Unilock Modular Workholding System Vol. 2

UNILOCK MODULAR WORKHOLDING SYSTEM VOL. 2

ZERO-POINT CLAMPING SYSTEM Meeting the challenge to set up every process as efficiently as possible with a simple clamping concept. In a competitive environment, all production cells need efficient workpiece handling solutions. Production diversity should not be a barrier. Let Unilock’s zero-point clamping system lead the way with efficient part loading solutions for low and high volume production runs. Unilock virtually eliminates all setup time and replaces it with production time. If your company needs to increase its agility, Unilock will allow you to run any job on any available manufacturing cell. You can interrupt jobs without incurring setup time and then switch back as needed. When all of your manufacturing cells have Unilock, work can quickly flow to any available resource. Get lean and agile on your shop floor with a comprehensive positioning and clamping system that can be applied to almost anything you manufacture or assemble.

2

OVERVIEW & APPLICATION EXAMPLES .......................................Pg. 4-9 ROUND CHUCKS Index ......................................................................................................... Pg. 11 ESM 138, ESM 138 Turbo, ERGO 138 & EFM 138 .................................... Pg. 12-19 ASM 90, ASM 120 & ASH 120 ................................................................... Pg. 20-25 ISM 160 ..................................................................................................... Pg. 26-27 MSM 170 ................................................................................................... Pg. 28-29 ESM 176 Turbo ......................................................................................... Pg. 30-31 HSM 196 ................................................................................................... Pg. 32-33 RECTANGULAR CHUCKS Index ......................................................................................................... Pg. 35 ESM 100/75 .............................................................................................. Pg. 36-37 AFM 105/65 .............................................................................................. Pg. 38-39 EDM 100/150 ............................................................................................ Pg. 40-41 AFM 146 ................................................................................................... Pg. 42-43 ESM 180/150 ............................................................................................ Pg. 44-45 PRE-ASSEMBLED CHUCKS Index ......................................................................................................... Pg. 47 MLM 150 & MCM 150 ............................................................................... Pg. 48-51 DLM 200 & DCM 200 ................................................................................ Pg. 52-55 QC 400 ...................................................................................................... Pg. 56-57 ERGO Base Stations ................................................................................. Pg. 58-59 Starter Kits ................................................................................................ Pg. 60-61 KNOBS & PALLETS Index ......................................................................................................... Pg. 63 Clamping Knobs ....................................................................................... Pg. 64-68 System 40 Pallets .................................................................................... Pg. 70-71 AUTOMATION CHUCKS Index & Overview ...................................................................................... Pg. 73-75 ESA 120/70 & ESA 110 .............................................................................. Pg. 76-79 NSA 125 .................................................................................................... Pg. 80-81 ESA 185 ..................................................................................................... Pg. 82-83 ASSF 170 & ASSF 250 ................................................................................ Pg. 84-87 Automation Accessories & Pallets ............................................................. Pg. 88-90 MULTI-AXIS SYSTEMS Index & Overview ...................................................................................... Pg. 93-94 5-Axis Duo Bridge .................................................................................... Pg. 96-97 First Grip .................................................................................................. Pg. 98-99 5-Axis Univice Synchro ............................................................................ Pg. 100-101 5-Axis Uniclamp ....................................................................................... Pg. 102-103 5-Axis System 40 Overview ...................................................................... Pg. 104 5-Axis Bases ............................................................................................ Pg. 106-111 5-Axis Table Adapters .............................................................................. Pg. 112-113 5-Axis Air Chuck ...................................................................................... Pg. 114-115 5-Axis Extensions, Reductions & Shims .................................................. Pg. 116-119 5-Axis ER Collet Chucks & Serrated Adapter ......................................... Pg. 120-121 5-Axis System 25 ...................................................................................... Pg. 122-123 5-Axis Uniflex System .............................................................................. Pg. 124-127 MINERAL CAST SYSTEMS Index ......................................................................................................... Pg. 129 Columns ................................................................................................... Pg. 130-131 Grid Columns ........................................................................................... Pg. 132-133 Pallets, Riser Pads & Custom Solutions ................................................. Pg. 134-135 ROBOT INTERFACES Index ......................................................................................................... Pg. 137 Grippers ................................................................................................... Pg. 138-141 ACCESSORIES Index ......................................................................................................... Pg. 143 Chuck & Subplate Air Fittings ................................................................. Pg. 144-147 Accessories & Repair Components ......................................................... Pg. 148-149 SERVICE & OPERATING INSTRUCTIONS .....................................Pg. 151

3

OVERVIEW

How it Works Unilock utilizes spring pressure to drive multiple clamping pins against a tapered clamping knob. Air pressure is used to compress the springs to back the clamping pins off of the clamping knob. This clamping process is achieved by bleeding the air pressure out of the chuck. To facilitate palletization, the clamping knob is attached to a base plate, fixture or directly to a workpiece. The result is quick and repeatable clamping. A hand locking version (no air required) is also available.

Features: • Clamping Mechanism: Heavy-duty die springs • Chuck Opening: Air pressure to compress springs • Clamping Stability: Low profile with matching taper wedges • Positional Accuracy: Adaptable to workpiece conformation • Unlocking Air Pressure: 75 PSI • Turbo Assist Clamping

Single Chuck Applications The Unilock clamping knob mates with the central taper in the chuck to establish the centerline location (XY reference in a Cartesian coordinate system). A timing pin or key locates in a notch or bushing to orient the coordinate system relative to XY and to restrict rotation. The Z reference in this same coordinate system is established by the bottom of the fixture or workpiece contacting the top ground surfaces of the chuck. These same mating surfaces (bottom of the fixture and top of the chuck) will control axial alignment. The clamping knob can be used for locking down a workpiece without influencing location if external features are used for positioning.

