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TITLE: 3481-ME4096 & 2383-ME4094-7 & 2382-ME4095-1 SWI:REVISION:DATE:PAGES:WORK STATION: VA-0015A2014-1-2# OF 32TMEC Technology in Motion STANDARD WORK.

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Presentation on theme: "TITLE: 3481-ME4096 & 2383-ME4094-7 & 2382-ME4095-1 SWI:REVISION:DATE:PAGES:WORK STATION: VA-0015A2014-1-2# OF 32TMEC Technology in Motion STANDARD WORK."— Presentation transcript:

1 TITLE: 3481-ME4096 & 2383-ME & 2382-ME SWI:REVISION:DATE:PAGES:WORK STATION: VA-0015A # OF 32TMEC Technology in Motion STANDARD WORK INSTRUCTION Trained and capable of performing this work: Date: Supervisor or engineer giving Approving to perform: Operator 2 Operator 5 Operator 6 Operator 4 Operator 1 Operator 3 On this page is information about operators that are trained and certified to perform this Standard Work. The operators signing below have read this SWI and have successfully performed the work described in it in the presence of the Supervisor or Engineer signing in the second column on the date in the third column. Operator 8 Operator 9 Operator 7 Operator 10

2 TITLE: 3481-ME4096 & 2383-ME & 2382-ME SWI:REVISION:DATE:PAGES:WORK STATION: VA-0015A # OF 32TMEC Technology in Motion STANDARD WORK INSTRUCTION Safety Requirements:Safety glasses In Process Check 1) 2) 3) Operator Maintenance 1) Expiration of Loctite 242 2) 3) Material / Components 1) Loctite 242 2) Motor Label 3) Screws (2) 4) Encoder Mounting Plate Place new motor label per pint on opposite side of leads. Top of label towards shaft. 2. Place motor onto an assembly fixture. Place the encoder mounting plate onto motor end cap. Align 2 screw holes to motor. 3. Dip screws into loctite 242 covering 3 to 4 threads. Thread into motor. 3/4 242 Tools & Fixtures 1) Standard Screw Driver 2) 3)

3 TITLE: 3481-ME4096 & 2383-ME & 2382-ME SWI:REVISION:DATE:PAGES:WORK STATION: VA-0015A # OF 32TMEC Technology in Motion STANDARD WORK INSTRUCTION Safety Requirements:Safety glasses In Process Check 1) 2) 3) Operator Maintenance 1) 2) 3) Material / Components 1) Encoder ) 3) 4. Tighten screws with standard screw driver to 2.9 in lb. 2.9in lb 5. Remove encoder housing with Allen wrench attached from packaging. Tools & Fixtures 1) 2.9 in lb torque driver 2) 3)

4 TITLE: 3481-ME4096 & 2383-ME & 2382-ME SWI:REVISION:DATE:PAGES:WORK STATION: VA-0015A # OF 32TMEC Technology in Motion STANDARD WORK INSTRUCTION Safety Requirements:Safety glasses In Process Check 1) Do not allow Allen wrench to fall out of encoder housing. 2) 3) Operator Maintenance 1) 2) 3) Material / Components 1) 2) 3) 6. Identify pin 2, remove with side cutter. PIN 2 7. Turn Allen wrench so set screw is visible in encoder hub. Tools & Fixtures 1) Side cutter 2) 3)

5 TITLE: 3481-ME4096 & 2383-ME & 2382-ME SWI:REVISION:DATE:PAGES:WORK STATION: VA-0015A # OF 32TMEC Technology in Motion STANDARD WORK INSTRUCTION Safety Requirements:Safety glasses In Process Check 1) 2) 3) Operator Maintenance 1) 2) 3) Material / Components 1) 2) 3) 8. Use wood end of cotton swab dipped in loctite 242 and apply to set screw, covering 3 to 4 threads Use cotton swab to wipe excess loctite from housing, leave loctite on 3 to 4 threads. 10. Back set screw out some to allow room for shaft to fit in hub. Align housing onto base plate. Tools & Fixtures 1) Cotton swab 2) 3)

