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In Focus - Archive April 2008
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With MAGNOS magnetic clamping technology, set-up times for ferromagnetic workpieces can be reduced significantly.
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01.04.2008 -
Fast setup, secure clamping, precise machining. What in the past met with minimal acceptance especially with respect to milling is increasingly becoming an insider’s tip for reducing set-up times and simultaneously improving the machining results. MAGNOS magnetic clamping technology from SCHUNK, the specialist in toolholding, workholding and gripper technology located in Lauffen, is based on the use of electropermanent magnets and bundles decisive advantages: magnetic clamping enables machining of the workpiece from five sides, without having to be clamped a second or even a third time. Large and small workpieces can be clamped safely on the same magnetic clamping plate. MAGNOS can also be adapted optimally to the contour of the workpiece. Thanks to electropermanent magnets, the power supply is necessary only for activating and deactivating the magnets. Handling of the system could not be easier: the ferromagnetic workpiece is positioned, the current is activated and in a fraction of a second the permanent electric magnet provides for secure holding – even after the current has been switched off again.
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Short payback period
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With MAGNOS, the workpiece is clamped within seconds. Fine adjustment of the clamping elements or changing the setup of the workpiece during the machining process are eliminated. Comparison measurements among users of MAGNOS magnetic clamping technology have shown that set-up times can be shortened by as much as 30 to 50 percent, significantly reducing machine downtimes. The investment costs for the new workholding technology therefore often pay for themselves within a very short period.
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Synergy of permanent and electric magnet
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After activation, the electric permanent magnet provides for secure holding without electricity.
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Electropermanent magnetic clamping technology from SCHUNK is based on the physical phenomenon of the force of magnetism, which is used for high precision and control in this workholding technology. The development of the electropermanent cycle is the ideal combination of permanent magnets and electromagnetic forces. The advantages are superior to both conventional magnetic clamping technology and electromagnetic clamping technology.
For optimum magnetic holding power, the flux area should be as large as possible. The workpiece must at least partially cover at least one magnetic north and one magnetic south pole, where the following general rule applies: the larger the surface or the more poles that are covered by the workpiece, the greater is the magnetic holding power. Larger workpieces do not necessarily have to cover the same number of north and south poles.
In electric permanent magnet clamping technology, the bonding force between the magnetic clamping plate and the workpiece is established within a fraction of a second. A further, continuous energy supply is not necessary. After disconnecting the control unit, the workpiece is clamped permanently, evenly and safely for an unlimited time.
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Long-lived design
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The sophisticated and high-quality design of the magnetic chucks ensures a long service life.
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MAGNOS magnetic clamping technology consists of ultra-high-quality square poles, which are arranged as north and south poles in a checkerboard pattern. The stable steel base body made of C45 is manufactured as a monoblock construction in state-of-the-art machining centers. Its stability, rigidity and robustness prevent vibrations and provide for excellent machining results and for a long service life of the magnetic clamping plate.
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The reversible AlNiCo magnets are embedded in a coil. The perfect, even winding and a special insulation ensure a controlled and even magnetic flux.
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Special insulation which is cut exactly to fit the base body ensures the exactly defined pole-reversible magnetic flux of the square poles. The magnetic clamping plates contain numerous magnetic coils, which surround a pole-reversible AlNiCo magnet. The perfect, even wire winding and additional special insulation ensure a controlled and stable magnetic flux. The stable MAGNO square poles, made of steel with a galvanized surface, are fastened s safely to the electromagnetic coil. A bore hole in the middle of the square poles is used to fasten pole extensions to the plate surface. In a special high-end sealing process, the spaces between the poles are filled with high-strength synthetic resin, which protects the components in the interior of the magnetic clamping plate against corrosion. It is also resistant to aggressive cooling emulsions.
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Numerous standardized magnetic chucks
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A large selection of standardized magnetic chucks in pole sizes 50 x 50 mm, 75 x 75 mm and 100 x 100 mm covers a large number of standard SCHUNK applications. It is also possible to combine several MAGNOS magnetic chucks with each other. Both horizontal and vertical clamping set-ups are possible.
