InfraStake Integration Guide

Original Instructions
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Introduction

These instructions are provided to guide you through the InfraStake integration process. We recommend reviewing all of the instructions before starting the integration process.

Infra Module Description and Spare Parts List

Before you begin, please refer to the Infra Module Description and Spare Parts List that was provided with your integration package. It describes the intended location of each InfraStake module relative to the parts that are to be assembled.

Mount the modules

  • Each InfraStake module should have an 11 mm (7/16″) diameter through-hole in the tooling plate centered over the boss location. This allows for some adjustment of the module relative to the boss.
  • Mounting hole options on the top of each module:

IS32M8 x 1.25 only
IS125M10 x 1.5 or 5/16"-18
ISM20M8 x 1.25 or 5/16"-18

  • The bolt should be used with an 8 mm (5/16″) hard washer to mount the InfraStake module to the tooling plate.
  • Once the InfraStake modules are properly positioned and the machine has produced acceptable parts, the modules can be dowelled to the tooling plate.

Note: The integrator is responsible for providing the appropriate machine safe guards to protect operators from all safety concerns. See InfraStake Safety Considerations for more information.

Position the modules

Set module height (if machine allows for Z-position adjustment of the module)

InfraStake modules are designed to clamp the parts at each stake point.

  1. Bring tool plate down into work position.
  2. Set module height to net out on parts to be staked.
  3. Secure Z-position of the module.

Center module

Proper alignment is critical to an optimal InfraStake process.

  1. De-energize punch cylinder.
  2. Remove concentrator (and reflector for IS32).
  3. Extend punch by hand
  4. Center the punch over the boss in the X and Y directions.
  5. Secure the X and Y position, being careful not to move the module.
  6. Replace concentrator (and reflector for IS32) and re-energize the punch cylinder.
  7. Stake parts to confirm module is centered over the boss.

Connect pneumatic components

The integrator is responsible for supplying pneumatic valves for the InfraStake system. Download the pneumatic schematic to properly plumb the pneumatic system.

  • InfraStake Punch Cylinder Specifications

ModulePunch Cylinder Bore SizePunch Cylinder Force with 550 kPa (80 psi)
IS3216 mm (0.63")110 N (25 lbf)
IS12514 mm (0.56")89 N (20 lbf)
ISM2014 mm (0.56")89 N (20 lbf)

  • Press Force: The InfraStake press assembly must apply enough downward force to counteract the total force from the InfraStake punch cylinders.
  • Punch Valve: One 2-position valve is required for the punches; additional valves are necessary if the punches are separated into groups. If Low-Pressure Boss Sensing was purchased, a 3-position double solenoid open center valves is required instead of a 2-position valve.
  • Cooling Air Valve: One 3-position double solenoid open center valve is required for cooling air.
  • Cooling Air Filtration: The cooling air circuit requires 0.01 micron filtration. The provided Dual Flow Cooling Air Kit should be installed between the cooling air valve and the InfraStake manifold as shown. If the incoming air supply is oily or dirty, additional filtration may be required.
  • Air Lines: Different colored air lines should be used for each circuit.

Plumb the InfraStake manifold

  • Port sizes:

PortInlet ODInlet IDOutlet ODOutlet ID
Punch Extend Port6 mm (1/4")4 mm (1/8")4 mm (5/32")2.4 mm (3/32")
Punch Retract Port6 mm (1/4")4 mm (1/8")4 mm (5/32")2.4 mm (3/32")
Cooling Air Port10 mm (3/8")6.5 mm (1/4")4 mm (5/32")2.4 mm (3/32")

  • Flow controls are installed in the cooling air outlet ports.
  • The InfraStake process requires two cooling air flow rates; a low flow rate while the lamp is on and a higher flow rate while the punch is extended.

Set the low-flow and high-flow cooling air

All modules connected to the same regulator will have the same cooling air flow rates and need to be treated as a group. Low-flow cooling air is controlled by the regulator. High-flow cooling air is determined by the unregulated machine pressure. Flow controls are used to tune the cooling air flow rates of each module in a group to be the same. Set the low-flow cooling air to the recommended values unless noted otherwise by an Applications Report.

