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CF-9 User's Guide

09/30/92

GPD Global 33

Appendices

Table of Contents

Appendix A - Die Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Forming Style Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Die Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Appendix B - Common CF-9 Lead Forms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Appendix C - CF-9 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Lead Forming Dies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   39
Component Detection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   39
Electronic Component Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   39
Footswitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   40
Lazy  Susan  (Rotating  Machine  Platform) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   40
Loose/Bulk Component Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   41
Taped Component Re-Reeler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   41
Work  Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   41

Appendix D - Electrical Schematic & Assembly Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

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Summary of Contents for CF-9

Page 1: ...Bills of Material Includes an illustrated bill of material with associated part numbers for each CF 9 subassembly Die Catalog Catalog of dies precisely manufactured by GPD Global to accurately form Radial components into a wide variety of component shapes Set Up Form Fill out this Set Up form and then use it as a guide for consistent results for each component part number 611 Hollingsworth Street ...

Page 2: ...1 June 4 2014 Prepared by GPD Global Documentation Department Copyright 2014 GPD Global All Rights Reserved GPD Global 611 Hollingsworth Street Grand Junction CO 81505 970 245 0408 CF 9 User s Guide CF 9 Radial Lead Forming Machine Part No 901 1 07 Serial No ...

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Page 4: ... EXPRESS OR IMPLIED WARRANTY INCLUDING ANY COSTS OR DAMAGE TO PROPERTY AND TO THE EXTENT PERMITTED BY LAW DAMAGES FOR PERSONAL INJURY THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES ANY IMPLIED WARRANTIES INCLUDING IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED IN DURATION TO ONE 1 YEAR FROM THE DATE OF RECEIPT OF THIS PRODUCT GPD S LIABILITY ON ANY CLAIM O...

Page 5: ...g notices are used in this document to emphasize chance of injury harm to life or limb due largely to something beyond one s control C A U T I O N Caution notices are used in this document to alert one to avoid danger or harm and where equipment might be damaged if care is not taken I M P O R T A N T Important notices are used in this document to call attention to imperative information NOTE Note ...

Page 6: ... 13 Die Installation 14 Station Adjustment 16 Component Alignment 17 Load Components 18 Power On 18 Process Components 19 Power Off 19 Preventive Maintenance 21 Troubleshooting 23 Slide Travel 24 Slide Clearance 25 Specifications 29 Suggested Spare Parts 31 Appendices 33 Appendix A Die Information 35 Appendix B Common CF 9 Lead Forms 37 Appendix C CF 9 Accessories 39 Appendix D Electrical Schemati...

Page 7: ...sition Adjustment 16 Figure 14 Die Block Assembly Adjusting Bolts 16 Figure 15 Component Position Relative to Tape Hole 17 Figure 16 Align Load Components 18 Figure 17 Die Block Assembly Lubrication 21 Figure 18 Die Block Assembly Maintenance 21 Figure 19 Die Block Assembly Slide Travel 24 Figure 20 Die Block Assembly Slide Clearance 25 Figure 21 Die Block Assembly Lubrication 26 Figure 22 GPD s C...

Page 8: ...ing on the components being processed and the desired component lead form the second station may be used to both cut and form just cut or be excluded in order to leave components on tape The indexing system the heart of the CF 9 drives the studded transfer belt The studs or pins on the belt pick up the tape holes and index exactly 1 2 12 70 mm every time The CF 9 is ruggedly constructed of heavy d...

Page 9: ...t forms and lead configurations Many different die sets for various transistor hole patterns are also available A minimal amount of preparation time is required to reset the machine for processing different component sizes Dies are easily replaced within minutes GPD s CF 9 dies are precisely manufactured using a unique die construction process Most dies are built with a sectional laminated constru...

Page 10: ...ral of the most common component forms the CF 9 produces are illustrated in the Common CF 9 Lead Forms appendix CF 9 Lead Forming Dies CF 9 Lead Forming Die sets are available to perform the following functions Produce both common and special configurations GPD is pleased to design custom dies for you If you have unusual requirements your GPD representative will be happy to assist you with any cus...

