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Assembly

ZeroClamp zero point clamping system

– manual

24

Tightening torques

Tightening torques of the (non-lubricated) screws

Pot Ø in mm

Bolt size

Tightening torque

90

M4

5 Nm

120

M6

14 Nm

138 & 190

M8

35 Nm

Tightening torques of the base-unit

Tightening torques oft he (non-lubricated) clamp bolts.

Note!

For the calculation formula and table values from the current technical
literature were used which represent the state of the art at the date of
this document.

The base-units are made of the following materials:

Aluminium: AlMg4,5 Mn F27 (EN AW 5083)

Permissible interfacial pressure: pG=230 N/mm

2

(Standard version)
Steel: 1.2312 (400CrMnMoS8-6)
Permissible interfacial pressure: pG=400 N/mm

2

(Costum made)

Head and thread friction is in the mounting case recognized as an non lubricated
with:

μ = 0.14

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Содержание NP90

Страница 1: ...O r i g i n a l A s s e m b l y a n d M a i n t e n a n c e I n s t r u c t i o n Zero Point Clamping Systems NP90 NP120 NP138 and NP190 Please keep this manual for future use and reference...

Страница 2: ...e manual This manual is the property of Messrs ZeroClamp GmbH with headquarters in 83052 Bruckm hl Germany This document must not be copied or otherwise reproduced either in part or in its entirety wi...

Страница 3: ...Mechanical data 12 3 1 1 Dimensions 12 3 1 2 Weights 12 3 1 3 Materials in contact with Cooling Lubricant CL 12 3 2 Pneumatic data 12 3 3 Clamping forces 13 3 4 Operation temperature 13 3 5 Operating...

Страница 4: ...40 7 2 3 Correlation table torque withdrawal force 41 7 2 4 Example determining the holding force 41 7 2 5 Calibrating the withdrawl force tester 41 7 2 6 Additional recommended safety measures 42 7 2...

Страница 5: ...ing this high quality and extremely precise zero point clamping system We reserve the right to make modifications regarding the design dimensions and material if this positively affects the productivi...

Страница 6: ...General Information ZeroClamp zero point clamping system manual 6 Scope of delivery Delivery includes Chuck Fastening screws O rings Air connection fitting...

Страница 7: ...n ISO 16156 Machine tools Safety Safety requirements for the design and construction of work holding chucks ISO 19719 Machine tools Work holding chucks Vocabulary Commissioning of the incomplete machi...

Страница 8: ...n clamped condition if the zero point clamping system is not in use for a longer period of time As a result the clamping force cannot be exerted or the zero point clamping system does not fully open w...

Страница 9: ...chuck thoroughly every time before you clamp a new part Ensure an exact concentric alignment of clamp bolt and chuck Check the clamping force of the zero point clamping system on a regular basis using...

Страница 10: ...ils the adherence to the assembly operation operation environment and maintenance specificati The manufacturer cannot be held liable if the system is used for any other purpose as those specified Prio...

Страница 11: ...nance and cleaning Everyone responsible for assembly operation and maintenance must have read and be familiar with the entire manual especially chapter one Safety and preferably provide a written conf...

Страница 12: ...Air hose 07 13 Viton FKM 70 1156 Air hose NBR 70 Perbunan O Ring HPP9441 05 Vulvanisation taper ring 10 17 Viton FKM60 1279 Vulvanisation taper ring Eladur 33 Polyurethan Elastomer Spacer 10 17 Viton...

Страница 13: ...with ingredients of the cooling lubricant CL used ZeroClamp has made comprehensive laboratory studies with regard to eventual incompatibilities Due to the high variety of CL s available on the market...

Страница 14: ...point clamping system Design layout Pos Description Pos Description 1 Hardened steel cone 6 Locking unit 2 Radial spring 7 Spacer Elastomer Viton Eladur 3 NBR Viton rubber 8 Air hose NBR Viton 4 Chuck...

Страница 15: ...d on the opened ZeroClamp chuck The spring elements keep the locking unit clamping wedges open with the help oft he air pressure inside the air hose Venting the air hose results in the positioning and...

Страница 16: ...elease coupling connecting block centering set alignment set pallets Modifying the chuck additional bores threads subsequent grinding etc or additional parts that are not included in the range of acce...

Страница 17: ...terference fit of the clamp bolt when using the clamp bolt in in house assemblies Please consult ZeroClamp when in doubt ZeroClamp cannot be held liable for any damage resulting from improper use Cove...

Страница 18: ...plate Specifically the clamping pots with media transfer require special protection when not in use Article no 24513 Sealing plate 2 point 120 mm pitch 200 mm Warning Only use sealing plates approved...

Страница 19: ...umstances pitting may occur on the aluminum plates particularly if the anodic coating has been damaged scratches Console Consoles serve to adapt the height and inside micrometer Exemplary illustration...

Страница 20: ...0003 or 10241 A safe unlocking of the central locking unit in the plug nipple can only be ensured when these couplings are used Connection block You can choose between different connection blocks Stan...

Страница 21: ...n exact concentric alignment of clamp bolt and chuck Caution When operating the zero point clamping systems the skin of your fingers can get caught between the clamping elements Do not reach inside th...

Страница 22: ...ry part connecting block using the functions clamping unclamping and blow out or via docking a quick release coupling to release Using alignment sets and centering sets only serves for pre centering t...

Страница 23: ...have been cleaned The O ring now insert carefully and lubricate with conventional machine grease Fitting and o ring The carefully lubricate fitting can be inserted in the airconnectionhole by lightly...

Страница 24: ...Note For the calculation formula and table values from the current technical literature were used which represent the state of the art at the date of this document The base units are made of the foll...

