The traditional clamping method is used to process large steel pipes of 3 to 8 meters. It is not only time-consuming and costly, but also cannot guarantee the deformation of the pipe during the clamping process, which causes quality problems. With the help of Xiongke, logistics and handling experts BLEICHERT Automation took a different approach and found a new and efficient clamping solution.
Optimize the gantry manufacturing process
In order to increase production flexibility and reduce procurement costs, BLEICHERT Automation in Osterlburken, in the Neckar-Odernwald region, like most machine and equipment manufacturers and system suppliers, chooses to produce their own regular use and needs. The basic components of on-time delivery.
With the SORALUCE Horizontal Boring and Milling Center SL-10000, this sophisticated automation, conveyor and storage system manufacturer not only realizes the internal production of the gantry, but also optimizes the manufacturing process, increasing productivity and flexibility. In the process, it is the Xiongke MAGNOS square magnetic pole clamping solution that plays a decisive role.
Flexible clamping solution for many parts
Michael Diemer, BLEICHERT Prefabrication Production Manager, said: 'This clamping system is very flexible and efficient, and has a high utilization rate, which greatly reduces our workload.' Eight 800 mm x 300 mm vertical installations of MAGNOS MFR-01-050 Square electromagnetic chuck, ST52 tube with a clamping length between 3,000 and 8,000 mm and a pipe width of 200 mm, 250 mm and 300 mm, very flexible and non-deformable.
In order to facilitate complete machining for one clamping, the electromagnetic chuck is mounted on a stable DEMMELER clamping bracket for free machining on five sides. The height of the electromagnetic chuck can also be flexibly adjusted on the grid and bolted. The clamping bracket can be moved in the X direction along the machine table and bolted or completely removed. This allows the device to be mounted on the side of the clamping bracket and suction cup at any time for emergency orders, without the need for expensive modifications.
The ability to quickly mount the clamping module with a pin to hold different pipe sections is the biggest advantage of the system. Simply remove a row of magnetic poles and immediately clamp different cross sections. If you want to machine a wider part, the whole The electromagnetic chuck can be rotated 90° and fixed upright.
The EASYTURN floating magnetic block can accommodate uneven workpiece surfaces. They float and perfectly match the shape of the workpiece, ensuring gentle and low distortion during the clamping process. This completely eliminates the special damage or deformation that is common when machining long tubes. Large-area clamping minimizes vibration and protects the machine tool spindle and cutting edge.
In one go, reliable and labor-saving
Conventional clamping uses pressure plates and hydraulic clamps. The pipe needs to be prepared in advance, clamped, and often needs to be reworked for several hours. The cost is very high. After using the MAGNOS, only one operator and one clamping can complete the clamp quickly. Hold, no preparation work, no rework.
The four outer corners of these tubes are clamped to the fixed magnetic block and the floating magnetic blocks are laid over the entire length. This maximizes the flexibility of the clamping system. Four fixed points ensure all the pipes. They all have the same end faces and can be modularly connected to each other without offset.
The machining process is very stable, 'In some positions, the machining depth is 5mm and the width is 75mm. We punch holes in the surface. Moreover, when drilling on five sides, the workpiece does not move. ' Diemer emphasizes. This Everything is done without additional clamping devices or positioning blocks.
Power saving and time saving
At BLEICHERT, each MAGNOS clamping module can form up to 32 working areas with a theoretical clamping force of 380 kg. If all eight modules are completely covered, a theoretical clamping force of more than 97 tons is produced, which ensures maximum maximum Process reliability. Moreover, the MAGNOS electromagnetic chuck is completely independent of the power supply during clamping. The electric pulse is only used for activation and release. The module is connected in series and connected to the MAGNOS control system. Within a few seconds, the energized activated permanent magnet ensures Continuously stable, no additional power is required thereafter.