Page 11: ... to the second die station while simultaneously indexing the next component into the first die station 4 Cuts the formed component from the tape in the second die station drops the component in the component bin and disposes of the tape down a waste tape exit chute while simultaneously forming the component at the first die station 5 Initiates next cycle NOTE Depending on the components being proc...

Page 12: ...ion 1 Item 2 Component Reel Ammo Pack Item 7 Die Block Assembly Station 2 Item 3 Tape Roller Guide Item 8 Component Bin Item 4 Tape Guide Arm Item 9 Tape Exit Chute Item 5 Taped Components Die Stations Station 1 is adjustable and normally used as a forming station Station 2 also adjustable is normally used as a cutting station More complicated forms may require Station 2 to complete the forming fu...

Page 13: ... the lower left corner of machine s back panel By inserting the supplied Allen Key in this port the operator can slowly operate the CF 9 manually moving all mechanisms during setup adjustment testing or troubleshooting to assure proper die and component positioning The hand crank can be used to move mechanisms in reverse only during setup and only when no components are loaded Safety Shield Not sh...

Page 14: ...ol The speed control regulates both the variable speed motor and power supply and enables the machine to operate in a range from 0 to 25 000 cycles per hour The operator has full freedom to select whatever speed is appropriate to the work being performed Reset Button As a safety feature power is not automatically restored by closing the safety shield To restore power it is necessary to close the s...

Page 15: ...rank Shaft Item 8 Cover Plate Item 3 Micrometer Scale Indicator Item 9 Crank Adjuster Item 4 Die Station Guide Shaft Item 10 Die Block Item 5 Die Block Adjusting Bolt Item 11 Wear Plate Item 6 Die Block Slide Micrometer Scale Indicator The micrometer scale indicator mounted on each die station makes the lead cut length adjustment operation quick easy and highly accurate to 0005 0 0127 mm ...

Page 16: ...orming style series is stamped on its right hand side of each die and knife Figure 5 Refer to the Die Information appendix for specifics Installation Marking Installation Color Dot Characters are stamped on the left hand side of each die half Figure 6 Item 1 to indicate proper die position in the forming and cutting stations Corresponding markings are stamped on each station s stationary plate Ite...

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Page 18: ...lacement on the machine The screws 1 4 20x1 2 for securing the reel holder and tape guide arm are located in the appropriate holes in the CF 9 s main frame C A U T I O N Never pull push or lift machine by reel holder or tape guide arm this could bend them out of alignment and seriously affect machine performance 5 Assemble safety shield with hinges and 10 32x3 8 screws attached to shield 6 Positio...

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Page 20: ... System identifies bent components and stops machine operations to prevent die breakage Refer to the CF 9 Accessories appendix Suggestions Use quality components on quality tape Planning prior to lead forming operations is suggested as this enables users to quickly produce the maximum number of components for a given system configuration W A R N I N G For operator and machine safety keep fingers c...

Page 21: ... place each die on proper die mounting surface Figure 8 Item 1 and bolt in place with a 5 8 15 75 mm screw Then manually turn machine s hand crank page 6 until die block slides Item 2 are in their fully closed position c Visually inspect alignment of die forming area to insure equal spacing on both sides Figure 9 Item 2 d Properly align die edges Item 1 in relation to each other centering each die...

Page 22: ...Station Adjustment on page 16 Suggestion Remove the small ejector brackets when not required to simplify die installation Two sets of ejector brackets are factory mounted on die Station 2 Figure 10 Each large ejector bracket Item 1 mounts to the Station 2 die block assembly with two screws Item 4 Each small ejector bracket Item 2 mounts to the large ejector bracket with two screws Item 3 Adjust fo...

Page 23: ... located on each station adjusting bolt The standard micrometer scale Item 2 attached to each station indicates the distance from the component s point of attachment on the tape to the point of station action on the component lead These scales are accurate to 0005 0 0127 mm Cut Lead Length Station Position Station Action Location Longest Fully retracted Zero 0 position the point at which Shortest ...

Page 24: ...imple matter of repositioning a pulley Figure 16 Item 4 C A U T I O N Testing component position relative to dies MUST be done prior to automatic machine operations To align components with die stations 1 Manually index machine with hand crank just until components are centered between dies and just before die touches component wires Turn hand crank slowly while visually inspecting for the relativ...

