助焊剂全自动喷涂设备使用说明书

目录

Contents 一：产品概述

Machine Instruction

二：技术规格说明

Instruction of Technology Data

三：操作指导书

Operation manual

四：常见故障处理

Common Fault Troubleshooting

五：维护与保养

Preventive Maintenance and Repairing

六：主要备件清单

Main spare part list

七：安全要求

Safe Requirement

一：概述Overview

本公司生产的助焊剂全自动喷涂设备主要分外置机和内置机，客户可根据实际需要进

There are two types machine model to be selected by customer, it is internal and external machine.

行选择。本说明书以GDFS-400W标准型为基础进行阐述。

The operation manual is base on GDFS-400W operation.

产品特点Machine feature：

1：采用图片处理的方式选择需要喷涂的区域，操作简单，定位精确；

With image processing to choose need spraying area, simple operation, and precise position.

相对于传统的多点测量编程，可减少误差，节省时间；

Programming time is very short and Zero missing comparing the traditional flux machine.

2：对于PCB板上需要重点喷涂区域可以进行定点喷涂；；

For more flux require area that machine can spray it with fixed point spraying method.

相对传统的全局喷涂，此项功能可大大减少助焊剂的使用量，节约成本；

Compare to traditional global spraying, the function can save more flux.

3：采用精密步进电机和高精度感应器的双轴喷涂平台，喷头可随承载PCB板的轨道同时X-Y table is using high accuracy step motor and driver, Spray head can follow pallet conveyor 同向运动，弥补了传统单轴喷涂的盲区。

moving direction, means the spraying no blind point with single Y axis.

4：用户权限分级管理；

User permissions classification management

5：报警信息界面显示，方便快速处理；

Warning message displays windows,convenient quickly to handle.

6：生产信息可根据条件查询和导出；

User can check production information conditionally.

7：可脱机运行，摆脱设备运行时对电脑的依赖；

Machine can run off line, computer can shut down when machine running.

二：技术规格说明GDFS-400W

?外观尺寸（L*W*H）：1200*1150*1300

Machine Dimension （L*W*H）：1200*1150*1300

?机器重量：250KG

Machine Weight: 250 Kg

?工作电压：220V±10%,50Hz;

Operating voltage: 220V±10%, 50Hz

?功率：1500W

Power: 1500W

?气压范围：0.2～0.4Mpa

Air pressure range：0.2～0.4Mpa

?适用线路板尺寸（mm）：Min:50*50 Max:400*400

Fitting PCB size（mm）：Min:50*50 Max: 400*400

?适用线路板重量：Max 10Kg

PCB and pallet weight：Max 10Kg

?适用线路板上部空间：120mm

PCB Upper space: 120mm

?适用线路板下部空间：30mm

Pallet lower Space: 30mm

?喷涂类型：区域喷涂和定点喷涂

Spray type: Area spray and fixed point spray

?助焊剂箱体容积：2L (Max)自动抽取

Flux tank volume: 2L (Auto feeding)

?助焊剂液位检测：低液位报警,抽取不到助焊剂报警

Flux liquid detecting: Lower warning and no liquid warning ?喷涂定位：手动图片编辑，托盘长宽设定，自动导入喷涂位置坐标

Spraying location: auto analysis programming and setting XY coordinator

三：操作指导书Machine Operation Manual

1: 准备工作Preparatory work

（1）：检查压缩空气过滤器是否有积水，如果有积水应及时排出；

Checking the air filter, if water found, empty the filter.

（2）：接通整机机电源，闭合断路器；

Connect the power and power on breaker switch.

*蓝色手柄在下方时为开路状态，推向上方为闭合状态

Blue hand shank: Upper is on, Lower is off

*左侧为整机电源断路器，闭合后整机所有用电设备通电；

Left breaker is machine power switch, if on, all element is power on.

*右侧为轨道电机断路器，仅把机器作为“轨道”使用时闭合；此开关闭合后

无法对轨道进行“运行”和“停止”操作；

Right breaker is conveyor power switch, if on, conveyor will always run

without control by machine controller

（3）：检查喷涂机轨道宽度设定是否与产品宽度一致，根据需要进行调整；

Inspect conveyor width is same to program setting, adjust it if need.

