Thermal Presses heat the staking
post/insert while applying pressure axially to permanently set the
parts. Advantages of the thermal heat staking / inserting process
include:
Reliable permanent inserts
No particulates or noise
Multiple level inserting/heat staking
Multiple size inserts
No whitening when degating
Better cosmetic appearance when
heat staking and swaging
High tolerance to mold release,
colorants and other additives
Tolerant of resin grade variations
and regrind percentages
Low initial equipment cost
Ease of operation and assembly
Handles slippery thermoplastics
Easier maintenance in a low-tech
environment
Heat Staking Press Features
120V AC model (up to 6 x 350 watt
heaters) and
240V AC model (up to 12 x 350 watt heaters)
3/4 ton, 1 ton and 1 1/2 ton models
Digital zone heat controller (80° F to 999°
F)
Modular master/slave temperature
controllers
Digital timer for weld time and
post-cool
Easy to use LCD touchscreen display
Setup mode jogs head down for probe alignment
Ultra rigid steel H-frame chassis
eliminates flexing to reduce functional and cosmetic defects
Pneumatic thruster with 4-inch (100mm)
stroke
Hydraulic speed control standard
Modular configuration means no more
knockouts and hand wiring of relays and controllers
Prewired and preprogrammed for optional
slide kits, post cool, and fixture clamping.
Thermal press applications include heat
staking, inserting, embossing, date coding and degating.
Automotive industry for door panels, map pockets,
light-pipe staking, consoles, arm rests and switch clusters. Medical
applications include blood-processing equipment, chemical pumps, fittings,
flow meters, IV drug delivery and surgical instruments. Consumer
Product applications include personal computers, portable telephones,
laser printers, copy machines, video games, speakers and appliance
components. Industrial
applications include conveyor systems, gears, pulleys, couplings, and
motor housings. Thermal presses
are also used in Toy Manufacturing and the Sporting Goods industry.
Dukane heat staking thermal presses can work with a variety
of materials including most amorphous and semi-crystalline thermoplastics
as well as liquid crystal polymers. Some difficult to weld plastics
are well suited to the thermal process including lubricious materials such
as PTFE. Soft thermoplastics such as PE and PP react favorably to
thermal inserting along with brittle materials such as 50% mineral-filled
PPO (Ryton) which flakes when subjected to ultrasonics. Call Dukane
for a complete list of materials suitable for thermal inserting/heat staking.
Heat staking work cell is ideal for
larger plastic applications that require multiple posts
staked. It is designed for applications such as,
exterior and interior automotive trim, appliance panels'
and large consumer electronic devices. What is unique
about this machine is that the independent actuators
attach to a solid horizontal bridge, versus other
machine designs that incorporate large platen actuation.
The independent actuators allow for the flexibility to
retool this machine for future applications. Each
actuator can be adjusted in the x y and z access, as
well as, with angular adjustment to deal with
applications that have a contoured shape. When heat
staking, the best post strength is achieved when the
speed at which the staking tool compresses the post
matches the melt velocity of the plastic material.
Hydraulic speed control on each actuator provides this
advanced level of melt speed control. The thermal
controls are Dukane's standard design that are modular
and can be easily upgraded by the user to add more
staking points. Additional PLC expansion is available to
add more part clamping, sensing, position sensors and
other features in the future.
User friendly operation is achieved through a color
touch screen HMI and one touch cycle initiation. Heater
burnout fault signals are optional. Safety guarding is
on three sides with a light curtain across the operator
load area, along with a bright work light.
Urethane-poured part nests eliminate marking on the
class A surface of the parts. The lower fixture nest is
mounted on a two-position linear ball bearing slide.
Servo pneumatic programmable stop positions are
optional. The slide mechanism gives the operator the
ability to load the part clear of the heated thermal
tips, safe and comfortable. Locking casters and or
leveling feet are available.
Specially made for the appliance
industry, this work cell is designed to attach metal clips to the
back of a cosmetic front panel. The heat staker simultaneously heat
stakes two posts on each of eight clips securely attaching them to
the panel.
The process starts when the operator manually loads a panel into
the fixture, and then loads eight clips onto the panel. The lower
nest is made of urethane to ensure that there is no marking on class
“A” surfaces. Next, four DE-STA-CO clamps are manually positioned to
hold the parts in place. Then the work table is moved into place,
and one DE-STA-CO clamp is closed to hold the table in position.
(Pneumatic clamps and an automated pneumatic slide table is
available as an option.) Part sensing detects that all clips are in
place, and eight heat staking heads extend (The head has a 5”
stroke.) to form the posts. Watlow temperature controllers monitor
the temperature of each staking tip, and an after staking feature
allows the staked heads to cool. This insures the stakes are solid
before the staking heads retract. The operator manually repositions
the table, and removes the completed part.
Control is provided by an Allen-Bradley Panelview 700 color touch
screen HMI interface. The device can be password protected and is
linked to the expandable A-B CompactLogix™ PLC. In addition, there
is easy access to an Opto-touch switch to begin a cycle, and to two
abort switches if the operator needs to stop the process quickly
The work table is a solid, one-inch thick extruded aluminum piece
with a Blanchard ground top giving the table superior rigidity. The
sides of the work cell have an extruded aluminum frame and clear
polycarbonate panels. The front and rear access doors are
key-lockable. (Interlock doors are an option.) A light curtain
protects the operator, while a Smog-Hog filtration system removes
fumes. The control cabinet can be locked to prevent tampering with
any of the process settings. Rugged leveling feet with swivel
casters are standard.
Call 630-797-4900 or e-mail us at for more
information.
for more
information.