6 TITLE: 3481-ME4096 & 2383-ME & 2382-ME SWI:REVISION:DATE:PAGES:WORK STATION: VA-0015A # OF 32TMEC Technology in Motion STANDARD WORK INSTRUCTION Safety Requirements:Safety glasses In Process Check 1)You will hear Encoder housing click twice when assembled properly to mounting plate. 2) To remove encoder: Un align hub (turn screw driver CCW on top of encoder to un align dots), Insert Allen wrench and turn set screw loose from shaft, Remove the 2 screws holding the encoder mounting plate to the motor end cap. Operator Maintenance 1) 2) 3) Material / Components 1) 2) 3) 11. Use palm of hand to snap encoder into place. 12. Apply light downward pressure on the Allen wrench with one finger, turn Allen wrench CW with other hand to tighten to shaft. Give ¼ turn past snug. 13. Remove Allen wrench, Throw away. Use a standard screw driver to align 3 dots on top of encoder housing to lock hub. Tools & Fixtures 1) 2) 3) 3 Dots

7 TITLE: 3481-ME4096 & 2383-ME & 2382-ME SWI:REVISION:DATE:PAGES:WORK STATION: VA-0015A # OF 32TMEC Technology in Motion STANDARD WORK INSTRUCTION Safety Requirements:Safety glasses In Process Check 1) Do not nick or scar any cables when cutting off tie. 2) 3) Operator Maintenance 1) 2) 3) Material / Components 1) Encoder Label 2) 3) 14. Apply label to encoder. Picture is for reference only. 15. Remove from fixture. Spin shaft, listen for rubs or unusual noise. 16. Remove the single cable tie that holds the cable in a bundle with a side cutters. Tools & Fixtures 1) 2) 3)

8 TITLE: 3481-ME4096 & 2383-ME & 2382-ME SWI:REVISION:DATE:PAGES:WORK STATION: VA-0015A # OF 32TMEC Technology in Motion STANDARD WORK INSTRUCTION Safety Requirements:Safety glasses In Process Check 1) 2) 3) Operator Maintenance 1) 2) 3) Material / Components 1) 2) 3) 17. Place motor onto an assembly fixture. 18. Connect encoder cable as shown in picture below. Tools & Fixtures 1) 2) 3)

9 TITLE: 3481-ME4096 & 2383-ME & 2382-ME SWI:REVISION:DATE:PAGES:WORK STATION: VA-0015A # OF 32TMEC Technology in Motion STANDARD WORK INSTRUCTION Safety Requirements:Safety glasses In Process Check 1) This is an important strain relief step. 2) 3) Operator Maintenance 1) 2) 3) Material / Components 1) Cable tie 2) 3) 20. Wrap encoder cable around zip tie once, then tighten to encoder and cut off extra tie. Tools & Fixtures 1) 2) 3) 19. Use a cable tie to connect encoder cable to encoder.

10 TITLE: 3481-ME4096 & 2383-ME & 2382-ME SWI:REVISION:DATE:PAGES:WORK STATION: VA-0015A # OF 32TMEC Technology in Motion STANDARD WORK INSTRUCTION Safety Requirements:Safety glasses In Process Check 1) Label is for reference only 2) 3) Operator Maintenance 1) 2) 3) Material / Components 1) Label 2) 3) 21. Find the center of the cable. Apply label to the center of the cable. label will go around all 3 cables. Tools & Fixtures 1) 2) 3) Label Finding Center Applying Label Completed

11 TITLE: 3481-ME4096 & 2383-ME & 2382-ME SWI:REVISION:DATE:PAGES:WORK STATION: VA-0015A # OF 32TMEC Technology in Motion STANDARD WORK INSTRUCTION Safety Requirements:Safety glasses In Process Check 1) Label is for reference only. 2) 3) Operator Maintenance 1) 2) 3) Material / Components 1) Label 2) 3) 22. Apply label 5 inches from end of cable. 5 Tools & Fixtures 1) 2) 3)

12 TITLE: 3481-ME4096 & 2383-ME & 2382-ME SWI:REVISION:DATE:PAGES:WORK STATION: VA-0015A # OF 32TMEC Technology in Motion STANDARD WORK INSTRUCTION Safety Requirements:Safety glasses In Process Check 1) 3481-ME4096 does not require step ME ) 3) Operator Maintenance 1) 2) 3) Material / Components 1) 2) 3) 23. Pull motor cables up towards shaft and tighten a cable tie around motor and cables. Cut off extra tie. 24. Neatly coil cables and loop through center of coil twice for a neat bundle. Tools & Fixtures 1) 2) 3)

