Staging Plate

This set of work instructions is out of date!

What's shown here is for v3.0.5 of the LumenPnP. Instructions for the latest version of Staging Plate still need to be written for LumenPnP v3.1.#.
The biggest differences not shown are:
1) Introduction of colored tubing
2) Introduction of an easily removable nozzle-rack
Please note - the QC Checklist is up to date.

Subassembly Prep

Install hardware into 3D printed components

Use an arbor press to insert the given quantities of M3-hex-nut into the following parts:
2x for y-coupler-bracket
3x valve-mount
4x for bottom-camera mount

Note

Be sure to change the arbor press tip for the different prints as needed.
Install 2x M3-square-nut pieces into each of the 2x vacuum-pump-mount (2x per pcs) with an arbor press
Install a ground-down metal pin tip in the arbor press chuck to help push these nuts to the proper installation depth
Confirm that the M3 threads are fully accessible
Install 4x rubber-band onto 2x vacuum-pump-mount (2x per pcs)

Preparing pneumatics system

Cutting tubing to length

Produce the required QTY of each of the pneumatic tubing
SEE ALIGNI for lengths

Attaching vacuum-pump cables

Prepare the following assemblies:

ASM-0004-01 [Left Head Wired Vacuum Pump Assembly]
ASM-0052-01 [Right Head Wired Vacuum Pump]

Build the assemblies per SOP-0002 and be sure to follow recent updates to Step 2 for the new labeling process:

Place and shrink a heat shrink tubing label onto CHA-0011-00 that says “P2”

Position the new “P2” label so that it covers over the original “P1” label, with the text orientation matching the image below

Set completed assemblies aside for later use

Labeling solenoid-valve cables

Use FBO-0022-00 [Epson LABELWORKS 224VSLPX Tape] to label PNU-0004-00 [solenoid-valve] cables the following way:
Half of the solenoid-valve units in a given production batch must be labeled “MOS 2” for left head pneumatics (LH/P1)
Half of the solenoid-valve units in a given production batch must be labeled “MOS 4” for right head pneumatics (RH/P2)
Attach the labels in the near the end of the cable connector as shown below -

Note

Templates for these label can be found on the Docker workstation PC’s Documents folder

Assembling left head / right read pneumatic systems

Connect all relevant pneumatic tubes to their respective values, pumps, and couplers by referencing the images shown below

Left Head Pneumatic System (P1)

Right Head Pneumatic System (P2)

Connect the left and right pneumatic systems together

Connect these two separate pneumatic systems together by installing y-coupler-bracket and valve-mount between the two halves

Attach each solenoid-valve to valve-mount with 2x M3x8 bolts
Make sure that the valves are installed in the correct location by matching them up with the embedded text found on valve-mount

After completing this step, set the completed pneumatics system aside for later use

Prepare additional components

Removing punch-out from `PCB-0003`

Remove the punch-out from center of PCB-0003 with flush cutters

Clean up hole with a razor blade after punch-out has been removed

Clean both sides of PCB-0003 with an IPA-soaked shop rag

Focus the bottom-camera

Use the bottom-camera-focus-jig to pre-focus bottom-camera

Loosen the set screw on the side of the lens, this will let the lens focal-point be adjusted
Be careful not to loosen it too much or the screw may fall out and get lost!

Remove the lens cap from bottom-camera
Rotate the camera lens back and forth to loosen any glue
Hold the PCB in one hand while twisting the lens body with your other hand
Don't be afraid to use a few pounds of force if needed

Install the bottom-camera fully into the bottom-camera-focus-jig
Put the JST-side of bottom-camera into the jig first
Connect the JST-side of the USB cable into the bottom-camera PCB

Connect the USB cable on bottom-camera-focus-jig to a computer and open its native camera viewing application
Use Photobooth if on Mac OSX or Cheese if on Linux
Confirm that the camera feed is running in 720p, sometimes it can launch in 360p or 480p
Within the camera viewing application, change the selected camera to PnP Bottom to view the camera feed of the bottom-camera

!!! warning "If the listed camera is something other than PnP Bottom, the device may either be incorrectly programmed or mixed up with a top-camera module" Please take this as an opportunity to double-check the device name even if the computer switched to the correct camera feed automatically.