（4）：打开电脑电源，确定电脑和控制器已联结并能正常通信；

T urn on the computer, confirm computer and Micro-processer is on line and

Communication is ok.

2：进入操作系统

Started computer and enter the operating system

（1）：在电脑主机页面双击打开“高达喷雾系统”

Double click "GaoDa spray system" to enter application software.

（2）：输入帐号和密码，点击“登录”，进入喷雾操作系统

Input user name and password, click "login", enter the spraying operating system （3）：操作分两种模式

Two modes of operation

A .没有项目:

No project existing

登录系统->新建项目->加载图片->剪贴->完成确认->重设产品长宽->进入“区域工具”按需要编辑喷涂区域->点击“保存项目”->点击“设备操作”->点击“喷涂当前项目”->点击“复位”->点击“开始”Log on to the system - > new project - > loading picture - > Clip - > completion confirmation - > reset the product aspect - > Enter "area tool" according to need to edit the spray area - > click "save project" - > click "operation" - > click "spraying current project" - > click "reset" - > click "start"

B.已有项目:

Existing project

登录系统->打开项目->选择要喷涂的项目->点击“设备操作”->点击“喷涂当前项目”->点击“复位”->点击“开始”

Log on to the system - > Open Project - > select target project - > click "spraying equipment operation" - > click "spraying current project" - > click "reset" - > click "start"

3: 以需新建项目为例介绍机器设置和编辑操作

Below is sample of new project setup to instruct machine setting and operation

3. 1: 托盘图片编辑

Pallet and PCB picture editing

3.1 A: 点击“新建项目”；

Click on the "new project

3.1 B: 点击“加载图片”，找到事先倒入到计算机中的待喷涂托盘的图片并加载；

* 注意示意图片的方向为俯视图，并且托盘运行方向与轨道一致，否则要进行旋转和镜像操作；

B: Click "loading pictures", find the advance picture to be painted and loading.

* Note the picture direction is bird view, and the pallet running direction

Same to conveyor running, if not, need to rotate and mirror image operation 3.1 C: 选择“缩放比例”，通常情况下0.3左右即可，根据实际情况而定；

Select "Scaling", normally according to actual, usually about 0.3 is fit

3.1 D: 选择“剪切”，将托盘整个选择并剪切下来即可，本图只是示范；

Select "shear", select and cutting down pallet size, this is a demonstration; 3.1 E: 点击“完成确认”，图片会自动加载到喷涂编辑区域；

Click "completion confirmation", the picture will be automatically loaded

into the spraying and editing area;

3.2：喷涂区域编辑Spraying area editing

3.2 A: 点击“重设产品长宽”，将测量好的托盘的长和宽输入电脑；

*注意测量和输入的单位要匹配,

*测量宽度时不包括挂在轨道链条或钩爪部分，一般托盘都有明显区分；

Click "reset the product size", input pallet length and width to related windows

* Note measurement data should be match input unit,

* Pallet width does not include hanging edge; it is obvious to find the hanging edge;

3.2 B: 点击“区域工具”里的“区域”, 进行对所需喷涂部分进行区域选定；

*为弥补照所示区域与实际区域的误差，所选定区域应略大于图示部分；

Click “area" on "regional tools ", selects the required spraying to drawing;

To compensate for deviation of actual area, drawing should be slightly larger actual area;

3.2 C: 点击“定点”，可根据实际需要对需进行重点喷涂的部分进行定点喷涂；

*可根据实际需要更改定点喷涂的喷涂时间

Click "point", Select some fixed point, can according to the need to fixed-point spraying;

* According to product require, change the spraying time of fixed-point spraying

3.2 D&E: 当区域或定点选定后，在上图的DE区域会自动显示所选定区域的坐

标，同时会显示区域编号，如果需要进行删除等操作，可双击DE部分的某个待编辑区域或在图片中进行选择和编辑；

*上图中只对部分区域进行了选定编辑，仅作参考

D&E: when the spraying area or point selected, will automatically display the selected zone coordinates in the D&E region on above graph , also display area number at the same time, if you need to delete, double-click the D&E target part of a region to edit, or select and edit in the picture;

*Above graph is only part of the region was selected and editor, for reference only

3.3 参数设置

P arameter settings

*本章节中所列举的参数的任何修改都会影响到设备的运行和使用，非指定或经过培训的人员禁止修改；客户在使用过程中应对使用人员进行分级授权管理！

*如果产品感应位置不动的情况下，参数无需调整，只进行3.1和3.2的新项目设定即可；

*In the chapter, any modification of parameters will affect equipment operation and running, non designated or training persons are prohibited for any operation, customer should be using staff grading authorization management system for any system operation!!!