4

OVERVIEW

SBC Knob Diametral Clearances

Multiple Chuck Applications Unilock is not restricted to one clamping knob. When the fixture or workpiece exceeds the work range of a single Unilock chuck, additional clamping knobs and chucks can be used to provide the necessary support and stability required for the process. There are only a few limiting factors as to the size of an array of chucks or in the weight of a workpiece. Undersized knobs provide clearances for large parts or out of position locations.

Type

Metric

Inch

SBC

.1mm .3mm .6mm

.004 .012 .024

SBCC SBCC

• SBA = Establishes centerline • SBB = Orients about centerline • SBC = Clamp only, no positioning

Designed for Manufacturing During day-to-day use, chucks can be cleaned with compressed air. The fit between the clamping rams and the chuck body will not allow air pressure to push chips inside of the chuck. If you get chips in the clamping pocket, simply blow them out with an air gun. When open, the wedges completely retract. The one-to-one length-to-diameter ratio of the pocket is easily cleaned. There is no need for a vacuum. The 40mm tall by 40mm diameter clamping knob is extremely stable and can double as a foot when moving fixtures and workpieces around the shop. You will not need protective sleeves or special shelving when storing or transporting Unilock palletized fixtures or workpieces. Male and female threads are available in multiple sizes.

Self-Guiding Design

23º

4.8mm

Unilock is designed to accept warped workpieces and fixtures. The shallow clamping pocket will allow a clamping knob to enter the chuck at an angle of up to 23 degrees. Undersized clamping knobs are also available. Standard and special Unilock clamping knobs will accommodate your out of position datums.

The radius on the smaller bottom diameter of the clamping knob addresses out of position loading conditions. When working with large workpieces that can warp, expand or contract, the knob can be used to help guide the clamping knobs to the center of the chuck.

5

OVERVIEW

Process Your Way to Savings Fixtures and workpieces are easily adapted to Unilock clamping knobs. Tremendous savings are available if the fixture or workpiece can be reoriented or transferred to machine additional features while remaining attached to the Unilock clamping components. On horizontal machines with columns, fixtures can be rotated 90 degrees or moved to the top. Transferring fixtured parts through as many operations as possible eliminates additional fixtures and clamping/unclamping time. Less clamping and unclamping of parts also reduces scrap and improves feature-to-feature accuracies.

Transfer Workpieces Between Processes • Vertical Machining Cells • Horizontal Machining Cells • High Speed Drilling and Tapping Centers • Surface and Cylindrical Grinding Cells

• Horizontal and Vertical Lathes • Coordinate Measuring Cells • Welding, Plasma and Laser Cells

Once you grab the part, use Unilock to send it to as many operations as possible without removing the part from the fixture. Unilock positions and clamps from one face, leaving the other faces available for machining. Rotary tables, angle/sine plates and multi-sided tombstones facilitate part reorientation for subsequent operations.

The user can expand the operational envelope of any Unilock chuck by adding external timing features and support for the portion of the workpiece or pallet that falls outside of the top of the chuck.

6

OVERVIEW

It’s Easy to Get Started Starter Kits help save time between part changes. Chucks are pre-mounted to a base plate which functions as a reference edge. With a single part number you get all the required components to be up and running immediately.

Working Solutions in Minutes Table chucks are mounted to base plates and are ready to be clamped to your workstation. These chucks are supported by pre-assembled pallets. Shown below are the Mono, Duo and Quad table chucks, along with their pallets. Pneumatic kits are also available so you can install a working solution in minutes.

Build Your Own Custom Solutions Unilock components can be purchased individually for incorporation into your own custom designs.

7

APPLICATION EXAMPLES

A Clamping System Flexible Enough to Change the Entire Table or Workpieces and Fixtures Unilock establishes predefined datums on all of your machines. When you load, lock and hit cycle start, there is no wasted time. A setup should always take the same amount of time. Unilock delivers scheduling flexibility and setup versatility. By using more than one chuck on a machine, you will be able to switch between multiple small parts or fewer large parts. Our predefined datums allow you to quickly and accurately convert your machining center from a headstock and tailstock setup to fixtures on the table.

Applications Are Endless – Limited Only by Your Imagination You can align all of your rotary table fixtures in seconds. As you move away from the spindle nose, Unilock’s heavy duty chucks will absorb the additional leverage and torque. Since individual Unilock components are sold separately, you can build specific solutions in-house, contact your tool and fixture provider or purchase them from one of our workholding associates. Unilock can be used in any configuration and in almost any process. A heavy cut requiring six chucks to stabilize the part for machining can be accurately positioned on a coordinate measuring machine with two small chucks or a single chuck and a timing feature.

8

APPLICATION EXAMPLES LARGE & SMALL PARTS

Large Parts Even Your Largest Machines Can Save Money Starting With Your Next Job Unilock provides undersized clamping knobs so you do not have to hold .0004" on fixture locations when your production tolerance is .005". These undersized knobs are a necessity if you want to mount knobs directly to warped or loosely toleranced workpieces. If you do not need to, or cannot hold a tight tolerance, simply select the appropriate undersized clamping knobs to accommodate your workpiece or fixture. Unilock’s heavy-duty clamping knobs are a necessity when you are using a hoist to load and unload your machine. With a length-to-diameter ratio of 1-to-1, Unilock’s 40mm clamping knob can be left on fixtures and workpieces without worry of damage during loading and unloading, storage or transfer. SBC Knob Diametral Clearances

Type

Metric

Inch

SBC

.1mm .3mm .6mm

.004 .012 .024

SBCC SBCC

Small Parts Remove Process Time – Save More Than Just Setup Time Before Unilock, three subsequent machining processes required the operator to clamp and unclamp the part three times. Now the same part is only clamped and unclamped once over these same three processes. Even when the time spent clamping and unclamping the part is minimal, it creates unnecessary labor and a chance for errors. Use Unilock so you can immediately increase your spindle uptime and decrease scrap due to part positioning and clamping errors. If a part has to be clamped and unclamped in a different fixture for each operation, considerable process time and money can be saved by leaving the part in the same fixture for as many operations as possible. The more expensive fixtures which hold machined parts for subsequent operations would also be eliminated.

