Equipment: Electrovert Vectra
Software: Wave II
Option: SmartLoad
1. Problem Description
During an investigation of SmartLoad positioning issues, ITW EAE Software Engineering reviewed three customer recipe examples.
The investigation identified incorrect Standby Start and End Window settings in all three recipes.
These settings prevented the machine from positioning correctly during SmartLoad operation.
2. Understanding Standby Windows
Electrovert's Start and End of Process Windows are referenced to the First Contact of the Wave.
The windows determine when the machine can begin positioning and when the positioning sequence ends in relation to wave contact.
Start of Process Window
Typically uses a negative value.
Must occur before initial contact with the wave.
Provides time for the machine to move into the required position before reaching the wave.
End of Process Window
Typically uses a positive value.
Must occur after the Start of Process Window.
Important: The End of Window must always occur after the Start of Process Window.
3. Findings from Customer Recipes
Software Engineering reviewed three recipes supplied by customer found that the Standby Start and End Window settings were incorrect in all three examples.
The customer explained that there was considerable distance between:
The edge of the pallet carriage and the PCB.
The PCB edge and the first connector requiring soldering.
The customer indicated that this distance could exceed 200 mm and therefore believed a positive Start Window value of at least 100 mm was appropriate.
However, Software Engineering explained that the process windows are referenced to the First Contact of the Wave, not simply the physical edge of the pallet or PCB.
The Start Window therefore needs to be positioned before initial wave contact to provide sufficient time for machine positioning.
4. Main Wave and Chip Wave Configuration
Software Engineering also recommended verifying the configured locations of:
Main Wave
Chip Wave
These positions should be checked against the actual machine configuration and factory reference values.
Incorrect wave location settings can affect the machine's ability to position correctly during SmartLoad operation.
5. Software Version Considerations
Software Engineering identified an additional software limitation.
In the software version being used by the customer the Auto Exit Wing could not be changed at the start of the Step-up Window.
A newer software revision was planned to introduce this capability.
Because the existing software could not change the Auto Exit Wing at the beginning of the Step-up Window, the Start of Process Window needed to occur before initial wave contact.
If the Start Window occurred after initial wave contact, the machine would not have sufficient time to reposition during SmartLoad operation.
6. Recommended Troubleshooting and Setup
When setting up or troubleshooting SmartLoad Standby Process Windows:
Open the affected machine recipe.
Review the Standby Start of Process Window.
Verify that the Start Window occurs before initial wave contact.
Review the Standby End of Process Window.
Verify that the End Window occurs after the Start Process Window.
Confirm that the window values are referenced to First Contact of the Wave.
Verify the configured Main Wave location.
Verify the configured Chip Wave location.
Compare the settings against the factory reference values.
Test SmartLoad operation and verify that the machine reaches the required position before wave contact.
7. Production Verification
After correcting the recipe settings or installing an applicable software revision:
Test each affected recipe individually.
Verify Standby Start and End Window positioning.
Confirm that the machine reaches the required position before wave contact.
Test the Auto Exit Wing behavior where supported by the installed software.
Verify proper positioning when switching between recipes using SmartLoad.
8. Summary
Incorrect Standby Start and End Process Window settings can prevent the machine from positioning correctly during SmartLoad operation.
The Start and End Process Windows must be configured relative to First Contact of the Wave.
The Start Process Window should occur before initial wave contact, and the End Process Window must occur after the Start Process Window.
Correct configuration of these windows, along with verification of Main Wave and Chip Wave locations, is essential for proper SmartLoad positioning.