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In Focus - Archives Décembre 2008
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Which clamping system enables the maximum flexibility and efficiency to be achieved? SCHUNK provides system-neutral advice and covers the entire range from simple quick-change jaws to complex clamping solutions for automated production.
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01.12.2008 -
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. Those that still have to reset their clamping devices on a stationary machine will struggle to maintain their place in the market in the future.
Quick-change jaw systems are an effective method of reducing machine shutdowns. For lathe chucks and stationary clamping solutions, they can reduce setup times by up to 90 percent, depending on the exact system.
The Lauffen-based clamping and gripping technology specialist SCHUNK is a renowned expert when it comes to providing efficiency in workpiece clamping on lathe chucks or stationary clamping systems. Depending on their requirements, users can choose the most appropriate solution for them from SCHUNK's broad range of quick-change solutions. Special solutions also pay for themselves quickly due to the often considerable savings in setup times.
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The very latest thing: Quick-change jaws for stationary clamping systems
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Changing jaw at the push of a button: The latest innovation from SCHUNK allows the jaw to be changed in seconds on stationary clamping systems.
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The most recent innovation from SCHUNK is a quick-change jaw system for TANDEM clamping blocks, which can be used to reduce the time for jaw changes from around 5 minutes in the past to just 10 seconds. To achieve this, SCHUNK fits a one-piece base jaw with a high-precision quick-change system, which allows the jaw to be completely changed without the need for tools.
At the push of a button, the operator controls a bolt, which disconnects a locking pin and thus releases the jaw. A diagonal pull then enables it to be changed in seconds. The new jaw is placed in the form-fit clamping by the operator and is immediately secured automatically by the integral "click-in system". This makes changing jaws properly a simple matter.
At the push of a button, the operator controls a bolt, which disconnects a locking pin and thus releases the jaw. A diagonal pull then enables it to be changed in seconds. The new jaw is placed in the form-fit clamping by the operator and is immediately secured automatically by the integral "click-in system". This makes changing jaws properly a simple matter. Operator errors are all but eliminated. The spring force of the locking pin means that the quick-change jaw is fixed in place even before the clamping force is applied. When clamped, the forces arising are absorbed in the form-fit and clearance free interface. The extremely high jaw change repeat accuracy is < 0.01 mm.
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The new quick-change system means that users of clamping blocks can now also enjoy the benefits of quick-change jaws. Changing jaws with different clamping contours ensure high flexibility and cover a variety of clamping ranges. In addition, qualified personnel are no longer required for most jaw changes and the error rate falls. Taking all these benefits into account, the costs of these sophisticated standard or special stationary workpiece clamping solutions from SCHUNK are generally amortized very quickly.
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Quick-change jaw or complete pallet change?
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Depending on the degree of flexibility required in stationary workpiece clamping, it may be worthwhile to incorporate a quick pallet change including clamping device rather than using a quick-change jaw on a single clamping device. The SCHUNK UNILOCK quick change pallet system allows the user to carry out all setup work outside the machine. The fully set up workpiece pallet with SCHUNK UNILOCK interface is then inserted precisely into the machine compartment in a matter of seconds. This can be done manually or, if required, fully automatically around the clock. Thanks to the standard clamping pin on the SCHUNK quick change pallet system, once clamped the workpieces can by moved to other processing stations on the fly.
When changing pallet using the SCHUNK UNILOCK, the user gains valuable processing time, which quickly pays off with high performance machines: Costs fall. At the same time, output and quality increase, because the system ensures maximum precision and operator errors in the clamping process in the machine are all but eliminated.
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Easy retrofitting of existing lathe chucks
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A combination of the BWT supporting jaw and BWW changing jaw turns conventional lathe chucks into quick-change chucks in no time.
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When it comes to lathe chucks, SCHUNK also provides a range of options for improving the flexibility of the machine while simultaneously cutting costs. A combination of the SCHUNK BWT supporting jaw and BWW changing jaw represents an ideal "quick change retrofitting kit" for conventional lathe chucks. This time-saving duo are fitted with 1/16" x 90° or 1.5 mm x 60° fine serration and can be used with numerous conventional lathe chucks. On this system, the operator uses an Allen key to unlock the changing jaw, fits a new jaw in the locking axis and closes the system. Changing the jaw takes no more than around five seconds.
An integral pressure pin prevents the locking axis from coming loose on its own. The BWW interchangeable inserts from SCHUNK guarantee an extremely wide clamping range without adjusting the supporting jaw. As the changing jaws are removed upwards, even the smallest clamping diameters can be realized. The extremely narrow tolerances of the contact and supporting surfaces ensures excellent stability and a repeat accuracy of < 0.02 mm.
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Multiple benefits thanks to convenient quick-change systems for lathe chucks
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Thanks to the large contact and support surfaces with narrow tolerances, this "retrofitting solution" from SCHUNK has excellent stability and a repeat accuracy of < 0.02 mm.