Before Unilock After Unilock Set Up Production Set Up Production Savings

Operation

Op-10 Lathe 3 hours

4 hours

1 hour

4 hours 2 hours 8 hours

2 hours 9 hours 6 hours

Op-20 Lathe 2 hours 10 hours 1 hour

Op-30 Mill

4 hours 11 hours 1 hour

Total

10 hours 25 hours 3 hours 14 hours 17 hours

9

10

ROUND CHUCKS

The round Unilock chucks come in diameters from ø90mm to ø196mm (ø3.543" to ø7.716") and body styles to fit a wide variety of applications. Chucks can be supplied with single notches, multiple notches or bushing holes for timing. Most body forms allow the use of turbo assisted clamping for higher retention forces.

NEW!

ESM 138 ........................ Pg. 12-13

ESM 138 Turbo .............. Pg. 14-15

NEW!

ERGO 138 ...................... Pg. 16-17

EFM 138 ......................... Pg. 18-19

ASM 90 .......................... Pg. 20-21

ASM 120 ........................ Pg. 22-23

NEW!

ASH 120 ......................... Pg. 24-25

ISM 160 ......................... Pg. 26-27

MSM 170 ........................ Pg. 28-29

ESM 176 TURBO ............ Pg. 30-31

HSM 196 ........................ Pg. 32-33

11

ESM 138

Our Most Popular Chuck The ESM 138 Unilock chuck is easily mounted in custom fixture designs, and its versatility makes it our best seller. Features: • Mid-sized diameter fits most applications • Top side mounting for ease of integration • Choose from air connections at bottom or side • Optional timing notch in face of chuck • Stainless steel body option (ESM 138-SS)

Available with Notches

Recommended Bolt Sizes

Clamping Force (lbs)

Air Connection

Chuck Model

Catalog Number

Notch (Width x Qty)

Weight (lbs)

M10 M12 M16 M20† M24† Spring Only Turbo Assist

Port Size Flange

15.270.100 15.270.107 15.276.100

ESM 138

990-1,320 3,300-3,520*

9.9

1/8

14 H7 x 1

3 3 3 3 3

3

ESM 138-SS

• Screws, screw covers and o-ring included * Sealed pocket required for turbo assist † Optional

AIR FITTINGS

ACCESSORIES

REPAIR COMPONENTS

PG. 144

PG. 148

PG. 149

12

ESM 138

Detail B

B

ø138 0

-.01

A

ø109

1/8 BSP Open Port (Ships Plugged)

ø110 0

-.01

Detail A Scale 2:3 ø8x2 O-Ring (Ships Unplugged)

ø12 R61 (M5 Port) R62 (O-Ring Port)

Open Port

• All dimensions are in millimeters • Dimensions marked are for notch option

13

ESM 138 TURBO

NEW!

Our Most Popular Chuck Has Been Improved The ESM 138 Turbo Unilock chuck comes with an air assisted clamping turbo function. This is accomplished by covering the piston with a sealed cover plate. It also has improved retention force with a new slide wedge actuation. Features: • Mid-sized diameter fits most applications • Top side mounting for ease of integration • Choose from air connections at bottom or side

• Optional timing notch in face of chuck • Same body and locating diameters • Same mounting bolt hole pattern • Same flange air port location • Same timing notch

Available with Notches

Recommended Bolt Sizes

Clamping Force (lbs)

Air Connection

Chuck Model

Catalog Number

Notch (Width x Qty)

Weight (lbs)

M10 M12 M16 M20† M24† Spring Only Turbo Assist

Port Size Flange

15.270.140 15.270.147

ESM 138 TURBO

990-1,320 3,300-3,520

9.9

1/8

3 3 3 3 3

3

14 H7 x 1

AIR FITTINGS

ACCESSORIES

REPAIR COMPONENTS

• Screws, screw covers and o-ring included † Optional

PG. 144

PG. 148

PG. 149

14

ESM 138 TURBO

Detail C

M8xP1.0 SHCS (6x)

C

ø138 0

-.01

A

B

ø109.75

1/8 BSP Turbo Port (Ships Plugged)

1/8 BSP Open Port (Ships Plugged)

ø110 0

-.01

Detail A Scale 2:3 ø8x2 O-Ring (Ships Unplugged)

Detail B Scale 2:3 ø8x2 O-Ring (Ships Unplugged)

M5

R61 (M5 Port)

M5

R61 (M5 Port) R62 (O-Ring Port)

R62 (O-Ring Port)

M5 Vent Port (Ships Plugged)

Open Port

Turbo Port

• All dimensions are in millimeters • Dimensions marked are for notch option

15

ERGO 138

NEW!

