FLEX SYSTEM DOCKING CONTROL TROUBLESHOOTING TOOL
Contents
1. 3 6 Once the tool starts you may see an msgbox shown above This is prompting for you to select an interface type You should only see this if you are working with Teradyne or Engineering interfaces If you see this on Intest then there is either a communication issue or there is an issue reading the Gusset sensors 4 TOOL DESCRIPTION 4 1 The tool is customized based on the interface type Each type falls into three classes these classes are Teradyne Dock 866 764 00 Engineering Dock 866 660 00 and Intest Dock 866 661 00 and 866 662 00 Below is an example of the three classes Teradyne Dock Interface Sls Sees Manipulator Power Avail EI Interdocke G Up DOCKING SENSOR STATES DUT UP View ible 4 View G OFF Manipulator Side Hanns DUT UP View C DUT DOWN View DOCKING SENSOR STATES DUT UP View Manipulator Side DOCKING SENSOR STATES Manipulator DUT UP View Power Availible 4 View c G FF Manipulator Side ANS DUT UP View C DUT DOWN View Dun Motor Interlock SS ASD NS REFRESH N Software Load ws AAAS G Up Dwn Motor Right Roller Left Roller C Clamped Clamped C Neutral Neutral C Push Dif Push Off Teradyne Dock 866 764 00 N DCB Version aa Kur 09030341 Rear Right C Di In Place FAM Sate Cov I Dib Present I Present Right Roller Left Roller C Clamped C Clamped C Neutral C Neutral C Push Ot C Push Off lt2. C Push Off Key Switches Front Right Front Left C Dib ln Place Dib ln Place C Dib Present Dib Present OPD 1 C DED Latch Safety Cover z Bypass DCB SN 1234054 7 Mode Date Code 031 Le Pressure 999 PSI N aion 2179 Degrees 0 Dut Up Rotation and Pressure 4 2 1 1 Sensor Refresh and Firmware Load The tool doesn t update automatically you will need to click on the refresh button in order to update the latest information from the controller PE PIC downloader 1 08 COM1 119200 v Bd T EEPROM Write F4 Cancel ESC 2000 EHL elektronika Petr Kolomaznik hittp www ehl c2z pic FREEWARE The tool also has included a method of updating the firmware located on the Docking Control Board The tool will launch the PIC downloader which defaults to the version shipped with the version of IG XL This can be changed by clicking browse and locating the version of software This also defaults to COM 1 but can be Docking Troubleshooting Tool Guide doc Page 8 of 14 Document Number N A Revision wk 3 Last Printed on 02 19 04 3 45 PM 4 2 1 2 4 2 1 3 4 2 1 4 4 2 1 5 4 2 1 6 4 2 1 7 changed based on the port that is connected The baud rate should also be filled in automatically to 19200 If this is not correct then just select it through the pulldown menu Controller ID and Software Info There are two fields located on
3. Front Right C pp C pp x Front Left c In Place C Dib Present DCB SN 1234054 Bypass Date Code 031 Rotation 2763 Degrees 0 Dut Up Engineering Dock 866 660 00 JOCE Version Des Left aiey Cover Db In Place L Di Present Di Peen ea Dib resent Right Roler C Clamped C Neutral C Push Off SN 1234054 perpe agg FSI Rotation 2171 Degrees 0 Dut Up Intest Dock 866 661 00 866 662 00 Docking Troubleshooting Tool Guide doc Page 7 of 14 Document Number N A Revision wk 3 Last Printed on 02 19 04 3 45 PM 4 2 There are Four systems to this tool Controller Inner Pull Down IPD Outer Pull Down OPD and Manipulator 4 2 1 Controller Teradyne Dock Interface DOCKING SENSOR STATES DUT UP View Manipulator Power Availible C ON Sensor L oy refresh and REFRESH W firmware RN load Interlocks SASS SY l WS S Controller Up Dwn gt Motor RCONTROLLER Actions ACTION RRS E S gt saare KY State DCB Version Hw C Sw 090303 1 iew DUT UP View C DUT DOWN View RS Software Load Controller ID and SW info OPD 3 C DPD Latch TRA Ke C OPD Latch C Dib ln Place Safely Cover C Dib In Place C Dib Present C Dib Present Controller Coarse LH Right Roller Left Roller C Clamped C Clamped Neutral C Push Off C Neutral