13 TITLE: 3481-ME4096 & 2383-ME & 2382-ME SWI:REVISION:DATE:PAGES:WORK STATION: VA-0015A # OF 32TMEC Technology in Motion STANDARD WORK INSTRUCTION Safety Requirements:Safety glasses In Process Check 1) 2) 3) Operator Maintenance 1) 2) 3) Material / Components 1) 2) 3) 25. Visually inspect that no connections are broken by performing the pull test. Tools & Fixtures 1) 2) 3)

14 TITLE: 3481-ME4096 & 2383-ME & 2382-ME SWI:REVISION:DATE:PAGES:WORK STATION: VA-0015A # OF 32TMEC Technology in Motion STANDARD WORK INSTRUCTION Safety Requirements:Safety glasses In Process Check 1) 2) 3) Operator Maintenance 1) 2) 3) Material / Components 1) 2) 3) 26. If motor passes pull testing, place a QC stamp on the motor to ensure inspection was complete. QC Tools & Fixtures 1) QC Stamp 2) 3)

15 TITLE: 3481-ME4096 & 2383-ME & 2382-ME SWI:REVISION:DATE:PAGES:WORK STATION: VA-0015A # OF 32TMEC Technology in Motion STANDARD WORK INSTRUCTION Safety Requirements:Safety glasses In Process Check 1) 2) 3) Operator Maintenance 1) 2) 3) Material / Components 1) 2) 3) 27. Locate Flextronics Test Box FT100. Flextronics 28. Locate the correct cable. FT4094 or FT4095 or FT Connect the cable to test box. Tools & Fixtures 1) Test Cable 2) Flextronics Test Box 3)

16 TITLE: 3481-ME4096 & 2383-ME & 2382-ME SWI:REVISION:DATE:PAGES:WORK STATION: VA-0015A # OF 32TMEC Technology in Motion STANDARD WORK INSTRUCTION Safety Requirements:Safety glasses In Process Check 1) 2) 3) Operator Maintenance 1) 2) 3) Material / Components 1) 2) 3) 30. Connect the test box cables to the motor. 32. Turn Test box On. Tools & Fixtures 1) 2) 3) 31. Set rotary switch to correct setting

17 TITLE: 3481-ME4096 & 2383-ME & 2382-ME SWI:REVISION:DATE:PAGES:WORK STATION: VA-0015A # OF 32TMEC Technology in Motion STANDARD WORK INSTRUCTION Safety Requirements:Safety glasses In Process Check 1) Use fingers to touch shaft to feel the motion of the turning shaft. 2) 3) Operator Maintenance 1) 2) 3) Material / Components 1) 2) 3) 33. Press reset switch. After all the lights go out, push the start switch. The run light should come on and the motor should run. After about 7 seconds, the motor should quit running and the pass light should come on. If the red light comes on (Fail), The motor is rejected and needs to be repaired. RESET START RUN 7 PASS FAIL Tools & Fixtures 1) 2) 3) Run PassFail Reset Start 34. Unplug the motor from the test cables.

18 TITLE: 3481-ME4096 & 2383-ME & 2382-ME SWI:REVISION:DATE:PAGES:WORK STATION: VA-0015A # OF 32TMEC Technology in Motion STANDARD WORK INSTRUCTION Safety Requirements:Safety glasses In Process Check 1) 2) 3) Operator Maintenance 1) 2) 3) Material / Components 1) 2) 3) 35. Insert the appropriate collet (per slip fit for motor shaft) into back drive. 36. Insert motor shaft into collet. Hand tighten collet, then use wrench to make snug. Tools & Fixtures 1) 2) 3)

19 TITLE: 3481-ME4096 & 2383-ME & 2382-ME SWI:REVISION:DATE:PAGES:WORK STATION: VA-0015A # OF 32TMEC Technology in Motion STANDARD WORK INSTRUCTION Safety Requirements:Safety glasses In Process Check 1) 2) 3) Operator Maintenance 1) 2) 3) Material / Components 1) 2) 3) 37. Locate proper cable for testing encoder line count. 38. Plug cable into encoder test box. 39. Plug test cable into motor. Tools & Fixtures 1) 2) 3)