Space Saving Chuck The 138 family of chucks has a new member with the all new ERGO 138 Unilock chuck. It has many new features, but the primary difference is it’s space saving height of 28mm. A savings of 11mm over the ESM 138 model. Features: • Mid-sized diameter fits most applications • Top side mounting for ease of integration • Choose from air connections at bottom or side

• Optional timing notch in face of chuck • Same body and location diameters • Same mounting bolt hole pattern • Same flange air port location • Increased inner support ring diameter • Knee locking mechanism

Available with Notches

UNCLAMPED

CLAMPED

Recommended Bolt Sizes

Clamping Force (lbs)

Air Connection

Chuck Model

Catalog Number

Notch (Width x Qty)

Weight (lbs)

M10 M12 M16 M20† M24† Spring Only Turbo Assist

Port Size Flange

15.270.110 15.270.117

ERGO 138

990-1,320 3,300-3,520

9.9

1/8

3 3 3 3 3

3

14 H7 x 1

AIR FITTINGS

ACCESSORIES

REPAIR COMPONENTS

• Screws, screw covers and o-ring included † Optional

PG. 144

PG. 148

PG. 149

16

ERGO 138

14 H7 (9x)

ø10 H7 Through All

1/8 BSP Open Port (Ships Plugged)

M8 SHCS (6x)

1/8 BSP Open Port (Ships Plugged)

ø138 0

-.001

A

B

ø110 0 ø109.05 -.01

C

Detail A Scale 2:3 ø8x2 O-Ring (Ships Plugged)

Detail C Scale 2:3 Air Cleaning (Ships Plugged)

Detail B Scale 2:3 ø8x2 O-Ring (Ships Plugged)

M7

ø12 M7

ø12 M7

Open Port

M5 Port for Drain or Cleaning (Ships Plugged)

Turbo Port

• All dimensions are in millimeters • Dimensions marked are for notch option

17

EFM 138

The Tombstone Specialist The EFM 138 Unilock flange mount chuck is easily mounted in custom fixture designs due to the reduced projection height. Especially suited for thinner walled tombstones. Features: • Mid-sized diameter fits most applications • Top side mounting for ease of integration • Reduced projection height by mounting in fixtures

• Optional timing notch in face of chuck • Stainless steel body option (EFM 138-SS)

Available with Notches

Recommended Bolt Sizes

Clamping Force (lbs)

Air Connection

Chuck Model

Catalog Number

Notch (Width x Qty)

Weight (lbs)

M10 M12 M16 M20† M24† Spring Only Turbo Assist

Port Size Flange

15.263.100 15.263.107 15.276.107

EFM 138

990-1,350 3,300-3,520

8

3 3 3 3 3

3

14 H7 x 1

EFM 138-SS

AIR FITTINGS

ACCESSORIES

REPAIR COMPONENTS

• Screws, screw covers and o-rings included † Optional

PG. 144

PG. 148

PG. 149

18

EFM 138

M8 Low Head SHCS (6x)

C

Detail C

0 -.01

138

B

ø109.3

A

0 -.01

ø110

M5

M5

Detail B Scale 2:3 ø7x1.5 O-Ring (Ships Unplugged)

Detail A Scale 2:3 ø7x1.5 O-Ring (Ships Unplugged)

ø10

ø10

Turbo Port

Open Port

62

62

• All dimensions are in millimeters • Dimensions marked are for notch option

19

ASM 90

Smaller Application Chucks As one of the smallest chucks in the Unilock family, the ASM 90 specialized in small jobs without creating obstructions Features: • Reduced diameter for small work or tight spaces • Integrated toe clamp lip

• Turbo option for increasing holding power • Air supply from bottom or side of chuck • Optional reference notch in face of chuck

Optional Through Hole

Recommended Bolt Sizes

Clamping Force (lbs)

Air Connection

Chuck Model

Catalog Number

Notch (Width x Qty)

Weight (lbs)

M10 M12 M16 M20† M24† Spring Only Turbo Assist

Port Size Flange

15.240.090 15.240.091

ASM 90

— — — 550-660

1,540-1,760

5.1

1/8

3 3

3

12 H7 x 1

AIR FITTINGS

ACCESSORIES

REPAIR COMPONENTS

• O-rings included † Optional

PG. 144

PG. 148

PG. 149

20

ASM 90

35 Min

1/8 BSP Open Port (Ships Plugged)

M5

1/8 BSP Tubo Port (Ships Plugged)

40 ø5 H7 (2x)

40

A

0 -.01

B

ø90

M4

M4

Detail B Scale 1:1 ø4x1.5 O-Ring (Ships Unplugged)

Detail A Scale 1:1 ø4x1.5 O-Ring (Ships Unplugged)

ø7

ø7

M5x.8 10 (8x)

Open Port

Turbo Port

• All dimensions are in millimeters • Dimensions marked are for notch option

21

ASM 120

A Grid Plate’s Best Friend Changing positions and jobs is no problem for this plate-friendly smaller, yet robust chuck with multiple positioning and securing options. Features: • Integrated toe clamp lip • Reduced diameter for small work or tight spaces • Jig ground reference pin location on bottom of chuck

• Air supply from bottom or side of chuck • Optional timing pin hole in face of chuck • Non-air mechanical version available

The manual version comes with a wrench for easy opening and closing.

The Model 120 chuck has a reference hole on center (shown here with a step pin). Threaded holes are also provided for mounting the chuck to a baseplate.

Optional Timing Pin Feature

Toe clamps can also be used to clamp the chuck in place.

