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In Focus - Archives Avril 2010
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With magnetic clamping technology the set-up costs for ferromagnetic workpieces can be considerably reduced.
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01.04.2010 -
Magnetism is one of the most fascinating and influential force of our universe. Engineers and technicians use this same force in order to clamp workpieces, or to reliably lift components. Magnetic clamping technology is well-established in various areas, such as grinding, milling, turning, mobile lifting units in production, and for huge crane constructions. Most engineers now know that magnetic clamping solutions reduce set-up times by about 80 percent, that workpieces are clamped without any deformation, and even coils can be reliably transported.
The principle function of the permanent or electro-permanent magnetic clamping technology is easy. In the "unclamped condition" the magnetic field flows within the module and has no influence to the outside. Through a short-term electric impulse, a lever mechanism or a pneumatic signal, the magnetic field is diverted to the outside and the magnetic clamping module is actuated. This process is absolutely reliable and doesn’t require a power supply or compressed air to maintain the magnetic field.
Two conditions are require for the mechanism to function: The workpiece must be ferro-magnetic and cover equal amounts of north and south pole. In order to achieve an optimum clamping force, the area of flux should be as big as possible. The bigger or the more poles that cover the workpiece, the greater the magnetic holding force.
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5-sided machining at a minimum set-up time. By using magnetic clamping technology, the workpiece is freely accessible from five sides, but stays perfectly fixed.
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The poles workholding magnets can be automatically adjusted individually to the workpieces, an advantage beneficial to the mold- and die production industry.
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Milling:
Five sides machined with just one set-up
The square or parallel pole plates of the electro- permanent magnets offer decisive advantages: The magnetic set-up allows machining of the workpiece from five sides without having to re-clamp a second or third time. This is an enormous advantage especially if large workpieces have to be machined. Neither adjustment of the clamping elements nor several set-ups of the workpieces during the machining process are necessary. The ferro-magnetic workpiece is positioned, the controller is actuated and in a fraction of a second the permanent electro magnet provides reliable clamping - even if the current supply is disconnected. Side by side comparisons have shown that between 30 and 50 percent of the set-up time can be saved. Since the machine down-times considerably decreases, the capital investment of a magnetic solution normally amortizes in a short period of time.
Moreover, large and small workpieces can be reliably clamped with the same magnetic plate. In order to compensate differences in height, the square or parallel poles can be individually adjusted to the workpiece contour. For parts with uneven surface the magnetic clamping technology is the ideal solution: the field density is strong enough to compensate rough surfaces.
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In contrast to conventional clamping methods, the magnetic clamping solution keeps the workpieces dimensionally stable.
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With this magnetic clamping solution large cast workpieces are surface clamped without any vibrations. This assures an optimum accessibility from five sides and a plane parallelity of 0,02 mm.
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Especially gentle
Magnetic clamping solutions are gentle with fragile or easily deformed workpieces because a magnet does not induce any external forces. A magnet simply makes the workpiece appear heavier. Therefore thin-walled workpieces are not deformed and can be made flat and true. When large surfaces of the workpieces are milled, a plane-parallel configuration of up to 0.02 mm can be achieved utilizing self shimming pole extenders. The first surface is rough machined, then the workpiece is turned, rough machined, unclamped and then reclamped for finish machining.
Magnetic surface clamping minimizes vibrations and prevents the cutting edge from damage. Particularly if high-quality tools are used, the magnetic clamping technology can reduce tool costs.
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In the pictured cast workpiece, the magnet is located within the hallow of the casting which assures fast, reliable and precise clamping which makes machining from all sides possible.
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Flat and jig milling:
Parallel pole technology is the state-of-the-art
The use of magnetic clamping technology is widespread for surface grinding. Small and large workpieces can be clamped in seconds. Even at jig milling machines, electro permanent magnets do not induce heat into the workpiece. This way, operators can precisely maintain the tightest tolerances.
