Equipment Manual

for

 

Operation of Automatic Lapping Plate  

Flatness Control on the  

PM5 Precision Lapping & Polishing Machine

Original English Version           

Ref: BE-01-52-7              

 

 

Logitech Limited Erskine Ferry Road, Old Kilpatrick, Glasgow G60 5EU, Scotland, UK

Tel: +44 (0) 1389 875444 Fax: +44 (0) 1389 879042 Fax: +44 (0) 1389 890856 (Sales)

e-mail: info@logitech.uk.com

www.logitech.uk.com 

EC Declaration of Conformity 

In accordance with EN ISO 17050‐1:2004 

We: 

of: 

 

in accordance with the following directive(s): 

 

BS EN ISO 9001:2008                         Quality Management Systems      2008 

BS 8888:2008                                      TPS – Technical Product Specification    2008 

2004/108/EC         The Electromagnetic Compatibility Directive  2004 

2006/95/EC         The Low Voltage Directive      2006 

2006/42/EC         The Machinery Directive      2006 

 

hereby declare that: 

Equipment:      PM5x and LA5x range of lapping and polishing machines 

Model Number(s):    1PM5x‐1; 1AL5x‐1; 1AP5x‐1; 1LP5x‐1 and 1LA5x‐1 plus 

variants 

Serial Number:  From  

56x‐xx‐05 onwards 

Where 56x = denotes the model number 

xx denotes the number built in the year to date and 05 

denotes the year ‘2005’ 

 

 

 

is in conformity with the applicable requirements of the following documents/standards: 

 

BS EN ISO 13849‐1:2008                    Safety of Machinery. Safety related parts of control 

systems. General principles for design.   

  2008 

BS EN 953:1997+A1:2009                  Safety of Machinery. Guards. General requirements for the 

design and construction of fixed and movable guards. 

            1997/09 

BS EN 60204‐1:2006 + A1:2009      Safety of Machinery. Electrical equipment of machines. 

General guidelines.        2006/09 

BS EN ISO 13857:2008                       Safety of Machinery. Safety distances to prevent hazard 

zones being reached by upper and lower limbs.   

            2008 

AND EMC Standard(s): 

BS EN 61326‐1: 2006  Electrical equipment for measurement, control and 

laboratory use           2006 

 

I hereby declare that the equipment named above has been designed to comply with the relevant 

sections of the above referenced specifications. The unit complies with all applicable Essential 

Requirements of the Directives. 

Done at: Logitech Ltd 

 

On 13th January 2011                   

    Document ref. No. 5600112 

BE-01-52-7 V0211 P age 2 of 10  

1. INTRODUCTION         

Monitor cable socket Plate flatness monitor  

                              

Support pill ar for m oni tor Monitor rol ler arm     

Figure C1: Elements of PM5 auto lapping plat e f latness control syst em  

  

The i nnovative Logitech l apping plate flatness control system is controlled from the "Process Data" section of the machine contr ol panel. The system al lows the operator to set a target value for the shape of the lappi ng pl ate, which i s then constantly checked by the pl ate flatness moni tor and displayed on the "Process Data" screen. Any var iations from this plate shape ar e automaticall y corr ected by the machine’s contr ol system whi le pr ocessi ng continues. Intended use: 

The PM5 autolap is a single workstation lapping and/or polishing machine, designed for small scale 

production work or research and development applications. It is intended for use with Logitech 

consumables for the lapping and polishing of a wide range of materials. This must be carried out as per 

the instructions for use provided in this manual in order to prevent damage to the equipment or 

materials being processed.  

It is not intended for any other use or with consumables not approved by the manufacturer. 

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2. SET-UP   

(For operati on of the basi c PM5 machine, and di agram s indicating the location of other machine par ts, see the rel evant equipment manual, ref. no. BE- 01-50.) Special requirements: 

It is intended that the machine be located in a room not subjected to extreme environmental 

conditions such as high humidity or temperature as this may adversely affect the electrical and 

electronic components of the unit. 

The machine is not sensitive to vibration and can be located on a standard work bench or table 

sufficient to hold its weight as specified in section 3.1 

The system should be situated away from areas of dust or particle contamination as this may affect the 

quality of the surface if airborne particulates become trapped in the abrasive layer. 

No special lighting is required for the system and the machine may be operated from 200 lux or above 

environment with no flicker or glare. The control display is a white on blue backlit display to aid 

visibility. 

