akrometrix TherMoire AXP 2.0 User manual

TherMoiré AXP 2.0
User Manual

TherMoiré AXP 2.0 User Manual
Page 2 of 29 40-5000-6900 Rev. D
Akrometrix Proprietary
Information
No reproduction, adaptation,
or translation without prior
written approval.
Warranty
The information contained in
this document is subject to
change without notice.
Akrometrix makes no warranty
of any kind with respect to this
information.
Akrometrix shall not be liable
for any direct, indirect,
incidental, consequential, or
other damage alleged in
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or use of this information.
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Microsoft®, Windows®,
Excel®, and Notepad® are
registered trademarks of
Microsoft Corporation.
TherMoiré® is a registered
trademark of Akrometrix, LLC.

TherMoiré AXP 2.0 User Manual
40-5000-6900 Rev. D Page 3 of 29
Contents
1Introduction.................................................................................................................4
1.1 Overview.............................................................................................................4
1.2 Warnings and Precautions..................................................................................4
1.3 System Configuration..........................................................................................7
1.4 System Components...........................................................................................8
1.5 Technical Support.............................................................................................10
2System Set-up and Use............................................................................................11
2.1 System Set-up...................................................................................................11
2.2 System Shutdown.............................................................................................12
2.3 Replacing a Grating ..........................................................................................12
2.4 Cleaning a Grating or Glass Window ................................................................12
3Temperature Control................................................................................................14
3.1 Manual Temperature Control ............................................................................14
3.2 Automatic Temperature Control........................................................................14
3.3 Removing and Changing Samples....................................................................14
4PLC Logic Conditions..............................................................................................16
4.1 E-Stop Alarms...................................................................................................16
4.2 Lid Operation and Lockouts ..............................................................................17
4.3 Heater/Blower/Exhaust Controls.......................................................................18
5Troubleshooting .......................................................................................................20
5.1 Troubleshooting Data Acquisition......................................................................20
5.2 Troubleshooting Oven Operation......................................................................20
Appendix A - Miscellaneous Information..................................................................22
A.1 Equipment Ratings............................................................................................22
A.2 Installation and Assembly..................................................................................22
A.3 Transport...........................................................................................................23
A.4 Disassembly......................................................................................................23
A.5 Ventilation .........................................................................................................24
A.6 Maintenance......................................................................................................24
A.7 Oven Lid Interlock Bypass.................................................................................25
A.8 Oven Over-Temperature Switch........................................................................26
A.9 EMO Pushbutton...............................................................................................26
A.10 Camera Lens.....................................................................................................26
Appendix B –Blower A/C Units .................................................................................28
B.1 Overview...........................................................................................................28
B.2 Facilities Requirements.....................................................................................28

TherMoiré AXP 2.0 User Manual
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1Introduction
1.1 Overview
The Akrometrix TherMoiré AXP 2.0 is a system designed for measuring sample
surface warpage as a function of temperature. It uses a full-field, non-contact optical
technique called shadow moiré in combination with automated image processing.
Samples are measured inside a computer-controlled oven chamber with a temperature
range from ambient to 300°C.
This manual describes the system hardware of the TherMoiré AXP 2.0. Data
acquisition is described in the Surface Measurement User Manual and analysis is
described in the Surface Analysis User Manual. Surface Measurement requires system
hardware to operate and, thus, will only be installed on the AXP 2.0. Surface Analysis
may reside on the AXP 2.0 computer and/or on a remote computer.
The main body of this manual emphasizes the system hardware and its operation.
A user unfamiliar with shadow moiré and its application in the TherMoiré system is
advised to first read Akrometrix Optical Techniques and Analyses 101, and Section 1,
Troubleshooting in order to make best use of the system.
Before operating the system, the user should carefully read Section 1.2.2, which
describes safety and health hazards associated with the system. The TherMoiré AXP 2.0
system contains a high temperature oven, motorized sample stages, and electrical
systems, all with the potential to injure if used or maintained carelessly.
Sections 1.3 and 1.4 identify system components and controls. Section 2
describes basic procedures for system setup and shutdown. Section 3 describes setting
up samples for measurement under thermal test. Section 4 describes PLC logic
conditions and Section 5 describes basic troubleshooting.
Appendix A describes recommended procedures for maintenance, transport and
disassembly of the system. This section also contains equipment ratings and technical
support material. Appendix B describes the Blower system and its operation.
1.2 Warnings and Precautions
1.2.1 Warnings and Notes in this Manual
Warnings and Notes are marked throughout the manual with these icons:
Figure 1.1 Warning Icon
Figure 1.2 Note Icon
Warnings are specific health hazards for the operator or potential sources of damage
to the AXP 2.0 system. Notes highlight system limitations or automatic responses that
may require corrective action by the operator for successful operation.

