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In Focus - Archive April 2011
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Due to the Quick-Change Pallet System, the pallet which is equipped outside the machine, is exchanged in no time at all.
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Pallet change
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04-01-2011 -
You cannot earn money with a turned off machine. However, in many companies the workpieces are still set-up in a complicated and time-consuming way on a grooved table while the plant is turned off. But solutions exist, which optimize the machine tool load. Modern quick-change pallet systems demonstrably accelerate the machining process, and at the same time, ramp up the precision and process reliability score. This leads to a reduction of set-up costs of up to 90%.
In the metal- and plastic machining industry, the pressure of process costs constantly increases. Those companies have an advantage, which constantly minimize set-up costs and manufacturing times while maintaining continuously high quality. Quick-change pallet systems are a crucial factor. With their help, clamping units are ready set-up workpiece pallets, or by using workpieces with a clamping pin. They can be fixed, positioned and clamped on the machine quickly and precisely, according to the reference value. The actual set-up operation takes place during machining and outside the machine. Output is increased, costs are lowered, and operator errors during the clamping operation are excluded. This applies even for orders which are on schedule, as well as "rush jobs", for which the manufacturing process has to be interrupted on short notice. Therefore the Quick-change pallet systems are rightly considered to be highly efficient set-up time killers.
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Efficient piece production: The Quick-Change Pallet System provides for flexibility.
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The unique combination of fast and clamping stroke ensures for the best gear ratios during the clamping operation.
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Important increases in productivity are possible
The productivity potential of a quick-change pallet system at your company could be easily determined. As a rule of thumb: the longer a machine has to be set-up, and the shorter the actual machining operation is, the faster the investment will pay off. Manufacturing examples of individual pieces and small batches show what is possible. If a machine should be stopped for set-up for 20 minutes, and will then machine the workpiece for 10 minutes, a quick-change pallet system could shorten the manufacturing process in the machine by about 66%. In other words: on one machine three times more components can be machined, making the productivity potential enormous.
In contrast to conventional set-ups, where clamping devices with clamping claws and blocks are used for laying them onto the grooved table to align them with a gauge, the quick-change pallet modules are directly integrated into the machine table, or are built up like a multi-fold clamping stations or tombstones on the machine table. The zero point is defined and a time-consuming alignment is not necessary. The male or female counterpart of the quick-change pallet module are the clamping pins or the clamping bushings, which are located in the changing pallets, the clamping units or directly at the workpieces. They are clamped via clamping slides, spindles or clamping rings.
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The VERO-S module from SCHUNK is fully equipped and made of maintenance-free stainless steel.
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All the functional components are made of stainless steel
The VERO-S quick-change pallet system from SCHUNK is a classic example. It clamps workpieces, pallets, clamping stations and tombstones via one or more clamping pins. In the quick-change pallet module clamping slides are radially aligned. They pull-in and lock the clamping pin and fixing or positioning is done via a short taper. It provides a repeat accuracy of less than 0,005 mm. In order to increase lifetime and process reliability, all the functional components of the VERO-S, such as base body, clamping pin and clamping slide are made of hardened stainless steel, and make the unit resistant to corrosion. Moreover, the maintenance-free module of the competence leader for clamping technology and gripping systems is completely sealed and protected against chips, dust and coolant.
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Centering and clamping
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Centering and clamping
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Easy exchange
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Pull-in forces of up to 40,000 N
Due to the patented fast- and clamping stroke, the VERO-S disposes of a pull-in force of up to 9,000 N. If the turbo function is actuated, which is integrated in every module, the pull-in force can achieve up to 40,000 N. This results in a higher rigidity of the complete clamping solution, and higher cutting parameters can be achieved. The extremely high shearing forces are also reliably absorbed, and the workpiece doesn’t change its position. Locking of the module is done mechanically via spring assembly. It is self-locking and form-fit clamping. Holding forces of up to 75,000 N are achieved.