20 TITLE: 3481-ME4096 & 2383-ME & 2382-ME SWI:REVISION:DATE:PAGES:WORK STATION: VA-0015A # OF 32TMEC Technology in Motion STANDARD WORK INSTRUCTION Safety Requirements:Safety glasses In Process Check 1) 2) 3) Operator Maintenance 1) 2) 3) Material / Components 1) 2) 3) 40. Be sure Main power is off, connect encoder test panel to oscilloscope. Set Channel A to A, Channel B to B. Set last knob to Ac. Set to ABZ, Set to A leads B, Set com sig. to Off, Set external Z to On. AA BBAc,A leads B, com sigOFF external ON Tools & Fixtures 1) 2) 3) A Ac B On Off A Leads B ABZ

21 TITLE: 3481-ME4096 & 2383-ME & 2382-ME SWI:REVISION:DATE:PAGES:WORK STATION: VA-0015A # OF 32TMEC Technology in Motion STANDARD WORK INSTRUCTION Safety Requirements:Safety glasses In Process Check 1) 2) 3) Operator Maintenance 1) 2) 3) Material / Components 1) 2) 3) 41. Set back drive box to 1000RPM; Direction is CW; Brake/Encoder is set in the middle Position. 1000RPM CW / 43. Turn oscilloscope to ON. Turn the main power switch on encoder test box to ON. Switch to Encoder on back drive box. Back drive should force motor to spin. ONONEncoder 42. Turn back drive Main Power to ON.ON Tools & Fixtures 1) 2) 3) Encoder

22 TITLE: 3481-ME4096 & 2383-ME & 2382-ME SWI:REVISION:DATE:PAGES:WORK STATION: VA-0015A # OF 32TMEC Technology in Motion STANDARD WORK INSTRUCTION Safety Requirements:Safety glasses In Process Check 1) Step 46, when doing multiple motors: switch back drive off, remove motor, insert new motor and turn back drive on again, Press reset and record line count verify correct oscilloscope reading. 2) Operator Maintenance 1) 2) 3) Material / Components 1) 2) 3) 44. Line count will be Graph on oscilloscope should have A leading B. A B Tools & Fixtures 1) 2) 3) A B 46. Shut off oscilloscope, Encoder test box, and Back drive. Remove motor from back drive. Skip to step 54 unless 3481-ME ME When Set to B leads A (Incorrect setting) B leading A,

23 TITLE: 3481-ME4096 & 2383-ME & 2382-ME SWI:REVISION:DATE:PAGES:WORK STATION: VA-0015A # OF 32TMEC Technology in Motion STANDARD WORK INSTRUCTION Safety Requirements:Safety glasses In Process Check 1) Only Performed on the 3481-ME4096 2) 3) Operator Maintenance 1) 2) 3) Material / Components 1) Fixture ) 3) 47. Set fixture onto press. Fixture is aligned to press by a hole in bottom of fixture Tools & Fixtures 1) 2) 3) Pin hole On fixture Pin

24 TITLE: 3481-ME4096 & 2383-ME & 2382-ME SWI:REVISION:DATE:PAGES:WORK STATION: VA-0015A # OF 32TMEC Technology in Motion STANDARD WORK INSTRUCTION Safety Requirements:Safety glasses In Process Check 1) Only Performed on the 3481-ME4096 2) 3) Operator Maintenance 1) 2) 3) Material / Components 1) 2) 3) 48. Slide pin press into collet. Use Allen wrench to tighten. 49. Loosen set screw on press with Allen wrench to insert the tooling into the press. Insert tooling and tighten. Tools & Fixtures 1) 2) 3)

25 TITLE: 3481-ME4096 & 2383-ME & 2382-ME SWI:REVISION:DATE:PAGES:WORK STATION: VA-0015A # OF 32TMEC Technology in Motion STANDARD WORK INSTRUCTION Safety Requirements:Safety glasses In Process Check 1) Only Performed on the 3481-ME4096 2) 3) Operator Maintenance 1) 2) 3) Material / Components 1) 2) 3) 51. Set motor into fixture. Align the hole in shaft and pulley to the pin in fixture. 50. Slide pulley onto shaft. Align hole in pulley with hole on the shaft. Tools & Fixtures 1) 2) 3)

