IMAGO Chip Shot Manual

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THE

IMAGO CHIP SHOT

FULL ASSEMBLY WALKTHROUGH

BY ACSYS ENGINEERING

2021

Table of Contents

Summary of Contents for IMAGO Chip Shot

Page 1 IMAGO CHIP SHOT FULL ASSEMBLY WALKTHROUGH BY ACSYS ENGINEERING 2021...
Page 2: Table Of Contents
TABLE OF CONTENTS • SAFETY INFORMATION………………………………………………...3 • OVERVIEW……………………………………………………………..6 • ASSEMBLY……………………………………………………………..10 • WIRING……………………………………………………………….33 • SOFTWARE TUTORIAL………………………………………………..42 • SYSTEM OPERATION………………………………………………….62 • TROUBLESHOOTING………………………………………………….67 • FINAL IMAGES……………………………………………………...…73...
Page 3: Safety Information
SAFETY INFORMATION...
Page 4 SAFETY INFORMATION • THE POWER SUPPLY IS EQUIPPED FOR 120/240 VAC WITH MANUAL SWITCHING. THE POWER SUPPLY IS ALREADY SET TO THE 240V SETTING. THE SWITCH MUST BE TOGGLED TO THE APPROPRIATE SETTING FOR YOUR COUNTRY/REGION. • ATTEMPTING TO POWER ON THE SUPPLY WITH THE INCORRECT SETTING SELECTED MAY RESULT IN SEVERE PHYSICAL HARM AND/OR DAMAGE TO THE SYSTEM.
Page 5 SAFETY INFORMATION • THE SYSTEM CONTAINS MOVING PARTS THAT ALSO POSE A RISK. A FEW IMPORTANT THINGS TO REMEMBER: • PLACE THE SYSTEM IN A CLEAR LOCATION AND ON A STABLE TABLE TOP • DO NOT RUN THE SYSTEM UNTIL THE ENTIRE RANGE OF MOTION IS CLEAR •...
Page 6: Overview
OVERVIEW...
Page 7 OVERVIEW • THE IMAGO CHIP SHOT SYSTEM ALLOWS FOR THE ACQUISITION OF HIGH RESOLUTION IMAGES OF CHIP TRAYS. THIS RASPBERRY PI CONTROLLED SYSTEM UTILIZES A MOTOR TO INCREMENT A TRAY OF CHIPS UNDER A FIXED CAMERA, ACQUIRES IMAGES, AND TRANSMITS THEM TO A COMPUTER TO BE ANALYZED •...
Page 8 OVERVIEW • THESE INSTRUCTIONS ARE SYSTEMATIC, PROGRESSING STEP BY STEP TO ENSURE CLARITY • THE PARTS NECESSARY FOR EACH STEP ARE CALLED OUT ON EACH SLIDE • THERE ARE ALSO IMAGES ON EACH SLIDE DETAILING THE LOCATION • FINALLY, THERE ARE INSTRUCTIONS AND NOTES OF THINGS TO KEEP IN MIND ON EACH STEP...
Page 9 • THE ONLY REQUIRED RESOURCES TO ASSEMBLE THE CHIP SHOT ARE INCLUDED, WHICH ARE AN ALLEN WRENCH SET AND ZIP TIES. EACH CHIP SHOT HAS A NEW METRIC ALLEN WRENCH SET AS WELL AS AMPLE ZIP TIES TO ROUTE CABLES AT THAT STAGE OF THE BUILD.
Page 10: Assembly
ASSEMBLY...
Page 11 ASSEMBLY – ITEMS OVERVIEW • A3-001 • 02-006 ALIGNMENT TRAY BACK JIG (DIM 2) SUPPORT • 02-005 • WATER CHIP TRAY PUMP • 02-002 • VXZ232CG CHIP TRAY BSMC WATER PLATE VALVE...
Page 12 ASSEMBLY – ITEMS OVERVIEW • 730-4514 • TMS IDS DOME LIGHT COOLANT TANK • 30345T347 • RASPBERRY PI EYE-T0-TAB LANYARD • 02-009 CRASH BAR • 86-573 HIGH- (WITH SPACERS) RES CAMERA...