The PM5x‐1 and LA5x‐1 series of machines in normal operation run at a noise level below 70dB (A).  

The machine was tested using a calibrated ISOTECH SLM‐52N sound level gauge over a one hour period 

and averaged below 70dB (A). Background levels were recorded at 52dB (A) +/‐2dB before and after 

the tests. The sound meter was placed 1m from the unit and facing the unit directly at a height 1.6m 

from the floor.  

Potential failures or breakdowns 

a)   Care must be taken when operating the joystick so as not to damage the universal movement. 

Gentle pressure is sufficient to move the joystick in any direction and excessive force will 

prematurely damage the mechanism 

b)  The Slurry feed chute angle adjustment wire must be bent slowly to the direction and angle 

required to place the slurry on the plate. Excess force can break the join and require it to be 

rebonded into the chute body 

c)   The machine operation software is stored within the main processor of the front panel and 

although the mains inlet line is fused any external power surge or electrical storm etc…may 

scramble the machine memory and require a system reset. A UPS unit in line would reduce the 

chance of this occurring  

 

2.1. SWITCH-ON  

Upon initial switch- on of the PM5 auto, the Logitech l ogo will appear, followed by the "Checking System Resources" screen. At thi s point the machine will ver ify that each of the r esources listed are present and available for use. Should each r esource be in working or der a tick wi ll appear next to them al l i n turn. In the unlikely event that the machine di scover s a fault with any of the resour ces listed, a cr oss (x) will appear next to the faul ty resource. It is recommended that should thi s occur you contact your near est Logitech representati ve.

BE-01-52-7 V0211 P age 4 of 10  

 

 

Once these initial checks ar e compl ete the m achi ne will move to a screen w ith the machine serial number and softwar e versi on displayed at the top. Below this infor mation ar e two choices:

 

 l Process Screen l Machine Set up

 Using the joystick, the operator should select "Machine Setup".

 

  

2.2. INITIAL CHECKI NG OF PLATE FLATNESS MONITOR  

The plate flatness monitor is calibrated at Logitech pri or to despatch of the machine. However, as it is a precision instrument, it is necessar y for the oper ator to check this calibrati on prior to the first use of the monitor in his or her own laboratory. If correctl y calibrated, it should al ways be possibl e to obtai n a monitor readi ng of between +/-10 m icrons, which should then be offset by zer oing the m onitor. If, however, after carr ying out the fol lowi ng steps it is outwith these tolerances, see section 2.3 "Initial Cali brati on of Plate Flatness Monitor".

 

 

After selecting "Machine Setup", the screen wil l change to show a screen sim ilar to "A" bel ow. To set up your PM5 for Automati c Lapping Plate Flatness Control, ensure that the "Process Type" display reads "Lapping", that the "Jig Type" display r eads as the correct jig being used and that the "Ar m C ontrol" display is changed to show "Flatness". At this point the scr een ("B") wil l displ ay an option for zeroing the monitor and a warning message telling the operator to remove the r oll er arm assembli es fr om the wor kstati on and m oni tor ar m.

  

A. Typical ini ti al machine setup screen B. Screen after selecting the Fl atness option

BE-01-52-7 V0211 P age 5 of 10  

Thoroughly clean the bearing surfaces of the Plate Flatness Monitor; cl ean the Granite Master Fl at Block supplied equally thoroughly. Attach the long monitor cable to the sockets on the monitor and the machine.

 

 

To zero the Plate Flatness Monitor, sel ect "Monitor Set-up" using the joystick. The scr een should change to display the "Raw Plate Shape" reading ("C ").

 

C. Averaging the monitor reading D. Show ing the "Actual Plate Shape" reading

 

E. Selecting "Auto Zero" F. "Zeroing" the monitor reading

  

The "Raw Plate Shape" repr esents a snapshot reading taken fr om the M oni tor whi ch is then aver aged against the "Actual Plate Shape" reading which is read from the monitor over a 30 second interval. During this time the operator i s not abl e to navigate away from this screen as the machine r equires to collect data fr om acr oss the m onitor. This informati on is then assi milated and processed before the readi ng is show n as in screen "D".

 

 

Once the "Raw Plate Shape" and the "Actual Plate Shape" information have been displ ayed, the operator should navigate to the "Auto Zero" option shown in screen "E".

