1. Purpose:

Termination of discrete wires to 'Direct Attach' based cable connectors.

2. Machine description:

• Cat. No.: DAH 182
• Single head, solder re-flow machine. The machine consists out of:
  • A jig that keeps the connectors (wafers) and wires in position. The jig is customised for each type of cable and connector combination. The jig is mounted on a standardised base. As such, an easy swap between harness types is warranted, during the production. Optionally, the jig can be equipped with a barcode label. As such, the machine can recognise which type of connector - cable combination is applied. Accordingly, the machine can start automatically the related solder program.

- A laser source that provides the energy, required in order to re-flow the solder junctions. The applied diode laser generates a continuous wave. Laser energy level and laser 'on time' are programmable.

- An xyz-manipulator that can position the laser optical system and the flux dispensing siring. By positioning the x- and y-axis, the manipulator can approach the different junctions of the connector in process. By means of the z-axis, the laser spot can be focused.

- An industrial PC and PLC based controller is responsible for the sequence of the machine. A tactile LCD display is acting as the human interface. By means of different graphical editor programs, the operator can program easily the required soldering programs. A diagnostic program, supports the operator by calibrating the machine.

- The machine is equipped with a laser safe protection guard. Opening the guard, will cut the laser- and motor power immediately.
- Short set-up times are achieved by means of the jig and solder program concept.

3. The proces:

• The operator places the connector in the dedicated jig.
• Clamp the prepared cable in the reserved position of the jig. As such, the connector(s) and the cable are in a correct position, in order to snap on the shielding easily.
• Slide the jig in the active position and close the safety guard.
• By finalising the process, open the protection guard and slide the jig to the load position.
• Depending on the applied connector type, the connector is composed out of different wafers. In such a case, a connector will be connected to the cable, wafer by wafer.
• Once the entire connector is attached to the cable, the assembly can be removed out of the jig.

4. Adjustments:

• In a low-power continuous wave mode, of the laser, the hot spot can be adjusted to a reference point on the jig.
• By means of the connector editor, the xyz positions of each junction of the connector can be programmed. Also the solder program for each junction can be programmed / adjusted. That means that for each separate junction, the laser energy, the laser 'on time' and amount of flux are under control. As such, a near perfect repeatability of the process is warranted.

5. General specifications:

• Colour : according to RAL 7032.
• Weight : 120 Kg
• Size : (w= 1300 mm) x (d= 1500 mm) x (h= 1540 mm)

6. Input material and functional requirements:

6.1. Discrete wire

• Plating : Positive experience is gathered with tinned and silver plated wire.
• Insulation : The insulation has to withstand the melting temperature of the applied solder.
  Indicative values:

  179 °C for 62 % Sn + 36 % Pb + 2 % Ag.
  224 °C for 96 % Sn + 4 % Ag (Lead free !!!)

• Types : Both insulated and drain wires are applicable. Also solid- and stranded wires are accepted by the machine.

6.2. Components

• Types : 'Direct attach' connectors equipped with stamped and formed contacts or pcb substrate. E.g.: Beamon, Gigabit Link, MCA, Argo, …

• Sizes

  : Minimum path size: (l=1,8 mm) x (w=0,7 mm).
  : Minimum pitch: 1,15 mm.
  : Minimum distance between the path/contact and the plastic body of the connector/wafer: 0,15 mm.
  : Connector/wafer parts should not disturb the laser beam, flux dispenser or wire positioning fingers.

• Finishing : The contacts have to be pre-tinned. 1mg of tin plating is
  required on a contact path of 1,8 x 0,7 mm.
• Colour : In order to reduce the absorption of the laser energy, the
  connectors/wafers should be manufactured from white plastic.

7. Machine input:

• Depends highly on the applied connectors and cables. Typical re-flow time per junction is 2 sec.

8. Safety and ergonomics:

• A safety guard protects the operator, he can not possibly injure himself in the operating area on rotating or moving parts when the machine is operating.
• Opening the safety guard, will put the machine in an interlock condition, i.e. no automatic axis or tooling movements are possible. Also the laser energy will be cut.
• The machine is equipped with a red coloured emergency stop button of the mushroom type. It allows the operator to stop the machine at any time. Machine operation can only be resumed by pulling back the emergency stop switch to its start position and pushing the 'Start' push-button.
• All the necessary safety instructions are mentioned by means of the conventional symbols or an English text.
• Noise level: max.75 dBA - measured at a height of 1.8 meter above the floor and at a distance of 1 meter from the machine.
• The protection guard is equipped with a filter window that stops the applied laser wavelength. Through the window, the operator can inspect the process.
• The machine is CE certified.

9. Enviromental conditions:

9.1. Ambient temperature

The ambient temperature is measured at a height of 1.5 m above the floor and at a distance of 1 m from the machine.

a. Normal range : + 15 to +30°C
b. Average value : ± 23°C
c. Maximum variation within a 5 min. period : ± 5°C

9.2. Humidity

a. Normal range (no condensation) : 40 to 70% R.H.
b. Range not resulting in constantly : 10 to 90% R.H.
reduced operation

9.3. Atmospheric pressure

Normal range: 533 - 1060 m bar.

10. Power connections:

10.1. Electrical

• The machine operates with a supply of single phase 230 Volt ± 10%, 50 or 60Hz ± 1% plus protective ground.
• Maximum current: 16 A.

10.2. Pneumatic

• Standard industrial compressed air supply: 6 bar - dry air.

11. Documents:

The machine documents are written in English and contain the following information:

• Mechanical assembly drawings plus part lists.
• Electrical drawings.
• Maintenance and safety instructions plus maintenance plan.
• Recommended spare parts list with Cat. No's.
• Installation and connection conditions (dimensions, weight, power sources).
• Operating instructions.
• Programming instructions.

12. Training

For each system, the supplier will provide training for the customer's engineers.
Language: English
The training will be split up in:

a) system overview
b) mechanical part + adjustments
c) programming
d) safety and maintenance
e) on the job training

The explanation on electrical diagrams, mechanical adjustment, system operation, programming and maintenance are done in such way that the customer is able to run the machine properly.
Travel charges, training fees and expenses are paid by the customer.

13. Installation:

The installation of the system will be accomplished by the manufacturer's personnel with the assistance of the customer's personnel.
A minimum of 4 weeks prior to delivery, the supplier submits to the customer the installation site requirements, containing the required physical dimensions, power, etc.

14. Warrenty:

12 months starting from the shipment date from the supplier's facility.

15. Options:

• Customised jigs for different connectors and cable configurations.
• Automatic jig recognition.

• Adapter for other supply voltages (e.g.: 2 x 110 Volt).