Recommended Bolt Sizes

Clamping Force (lbs)

Air Connection

Chuck Model

Catalog Number

Notch (Width x Qty)

Weight (lbs)

M10 M12 M16 M20† M24† Spring Only Turbo Assist

Port Size Flange

15.270.150 15.270.155 15.270.161 15.270.160 15.270.180 15.270.185

ASM 120

8 H7 x 1

770-990 2,860-3,300*

1/8

P

P

P

— — —

8.8

ASM 120-SS

8 H7 x 1

ASM 120M

1,760-2,200

— —

8 H7 x 1

AIR FITTINGS

ACCESSORIES

REPAIR COMPONENTS

• O-rings included * Sealed pocket required for Turbo Assist † Optional

PG. 144

PG. 148

PG. 149

22

ASM 120

0 -.01

40

0 -.01

ø120

1/8 BSP Open Port (Ships Plugged)

ø8 H7

ø5 H7 (2x)

ø12 H7

55.5

A

M4

Detail A Scale 2:3 ø4.5x1.5 O-Ring (Ships Unplugged)

ø7.50

Open Port

• All dimensions are in millimeters • Dimensions marked are for notch option

23

ASH 120

NEW!

A New Member of the 120 Family The 120 family has a new manual version. The ASH 120 is the same diameter and height as its original ASM 120 version but now has a new clamping actuation system. Rather than the handle rotating 180° about the axis of the pin, the wrench swings 90° about the axis of the chuck.

The ASH 120 comes with a wrench for easy opening and closing. The wrench swings 90° about the axis of the chuck.

Recommended Bolt Sizes

Clamping Force (lbs)

Chuck Model

Catalog Number

Notch (Width x Qty)

Weight (lbs)

M10

M12

M16

M20†

M24†

Manual Only 1,760-2,200

15.270.170

ASH 120

14 H7 x 1

8.8

3

3

ACCESSORIES

REPAIR COMPONENTS

How it Works

PG. 148

PG. 149

Clamping Knob

Chuck Body

Clamping Pin

Scroll

Open

Clamped

24

ASH 120

ø80 B.C.

ø12 H7 Through All

M6 Screws Included For Mounting (6x) (All Others Are Not To Be Removed)

ø120 0

-.01

ø5H7 10 (2x)

M6x1 8 (6x)

• All dimensions are in millimeters

25

ISM 160

The Rotary Expert The ISM 160 chuck is a single chuck solution for the face of 4th and 5th axis rotary tables. Exterior timing features are comparable with MCM 150 & MSM 170 chucks. Timing pin slot allows timing pin to match non-standard pallet sizes.

Features: • Simple surface mount design • Now available with A2-6 mounting • Dowel pins into location • Supports 60º and 90º t-slots • Air assisted clamping option • Low profile 46mm (1.811") • Through-hole eases cleaning • Multiple indexing options

AIR FITTINGS

Slot Allows for Variations in Radial Pin Location

PG. 144

ACCESSORIES

PG. 148

REPAIR COMPONENTS

PG. 149

Recommended Bolt Sizes

Clamping Force (lbs)

Air Connection

Chuck Model

Catalog Number

Notch (Width x Qty)

Weight (lbs)

M10 M12 M16 M20† M24† Spring Only Turbo Assist

Port Size Flange

14 H7 x 1 12 H7 x 4 10 H7 x 2

15.260.160

ISM 160

— — 1,100-1,540 3,300-3,740

12.1

1/8

3 3 3

3

15.300.008

ISM 160 (A2-6)

• No hardware included † Optional

Adapter Plate for ISM 160 to HAAS 160 Size Indexers and Trunnions

Features: • Replaces t-slot platter • Allows for both open and turbo • Low 20mm height

Chuck Model

Indexer Model

Catalog Number

15.260.164

ISM 160

HAAS 160

• Other sizes available upon request • Please contact BIG KAISER Engineering Dept. for additional information

26

ISM 160

13 TYP

M5 Open Port ø8x2 O-Ring (Ships Plugged)

52.5

0 -.01

ø162

0 -.005

46

15

14 H7

14

1/8 BSP Open Port (Ships Unplugged)

ø12 H7 (4x)

12 H7 Through All (2x)

22

1/8 BSP Turbo Port (Ships Unplugged)

• All dimensions are in millimeters

27

MSM 170

Larger More Robust Chucks The rigidity of the MSM 170 design allows for use in the highest precision operations in all types of applications and environments. Features: • Large diameter, heavy duty mechanical clamping • Clamping lip for top side table clamping • Threaded holes for bottom side clamping to plates • Integrated timing pin locations every 90 degrees • Air supply from bottom or side of chuck

Recommended Bolt Sizes

Clamping Force (lbs)

Air Connection

Chuck Model

Catalog Number

Notch (Width x Qty)

Weight (lbs)

M10 M12 M16 M20† M24† Spring Only Turbo Assist

Port Size Flange

15.260.100

MSM 170

12 H7 x 4

1,650-1,980 3,520-4,400

16.5

1/8

3 3 3 3 3

3

AIR FITTINGS

ACCESSORIES

REPAIR COMPONENTS

• O-ring included † Optional

Optional Mounting Ring

PG. 144

PG. 148

PG. 149

Catalog Number 15.260.200

• Other sizes available upon request • Please contact BIG KAISER Engineering Dept. for additional information

28

MSM 170

ø12 H7 (4x)

0 -.01

164

1/8 BSP Open Port (Ships Plugged)

ø10 H7 (2x)

A

150 +.01 -.01

0 -.01

ø69

Detail A Scale 2:3 ø8x2 O-Ring (Ships Unplugged)

ø12

M10 (4x)

• All dimensions are in millimeters

29

ESM 176

The Heavyweight Champion Due to its size and shoulder screw mounting, the ESM 176 Unilock chuck excels in handling heavyweight fixtures. Features: • Flange design for top side mounting • Large diameter with turbo clamping for more rigidity

• Air supply from bottom or side of chuck • Optional reference notch in face of chuck

Available with Notches

Recommended Bolt Sizes

Clamping Force (lbs)

