CORFIN AUTOMATION

The DTS-400 is an automated in-line tinning system for a wide range of components such as DIPs, SIPs, most configurations of SOICs and PLCCs and for power devices such as TO-220, TO-247, etc. Component grippers are designed to handle devices in singulated form, but it is also possible to specify conveyor set-ups that will handle a wide variety of components in strips or lead frames.
The optional CF continuous feed conveyor is equipped with special grippers, with multiple titanium blades, designed to handle components fed continuously into the system, without the requirement for singulation at the input. This system is suitable for high throughput processing of a wide range of radial lead components, such as SIP, TO and other power devices.
The system is typically used to comply with the solderability and cleaning requirements of MIL-STD 2000, MIL-PRF-19500, MIL-PRF-38534, and MIL-PRF-38535.
The system may be specified to run lead-free alloys with little or no equipment modification. To convert existing machines to lead-free requires only a change in solder module to avoid contamination.

The DTS-400 is comprised of a central processing module and may be equipped with several input and output handling options, depending on the user’s requirements. The system may be placed in-line with trim & form, inspection, or other equipment to reduce or eliminate handling.

The central processing module is a completely enclosed welded tubular steel structure. Sliding glass panels are provided in the front and rear of the system so the process may be easily viewed and monitored. Vent stacks are located along the top of the system The standard system has a footprint of 186" long by 34" wide by 74" high (4725 x 864 x 1880mm). It includes:         

The system is equipped with explosion-proof interior lighting, giving good visibility in the process area. Spill trays with drains under each module facilitate clean-up and maintenance.
Operator controls are located above the process modules on the upper panel.  These include Emergency Stop buttons at each end of the system and Alarm Reset switches. Controls and indicators for Service Utilities, Conveyor Control, Alarm Status and specific module control settings are also located on these panels.
Door and Window interlocks prevent operators from accessing the interior of the system during processing. The standard door interlock package provides interlocks on all doors covering electrical power cabinets. The standard window interlock package provides interlocks on all sliding windows covering the main processing module.

COMPONENT CONVEYOR

The variable speed component conveyor has a range of 0 to 30 feet per minute (0 - 9.1 m/min). The standard conveyor comes with 6 component carrying grippers per foot of conveyor chain. This gives a typical throughput of 7,200 components per hour (based on 6 grippers/ft and conveyor speed of 20 feet per minute). Depending on the process requirements and the gripper design, the system can be optionally equipped with 8 or 12 grippers per foot, increasing the typical throughput to 9,600 - 14,400 components per hour. It is also possible to process components in lead frame strips, giving throughput rates as high as 75,000 parts per hour, depending on component size.
The unique design of the gripper assemblies with custom fingertips allows them to hold the components by the body. This feature allows for in-line processing of the components and ensures part-to-part repeatability. The conveyor chain and cam-actuated gripper assemblies are all constructed of stainless steel to prevent corrosion by flux fumes from the process. The snap-fit fingertips, designed so they can be changed quickly, are made from titanium which has good corrosion resistance and is non-wetting.
Also incorporated as a standard feature is a finger cleaner, located directly above the post-cleaning module. It uses tap water to completely rinse the conveyor chain, gripper assemblies and fingers, eliminating flux residue build-up and reducing maintenance. Sheet metal safety guards with clear acrylic windows are provided to enclose the conveyor and fingers at each end of the system.

PRE-CLEANING MODULE

The precleaning module is designed to remove severe oxidation from component leads prior to the tinning process. The module is comprised of three stages.
The first stage is the deoxidizer tank, which is completely enclosed and has its own venting system. It utilizes a variable speed D.C. motor driven recirculation pump to provide a turbulent bi-directional wave for effective removal of oxides from the component leads. CPVC construction makes it compatible with most commercial pre-cleaning solutions. A Teflon coated immersion heater is provided to heat the pre-cleaning liquid and a digital temperature controller maintains the set temperature. The immersion heater is protected by a compressed air purge and flow switch. A separate pump is provided to feed pre-clean solution from a container housed in the base of the machine in order to maintain the correct liquid level in the tank. This auto liquid feeder provides level control with a high and low limit.
The second stage is an aqueous spray rinse with fresh hot water feed. This removes residual precleaning solution from the components and prevents contamination of the flux. A set of compressed air blow-off nozzles follows the spray rinse.
The third stage is a compressed air blow-off module which removes residual rinse water from the devices.

