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.
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 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.
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.
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.
BENEFITS
PRECISE
ADJUSTABLE
INTUITIVE
STRONG PARTS
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.
TIGHT JOINTS
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!
SAFE AND NON-INVASIVE
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.
NO A-SURFACE MARKING
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.
STRONG PARTS
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.
TIGHT JOINTS
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!
SAFE AND NON-INVASIVE
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.
NO A-SURFACE MARKING
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.
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
Satellite-66
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.