* If the product detects sensor position without moving, the following parameters adjustment is not required, only 3.1 new projects and 3.2 setting;

3.3A: 待喷涂产品感应器位置：此参数为某些不能感应托盘进盘边缘而设置，例如某些只

能感应电路板上某个特定的零部件；该参数指感应点到托盘进盘边沿的距离，输入时要注意测量值与输入值的单位要统一；采用对射光纤感应的机器不需要设置此参数；

Product detecting sensor position: this parameter is for product detecting point setting, such as detecting point a specific components, the data is distance of detecting point to the tray edge, input data unit should be same the measurement data; the optical fiber sensing does not need to set this parameter

3.3B: 产品感应滤波：此参数为解决不同的托盘之间长度有偏差时进行过滤而设置的，通

常情况下设置为5，当然根据实际情况可能有不同设置；

Product of detecting filtering: this parameter setting is due to each pallet actual length slightly deviation, usually setting data is 5, of course, according to the actual situation may be different setting;

3.3 C: 喷嘴定位速度：指喷涂开始时喷嘴由原点运行至喷涂起始处时的速度，其值须

与喷嘴喷涂速度匹配，否则会造成喷嘴晃动过大；

N ozzle positioning speed: it is nozzle moving speed when nozzle no any spraying action, it must match the nozzle spraying speed, otherwise, it will cause excessive shake nozzle;

3.3 D: 喷嘴喷涂速度：指喷嘴在指定喷涂区域内的运行速度，其值须与喷嘴定位速度

及轨道运行速度匹配，否则会造成各种超程报警；

N ozzle spraying speed: it is nozzle moving speed when nozzle spraying within the region, the value must match the nozzle location and conveyor running speed, otherwise it will cause various over travel warning;

3.3E: 轨道电子齿轮分子：为轨道驱动轴驱动齿轮的周长值，此值的任何修改都会造成

轨道速度计算值与实际运行值之间有误差，会立即影响到喷涂的精确，甚至会造成喷嘴与轨道运行匹配问题，造成频繁报警；

Rail electronic gear numerator: it is drive gear perimeter of rail drive shaft, any modification of this value will cause the orbital velocity calculation error between the actual values, will affect the spray nozzle location accurate, even cause the track running matching problem, resulting in frequent alarm;

3.3 F: 电子齿轮分母：根据所选用的Encoder型号/参数不同而有不同的设定，如果在

使用过程中出现必须更换Encoder的情况，必须保证型号及参数与原来的完全一致；

Electronic gear denominator: according to the selected different Encoder type and parameters are for different settings, if must be replaced Encoder when it failure, must ensure that the models and parameters is same the original completely consistent;

3.3 G: 喷嘴分辨率：指单点喷涂时在PCB上形成的圆形直径，区域喷涂时指单次喷涂

的宽度值.

Nozzle resolution ratio: it is nozzle spraying point diameter formed on the PCB, a

regional spraying is single spraying width value formed on PCB.

3.3 H: 喷嘴位置X: 喷嘴居于原点时其中心到感应点中心的水平距离.

Nozzle position X: it is the horizontal distance from the center point of nozzle on origin position to the product detect sensor.

3.3 I: 喷嘴位置Y: 喷嘴居于原点时其中心到轨道固定边的距离

N ozzle position Y: it is the distance from the center point of nozzle in origin

position to fix rail edge.

