UNILOCK Modular Workholding System Vol. 3

MODULAR WORKHOLDING SYSTEM VOL. 3

2

OVERVIEW& APPLICATION EXAMPLES

4-9

ROUND CHUCKS

10-27

RECTANGULAR CHUCKS

28-33

PREASSEMBLED CHUCKS

34-47

KNOBS, BALLS AND PALLETS

48-61

AUTOMATION CHUCKS

62-71

MULTI-AXIS SYSTEMS

72-107

STABILIZER SYSTEM

108-115

ACCESSORIES & MAINTENANCE

116-125

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 Type Metric Inch SBA .005mm .0002 SBB .005mm .0002 SBC .1mm .004 SBCC .3mm .012 SBCC .6mm .024 SBA = Establishes centerline SBB = Orients about centerline SBC = Clamp only, no positioning • See pg. 50 for more details on knob functions

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 clearance for large parts or out-of-position locations.

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

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

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 preassembled pallets. Shown below are the Mono, Duo and Quad table chucks, along with their pallets. Pneumatic kits are also available to 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

SCHEDULING FLEXIBILITY AND SETUP VERSATILITY 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.

USE IN ANY CONFIGURATION AND PROCESS Applications Are Endless – Limited Only by Your Imagination 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 or contact your tool and fixture provider. UNILOCK can be used in any configuration 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 PARTS Save Money on 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 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 the 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 SBA .005mm .0002 SBB .005mm .0002 SBC .1mm .004 SBCC .3mm .012 SBCC .6mm .024

SBA = Establishes centerline SBB = Orients about centerline SBC = Clamp only, no positioning • See pg. 50 for more details on knob functions

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 for 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 to immediately increase 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. This also eliminates expensive fixtures on subsequent operations.

Before UNILOCK After UNILOCK Set Up Production Set Up Production Savings

Operation

2 hours 9 hours 6 hours 18 hours

Op-10 Lathe 3 hours

4 hours

1 hour

4 hours 2 hours 8 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

9

10

ROUNDCHUCKS FITS A VARIETY OF APPLICATIONS ESM 138A

12-13

ERGO 138

14-15

EFM 138

16-17

ASM 90A

18-19

ASH 120

20-21

ISM 160

22-23

ESM 176

24-25

HSM 196

26-27

11

ROUND CHUCKS

ESM 138A Air-Assisted Clamping Turbo Chuck With an air assisted clamping turbo function. It also has improved retention force with a new slide wedge actuation. This is accomplished by covering the piston with a sealed cover plate.

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

Catalog Number

Notch (Width x Qty)

Weight (lbs)

Description

M10 M12 M16 M20† M24† Spring Only Turbo Assist Port Size Flange

15.270.140A 15.270.147A

ESM 138A

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

1/8

9.9

P P P P P

P

14 H7 x 1

ACCESSORIES

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

DUST COVERS PG. 122

REPAIR PG. 123

KNOBS PG. 49

AIR FITTINGS PG. 118

12

ROUND CHUCKS

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

13

ROUND CHUCKS

ERGO 138 A Space Saving Chuck A chuck height of 28mm, a height 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

• Same mounting bolt hole pattern • Same flange air port location • Increased inner support ring diameter • Knee locking mechanism

• Optional timing notch in face of chuck • Same body and location diameters

unclamped

clamped

UNCLAMPED

CLAMPED

Available with Notches

Recommended Bolt Sizes

Clamping Force (lbs)

Air Connection

Catalog Number

Notch (Width x Qty)

Weight (lbs)

Description

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

1/8

9.9

P P P P P

P

14 H7 x 1

ACCESSORIES

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

KNOBS PG. 49

AIR FITTINGS PG. 118

DUST COVERS PG. 122

REPAIR PG. 123

14

ROUND CHUCKS

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

M7

Ø12

Open Port

M5 Port for Drain or Cleaning (Ships Plugged)

Turbo Port

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

15

ROUND CHUCKS

EFM 138 Suited For Thinner Walled Tombstones Flange mount chuck is easily mounted in custom fixtures due to the reduced projection height.