Page 13 ASSEMBLY – HARDWARE OVERVIEW • DROP IN T-NUTS • FLATHEAD SCREWS • BUTTON HEAD • SOCKET HEAD SCREWS CAP SCREW • SOCKET HEAD • THUMB SCREW CAP SCREW - STAINLESS...
Page 14 ASSEMBLY- STEP 1 M5x35mm • FEED SCREW THROUGH • SIZE 4 ALLEN, BAG A • REPEAT FOR OTHER PAIRS END HOLE AND TIGHTEN • REMOVE SCREW • LINE UP IN 1 – 3 – 5 • ENSURE TRAY TAB IS CONNECTING THE WEDGE HOLES AS SHOWN NORMAL TO INSPECTION...
Page 15 ASSEMBLY- STEP 2 M6x12mm • SIZE 4 ALLEN • SIZE 4 ALLEN • REMOVE THE FLATHEAD SCREWS FROM • FEED THEM THROUGH THE HOLES ON THE THESE TWO RISERS INSPECTION PLATE • TIGHTEN THE PLATE DOWN INTO THE RISERS...
Page 16 ASSEMBLY- STEP 3 • THIS IS THE POSITION • SIZE 5 ALLEN • MAKE SURE THE ONE TAB EXTRUSION IS FLUSH TO • SLIDE EXT. 1 UP THE TAB AND BOTTOM AGAINST THE POSITION EXTRUSION FRAME ONE TAB...
Page 17 ASSEMBLY- STEP 4 OPPOSITE SIDE OF POSITION ONE TAB • SIZE 5 ALLEN • SLIDE EXT. 2 ONTO BOTTOM EXTRUSION • CIRCLED IS THE POS. 2 TAB • PRESS EXT. 2 UP AGAINST THE TAB. MAKE SURE IT’S FLUSH...
Page 18 ASSEMBLY- STEP 5 • SIZE 5 ALLEN • LINE UP EXT. 3 ONTO POS. 3 DRAWING • 39.5 CM FROM MOTOR END, YOU’LL SEE THE POS. • MAKE SURE EXT. 3 SLOTS 3 DRAWING LINE UP WITH EXT. 2 AND LOWER FRAME SLOTS...
Page 19 ASSEMBLY- STEP 6 • SIZE 5 ALLEN • SLIDE EXT. 4 BETWEEN EXT. 2 AND 3, WITH SCREWS • THE SPACE BETWEEN EXT. 2 FACING OUT AND EXT. 3 IS CIRCLED ABOVE • EXT. 4 HEIGHT FROM BOTTOM FRAME IS 30.5 CENTIMETERS...
Page 20 ASSEMBLY- STEP 7 • SIZE 5 ALLEN • 1) SLIDE EXT. 5 BETWEEN EXT. 1 AND EXT. 2 (PLATE SIDE NEAR EXT 2/3 AS SHOWN), ALIGNMENT JIGS ARE THERE TO AID YOU • 2) SLIDE EXT. 6 BETWEEN EXT. 1 AND EXT. 2 SO THAT THE TOP IS FLUSH ACROSS...
Page 21 M6x12mm ASSEMBLY- STEP 8 • SIZE 4 ALLEN, BAG A • SCREW THE FLATHEADS THROUGH THE PUMP MOUNT PLATE INTO • UNSCREW THE FLATHEADS FROM THE T-NUTS THE T-NUTS • DROP IN T-NUTS IN BETWEEN EXT. 2 AND EXT. 3...
Page 22 ASSEMBLY- STEP 9 M6x10mm • REMOVE SOCKET HEAD SCREWS FROM • SIZE 4 ALLEN T-NUT AND DROP THE T-NUTS IN • IDENTIFY THE H1 AND H2 • POSITION THE VALVE MOUNTING DRAWINGS ON THE SIDE OF EXT. BRACKET AS INDICATED BY THE DESIRED HEIGHTS DRAWING •...