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Up to 105 tons of holding power per square meter
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Magnetic chucks from SCHUNK are available in two different versions: M1 and M2. The holding power with an air gap of 0 is 15.2 daN per square centimeter of pole surface. A MAGNOS chuck with 48 poles measuring 50 x 50 mm therefore has a holding power of ca. 18 t. The total holding power per square meter is then an impressive 105.6 tons for a pole size of 50. The chuck type M1 with a high density of the penetrating magnetic field is sufficient for 80 percent of all applications. M2 chucks have an even higher density of the penetrating magnetic field, which ensures high holding forces even with an enlarged air gap. This means decisive advantages especially in the machining of cast and forged parts, and of twisted materials. SCHUNK offers an M2 version for all pole sizes.
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Low tool wear and high surface quality
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As opposed to conventional clamping, MAGNOS magnetic clamping technology holds the workpiece firmly but gently, so that it fully retains its dimensional stability.
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Since the workpiece is clamped evenly over the entire surface due to the high holding force of the electric permanent magnets, MAGNOS effectively minimizes vibrations during machining. This improves the surface quality and significantly increases the precision of the workpiece.
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During rough machining, magnetic clamping technology achieves parallelism of less than 0.02 mm.
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Parallelism up to 0.02 mm can be achieved on planar workpieces by means of magnetic clamping technology. To achieve this, the first surface is first roughened. Then the workpiece is turned, roughened, released and smoothed. The workpiece is then turned again and the first surface is smoothed. Due to the longer life of the cutting edges, MAGNOS also reduces tool costs significantly.
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Solid and yet gentle
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MAGNOS magnetic clamping technology is suitable for horizontal or vertical clamping set-ups.
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Planar clamping via the permanent magnet prevents deformation of the workpiece. This is a major advantage especially with thin-walled or sensitive workpieces. Workpiece distortion, deformations due to concentrated clamping forces or damage to the surface are practically impossible.
MAGNOS magnetic clamping technology is used in the manufacture of moulds, and in plant engineering and machine construction. It is suitable for all applications that require machining of ferromagnetic parts. The system is especially advantageous when working with larger workpieces, such as those found in the printing industry.
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Perfect adaptation to workpiece contours
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The poles of the magnetic chuck can be adapted individually to the workpiece - a significant advantage of magnetic clamping technology in moldmaking, for example.
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Where different clamping heights and workpiece contours are used, magnetic clamping technology again is one step ahead: pole extensions allow the magnetic clamping plate to adapt to the individual workpiece in order to ensure that it is held securely. Separate supports and shims are no longer necessary. This significantly reduces the set-up time and provides for secure holding during 5-sided machining.
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5-sided machining with minimum set-up times. MAGNOS magnetic clamping technology ensures that the workpiece is accessible on five sides while being held absolutely securely.
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SCHUNK recommends that exchangeable pole extensions always be used together with magnetic clamping plates. These comparatively low-cost wear parts ensure optimum 5-sided access. Wear on the surface of the high-quality quadratic pole plate is also reduced. Rigid pole extensions are used with smooth and even workpiece surfaces. On very uneven workpieces, on the other hand, such as scaled surfaces or flame-cut parts, the mobile pole extensions, in combination with three rigid pole extensions, compensate the uneven areas, so that the workpiece is not distorted during clamping.
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Due to flexible pole extensions, the magnetic force can be deflected.
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Due to the unique modular design of the EASYTURN pole extension, the magnetic clamping force can be moved in the horizontal and vertical axes, depending on the workpiece clamping setup. This flexible axis alignment in two directions is enabled by the connection of a fixed pole with a spring core, a buffer zone and a reversible coupler. Corresponding to the setting, the flexible upper part of the pole adapts to the workpiece by an angular movement upwards or sideways. By reversing the coupling 180°, the magnetic force is changed 90° from horizontal to vertical. The magnetic force is then exerted laterally onto the workpiece. In this manner, uneven or round workpieces can be securely clamped from two sides.
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Low investment costs, flexibility and independence
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MAGNOS magnetic clamping technology can be used independent of a particular machine, requires little advance planning and no system technology or system integration. No intervention in the machine programming is necessary. For this reason, magnetic clamping technology is also suitable as a supplementary clamping solution in modern production processes.
