Sonitek Spectrum series heat staking systems

Introducing our new line of heatstaking systems: The SPECTRUM SERIES!

Why "SPECTRUM"? We used the moniker "Spectrum" because the new product line "truly covers the broad range of uses" this new product line was designed for! Bench-top use, modular use in semi automated systems or precision linear actuators/thrusters for ganging up into fully automated systems!
With a new ergonomic work base for bench-top use the Sonitek Spectrum Series Heatstakers can also be taken apart right down to the linear actuator and with our new modular power supplies it's a snap for system integrators to install them into any custom automation in any orientation!
For companies with low or moderate volumes our bench-top model is designed to be used day-in and day out 24-7! Keep the parts coming! Spectrum can take the heat! For new product developers you can use the Spectrum line to set up and develop the correct process for your application on the benchtop system then take the unit apart and install it directly into an automated system with our column and hub for mounting to your machine base or remove the linear actuator and mount the linear actuator in any orientation directly onto your own machine frame! Gang them up, side, horizontally opposed or upside down and process many parts at the same time!
Not only was the spectrum series designed for providing our customers with enhanced performance and reliability we also introduced many new safety features designed to reduce risks of injury or property damage. There is no safer, more reliable standard off the shelf heat staking system available in the marketplace! We're Sonitek and we know what were talking about! Its meets, exceeds and complies with OSHA, NEC, CE, CSA This new and innovative product line will compliment our existing 500 series workhorses used worldwide!

PRESS & ACTUATOR FEATURES:

Ergonomic cast aluminum Work Base and center-less ground heavy duty column.
New intrinsically Safer ZERO FORCE safety start switches with self diagnostic LED's and FAIL SAFE circuitry to prevent any cross talk and/or unacceptable noise to prevent false firing. In addition these new safety switches CAN NOT be defeated with foreign objects preventing operators who attempt to start machines in an unsafe position in attempts to defeat anti tie down circuitry.
" The Ergo-Base has two sets of 3/8-16 tapped holes (same as sonic welders) on 7" and 10" circle bolt pattern. (for those of you who may have mistakenly been advised to use ultrasonic welders for insertion or staking) your fixture is directly interchangeable with our new heatstaker!
Rigid intelligent actuator with integrated hydraulic speed control and micro-adjustable scaled positive stop directly over the work piece.
Narrow Geometry Design allows multiple units to be ganged together for large multi-point applications requiring individual control.
Counter balanced head with adjustable easy access clamps allows easy gross head height adjustment on column.
Rigid four post ram design uses internal "die-set" design for maximum rigidity under high loads. " Programmable Controller
Dual pressure transducers for pressure monitoring.
Self Diagnostic features provides faults with explanations on operator panel.
Integrated test point junction for all external signals for machine diagnostics
All sensors and external devices connected via quick connect fittings for easy and fast repairs/replacement " Power Supply controller uses all digital and external controls and has no internal pneumatic components that can contaminate the electrical enclosure.

USER INTERFACE and PROCESS CONTROLS: (Press/Actuator functions)

MENU DRIVEN TOUCH SCREEN CONTROLS: Our NEW "user friendly" touch screen operator interface with four line multicolor backlit display has password protection and allows you to enter and store new process controls for both the press and integrated temperature controls with the latest technology including:

LAST RESULTS DISPLAY: Screen shows results of last cycle!

TOOL SET UP ASSISTANT!: allows technician to set up tools using a low pressure head down/up set up mode with JOG mode!

FOUR CHANNEL DIGITAL PRESSURE MONITOR: provides complete control and monitoring of all pressure related devices. Settable limits in +/- .1 psig increments monitor main incoming air pressure to prevent high or low air supply from effecting application results from main pressure setting.

STAKE FORCE PRESSURE CONTROL: monitors pressure and staking forces during the dwell staking time to ensure the application is staked at the right forces and pressure. Settable in .1 psig increments.

PRESSURE LOSS SAFETY CONTROL: This unique feature shuts off all heaters anytime incoming air supply pressure is turned off or lost. Now your heated tooling will not descend on any machine inadvertently left on overnight or during initial set up of new tooling!

LOW VOLTAGE CONTROLS: All system controls are using 24 VDC circuits (except for heaters).

MASTER CONTROL RELAY: (MCR) Safety feature uses double redundancy safety relays with reset required when an abort signal or loss of power takes place.

MAX CYCLE TIME LIMITER: Settable timer for press dwell time aborts cycle when maximum time limit reached. Ideally used for high volume or time sensitive production systems by allowing system to continue on an increasing output.