Page 23 ASSEMBLY- STEP 10 M5x10mm • LOOSEN THE BUTTON HEAD • SIZE 3 ALLEN SCREWS IN THE T-NUTS ON EXT. 4 • SEE EXT. 2, 3, 4 • FEED SCREWS THROUGH THE HOLES ON THE TANK • MOUNT THE TANK ONTO EXT. 4 AS SHOWN...
Page 24 ASSEMBLY- STEP 11 • SIZE 5 ALLEN • LINE UP WITH ALIGNMENT • SLIDE THE RASPBERRY • THE RASPBERRY PI EXT. PI’S EXTRUSION INTO HEIGHT SHOULD BE 32.5 CM EXT. 1 ABOVE BOTTOM FRAME...
Page 25 M4x10mm M4x6mm ASSEMBLY- STEP 12 • SIZE 3 ALLEN • FEED THE SCREWS THROUGH THE CAMERA • UNSCREW THE 4 CORNER STAGE INTO THE CAMERA SOCKET HEAD SCREWS, STAGE MOUNTING PLATE NOT THE TWO CENTRAL FLATHEAD SCREWS...
Page 26 M4x10mm ASSEMBLY- STEP 13 • SLIDE THE DOME • THE THUMB SCREWS ON • THIS IS THE CAMERA AFTER LIGHT UP ONTO THE THE DOME LIGHT CAP IT IS MOUNTED IN THE CAMERA MUST LINE UP WITH PREVIOUS STEP SLOTS ON THE CAMERA •...
Page 27 M4x10mm ASSEMBLY- STEP 14 • SIZE 3 ALLEN • FEED THE SCREWS THROUGH THE LANYARD • UNSCREW THE TWO EYE AND INTO THE BLACK SOCKET HEAD CAMERA STAGE SCREWS MOUNTING PLATE...
Page 28 ASSEMBLY- STEP 15 CRASH BAR ABOVE CHIP TRAY TABS • SIZE 4 ALLEN • FEED SCREWS THROUGH CRASH BAR INTO T-NUTS • REMOVE SCREWS FROM T-NUTS • ENSURE CRASH BAR IS PARALLEL WITH THE CHIP TRAY PLATE ABOVE THE CHIP TRAY TABS, AND BELOW THE BOTTOM OF THE DOME LIGHT...
Page 29 ASSEMBLY- FRONT VIEW...
Page 30 ASSEMBLY- TOP VIEW...
Page 31 ASSEMBLY- LEFT AND RIGHT VIEWS...
Page 32 ASSEMBLY- REAR VIEW...
Page 33: Wiring
WIRING...
Page 34 WIRING • NO WIRING IS NECESSARY FOR THE COMPLETION OF THE ASSEMBLY. THE WIRING HAS BEEN COMPLETED WITH QUICK CONNECTORS FOR YOUR CONVENIENCE. SIMPLY CONNECT THE CABLES WITH LIKE LABELS WHEN YOU ARE READY TO PLUG IN. • ZIP TIE MOUNTS ARE LOCATED AT RECOMMENDED INTERVALS FOR ROUTING. PLACE THE CABLES ON THE MOUNT (AS SHOWN) AND USE A ZIP TIE TO SECURE THEM •...
Page 35 WIRING-CABLE INVENTORY • COMPLETE LIST OF CABLES IN THE SYSTEM: • POWER – VAC MAIN POWER SUPPLY CABLE • PI PWR – POWER TO THE RASPBERRY PI • LIM SWITCH – SIGNAL BETWEEN PI AND LIMIT SWITCHES • LIGHT – POWER AND CONTROL OF THE DOME LIGHT •...
Page 36 WIRING-ROUTING • IMAGE ONE: POWER SUPPLY BUNDLE...
Page 37 WIRING-ROUTING • IMAGE 2: EXTRUSION 1 BASE...
Page 38 WIRING-ROUTING • IMAGE THREE: MOTOR AND LIMIT SWITCH CABLES...
Page 39 WIRING-ROUTING • IMAGE FOUR: MAIN BUNDLE...
Page 40 WIRING-ROUTING • IMAGE FIVE: CAMERA AND WATER CABLES...
Page 41 WIRING-ROUTING • IMAGE SIX: PUMP, VALVE, AND TANK...
Page 42: Software Tutorial
SOFTWARE TUTORIAL...
