with a throughput of 7+ panels per minute!

he latest development by Multiline in post etch punching is the
Optiline PE/ATP. Multiline offers three models to choose from. The ATP 1000, 3000 and 5000 all offer thin material capability down to 2 mil core at speeds for most innerlayers exceeding 7+ panels per minute. The ATP 1000 and ATP 3000 are both manually loaded and roughly located by the operator on a pre-positioning table at the front of the machine. The ATP 5000 is a completely automatic machine which requires no operator to run panel lots and can be incorporated with material feeders and stackers.

The Optiline PE/ATP is an advanced automated system for precise Post Etch Punching of innerlayers. The main elements of the Optiline PE/ATP are a panel feed system, a video control package, and a punch-and-die system engineered to repeatably pierce an accurate registration tooling pattern.

The ATP 1000, 3000 and 5000 all offer thin material capability down to 2 mil core at speeds for most innerlayers exceeding 7+ panels per minute.

The ATP 1000 and ATP 3000 are both manually loaded and roughly located by the operator on a pre-positioning table at the front of the machine. The ATP 5000 is a completely automatic machine which requires no operator to run panel lots and can be incorporated with material loaders and stackers.

Changing panel sizes (moving the punch and dies to the correct position) is normally done by hand with the aid of a special adjustment tool for safety and speed. In the ATP 3000 and 5000 panel size selection is automatic. The panel size desired is either typed in the keyboard or in the case of the ATP 5000 it can be automatically input by the optional in-line panel measuring device.

The Automatic Feed provided, on the ATP is designed to feed thin core, (.002"/0.05mm thick). The conventional belt drive system is replaced with a linear motor transport system which actually grabs the leading edge of the innerlayer with two vacuum grippers and pulls it into the machine. Once in the machine, the innerlayer is released and the gripper returns to the pre-alignment position. The innerlayer is positioned and punched and a second set of grippers carries it out the back to an offload station. By gripping and lifting, the thin core can be fed through the machine without bending or otherwise damaging it. To assist transporting and prevent damage the innerlayer is conveyed on a cushion of air.

All three Optiline PE/ATP machines utilize the same vision, algorithms and "X", "Y", "Ø" positioning system as the standard Optiline PE. Two fiducial marks which are part of the etched image are used to locate the innerlayer with respect to the punch. Two digital video cameras are used to recognize the targets in the field of view and to feed accurate digital information about their precise location to the positioning system. The microprocessor directs an "X", "Y", "Ø" (rotary) table to position the targets on the innerlayer to preset "null points" within the video system. Any deviation in target location due to dimensional changes in the material is averaged and the system splits the difference automatically. On completion of the stage movements, the punch automatically cycles.

Industry demands for Total Quality Management (TQM) utilizing statistical process control, have required the addition of a more powerful computer system to the Optiline PE. This enables major enhancements to the OPE which eliminate any operator intervention and provide statistical process control and spread data collection.

Series 5000 Controller - is included as standard on the ATP 1000, 3000 & 5000 and is built into each machine, eliminating a separate console.

Features of the Series 5000 controller include:
Automatic Target Acquisition- This feature eliminates the need for the operator to set the electronic cross hair to establish the machine reference to the tooling. The Series 5000 automatically calculates the reference zero from the tooled reference position and assigns it as the null point.

Automatic Sensitivity- The Series 5000 automatically sets sensitivity with the added benefit of being capable of resetting the sensitivity if the target varies slightly. It accomplishes this by averaging the first three panels and using this average to set the machine sensitivity. Every panel is then run by comparing its specific setting to the average. If a greater than 10% variation exists in any panel, the sensitivity is set for that panel. The setting is then reset and each subsequent panel will again be compared to the original average. With this feature, target visual noise and target bleed through common thin core are ignored, thus increasing panel-to-panel repeatability.

Statistical Process Control- the statistical package on the Series 5000 controller provides a graphic representation of the actual target positions (SPREAD) in relation to the high and low tolerance limits selected for run. This information is recorded and stored on the hard drive. It can be retrieved by various programmed parameters or fields which are filled in by the operator during the initial job setup. These fields are: Part Number, Job Number, Panel Size, Operator and Date.

Full (Multiple Position) Die Blocks are standard on all Optiline PE/ATP machines
The bottom die block contains all the die positions to accommodate the panel sizes covered by the machine (up to 24" x 28" in a standard OPE-ATP). This design serves a dual purpose. In the ATP 3000 and 5000 where the setting of panel size tooling is automatic, the Full Die Block eliminates the need to move the bottom tooling. The Full Die Block also provides a flat continuous surface designed to transport thin core down to (0.002"/0.05mm thick) eliminating any openings or voids in the bottom table which can cause feeding problems.

Automatic Punch Block Adjustment-Standard on the ATP 3000 + 5000
The bottom die block assembly will be extended to include all the panel sizes which are required. The block will include multiple die positions as well as a master reference target. The top punch block is a single position block and moves automatically to the correct panel size. Air bearings are incorporated in the top tooling to ease movement and eliminate wear. The punch-and-die blocks are easily removable to facilitate easy maintenance and allow interchangeably of blocks when punching thick material.