INTEGRATED PARTS COUNTERS: allows presets or total machine cycle counts with a non-reset-table total cycle counter!

PRESSURE SAFETY HEAD LOCK: this unique new safety feature prevents head from descending or dropping during any loss of supply pressure!

USER INTERFACE PROCESS CONTROLS: (Process Temperature related)

NEW HEATER CONNECTORS: Our new "quick-lock" heater connectors now feature safety locks and have integrated "make first-break last" grounding for additional safety. These connectors are IP-65 compliant and UL listed.
POST-COOLING PRESSURE CONTROL: program and monitor cooling air during post cool process!
SECONDARY POST COOLING STRIP CONTROL: Settable program to allow parts to continue cooling when heated tool retracts slightly. Used when parts have been clamped and require additional clamping and cooling after heatstaking. Applications include gaskets swaged in or other internal components that may still apply upward forces loosening the warm bosses. Cools and sets up plastic memory to prevent loosening.
PREHEATING INSERTS: Settable in distance and time this feature stops the travel of the tooling at desired location and under no force preheats your inserts PRIOR to installing them preventing any cold pressing or hoop stress!
PROCESS CONTROL LIMITS EXPANDED: Control Pressure, Time, Force and Temperature with programmable settable upper and lower limits each with their own individual lockable parameters!
NEW TEMPERATURE CONTROLLERS! Integrated Microprocessor based Auto-tuning PID temperature controller is programmed by the same touch screen menu driven control system. No more separate or expensive temperature controllers to deal with. Temperature ranges settable in F or C.
MULTI-ZONE TEMPERATURE CONTROLLERS:program one or more integrated individual temperature zones or points from the touch screen.
AUTO-TUNE:from set point or cold start!
OUTPUT CYCLE TIME CONTROL:settable values for temperature controller allows user to program output cycle for heaters, solid state relays and even contacts (if used). It provides a stable constant load for electrical components with more precise temperature control.
CONTROL RESPONSE TIME: settable in three preprogrammed modes for the temperature controller's response time to eliminate or minimize temperature overshoot and provide more stabilized set points for complex tooling designs.
MAXIMUM OPERATING TEMPERATURES: Settable range of maximum operating set point temperatures to prevent overheating of tooling. Settable up to 1000 degrees F.
SET POINT ALARMS: Settable Out-of Temperature set point alarms in 1 degree increments! Program different allowable limits for high and low limits! Machine will not operate when out of temperature and changes the operator interface into a RED warning light and displays information about default it automatically resets the "READY" signal when temperature returns back within temperature set point limits and panel turns back to green.
HEATER RUN AWAY PROTECTION! Any heater or thermocouple failure will shut the system down and provide alarms! System monitors for open heaters and/or open thermocouples or settable maximum operating temperatures up to 1000 degrees!
INTEGRATED PARTS COUNTERS: allows presets or total cycle counts with a non-reset-able total cycle counter!
MULTI-LINGUAL DISPLAY: available in any language and currently standard in English and Spanish

AUTOMATION READY OPTIONS: "We make it easy for you to integrate and handshake with our NEW system controller!"

Remote start cable with dry contact closures for start, stop, e-stop/abort, and remote reset.
Machine READY signal " Machine BUSY signal
Head Down and End of stroke signals
Head up (top of stroke) signal
Special or Custom Programming available for any system control handshaking through our advanced controls department

AVAILABLE OPTIONS:

CUSTOM HEATED TOOLING: All tooling and components designed and built by "in-house" by Sonitek.
DUAL PRESSURE, stake at two different pressures
Force Transducer: Measure force with a load cell. Note only provides gross force measurement.
Quick-Change Tooling Mount (precision dovetail/saddle design) allows for rapid tooling changeover even when tooling is still hot!
Extended Stroke: for hard to reach depths extend the stroke to any length*
*Requires RFQ and spec.
Pneumatic or Manual Slide Tables: Load and/or assemble parts out and away from heated tooling. " Pneumatic clamping: provides precise control of pre and post clamping of parts when required.
Rotary Turntables: increase productivity with two position (or more) rotary system. Load and Unload during the staking time!
Part Presence Sensing: Use laser or other sensors to determine parts loaded properly.
Safety Guarding: available with static guards or electronically interlocked.
Machine Stands: Built in house from heavy duty welded construction the machine stands are available with 5: urethane locking casters, leveling foot pads or both!
Extended Columns for floor height or tall applications.