Page 43 SOFTWARE TUTORIAL • THE SOFTWARE HAS BEEN SPECIALLY DESIGNED TO BE BOTH EASILY INTERFACEABLE AND HIGHLY FUNCTIONAL. OVER THE NEXT FEW SLIDES WE WILL EXPLORE THE MENUS, CONTROLS, AND VARIOUS OTHER NOTES ON THINGS THAT COULD COME UP • IF YOU’RE IN THE SOFTWARE AND ARE CONFUSED, GIVE THIS QUESTION MARK A TAP...
Page 44 SOFTWARE TUTORIAL • THIS IS THE FIRST SCREEN TO POP UP AT STARTUP. PRESS THE HOME BUTTON AND ALLOW THE MOTOR TO HOME ITSELF...
Page 45 SOFTWARE TUTORIAL • THIS IS THE MAIN MENU, THE FIRST THING THE SCREEN WILL SHOW UPON POWER UP. THERE ARE A FEW OPTIONS FROM HERE: • START – RUNS THE CURRENTLY SELECTED ROUTINE. CHANGES TO “RUNNING” WHEN A PROGRAM IS RUNNING •...
Page 46 SOFTWARE TUTORIAL • MORE INFO ON THE : • USE SPRAY – TOGGLES THE WATER SPRAY FUNCTION ON FOR THE ROUTINE • HOME – HOUSE ICON IN THE TOP RIGHT. RETURNS USER TO THE HOME SCREEN • SETTINGS – GEAR ICON. TAKES USER TO THE SETTINGS MENU SELECTION SCREEN •...
Page 47 SOFTWARE TUTORIAL • SHOWN IS THE SETTINGS MENU • MOTOR SETTINGS – DISPLAYS THE MOTOR SETTINGS • GENERAL SETTINGS – DISPLAYS NON MOTOR SETTINGS...
Page 48 SOFTWARE TUTORIAL-MOTOR SETTINGS • MOTOR SETTINGS • ACCELERATION: ADJUSTS RATE OF ACCELERATION • DEACCELERATION: ADJUSTS RATE OF DEACCELERATION • MAX VELOCITY: ADJUSTS TOP VELOCITY DURING ROUTINE • CURRENT: ADJUSTS THE MOTOR CURRENT...
Page 49 SOFTWARE TUTORIAL-MOTOR SETTINGS • MOTOR SETTINGS CONTINUED • HOME MOTOR – REHOMES THE MOTOR. THIS IS A GOOD IDEA BEFORE TEACHING A NEW ROUTINE, WHICH WE WILL GO OVER LATER • RESTORE DEFAULTS – REVERTS ALL SETTINGS TO THEIR DEFAULT VALUES.
Page 50 SOFTWARE TUTORIAL- GENERAL SETTINGS • GENERAL SETTINGS • TRIGGER DELAYS – SETS THE DELAY TIMER BEFORE AND AFTER THE CAMERA TRIGGERS DURING A ROUTINE • PUMP PRIME – TIMER FOR HOW OFTEN THE PUMP ACTIVATES • SPRAY ON – TIMER FOR NOZZLE SPRAY •...
Page 51 SOFTWARE TUTORIAL-MANUAL JOG • MANUAL JOG • POSITION – JOGS THE INSPECTION TRAY • SPEED – ADJUSTS JOG SPEED • CAMERA – TAKES AN IMAGE • LIGHT – TOGGLES THE LIGHT ON/OFF • DROPLET – TOGGLES PUMP ON/OFF • SPRAY BOTTLE – MANUALLY SPRAYS THE NOZZLE...
Page 52 SOFTWARE TUTORIAL- ROUTINES • TO MAKE A NEW ROUTINE, TAP THE ROUTINE SELECTOR ON THE HOME PAGE AND SELECT “NEW ROUTINE” • THERE ARE TWO WAYS TO TEACH A NEW ROUTINE. DESCRIPTIONS OF PROCESS LISTED UNDER BOTH OPTIONS • STEP MODE •...