Rotate the camera lens until the live viewport shows the datum board as focused as possible
Before and after lens focusing:

Once the camera is focused, tighten the set screw to lock in the focus adjustment
Put a blue dot on the camera PCB with a sharpie to denote that the camera has passed testing

Remove the bottom-camera from the bottom-camera-focus-jig and immediately replace the lens cap
Return the bottom-camera to the red esd-safe bag

Creating bottom-camera-assembly

Attach bottom-camera and bottom-camera-cover to bottom-camera-mount with 4x M2.5x8 bolts

Confirm bottom-camera's JST connector is next to the zip-tie cable strain relief feature, as indicated below:

Clean bottom-light-mount print by removing any loose stringy plastic with a heat gun and/or razer blade (as needed)
Install bottom-ring-light into bottom-light-mount

Assemble nozzle-rack

Install all 6 different nozzles onto the nozzle-rack, ensuring that each nozzle can pop in and out relatively easily

Place a rubber-band around the nozzle-rack after each nozzles has been installed
This is to keep them from falling off the staging-plate in transit to the customer

Insert 2x m3-hex-head-bolt into the left and right outermost slots on the nozzle-rack

!!!note - This photo is out of date, it should show 2x M3-hex-head-bolt instead of nuts - These slots have a loose fit so use care to avoid losing a bolt during handling

Final Assembly

Installing bottom-camera-assembly

Attach bottom-camera-assembly onto staging-plate with 4x M3x16 bolts

The JST cable connector found on bottom-ring-light should match the orientation shown below when installed - as close to the Opulo logo as possible and in line with staging-plate column 18

The usb-cable connector found on bottom-camera should match the orientation shown below when installed - as close to the Opulo logo as possible

Installing pneumatics-system

Attach y-coupler-bracket onto staging-plate with 2x M3x10 bolts
Attach pump-mount onto staging-plate with 2x M3x10 bolts
Attach valve-mount onto staging-plate with 3x M3x8 bolts

Installing nozzle-rack

Attach the finished nozzle-rack to the staging-plate with 2x M3x10-hex-bolt and 2x M3-wing-nut
The text on nozzle-rack should match the orientation of the staging-plate column numbers

!!!note "This photo is out of date"

Installing the motherboard

Install 4 M3x25mm standoffs onto staging-plate
Place in positions shown below with 4x M3x10 bolts

Install bottom-ring-light cable
This cable should pass through the bottom and top right standoffs on its way to bottom-ring-light
Make sure that UL label is on the side of the cable closer to the motherboard

Drill out the M3 mounting holes in mobo-bottom-cover to an M3 bolt has generious clearence
Pass the RH/LH vacuum lines and up-light-harness through the mobo-bottom-cover and motherboard
Take care to avoid having the vacuum lines twist around each other between the y-coupler pieces and mobo-bottom-cover

Connect the vacuum lines and cable into the motherboard where appropriate
LH --> VAC1 on motherboard
RH --> VAC2 on motherboard

Bolt motherboard to standoffs in 2 initial locations with M3x10 bolts- bottom left and top right
Inspect both vacuum lines to see if either appears pinched on the backside of the motherboard
If either vacuum line appears pinched, push the line into the motherboard to increase the slack in the line between mobo-bottom-cover and the respective y-coupler

Connect all pump and valves cables into the motherboard while matching the cable labels to the motherboard connector labels
Avoid needless twisting of the cabling

Install mobo-top-cover
Bolt mobo-top-cover to the top left and bottom right standoffs with 2x M3x30 bolts
Hand tight is OK as the customers need to be able to remove this piece during machine setup

Slide the mobo QC receipt between mobo-bottom-cover and staging-plate after the mobo-top-coveris attached

Install datum-board and datum-board-mount

Use four M3x16mm screws and four M3 nuts to secure the datum-board and datum-board-mount to the staging-plate on the rear of the bottom-camera, through holes: B18, A19, A21, B22.
Use a 2.5mm hex wrench and a 5.5mm (6mm if 5.5mm is unavailable) socket wrench to tighten these M3x16mm screws
The fisheye calibration pattern should be facing down, and the gold grid lines and fiducial in the center of the Opulo logo facing upwards

Attach Machine Serial # Label

Install a unique Machine Serial # sticker onto the bottom of the staging-plate

!!!note - The up-light-harness shown above is installed backwards - The up-light-harness label should be on the motherboard side - The side plugged into bottom-ring-light should be unlabled

Performing cable management

Clamp cables in the locations shown below with 6x peek-cable-clamps, 6x m3-hex-nut, and 6x m3x14 bolts

QC Checklist

Run the staging plate assembly through the QC inspection form found here:

https://docs.google.com/forms/d/e/1FAIpQLSf1HXndxFzhRyJsBtHUMHoJEiU_ig9z8cUJpGCH4vcM8OR5mQ/viewform