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

Available with Notches

Recommended Bolt Sizes

Clamping Force (lbs)

Air Connection

Catalog Number

Notch (Width x Qty)

Weight (lbs)

Description

M10 M12 M16 M20† M24† Spring Only Turbo Assist

Port Size Flange

15.263.100 15.263.107

EFM 138

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

8

P P P P P

P

14 H7 x 1

ACCESSORIES

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

KNOBS PG. 49

AIR FITTINGS PG. 118

DUST COVERS PG. 122

REPAIR PG. 123

16

ROUND CHUCKS

M8 Low Head SHCS (6x)

C

Detail C

0 -.01

138

B

A

Ø109.3

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

17

ROUND CHUCKS

ASM 90A For Smaller Applications As one of the smallest chucks, the UNILOCK ASM 90A chuck is for use 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

Catalog Number

Notch (Width x Qty)

Weight (lbs)

Description

M10 M12 M16 M20† M24† Spring Only Turbo Assist

Port Size Flange

15.240.090A 15.240.091A

ASM 90A

— — — 550-660

1,540-1,760

1/8

5.1

P P

P

12 H7 x 1

ACCESSORIES

†Optional • O-rings included

KNOBS PG. 49

AIR FITTINGS PG. 118

DUST COVERS PG. 122

REPAIR PG. 123

18

ROUND CHUCKS

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

19

ROUND CHUCKS

ASH 120 Same Diameter and Height as the Original UNILOCK ASM120 The UNILOCK ASH 120 is the same diameter and height as the UNILOCK ASM 120 but has a new clamping actuation system. Rather than the handle rotating 180º about the axis of the pin, the wrench swings 90º about the axis of the chuck.

WRENCH Comes with a wrench for easy opening and closing. The wrench swings 90º about the axis of the chuck.

Catalog Number

Description

15.270.170.1 15.270.170.2

Wrench (red)

Safety Wrench with Spring (blue)

Recommended Bolt Sizes

Clamping Force (lbs)

Catalog Number

Notch (Width x Qty)

Weight (lbs)

Description

M10

M12

M16

M20†

M24†

Manual Only

15.270.170 15.270.177

ASH 120

1,760-2,200

8.8

P

P

14 H7 x 1

ACCESSORIES

†Optional

KNOBS PG. 49

DUST COVERS PG. 122

REPAIR PG. 123

HOW IT WORKS

Clamping Knob

Chuck Body

Clamping Pin

Scroll

OPEN

CLAMPED

20

ROUND CHUCKS

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 • Dimensions marked are for notch option

21

ROUND CHUCKS

ISM 160 For the Face of 4th and 5th Axis Rotary Tables

A single chuck solution for the face of 4th and 5th axis rotary tables. Exterior timing features are comparable with the UNILOCK MCM 150 & UNILOCK 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

Slot Allows for Variations in Radial Pin Location

Recommended Bolt Sizes

Clamping Force (lbs)

Air Connection

Catalog Number

Notch (Width x Qty) Ø14 H7 x 1 Ø12 H7 x 4

Weight (lbs)

Description

M10 M12 M16 M20† M24† Spring Only Turbo Assist

Port Size Flange

15.260.160

ISM 160

— — 1,100-1,540 3,300-3,740

1/8

12.1

P P P

P

15.300.008

ISM 160 (A2-6)

Ø12 H7 x 2

ACCESSORIES

†Optional • No hardware included

KNOBS PG. 49

AIR FITTINGS PG. 118

DUST COVERS PG. 122

REPAIR PG. 123

ADAPTER PLATE For ISM 160 to HAAS 160/210 Size Indexers and Trunnions

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

Catalog Number

Indexer Model

Description

15.260.164 15.260.166

HAAS 160 HAAS 210

ISM 160

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

22

ROUND CHUCKS

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

23

ROUND CHUCKS

ESM 176 For Handling Heavyweight Fixtures Excels in handling heavyweight fixtures, due to its size and and higher retention force.

