UNILOCK Supplemental Modular Workholding System Vol. 2

SUPPLEMENTAL PRODUCTS UNILOCK MODULAR WORKHOLDING SYSTEM VOL. 2

2

ROUND CHUCKS

4-17

ERGO138-PREASSEMBLED BASES OVERVIEW

4-5

E100

6 7 8 9

E100-V1 E100-V2

E200 E300 E400 E600 E800 E1000

10

11-12

13 14 15

MULTI-AXIS SYSTEM

16-31

SYSTEM 68 FOR 5-AXIS

16-19 20-21 22-27 28-31

ESA125/85

5-AXIS STABILIZER UNIFLEX BALL SYSTEM

UNIFLEX SYSTEM 50

3

ROUND CHUCKS

ERGO138-PREASSEMBLED BASES OVERVIEW Preassembled Double Table Chucks Base stations with the new ERGO 138 chuck save 11mm of height compared to ESM 138. Available with turbo out of the box. • Mid-sized diameter chuck fits most operations • Finish ground steel baseplate • Predesigned solutions for up to 10 chucks • Optional timing notch in face of ERGO 138 chucks

Metric (mm)

Imperial (in)

Catalog Number

Page Number

Number of Chucks

Length

Width

Height

Length

Width 5.866 7.480

Height

15.270.370 15.270.370.1 15.270.370.2 15.270.371 15.270.372 15.270.373 15.270.374 15.270.375 15.270.376

6 7 8 9

196 240 240 396 595 395 596 796 996

149 190

7.717 9.448 9.448

1 1 1 2 3 4 6 8

19

.748

196 195 395 395 396 396

50

15.591 23.425 15.551 23.465 31.339 39.213

7.717 7.677

1.969

10 11 13 14 15

15.551 15.551 15.591 15.591

60

2.362

10

• No hardware included

4

ROUND CHUCKS

ERGO138 — WELDING Four ERGO E600 bases are used to hold welding fixtures allowing for the quick changeover of fixtures when the production changes from one series of parts to another. There is no need to ‘retouch points’ between changes as the system repeatability of .005 μm (.0002") is greater then needed in most welding applications.

ERGO138 — TIMING BLOCK The ERGO E100 base can be modified by the end user to accept a timing block allowing for the timing of smaller fixtures at 45° or 135°. The ERGO E100 V1 and V2 bases offers a 45° timing block mount with no modification. The V1 also has a single 14mm H7 timing notch. In all cases the block (15.270.331) is sold separately.

ERGO138 E300 – ROUND, SPECIAL ITEM Special versions of round bases can be built to customer specifications. For assistance, please consult the BIG KAISER Eng. Dept.

5

ROUND CHUCKS

E100—15.270.370

Timing Block 15.270.331 (Sold Separately) Base to be Modified by End User

ø18 H7 +. 0 1 8 0

6.5

M8x1.25 16 (2x)

196 160

ø138

1/8G Turbo

1/8G Open

ø12

10

ø12 H7 6

62 ±.01

62 ±.01

• All dimensions are in millimeters • For detailed information on additional mounting hole locations, please consult the BIG KAISER Eng. Dept.

6

ROUND CHUCKS

E100 V1—15.270.370.1

240 205

ø138

55

All Holes are Coverd

A

Detail A Scale 1:1

1/8G Open

1/8G Turbo

ø12 H7 6

ø12 H7 10

62 ±.01

• All dimensions are in millimeters • For detailed information on additional mounting hole locations, please consult the BIG KAISER Eng. Dept.

7

ROUND CHUCKS

E100 V2—15.270.370.2

240 205

Timing Block 15.270.331 (Sold Separately)

ø138

ø18 H7 +. 0 1 8 0

6.5 (8x)

(Ships With Cover)

(Shipped Plugged) M8x1.25-6H 16 (16x)

1/8G Turbo

1/8G Open

ø12 H7 10

ø12 H7 6

62 ±.01

• All dimensions are in millimeters • For detailed information on additional mounting hole locations, please consult the BIG KAISER Eng. Dept.