Page 53 SOFTWARE TUTORIAL- STEP MODE • FIRST SCREEN: SETS THE START POSITION FOR THE ROUTINE • JOG TO THE DESIRED STARTING POSITION • ADJUST JOG SPEED WITH THE SPEED FUNCTION • USE THE CAMERA AND LIGHT FUNCTIONS TO DIAL IN HOW YOU WANT YOUR FIRST IMAGE TO LOOK...
Page 54 SOFTWARE TUTORIAL- STEP MODE • SECOND SCREEN: SETS THE END POSITION FOR THE ROUTINE • JOG TO THE DESIRED END POSITION • ADJUST JOG SPEED WITH THE SPEED FUNCTION • USE THE CAMERA AND LIGHT FUNCTIONS TO DIAL IN HOW YOU WANT YOUR LAST IMAGE TO LOOK...
Page 55 SOFTWARE TUTORIAL- STEP MODE • THIRD SCREEN: SETS THE NUMBER OF STEPS IN THE ROUTINE. THIS IS ESSENTIALLY THE AMOUNT OF IMAGES THAT WILL BE ACQUIRED BETWEEN THE STARTING AND END POINTS • THE IMAGES WILL BE EVENLY SPACED BETWEEN THE USER START AND END POSITIONS DEFINED IN THE PREVIOUS SCREENS...
Page 56 SOFTWARE TUTORIAL- STEP MODE • FINAL SCREEN: NAMES THE ROUTINE • NAME THE ROUTINE ANYTHING YOU WANT • HIT SET WHEN FINISHED. THIS WILL CAUSE THE SYSTEM TO RESET POSITION. THE NEWLY CREATED ROUTINE WILL BE SAVED • HIT THE ESCAPE BUTTON IN THE BOTTOM RIGHT TO RETURN TO THE HOME SCREEN WITHOUT SAVING...
Page 57 SOFTWARE TUTORIAL- DISTANCE MODE • FIRST SCREEN: SETS THE START POSITION FOR THE ROUTINE • JOG TO THE DESIRED STARTING POSITION • ADJUST JOG SPEED WITH THE SPEED FUNCTION • USE THE CAMERA AND LIGHT FUNCTIONS TO DIAL IN HOW YOU WANT YOUR FIRST IMAGE TO LOOK...
Page 58 SOFTWARE TUTORIAL- DISTANCE MODE • SECOND SCREEN: SETS THE DISTANCE PER STEP FOR THE ROUTINE • HELPFUL TO GET CONSISTENT DISTANCE BETWEEN IMAGES. PARTICULARLY USEFUL FOR CHIP TRAYS WITH UNIFORM SLOT SIZES • FIGURE OUT THE DESIRED DISTANCE BEFORE MAKING IT TO THIS SCREEN...
Page 59 SOFTWARE TUTORIAL- DISTANCE MODE • THIRD SCREEN: SETS THE NUMBER OF STEPS IN THE ROUTINE. THIS IS ESSENTIALLY THE AMOUNT OF IMAGES THAT WILL BE ACQUIRED BETWEEN THE STARTING AND END POINTS • THE IMAGES WILL BE EVENLY SPACED GIVEN THE STEP DISTANCE SPECIFIED IN THE PREVIOUS STEP •...
Page 60 SOFTWARE TUTORIAL- STEP MODE • FINAL SCREEN: NAMES THE ROUTINE • NAME THE ROUTINE ANYTHING YOU WANT • HIT SET WHEN FINISHED. THIS WILL CAUSE THE SYSTEM TO RESET POSITION. THE NEWLY CREATED ROUTINE WILL BE SAVED • HIT THE ESCAPE BUTTON IN THE BOTTOM RIGHT TO RETURN TO THE HOME SCREEN WITHOUT SAVING...
Page 61 SOFTWARE TUTORIAL- DELETING ROUTINES • MAKE SURE THE ROUTINE TO DELETE IS SELECTED • CLICK THE ROUTINE BUTTON TO BRING UP THE LIST • CLICK THE ROUTINE TO DELETE • PRESS DELETE BUTTON • WILL BE ASKED FOR CONFIRMATION...
Page 62: System Operation
SYSTEM OPERATION...
