What may be happening is an early trigger of your vacuum sensors during production due to a clogged tip or vacuum line in the head. What happens during production is that the Y axis gets into position, and then the vacuum sensor input is monitored on each spindle. The spindle will go down until the vacuum transition is seen. If you have a marginally clogged line, it is possible that the vacuum reading fluctuates just enough to meet the transitional requirement. In this condition, the vacuum condition is met immediately and the machine moves the Y axis along to the vision station and "thinks" it has a part. The spindle may just jitter or not move down at all. Your AVX most likely has the ANALOG vacuum sensors; they will be on the head and blue in color. With a clogged line, your static readings will be high and probably rather close to your vacuum transition for your part type/part number. Your static vacuum readings on each spindle with NO tool tip should be up over 3500; anything lower will be suspect. In addition, check your tool tip to make sure that it is not clogged. If I recall, there is also a threshhold setting for each tooltip. Since your problem is always with one component, it could be as simple as a vacuum setting or simply luck of the draw that every other part is alright.
Move the part to the other side and re-optimize and see if the problem follows the part or the head. If the problem folows the part, I would definitely suspect a tool vacuum or part vacuum setting, more likely the part type.
It's been a while, but I have seen this condition before and while I forget the exact names of the parameters, you should be able to find them fine.
Your Contact 3AVX does NOT have Z motors (the Z axis are pneumatically driven). The CS3Z had Z motors.
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