3.3 J: 产品检测信号过滤: 设置一个规定距离，其间感应器都有信号输出电脑才认为有

托盘进来，否则判定为误感应，机器不会动作；该参数的作用是屏蔽误感应信

号；

Product detection signal filtering: Set a prescribed length, which are signal output,

it is means system detected product, otherwise, system judged as wrong induction,

the machine does not action; the parameters of the induction signal is shielded error;

3.3 K: 产品检测信号电平：根据所设定的感应器的输出信号，选择高或低电平为有效

信号；

Product detection signal level: according to the output signals of the sensor set,

choose high or low level of effective signal;

3.3 L&M: 这两个区域内的参数为机器出厂设定参数，正常情况下无需更改；

L&M area parameter is factory origin setting, normally, without change;

4：机器运行操作

Machine operation instruction

当1-3步骤完成后，点击操作界面左侧工具栏的“设备操作”，会弹出运行对话和演示框并

可以对机器进行运行操作

When the 1-3 step is completed, click interface left Toolbar "operation", will pop up dialog box,

Then can operate and demonstrate the machine

4.0 A: “喷涂当前项目”: 指喷涂指定的单个项目

"Spraying current project": it is means that machine should spray selected project.

4.0 B: “喷涂选择项目”指多产品并行时, 将并行的喷涂项目加载到喷涂列表；

"Select spraying project"：loading multiple spraying project to spraying list when multiple project running;

*此项目为产品附加的选项功能，需要根据客户的要求而选用。

* This is optional function, according to customer requirement to equip.

4.0 C: 点击“复位”

Click "reset”

4.0 D: 点击“开始”，设备开始运行；

Click "start", equipment running;

4.0 E：选择区域喷涂范围的模拟显示颜色；

Selected to different displaying colors of spraying range

4.0 F: 选择定点喷涂范围的模拟显示颜色；

Selected to different displaying color of fixed-point spray range

4.0 G: 喷涂过程模拟显示区域；

Spraying process simulation display area;

机器设置部分补充说明：

The machine setting part Noted:

1：托盘照相时应尽量使相机与托盘保持平行，尽量避免照片变形，否则喷涂时会产生位置误差；

When take pallet photo, should try to make the camera with the pallet to keep parallel, try to avoid photo deformation, or spraying will produce position error;

------建议购置选配部件托盘照相平台Proposed purchase - selection part tray photographic platform

2：3.2 A项托盘尺寸测量说明

Pallet size measurement description

●X为托盘长度（与轨道运行方向一致）

●X is pallet length (consistent with the rail running direction)

●Y为托盘宽度（与轨道运行方向垂直）

●Y is pallet width (perpendicular to the rail direction)

3

X1为3.3 H项中的测量值，X2为要输入的喷嘴X值

X1 is 3.3 H measurement values, X2 is the value entered for nozzle X

5：用户权限及帐号管理操作

User authorization and account management operations

5.1 以取消操作员级别更改密码的权限为例进行操作说明

As cancel the operator level password to change permissions for an operating instructions sample

5.1 A: 点击“用户管理”

C lick “User management"

5.1 B: 点击“权限管理”

Click on the "Rights management"

5.1 C: 在弹出的对话框中选择操作员-更改密码对应框并双击，会弹出“用户权限管理”对话框；

Pop-up dialog box and select operator - change password corresponding frame and double click, pop up "user management" dialog box;

5.1 D: 去掉“更改密码”选项前的选中符号V；

Cancel symbol V of "change password"

5.1 E: 点击”保存”, 这样操作员级别的“更改密码”权限便被取消了。

Click "save", the permissions of “change password” will be cancelled on operator level

5.2 用户帐号操作

User account operation

5.2 A: 点击“用户管理”及下拉菜单中的“新增用户”，会弹出“新增用户”对话框；

Click on the "user management" and the drop-down menu in the "new users", "new

users" dialog box will pop up

5.2 B: 在“用户编号”中输入员工工号----工号在公司员工管理是与员工身份对应并唯

一的；

Input the employee number on "user ID" dialog box, the employee number is only

ID in the management system of the company employees;

5.2 C: 在“用户名称”中输入员工姓名；

Input employee name on "user name" dialog box;

5.2 D: 在“用户密码”中输入员工登录系统时的初始密码;

Input origin password of login system employees on "password" dialog box;

5.2 E: 在“用户权限”中选择与其职务对应的权限；

Choose their positions in the corresponding permissions on "user permission"

5.2 F: 点击“新增”，这样一个经过授权的新用户便添加成功了

Click "add", so a new user authorization was added successfully.