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The integrated quick-change jaw systems on the SCHUNK lathe chucks are extremely effective. In small and medium-scale production, they bring users several benefits: The quick-change chucks reduce the actual change-over time for the three jaws from five minutes to well below one. In addition, there is no need to repeatedly bore out the soft top jaws. Because of the excellent repeat accuracy of as little as < 0.02 mm they only need to be bored out the first time and can then be used again and again. This saves the user the time-consuming boring out of soft jaws during each set-up process.
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Huge cost savings
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What initially looks like just a few minutes adds up to a sizeable amount over the course of a year. Assuming a boring out time of 20 minutes for each soft jaw set, the total time saving for each jaw change is around 4 minutes of change-over time + 20 minutes boring out time = 24 minutes. Based on just a single jaw change per day and a machine hourly rate of 100 Euro, this daily time saving is worth €40. Over 220 working days, the cost savings per year amount to a substantial € 8,800. This example shows that quick-change jaw systems bring considerable cost savings and enable a big competitive advantage to be achieved.
What's more, fewer top jaws are required because eliminating the constant reboring of the jaws significantly extends their service life. Thanks to the excellent repeat accuracy and the flexible alignment of the chucks on the machine spindle, the jaw sets can also be used on different chucks.
Compared to the combination of supporting jaw and changing jaw outlined above, the integrated quick-change solution for SCHUNK lathe chucks also offers further advantages: The integrated system is constructed lower, the weight of the jaws is reduced and, when using monoblock jaws, the repeat accuracy increases further because there is only one interface instead of two.
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SCHUNK quick-change systems are easy to operate
and provide added safety
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The integrated quick-change jaw systems are supremely easy to handle. With the ROTA THW series power chucks from SCHUNK, a quarter turn with the jaw change key is all it takes to disconnect the base jaw serration with an open chuck. Once the new jaw has been fitted and the wedge-bar serration has securely engaged with the base jaw serration, the key can be turned back. A spring mechanism then ejects the key, thus preventing it from accidentally being left in the chuck body. Incorrect operation when changing jaws is thus eliminated. For the ROTA THW plus, the entire jaw change takes less than 60 seconds.
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1) The ROTA THW plus wedge bar power chuck from SCHUNK is extremely flexible and accurate.
2) Jaw changing is accurate, fast and safe: Release the tension.
3) Safe jaw changing with the jaw key.
4) Clamp new workpiece.
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Accurate and safe: The convenient ROTA-S plus from SCHUNK allows extremely fast jaw changes without tools and absolutely secure workpiece clamping.
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The ROTA-S plus manual chuck from SCHUNK has an even more convenient design. There is no need for any tools at all when changing the jaws. A gold-colored button on the chuck body operates a plunger pin, which disconnects the relevant jaw. After a few seconds to change the jaw, the plunger pin automatically positions the base jaw in relation to the wedge-bar serration and secures it against falling out. A lock bolt in the wedge bar automatically guarantees that the two serrations engage fully with one another. In addition, an indicator pin provides visual safety when turning. As long as the pin is visible, the machine cannot be started. The pin only disappears into the chuck when the chuck is correctly closed and the workpiece is securely clamped.
The safety features on the SCHUNK quick-change chucks increase working safety on the lathe. At the same time, they allow expensive system failures and costly damage caused by operator errors to be significantly reduced.
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Wide range of SCHUNK lathe chucks with integrated quick-change system
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The following SCHUNK lathe chucks are fitted with quick-change jaw systems as standard:
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Crucial: Expert advice and efficiency analysis
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The overview shows the wide range of options for using sophisticated clamping devices to remain flexible, improve quality and cut costs. It is notable that what at first glance seem to be expensive solutions bring huge benefits in the longer term and can often be amortized very quickly. However, depending on the application even a relatively moderate investment in quick-change solutions can achieve considerable savings. This is why SCHUNK consultants support users in choosing appropriate clamping solutions and analyzing the efficiency of the individual systems. This ensures that the user achieves an optimum cost/benefit ratio.
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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.
 Pour en savoir plus…
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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.
Pour en savoir plus…
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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.
Pour en savoir plus…
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09.2008
Cleanroom
The importance and the use of cleanrooms in assembly and handling are constantly increasing.
Pour en savoir plus…
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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.
Pour en savoir plus…
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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.
Pour en savoir plus…
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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.
Pour en savoir plus…
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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.
Pour en savoir plus…
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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.
Pour en savoir plus…
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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
Pour en savoir plus…
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02.2008
Vibration damping
Improves surface quality and reduces wear on the tool and spindle.
Pour en savoir plus…
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In Focus - 2013
In Focus - Archives 2012
In Focus - Archives 2011
In Focus - Archives 2010
In Focus - Archives 2009
In Focus - Archives 2008
In Focus - Archives 2007
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