InfraStake Integration Software Guide

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This guide describes the features and functions of the InfraStake Integration Software. The software is organized into four main tabs: Home, Monitor, Process, and Setup.

Home tab is used for part selection, rework, and exiting back into the main program of the machine.

Monitor tab contains process monitoring, fault history, and maintenance information.

Process tab is used to set up the InfraStake process, both manually or with the Processing Assistant.

Setup tab is used to configure the tool, module, and part setup, as well as manually control the InfraStake modules for troubleshooting.

Each software screen contains an information button and a learn button. These buttons reveal information about the software and provide descriptions of the many features of the InfraStake process.

Tap the information button to access the following:

  • Color-coded legend
  • Select software unit system
  • Extol contact information
  • Software version information

Tap the learn button to learn about features in the software. After tapping the button, learn icons will appear over the features on the screen. Tap one to learn more about it.

Home

Use the Home screen to select which parts are being staked. The Setup and Process screens will need to be completed before this screen is usable.

This screen also includes the Rework button. Use rework mode to stake select points individually.

Lastly, the Exit button allows the user to exit back to the main program of the machine.

Monitor

Part SPC

Access pass/fail information for the last 50 parts staked.

Module SPC

Monitor module-specific process data, including boss height and stake height, in both graphical and tabular form. Data for each module is stored for the 50 most recent cycles.

Set upper and lower limits for each variable and the software will automatically calculate the mean, standard deviation, and process capability for the last 50 cycles.

Fault History

Access information for the last 100 module faults.

Maintenance

Monitor the maintenance status of each module. This includes lamp total on-time, lamp cycles, and average on-time per cycle. Use this information to determine when to replace the lamp. Once a lamp has been replaced, use this screen to reset the on-time and cycle counters.

Monitoring Setup

Set up process monitoring for each module. Process monitoring options include:

  • Lamp On Verification
  • Boss Height Verification
  • Stake Height Verification

Set Limits

Set upper and lower limits for the boss height and stake height of each module independently. Manually enter the settings or use the current position of the punch to teach the pass/fail targets.

Process

Module Recipe

We recommend using the Processing Assistant to set up the InfraStake process. Manually set up the recipe for each module using the Module Recipe screen.

Use the Smart Adjust feature to hold Total Energy constant while adjusting other parameters. The software will automatically adjust the other parameters to maintain a consistent Total Energy. For example, if Ramp Time is increased, Soak Time will decrease and Soak Power will increase. This will result in a lower Total Heat Time. A primary use for this feature is minimize smoking when shortening Total Heat Time.

Process Parameters

Ramp Time is the first phase of the heat cycle during which the boss ramps up in temperature. Ramp time is the length of time a lamp stays on at full power.

Soak Time is the second phase of the heat cycle during which the heat soaks into the boss. Soak Time is the length of time a Lamp stays on at a reduced power level.

Soak Power is a reduced power level used during the second phase of the heat cycle, during which the heat soaks into the boss.

Total Energy is the energy generated by the lamp during a heat cycle and is the amount needed to form the boss. (Not all of the energy reaches the boss.)

Total Energy = (Ramp Time x 100%) + (Soak Time x Soak Power); if multiplied by the lamp wattage, this gives energy in Joules.

Total Heat Time is the total amount of time the lamp is on during a cycle.

Punch Time is the total time the punch remains extended (stake position). During punch time the punch is typically being cooled with high-flow cooling air so that the melted plastic under the punch solidifies before the punch is retracted. Adequate punch time is required to prevent plastic sticking and stringing during punch retract. Punch time applies to all modules that share a valve group (zone).

Total Cycle Time is the total length of time to complete the InfraStake process.

Processing Assistant

The Processing Assistant is the best way to set up an InfraStake recipe.

The InfraStake Processing Assistant is like having an Extol technician built into the machine. This intelligent tool 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.

The Processing Assistant asks the user a series of questions and iteratively stakes test parts. The software finds a recipe that produces a complete stake without smoking in the shortest cycle time. Eliminating smoking will reduce maintenance by keeping the reflective surfaces cleaner and ensuring that the plastic is not degraded during heating.

Process Troubleshoot

Use this extension of the Processing Assistant to correct process issues such as incomplete staking or smoking, without interrupting production.

Setup

Tool Setup

Set up the tool configuration on the Tool Setup screen. A tool refers to a physical set of modules and is not necessarily associated with a fixture change.

Select how many tools are used by the machine, the number of modules present on each tool, and which parts are being joined by each tool. This helps organize the parts and keep track of maintenance for each module.

Module Setup

Set up the module configuration on the Module Setup screen.

Assign the valve group that each module is using for cooling air and what type of punch sensor is used on each module.

Part Setup

Set up the part configuration on the Part Setup screen.

Assign modules to parts. Use multiple parts on a tool when not all of the modules need to be used at the same time.

Manual Control

Manually operate the InfraStake modules on the Manual Control screen for troubleshooting.

Manual functions include:

  • Extend and retract punches (forming tools inside the InfraStake modules)
  • Turn cooling air on and off
  • Turn lamps on and off

Note: The machine program must first be set to manual mode to use this screen.