ROBOTIC HEAT STAKING CELL

More About Heat Staking

Heat staking is one of many ways to weld plastic parts together. This method uses simple studs to permanently join the elements with a tight and clean staking process. The principle is quite simple. The InfraStake tool heats the plastic part to soften it, and then, applies pressure to form a stud to retain both components together.

While some heat staking processes are hot and sticky, the Extol InfraStake technology makes it precise, clean, and safe. The IR lamp softens the plastic, and then a non-heated punch forms the stake according to the chosen staking types.  The infrared energy is focused radially on the plastic to heat it, so the module stays cool.

Starting at
$81,300 USD

Robotic heat staking cell

More affordable than ultrasonic staking, the InfraStake technology, combined with the versatility and the modularity of the Comet-44 or the Satellite-66 cell makes the Heat Staking bundle the perfect combination for any kind of business.

More affordable than ultrasonic staking, the InfraStake technology, combined with the versatility and the modularity of the Satellite-66 cell makes the Heat Staking Cell the perfect combination for any kind of business.

The 4-steps routine is simple, fast, and consistent to provide the best staking possible.

Clamp Process Step

Clamp

Heat Process Step

Heat

Form Process Step

Form

Retract Process Step

Retract

Robotic Welding Assistant Single Gripper EOAT

The infraStake Module

To improve Heat Staking applications, Extol innovated with an integral clamping system that creates the tightest, strongest stake joints. The IR lamp is the game-changer in this technology. It focuses the energy on the plastic and efficiently heats it up without inducing stress in the plastic. Nevertheless, the InfraStake module is easy to disassemble if any maintenance is needed.

The Extol Control Program

The InfraStake Processing Assistant software is improved to more precisely control the power level to match the rate of heating needed to avoid melting or burning the component. The smart processing algorithm makes setting up the process easy, intuitive and provides full quality assurance through increased process monitoring.

Robotic Welding Assistant Controller 1
Robotic Welding Assistant Controller 2

The Extol control platform (Available on demand)

The InfraStake Processing Assistant software is improved to more precisely control the power level to match the rate of heating needed avoiding melting or burning the component. The smart processing algorithm makes seging up the process easy, intuitive and provides full quality assurance through increased process monitoring.

Robotic Welding Assistant

The DIY Robotics Cell

To support the pressure applied by the InfraStake tool, the Satellite -66 cell has been equipped with a FANUC Robot M- 20iB/35S, capable of supporting up to 35kg of pressure. This makes the whole process stable and consistent.

The Heat Staking Cell has been developed to provide reliability and flexibility in the staking process. The combination of the Extol tools with the DIY Robotics cells makes this industrial robotic kit unique.

BENEFITS

Precise Logo
PRECISE
Adjustable Logo
ADJUSTABLE
Intuitive Logo
INTUITIVE

InfraStake produces the strongest parts of any plastic staking technology. The technology heats up the plastic boss to a semi-molten state before staking. This allows the material to flow when it is formed and reduces any internal stresses that can occur with other processes.

InfraStake modules are designed to clamp the components during the staking process. Each module clamps directly at each stake point with independent pressure to ensure the assembly is tight when the staking process is complete. A tight joint means no buzzing, squeaking, or rattling!

InfraStake is safe to use with sensitive parts such as electronic components. The modules do not vibrate like ultrasonic staking and they don’t blast the parts with excessive heat like hot air staking.

InfraStake doesn’t cause any damage to the A-surface of the parts being staked. There is no excessive heat or vibration. So, beautiful parts stay pristine, unscuffed, and unmarred.

InfraStake produces the strongest parts of any plastic staking technology. The technology heats up the plastic boss to a semi-molten state before staking. This allows the material to flow when it is formed and reduces any internal stresses that can occur with other processes.

InfraStake modules are designed to clamp the components during the staking process. Each module clamps directly at each stake point with independent pressure to ensure the assembly is tight when the staking process is complete. A tight joint means no buzzing, squeaking, or ragling!

InfraStake is safe to use with sensitive parts such as electronic components. The modules do not vibrate like ultrasonic staking and they don’t blast the parts with excessive heat like hot air staking.

InfraStake doesn’t cause any damage to the A-surface of the parts being staked. There is no excessive heat or vibration. So, beautiful parts stay pristine, unscuffed, and unmarred.