Recommended Low-Flow Cooling Air:

IS3250 SCFH
IS12525 SCFH
ISM2025 SCFH
Set the cooling air valves by group according to the following steps:

  1. Completely open all flow controls in one group.
  2. Turn on the low-flow cooling air.
  3. Measure the low-flow cooling air of a module by disconnecting the cooling air line from the module and connecting it to the union fitting on the 0-100 SCFH flow meter included in the package.
  4. Use the regulator to adjust the low-flow cooling air in one group to be near the recommended value.
  5. Use the flow controls to fine tune each module to the same low-flow value; lock each flow control when the low-flow cooling air is correct.
  6. Repeat process for each group of modules.

Clean, dry, non-lubricated compressed air is essential to the InfraStake process.

Connect module power cables

The integration package contains one of the following connection styles:

  • Flying leads: terminated as desired
  • Bulkhead connectors: mounted in a junction box
  • In-line connectors: mounted in a bracket or secured as necessary

Connect module sensor cables

The integration package may contain analog and/or digital sensors used for process monitoring. Connect the sensors to the supplied M8 cable.

  • IS32: Analog
  • IS125: Digital
  • ISM20: Digital

InfraStake Module Power Connector

Lamp connection is not polarity dependent.

PinIS32 & IS125ISM20
1Lamp Output (0 VDC)Lamp Output (0 VDC)
2Lamp Power (+12 VDC)Not Used
3Not UsedLamp Power (+12 VDC)
4Not UsedNot Used

Male connector viewed from pin side

InfraStake Module Sensor Connector

This cable needs to be properly wired as an input to the machine controller.

PinDescriptionColor
1Positive*brown
2Input/Signalblack
3Common (0 VDC)blue
-shield
*5-32 VDC Digital
*10 VDC Analog reference voltage

Male connector viewed from pin side

Clamp

Heat

Form

Retract

Process sequence

  1. The machine extends the InfraStake module and clamps the parts together.
  2. The controller turns on the low-flow cooling air and the lamp.
  3. The lamp and the low-flow cooling air stay on for the duration of the heat time.
  4. The controller turns off the lamp and extends the punch to form the boss and the high-flow cooling air turns on.
  5. When the punch time expires, the punch retracts while the parts are still clamped together. High-flow cooling air remains on.
  6. The machine retracts the InfraStake module.
  7. When the high-flow cooling time expires, the cooling air switches back to low-flow and the cooling air timer starts.
  8. The low-flow cooling air remains on until the cooling air timer expires.

Note: If the next machine cycle starts before the high-flow timer expires, then the cooling air will switch to low-flow.

Process settings

  • Application Report: If parts were provided to Extol, there may be an Application Report that includes the appropriate process settings. If not, the settings can be established using the Processing Assistant.
  • Processing Assistant: The Processing Assistant is able to find the optimal staking process for an application. Activate the Processing Assistant and follow the prompts to set up the InfraStake process.

Note: Excessive heat, resulting in plastic degradation should be avoided.

Process Monitoring Setup

Use the following instructions to set up InfraStake process monitoring. IS32 modules have an integrated analog sensor that is easily programmed through the HMI with the InfraStake Integration Software. IS125 and ISM20 modules use digital sensor(s) which must be physically adjusted to the proper position.

Stake Height / Full Stroke Verification Setup

After setting up the InfraStake process…

  • Load a good, staked part.
  • Bring press to work position.
  • Extend punches.
  • On the HMI, select the Monitor tab and open the Monitoring Setup screen.
  • Select which module you wish to program
  • Turn on Stake Height or Full Stroke Verification
  • Set punch postion
    • IS32: Go to Limits Setup and teach module under Stake Height Verification. Set upper and lower limits.
    • IS125: Loosen sensor on module by turning screw 1/4 turn and adjust until sensor turns on. Retighten sensor.
    • ISM20: Loosen sensor clamp on module by partially unscrewing band clamp and adjust until sensor turns on. Retighten sensor.

Boss Height / Boss Presence Verification Setup

After setting up the InfraStake process…

  • Load a good, unstaked part.
  • Bring press to work position.
  • Extend punches.
  • On the HMI, select the Monitor tab and open the Monitoring Setup screen.
  • Select which module you wish to program
  • Turn on Boss Height or Boss Presence Verification
  • Set punch postion
    • IS32: Go to Limits Setup and teach module under Boss Height Verification. Set upper and lower limits.
    • IS125: Loosen sensor on module by turning screw 1/4 turn and adjust until sensor turns on. Retighten sensor.
    • ISM20: Loosen sensor clamp on module by partially unscrewing band clamp and adjust until sensor turns on. Retighten sensor.