The panel size information is fed to the machine via operator input at the console. The punches and cameras are automatically positioned by stepping motors to the correct panel size. Once in approximate position, the block is mechanically located by automatically inserting a precision ground pin into the jig ground location specific to that panel size. This combination of motor positioning and tooled mechanical fit gives quick changeover but still assures positional accuracy.

Features of the ATP 1000 and 3000
The Optiline PE/ATP 1000 and 3000 are automatic Post Etch Punches which are manually fed by an operator. The etched innerlayers are placed onto a pre-alignment station which increases the speed of the machine and eliminates the need to crowd panels off of two edges. This station is a table which extends from the front of the machine with two low magnification cameras mounted on a moveable rail. The low magnification cameras are set to the same panel size as the primary cameras in the machine. The operater then locates the panel under the cameras on the pre-alignment table and pushes the start button. The panel is transported from the pre-alignment table into the machine by a linear motor vacuum feed device. To insure safe and fast loading the platform becomes an air table while the innerlayer is being transported.

OPE/ATP 5000
The Optiline PE/ATP 5000 is a fully automatic Post Etch Punch and requires no operator intervention. It can be fed from either a loader or a conveyor and it includes all the common features of the ATP's.

Panel Pre-Positioning Station and Video Pre-alignment
A specially designed thin material crowd station at the front of the machine accepts innerlayers from a feeder or incoming conveyor line. The innerlayer is crowded to the center of the station where it is then picked up and transported to the automatic video pre-alignment cameras by the innerlayer transport system. The automatic video pre-alignment section utilizes two CCD cameras and an "X", "Y", "Ø" (rotary) positioning system. The cameras are low magnification which allow a large field of view for rough alignment of the innerlayer. Once the panel is roughly positioned it is picked up by the innerlayer transport system and accurately moved inside the machine for final positioning and punching.

Optional Automatic Panel Measuring Station
An automatic panel measuring device can be added to the conveyor/crowder section of the ATP 5000. As the panel passes from the conveyor section to the crowder section, a light bar sensor measures the length of the panel (X) Dim and a separate sensor measures the width (Y) Dim. The sensors send the information to the unit and a determination is made as to which, if any, punch blocks need to be moved to a new position. This feature eliminates the need for an operator to input the panel size and allows the machine to process different panel sizes without shutting down the line. This feature automatically sets the panel pre-positioning station, the punch block positions, the camera positions and the pick-and-place locations on the material transport system.

Multiline Technology offers a complete line of Optiline PE (OPE) Post Etch Punches to match the needs of every Multilayer Manufacturer. The common denominator which runs through all of these machines is precision. Every machine is built on a four post die set which assures the perfect alignment of the punch and die. This type of construction is the only acceptable method of building precision tooling which must remain accurate in a high production atmosphere. Precision ground hardened chromium steel alloy pins in the top of the die set align with preloaded ball bearing bushings in the bottom component eliminating friction and naturally decreasing wear. Since the punch-and-die blocks are then mounted to the die set, the highest degree of accuracy can be maintained even after millions of cycles.

If the tooling pattern is standard Multiline 4 slot, 4 slot/4 hole or any pattern which allows multiple position castings and interchangeable punch-and-die blocks, this method of construction offers many advantages over fixed die plate type tooling. Among the major advantages are adjustability and interchangeability.

1. Adjustability - Even if you presently have only a few panel sizes the pressure to get the best material yield may eventually dictate the need for another panel size. The OPE punch-and-die blocks can be adjusted to punch a range of panel sizes from 10"x 12" to 24"x 28" in a matter of minutes.
2. Interchangeability - This is an important feature of all Multiline Post Etch Punches since it prevents downtime and greatly enhances the capability of the machine. When the punches and dies wear from normal use they must be removed and sharpened. Manufacturing techniques are used at Multiline which insure that the standard OPE punch-and-die blocks are interchangeable with all others.

If your machine needs sharpening, in most cases you can rent a replacement set of tooling, replace worn punches and dies, and send yours back to Multiline for sharpening.

If you have the need to punch thicker material than .032", a set of special sized punches and dies are necessary to produce the correct size hole. Different thickness materials exhibit different results when punched. The material has a memory which causes a shrinking or contracting of the hole after punching. The punches and dies are sized to compensate for this, however, different ranges of thickness require different tooling. The interchangeable punches and dies in the Multiline OPE offer the ability to punch varying thicknesses of materials with perfect hole sizing by simply removing one set of punches and dies and putting in another. The standard sizes available are:
- 1 Type Blocks: .002" to .031"
- 2 Type Blocks: .032" to .062"
- 3 Type Blocks: .063" to .093"

The types of Optiline PE's available:
1. Manual OPE- low cost machine for small volume/operator dependent.
2. Semi-automatic OPE- economically priced, medium volume machine with computer assist.
3. Automatic OPE- considered the standard, manual load and unload, automatic vision and positioning system.
4. OPE-ATP 1000- manual pre-alignment, thin material feed, automatic vision and positioning system and automatic unload.
5. OPE-ATP 3000- 1000 with the addition of automatic adjusting punch blocks for panel size.
6. OPE-ATP 5000- completely automatic capable of being fed from a stacker or directly from the DES line.

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