Turning and circular grinding:
Deformation-free clamping of huge rings
For turning and grinding of ring-shaped components, radial pole magnetic clamping technology is used. Thus large workpieces are clamped reliably and deformation-free on grinding machines and lathes - a decisive advantage over face plates and jaw boxes. Up to a diameter of 4,000 mm the radial pole magnets can be made from one piece to provide stability for every clamping operation. In case of large plate diameters however, a segment design is recommended, in order to facilitate transportation of the magnetic chucks.
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Up to a diameter of 4,000 mm radial pole magnets are manufactured from one piece. This assures an extremely stable clamping of the workpieces.
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The hybrid chuck ROTA NCM from SCHUNK offers enormous advantages: Minimum set-up times, deformation-free clamping and no vibrations.
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Hybrid chucks combine radial pole technology and centering chucks
The advantage of radial pole magnets is the variable power level adjustment, by which the workpieces can be easily aligned before the electro permanent magnet provides maximum hold. Due to the surface clamping, the workpieces stay within its shape and can be machined from three sides. Magnets provide excellent vibration dampening characteristics. Hybrid chucks are even more efficient, because the centering technology of conventional 3 or 6-jaw centering chucks is combined with the surface clamping technology of a radial magnet. With these chucks the workpieces are automatically centered from inside or outside and are clamped within seconds. In case of applications on grinding machines or lathes with pneumatic or hydraulic actuation, the hybrid chucks reduce the set-up times by about 80 percent and thus significantly increases productivity. Depending on the application, SCHUNK offers both radial pole magnets with automatic demagnetization, or with very high magnetic forces.
Lifting loads:
Fast and reliable
Lifting magnets are used for applications in the field of intra-logistics. While very powerful, they can gently grip the component . For transportation of sensitive or thin-walled workpieces, lifting magnets are the ideal solution. Another field of application is handling of tubes, cylindrical components, large metal or cable rollers, otherwise called "coils". While conventional lifting equipment can cause mechanical damages at the surface or deform the shape of the workpieces, these types of damages can be avoided, if lifting magnets are used.
On the one hand lifting magnets are available as a compact unit, which are actuated mechanically by a lever mechanism, or pneumatically actuated. On the other hand crane constructions for large tubes or steel plates are normally actuated with electro-permanent magnets and remote control.
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Innovative: The MAU magnetic gripper from SCHUNK assures reliable and firm clamping during handling of ferro-magnetic workpieces.
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Handling components:
Magnetic clamping technology for robots
A magnet gripper for robots shows how versatile magnetic clamping solutions can be used: Adjusted to a robot arm the light-weighted magnetic gripper provides a reliable hold in small working areas. Electro permanent magnets can be actuated within seconds.
Comprehensive expertise for standard and special solutions
As an industry leader for toolholding, workholding and gripping systems, SCHUNK offers a broad portfolio of standardized magnets for every imaginable application, while they have also developed sophisticated special solutions based on magnetic clamping technology. The comprehensive experience of SCHUNK pays off in all modern fields of clamping technologies. This networked knowledge is the basis for innovative and striking solutions.
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12.2010
Clamping large turned parts safely
Launched from the energy technology, machining of large parts on lathes has become more important in the past few years. This causes a lot of pressure which has to be absorbed by the clamping device. This factor makes it all the more surprising that many users still use traditional clamping solutions, which are costly to set-up, clean and maintain. Modern clamping devices do more than assuring safe clamping, they increase precision of the workpiece, reduce set-up times, and minimize maintenance efforts. This also applies for chucks and jaw boxes.
 Pour en savoir plus…
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10.2010
Grippers with additional benefits
The figures speak for themselves: SCHUNK, the leading expert for clamping technology and gripping systems has sold thousands of sensors for handling applications. While the status of the actuator has been monitored in the past, modern sensors transform the grippers into intelligent helpers, which can measure, inspect, sort and accelerate the whole process simultaneously. The question on their efficiency potential is answered with an overview of the current sensor systems for handling applications.