4. unlike the Tiger system s is completely independent to the manipulator Fences Testhead Backplane Figure 1 The IPD mechanism will be used to secure the DIB to the Testhead during production test and customer test This is achieved by the movement of four synchronized rollers refer to Figure 1 above The rollers are linked to a chain which are moved by the motor To ensure the chain is positioned along the outer ring and all the gear wheels are engaged a spring tensioner is present Located next to the motor Refer to Figure 2 The OPD modules are similar to the Catalyst K Dock modules They are pneumatic activated by solenoid valves mounted to the outer ring This is actual control is provided by the controller board The control board will send signals to the solenoid valves resulting in the switching the airflow to the different ports of the OPD units Docking Troubleshooting Tool Guide doc Page 4 of 14 Document Number N A Revision wk 3 Last Printed on 02 19 04 3 45 PM Spring Tentioner Solenoid Figure 2 The control consists of one unit the controller board The controller will be used to detect the status of the sensors as well as the control the motor and solenoid for IPD and OPD respectively The controller also contains control code to ensure the docking sequences occur properly 2 1 Revision History Description of Change 01 23 04 Steve Ford Created Docking Troubleshooting Tool Guide doc Page
5. 5 of 14 Document Number N A Revision wk 3 Last Printed on 02 19 04 3 45 PM 2 2 Glossary Customer Verification similar to PV but not as thorough Device Interface Board ng PD d the outer position position DIB Released DIB position where the RF connector forceses are released rollers are located in the inner position OPD Outer Pull Down unit that mounts a peripheral to the testhead OPD Extende Stage where the OPD pin is elongated to accept the groove module OPD Latched Stage where the OPD pin locks the groove module to the testhead OPD Retracted Stage where the OPD pin pulls the groove module down Outer Describes the plate in which all mechanics and boards mount Ring Interface Plate PHSB Pogo Device used to mount interface cables and align the interface assembly Header Support Beam Docking Troubleshooting Tool Guide doc Page 6 of 14 Last Printed on 02 19 04 3 45 PM back Document Number N A Revision wk 3 3 LAUNCHING TOOL 3 1 Un Zip the sock on the left top of the testhead 3 2 The Hookup serial cable from testhead sock to either serial port A or B on tester computer 3 3 Browse to C Program Files Teradyne G XL lt version gt bin 3 4 Search for SystemDockingGUL exe 3 5 Double click on SystemDockingGUI exe or select and hit enter GUI will display error if not connected to controller first Interface Type SEE Select interface type from list below Enaineering_D ock
6. Left Sensors C Dib ln Place NC Dib ln Place Cover 4 jo Safety Cover SR P i Da 4 F Dib Freze Present J Dib Present resen Coarse R Date Time Description Alignment Dib Roller Position Sensors f Left Roller C Clamped f Right Roller C Clamped C Neutral C Neutral C Push Off C Push Off Front Right Front Left Dib In Place Dib In Place Bee Dib Present C Dib Present C OPD Latch e Maintenace Safety Cover z Mode pass Pressure 399 PSI Rotation 2179 Degrees 0 Dut Up 4 2 2 1 Inner Pull Down State The Inner Pull Down State displays the state the controller reads the IPD system is currently in Below is a list of possible states Dib Present IPD Docking IPD Docked IPD Undocking IPD Undocking Push Off IPD Undocking Missing Dib In Place Error Gravity Sensor Interlock Timeout Error IPD Motor Overcurrent Error Missing Dib In Place Error Missing Dib Present Error 4 2 2 2 Corner Dib Sensors There are 4 sensors mounted on the interface located in the area of each corners of the DIB The corner dib sensors are used to detect the presents of a dib and if the dib is pulled down The terms used to describe if a DIB Docking Troubleshooting Tool Guide doc Page 10 of 14 Document Number N A Revision wk 3 Last Printed on 02 19 04 3 45 PM is placed on the testhead is Dib Present and the term used to describe if a DIB is pulled down is Dib In Place The to
7. Docking Troubleshooting Tool Guide doc Page 1 of 14 Document Number N A Revision wk 3 Last Printed on 02 19 04 3 45 PM FLEX SYSTEM DOCKING CONTROL TROUBLESHOOTING TOOL Docking Troubleshooting Tool Guide doc Page 2 of 14 Document Number N A Revision wk 3 Last Printed on 02 19 04 3 45 PM 1 Table of Contents TAPEE OF CONTENTS sicccivccsbicsecciecciecosesesecosocenecossoesecenndese coaseenesen coon ceosonesoseaceencestovenoses cuioncessovesessscveucess opeuseeacnonceoseuees 2 2 OVERVIEW A EEE EEE A E E dodecssenudoseosivesteseees 3 2 1 DOCUMENT OBJECTIVES ssessssse seer trtr ertr tr treten ertr r rtr rentrer r reren Erener errr er ereere eet ERROR BOOKMARK NOT DEFINED 2 2 REVISION HISTORY OTENE EE ETA AAE EE 4 2 3 GILOSSARY A E E E E A AE EAE EE E E O E S E O 5 3 TEST PROCESSES BACK cscsscssssssccssssscsessnsesnsessensssnsssssesscsssssssesscssscssscsesesesessssssesssessneeseassscssnessnsssnsscnseonsoss 6 Docking Troubleshooting Tool Guide doc Page 3 of 14 Document Number N A Revision wk 3 Last Printed on 02 19 04 3 45 PM 2 Overview The FLEX Testhead Interface contains both docking mechanics and docking controls The interface mechanics has two separate sets of mechanisms that will be used for a complete docking solution The two mechanisms include the docking Outer Pull Down modules OPD module and the DIB Device Interface Board Inner Pull Down IPD The control portion of the interface