8

ROUND CHUCKS

E200—15.270.371

396 200 ±.01 370 ±.01

ø14 H7 (5x) Thru All

ø138

ø138

1/4G Open (4x)

1/4G Turbo (4x)

• All dimensions are in millimeters • For individual chuck operation, please consult the BIG KAISER Eng. Dept.

E200—FOR TIMING (REQUIRES MODIFICATION)

Timing Block 15.270.331 (Sold Separately) Base to be Modified by End User

M8x1.25

16 (2x)

ø18 H7 +. 0 1 8 0

8.5

• All dimensions are in millimeters • For detailed information on additional mounting hole locations, please consult the BIG KAISER Eng. Dept.

9

ROUND CHUCKS

E300—15.270.372

595

200 ±.01

200 ±.01

100 ±.01

100 ±.01

14 H7 (4x) Thru All

ø138

ø138

ø138

• All dimensions are in millimeters • For detailed information on additional mounting hole locations, please consult the BIG KAISER Eng. Dept.

10

ROUND CHUCKS

E400—15.270.373

200 ±.01 320 ±.01 395

ø14 H7 (5x) Thru All

ø138

ø138

1/4G Turbo

1/4G Open

• All dimensions are in millimeters • For detailed information on additional mounting hole locations, please consult the BIG KAISER Eng. Dept.

11

E400 The ERGO E400 base stations shown above are mounted together for a master reference system on the table to the machine. They are also pneumatically linked to operate in unison. The vise plate (left bottom) and the grid plate (right bottom) are easily swapped or removed entirely. Then, when needed, replaced within .0002" (.005μm) of their original location.

12

E600—15.270.374

595

280 ±.01

280 ±.01

200 ±.01

200 ±.01

ø14 H7 (3x) Thru All

ø138

1/4G Turbo

1/4G Open

• All dimensions are in millimeters • For detailed information on additional mounting hole locations, please consult the BIG KAISER Eng. Dept.

13

ROUND CHUCKS

E800—15.270.375

796

200 ±.01

200 ±.01

200 ±.01

ø138

1/4G Turbo

1/4G Open

• All dimensions are in millimeters • For detailed information on additional mounting hole locations, please consult the BIG KAISER Eng. Dept.

The ERGO E800 preassembled bases shown with custom mounting holes to match the T-slot pattern of the customer’s machine. • For additional information on base modifications, please consult BIG KAISER Engineering Dept.

14

ROUND CHUCKS

E1000—15.270.376

996

200 ±.01

200 ±.01

200 ±.01

200 ±.01

ø138

1/4G Turbo

1/4G Open

• All dimensions are in millimeters • For detailed information on additional mounting hole locations, please consult the BIG KAISER Eng. Dept.

The ERGO E1000 preassembled base shown with four customer-designed fixtures. Standard fixture pallets are available in either aluminum or steel and various sizes and thickness. Please see UNILOCK Vol. 2, Pg. 70-71.

15

MULTI-AXIS SYSTEM

SYSTEM 68 FOR 5-AXIS The original SYSTEM 40 for 5-Axis modular workholding system now has a larger cousin with the addition of the SYSTEM 68 for 5-Axis product line. It is composed of a base chuck, an optional ground plate, two styles of reductions, and offers additional knob options that are compatible with the original ESM 180/150 pneumatic chuck. • Manual • Two reduction options • Compatible with smaller SYSTEM 40 for 5-Axis • Large robust knobs for M24 & M30 SHCS and M24 precision shoulder screws • Knobs are compatible with ESM 180/150 pneumatic chuck.

Reduction

Base Chuck

Table Adapter

16

MULTI-AXIS SYSTEM

SYSTEM 68—BASE CHUCK

ø100 B.C.

ø12.01 20 (2x)

M12x1.75 20 (4x)

ø138

M16

ø25 H7

SW 10mm Torque 30 Nm

83

Catalog Number

Weight (lbs.)