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

Catalog Number

Notch (Width x Qty)

Weight (lbs)

Description

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

1/8

17.5

P P P P P

P

25 H6 x 1

ACCESSORIES

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

KNOBS PG. 49

AIR FITTINGS PG. 118

DUST COVERS PG. 122

REPAIR PG. 123

24

ROUND CHUCKS

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

25

ROUND CHUCKS

HSM 196 Work Can Pass Through 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

Catalog Number

Notch (Width x Qty)

Weight (lbs)

Description

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

1/8

19.3

P

P

ACCESSORIES

†Optional • Screws, screw covers, O-rings and timing bushing included • See pg. 55 for M74 option

KNOBS PG. 49

AIR FITTINGS PG. 118

DUST COVERS PG. 122

REPAIR PG. 123

26

ROUND CHUCKS

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

(Not for Location)

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

27

28

RECTANGULARCHUCKS SUITED FOR MONO-CHUCK APPLICATIONS AFM 105/65 30-31 ESM 180/150 32-33

29

RECTANGULAR CHUCKS

AFM 105/65 For Small Footprints 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 indexing (4x) • Elevated for 5-axis accessibility

Recommended Bolt Sizes

Clamping Force (lbs)

Air Connection

Catalog Number

Notch (Width x Qty)

Weight (lbs)

Description

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

1/8

6.3

P P

P

12 H6 x 2

ACCESSORIES

†Optional • No hardware included

KNOBS PG. 49

AIR FITTINGS PG. 118

DUST COVERS PG. 122

30

RECTANGULAR CHUCKS

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 (3x) Through All

55

• All dimensions are in millimeters

31

RECTANGULAR CHUCKS

ESM 180/150 For Large Part Manufacturing

Uses the UNILOCK 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

Recomneded Bolt Size

Clamping Force (lbs)

Air Connection

Catalog Number

Notch (Width x Qty)

Weight (lbs)

Description

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

1/8

26.5

P

P

ACCESSORIES

KNOBS PG. 49

SYSTEM 68 PG. 101

AIR FITTINGS PG. 118

32

RECTANGULAR CHUCKS

180

125

M12 SHCS (4x)

1/8 BSP Turbo Port (Ships Unplugged)

1/8 BSP Open Port (Ships Unplugged)

A

B

Ø124.70

Ø12 M5

Ø125 h6

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

33

34

PREASSMBLEDCHUCKS PROVIDES EASY MOUNTING OF THE CHUCKS ERGO138 PREASSEMBLED BASES 36-37 E100 38 E100 V1 39 E100 V2 40 E200 41 E300 42 E400 43-44 E600 45 E800 46 E1000 47

35

PREASSEMBLED CHUCKS

ERGO138 PREASSEMBLED BASES Preassembled Double Table Chucks Base stations with the ERGO 138 chuck save 11mm of height compared to ESM 138. Available with turbo out of the box.

FEATURES • 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 7.480 7.717 7.677 15.551 15.551 15.591 15.591

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

149 190 190 196 195 395 395 396 396

7.717 9.448 9.448

1 1 1 2 3 4 6 8

50

15.591 23.425 15.551 23.465 31.339 39.213

1.969

10 11 13 14 15

60

2.362

10

ACCESSORIES

• No hardware included • See pg. 14 for ERGO 138 chuck specifics

KNOBS PG. 49

AIR FITTINGS PG. 118

DUST COVERS PG. 122

REPAIR PG. 123

36

PREASSEMBLED 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 Engineering Dept.

37

PREASSEMBLED CHUCKS

E100

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 H7 10 (2x)

Catalog Number 15.270.370

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 Engineering Dept.

38

PREASSEMBLED CHUCKS

E100 V1

240 205

Timing Block 15.270.331 (Sold Separately)

Ø138

All Holes are Coverd

Ø18 H7 +. 0 1 8 0

6.5 (8x)

(Ships with Cover)

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

G1/4 Turbo

G1/4 Open

Ø12 H7 10

Ø12 H7 6

62 ±.01

Catalog Number 15.270.370.1

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

39

PREASSEMBLED CHUCKS

E100 V2

240 205

Timing Block 15.270.331 (Sold Separately)

Ø138

55

A

All Holes are Coverd

Ø18 H7 +. 0 1 8 0

6.5 (8x)

(Ships with Cover)

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

Detail A Scale 1:1

G1/4 Open

G1/4 Turbo

Ø12 H7 6

Ø12 H7 10

62 ±.01

Catalog Number 15.270.370.2

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

40

396

PREASSEMBLED CHUCKS

370 +.01 -.01 200 +.01 -.01

E200

396

370 +.01 -.01 200 +.01 -.01

Ø14 H7 (5x) Through All

Ø14 H7 (5x) Through All

Ø138

Ø138

Ø138

Ø138

1/4G Open (4x)

1/4G Turbo (4x)

1/4G Open (4x)

