ISM33 Inserter
Heat Set Threaded Insert Installation
Press Steel & Brass Inserts
The ISM33 Inserter heats and presses
steel and brass threaded inserts into injection molded and 3D printed parts
Precise, Consistent Insertion
Insertion is repeatable & controllable
with depth accuracy to .002"
Fast, Non Contact Heating
Unique air cooled induction heating head mounts in an adjustable platform. Heats 6mm steel inserts to 300C in 2 Seconds
Temperature Sensing
An available infrared sensor monitors
insert temperature after heat to verify
that it's been heated to set temperature.
Unique Insert Pickup Head
The patent pending head securely picks
up and supports the insert for heating &
pressing. It's air cooled, low heat transfer
design helps insure consistent heating
cycle to cycle.
Insert Delivery Disc
The Insert Disc stores up to 48 inserts
for hands free loading onto the pickup head. It can be changed in seconds
Precision Linear Actuator
The 300mm linear actuator is supported
by 4 bearing blocks and mounted on a
structural aluminum support to eliminate
deflection when pressing.
Easy Touchscreen Setup & Control
7" Touchscreen enables easy setup of
all parameters including heat time and power, locations and insertion depth
Adjustable Heating Platform
The heating platforms adjusts to allow
parts up to 12" high. It is spring loaded
to prevent contact damage.
Recipes & Data History
All parameters can be saved as recipes
and easily downloaded. Critical data
can be recorded for each cycle.
Basic Operation
The basic operation of the ISM33 is described below for heating and pressing inserts into a 2 position part using a sliding fixture. All of the parameters required for insertion have been entered using the SETUP function on the touchscreen.
Place The Part In The Fixture
The operator places the part in the fixture and secures it in
place. The part must be properly secured in order to achieve
repeatable insertion results.
Pickup The First Insert
Insert pickup can be operated in manual or automatic mode.
In manual mode, press the Pickup button to load the insert
onto the heating head. In automatic mode, the insert disc will automatically index to position and pickup the insert to be ready for the insertion cycle.
Press The Start Button
When the Start button is pressed, the insert will move down to
the preset location in the heating head
Heat The Insert
The insert will heat for the preset time and power level. Typical heating times are 2 - 5 seconds.
Check The Temperature
After heating the insert descends down to the infrared temp
sensor. This checks the temperature against preset values. If
OK, insertion proceeds. If not, the pickup head returns home and a warning message is displayed on the touchscreen.
Press The Insert Into The Part
The insert then moves to be pressed into the part. As it begins
to enter, the insertion speed can be changed if needed to help prevent flashing of the plastic.
Hold & Cool The Insert
An air stream then turns to set the insert in the plastic. The insert is held in place for a set time to insure it is fully set and to prevent it from raising up due to outgassing.
Insertion 1 Complete
Insertion is complete. The pickup rod and head returns to the home position. In auto mode, when the head reaches home the insert disc rotates to the next available insert and it is picked up and ready for the next cycle.
Slide The Fixture To Position 2
The operator then slides the fixtured part to position 2. A limit switch verifies the location.
Press Start & Repeat
The next insert is then heated, checked and pressed into the part. At the end of the cool down and hold time the pickup head begins to move up and the finished part can be removed from the fixture.
Next Insert Is Loaded
When the pickup head returns home, the next insert is loaded and ready for another part.
Features
Pressure Arm
Actuator
Carriage
300mm Linear
Actuator
Hearting Platform
Pivot
3" x 3" Structural
Aluminum Support Tower
Pickup Rod
And Head
Insert Disc
Heating
Platform
Light Shield
Safety Fence
7" Touchscreen
Control Panel
1/2" Aluminum
Fixture Plate
16 ga steel electronics
enclosure
Start Button
& E Stop
Components
Heating
Platform
The heating platform incorporates the induction heating head, the laser sighting aid, the infrared temperature sensor and the insert disc. Platform arms are pivoted to allow it to breakaway
and stop motion if contact should occur.