26 TITLE: 3481-ME4096 & 2383-ME & 2382-ME SWI:REVISION:DATE:PAGES:WORK STATION: VA-0015A # OF 32TMEC Technology in Motion STANDARD WORK INSTRUCTION Safety Requirements:Safety glasses In Process Check 1) Only Performed on the 3481-ME4096 2) 3) Operator Maintenance 1) 2) 3) Material / Components 1) 2) 3) 52. Insert a pin into the pulley. Align tooling to top of pin. 53. Press pin into place. Tools & Fixtures 1) 2) 3) 54. Move to shipping

27 TITLE: 3481-ME4096 & 2383-ME & 2382-ME SWI:REVISION:DATE:PAGES:WORK STATION: VA-0015A # OF 32TMEC Technology in Motion STANDARD WORK INSTRUCTION Safety Requirements:Safety glasses In Process Check 1) For 4097 & 4095 use a box 18 x 12 x 10. 2) For 4096 use a box 18 x 12 x 12. 3) Operator Maintenance 1) 2) 3) Material / Components 1) 2) 3) Tools & Fixtures 1) 2) 3) 55. Take a flat cardboard box, fold into shape. Use staple gun to put 3 staples into seam. 56. Use packaging tape to cover staples and seam. Tape should overlap on each side 5 inches. 5.

28 TITLE: 3481-ME4096 & 2383-ME & 2382-ME SWI:REVISION:DATE:PAGES:WORK STATION: VA-0015A # OF 32TMEC Technology in Motion STANDARD WORK INSTRUCTION Safety Requirements:Safety glasses In Process Check 1) 3481-ME4096 can only ship 4 motors per 18 x 12 x 12 box. 2) 2383-ME4094 & 4095 can ship 6 motors per 18 x 12 x 10 box. 3) Operator Maintenance 1) 2) 3) Material / Components 1) Foam 2) 4 star foam 3) 6 star foam Tools & Fixtures 1) 2) 3) 57. Flip box over, insert 2 layers of foam Insert 3 layers of star foam (6 stars) for 3482-ME4095 & Insert one layer of star foam (4 stars) for 3481-ME ME4095 & ME star 6 Star

29 TITLE: 3481-ME4096 & 2383-ME & 2382-ME SWI:REVISION:DATE:PAGES:WORK STATION: VA-0015A # OF 32TMEC Technology in Motion STANDARD WORK INSTRUCTION Safety Requirements:Safety glasses In Process Check 1) 2) 3) Operator Maintenance 1) 2) 3) Material / Components 1) 2) 3) Tools & Fixtures 1) 2) 3) 59. Tuck encoder wires close to motor if needed 60. Place a motor into an ESD bag, Encoder to the inside. ESD

30 TITLE: 3481-ME4096 & 2383-ME & 2382-ME SWI:REVISION:DATE:PAGES:WORK STATION: VA-0015A # OF 32TMEC Technology in Motion STANDARD WORK INSTRUCTION Safety Requirements:Safety glasses In Process Check 1) 2) 3) Operator Maintenance 1) 2) 3) Material / Components 1) 2) 3) Tools & Fixtures 1) 2) 3) 61. Place 6 motors in box, encoder side down Press down on cables and bags to get cables to lay nicely in box. ESD

31 TITLE: 3481-ME4096 & 2383-ME & 2382-ME SWI:REVISION:DATE:PAGES:WORK STATION: VA-0015A # OF 32TMEC Technology in Motion STANDARD WORK INSTRUCTION Safety Requirements:Safety glasses In Process Check 1) 2) 3) Operator Maintenance 1) 2) 3) Material / Components 1) 2) 3) Tools & Fixtures 1) 2) 3) 63. Place 1 layer of foam in box, press down. 64. Close Box. 65. Staple at both ends. Apply tape. 66. Ship.

32 TITLE: 3481-ME4096 & 2383-ME & 2382-ME SWI:REVISION:DATE:PAGES:WORK STATION: VA-0015A # OF 32TMEC Technology in Motion STANDARD WORK INSTRUCTION Signatures of Authorization Production:Manufacturing:Quality:Design:Other: Revision:Date:Reason for Change:Editor: A6/20/2007New SWI Introduction.Andy Isder


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