8. Off C Neutral Push Off lt gt Front Right Front Left C Dib ln Place C Dib ln Place C Dib Present C Dib Present Safety Cover DCB SN 1234D54 Mode Bypass Date Code 031 Rotation 2179 Degrees 0 Dut Up OPD 1 C DPD Latch Pressure Docking Troubleshooting Tool Guide doc Page 11 of 14 Document Number N A Revision wk 3 Last Printed on 02 19 04 3 45 PM Intest Dock OPD System Intest Dock Interface DOCKING SENSOR STATES DUT UP View Manipulator Power Availible View DUT UP View C DUT DOWN View pas Manipulator Side ANA epee REFRESH NW Software Load C OPD State Interlocks Up Dwn Motor CONTROLLER ACTION Bea Version Gusset aw Bea 1 Sensors Rear Right CS Left r Dib In Place A Safely Cover Dib In Place C Dib Present Present Dib Present CAM Sensor Description Right Roller Left 2E C Clamped Clamped C Neutral Push Off C Neutral Push Off Front Right Front Left Dib In Place C Dib ln Place C Dib Present C Dib Present Mode pass 999 PS Rotation 2 471 Degrees 0 Dut Up Pressure 4 2 3 1 Outer Pull Down State The OPD State displays the state the controller reads the OPD system is currently in Below is a list of possible states Intest states only represented in RED Teradyne states only represe
9. e and time stamped with a brief description of the fault The date and time does have a limitation where time the system is shutdown main power the controller is not aware of The result is the date and time maybe inaccurate if the system is off for multiple days Rotation and Pressure The controller measures the rotation of the testhead to prevent IPD undocking so DIB doesn t fall on the floor The angle is represented in the tool DUT UP is considered 0 degrees This doesn t represent direction so you will not see indications The Pressure is read from the sensor in the support cabinet This pressure is required to activate the cutoff solenoid The cutoff solenoid is on the output of the regulator so this could read within the specified pressure but no air could be provided to the interface NOTE the controller counts the number of times the pressure drops below the cutoff and locks the cutoff value if the pressure drops more than three times Docking Troubleshooting Tool Guide doc Page 9 of 14 Document Number N A Revision wk 3 Last Printed on 02 19 04 3 45 PM 4 2 2 Inner Pull Down IPD Items Teradyne Dock Interface DOCKING SENSOR STATES Manipulator DUT UP View Power Availible View fou Manipulator Side DUT UP View p C DUT DOWN View L Software Load Interlocks Up Dun gt Motor i IPD State ACTION NS DCB Version Hw C Corner SW 090303 1 S Dib Safety DPD Latch Rear Right Rear
10. nted in BLUE Common states are in BLACK Manual OPD State Manual Docking Manual Undocking Coarse Alignment Present OPD Latch Made All OPD Latches Made OPD Docked OPD UnDocked Gusset Made All Gussets Made Power Assist Dock OPD Between States gussets OPD Between States no gussets Error OPD Between States gusset Error Docking Troubleshooting Tool Guide doc Page 12 of 14 Document Number N A Revision wk 3 Last Printed on 02 19 04 3 45 PM 4 2 3 2 4 2 3 3 4 2 3 4 Outer Pulldown Modules Sensors Gusset Sensors The outer pulldown module sensors for Teradyne Docking interfaces and gusset sensors for Intest dock interfaces are the same item except of the label These detect the presents of the peripheral plate The tool option button will fillin in the presents of that sensor being triggered Coarse Alignment Sensor The coarse alignment sensor is only contained on the Teradyne Dock interface The sensor provides the ability to detect if the peripheral is close to interface The tool option button will fillin in the presents of that sensor being triggered CAM Sensors The CAM sensors are used to determine the state the Intest Dock Due to the manual capability of the intest this is important for the control to identify the state Below is the sensor output verse docking state diagram CAM 1 a ee as CAM 2 4 UNDOCK DOCK Docking Troubleshooting Tool Guide doc Page 13 of 14 Document Numbe