1/4G Turbo (4x)

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

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

Catalog Number 15.270.371

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

41

PREASSEMBLED CHUCKS

E300

595

+.01 -.01

200 +.01 -.01

200

100 +.01 -.01

+.01 -.01

100

14 H7 (4x) Through All

Ø138

Ø138

Ø138

Catalog Number 15.270.372

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

42

PREASSEMBLED CHUCKS

E400

395

200 +.01 -.01 320 +.01 -.01

Ø14 H7 (5x) Through All

Ø138

Ø138

1/4G Turbo

1/4G Open

Catalog Number 15.270.373

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

43

PREASSEMBLED CHUCKS

E400 The ERGO E400 base stations shown above are mounted together for a master reference system on the table of 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" (.005mm) of their original location.

44

PREASSEMBLED CHUCKS

E600

595

280 +.01 -.01

+.01 -.01

280

200 +.01 -.01

+.01 -.01

200

Ø14 H7 (3x) Through All

Ø138

1/4G Turbo

1/4G Open

Catalog Number 15.270.374

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

45

PREASSEMBLED CHUCKS

E800

796

Catalog Number 15.270.375

+.01 -.01

200 +.01 -.01

+.01 -.01

200

200

Ø138

1/4G Turbo

1/4G Open

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

46

PREASSEMBLED CHUCKS

E1000

996

200 +.01 -.01

200 +.01 -.01

+.01 -.01

+.01 -.01

200

200

Catalog Number 15.270.376

Ø138

1/4G Turbo

1/4G Open

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. See pg. 59. • All dimensions are in millimeters • For detailed information on additional mounting hole locations, please consult the BIG KAISER Engineering Dept.

47

48

CLAMPINGKNOBS PROVIDES HIGH ACCURACY LOCATION

OVERVIEW

50

SYSTEM 40 KNOBS

51-53

SYSTEM 25 KNOBS

54

SYSTEM 90 KNOBS

55

SYSTEM 68 KNOBS

56

CLAMPINGBALLS PROVIDES HIGH DEGREE OF FLEXIBILITY

5-AXIS STABILIZER BALLS

57-58

PALLETS PROVIDED FULLY ASSEMBLED

SYSTEM 40 PALLETS

59-61

49

KNOBS, BALLS AND PALLETS

CLAMPING KNOBS Can be attached to fixtures or directly to workpieces. Our standard knobs can be mounted in a blind hole from the bottom or pulled up from the top. Standard clamping knobs accept the following: OPTION 1: PASS-THROUGH BOLT – The bolt is inserted past the clamping knob and threads into the workpiece or fixture. OPTION 2: CAPTIVE SET SCREW – The set screw is captivated between the knob and the workpiece or fixture. OPTION 3: RETAIN FROM TOP – The bolt passes through the workpiece or fixture and pulls the knob into position.

OPTION 1: PASS-THROUGH BOLT

OPTION 2: CAPTIVE SET SCREW

OPTION 3: RETAIN FROM TOP

Option 2 not recommended for B Type. ! CAUTION

Standard clamping knobs have a metric positioning boss which is Ø25mm and ground to a fit of h6. This boss is 5mm tall. The overall measurements of the clamping knob is Ø40mm by 40mm 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" (.005mm).

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.

50

KNOBS, BALLS AND PALLETS

35

SYSTEM 40 KNOBS

Ø25 H7 +. 0 2 1 0

35 Contact Pads (B Type Only)

35

5

A

Ø25 H7 +. 0 2 1 0

Ø25 H7 +. 0 2 1 0

Contact Pads (B Type Only)

Contact Pads (B Type Only)

5

5

A

A

35

35

Ø25 H7 +. 0 2 1 0

Ø25 H7 +. 0 2 1 0

Contact Pads (B Type Only)

Contact Pads (B Type Only)

5

5

A

A

Hex

A

Hex

Hex

Section A-A

A

A

Hex

Hex

A

A

Knob Type

Catalog Number

Repeatability (in)

Internal Thread

Pass-Through Bolt Size

Description

Hex

15.260.300 15.260.301 15.260.302 15.260.303 15.260.304 15.260.400 15.260.401 15.260.402 15.260.500 15.260.501 15.260.502