Air Connection

Chuck Model

Catalog Number

Notch (Width x Qty)

Weight (lbs)

M10 M12 M16 M20† M24† Spring Only Turbo Assist

Port Size Flange

15.272.170 15.272.171

ESM 176 Turbo

1,540-1,760 4,180-4,840

17.5

1/8

3 3 3 3 3

3

25 H6 x 1

AIR FITTINGS

ACCESSORIES

REPAIR COMPONENTS

• Screws, screw covers and o-rings included • Notched version comes with timing bushing and all hardware listed above † Optional

PG. 144

PG. 148

PG. 149

30

ESM 176

M8 SHCS (6x)

C

Detail C

0 -.01

ø176

B

A

0 -.01

ø138

1/8 BSP Turbo Port (Ships Plugged)

1/8 BSP Open Port (Ships Plugged)

Detail B Scale 2:3 ø8x2 O-Ring (Ships Unplugged)

Detail A Scale 2:3 ø8x2 O-Ring (Ships Unplugged)

ø12

ø12

76

76

Turbo Port

Open Port

• All dimensions are in millimeters • Dimensions marked are for notch option

31

HSM 196

The Vacant Rotator The HSM 196 chuck can be used on the face of 4th and 5th axis rotary tables, lathes or mills where the center of rotation provides a through-hole to bury the workpiece. Features: • 61mm (2.4") through capacity • Work can pass through chuck • Rotational limit = 3,000 RPM • Air assisted clamping option • Three clamping wedges for added stability • Bolts into place from top side

Available with Notches

Recommended Bolt Sizes

Clamping Force (lbs)

Air Connection

Chuck Model

Catalog Number

Notch (Width x Qty)

Weight (lbs)

M10 M12 M16 M20† M24† Spring Only Turbo Assist

Port Size Flange

15.274.407

HSM 196

25 H6 x 1

— — — —

1,980-2,200 4,400-5,060

19.3

1/8

3

3

AIR FITTINGS

ACCESSORIES

REPAIR COMPONENTS

• Screws, screw covers, o-rings and timing bushing included • M74 option (See Pg. 68) † Optional

PG. 144

PG. 148

PG. 149

32

HSM 196

1/8 BSP Open Port (Ships Plugged)

B

B

1/8 BSP Turbo Port (Ships Plugged)

M8 SHCS (6x)

87.5 +.002 -.002

Section B-B

ø12 n6

0 -.01

ø196

ø61 ø159

A

0 -.01

ø160

Detail A Scale 2:3.5 ø8x2 O-Ring (Ships Uplugged)

M6

ø12

Turbo Port

Open Port

• All dimensions are in millimeters

33

34

RECTANGULAR CHUCKS

Rectangular Chucks Unilock rectangular chucks are well suited for mono-chuck applications. They are available in several sizes, and when matched to the footprint of the workpiece, they provide maximum access from the remaining five sides. The EDM 100/150 has the lowest profile of all Unilock chucks, and the new AFM 146 is not far behind. The AFM 105/65 and the ESM 100/75 are the two narrowest chucks in the Unilock family and can be placed very close to the edge of a fixture or workpiece. For extremely large and heavy parts, the new ESM 180/150 with a new robust knob series is your answer.

ESM 100/75 ................... Pg. 36-37

AFM 105/65 ................... Pg. 38-39

EDM 100/150 ................. Pg. 40-41

AFM 146 ........................ Pg. 42-43

NEW!

ESM 180/150 ................. Pg. 44-45

35

ESM 100/75

Perfect for Small Spaces The ESM 100/75 can be assembled directly to machine tables as well as installation into angle plates, tombstones or pallets. Features: • Flange mounting design • Reduced size for small work or tight spaces • High clamping force in a small package • Edge of chuck can be used as a timing surface • Turbo option for increased holding power

Recommended Bolt Sizes

Clamping Force (lbs)

Air Connection

Chuck Model

Catalog Number

Notch (Width x Qty)

Weight (lbs)

M10 M12 M16 M20† M24† Spring Only Turbo Assist

Port Size Flange

15.272.175

ESM 100/75

— — — 440-660

3,300-3,520

4.5

1/8

3 3

3

AIR FITTINGS

REPAIR COMPONENTS

• Screws, screw covers and o-rings included † Optional

PG. 144

PG. 149

36

ESM 100/75

70

M8 SHCS (4x)

100 +.001 -.001

57

B

A

ø71

ø72 +.001 -.001

Detail A Scale 2:1 ø4x1.5 O-Ring (Ships Unplugged)

Detail B Scale 2:1 ø4x1.5 O-Ring (Ships Unplugged)

ø7 M3

ø7 M3

1/8 BSP Open Port (Ships Plugged)

1/8 BSP Turbo Port (Ships Plugged)

28.5

28.5

• All dimensions are in millimeters

37

AFM 105/65

The Small Footprint Expert The AFM 105/65 chuck is an excellent choice for single chuck applications on multi-axis machines and work cells where clearance is needed to access all available sides of the part.