11. ol option button will fillin in the presents of that sensor being triggered 4 2 2 3 Dib Roller Position Sensors The Dib Roller Position Sensors are located under the IPD rollers on both sides of the IPD opening in the center of the interface plate These sensors have three locations Docked UnDocked and Released Theses locations are represented in the tool as Neutral Clamped and Push Off respectively 4 2 2 4 Safety Cover The safety cover item detects the presents of the DIB cover This has been also known as the TUV cover The tool option button will fillin in the presents of the cover Note in order for the cover to be detected the DIB must be fully docked 4 2 3 Outer Pull Down OPD Items Terdadyne Dock OPD system Teradyne Dock Interface DOCKING SENSOR STATES DUT UP View Manipulator Power Availible C ON View DUT UP View C DUT DOWN View Manipulator Side SASANAAS TR REFRESH Software Load ie Cc OPD State Interlocks Up Dun Motor CONTROLLER L ACTION _ DCB Version OPM Hw C Sw 090303 1 Sensors OPD 3 OPD 2 C OPD Latch paama cale C OPD Latch C Dib In Place r Safety Cover Dib ln Place C Dib Present Present C Dib Present Coarse Date Time Description Coarse Alignment Alignment Sensor Right Roller Left Roller Clamped Clamped Neutral C Push
12. r N A Revision wk 3 Last Printed on 02 19 04 3 45 PM 4 2 4 Manipulator Teradyne Dock Interface L DOCKING SENSOR STATES DUT UP View Manipulate Z Power ower Availible and Speed OFF Manipulator Side SASSO p l OPD Z Motion OPD Interlocks STATE EZ L IPD CONTROLLER IPD N ACTION STATE IPD UnDocked DCB Version Hw C Sw 090303 1 View DUT UP View C DUT DOWN View Z Motor State OPD 3 OPD 2 C DFD Latch Riser Aight Nek C DFD Latch C Dib ln Place C Dib ln Place Present C Dib Present C Dib Present Date Time g Coarse Alignment Right Roller Left Roller Clamped Clamped Neutral Push Off C Neutral C Push Off Front Right Front Left Dib In Place Dib In Place C Dib Present C Dib Present Safety Cover s DCB SN 1234D54 Mode Bypass Date Code 031 S g99 PSI Rotation 2179 Degrees 0 Dut Up OPD 1 C DPD Latch Pressure 4 2 4 1 Z Motor State The Z Motor State displays the state the controller reads the Z motion system is currently in Below is a list of possible states Pwr Off Idol Pwr On Idol Slow Up Slow Down Pwr On Idol Fast Up Fast Down Z Motor Fault Error 4 2 4 2 Z Power and Speeds The Z power and Speeds show the user what state the Z motion power and speed the system is currently at The
13. re is two speeds to the interface High or FAST and low or SLOW The tool option button will fillin to indicate the current mode Another feature of this tool in regards to the manipulator is the ability to click ON or OFF the power and change the controller mode Docking Troubleshooting Tool Guide doc Page 14 of 14 Document Number N A Revision wk 3 Last Printed on 02 19 04 3 45 PM 4 2 4 3 Z Motor interlocks The Z Motor system has three features of fault detection These features are limit switch UP limit switch DOWN and Motor Fault represented by UP DWN and Motor on the tool user interface A fault is indicated by the filling in of the option button
14. the tool that display the controller info The first is the info centered at the top of the black interface outline This displays the HW rev and current firmware version label SW The second is located on the tool s bottom left witch contains the control board serial number and date code Key Switches There are two key switches located on the front of the interface These two switches are maintenance and the safety cover bypass The maintenance mode switch is used often to reset controller faults and return the system back to a default state The safety cover bypass allows the user to operate the system without the presents of the safety cover or TUV cover The tool option button will fillin in the presents of the key being ON or enabled Layout View The layout view allows the user to determine how they would like to display the interface items The two modes are DUT UP and DUT DOWN This feature is meant to aid in troubleshooting and avoid confusion of left right sensors mix ups Controller Actions State The Controller Actions State displays the state the controller is currently in Below is a list of possible states Idol Pressure Normal Low Pressure Error Pressure Shut Off Error Disconnected Hose Error Controller Fault Log The fault log contains a list of the faults the controller has encounter during operation The faults are numbered and listed earliest to latest To aid in identifying the fault they are dat
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