Award winning RCDs feature hot air staking
A
Phasa Developments product story
Edited by the Engineeringtalk editorial team
Nov 7, 2000
Plastic hot air staking technology from Phasa Developments is proving to be the ideal high speed assembly method for a new range of award winning plug-in RCD (Residual Current Device) modules
Plastic hot air staking technology from Phasa Developments is proving to be the ideal high speed assembly method for a new range of award winning plug-in RCD (Residual Current Device) modules developed by Harlow-based mechatronics specialist, PBT Ltd.
The safety critical products, which won the coveted Supreme Award at Electrex 2000 for their design innovation and ultra-fast response times, call for permanent and tamper-proof fixing of high speed piezo-ceramic actuators within durable two-piece thermoplastic housings.
Further key manufacturing criteria include the fixing method's ability to ensure consistent and aesthetically pleasing deep-stake forms within recessed areas of the body in order to complement the stylish lines of the finished product.
The use of hot air staking - which employs the principle of directing air at between 150 and 400oC to locally heat pre-moulded pegs, ribs or collars, so that they can be re-shaped, clamped and subsequently cooled into a new form - overcomes potential damage to the modules' sensitive electronic components caused by ultrasonic welding operations.
In addition, it eliminates the need for expensive threaded fasteners - minimising raw material costs, while maintaining the highest levels of end user safety.
Continuous refinement by Phasa Developments over the past 15 years means the plastic hot air staking process is today capable of achieving in excess of 200 stakes in a single operation.
To meet PBT's specific production requirements, Phasa equipped one of its type 10/30 machines with interchangeable tooling to provide the required three point fixing on all three models in the range.
With typical cycle times of 15 second for each product variant, the machine provides floor-to-floor times of 25 seconds per unit.
The fastening system's precise control of all process parameters also ensures the required levels of manufacturing consistency.
In studies undertaken in conjunction with the University of Hertfordshire, Phasa equipment has repeatedly achieved Cpk values of more than 2.0 - the equivalent of less than one reject part per million operations.
"The ability to demonstrate the total capability of the process was a key factor in winning this contract," says Phasa's John Neugebauer.
"A high proportion of our work is involved with the automotive, electrical equipment, IT and domestic appliance industries.
However, hot air staking's versatility also enables it to be used for roll forming plastic tabs or collars to secure bearings, glass panels and loud speakers; to weld fabrics and felts, and to carry out a host of other manufacturing assembly operations.".
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