Pour en savoir plus…
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09.2010
Gripping Technology for Industrial Robots
Industrial robots work quickly, reliably and never stop. The achieved output and quality significantly depends on the individual periphery, particlularly of the gripping sytems. In the hunt of the optimum gripper, engineers and users have to consider a large variety of influencing factors. In addition to efficiency and process-reliability, sustainability of the gripping systems playes an increasing role.
Pour en savoir plus…
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08.2010
Efficient toolholders for automated tool grinding
For tool grinding the toolholder plays an essential role because microns will decide the quality of the manufactured tool edges. In view of small batch sizes and various tools, a multi-purpose toolholder is needed. The holder would have to be precise for exact cutting edge geometries and surfaces, slim to avoid interference between the grinding wheel, powerful for very short clamping depths, and have a high material removal rate as well. Flexibility is also required for covering many different shaft diameters. All of these requirements are persuading companies to use automated grinding machines in order to reduce their current costs.
Pour en savoir plus…
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07.2010
Pick & Place Solutions in Comparison
In order to assemble components fast and precisely, operators can choose between many different Pick & Place solutions. The performance features of the systems vary from each other. To find the best solution, the advantages and disadvantages of each system should be compared.
Pour en savoir plus…
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06.2010
Energy efficient gripping
In the best of case scenario, energy-efficient automation modules should reduce energy consumption of the handling system and increase cycle times and output. It helps conserve the environment and saves money if you focus both measures.
Pour en savoir plus…
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05.2010
Factor of Success Engineering -
With virtual simulations to the optimum clamping solution
How does a component deform during the clamping process and machining? Which clamping solution assures that the workpiece has the exact dimensions? How can an existing clamping device be ideally used? Virtual simulations are giving valuable answers to these and simular questions. By means of the Finite Elements Method (FEM) deformations and component payloads can be calculated, which allows a comparison of the individual clamping options and how to optimize them. In turn, process and investment reliability are increased, development times shorten, the selection of the suitable clamping device is easier and costs are lowered.
Pour en savoir plus…
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04.2010
Magnetic Clamping Technology - efficient at a variety of tasks
Magnetism is one of the most fascinating and influential force of our universe. Engineers and technicians use this same force in order to clamp workpieces, or to reliably lift components. Magnetic clamping technology is well-established in various areas, such as grinding, milling, turning, mobile lifting units in production, and for huge crane constructions. Most engineers now know that magnetic clamping solutions reduce set-up times by about 80 percent, that workpieces are clamped without any deformation, and even coils can be reliably transported.
Pour en savoir plus…
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03.2010
EU-funded project pushes on the service robots
Experts predict an increase in the pursuit of service robotics. This is no surprise: Modern robot applications offer an enormous potential to the economy and society. Pilot applications already show how robots might become more and more the intelligent helpers of humans. In addition to universities and other research institutes, industrial enterprises should focus on development in this sector, and make it a reality. Therefore the European Union has decided to subsidize the transfer of knowledge between research institutes and industry financially support this pursuit as well.
Pour en savoir plus…
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02.2010
Flexible packing and palletizing
Adaptive handling systems provide dynamics and profitability if comprehensive ranges and frequent changes in assortment are given.
Every week a new product generation replaces the previous one. These products, which provide new impulses in trade, are a real challenge for the packing process. Faster, process reliable, and flexible automated solutions are in constant demand. They help to keep the handling costs under control, even at an increasing product variety.
Pour en savoir plus…
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01.2010
How operators "play it safe" during turning operation
If a workpiece loosens from the chuck on a lathe, it can be dangerous to those working in the manufacturing hall. Because of this, the Employer’s Liability Insurance Associations, Standards and Safety Commitees, do everything in their power, to avoid accidents.
Pour en savoir plus…
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In Focus - 2013
In Focus - Archives 2012
In Focus - Archives 2011
In Focus - Archives 2010
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