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1.2.2 Health and Safety Hazards
•The AXP 2.0 system has been designed to minimize the potential for user injury.
Safety systems, including the oven and electrical enclosure interlocks, should not
be tampered with, circumvented, or left in a permanent over-ride state.
•Staring into the oven while a profile is running increases the risk of eye damage
from IR radiant energy. Even though the oven has been designed to mitigate this
risk, the TherMoiré oven requires the use of IR energy. The only sure way to
eliminate this risk is to not look into the oven while a profile is running.
•Surfaces both inside and outside the oven chamber can reach extreme
temperatures during system operation and can harm the user without proper
precautions. Care should be taken in opening the oven after a temperature cycle.
The user should only touch the oven lid by its handle or use hand protection.
Internal oven surfaces can remain at extreme temperatures even after the sample
reaches room temperature. The user should exercise care before touching the
sample, sample supports, or other internal surfaces after a temperature cycle.
•The system should notbe used with samples that can catch fire or emit toxic gases
during sample heating.
•Motorized translation of the sample support stages can create the potential for
pinch-points between moving and stationary components, especially the sample
support arms and the oven walls. Keep hands out of the oven during sample stage
translation. Keep the stage translation path free from obstruction.
•Close the oven lid carefullyto avoid catching fingers or damaging the glass grating.
•External electrical and compressed air connections must be installed safely and
meet all relevant requirements and building codes.
•Do not operate the light sources with the fiber optic bundle connectors removed
from the light source housings.
•Do not sit or stand on any part of the system enclosure, including the electrical
box. Do not place loads greater than 25 kg (55 lbs) on top of the system.
•Lock system casters when not being moved. Follow transport procedures
described in Appendix A.3 when moving system. Do not move system on surfaces
with a tilt greater than 10 degrees from horizontal.
•Special care should be used when operating the system manually or using
specialized diagnostic programs. Temperatures or motions outside the normal
range of operation may be possible under these conditions and the system should
be monitored carefully.
•Do not position the system such that the electrical interlock is inaccessible.
•MSDS data sheets for all supplied chemicals are available upon request.

TherMoiré AXP 2.0 User Manual
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1.2.3 System Operating Precautions
•Do not install additional software on the TherMoiré computer, change computer
system settings, or upgrade system software or hardware without consulting
Akrometrix. Unauthorized modifications can cause problems in normal system
operation.
•Close the oven lids with care. Make sure there is adequate clearance between the
glass grating and sample supports or samples before closing the oven lid. If the
grating is discolored by outgassing products, clean it using rubbing alcohol or glass
cleaner before performing another temperature cycle.
•Do not touch the heating elements in the IR heater bank. Clean any debris that
falls onto the heater elements as soon as possible. Heat cycles can “bake” oils and
other organic materials onto the oven bank surfaces making them harder to clean
as more heat cycles are applied.
•The sample support should not be loaded with a sample weighing greater than 10
lbs (4.5 kg). Loads exceeding 10 lbs may cause harm to the stage motion
components.
•In order to eliminate any eye, hand, or back strain, adjust the monitor and keyboard
cart for ease and comfort of use. The monitor can be tilted and raised on its
pedestal. The cart can be raised and lowered for proper hand position on the
keyboard.
1.2.4 Warning labels used on the TherMoiré AXP 2.0
Figure 1.3 Danger High Voltage Label
Figure 1.4 Danger Arc Flash Label
These labels are mounted to the electrical panel as a reminder that the voltages
inside the enclosure are lethal.
Figure 1.5 Warning Burn Hazard Label
This label is mounted by the oven handle as a reminder that the contents of the oven
can be hot after a sample run is complete.