Page 25: ...oling C A U T I O N If machine is not properly adjusted damage to components and dies may result 6 If further adjustments are necessary repeat Setup procedure on page 13 Power On 1 Close and lock safety shield in place with safety shield lock Figure 16 Item 2 W A R N I N G For operator s safety do not operate machine without safety shield in place and do not defeat the safety switch 2 Set speed co...

Page 26: ...er adjustments if necessary to achieve desired results C A U T I O N Testing component position relative to dies MUST be done prior to automatic machine operations 5 Increase machine speed rate to desired setting and process components 6 To process a different component form or type repeat Setup procedure on page 13 Power Off 1 Set speed control to zero 0 2 Turn power switch to OFF 3 Remove all di...

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Page 28: ...laced for many years provided the machine is used according to instructions Preventive Maintenance Schedule Interval Location Action Daily Dies Knives Remove all dies knives inspect for wear and clean 8 hours of with rust inhibitor operation Inspect for foreign matter or dust build up Brush clean Die Block Assembly Inspect and lubricate eccentric shafts and bushings Figure 17 Item 1 and die block ...

Page 29: ... Inside Cabinet Inspect component drive belt for proper tension Spray molly grease on gears Wipe off excess oil Lightly grease cam lobes and cam follower rollers Wipe off excess grease Check motor brushes and motor drive belt Replace if they appear worn or frayed CAUTION DO NOT attempt to remove or replace a drive belt without first loosening the motor mount screws Yearly Safety Shield Apply a dro...

Page 30: ...stallation instructions Foreign matter dust build up Inspect and clean per Preventive Maintenance Incorrect slide gap Check gap with gauge block per Slide Travel Incorrect die alignment Inspect and set per Die Installation Incorrect slide clearance Inspect and set per Slide Clearance Incorrect size screw securing die Secure die with correct size screw Machine performance Foreign matter dust build ...

Page 31: ...e not plugged in Plug machine in per Specifications Machine not turned on Turn machine on per Operating Instructions Speed control set to zero 0 Set speed control to appropriate operating speed Drive pulley set screws loose Tighten set screws Incorrect size screw securing die Secure die with correct size screw Slide Travel To adjust slide travel 1 Unplug machine 2 Insert provided 1 934 gauge block...

Page 32: ... parts a Remove and discard set screws in cover plate Figure 20 Item 6 b Remove slide Item 9 from die block c Use a degreaser brake cleaner to remove all oil from slide die block and wear plate Items 9 8 and 7 C A U T I O N Do not expose micrometer scales to degreaser brake cleaner as it clouds the clear face plate d Measure all surfaces for wear and inspect for scratches and gouges Replace parts ...

Page 33: ... set the clearance to 0007 001 0178 0254 mm by pulling up on die screw After clearance is set verify that slide moves freely NOTE If slide does not move freely loosen outer set screw slightly Recheck clearance g Secure screws by applying modest amount of penetrating thread locker Loctite 290 h Repeat step 4 for remaining slides 5 Lubricate parts a Generously apply 5 weight oil 3 in 1 to all sides ...

Page 34: ...r to allow oil to distribute evenly During this time period slowly increase machine speed and check cover plate and die block for heat C A U T I O N IF EXCESSIVE HEAT IS DETECTED OR A SQUEAK IS HEARD STOP THE MACHINE REPEAT COMPLETE SLIDE CLEARANCE PROCEDURE f Reassemble the following Digital scale lower mounting block screws Belt guide and pressure plate Component transfer belt Adjust so belt is ...

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Page 36: ...12 00 inches 304 80 mm 13 25 inches 336 55 mm 13 50 inches 342 90 mm CF 9 with Reel Holder Work Station 18 62 inches 29 50 inches 472 95 mm 749 30 mm 13 25 inches 26 00 inches 336 55 mm 660 40 mm 28 00 inches 39 00 inches 711 20 mm 990 60 mm CF 9 Weight Standard CF 9 58 lbs 26 31 kg Capacities Production Rate The CF 9 is capable of forming and cutting up to 25 000 components per hour Micrometer Sc...