 

 

NB If the reading i s not between +/-10 microns it w ill be necessary to recalibrate the monitor as described in the next section of this manual.

 

 

Select the "Auto Zero" option by pressi ng the button on top of the joysti ck and the m achine will "Zero" the monitor, as show n in screen "F". Thi s operation involves the machine taking the averaged reading from the "Actual Plate Shape" and recognising it as being the offi ci al zero readi ng, i .e. a completely flat reading whi ch will be used throughout the lappi ng process.

 

 

At this point the monitor has been zer oed and the oper ator can exit this screen, returning to the "Machine Setup" screen.

 

 

The l ong monitor cable should be removed from the monitor.

BE-01-52-7 V0211 P age 6 of 10  

This procedure for zeroi ng the monitor is all that should be required on a day-to-day basis. H owever, if when usi ng the machine for the first ti me, a reading between +/-10 microns cannot be obtained, it is necessar y to calibr ate the monitor.

 

  

2.3. INITIAL CALIBRATI ON OF PLATE FLATNESS MONITOR  

The procedure for re- calibrati on of the plate fl atness moni tor is detailed in the fl ow chart ( Figure C3). Letters refer to the parts i n Figure C 2 below.

 

       

B A      

C C

 

D     

 Figure C2: Plate Flatness Monitor

BE-01-52-7 V0211 P age 7 of 10  

Clean diamond face on th e flat ness monitor & on the mast er flat block.

Figure C 3: Adjust ment of Plate Flat ness Monitor

 

 

Place monitor gen tly on master fla t blo ck. Move slow ly across the m aster flat. Is the re ading within t he +/- 10 micr ons limit?

 

NO

Disconnect mon itor cable. Remove loading weight ( A).

YES  

Select "Exit"

 

  

Loosen the two sid e clamp screw s ( C) . Connect mon itor cable between m onito r and m achine; switch on machine

and navigate to "Machine Set-up ", "Monitor Se t-up".    

Loosen the thr ee top holding scre ws (B). Pr ess dow n on top of the mo nitor to simu late th e load ing w eig ht. Wind th e adju stme nt collar

to a reading of 2 con cave to 2 convex micr ons (clockwise to convex & anti-clo ckwise to conca ve) .

  

Fully re- tig hten the thr ee holding scr ews (B) - this will r esult in the rea dout movin g towar ds convex & ideally to within 4-6 micr ons

convex. Tighten th e two side clamp screw s (C) .    

Remo ve cable, re place we ight ( A) and reconnect cable. Is the monitor read ing w ith in the +/- 1 0 micr ons limit?

 YES

  Select "Exit"

 

R e-assemble monitor

 NO

 

  

Is the value high er than 10 micr ons Vex?

 NO

 

Is the value low er than 10 micr ons Cave?

YES  Remove we ight and wind the ad justment collar (D ) anti-clockw ise to a r eading mor e

concave than the or iginal setting.

 

YES  

Rem ove weight and w ind t he adjustm ent collar (D) clockwise to a r eading of a litt le more concave than the

original setting.    

Fully re -tighten the screw s ( B); the concavity will r educe and come back tow ard th e +/-1 0 micr on range . Replace

weight.   

Is t he monitor r eading within the 4- 6 micr ons Vex? NO  

 YES

 Select "Exit"

   

 Re- assem ble monit or

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When re-assembling the monitor, tighten the si de clamp screws (C), and recheck the settings agai n on the Process D ata Display screen, in order to ensure that no movement has taken place.

 

 

Once cali brati on of the monitor has been completed, i.e. the reading shows a value between 10 microns concave and convex (i deally ar ound 4 to 6 µm convex), and the monitor has been re- assembled, reset the monitor using the procedure detai led in section 2.2.

 

 

It should be noted that, in or der to maintain the accuracy of the autol ap system, it is necessary to recalibrate the external moni tor on a r egular basis. Logitech recommend that this acti on should be carri ed out if the error is more than 5 micron concave when the monitor is checked using the "Monitor set up screen". Follow the steps for recalibrati ng the m onitor and set i t to approximately 4 to 6 m icron convex. This will lengthen the time that the monitor wil l remain in range without having to recalibrate it m ore often than 4 to 6 weeks.