Features: • Simple surface mount design • Dowel pins into location • Bolt through or toe clamp

• Ground edges for orientation • Air assisted clamping option • Turbo option for increased holding power

• Optional robot gripper version • Supports 90 degree (4x) indexing • Elevated for 5-axis accessibility

Recommended Bolt Sizes

Clamping Force (lbs)

Air Connection

Chuck Model

Catalog Number

Notch (Width x Qty)

Weight (lbs)

M10 M12 M16 M20† M24† Spring Only Turbo Assist

Port Size Flange

15.272.165 15.272.166

AFM 105/65

— — — 660-880

1,980-2,200

6.3

1/8

3 3

3

12 H6 x 2

AIR FITTINGS

ACCESSORIES

• No hardware included † Optional

PG. 144

PG. 148

Available as Robot Gripper Option (See Pg. 140)

38

AFM 105/65

120

1/8 BSP Turbo Port (Ships Unplugged)

40 Min

1/8 BSP Open Port (Ships Unplugged)

M8 SCHS (4x)

0 -.001

105

0 -.001

140

Optional M4x.7 Ports (2x) (Ships Plugged)

120 +.01 -.01

60 +.01 -.01

ø12 F7 Through All (3x)

55

• All dimensions are in millimeters

39

EDM 100/150

The EDM Specialist The EDM 100/150 chuck is designed to operate in submerged environments. Completely sealed and produced from stainless steel, this chuck can be used in Wire EDM and Water Jet machines. This chuck provides an open interface and clamping knobs can be loaded from the top or bottom side. This chuck is compatible with the entire Unilock product range as it uses the standard sized System 40 clamping knob. With a total height of 39mm (1.535"), this chuck delivers the lowest stack height in the Unilock family.

Features: • Turbo option for increased holding power • Weight: 3.35 kg (7.3 lbs) • Knob can be retained from both sides • Chuck can be mounted on any face

Recommended Bolt Sizes

Clamping Force (lbs)

Air Connection

Chuck Model

Catalog Number

Notch (Width x Qty)

Weight (lbs)

M10 M12 M16 M20† M24† Spring Only Turbo Assist

Port Size Flange

15.272.150

EDM 100/150

— — — 440-550

1,100-1,350

7.3 — REPAIR COMPONENTS 1/8

3 3

AIR FITTINGS

• No hardware included † Optional

PG. 144

PG. 149

40

EDM 100/150

25

M6 (4x)

0 -.005

39

50

25

50

M6 (4x)

Plug Screws (8x) Do Not Remove

M8 SHCS

15

15

12.5

14

1/8 BSP Turbo Port (Ships Unplugged)

1/8 BSP Open Port (Ships Unplugged)

25

M6 (4x)

• All dimensions are in millimeters

41

AFM 146

The Instant Out of the Box Solution The AFM 146 chuck is an excellent choice for multiple chuck applications on multi-axis machine tables and other work cells where a low stack height is important. Can instantly mount directly to your machine table right out of the box.

Features: • Simple surface mount design • Dowel pins into location • Bolt through or toe clamp

• Ground edges for orientation • Air assisted clamping option • Turbo option for increased holding power • Low profile 46mm (1.811") • Through-hole eases cleaning

Recommended Bolt Sizes

Clamping Force (lbs)

Air Connection

Chuck Model

Catalog Number

Notch (Width x Qty)

Weight (lbs)

M10 M12 M16 M20† M24† Spring Only Turbo Assist

Port Size Flange

15.260.146

AFM 146

14 H7 x 1

— — 1,100-1,540 3,300-3,740

9.2

1/8

3 3 3

3

AIR FITTINGS

ACCESSORIES

REPAIR COMPONENTS

• No hardware included † Optional

PG. 144

PG. 148

PG. 149

42

AFM 146

146 120 +.01 -.01

ø12 H7 Through All (2x)

ø14 H7 7

46

46

1/8 BSP Open Port (2x) (1 Ships Plugged) (1 Ships Unplugged)

1/8 BSP Open Port (2x) (1 Ships Plugged) (1 Ships Unplugged)

100

15

A

B

ø37.50 Through All (Not for Location)

Detail A Scale 2:2.5 ø8x2 O-Ring (Ships Plugged)

Detail B Scale 2:2.5 ø8x2 O-Ring (Ships Plugged)

M4

M4

ø8

ø8

ø12 H7 12 (4x)

50 +.01 -.01

+.01 -.01

50

• All dimensions are in millimeters

43

ESM 180/150

NEW!

A Leap Forward in Heavy Part Workholding The ESM 180/150 uses the System 68 knob which allows for the use of larger fasteners. By having the highest retention forces available, it can be used in many industries that specialize in large part manufacturing such as Energy, Aerospace, Agriculture and Construction.

Features: • Highest retention forces • Large surface area • Turbo option for increased holding power • Edge of chuck can be used as a timing surface

Recommended Bolt Size

Clamping Force (lbs)

Air Connection

Chuck Model

Catalog Number

Notch (Width x Qty)

Weight (lbs)

M10 M12 M16 M20 M24 Spring Only

Turbo Assist

Port Size Flange

15.500.590

ESM 180/150

— — — —

9,000-10,000 13,000-15,000 26.5

1/8

3

3

AIR FITTINGS

PG. 144

M24 ø57

35

10

24

• All dimensions are in millimeters

Knob Type

Catalog Number

Internal Thread

Pass-Through Bolt Size

Description

Undersize

Hex

15.500.593 15.500.594 15.500.595

A B C

SBA Clamping Knob Absolute Position SYS 68 (SHCS M24) SBB Clamping Knob Oreintation SYS 68 (SHCS M24) SBC Clamping Knob Retention Only SYS 68 (SHCS M24)

.0004

M24

.0040

44

ESM 180/150

180

125

M12 SHCS (4x)

1/8 BSP Turbo Port (Ships Unplugged)

1/8 BSP Open Port (Ships Unplugged)

A

B

ø125 h6

ø12 M5

ø124.70

ø12 M5

Detail A Scale 2:3 ø12x2 O-Ring (Ships Unplugged)

Detail B Scale 2:3 ø12x2 O-Ring (Ships Unplugged)

42.50

42.50

• All dimensions are in millimeters

45

46

PRE-ASSEMBLED CHUCKS

Just as the name implies, these chucks are sold mounted to a base plate. The base plate provides easy mounting of the chucks to the machine table as well as a pre-plumbed air supply. All bases provide either notches or a ground edge to square the chucks to the machine table.