Страница 25: ...on the actually occurring forces and surface pressures at the base plates Please ensure in their own interest to comply with the conditions for fitting the screw head and thread not greased counterbo...

Страница 26: ...res 6H7 10 deep 0 90 270 8H7 12 deep 0 120 240 10H7 16 deep 0 120 240 10H7 16 deep 0 90 270 H Standard depth chuck section 181 241 19 28 I J Installation depth 5 22 5 28 5 33 5 38 Surface finish Rz 6...

Страница 27: ...torque Nm 10004 18M16 18 k6 M16 18H7 18 0 02 0 03 6 mm 24 mm 35 10005 16M8 16 k6 M8 16H7 16 0 02 0 03 6 mm 24 mm 17 10006 16M10 16 k6 M10 16H7 16 0 02 0 03 6 mm 24 mm 35 10098 18M12 18 k6 M12 18H7 18...

Страница 28: ...ondition if the zero point clamping system is not in use for a longer period of time As a result the clamping force cannot be exerted or the zero point clamping system does not fully opened when used...

Страница 29: ...Operation ZeroClamp zero point clamping system manual 29...

Страница 30: ...r of the fixture if a controlled chip transport cannot be ensured Otherwise the clamping pot can be covered partly Inaccuracy of the surfaces caused by wear will also prevent that the correct clamping...

Страница 31: ...ex and dynamic process The static examination of the system shall rather serve to estimate the level of the potential dangers The level of potential danger rises with increasing processing height z ro...

Страница 32: ...ng workpiece on a baseunit with four clamping pots with a pitch of 200 mm By not lying on the rotational axis center of gravity m creates these an imbalance Fzentri Parameter n rotational speed U min...

Страница 33: ...Sicherheit S MAuszug MSchnitt Unwucht As this is a static examination the safety factor for this estimate should be S 3 7 1 2 Sample calculation 1 This sample calculation is about a base unit with fo...

Страница 34: ...25000 N 0 26 m 6500 Nm M 0 2 1500 Nm 2 6500 Nm 1200 Nm 164 Nm Sicherheit S 16000 Nm 1364 Nm 11 73 The security is over 3 The system is to be regarded as safe 7 1 3 Sample calculation 2 The second app...

Страница 35: ...uszug pull out force clamping pot N MSchnitt FSchnitt hs MKipp MSchnitt FRes MKipp d FRes FAuszug Sicherheit S FAuszug FRes As this is a static examination the safety factor for this estimate should b...

Страница 36: ...Kipp d 690 Nm 0 06 m 11500 N FRes FAuszug Sicherheit S FAuszug FRes 2 25000 N 11500 N 4 34 The security is over 3 The system is to be regarded as safe These sample is only conditional suitable for man...

Страница 37: ...clamping pots 120 mm Even in this situation it is necessary to ensure that the torques are in equilibrium Parameter hs height cutting force m hg height emphasis m a lever arm pull out force 1 m b lev...

Страница 38: ...he safety factor for this estimate should be S 3 Drilled with a cutting force of 6 1 kN at a height of 0 5 m Depending on material tool and cutting parameters Also acts a weight force of the workpiece...

Страница 39: ...amp zero point clamping system manual 39 M 0 1500 Nm 6400Nm 12650Nm 3050Nm 1600Nm MAutzug Gewicht 22150Nm MAuszug 3050 Nm Sicherheit S 22150 Nm 3050 Nm 7 26 The security is over 3 The system is to be...

Страница 40: ...clamp bolt counter clock wise view from below on the clamp bolt out of the withdrawal force tester up to the stop 7 2 2 Applying torque 1 Supply compressed air to the chuck open it up 2 Mount the wit...

Страница 41: ...amp bolt is yanked out which results in wear at the clamp bolt If this occurs repeatedly it can lead to the wear at the clamp bolt preventing the generation of the required holding force even if the c...

Страница 42: ...ot initiate any clamping force the safety function is passive and self locking Preparing of chuck and clamp bolt Caution The zero point clamping system only operates reliably when the clamp bolt lies...

Страница 43: ...ng manual when using connecting blocks Using of locking bolts If clamp bolts are not used they have to be sealed with locking bolts This prevents the chuck from filling up with lubricoolant as well as...

Страница 44: ...efore putting it into storage After having cleaned the mechanical parts in the chuck spray it with fine oil approved agents see 8 4 Cleaning and while operating the clamping mechanism Caution If clamp...

Страница 45: ...ly basis Caution The clamping sheets in the zero point clamping system may adhere in clamped and non clamped condition if the zero point clamping system is not in use for a longer period of time As a...

Страница 46: ...ires special tools If the chuck is in need of repair please contact ZeroClamp The zero point clamping system is designed for low maintenance operation and opening or disassembling of the unit is norma...

Страница 47: ...o remove any dirt Caution Carry out the cleaning without a component clamping device only when the machine door closed Flowing chips may cause injury 8 3 3 Spraying the mechanical parts Spray fine oil...

Страница 48: ...nts WD 40 Ballistol Hebro Multiplus Inappropriate cleaning and care agents Acids Leaches Aggressive media not approved cleaning and care agents 9 Residual Risks Risk description Reducing risks Non obs...

Страница 49: ...10 Cover sheet 21 D Declaration of incorporation 7 Description of the system 18 Dimensions 12 Disassembly 48 F Formulas and modelled presentation35 L LC Influence 17 Locking bolt 21 Locking bolts usag...

Страница 50: ...Attachments ZeroClamp zero point clamping system manual 50 11 Attachments...

Страница 51: ...Attachments ZeroClamp zero point clamping system manual 51...

Страница 52: ...Attachments ZeroClamp zero point clamping system manual 52...

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