Heating
Platform
Adjustment
The platform can be moved up and down.
Adjustment is made by turning the knob as shown
in the video on the right.
Heating Head
The heating head mounts interior
to the platform inline with the pickup
head. It is easily changed and available
in multiple sizes to heat inserts from
3mm to 10mm ID
Temperature Sensor
The infrared temperature sensor mounts
directly below the heating head. After
heating the insert lowers in line with
the sensor and the temperature is
checked to insure it has been heated OK.
Laser Sighting
Laser sighting crosshairs help to
locate the insertion point in setup.
They are turned on & off by a
button on the touchscreen.
The insert disc system enables hands free loading of the threaded inserts on to the pickup head. Discs are available for 4mm to 10mm ID brass & steel inserts and can be customized for any shape or height. Capacity varies from 18-48 inserts depending on size.
Inserts are loaded onto the pickup head at
the end of each heating and pressing cycle,
freeing up the operator to load and unload
arts into the fixture.
The disc is easily removed and replaced for
reloading. Spare discs are readily available
and can be loaded in just a few seconds.
The platform can be
raised to process parts
up to 12" high.
Platform height is
indicated by a scale
next to the ball screw
adjustment mechanism.
Insert Delivery Disc
Changing
The DIsc
Insert Pickup Head
The patent pending insert pickup head
picks up and securely holds the inserts
for heating and pressing.
The head is air cooled and specially
designed to minimize it heating in the electromagnetic field as the insert
is being heated and to reduce heat
transfer from the insert.
This enables the head to maintain a
consistent low temperature and insure
that heating of the insert is the same
cycle to cycle.
Part Fixtures
Part Fixtures are required to securely hold parts in position
and to align the heating head and insert with the insertion
location on the part. Fixtures typically incorporate limit switches or other devices to insure accurate location. A port on the rear of the ISM33 unit is available for limit switch connection.
We can design, fabricate
and test custom fixtures for
your part(s) to be included
with the shipment of the
system.
Touchscreen Controls
The Touchscreen is used to setup all operating parameters, store recipes, display system status, display historical data and more. The primary displays and their functions are described below.
Setup Screen
The Setup screen is used to determine and enter all basic operating parameters for insertion. It enables precise control of the linear actuator for setting pickup, heating and insertion locations. Using the variable jog rate control, movement as low as .002" can be achieved. Some of the settings available include:
Heating Time
Heating Power
Travel Speed
Insertion Speed
Min/Max Temp
Jog/Move
Pickup Location
Heating Location
Insertion Location
Go To Set Location
Current Location
Cool/Hold Time
Run Screen
The RUN screen is used by an Operator for pressing the insert into the part after setup has been completed. Typically,
the SETUP function is password protected. The RUN screen is not. It provides only the functions necessary for basic operation, including controlling pickup up of the inserts.
The RUN screen also includes a current status display. This
display changes as the status changes, e.g. Ready, Heating,
Temperature, Pressing, Cooling etc. It also displays Fault messages if any issues should occur during the process.
Ready
Press
START
Recipe Entry
The Recipe Screen allows entry of all operating parameters as a recipe along with ID number and name up to 10 digits. An unlimited number of recipes can be entered.
To call up a recipe, just select it from the list. It can then be revised if required or downloaded for operation. When downloaded, all current values will be displayed on the setup screen. The recipe screen also enables entering the # of the insert disc being used so that disc indexing is correct.
Other Setup Functions
Additional Setup functions are available that are not required for standard operation. These include 2 cycle counters, one for displaying # of cycles since last power on and one for total along with an option for displaying the count on the Run screen.
Other functions include temperature display adjustment, read time delay for reading the temperature and a button to access the historical display screen.
Data Display Screen
Certain operating parameters, primarily insert temperature and heating power, are recorded for every insertion cycle.
This data can then be reviewed at a later time if needed.
Data for up to 10,000 cycles are recorded and time stamped.
The display can be reset at any time.