The advantage of the VERO-S towards other quick-change pallet systems is, that during machining no compressed air has to be connected. The workpieces remain safely clamped, even if the pressure of the air system should break down. For opening the module, a pneumatic system pressure of 6 bars is enough. The SCHUNK standard versions are equipped with an air purge connection as well as a clamping slide monitoring system, and if necessary every module can be automatically loaded. Since the module is equipped with bottom and lateral air connections, they can be flexibly installed in any desired position. On option, the VERO-S can be equipped with special sealing elements. Then it can be actuated with non-lubrified air.
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The modular system from SCHUNK offers an extensive range of clamping units for every machine type.
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Individual clamping devices
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A complete modular system
If a user decides for the first time to buy a quick-change pallet system, it is imperatrive to understand two important aspects: The system should be easily retrofittable to already existing machines. In this point the pneumatic modules have an advantage. In contrast to the hydraulic media, compressed air is normally provided by every machine, and the system should also be updated in order to avoid isolated applications. With its standard full equipment, and its compatibility to the predecessor, the VERO-S can score here, too.
SCHUNK goes even one step further. For the first time ever, the whole stationary workpiece clamping is bundled to one single modular system. It comprises the quick-change pallet system, but also pneumatic and hydraulic clamping blocks, lathe chucks, double and multi-functional vises, multi-functional clamping stations, magnetic chucks, clamping pallets and tombstones. The innovative family-owned company is able to put their years of experience into the modular system. Even individual clamping devices for high-precision manufacturing or particularly sophisticated clamping tasks within the modular system are feasible. The uniform interface of the quick-change pallet system ensures that the special clamping units can be replaced quickly and precisely.
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Manufacturing around the clock: VERO-S NSA plus provides for precision and process reliability for automatic machine loading.
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Module for automated manufacturing
Particularly for automatic pallet change SCHUNK has developed the compact NSA plus quick-change pallet module. It is extremely compact in design, and there is plenty of room left for the workpiece and the axis motion in the machining area. The module can be directly integrated into the machine table. Another very important point is that the short taper is cleaned of chips and dirt during the pallet change with a forced air flow, which ensures a chip-free flat work surface for the workpieces. Then a low-wear centering sleeve carries out pallet centering according to the reference dimensions. If the turbo function is activated, the pull-in force of the VERO-S NSA plus 120 amounts up to 13,000 N. The holding force achieves more than 100,000 N. The module is locked via two clamping slides, which ensure form-fit, self-locking fixing of the centering sleeve. Thereby the repeat accuracy amounts to less than 0,005 mm. At the same time, along with the air control it can be interrogated, whether the pallet is precisely clamped or not. Process faults and errors during machining are avoided from the beginning. The pallet removal is also a very sophisticated thing: Via a pneumatic system pressure of 6 bar the module is unlocked. At the same time a lifting pin lifts the pallet and thus facilitates the automatic exchange with, for example, a robot.
Conclusion:
In order to be cost-effective and flexible, the use of the quick-change pallet system should be any manufacturers first choice. Particularly customers with a broad business activity, diversity in versions and small series profit from a uniform and a universal quick-change pallet solution as it is given by the VERO-S. It is the basis for expanding the main time of existing machines, to reduce set-up costs, and to ensure a maximum machining quality at the workpiece. This investment often pays off in a very short period of time.
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2011-12
Clamping solutions for automated mass production
Efficient manufacturing means automated manufacturing. This particularly applies if large series are machined. This is when the clamping vises, which are the direct interface to the workpiece, playing an important role. In only a few seconds, they have to mount the components, safely and precisely align them, clamp them with-out deformation, and after machining they have to be reliably released. In view of the several million clamping cycles, which have to be carried out by many clamping vises being exposed to chips and coolant, process reliability is one of the decisive factors of success.
 more...
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2011-11
Modularity the factor of success
When designing gripping systems for handling and assembly applications, standardized modular systems will play an increasingly important role in the future. They reduce the necessary time for project planning and commissioning, and lower the investment costs. Due to the standardization, they offer optimum preconditions for stable processes. Since modular designed units can be flexibly modified and enlarged, they can be re-configurated for any changes that come up in the future.
more...
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2011-10
Producing more efficient
For a number of years, everybody was talking about the energy efficiency issue. Increasing energy costs, a growing environmental awareness, and the political guidance were all triggers for many companies to highlight the energy consumption of machines and components in their communication with the public. Efficiency is much more than simple energy efficiency now, especially when considering the
time- and cost aspects in regards to efficiency. When all these factors have been considered in a holistic way, the full potentials for modern machining and production become visible. The modern clamping devices and gripping systems make it clear how complex the possibilities are.
more...