15.500.710

14.1

• All dimensions are in millimeters

SYSTEM 68—TABLE ADAPTER

Chuck Sold Separately

ø100 B.C.

ø12.1 (4x)

ø13.5 Thru All (4x) ø20 12

Catalog Number

Weight (lbs.)

ø25 H7 +. 0 2 1 0

15.500.740

36.4

• All dimensions are in millimeters • Other heights available upon request

□235

17

MULTI-AXIS SYSTEM

SYSTEM 68—REDUCTION The SYSTEM 68 reduction is used to reduce the clamping base body from ø138mm to ø80mm allowing for clamping of workpieces with a limited supporting surface. It is offered with a M24 bolt and only comes in one standard height.

SYSTEM 68 TO SYSTEM 40—REDUCTION The SYSTEM 68 to SYSTEM 40 reduction is used in cases where a fixture already has the smaller System 40 clamping knob. This allows the reuse of current fixtures without the need to modify or replace them.

ø80

ø80

System 40 Knob (Sold Separately)

M24xP3

ø25 h7

Hex 6 (Max 15 Nm) (Max 11 ft-lbs)

System 68

ø38

ø138

Hex 10mm

ø138

Catalog Number

Weight (lbs.)

Catalog Number

Weight (lbs.)

15.500.720

9.7

15.500.731

10.3

• All dimensions are in millimeters • Bolt Included • For other length options, please consult the BIG KAISER Eng. Dept.

• All dimensions are in millimeters

SYSTEM 68—CLAMPING KNOBS

Standard clamping knobs have a metric positioning boss which is ø57mm and ground to a fit of h6. This boss is 10mm tall. The overall measurements of the clamping knob are ø40mm by 68mm tall.

The SBA Knob is ground to fit with the center ground taper of the chuck. This fit establishes centerline location. This location will repeat to better than +/-.0002".

The SBB Knob is ground like a diamond pin and orients your work relative to the centerline of the SBA Knob.

The SBC Knob is ground undersize. It will bring the bottom of the workpiece or fixture down on the top of the Unilock chuck.

18

MULTI-AXIS SYSTEM

SYSTEM 68—CLAMPING KNOBS

øD H7 Thread

ød

Knob Type

Fig. 1

Bolt Size

Thread øD H7

M24xP3

ød h6

øD H7

Knob Type

ø35

Fig. 2

Hex 10mm

Catalog Number

Knob Type

Fig.

Description

Bolt Thread

øD/ød

15.500.593 15.500.594 15.500.595 15.500.596 15.500.597 15.500.598 15.500.603 15.500.604 15.500.605 15.500.606 15.500.607 15.500.608

A B C A B C A B C A B C

1 1 1 1 1 1 1 1 1 2 2 2

SBA Clamping Knob-Absolute Position SYS 68 (SHCS M24) SBB Clamping Knob-Orientation SYS 68 (SHCS M24) SBC Clamping Knob-Retention Only SYS 68 (SHCS M24) SBA Clamping Knob-Absolute Position SYS 68 (SHCS M30) SBB Clamping Knob-Orientation SYS 68 (SHCS M30) SBC Clamping Knob-Retention Only SYS 68 (SHCS M30) SBA Clamping Knob-Absolute Position SYS 68 (SHCS M24) SBB Clamping Knob-Orientation SYS 68 (SHCS M24) SBC Clamping Knob-Retention Only SYS 68 (SHCS M24) SBA Clamping Knob-Absolute Position SYS 68 (ø25 PASS THRU) SBB Clamping Knob-Orientation SYS 68 (ø25 PASS THRU) SBC Clamping Knob-Retention Only SYS 68 (ø25 PASS THRU)

M24 M24 M24 M30 M30 M30 M24 M24 M24 M24 M24 M24

57H7/57h6 57H7/57h6 57H7/57h6 57H7/57h6 57H7/57h6 57H7/57h6 25H7/25h6 25H7/25h6 25H7/25h6 25H7/25h6 25H7/25h6 25H7/25h6