ROBOTIC COMPATIBILITY

Comet-44 with
LR MATE 200iD/14L

Comet-44 LR-MATE 200iD/14L
timer - icon

500 mm/s

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911 mm

kg icon

14 kg

Satellite-66 with
M-20iB/35S

Satellite-66 M-20iB/35S
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4000 mm/s

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1445 mm

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35 kg

Robotic Heat Staking Cell with
Other Robot Options

Robotic Heat Staking Cell

Contact us for more information

FEATURES

  • Mobile and modular, increasing its versatility when needed.
  • Removable lamp that does not require the removal of the lamp holder for easy manipulation.
  • Interchangeable punch to fit various needs.
  • Intuitive software to optimize the staking process.
  • FANUC Robot M-20iB/35S that supports up to 35 kg of pressure.

FEATURES

  • Mobile and modular, increasing its versatility when needed.
  • Removable lamp that does not require the removal of the lamp holder for easy manipulation.
  • Interchangeable punch to fit various needs
  • Intuitive software to optimize the staking process.
  • FANUC Robot M-20iB/35S that supports up to 35 kg of pressure.
Mechanical IS32 IS125 ISM20
Length 213.2 mm (8.392″) 161.4 mm (6.353″) 161.4 mm (6.353″)
Diameter 31.6 mm (1.245″) 31.4 mm (1.235″) 20.0 mm (0.787″)
Module Mounting Thread M8x1.25 M8x1.25 or 5/16″-18 M8x1.25
Punch Position Sensor Integrated Linear Potentiometer* Auxiliary Hall Effect Sensor Auxiliary Hall Effect Sensor
Punch Position Sensor Tolerance +/- 0.05 mm (0.002″) +/- 0.5 mm (0.02″) +/- 0.5 mm (0.02″)
Pneumatic
Pressure 550 kPa (80 psi) 550 kPa (80 psi) 550 kPa (80 psi)
Air Flow (per module) 90 SCFH 90 SCFH 90 SCFH
Punch Cylinder Bore 16.0 mm (0.630″) 14.2 mm (0.563″) 14.2 mm (0.563″)
Punch Cylinder Force 110 N (25 lbf) 89 N (20 lbf) 89 N (20 lbf)
Electrical
Wattage 100 W 100 W 35 W
Voltage 12 V 12 V 12 V
Amperage 8.3 A 8.3 A 2.9 A
Lamp Type Tungsten Halogen Tungsten Halogen Tungsten Halogen
Available Power Supply Models PM400 PM400, PSC, PSCMN PM400, PSC, PSCMN
Module Power Connections flying lead (2 m) or fieldwireable Amphenol flying lead (1 m) or connected Amphenol connected Eurofast
Machine Power Connections none, bulkhead, or in-line none, bulkhead, or in-line none, bulkhead, or in-line

*Analog card and 10 V power supply required.

  • Weight: 1293 kg (2850 lbs)
  • Wheels with integrated leveling pads
  • Integrated electrical cabinet (32 in/32 out available user I/O’s)
  • Integrated pneumatic panel (4 valves 5/3 open-center 6 mm ports)
  • Meets the CSA requirements
  • Easily adaptable for custom needs
  • Pre-secured robotic environment
  • Completely modular
  • 480 VAC three phases
  • EtherNet/IP communication
  • Karel
  • DCS
  • Basic interference check
  • Collision Guard
  • Constant Path

Included software :

  • Background logic programs for alarms, lights, locking sequence, and timers for the general operation of the robotic cell
  • Two HMI pages; one for the general operation of the cell and one for product selection
  • 10 programs associated with the product selection HMI page
  • The cell is programmed to be operated with 3 buttons (stop, reset, start). It starts the main program that calls the selected product
  • One homing program selectable by a macro

Comet-44

C33-Datasheet-A - image
C33-Datasheet-B - image
C33-Datasheet-C - image

Satellite-66

S55_DimensionsSheetA - image
S55_DimensionsSheetB - image
S55_DimensionsSheetC - image

ACCESSORIES

Compatible with standard DIY Robotics accessories and easily adaptable for custom needs.

Robotic Heat Staking Cell

Installation

The Heat Staking Cell can be integrated into your production line with only 10 simple steps. Before the robotic cell arrives at your factory, make sure its space has been prepared. The floor does not need to be perfectly leveled, as you will be able to adjust the cell by handling the pre-integrated ratchet handles on the wheels. The cell needs an electric and a pneumatic connection. Make sure you have both of them set up.

You can find more specifications about the Heat Staking Cell installation procedure on the documentation shared on our website. Remember that DIY Robotics provides free support to help you at any moment if needed.

We can assist you in many ways

As our mission is to make industrial robotics accessible to all, we have developed several tools to guide you towards your own Industrial Revolution. Visit our forum for free programming, engineering, designing, and troubleshooting support. You can also use our payload calculator to make sure the robot you selected can manipulate the EOAT you designed, or you can talk to one of our experts if you have any additional questions.