5.2 G: 点击“用户列表”可以查看所有可以登录本系统的人员信息，密码为“*”显示；

Click on the "user list" can view all can log on the system of personnel information,

the password is "*" display;

5.2 H: 同时在“用户管理”对话框中也可对用户进行修改和删除等操作；

At the same time, on "user management" dialog box can also modify and delete

operations to the user;

6：信息查询及导出

Information checking and export

6.1 设备运行时实时状态及动作查询

Real-time status and action checking when the equipment is running

根据客户所选择的操作版本不同，机台运行实时状态查询略有不同

According to machine version, real-time state checking is slightly different

6.1.1 操作系统为5.0及以上版本查询

Operating system is 5.0 and above version checking

直接点击A“处设备状态”，即可弹出设备运行的实时状态，某项正在运行时，

其前面圆形标示框会显示红色，实时状态栏下半部分显示的是需要用数字监控

的部分参数，例如轨道运行速度等；

Click on the A "equipment", real time operation can eject device, when a item

running, its front circular mark box will be displayed in red, real-time status bar is

displayed that need use some data of digital monitoring on the lower half, such as

orbital speed, etc.;

6.1.2 操作系统为5.0以下版本实时状态查询步骤如下

Real-time state checking steps are as follows for operating system below 5.0 versions

6.1.2 A: 点击“查看状态”

Click on "view state”

6.1.2 B: 在设备状态对话框中调整“透明度”，此时可以查看设备运行状态，输入/输出

状态，设备故障状态和其它信息状态；这些都是设备的实时运行状态；

Adjustment "transparency" in the equipment status dialog box, you can view the

running state of the equipment, input / output port state, The equipment fault state

and other state information; these are real-time running status of equipment;

6.1.2 C: 点击“关闭”，结束查询；

Click "close", the end of checking;

6.2 历史信息查询及导出

The historical information checking and export

设备在运行过程中会自动保存登录，报警，喷涂等相关信息，便于日后的生产

管理和质量跟踪，查询和导出步骤如下

Equipment will automatically save the login, alarm, spraying and other related

information in the operation process, it is convenient for production management and

quality tracking later, checking and export steps are as follows:

6.2 A: 点击“报表管理”；

Click “report management ";

6.2 B: 输入“用户编号”；

Input "user id";

6.2 C: 输入“项目名称”;

Input "project name";

6.2 D: 输入“开始日期”;

Input "starts date";

6.2 E: 输入“结束日期”；

Input "end date";

6.2 F: 点击“查询”，会列出符合条件的信息，如果某个条件项目为空，系统默认为该

项目为“全部”，如：“项目名称”为空，默认为要查询所有项目；

Click "Checking", will list the information, if a project is empty, the default action is

for "all" in system, Such as: "project name" is empty, the default action is to check

all items;

6.2 G: 如果需要导出查询信息，点击“报表导出”；

If you need to export checking information, click "export report";

6.2 H: 选择需要导出报表的格式，并设置导出的路径后即可导出报表；

Select to exporting report format and after set the export path, that can be derived;

四：常见故障处理

Common fault Troubleshooting

4.1 喷涂位置偏差

Spraying position deviation

*检查喷嘴坐标值是否设置正确或被更改；

Check the nozzle coordinate values are set correctly or altered;

*检查感应器位置是否有移动；

Check the PCB detect sensor whether be moved location;

*检查产品项目有没有选正确，

Check the product project is right or not,

*检查喷嘴位置是否变动或部分堵塞；

Check whether changes or partially blocked nozzle position;

4.2 感应不到托盘

Pallet can’t be detected

*检查光纤感应器表面是否脏污，对射光纤发送和接收端都需检查，聚光光纤检

查聚光头镜面；

Check the fiber sensor surface is dirty or not, checks on the optical fiber transmitting

and receiving end, inspect focusing head mirror;

*检查感应器输出电平是否设置正确；

Check the output level is set correctly;

*检查感应器位置是否变动

Check sensor whether the change of position;

*检查光纤与光纤放大器接触是否完好;