• All dimensions are in millimeters

19

MULTI-AXIS SYSTEM

ESA125/85—FLAT CHUCK The ESA125/85 FLAT CHUCK is a new body form for the SYSTEM 40 knob for smaller parts and machines with smaller work envelopes. The clamping is manual, eliminating the need for air. The use of a torque limiting wrench is recommended in cases where a lighter retention force is required and to limit overtightening. The chuck can be used on its own or in combination with other chucks. •Compact body form •Precision timing slots on the top face •Precision location bores on the bottom face •Mounting via M12 or M16 screws

Clamping Pin

Body

Locking Screw

Clamping Pin

M6 X 1 Mm Extended Point Screw L16

Chuck Model

Catalog Number

15.250.160

ESM125-85

20

MULTI-AXIS SYSTEM

ESA125/85—FLAT CHUCK

125

50

25 H7 13 (2x)

ø16 H7 Thru All

HEX 8 15 Nm (11 in-lbs)

Note: Do Not Remove Lock Screw

12.50 (For M12 SHCS)

16.50 (For M16 SHCS)

5

12.50

12.50

50 ±0.01

50 ±0.01

15.250.161

15.250.162

ø20 H7 7 (2x)

• All dimensions are in millimeters • 2 pcs. of each washer included with chuck

21

STABILIZER SYSTEM

5-AXIS STABILIZER UNIFLEX BALL SYSTEM (ø25.4)

Provides lateral support for tall parts during machining, welding or assembly processes. Allows for the transfer of loads to the table or base. •Compatible with standard UNILOCK SYSTEM 40 chucks, Manual 5-Axis clamping units & UNIFLEX clamping system • Fine adjustment unit allows for adjusting the position of parts as needed Options: • Magnetic base • Tab/flange gripper • Direct ball attachment with no location requirement

• 5 fixed length extensions • 2 adjustable length bases

22

STABILIZER SYSTEM

5-AXIS STABILIZER PART ATTACHMENT OPTIONS These items allow you to attach or grab the workpiece(s) via a variety of different methods. 1) Mounting Ball 2) Mounting Screw 3) Tab/Flange Gripper 4) Magnetic Base

3

2

1

5

6

4

TABLE ATTACHMENT OPTIONS These items are used at the bottom of the stabilizer system and allow it to be rigidly fixed in place. 4) Magnetic Base 5) Mounting Screw via T-Slot Nut 6) UNILOCK SYSTEM 40 Knob Adapter

23

STABILIZER SYSTEM

5-AXIS ADJUSTABLE STABILIZER—BASE

L1

L2

8 Hex

Ball Size

SW

Ball Size

Catalog Number

Length L1 (mm)

Length L2* (mm)

Clamping Ball (mm)

Weight (lbs.)

Description

15.252.009 15.252.010 15.252.011 15.252.012

5-Axis Adjustable Stabilizer Base 255-305mm (ø25.4) 5-Axis Adjustable Stabilizer Base 400-550mm (ø25.4) 5-Axis Adjustable Stabilizer Base 350-450mm (ø50) 5-Axis Adjustable Stabilizer Base 450-650mm (ø50)

255-305 400-550 350-450 450-650

187 287 257 356

4.3 5.3

ø25.4

14.7 16.9

ø50

*L2 at minimum position • 2x balls are included; clamps can be ordered separately

5-AXIS FIXED STABILIZER—EXTENSION

Thread

SW

Thread

Diameter

Catalog Number

Length (mm)

Diameter (mm)

Wrench (SW)

Weight (lbs.)

