Induction heat staking Benefits
Meets tight production tolerances with precise localized heat to small areas creating pinpoint accuracy
Increases production rates with faster heating cycles
Reduces defect rates with repeatable, reliable heat
Eliminates variability from operator-to-operator, shift-to-shift
Maintains metallurgical characteristics of the individual metals
Multiple torches were required for this application previously, so the compact EASYHEAT minimized the required footprint for heating. With induction you can expect the same result every time, while variability is often observed with a torch
The power was turned on for five seconds and the part was monitored during heating and for 15 seconds after.
An EASYHEAT and its workhead require a minimal footprint, saving the client valuable floor space compared to heating alternatives
It took 5 seconds with a 2 kW EASYHEAT to reach temperature, which melted the plastic for a solid bond without cracking the molded plastic.
Using induction heating, the parts came to the required temperature in just 15 seconds in a highly repeatable heating method and a coil plate could offer protection against operator movement/errors
Induction offers dramatically faster heating when compared to ultrasonics; faster heating means there is the potential to dramatically increase production rates with a highly repeatable and easy-to integrate processes.
Innovation: Ambrell's Applications Lab was able to solve a problem that a competitor couldn't solve, which is a key benefit when purchasing induction solutions from Ambrell
With a more reliable induction heating system, they will not have to worry about lost production due to power supply issues that come with an unreliable system
Outdated equipment and poor responsiveness drove this customer to a new vendor who could help them with new or improved processes for new or enhanced solutions
Induction is used to bond the device sheath to collet. Innovative coil design lifts production rate.
Induction heating provides hands-free heating that involves no operator skill for manufacturing, even distribution of heating and localized application of energy limits temperature drift
A three turn helical coil is used to heat the brass bushing. The brass bushing is heated for 2 seconds and then placed on the wire connector & pressed into position.
Induction heating provides 'greener' manufacturing of pallets using reusable, recyclable materials, hands-free heating that involves minimal operator skill for manufacturing and even distribution of heating
This application has three different coils for varying hole patterns. A three turn oblong coil is used to heat 2 brass inserts in close proximity.
Induction heating provides increased production speed, simpler tooling for customer, hands-free heating that involves no operator skill for manufacturing
Induction heating provides hands-free heating that involves no operator skill for manufacturing, only the metal shaft is heated so the motor is not affected, increased production due to rapid heating, decreased failure rate, originally used glue which ran into motor and caused failure and stronger bond
The brass inserts are to be heated prior to insertion into a plastic automotive sub assembly
Heating is to be accomplished within 5 seconds, and can be done in a helical coil since pick and place manufacturing is employed.
To heat internally threaded steel inserts to a temperature above 650F for insertion into plastic lawn chair assemblies.
To heat the ends of 0.072-inch spring wire, spaced 1/2 inch apart, uniformly for the application of nylon powder on a 1inch length of the end.
To heat threaded steel studs for insertion into a plastic tail-light assembly at 450°F.
Heat Staking Basic Design Guidelines
Thermoplastics will flow at elevated temperatures and the solidified polymer can be re-heated to re-flow around the insert. Thermosetting polymers, once the shape has been cast, will no longer melt or flow on reheating. Table 1 shows some typical temperatures, time and power required for different materials, as established in the Ambrell Applications Lab.
The diameter of the insert hole must be the correct size to allow the plastic to flow around the insert. If the hole is too small,extra plastic will be displaced. This displaced plastic is commonly called ‘flash.’ Excessive heat and pressure may also cause flash. If the hole is too large, not enough plastic will flow into the fins and knurls to achieve the desired holding strength.
We have collected these 10 popular Application Notes to help you understand the many ways induction heating can improve your heating processes.