As a precision electronic manufacturing equipment, the LTCC chamfering and sorting machine is mainly used for chamfering processing and defect screening of LTCC substrates. The accuracy of the equipment directly affects the performance stability of electronic components. In view of the brittleness of LTCC materials and the strictness of processing requirements, a scientific maintenance system should focus on three cores: maintaining mechanical accuracy, ensuring the stability of the optical system, and guaranteeing the reliability of electrical control. The following is a maintenance specification verified by industry practice:
1. Daily Maintenance
（1） Cleaning of LTCC Chamfering and Sorting Machine Surface and Working Environment
• Before starting the machine every day, clean the worktable of the equipment and the surrounding area of the chamfering mechanism with a dry and dust-free soft cloth, focusing on removing residual ceramic powder (LTCC materials contain alumina, and long-term accumulation will lead to increased wear of mechanical parts).
• The working environment should be kept at a constant temperature and humidity. Check the workshop environment monitoring instruments daily to avoid fogging of optical lenses or thermal expansion and contraction of metal parts caused by drastic fluctuations in temperature and humidity.
（2） Pre-inspection of Key Parameters of LTCC Chamfering and Sorting Machine
• After starting the machine, first confirm the air pressure value (standard range 0.5-0.6MPa), and check whether the air circuit is unobstructed through the air pressure monitoring module of the equipment. If the pressure fluctuation exceeds ±0.02MPa, immediately check whether the filter is blocked (it is recommended to replace the filter element in the air source processor every day).
• Check the speed feedback value of the chamfering tool. The deviation from the nominal parameter of the equipment should be ≤5%. If the deviation is too large, stop the machine to check the status of the spindle bearing.
2. Maintenance of Core Components of LTCC Chamfering and Sorting Machine
（1） Chamfering Mechanism System
• Tool components: Use a special torque wrench to disassemble the tool, and check whether there are cracks or wear on the blade with a 50x magnifying glass. If the cumulative processing quantity reaches 5000 substrates, it must be replaced compulsorily regardless of the appearance.
• Feed guide rail: Dip a dust-free cloth with special fluorine lubricating oil, apply it evenly along the axial direction of the guide rail. After application, manually run the feed shaft for 3 reciprocating strokes to ensure that the lubricating oil is fully penetrated. It is strictly forbidden to use mineral oil to avoid chemical reaction with the guide rail material.
（2） Optical Sorting System
• Lens and light source: Use a lens-specific air blower to remove surface dust, then dip Zeiss lens paper with absolute ethanol (purity ≥99.7%) to wipe the lens in a spiral manner to avoid scratching the coating. Check the brightness uniformity of the LED light source array. If the attenuation of a single lamp bead exceeds 20% (detected by the brightness calibration function of the equipment), the light source module must be replaced as a whole.
• Image sensor: Run the dark current detection through the equipment diagnosis mode every month to ensure that the sensor noise value is ≤10mV. If it exceeds the threshold, contact the manufacturer for professional calibration.
3. Maintenance of Electrical and Control Systems of LTCC Chamfering and Sorting Machine: Ensuring Operational Stability
（1） Electrical Cabinet and Wiring Maintenance
• Open the electrical cabinet every quarter, use an anti-static vacuum cleaner to remove internal dust, focusing on cleaning the heat sinks of the servo driver and PLC module. Check the terminal block and fasten it with a torque screwdriver according to specifications to prevent poor contact due to vibration.
• Regularly (it is recommended to do it every six months) conduct insulation resistance test on the servo motor. Use a 500V megohmmeter to measure the insulation resistance between the winding and the shell, which should be ≥100MΩ. Otherwise, stop the machine to check for moisture or winding aging.
（2） Software System Maintenance
• Every week, through the data backup function of the equipment, store key data such as sorting parameters and image templates to an encrypted USB flash drive. The backup file must include the equipment serial number and backup date.
• It is forbidden to upgrade the equipment operating system or modify the registry parameters without authorization. Software faults should be handled by the original factory engineers through the remote diagnosis system.
4. Long-term Shutdown Maintenance of LTCC Chamfering and Sorting Machine
• Execute the tool homing program and then power off, apply anti-rust grease on the surface of the chamfering tool, and cover it with a special protective cover.
• The optical lens should be installed with a moisture-proof and dust-proof cover, and the whole equipment should be covered with an anti-static dust cover. Silica gel desiccant should be placed in the cover.
• Before reusing, it is necessary to carry out an empty machine operation test: run 3 no-load cycles continuously, monitor the positioning accuracy of each axis, and put it into production only after confirmation.
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