Description

Thread

15.252.030 15.252.031 15.252.032 15.252.033 15.252.034 15.252.040 15.252.041 15.252.042 15.252.043

5-Axis Fixed Stabilizer Extension (ø25xL75mm) 5-Axis Fixed Stabilizer Extension (ø25xL100mm) 5-Axis Fixed Stabilizer Extension (ø25xL150mm) 5-Axis Fixed Stabilizer Extension (ø25xL500mm) 5-Axis Fixed Stabilizer Extension (ø25xL250mm) 5-Axis Fixed Stabilizer Extension (ø40xL100mm) 5-Axis Fixed Stabilizer Extension (ø40xL150mm) 5-Axis Fixed Stabilizer Extension (ø40xL250mm) 5-Axis Fixed Stabilizer Extension (ø40xL500mm)

75

.3 .4 .8

100 150 500 250 100 150 250 500

25

M16xP1.5

21

2.6 1.4

.7

1.2 2.2 3.9

40

M27xP2

36

24

STABILIZER SYSTEM

5-AXIS STABILIZER—END CLAMP

Ball Size

Catalog Number

Ball Size

Length (mm)

Description

Thread

SW Weight (lbs.)

Hex 8

15.252.001 15.252.002

5-Axis Stabilizer End Clamp (ø25.4) 5-Axis Stabilizer End Clamp (ø50)

ø25.4

75

M16xP1.5 21

3.4

ø50

92.6

M27xP2

36 TBA

• Ball included

SW

Thread

5-AXIS STABILIZER—BRACKET

3-60mm (W/ M12xL16 SHCS) 60-100mm (W/ M12xL100 SHCS)

79

Ball Size

Catalog Number

Ball Size

Weight (lbs.)

Description

15.252.070 15.252.071

5-Axis Bracket Stabilizer (ø25.4x4) 5-Axis Bracket Stabilizer (ø50x4)

ø25.4

3.4 5.1

ø50

• One ball included; additional balls can be ordered separately

5-AXIS FINE ADJUSTABLE STABILIZER—EXTENSION

Thread

øD1

Thread

øD1

Hex 8

Hex 8

Catalog Number

Length (mm)

øD1 (mm)

Weight (lbs)

Description

Fig.

Thread Wrench (SW)

5-Axis Fine Adjustable Stabilizer Extension (ø25)

15.252.020

1 120-160 25 M16xP1.5 21

2.6

SW

SW

5-Axis Fine Adjustable Stabilizer Extension (ø50)

15.252.021

2 173-213 40 M27xP2

36

3.7

Thread

Thread

Fig. 1

Fig. 2

• Hex nut included

25

STABILIZER SYSTEM

5-AXIS STABILIZER—BALL TO KNOB ADAPTOR

Ball Size

Catalog Number

Ball Size

Length (mm)

Weight (lbs.)

Description

15.252.060 15.252.061

5-Axis Stabilizer Ball to Knob Adaptor (ø25.4 x SBA40) 5-Axis Stabilizer Ball to Knob Adaptor (ø50 x SBA40)

ø25.4

35 24

1.5 2.4

ø50

System 40

ø78

5-AXIS STABILIZER—MOUNTING SCREW

Catalog Number

Length (mm)

Weight (lbs.)

Description

Thread Ball Size

Length

15.252.080 15.252.081 15.252.082 15.252.083 15.252.084 15.252.085 15.252.086 15.252.087 15.252.089

Stabilizer Mounting Screw M12 (ø25.4) Stabilizer Mounting Screw M14 (ø25.4) Stabilizer Mounting Screw M16 (ø25.4) Stabilizer Mounting Screw M18 (ø25.4) Stabilizer Mounting Screw M20 (ø25.4) Stabilizer Mounting Screw M24 (ø25.4) Stabilizer Mounting Screw M24 (ø50) Stabilizer Mounting Screw M30 (ø50) Stabilizer Mounting Screw M36 (ø50)

M12xP1.75

.4 .4 .4 .4 .4 .9

Ball Size

M14xP2 M16xP2

40

ø25.4

M18xP2.5 M20xP2.5

50

M24xP3 M24xP3

50 60 70

1.2 1.3 1.5

M30xP3.5

ø50

M36xP4

• T-nut not included

5-AXIS STABILIZER—BALL AND COLLAR

M10 ø18 H7 +. 0 1 8 0

Fig. 1

Fig. 2

Fig. 3

Catalog Number

Height (mm)

Weight (lbs.)