A B C

SBA—Absolute Position

.0002 .0002 .0040 .0120 .0240 .0002 .0002 .0040 .0002 .0002 .0040

M12 M12 M12 M12 M12 M16 M16 M16 M20 M20 M20

M10 M10 M10 M10 M10 M12 M12 M12 M14 M14 M14

10mm 10mm 10mm 10mm 10mm 17mm 17mm 17mm 17mm 17mm 17mm

SBB—Orientation

SBC—Undersized .1mm—Downward Clamping Only SBCC—Undersized .3mm—Downward Clamping Only SBCC—Undersized .6mm—Downward Clamping Only

CC CC

A B C A A A

SBA—Absolute Position

SBB—Orientation

SBC—Undersize .1mm SBA—Absolute Position

SBB—Orientation

SBC—Undersize .1mm

• For inch options please consult the BIG KAISER Engineering Dept. • All dimensions are in millimeters

SYSTEM 40 T-SLOT KNOBS

Thread

Thread

Thread

T-Slot

T-Slot

T-Slot

Thread

Thread

T-Slot

T-Slot

Knob Type

Catalog Number

Repeatability (in)

Description

Thread

T-Slot

15.250.360 15.250.361 15.250.366 15.250.367 15.250.362 15.250.363 15.250.364 15.250.365

A C A C A C A C

SBA—Absolute Position SBC—Undersized .3mm SBA—Absolute Position SBC—Undersized .3mm SBA—Absolute Position SBC—Undersized .3mm SBA—Absolute Position SBC—Undersized .3mm

.0002 .0040 .0002 .0004 .0002 .0040 .0002 .0040

M10xP1.5 M10xP1.5 M12xP1.75 M12xP1.75 M12xP1.75 M12xP1.75 M12xP1.75 M12xP1.75

14mm 14mm 16mm 16mm 18mm 18mm 22mm 20mm

• T-nuts and fasteners are included • Inch t-slot versions available upon request • All dimensions are in millimeters

51

Hex 10

Ø12 H6 +. 0 11 0

SYSTEM 40 Pass-Through Ø12mm Screw

Thread G

hread G

Thread G

KNOBS, BALLS AND PALLETS

12

L 1

L 2

SYSTEM 40 PASS-THROUGH Ø12MM KNOBS AND SCREWS

Hex 10

Ø12 H6 +. 0 11 0

Ø12 H6 +. 0 11 0

SYSTE Pass- Ø12m

Thread G

Thread G

Thread G

Screw

Knob

SYSTEM 40 Pass-Through Ø12mm Knob

Ø18.5

Ø12 H6

Knob Type SBA SBB

Knob Catalog Number

15.250.317 15.250.318 15.250.319

Screw

SBA

Knob

Ø18.5

12.5

L 1

12

L 1

L 2

L 2

Ø16 H6 +. 0 11 0

Hex 14

Hex 10

Thread G

read G

Thread G

SYSTEM 40 Pass-Through Ø12mm Screw

12.5 SYSTEM 40 Pass-Through Ø16mm Screw

L 1

L 2

Screw Catalog Number

ØD 1

Thread (G)

L 1

L 2

L 3

L 4

Ø16 H6 +. 0 11 0

15.250.540 15.250.541

12 12

M12xP1.75 M12xP1.75

50.0

22.0 22.0

30.0 35.0

8.0

Ø16 H6 +. 0 11 0

Hex 14

Thread G Ø12 H6 +. 0 11 0 55.0

13.0

Thread G

Thread G

SYSTEM Pass-Thr Ø16mm S

• All dimensions are in millimeters • Other sizes available upon request; please consult the BIG KAISER Engineering Dept.

