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UP3000 ULTRAFLEX

THE INDUSTRY CHOICE FOR SPEED, ACCURACY AND FLEXIBILITY

UP3000 ULTRAFLEX

HIGH END PRINTER MARKET

Introduced in 1995 - Only true High-End printer in market

800 + installs worldwide

80 % of sales are repeat customers

Design concept:   High-End Printer,

     with advanced features and options for advanced high speed applications

Focus on  High Speed, Accuracy and Reliability  while providing Ultra-Flexibility.

Design fits Double-sided, High-changeover environments with a large variety of board sizes.

 

UP3000 ULTRAFLEX
Frame Design

 

New frame design that is Dynamically tuned

Centernest strengthened to handle new design

Cross member added for increased strength

Three fold increase in Stiffness

UP3000 ULTRAFLEX
Frame Design

 

UP3000 ULTRAFLEX Frame Design 

UP3000 ULTRAFLEX
DRIVER POD(outside)

UP3000 ULTRAFLEX DRIVER POD(outside)

 

UP3000 ULTRAFLEX
DRIVER POD(inside)

UP3000 ULTRAFLEX DRIVER POD(inside)

UP3000 ULTRAFLEX
COMPUTER POD

UP3000 ULTRAFLEX COMPUTER PODUP3000 ULTRAFLEX COMPUTER POD

New Pentium Computer

Change in MUX card #3

New mechanical pod and I/O track cover locks.

 

UP3000 ULTRAFLEX
AC POD

 Solid State Relays

The addition of the Safety Relay

New Breakers

 UP3000 ULTRAFLEX
New “Print Engine”

 

 UP3000 ULTRAFLEX New “Print Engine”

UP3000 ULTRAFLEX
SUB-FRAME

UP3000 ULTRAFLEX SUB-FRAME

Parallelism achieved though castings

Stepper motor control
( small distance movement)

Accuracy 2000 micro-steps per revolution = 16 mm

 Direct Drive Servo Motor 

Increased resolution

12,800 micro-steps per Revolution

Increased Speed Possible

 UP3000 ULTRAFLEX
Z-AXIS

 UP3000 ULTRAFLEX Z-AXIS

 UP3000 ULTRAFLEX Z-AXIS

Z - AXIS

Servo Motor Design

New Linear Bearing Design

New Linear Bearing Design

Hollow Core Servo Motor

Direct Drive Lead Screw

Maximum resolution and stiffness during movement for improved Snap-Off

 UP3000 ULTRAFLEX
Z+Theta SERVO MOTORS

Both the Z and Theta use Resolver feedback.

 

Both Servos need Step and Direction signals to work. The Theta motor needs a Positive signal to enable and the Z motor needs a Negative signal to enable.

 

The servos have a digital display letting you know the condition of the servo:

1.   On the Z motor servo a dash (-) indicates that it is OK.

2.   On the Theta motor servo a Zero (0) and a period (.) indicates that it is OK.

 

 Direction signal for the theta axis only is a differential signal.  For this reason Motion Multiplex (mux) #3 is different from the others and no longer interchangeable with the other mux cards.

 UP3000 ULTRAFLEX
 Centernest

 Snugger system uses two pistons at ends of bar

Results in more flexible and repeatable board handling

Snugger Height - Four Inter-Dependent Fine Pitch Motors
(the eccentrics are no longer used for snugger height)

New Flipper Design

Handles difficult boards

Handles difficult boardsHandles difficult boards

UP3000 ULTRAFLEX
 Vacuum Shut off

 Immediately shuts off vacuum for better stencil release.

Results in more flexible and repeatable board handling

Results in more flexible and repeatable board handlingResults in more flexible and repeatable board handlingResults in more flexible and repeatable board handling

 

 

UP3000 ULTRAFLEX
 Flipper Enhancements

 

1. They ride on a four bar linkage.

 

2. Can be changed to a thinner flipper, 0.005 (5mil) so you can print

      with the flippers on.  (Not available at this time)

 

3. There are 2 pistons for extending and one for retracting (retract piston

    is spring loaded).

 

4. Pistons have a Lip seal that go into the piston block.

 

Note:     Prior to disassembly Shut down the air, if done with the air on,  

            pistons will go flying.     