WAVE FLUXING MODULE

The fluxing module has a wave flux pot constructed of PVC. The height of the flux wave is adjusted by a thumb wheel potentiometer which controls a variable-speed D.C. motor pump. Air knives are used to remove excess flux thereby eliminating solder splash and solder balls during the soldering process. A drain is provided, as is overflow protection. This allows for speedy clean-up at the end of the work schedule, or rapid changeover if more than one type of flux is being used. This module can accommodate all standard flux types. 

FLUX DENSITY CONTROL SYSTEM 

The flux density controller is designed to control the specific gravity of the flux. Once the operator has set the recommended specific gravity, the controller will automatically add the necessary amount of flux or thinner to maintain the setting and the proper level in the flux pot. The FDC unit has a built-in temperature compensation feature.

PREHEATER MODULE - RADIANT

The preheating module utilizes radiant heating elements in a stainless steel enclosure. The module has a digital temperature controller with one thermocouple located at the midpoint of its 18" (457mm) overall length

SOLDER MODULES

The solder module has a stainless steel solder pot. The solder pot rolls in and out by means of a lead screw to facilitate position adjustment and access for maintenance. A positive stop ensures repeatability when returning to the operating position. The pot has a thermally protected D.C. motor driven pump, which provides precise wave height control in the solder nozzle, adjustable via thumbwheel potentiometer. Standard or optional custom designed wave nozzles are available.
The module is equipped with a digital temperature controller with high and low temperature alarms (audible and visual). A low solder level alarm is also standard. The system uses two non-contact heaters, which uniformly heat the walls of the pot, thereby minimizing the danger of an eruption during the warm-up phase. Corfin's dual chamber pot is designed to draw solder from the base of the pot, eliminating dross recirculation through the wave.

INERTING SYSTEM

The solder pot is equipped with an inert gas enclosure around the solder wave, with stainless steel gas diffusers that provide a non-turbulent protective gas cover over the wave. The controlled atmosphere reduces dross formation on the solder wave, promotes wetting and ensures uniform solder coverage of the component leads. The process of solder coating component leads is greatly enhanced by the inerting process, with the virtual elimination of icicles and flags. A stainless steel shroud that covers the rear of the solder pot, including the pump area, is injected with inert gas to reduce the formation of dross and black powder from the pump shaft. Consumption of solder and maintenance times are greatly reduced by the inerting system. 

COOLING MODULE 

Following the soldering module is a cooling module that uses compressed air to reduce the temperature of the device. This eliminates the possibility of thermal shock when the components enter the post-cleaning section.

POST-CLEANER MODULE

A two stage stainless steel cleaning module is supplied with all DTS-300 systems. The standard configuration for aqueous cleaning has a turbulent wave wash section with recirculating pump, followed by a spray rinse section. Hot feed water is supplied to the rinse section, ensuring that the components are rinsed clean before exiting the module. The rinse water then cascades to the wash section and is recirculated by pump through the turbulent wave nozzle. An immersion heater located in the wash section maintains the water at the set temperature.
Overflow from the wash section goes to drain, or may be recycled through an existing or optional recovery/treatment system. The post-cleaning module may be supplied with tap, reverse osmosis, or deionized water depending on customer process requirements. Flow rate for the cleaning module is adjustable via a flow meter; generally 1.5 – 2.5 gpm (5.7 – 9.5 litres/min) provides good cleaning results.

POST-CLEAN BLOW-OFF / DRYER

At the exit end of the cleaning module there are two air blow-off nozzles that remove the large droplets of water. Devices then enter the drying module where specially designed nozzles remove residual water. 

HOT AIR DRYER MODULE

A hot air dryer is installed just prior to the discharge of the components, thus assuring that all moisture is removed prior to repackaging. It uses compressed air feeding through in-line heaters into a stainless steel enclosure that directs the hot air stream through slot nozzles on either side of the component. The thermocouple sensor is in the hot air stream and feeds back actual air temperature to a digital controller with high and low limit alarms. 

NOTE: Selection of optional process modules is limited by available space in the central frame. They may also replace standard modules, with appropriate price adjustment. Consult Corfin for details and pricing of the process configuration best suited to your specific requirements. 