Screw

Knob

SYSTEM 40 Pass-Through Ø16mm Knob

Ø21

SYSTEM 40 Pass-Through Ø12mm Knob

Ø18.5

Ø16 H6 +. 0 1 0

Screw

Knob

Ø21

12.5

L 1

L 2

52

Hex 14

SYSTEM 40 Pass-Through

Ø16 H6 +. 0 11 0

Hex 14

Hex 10

Thread G

Thread G

Thread G

SYSTEM 40 Pass-Through Ø12mm Screw

SYSTEM 40 Pass-Through Ø16mm Screw

KNOBS, BALLS AND PALLETS

12.5

L 1

L 2

SYSTEM 40 PASS-THROUGH Ø16MM KNOBS AND SCREWS

Ø16 H6 +. 0 11 0

Ø16 H6 +. 0 11 0

Hex 14

Ø12 H6 +. 0 11 0

Thread G

Thread G

Thread G

SYSTEM Pass-Thr Ø16mm S

Screw

Knob

SYSTEM 40 Pass-Through Ø16mm Knob

Ø21

SYSTEM 40 Pass-Through Ø12mm Knob

Ø18.5

Ø16 H6 +. 0 1 0

Knob Type SBA SBB

Knob Catalog Number

15.250.307 15.250.308 15.250.309

Screw

SBC

Knob

Ø21

12.5

L 1

L 2

Hex 14

SYSTEM 40 Pass-Through Ø16mm Screw

Screw Catalog Number

ØD 1

Thread (G)

L 1

L 2

L 3

L 4

15.250.520 15.250.521 15.250.529 15.250.530 15.250.533

16 16 16 16 16

M16xP2 M16xP2

Ø16 H6 +. 0 11 0 55.0

25.0 24.0 18.0

35.0 23.5 17.5

10.0

43.5 37.5 28.0 28.0

— — — —

M12xP1.75 M12xP1.75 M10xP1.5

— —

8.0 8.0

• All dimensions are in millimeters

SYSTEM 40 Pass-Through Ø16mm Knob

Ø21

53

KNOBS, BALLS AND PALLETS

SYSTEM 25 KNOBS

M10 SHCS

19.5

Contact Pads (B Type Only)

A

5

Section A-A Scale 1:1

A

M8 C-Sink Cap Screw

Fig. 1

Thread

Thread

Ø10.5

Ø12 G6 +.017 +.006

Ø16

Fig. 3

Fig. 2

Knob Type

Catalog Number

Location Diameter

Internal Thread

Pass-Through Thread

Weight (lbs)

Description

Hex

Fig.

15.255.400 15.255.401 15.255.402 15.255.410 15.255.411 15.255.412 15.255.420 15.255.421 15.255.542

A B C A B C A B C

SPA25—Absolute Position

SPB25—Orientation

Ø18 h6

M10

M8

8

1

.11

SPC25—Undersized .1mm SPA25—Absolute Position

SPB25—Orientation

Ø18 h6

M8

— 2

.11

SPC25—Undersized .1mm

SPA25—Absolute Position (Thru Bore)

Ø12 G6

M8/M10/M12

— 3

.11

SPB25—Orientation (Thru Bore)

SPC25—Undersized .1mm (Thru Bore)

• All dimensions are in millimeters • See pg. 98 for compatible chucks

SYSTEM 25 SHOULDER SCREWS

Catalog Number

Shoulder Diameter

Weight (lbs)

Thread

L 1

L 2

L 3

Hex 8

35 Min. 15.255.427 15.255.428 15.255.425 15.255.426

28.0 17.5 14.5 11.5

45.7 35.7 32.7 29.7

M12xP1.75

Ø12 h5

14.4

.04

M10xP1.5 M8xP1.25

L 1

L 2

L 3

• All dimensions are in millimeters • Other sizes available upon request; please consult BIG KAISER Engineering Dept.

54

KNOBS, BALLS AND PALLETS

SYSTEM 90 KNOBS

55

5

5

5

HSR Form

35

20

35

HSI Form

HSF Form

Knob Type

Catalog Number

Description

Undersize

15.274.300 15.274.303 15.274.301 15.274.303

A B A A

HSI 90—SBA HSI 90—SBB HSF 90—SBA HSR 90—SBA

.0002 .0002 .0002 .0002

• All dimensions are in millimeters • See pg. 26 for HSM 196 chuck

55

KNOBS, BALLS AND PALLETS

SYSTEM 68 KNOBS

ØD H7 Thread Thread ØD H7

Ød Ød

Knob Type Knob Type

Fig. 1 Fig. 1

Bolt Size Bolt Size

Thread ØD H7 Thread ØD H7

M24xP3 M24xP3

Ød h6 Ød h6

ØD H7 ØD H7

Knob Type Knob Type

Ø35 Ø35

Fig. 2 Fig. 2

Hex 10mm Hex 10mm

Knob Type

Catalog Number

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—Absolute Position

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

SBB—Orientation

SBC—Retention Only SBA—Absolute Position

SBB—Orientation

SBC—Retention Only SBA—Absolute Position

SBB—Orientation

SBC—Retention Only SBA—Absolute Position

SBB—Orientation

SBC—Retention Only

• All dimensions are in millimeters

56

KNOBS, BALLS AND PALLETS

5-AXIS STABILIZER BALL TO KNOB ADAPTOR

Ball Size

Catalog Number

Ball Size

Length (mm)