 UP3000 ULTRAFLEX
New Flipper Design Movement

 

 UP3000 ULTRAFLEX New Flipper Design Movement

UP3000 ULTRAFLEX
BOARD THICKNESS AXIS

UP3000 ULTRAFLEX BOARD THICKNESS AXISUP3000 ULTRAFLEX BOARD THICKNESS AXISUP3000 ULTRAFLEX BOARD THICKNESS AXIS

UP3000 ULTRAFLEX
Calibrating Snugger Height

1)   Calibrating  the BD_THICK sensor.

 

       **This sensor is used as a mid type sensor. During reset the BD_THICK Screw comes out of the screw housing until the sensor is turned on then it travels inward.(Negative) -0.270 inches--- This is the Negative software limit. If the sensor is set incorrectly it will bind at this point. Then when it steps off to its  default value the motor screw will move off at different setting depending on how much it was bound up during over-travel.

 

      1. In axis base settings with the Z-axis at board transport height  Jog the BD_THICK axis negative until the motor stops turning.

        

      2. Slowly jog the axis positive ( Move Upward ) until the knob on top of the motor just starts to move about 1/8 to 1/4 of a turn.

 

      3. Hit exit on the mouse then select "RESET AXIS" on the axis base setting screen. This will reset the counter on the BD_THICK axis.

 

      4. Jog the BD_THICK axis to 0.280 and set the BD_THICK Sensor to "Just off".

 

      5. Next jog the axis positive to 0.290  the SENSOR should turn on before it gets to 0.290

        

      6. Finally slowly jog the z axis up and verify that the striker plate will not contact the BD_THICK SENSOR. If it does the sensor will have to be reset (redo procedure)

      

NOTE: After calibrating the BD_THICK sensor the motors will have to be retimed and snugger height will have to be redone.

            Also after calibrating snugger height the machine MUST be powered down before verify

 2)   Timing the board thickness motors.

 

         1.      Always check snugger height with the table at vision height.  At snugger height eccentrics may be touching. The newest software allows the snugger height to be checked at snugger height but it is best to verify at vision height.

        

         2.      Turn off Stepper Power 2 through the I/O screen.

 

         3.      Measurement should be with Z-track on. Make your measurement at the end of the rails.

 

         4.      Your reference will be on the left front adjustment (This is your reference adjustment, DO NOT TOUCH.) The three other points where you’ve made adjustments should be within 0.001 mil.

 

         7.      Of the three adjustments, two have the thumbscrew adjustments on top, the right rear the adjustment is on the bottom.

 

         8.      Turn Stepper Power 2 back on and Reset the machine.

 

3)  Perform the Calibrate Snugger Height through Base Settings screen.

 

         1.      Verify the correct board thickness is entered in Setup Page 1.  

 

         2.      Follow instructions on the screen. Then after completion power down.

        

         3.      Power up, reset and verify  snugger height.

 

UP3000 ULTRAFLEX  DOS Software Changes

UP3000 ULTRAFLEX
 DOS Software Changes

 The  .100 file extension.                   (used for Ultraflex only)

 Version 8.1+ will need a jumper on LRDB J21 (it should already be there)

Gem screen access.

The Key pad accessory.

New axis BD_THICK.100

UP3000 ULTRAFLEX Slow Snap-Off Hardware

UP3000 ULTRAFLEX
Slow Snap-Off Hardware

Z- axis redesigned with slow snap-off in mind

Enhanced Resolution of Servomotors

Increments of movement - 0.0003”

Controlled harmonics

 Release profile now programmable with up to 5 separate sections

Up/ Down - breaks bond of paste and stencil

Continuous - vibration free release

Stepped - introduce controlled harmonics

UP3000 ULTRAFLEX  NT Software

UP3000 ULTRAFLEX
 NT Software

DOS standard with Ultraflex release - 8.1

Windows NT available Q4 - year 2000

Icon-Based User Interface

Designed with operator in mind

Multi-tasking capability

New wiper profile

SPC Trend analysis display

UP3000 ULTRAFLEX  Reliability

UP3000 ULTRAFLEX
 Reliability

 The simpler the manufacturing process
the more reliable the machine

Manufacturing methods built into design

Modular manufacturing design.

Pre-tested sub-assemblies.

Meets present UL and CE requirements

UP3000 ULTRAFLEX

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