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2011-09
Welding demanding materials crack- and pore-free
Laser welding technology is second-to-none, regardless of whether you are dealing with gears and injection molds or delicate and challenging welding works. When conventional cw lasers and many Nd:YAG-lasers reach their limits, modern process strategies can help to machine demanding welding metallurgies, different types of materials, or micro components process reliably and efficiently. Laser welding is particularly used if components have to be joined at a high welding speed, because slim welding seams, and a low thermal distortion are required. Compared with other welding techniques, the energy during laser welding fully penetrates into the material.
more...
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2011-08
More than a "Stopgap":
Intermediate sleeves ensure safe clamping and precision
They appear to be unimposing - but they are located at a decisive interface in the chain of the metal cutting process. Between toolholder and workpiece, the intermediate sleeves influence reliability and precision of the clamping operation. The thin-walled, mostly slotted precision sleeves cover the difference between the clamping diameter of the toolholder, and the workpiece which has to be clamped. Functioning like reduction inserts, they multiply the fields of application of the toolholders or arbors, compensate tolerances, and ensure safe and gentle clamping of gear wheels. The newest sleeve design can do even more. Intermediate sleeves with nozzle effect extend the tool service life and increase the volume machining.
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2011-07
Changing, machining, compensating -
current trends in robot accessories
In dealing with industrial robot efficiency cycle rate and process reliabilty largely depend on their front ends, the grippers and other tools, but also from the effectors’ interfaces to the robot arm. Robot accessories have a great influence on the robot’s performance, flexibility and fields of application. Latest developments of quick-change systems, driven tools, compensation units, and power sensors show that the potentials of modern accessory components are enormous. Experts assume that their importance for handling, assembly and manufacturing will continuously increase.
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2011-06
Deformation-free clamping:
From the plastic chuck jaw to the hybrid chuck
In case of rings, housings and other workpieces which are highly deformable dur-ing processing, conventional 3-jaw chucks quickly reach their limits. If the clamping forces are too low, there is no secure hold. If they are increased, workpieces de-form, and precision is reduced. A comparison shows the alternatives, the differ-ence between them, and how users can achieve an optimum result.
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2011-05
Service robotics is the future key market
Insiders are convinced that golden times lie ahead for service robotics. Around the world companies and institutes have recognized the potential of robots as helpers for humans, and are working on everyday solutions. All different kinds of businesses are interested in service robotics, from large companies, to innovative startups, and also conventional manufacturers of industrial robots, electronic and automation components.
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2011-04
Having set-up times under control
You cannot earn money with a turned off machine. However, in many companies the workpieces are still set-up in a complicated and time-consuming way on a grooved table while the plant is turned off. But solutions exist, which optimize the machine tool load. Modern quick-change pallet systems demonstrably accelerate the machining process, and at the same time, ramp up the precision and process reliability score. This leads to a reduction of set-up costs of up to 90%.
more...
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2011-03
Toolholders for micro cutting
Clamping tools used for micro cutting have their own rules. The subtle tools, the high spindle speeds, and the extreme precision requirements are a challenge for every tool manufacturer and user. Those who want to achieve continuously precise results, need mountings with a high run-out accuracy and balancing grade. Moreover, they should be as slim as possible and resistant to dirt. Furthermore, they have to assure that even small tools can be precisely adjusted and exchanged.
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2011-02
Leight-weight design increases efficiency of Gripping Systems
Light-weight modules are now playing an increasing role in the area of gripping systems. Integrated into the system, they are saving energy at the same efficiency, or achieve a considerably higher efficiency at the indentical energy consumption. In both cases, the efficiency of the whole system is increasing. This is why the lightweights are so interesting for plant manufacturers, system integrators, and users. Since light-weight solutions had the reputation of being overly expensive in the past, recent developments now show that efficiency and cost control can go hand-in-hand. Modern designs, materials and techniques are paving the way to lighter solutions, which are rigid and robust, too. This also offer many more advantages.
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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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