Weight (lbs)

Description

15.252.060 15.252.061

SBA40 SBA40

Ø25.4

35 24

1.5 2.4

Ø50

SYSTEM 40

Ø78

5-AXIS STABILIZER BALL MOUNTING SCREW

Catalog Number

Ball Size

Length (mm)

Weight (lbs)

Thread

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

M12xP1.75

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

Ball Size

M14xP2 M16xP2

Hex Nut

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

15 15 25

.1 .2 .2 .4

5-Axis Stabilizer Ball and Collar with Locating Pilot 5-Axis Stabilizer Ball and Collar with Locating Pilot 5-Axis Stabilizer Ball and Collar Set (Ø25.4)

1/2/3

15 or 25

*Set includes 1 ball and 3 collars • See pg. 58 for Ø50 balls

57

ø22

KNOBS, BALLS AND PALLETS

5-AXIS STABILIZER BALL LOCATION TYPE

ø25 h6 ø22 (ø32.50)

ø24.50 ø17

ø24.50 ø17

Catalog Number

Weight (lbs)

15.252.100

.9

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

5-AXIS 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

øD ød

58

KNOBS, BALLS AND PALLETS

SYSTEM 40 PALLETS Preassembled with Knobs and Handles Pallets are provided fully assembled with their required quantity of UNILOCK knobs and lifting handles, and are available in either steel or aluminum. SYSTEM 40 MONO PALLET The UNILOCK ESM 138 chuck accepts a 14mm key or pin. The UNILOCK ESM 176 chuck accepts a 25mm key or pin.

CAN BE CONFIGURED FOR THE FOLLOWING CHUCKS • ESM/EFM/ERGO 138 • MLM/MCM 150 • ISM 160

• MSM 170 • ESM 176 TURBO • DC 200

SYSTEM 40 DUO & QUAD PALLET Duo and Quad pallets with load on the UNILOCK QC 400 or any set of chucks on 200mm spacing. Can be configured for the UNILOCK ERGO base stations While loading and unloading work into the fixture, the holes in the bottom of the pallet mate to setup plates that stabilize the pallet for safe operation outside of a UNILOCK chuck.

Pallet Type Mono Mono Mono Mono

Pallet Name

Catalog Number

Thickness (mm)

Length (mm)

Width (mm)

Length w/ Handles (mm)

Timing Pin Pitch T (mm)

Pin Dia. ØD (mm)

Weight (lbs)

Material

15.260.640 15.260.540 15.260.667 15.260.645 15.270.640 15.270.540 15.270.545 15.270.645 15.270.644

AP200 SP200

Aluminum

25 20 25 25 25 20 25 20 25

199 199 199 199 399 399 599 599 399

199 199 199 199 199 199 159 159 399

266 266 266 266 470 470 681 681 470

81 81 61 76 — — — — —

12 12 14 25 — — — — —

6.6

Steel

15.4

AP200-138 AP200-176

Aluminum Aluminum Aluminum

6.6 6.6

Duo Duo Trio Trio

AP400 SP400 AP300 SP300

13.2 30.8 34.3 16.3 26.4

Steel

Aluminum

Steel

Quad

AP400x400

Aluminum

SYSTEM 40 PALLET STAND Used to stabilize a pallet while it is being worked on outside of the machine.

Stand Type

Catalog Number

15.260.800

Mono

Duo

15.270.800

Quad

59

KNOBS, BALLS AND PALLETS

SYSTEM 40 MONO PALLET

ØD m6 ØD m6

25 (Aluminum) 20 (Steel) 25 (Aluminum) 20 (Steel)

199 199

SBA40 Knob SBA40 Knob

SYSTEM 40 DUO PALLET

399 200 ±.015 399 200 ±.015

25 (Aluminum) 20 (Steel) 25 (Aluminum) 20 (Steel)

SBA Knob SBA Knob

SBB Knob SBB Knob

• All dimensions are in millimeters

60

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