PREHEATERS

The standard 18” radiant preheater may be supplemented with an additional 12” or 18” radiant preheater, or with a 9” or 18” convection preheater. The standard radiant preheater may also be replaced by the 18” convection preheater. This provides a flexible arrangement of preheating to meet a wide range of process requirements. It should be noted that adding preheaters may necessitate the removal of other process modules to create the required space.
The convection preheaters use compressed air feeding through in-line heaters into a stainless steel enclosure that directs the hot air stream through slot nozzles on either side of the component. The thermocouple sensor is in the hot air stream and feeds back actual air temperature to a digital controller with high and low limit alarms.

HIGH TEMPERATURE SOLDER MODULES

For certain alloys and processes, higher than normal operating temperatures are required. A specially treated stainless steel solder pot, pump and nozzle assembly are available for operating temperatures in excess of 650°F (343°C.). This option is also required if lead-free alloys are used in the process. 

SECOND SOLDER MODULE 

A second solder module can be installed for processes requiring a double pass, or two different wave configurations. The second solder module may be the same as the standard 9” wide module, or a 12” wide module if longer dwell time in the solder is required. The 12” module may also replace the standard 9” wide module, with the appropriate pricing adjustment. 

SOLDER MODULE AUTO JACKING SYSTEM 

The solder module is mounted on a heavy-duty motorized jacking system, which raises and lowers the module through a range of approximately 2.5 inches (65 mm). In the event of a machine stoppage, which would normally result in the main conveyor beam lifting clear of the process modules, the solder module will instead jack down so that the solder wave is below the component leads. Other process modules such as flux wave, etc will switch off. The system can then resume operation, without requiring manual intervention to clear components from the input and output areas. The raise/lower function of the main conveyor is still available, but is selected only when required by the operator. 

SOLDER EXHAUST MODULE

The supplementary solder exhaust module is located directly at the solder wave area and extracts fumes as soon as components touch the solder. This minimizes the spread of fumes through the interior of the machine and is recommended when solder coating large surface areas, which may generate excessive flux fumes. 

EXITING CAM OVER SOLDER POT

A cam over the solder pot increases the exit angle thereby guaranteeing uniformity of solder coverage and no bridging on horizontal leads. 
NOTE: The exiting cam cannot be used with the CF conveyor option. 

AUTOMATIC SOLDER WIRE FEEDER

This unit draws solder wire from a 44 lb (20 kg) spool. When a signal is received from a fixed probe at the surface of the solder, the DC motor/wire feeder drives the required quantity of solder wire through a guide tube into the solder pot. The probe is positioned to maintain a constant pre-set solder level. The unit is self contained and functions automatically. 

CF CONTINUOUS FEED CONVEYOR

The CF continuous feed conveyor is equipped with special grippers, with multiple titanium blades, designed to handle components continuously fed into the system, without the requirement for singulation at the input. This system is suitable for high throughput processing of a wide range of radial lead components, such as SIP, TO and other power devices. 
The variable speed component conveyor has a range of 0 to 30 feet per minute (0 - 9.1 m/min). The stainless steel and titanium gripper assemblies link together through the process to form a continuous carrier that ensures accurate and reliable pick-up of components. Depending on the process requirements and the component size, throughputs in excess of 45,000 parts per hour are possible. 
NOTE: The solder jacking option is recommended for machines equipped with the CF conveyor.

INPUT /OUTPUT HANDLING

A range of manual and automatic handling equipment allows the user to choose the degree of automation that best suits the application. The input / transfer module accumulates and singulates the components for pick-up by the conveyor. This may be fed manually or interfaced with the automatic or semi-automatic handling options offered by Corfin, or with other third party handling equipment. Similarly, at the output end, the transfer discharge module can be interfaced with different handling options. The input and output can be set up to automatically load/unload using tubes, trays, bulk, etc, or any combination required. Request further information from the Corfin. Some of the options offered by Corfin are as follows:

INPUT /TRANSFER - ACCUMULATOR AND SINGULATOR

The input module is designed to accumulate components received from the loading module. It then singulates these components as they move onto the transfer conveyor. This transfer conveyor is synchronized with the finger assemblies on the component conveyor. This method of device transfer allows us to handle a number of different length components with no changeover required. Input modules are designed and available for most standard device types and widths. Transfers will vary according to component types and widths. 
NOTE: With the optional CF continuous feed conveyor, singulation of the devices is not required.       

OUTPUT /TRANSFER -  TRANSFER AND DISCHARGE ASSEMBLY

The Output Module receives the devices from the component conveyor and transfers them to the unload module. It also counts the devices to ensure an accurate number is loaded into each tube or tray. Output modules are available for most standard device types and widths.