MAGNOS in combination with quick-change clamping system
In combination with the SCHUNK UNILOCK quick-change clamping system MAGNOS is even more efficient. Maximum flexibility in production and an enormous reduction in set-up times are convincing arguments for such a combination. The magnetic chucks can be changed within seconds with repeat accuracy < 0.005 mm. Moreover, clamping on the magnetic chuck with a SCHUNK UNILOCK interface ensures maximum holding force together with exact positioning of the magnetic chuck on the machine table. The system is controlled by a separate control unit.
Lifting magnets with identical technology
Magnetic clamping solutions from SCHUNK are used successfully as lifting magnets in the intralogistics sector. With low impact and high power, they are the ideal solution for the transport of sensitive or thin-walled workpieces. Mechanical damage to the surface or form, as can be caused by single-point fastening with conventional lifting gear, is eliminated.
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Magnetic clamping technology for robots
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Innovative: The magnetic gripper MAU from SCHUNK ensures secure and solid holding during handling of ferromagnetic workpieces.
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SCHUNK offers an innovative solution based on magnetic clamping for the handling of ferromagnetic workpieces. The MAGNOS magnetic gripper MAU from SCHUNK opens up an entirely new perspective: Adapted to a robot arm, the lightweight magnetic chuck provides safe holding in minimum space. The magnetic gripper makes handling of ferromagnetic workpieces child’s play. The electric permanent magnets can be activated within seconds. They hold the workpiece absolutely safely even in case of power outage.
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Comprehensive quality requirements
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As the world leader in toolholding and workholding technology, quality and customer service are top priorities at SCHUNK also with respect to magnetic chucks. The solid construction of the magnetic chucks from SCHUNK ensures a long service life. The control unit is likewise compact and rugged, which is especially important in the event of frequent switching processes. SCHUNK also offers a repair service for the economical repair of magnetic chucks regardless of the manufacturer. This is SCHUNK’s contribution to establishing this innovative technology on a broad basis.
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12.2008
Quick jaw change brings flexibility and substantial savings
Flexibility in production is a crucial competitive advantage. Only companies that can respond to demand with flexible yet absolutely precise production can supply their customers rapidly with a constantly increasing variety of products without needing to build up expensive and inefficient stocks.
 more...
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11.2008
Pneumatics or mechatronics? … It all depends!
To date, pneumatically driven gripper modules have been used primarily in gripper technology. Recently, however, more and more electric grippers have been coming onto the market. Both competing systems have powerful arguments in their favor.
more...
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10.2008
High-Performance-Cutting (HPC)
Hard on the outside, clever on the inside: Toolholder systems developed especially for HPC that have strong rigidity as well as good vibration dampening provide clear benefits for HPC.
more...
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09.2008
Cleanroom
The importance and the use of cleanrooms in assembly and handling are constantly increasing.
more...
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08.2008
Clamping Force / Torque
We are frequently confronted with torques on a daily basis, even though we do not recognize them as such.
more...
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07.2008
Convenient robot or attractively priced spindle gripper?
A significant potential for increasing efficiency in modern machining processes is the automated loading and unloading of the machines.
more...
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06.2008
Polygon clamping technology - round pegs in polygonal holes
The principle behind polygon clamping is surprisingly simple. The know-how that makes it work is however highly advanced.
more...
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05.2008
Packaging
A package for everything
Packaging is a universal function that is required in practically every industry and meanwhile is so important that it has become a separate industry itself.
more...
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04.2008
Magnetic clamping technology has strong attraction
Workpiece clamping with electroermanent magnets reduces set-up times by up to 50 percent and brings about significant advantages especially in the manufacture of large parts.
more...
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03.2008
Quick-change systems speed up production
Changing systems for components such as grippers and tools add a high degree of flexibility to production processes
more...
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02.2008
Vibration damping
Improves surface quality and reduces wear on the tool and spindle.
more...
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In Focus - 2013
In Focus - Archive 2012
In Focus - Archive 2011
In Focus - Archive 2010
In Focus - Archive 2009
In Focus - Archive 2008
In Focus - Archive 2007
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