Check the optical contact with the optical fiber amplifier is intact;

*检查对射光纤输出、输入是否正确，轨道下方光纤为光线输出，上方接收光纤；

check on the optical fiber output, the input is correct, below the orbit of optical fiber

as the light output, at the top of the receiving fiber;

4.3 喷嘴喷涂异常

Nozzle spray anomaly

*检查喷嘴是否堵塞；

Check nozzle whether plugged;

*检查助焊剂管路是否变形堵塞；

Check whether the flux pipeline deformation leading blockage;

*检查流量计是否打开或堵塞；

Check flux flow meter whether open or block;

*检查喷嘴气路是否堵塞；

Check the nozzle gas supply pipeline whether is blocked;

4.4 助焊剂供应异常

Flux supply abnormally

*检查液位感应器是否损坏；

Check the liquid level sensor whether is damaged;

*检查液位检测管是否脏污；

Check the liquid level detecting tube whether is dirty;

*检查隔膜泵是否堵塞；

Check the diaphragm pump whether is blocked;

*检查逆止阀或过滤器是否堵塞

Check the check valve or filter whether is blocked;

4.5 隔膜泵抽不了助焊剂

Diaphragm pump can’t draw the flux

*在“演示测试”里点击“加松香测试”检查隔膜泵是否工作；

In "demonstration test" click "Flux adding test" to check whether is working of diaphragm pump;

*助焊剂上行管不能为空;

Flux ascending pipe cannot be empty;

4.6 点击“开始”，轨道不运动

Click "start", the rail can’t move

*检查急停按钮是否被按下；

Check the emergency stop button whether is pressed;

*检查编码器与轨道传动轴接触良好；

Check the encoder and the track shaft whether good contact;

五：维护与保养

Preventive Maintenance and Repairing

5.1 压缩空气过滤器

Compressed air filter

过滤器中残留的压缩空气里的水汽应及时排出----------建议1次/天

The residue water should be promptly discharged in the compressed air filter - 1 / day

5.2 助焊剂容器清理

The flux container cleaning

助焊剂容器会残留松香中的杂质，应该定期清理------- 建议1次/2星期

Flux container will be the residue of rosin, should be cleaned regularly - 1 /2 week

5.3 喷头清理

Nozzle cleaning

如果长时间停机，喷头中的残留助焊剂会凝固结晶，应及时清理-----建议1次/

星期

If long time stop, the residual flux will be solidification in the nozzle, should be

cleared up, 1 times / week

5.4 感应器清理

PCB detecting sensor cleaning

如果使用光纤做感应器，光纤头应定期清理-------建议1次/星期

If the use of fiber sensors, optical fiber head should be cleaned regularly - advice

1times / week

5.5 平台润滑

Platform lubrication

本机采用的XY平台滑杆和丝杆因长期工作，需要定期润滑保养-------建议1次

/月

This machine adopts XY platform, need regular lubrication and maintenance - 1 /

month

六：主要备件清单

Main spare parts list

说明：

Noted:

本公司对以上备件在正常使用情况下的承保期为1年；对在此期间的非人为误操作造成的零部件损坏免费进行更换。

All part in the list is year of warranty tine; for during the period of artificial mis-operation caused parts damage free replacement.

七：安全要求

Safety requirements

7.1 本机采用高速电机驱动，运行期间所有安全门均须关闭;

Machine uses high speed motor drive, during the operation of all safety doors must

be closed;

7.2 维修保养时必须停机并切断电源;

When repairing and maintenance must be shut down and cut off the power supply;

7.3 维护助焊剂相关部件时必须戴橡胶手套和护目镜;

Maintenance flux components must wear rubber gloves and goggles;

7.4 关机时应先退出运行的软件，再正常关闭计算机电源，第三步是关闭整机电源；

when shut down machine, should withdraw from the operation of the software, and

power off the computer normally, the third step is to shut down the power supply;

开机时与此步骤相反；

First power on machine, starts the computer, and starts the operation software.

Notes:

对违反本操作步骤造成的文件丢失，硬件损坏本公司认为是人为损坏，不在保修范围；

Lost in violation of the operation steps resulting in the paper, hardware damage not covered under warranty;