Page 37: ...imum operating clearance Custom tooling or custom taping may be required in certain instances GPD CF 9 Taping Specification Limits Symbol Definition Inch MM X Height to seating plane formed leads 300 010 7 62 0 25 Y Operating Clearance All dies except style 8A 300 minimum 7 62 minimum Seating plane straight leads 8A style die 350 minimum 8 89 minimum E I A Taping Specification Limits Symbol Defini...

Page 38: ...1 2 120V 60Hz Spare Parts Kit 1 consists of the following items BELTS 901 3 101 Transfer Belt 1 D0001 Motor Belt 1 INDEX WHEEL ASSEMBLY 806 1 3 Roller 16 G1007 Retaining Ring 16 FUSE 4300 0026 Fuse MDL 5A Slow Blow 1 925 1 3 230V 50 60Hz Spare Parts Kit 1 consists of the following items BELTS 901 3 101 Transfer Belt 1 D0001 Motor Belt 1 INDEX WHEEL ASSEMBLY 806 1 3 Roller 16 G1007 Retaining Ring 1...

Page 39: ...Number Part Description Qty 120V 60 Hz Spare Parts G1003 Circlip 10 L0503 Bushing 2 L0601 Bushing 2 2200 0008 Speed Control 120V 60 Hz 1 821 4 12 Circlip Plier 1 901 1 102 Die Station 2 1 925 1 2 Spare Parts Kit 120V 1 230V 50 60 Hz Spare Parts G1003 Circlip 10 L0503 Bushing 2 L0601 Bushing 2 2200 0014 Speed Control 230V 50 60 Hz 1 821 4 12 Circlip Plier 1 901 1 102 Die Station 2 1 925 1 3 Spare P...

Page 40: ... 35 Appendix B Common CF 9 Lead Forms 37 Appendix C CF 9 Accessories 39 Lead Forming Dies 39 Component Detection System 39 Electronic Component Counter 39 Footswitch 40 Lazy Susan Rotating Machine Platform 40 Loose Bulk Component Feeder 41 Taped Component Re Reeler 41 Work Station 41 Appendix D Electrical Schematic Assembly Drawing 43 ...

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Page 42: ... Forming Style Series Number Description 1 Die 3 Lead Radial typically TO 92 In Line 2 Die 2 Lead Radial Stand Off Opposing Dimple 2C Die 2 Lead Radial Lock In Stand Off Opposing Dimple 3 Die 2 Lead Radial Lock In Stand Off 4A Die 2 Lead Radial Spreading 4B Die 2 Lead Radial Reducing 5 Knife 7 Die 2 Lead Radial 90 Bend 8A Die 2 Lead Radial Spreading Lock In Stand Off 8B Die 2 Lead Radial Reducing ...

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Page 44: ...h Lock In Form 905 1A Middle Lead Offset 905 4B Reducing Form Form 905 1CA In Line Lock In 905 7 90 Angle Bend Stand Off Form 905 1H4 Middle Lead Offset 905 8A Spread Form with 905 1H5 with 3 Lead Lock In Lock In Stand Off 905 1L4 Form 905 2 Stand Off with 905 8B Reducing Form Opposing Dimple with Lock In Stand Form Off 905 2C Lock In Stand Off 905 10 Low Profile Stand with Opposing Off Lock In Fo...

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Page 46: ... with a new die Standard dies are secured in place with 10 32x5 8 screws these accompany the CF 9 machine When a special die requires a longer screw it is supplied with the die Most cutting and forming needs are covered with the standard dies we offer However if you have unusual requirements GPD will be pleased to design custom dies for you Your GPD representative will be happy to assist you with ...

Page 47: ...e CF 9 power switch to the AUX position and depress the footswitch to operate the machine Footswitch Installation 1 Turn power switch to off 2 Set speed control to zero 0 3 Insert footswitch plug into accessory outlet on CF 9 s control panel and turn clockwise to lock in place 4 Set power switch to AUX position The auxiliary mode indicator lights 5 Set speed control to desired operating speed To r...