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1.3 System Configuration
Figure 1.6 Overall System Components

TherMoiré AXP 2.0 User Manual
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Figure 1.7
Electrical Cabinet
Buttons
Figure 1.8 Oven Components
1.4 System Components
Every TherMoiré system consists of three main hardware components. In essence,
these components do not change for different sized TherMoiré systems. These include:
•an Oven
•a Grating and Linear Motion Stage
•a Camera and Light Source
It is important to understand the basic design and operation of these components in
order to fully utilize the system’s capabilities. See the following sections for a brief
description of each component.
1.4.1 Oven
The AXP 2.0 oven is an infrared oven consisting of both bottom and top heater
elements. The bottom heater element is composed of two zones (Figure 1.9), one inner,
and one outer. The bottom heater power to each zone can be controlled as a percentage
when running a thermal profile. The top heater elements are positioned at the front and
back of the oven, above the grating. These elements can be turned on or off and the
Glass Lid
Main Lid
Grating
Exhaust Inlets

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feedback thermocouple can be set to either TC1 or TC2, depending on how the user has
the test set up. PID control to follow an input profile is provided by a PLC unit located in
the electrical cabinet. In addition, cooling is provided by Exhaust fans which pull air out of
the oven chamber from towers on the left and right sides and through holes in the bottom
of the oven. Blower units force sub-room temperature air into the oven through holes in
front and back of the oven, below the grating. Additionally, when cooling is enabled, air
inlets in the front and back of the oven lid allow air to enter into the oven when pulled by
the exhaust. The oven is sealed so that fumes, which may be generated from samples
inside the oven, are directed out of the system exhaust.
Figure 1.9 Oven Bottom Components
Temperature control can be operated manually, or automatically, via the Thermal
Profiler software. Please see the Thermal Profiler User Manual for instructions on
automatic or manual temperature profiling.
Inner Heater
Zone
Outer Heater
Zone
Blower Outlet
Blower Outlet
(inside front
wall)
Exhaust Inlets

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1.4.2 Grating and Linear Motion Stage
In standard configuration, each AXP 2.0 system is provided with a Ronchi ruled 100
lines per inch grating. Akrometrix has found that this frequency grating provides a good
compromise between working distance and accuracy. Other grating frequencies are
available but there are trade-offs associated with their use. Please see the Akrometrix
Optical Techniques and Analyses 101 document for more details.
A linear motion stage drives the sample support up and down to achieve phase
stepping in the AXP 2.0. Two motors are used, one on each side of the oven, and are tied
together so that they move as one unit. They are attached to linear motion stages that
provide a 2 inch (5.08 cm) range of travel. Limit switches prevent the motors from
operating past the stage travel limits. Control over these motors is done exclusively using
the Surface Measurement software. Please see the Surface Measurement User Manual
for instructions on their use.
1.4.3 Camera and Light Source
The system is equipped with a single 1.4 megapixel camera to capture image data
through the oven window. This camera ispaired with a12.5 –75 mm zoom lens to provide
either a full 375 x 375 mm or variable field of view.
An LED light source feeds light to a pair of fiber optic line lights which are pointed at
the mirror on the left side of the unit. The light source should be set to maximum intensity
for shadow moiré tests and can be set to a lower intensity for DIC focusing purposes.
1.5 Technical Support
For technical support, contact Akrometrix:
Akrometrix
2700 NE Expressway
Building B, Suite 500
Atlanta, GA 30345
404-486-0880
404-486-0890 (fax)
[email protected]
http://www.akrometrix.com
When contacting Akrometrix, please provide the system serial number, the version
numbers of the Akrometrix software being used, a description of the problem or question,
and contact information for reply. If the question concerns a particular measurement or
analysis, please provide electronic copies of the phase images, reference images, and
final results and a description of data acquisition and/or analysis conditions. If theproblem
concerns changes or failure in general system operation, please describe any events or
system modifications that occurred immediately before the problem arose.