Page 63 SYSTEM OPERATION • IF EVERYTHING HAS BEEN ASSEMBLED, PLUGGED IN, AND POWERED ON PROPERLY, THE SYSTEM OPERATION ITSELF IS SIMPLE! MOST OF THE OPERATION IS CARRIED OUT BY THE SYSTEM ITSELF, BUT THERE IS A SMALL OPERATOR ROLE. THIS SHORT SECTION WILL DETAIL THAT ROLE, AND OFFER SOME TIPS THAT SHOULD HELP IN THE DAILY OPERATION.
Page 64 SYSTEM OPERATION • OPERATOR ROLE: • CHECK THE BELT TENSION (SEE SLIDE 65) • LOAD CHIP TRAY ONTO INSPECTION PLATE • SLIDE CHIP TRAY LID INTO FINGER SLOTS • ADJUST INSPECTION PLATE TAB WITH THUMB SCREWS TO SECURE IN PLACE •...
Page 65 SYSTEM OPERATION- TENSIONING THE BELT • THE MOTOR BELT MIGHT NEED TO BE TENSIONED IF THE BELT IS TOO LOOSE 1. LOOSEN THE M8 HEX NUT AND MOUNTING SCREWS ON THE SIDES OF THE BRACKET 2. TIGHTEN THE M8 SCREW ON THE END 1A AND FLIP SIDE OF THE MOUNT UNTIL THE BELT IS TENSIONED...
Page 66 SYSTEM OPERATION- NOZZLE OFFSET • THE DISTANCE BETWEEN THE WATER NOZZLE AND THE CAMERA MUST BE SET 1. HOME THE MOTOR, THEN OPEN MANUAL JOG SCREEN 2. LINE UP THE FIRST SLOT ON THE CHIP TRAY UNDER THE WATER NOZZLE AND RECORD THE POSITION VALUE 3.
Page 67: Troubleshooting
TROUBLESHOOTING...
Page 68 TROUBLESHOOTING- BAD IMAGES • OUT OF FOCUS • OUT OF FOCUS WHILE MACHINE IS STILL: • ROTATE THE CAMERA LENS (EASIEST TO DO THIS BY ROTATING THE DOME LIGHT ITSELF) • TAKE IMAGES PERIODICALLY TO ANALYZE THE FOCUS USING THE MANUAL JOG MENU’S CAMERA FUNCTION •...
Page 69 TROUBLESHOOTING- INCONSISTENT WATER • CHECK THAT THE WATER TANK IS FULL • CLEAN NOZZLE • MANUALLY DISPENSE WATER (CHECK SOFTWARE TUTORIAL, SLIDE 40) • LOOSEN THE SOCKET HEAD SCREWS AND SLIDE THE NOZZLE CLOSER OR FARTHER FROM THE TRAY (CHECK THAT THE VALVE REMAINS ABOVE THE CHIP TRAY TABS) •...
Page 70 TROUBLESHOOTING- IMAGES ARE CROOKED • THE TRAY WAS NOT SET IN PROPERLY. FOLLOW THE ALIGNMENT INSTRUCTIONS DETAILED IN THE SYSTEM OPERATION SECTION...
Page 71 TROUBLESHOOTING- SOFTWARE FROZEN • CYCLE POWER: • SHUT OFF THE POWER SUPPLY • WAIT A FEW SECONDS • TURN THE POWER SUPPLY BACK ON • ALLOW SYSTEM TO COOL...
Page 72 TROUBLESHOOTING- INSPECTION TRAY NOT MOVING • GO TO THE MANUAL JOG MENU. DOES IT SAY “COLLISION DETECTED”? • YES • TENSION THE BELT ACCORDING TO THE NEXT SLIDE • DECREASE ACCELERATION, DEACCELERATION, MAX VELOCITY VIA THE MOTOR SETTINGS MENU • NO •...
Page 73: Final Images
FINAL IMAGES...
Page 74 FINAL MACHINE: FRONT...
Page 75 FINAL IMAGES: ANGLE 1...
Page 76 FINAL IMAGES: ANGLE 2...
Page 77 FINAL IMAGES: SIDE...
Page 78 FINAL IMAGES: BACK...
Page 79 THANK YOU!