Fig.

Description

15.252.380 15.252.381 15.252.382 15.252.005

1 2 3

5-Axis Stabilizer Ball and Collar 5-Axis Stabilizer Ball and Collar 5-Axis Stabilizer Ball and Collar

15 15 25

.1 .2 .2 .4

1/2/3

5-Axis Stabilizer Ball and Collar Set (ø25.4)

15 or 25

• Set (15.252.005) contains 1 ball and 3 collars • See Pg. 29 for ø50 balls

26

STABILIZER SYSTEM

5-AXIS STABILIZER—MAGNETIC BASE

Max 45º In All Directions

71

161

64

Fig. 2

Fig. 1

71.9

160

78

Fig. 3

Load Capacity*

Catalog Number

Ball Size

Qty. of Balls

Weight (lbs.)

Description

Fig.

(lbs.)

(kg) 150 150 125 250

15.252.055 15.252.056 15.252.068 15.252.069

5-Axis Stabilizer Magnetic Base 150kg (1x ball, ø25.4) 5-Axis Stabilizer Magnetic Base 150kg (2x ball, ø25.4) 5-Axis Stabilizer Magnetic Base 150kg (1x ball, ø50) 5-Axis Stabilizer Magnetic Base 250kg (1x ball, ø50)

330 330 275 550

1 2 1 1

7.5 7.5

1 2

ø25.4

34.1 34.2

ø50

3

Not for lifting. Do not stand or lift loads overhead. ! CAUTION

• All dimensions are in millimeters • Two balls included with Fig. 2 • Load rating is for flat surfaces; for round surface holding, please consult the BIG KAISER Eng. Dept.

27

MULTI-AXIS SYSTEMS

UNIFLEX SYSTEM 50 The UNIFLEX SYSTEM has expanded to include ø50mm balls and clamping bases. The UNIFLEX SYSTEM 50 BALL is available in two configurations: a location type with a ø25mm removable locating collar and a grip type which has serrations only. The ball is made from hardened steel like that used in industrial bearings. The base is available in two heights: 110mm or 59mm to the center of the ball. The 110mm base also has the ability to be clamped on top of a SYSTEM 40 knob, allowing it to be used with the standard UNILOCK system chuck. Both bases can be easily toe clamped to standard t-slots or grid plates via their flanges. The bases are designed to support 10 tons each; when clamped at 14 ft-lbs, apply 4500 lbs of clamping force. • Grip type should not be used on finished surfaces

28

MULTI-AXIS SYSTEMS

STABILIZER BALL—LOCATION TYPE

ø25 h6 ø22 (ø32.50)

ø24.50 ø17

Catalog Number

Weight (lbs.)

15.252.100

.9

• All dimensions are in millimeters • M16 x L50 SHCS not included

STABILIZER BALL—GRIP TYPE

øD ød

Catalog Number

Screw Size

Weight (lbs.)

ød

øD

h

15.252.101 15.252.102

M16 M12

17 13

24.5 18.5

16.5

.9 .9

13

• All dimensions are in millimeters • Mounting screw not included • This will mare surfaces and should be used with rough surfaces

29

MULTI-AXIS SYSTEMS

UNIFLEX SYSTEM 50—BASE

Ball Size: ø50 (Not Included)

System 40 Knob (Not Included)

HEX 6 (15 Nm 11 ft-lbs)

80

50

ø25 H6 5.50

M12x1.75

M10x1.5

15 (4x)

27.50

Catalog Number

Weight (lbs.)

15.252.200

5.2

• All dimensions are in millimeters • For SYSTEM 40/50 KNOBS; please see UNILOCK Vol. 2, Pg. 64

30

BIG KAISER Precision Tooling Inc. A Member of the BIG DAISHOWA Group 2600 Huntington Blvd | Hoffman Estates, IL 60192 | P: (224) 770-2999 | F: (224) 770-2997 | bigkaiser@us.bigkaiser.com | www.bigkaiser.com

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