Page 48: ...matic insertion in one operation With this accessory the CF 9 feeds taped components into the first die station forms them skips the normal trim operation and sends components straight to the Re Reeler Special flattening blocks can be inserted in the trimming station if additional dimple alignment is required The re reeler automatically reloads the taped components back on a reel after the forming...

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Page 50: ...CF 9 User s Guide 09 30 92 GPD Global 43 Appendix D Electrical Schematic Assembly Drawing Drawing Title Drawing Number CF 9 Electrical Schematic 0098001A CF 9 Electrical Assembly Drawing 0098002A ...

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Page 54: ...ter 29 Production Rate 29 Component 3 Lead Radial 35 37 Alignment 17 Ammo Pack 5 19 Bent 13 Bin 5 11 Body Height 15 Body Thickness 15 Counter 39 Feeder 41 Leads 13 Load 18 Loose 41 Pathway 18 Pitch 13 Process 19 Re Reeler 41 Reel 5 19 Reel Tape 13 Tape Pressure Plate Lever 6 Taped 5 TO 92 Transistors 3 Transfer Belt 6 Component Detection System 13 39 Control Panel 7 Accessory Outlet 7 Fuse 7 Power...

Page 55: ...ies 9 35 Forms Complicated Lead 15 Lead 3 37 Function CF 9 3 Dies 3 Station 1 5 Station 2 4 5 Fuse 7 G Gauge Block 24 Guide Shaft 8 H Hand Crank 6 13 14 17 18 23 I Indexing System 1 Installation 11 Color Dot 9 Die 14 Die Markings 9 Die Position 9 Ejector Brackets 15 Electronic Component Counter 40 Footswitch 40 Marking 9 K Knives 9 L Lazy Susan 11 40 Lead 13 17 3 Lead Radial 35 37 Center to Center...

Page 56: ...lock 24 Spare Parts 31 Specifications 29 Taping 30 Speed Control 7 11 18 19 Station Action 16 Adjustment 16 Guide Shaft 8 Position 16 Station 1 5 14 Station 2 4 5 14 15 Work 41 T T1 9 25 T2 9 25 Tape 13 Exit Chute 1 5 Guide Arm 5 11 Hole to Lead Distance 17 Hole to Hole Spacings 3 Operating Clearance 30 Pressure Plate Lever 6 Roller Guide 1 5 Taped Component Re Reeler 41 Taped Components 5 Custom ...

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Page 58: ...on 2 2 June 3 2014 Prepared by GPD Documentation Department Copyright C 1992 1996 2002 2007 2014 GPD Global All Rights Reserved GPD Global 611 Hollingsworth Street Grand Junction CO 81505 970 245 0408 FAX 970 245 9674 CF 9 Bills of Material Exploded Views Part No 901 1 02 ...

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Page 95: ...ly 925 1 2 SPARE PARTS KIT 120V Effective As of 11 03 11 ITEM PART DESCRIPTION QTY UM 1 SACAN1032062 DIE SCREW 6 EA 2 901 3 10 TRANSFER BELT 1 EA 3 4300 0026 FUSE SLOW BLOW 3 EA N S Not Shown N S S Not Sold Separately Page 36 General Production Devices 06 03 14 ...

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Page 106: ...ell as TO 92 Transistors CF 9 Component Forming Dies can be ordered to form a wide variety of component shapes Both common and special configurations can be produced by using CF 9 Component Forming Dies Component Forming Dies CF 9 611 Hollingsworth Street Grand Junction CO 81505 Tel 970 245 0408 Fax 970 245 9674 Web www gpd global com GPD Part No 905 00 ...

Page 107: ...or a configuration not shown in the catalog additional information is required component samples pc board samples and desired lead form configuration print sketch or sample Special dies may be subject to a pre determined engineering charge In some cases we may not be able to accomplish the requested form due to machine and die limitations Standard Delivery Times Standard dies Stock to 4 weeks Modi...

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Page 195: ... turn machine until first part exits machine 2 Install dies as shown below 8 Check component for proper form 3 Adjust die stations to digital settings shown below 9 Fine tune digital settings for proper form as required 4 Manually turn machine to check alignment of dies 10 Start machine 5 Install ejector bracket if required 11 Adjust machine speed to 6 Load parts ...

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