Sensor

    3. Remove screw that hold bracket to sensor box 4. Replace with new sensor box 5. Attach to cure tube 6. Return bad sensor and box to Ultra Optics THERE IS A CORE CHARGE FOR THIS SENSOR AND BOX Conveyor blocked sensor 1.

  • Page 44: Replacing The Spindle Motor Assembly

    Replacing the Spindle Motor Assembly 1. Remove the suction cup. 2. Disconnect the spindle motor power cable from the back of the spindle. 3. Disconnect the vacuum tubing from back of the spindle. 4. Loosen the bolt on the front tip of the spindle swing arm. 5.

  • Page 45: Spindles

    Spindles 1. Remove small access panel on left side of the 44R and locate the wash, coat, and spin off potentiometers. 2. On the touchscreen, press the Diagnostics tab. 3. Turn on Manual Controls. 4. Press the Spindle RPM Controls menu button.

  • Page 46: Air Regulator Adjustment

    Air Regulator Adjustment 1. Take off the large removable panel on the left side of the 44R. 2. Locate either of the air regulator mounted on the inner well. 3. Check that the air gauges on the regulators are reading 80 PSI.

  • Page 47: Alarm Codes

    Alarm Codes Alarm Message Cause R0184 Coating Empty This alarm occurs when 1000 lenses have been coated since the coating low warning first appeared. Until coating is added machine will not run any more lenses. R022F E-Stop Emergency stop button has been pressed. R0176 Failed To Load Lens Robot was unsuccessful in loading a lens into spindle 1.
  • Page 48 R000A No Rbt. Act. Of Swap Lens Robot did not acknowledge the PLC's request to swap Cmd. lenses. Is communication cable connected? Check orange power light is lit on robot. R0009 Rbt. Failed To Exe. Load Robot did not send confirmation that the load lens Lens Cmd.
  • Page 49 position. R0051 Servo Lost Home Position The servo drive has lost its home position. Check servo drive status and the wiring of the Absolute Position Valid signal from the servo drive to the PLC. R017D Spindle 1 Lost Lens Check spindle vacuum, should be over 16. Check vacuum tubing connections, blocking for incomplete sealing area for suction cup, bad vacuum gauge, or bad wiring connection at vacuum gauge.
  • Page 50 R0219 Spindle Out Of Sequence Spindle arm indexed to an unexpected position. Check spindle alignment prox and/or servo drive programming. R0181 Spindle Up Cmd. Failed Spindle up command failed. Spindle was sent up; but the up position prox was never detected. Check the up position prox switch.

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