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Problems placing PLCC4 parts with Fuji IP1 - any help/ideas?

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#56938

Problems placing PLCC4 parts with Fuji IP1 - any help/ideas? | 15 October, 2008

I have a Fuji IP1 using the MCS control system. Everything works fine, but it seems to have tons of problems placing PLCC4 parts (Osram Power TopLED). Some reels I load up it will give a vision processing error for about 1 out of 10 parts. Other reels I load it will place 1 part and error 5 parts in a row. I have checked the feeders and they all seem to be OK. The error is "ImageProcess D080(0000)" - a vision error. This specific error is not listed in the manual. I called Fuji and they didn't want to help, saying they no longer support this machine. I told them all I wanted was a definition of the error message. The guy said D means device (part info), so it must be either the body length/width, pick-up position, or tolerance on the leads.

Well, I adjusted all of those to their maximums without much effect. I also tried adjusting the CCD Level and that didn't help either. I've tried 3 different vision modes but none of them work correctly.

Rather than just start messing with settings with no direction, does anyone have any ideas what I should try to resolve this problem? The components are not fine pitch at all, so I don't really need the system to be verifying the length of the leads or anything... I wish there was a way to turn off the vision processing for this part!

Anyone using an IP1 and have a part definition for a PLCC4 LED? If so, can you provide your settings? Or perhaps someone knows these machines and has an idea what I can check to get it working right?

Thanks!

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#56939

Problems placing PLCC4 parts with Fuji IP1 - any help/ideas? | 15 October, 2008

set the vision number to 255 in the PD. This will shut off the vision processing

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#56940

Problems placing PLCC4 parts with Fuji IP1 - any help/ideas? | 15 October, 2008

255 shuts it off, but if I remember correctly 254 still uses vision but passes almost everything?

You might want to give 254 a try before resorting to 255. I believe 254 will still correct some pickup offsets. And iirc 255 isn't in the manual but someone told me about it.

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#56941

Problems placing PLCC4 parts with Fuji IP1 - any help/ideas? | 15 October, 2008

Thank you Dana and Stephen, I will give it a shot now. I'm not surprised it's not in the manual... apparently there is tons of stuff not in the manual and Fuji tells me they have no idea what half of the unwritten stuff means :)

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#56944

Problems placing PLCC4 parts with Fuji IP1 - any help/ideas? | 15 October, 2008

I tried vision code 254 which gave the same error rate as before (although it was a different error, 4001 this time)... then I switcehd to 255 which almost never gives an error except for a mis-picked component.

However, the parts are now very inaccurately placed on the board. There is a lot of space in the pockets of the embossed tape, so I think it's not really able to center correctly on vision mode 255, and those boards will require manual movement of most of the placements to get them just right.

Anyone have any ideas on how to get this working? There are other PLCC (such as PLCC-32 and PLCC-44) components defined with vision code 102 and 105. 102 says it's for PLCC and 105 isn't in my manual, but I suspect it's the same but for a newer version of the firmware.

I was originally using 105 but I tried switching to 102 prior to just turning it off with 255. I tried adding 1mm to the pick-up tolerance, as well as setting the lead tolerance to 60%. I also tried setting the X and Y dimension tolerances to 0.6mm with no luck (they were originally 0.2mm as per manufactuers specs).

Any other suggestions? One thing I noticed is when I went to set the CCD level, I manually pick a part and place it on the nozzle, then when I hit start to capture the image, and press F->2, I have to scroll down to the bottom to see the image... and the outline of the legs isn't very clear. The legs are sort of blurred together. I had tried lowering the CCD offset in the part definition to -50, but it still looked bad. Could this be the source of the problem? When I captured the image manually, then went into F->2 (to show the image as binary bits), the whole screen was just cluttered with random blocks. It didn't resemble a part at all.

Vision & centering works perfectly with all the other parts - including SOIC's, 0805, 0603, 1206, SOT23-5 and tons more - I maybe 1 part in several hundred... so the vision system seems to be working fine. I just can't get it to like the PLCC LED's.

The only thing about the PLCC's I was thinking may be an issue is their housing is white plastic, whereas most chips are black (although the bottom of an 0805 is white too). Any suggestions? Try lowering the CCD level more?

Thanks in advance for any advice.

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#56968

Problems placing PLCC4 parts with Fuji IP1 - any help/ideas? | 16 October, 2008

Is the nozzle used to pick the offending used to pick other parts in this program? Have had experience where the LED's inside the nozzle backlight have broken down causing Vision Processing errors. And worth making sure that the brushes on the head are giving a good contact onto the nozzle backlight. As you say using Vision type 255 will throw placement all over the place. You could maybe try using the Vision type that reads from corner to corner, can't remember of hand what the number is. (St Andrews flag style)

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#56973

Problems placing PLCC4 parts with Fuji IP1 - any help/ideas? | 17 October, 2008

Check the image using the fast inching [F] and axis selection [2]. After vision error, press [F] then [2]. The monitor will display a binary images. You will now have a visual look on how the error occurs. Adjust the CCD level of the camera until you get a good image of the part.

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#56974

Problems placing PLCC4 parts with Fuji IP1 - any help/ideas? | 17 October, 2008

Hi, When you tried vision type 254, did you change the size of the body? On 254 the body size should be the outer dimension of a component, so on a PLCC (or any other component) the leads should be included in the body size as well. One other thing regarding vision type 254, change to back light instead of front light.

Best Regards,

Tegel

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#56983

Problems placing PLCC4 parts with Fuji IP1 - any help/ideas? | 17 October, 2008

If is IP-1, is using SMD2 vision instead of SMD3 (CPIV-IP3, CP6,7, etc) if so, you must use Vision Number instead of Vision type... if you're using fuji flexa just press F1 on vision number and you will se most common vision numbers depending on shape)

We got rid of 2 IP-2 because are inacurate-slow-troublemaker machines (due to it's age and weak maintenance) and I surprised when read about you working with an IP-1!!!

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