 

  

2.4. SYSTEM CHECKS  

Having returned to the "Machi ne Setup" screen, the operator should now select "Exit", havi ng ensured that al l r oll er arms have been r emoved from each of the workstations and monitor support pil lar. The machine will now display a "Confirm Action" scr een whi ch will ask the operator whether the jig shown is indeed the correct one. If the jig shown is correct, select "OK" whi ch wi ll lead to a further "Confi rm Action" screen being displayed warni ng that the pil lar arm is about to be moved to the process posi tion. Select "OK" only i f the roll er arms have been r emoved from both the workstation and monitor pillars.

 

 

The machi ne wil l carry out a short series of internal system checks, and set the wor kstati on and monitor support pillar to thei r mid positions, allowing the roller arm s to be cor rectly positioned.

 

 

NB This only occurs after i nitial switch-on of the machine; it does not recur at any point during processing. However, shoul d the emer gency stop button be pressed, it will be necessar y to switch the machine on again.

 

  

2.5. POSITIONING OF ROLLER ARMS AND MONITOR  

(Refer to Figure C4.) This i s car ried out w ith the aid of the Positi oning Tool supplied and the l apping jig to be used, after the machine has carried out i ts system checks.

 

 

NB This procedure applies w hen ini tially setting up the machine for use or if the roller arm s have been removed for any reason, such as cleani ng or mai ntenance. If the arms have previously been set, there should be no need to re-position them.

 

 

Firstly, place the Posi tioni ng Tool i n the centre r ecess of the l apping plate. Loosely position the roller arm for the Plate Flatness Monitor on the suppor t pi llar ; do not fully ti ghten the clam p scr ew until the arm has been positioned.

 

 

Place the Pl ate Flatness M onitor in its appr oximate posi ti on in the monitor r oller arm . Ensure that the r im of the monitor ’s outer stop ring is positioned against the raised secti on of the Positioning Too and tighten the clamp screw.

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Plate Flatness M onit or

 Positioning tool

 

Lapp ing jig          

 Roller ar m bearings

 

  

Lapping plate  

  

Po sitionin g tool  

 Plate Flatness Monitor

Roller arm bearings

 

        

Lapping jig    

Figure C4: Posit ioning of Roller Arms   Repeat the above procedure for the other roller arm, but using the j ig placed against the Posi tioni ng Tool for pr ecise l ocation before ti ghtening the cl amp scr ew on the ar m.

 

 

Finally, attach the short m onitor cable between the Plate Flatness Monitor and the monitor cable socket.

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3. SAMPLE LAPPING  

  

3.1. SETTING A TARGET PLATE SHAPE  

After the m achi ne has completed its internal system checks, select the "Process Screen" option and the machine wi ll allow the oper ator to star t pr ocessing - wi th a zero flatness target. Alternatively, the operator can choose to set a specifi c target value.

 

 

The tar get can be altered by selecting the "Flatness" option w ith the j oystick on the "Process Scr een", as shown below. From thi s screen the oper ator can choose to make the plate convex, concave or return i t to a flat target. The position of the T on the line denotes the val ue being set in r elati on to the zero value.  

(i) Target set to zero

                

(ii) Target set convex  

 

(ii i) Target set con cave  

Figure C5: Setting Target Plate Shape

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3.2. MONITORING PROCESSING USI NG THE PROCESS DATA SCREEN  

The actual plate value is shown by the arrow sym bol directl y above the T and duri ng processing this symbol will shi ft toward the T symbol as the plate shape changes to reflect the target value. This allow s the operator to moni tor the plate shape throughout processing and to observe how any i nitial devi ations fr om the target shape ar e automati cally cor rected by the auto functi on.

 

 

Logitech recommended tol erances are +/-2 mi crons, i.e. al though the machine will work to the pr ecise target, a value within 2 microns of this shoul d also be considered as acceptable.

 

  

3.3. LAPPING HARD MATERIALS  

When lapping par ti cularly hard materials on the PM5 auto, the operator may find that the deviation from the target value remains, even though the machine has moved to cor rect this. This is quite normal when lappi ng hard samples. The deviation from the zero tar get will onl y be in the order of a few microns over the plate track, and therefore the individual sampl es will hardly be affected.

 

 

To help return the plate to a flat shape, pl ace the lapping plate test bl ock supplied in the ri ght- hand roller arm and r un thi s, with the l oading weight on top and with a supply of lappi ng abrasive from the autofeed cylinder, until the shape displayed on the Process Scr een is within 2 microns of flat.