SEMI-AUTOMATIC LOAD / UNLOAD

LOAD-END TUBE HANDLER / 2 POSITION STAR INDEX

This option provides semi-automatic feeding into the input/transfer of the DTS system. The operator places two full tubes into the star-index loader. The loader is then moved in line with the feeding slide to the tinning system and the tube empties. When the first tube is empty the operator manually moves the star indexer to position 2, and while this tube empties replaces the first tube with a full one. This operation is repeated as each tube empties. 

UNLOAD-END TUBE HANDLER / 2 POSITION SHUTTLE

The shuttle is interfaced with the output/transfer to provide semi-automatic loading of the processed parts back into tubes. When one tube is filled, the operator switches the shuttle to an empty tube. While the second tube is filling, the first is removed and replaced with an empty tube, and the process repeated.

ADDITIONAL INSERT SETS

The star index loader and unload shuttle come equipped with a set of inserts (4), dedicated to a tube/component type. To change over to a different tube/component type requires only changing the inserts, supplied as a set of four.

AUTOMATIC TUBE HANDLER 

The handler takes tubes from the magazine and automatically advances them into the loading position. Tubes are then indexed to the emptying position, and the components slide out of the tube into the input/transfer of the machine. When the sensors indicate that the tube is empty, it is ejected and a new tube is brought into position. At the output end, a similar operation takes place with empty tubes being retrieved from the magazine, and filled with processed parts delivered from the output/transfer. The handler is customized to accommodate the user's tube and component type(s), and is controlled via the machine's PLC. This system provides for continuous operation at high throughput rates.

AUTOMATIC TRAY LOADER / UNLOADER 

The 15 tray automatic loader consists of two magazines, each with a 15 tray capacity. Full trays are loaded into the one magazine; after the components have been offloaded for processing, the empty trays are transferred into the second magazine. A tilting table, located between the two magazines, aligns the tray with the input/transfer. As the tray is indexed, each row empties its components into the transfer slide. At the output end, the system can be equipped to feed the processed parts automatically back into trays, or may be equipped with tube, or other handling equipment depending on customer requirements.

COMPUTER CONTROL PACKAGE

The Computer Control and Data Acquisition Package consists of a customized version of Wonderware's Intouch. Intouch process control software allows users to monitor, control, generate alarms, store data, and graphically display archived data. Corfin has used Intouch and its many powerful features to produce a data acquisition package designed specifically for your tinning system. 
Intouch runs on a personal computer supplied as part of this option package and interfaces with the Programmable Logic Controller (PLC) on the tinning system. The program is easy to install and easy to use. A printer (not supplied) is recommended if hard copy printouts are desired. The printer must utilize the parallel printer port. 

UPPER PANEL COVERS AND LOCKS

Transparent acrylic panels can be installed with locks to restrict access to any of the process controls on the overhead panels. Strategic cut-outs in the panel can permit operator access to customer specified controls. 

ADDITIONAL SET OF INSTRUCTION MANUALS

The hard-copy operating manual for the system is normally supplied in two 3-ring binders; one with the operating and maintenance instructions; one with a full set of bills, assembly drawings, and electrical schematics. This option provides a full duplicate set of binders. 

CD-ROM ELECTRONIC MANUAL

The operating manual, with full system bills of materials, assembly drawings, and electrical schematics are supplied on CD-ROM allowing loading to standard PC. The electronic manual has internal "links" for ease of access. Any part of the manual, including drawings, can then be printed out if a duplicate copy is required. 

SPARE PARTS KIT

The spares kit is recommended to ensure that first line spare parts are available at customer location. The 5% of system cost guideline is normally sufficient to ensure a comprehensive range of essential spares. 

Safety features are built into the DTS systems and are clearly outlined in the system's complete operating manual. 
Audio and visual alarms are standard on the system to monitor the levels and temperature in each module and report any fault conditions. The operator may stop the audible alarm using the alarm reset button, however the visual alarm will continue until the fault condition is corrected.
If the conveyor is stopped for any reason while processing components, the entire conveyor assembly automatically lifts clear of the process modules, eliminating the potential for thermal or chemical damage to any components that are in process. 
An exhaust system with interlock ensures that all process fumes are evacuated from the machine. Where appropriate, local venting at the process modules supplements the overall evacuation of the process chamber.
Door and window interlocks protect the operator from electrical hazards and from moving parts in the process chamber.