MCM 150 ...........................Pg. 50-51

MLM 150 ........................ Pg. 48-49

DCM 200 ............................Pg. 54-55

DLM 200 ........................ Pg. 52-53

NEW!

ERGO Base Stations .........Pg. 58-59

QC 400 ........................... Pg. 56-57

Starter Kits ................... Pg. 60-61

47

MLM 150

Pre-Assembled Single Table Chucks Four adjustment slots allow for quick positioning on t-slot tables. Additional clamping chucks be used to create an array and provide orientation. Features: • Base plate for mounting on machine tables • Air supply from side of base plate • Optional timing notch in face of chuck • Keyways on bottom for positioning on work table • Utilizes ESM 138 Unilock chuck

Available with Notches

Recommended Bolt Sizes

Clamping Force (lbs)

Air Connection

Chuck Model

Catalog Number

Notch (Width x Qty)

Weight (lbs)

M10 M12 M16 M20† M24† Spring Only Turbo Assist

Port Size Flange

15.270.350 15.270.355

MLM 150

990-1,320

15.4

1/8

3 3 3 3 3

12 H6 x 1

AIR FITTINGS

ACCESSORIES

REPAIR COMPONENTS

• No hardware included † Optional

PG. 144

PG. 148

PG. 149

48

MLM 150

1/8 BSP Open Port (Ships Unplugged)

0 -.01

56

150

20 H6 (4x)

21

6

9 Max

14 H6

• All dimensions are in millimeters • Dimensions marked are for notch option

49

MCM 150

Pre-Assembled Single Table Chucks The MCM 150 is prepared to accept four hardened 12mm index bushings, one every 90 degrees. Order one index bushing to orient a pallet with a single knob. If you need to execute multiple 90 degree indexes, additional bushings can be installed. Features: • Base plate for mounting on machine tables • Air supply from side of base plate • 90 degree (4x) indexing • Optional timing notch in face of chuck • Keyways on bottom for positioning on work table • Utilizes ESM 138 Unilock chuck

Recommended Bolt Sizes

Clamping Force (lbs)

Air Connection

Chuck Model

Catalog Number

Notch (Width x Qty)

Weight (lbs)

M10 M12 M16 M20† M24† Spring Only Turbo Assist

Port Size Flange

15.270.250

MCM 150

12 H6 x 4†

999-1,320

17.8

1/8

3 3 3 3 3

AIR FITTINGS

ACCESSORIES

REPAIR COMPONENTS

• No hardware included † Optional

PG. 144

PG. 148

PG. 149

Optional Air Pass-Through

Catalog Number 15.260.725

• Other sizes available upon request • Please contact BIG KAISER Engineering Dept. for additional information

50

MCM 150

0 -.01

56

150

47

1/8 BSP Open Port (Ships Unplugged)

ø18 H7 (4x)

20 H7 (4x)

21

6

Bushing Hole Locations (4x) (Bushing Part Sold Separately) 15.260.309

• All dimensions are in millimeters • Dimensions marked are for notch option

51

DLM 200

Pre-Assembled Double Table Chucks Designed to accept a large single pallet or two smaller pallets. A single external air connection operates both chucks simultaneously. Features: • Base plate for mounting on machine tables • Air supply from side of base plate • Optional timing notch in face of DLM chuck • Keyways on bottom for positioning on work table • Utilizes ESM 138 Unilock chucks

The DLM 200 chuck does not have timing pin bushing locations. If you want to orient a double pallet with this chuck, add one timing pin notch. If you need to run two single pallets, add a timing notch for each chuck.

Recommended Bolt Sizes

Clamping Force (lbs)

Air Connection

Catalog Number

Notch (Width x Qty)

Weight (lbs)

Chuck Model

M10 M12 M16 M20† M24† Spring Only Turbo Assist

Port Size Flange

15.270.300 15.270.307

DLM 200

1,980-2,640*

37.4

1/8

3 3 3 3 3

14 H7 x 1

AIR FITTINGS

ACCESSORIES

REPAIR COMPONENTS

• No hardware included † Optional * Combined value of two chucks

PG. 144

PG. 148

PG. 149

52

DLM 200

200

0 -.01

60

140

21

Air Passage Cover Plates Do Not Remove

6

1/8 BSP Open Port (2x) (1 Ships Plugged) (1 Ships Unplugged)

14

9 Min

14 H6

• All dimensions are in millimeters • Dimensions marked are for notch option

53

DCM 200

Pre-Assembled Double Table Chucks The DCM 200 chuck is designed to process two single pallets or one double pallet. Each chuck has a position for a timing pin bushing every 90 degrees. Features: • Base plate for mounting on machine tables • Air supply from side of base plate • 90 degree (4x) indexing • Keyways on bottom for positioning on work table • ø25mm locating hole

• Single chuck operation capability • Utilizes ESM 138 Unilock chucks

Recommended Bolt Sizes

Clamping Force (lbs)

Air Connection

Chuck Model

Catalog Number

Notch (Width x Qty)

Weight (lbs)

M10 M12 M16 M20† M24† Spring Only Turbo Assist

Port Size Flange

15.270.200

DCM 200

12 H6 x 8

1,980-2,640*

46.2

1/4

3 3 3 3 3

AIR FITTINGS

ACCESSORIES

REPAIR COMPONENTS

• No hardware included † Optional * Combined value of two chucks

PG. 144

PG. 148

PG. 149

54

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