Our multi-axis workholding products are designed to provide flexibility and functionality for 5-axis machining and 5-sided machining via multiple part transfers. We also offer solutions for machines with retrofit 4th/5th axis tables. UNILOCK can help you to maximize the benefits of your machine design through efficient workholding.
MODULAR WORKHOLDING SYSTEM VOL. 3
2
OVERVIEW& APPLICATION EXAMPLES
4-9
ROUND CHUCKS
10-25
PREASSEMBLED CHUCKS
26-37
KNOBS, BALLS AND PALLETS
38-51
AUTOMATION CHUCKS
52-61
MULTI-AXIS SYSTEMS
62-93
STABILIZER SYSTEM
94-101
ACCESSORIES & MAINTENANCE
102-111
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. 40 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. 40 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 138A
16-17
ASM 90A
18-19
ASH 120
20-21
ISM 160
22-23
ESM 176A
24-25
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 G1/8"
9.9
P P P P P
P
14 H7 x 1
ACCESSORIES
†Optional • Screws, screw covers and O-ring included
KNOBS PG. 40
AIR FITTINGS PG. 104
DUST COVERS PG. 109
REPAIR PG. 110
12
ROUND CHUCKS
M8 SHCS (6x) Inlcuded (Sholder Screw with Notched Chuck (1x))
53
G1/8" “Turbo” (Clamp) Ships Plugged
Ø121 B.C.
G1/8" “Open” (Unclamp) Ships Plugged
Ø138 0
-.01
Ø109.90
Ø110 0
-.01
Ø8x2 O-Ring Port “Open” (Unclamp)
Ø8x2 O-Ring Port “Turbo” (Clamp)
Ø8x2 O-Ring Port “Confirmation” (Unclamp Confirmation)
• 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
G1/8"
9.9
P P P P P
P
14 H7 x 1
ACCESSORIES
†Optional • Screws, screw covers and O-ring included
KNOBS PG. 40
AIR FITTINGS PG. 104
DUST COVERS PG. 109
REPAIR PG. 110
14
ROUND CHUCKS
14 H7 (9x)
Ø10 H7 Through All
G1/8" BSP Open Port (Ships Plugged)
M8 SHCS (6x)
G1/8" 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 138A 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
15.263.100A 15.263.107A
—
EFM 138A
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. 40
AIR FITTINGS PG. 104
DUST COVERS PG. 109
REPAIR PG. 110
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
G1/8"
5.1
P P
P
12 H7 x 1
ACCESSORIES
†Optional • O-rings included
KNOBS PG. 40
AIR FITTINGS PG. 104
DUST COVERS PG. 109
REPAIR PG. 110
18
ROUND CHUCKS
32.5 39
M5x.8 5.5
G1/8 "Open" (Unclamp) Shipped Plugged
G1/8 "Turbo" (Unclamp) Shipped Plugged
81 Ø84.8 Ø90 0
B
-.01
A
Detail A Scale 1:1 Ø4x1.5 O-Ring (Ships Unplugged)
Detail B Scale 1:1 Ø4x1.5 O-Ring (Ships Unplugged)
Ø0
Ø0
M5x0.8 - 6H
10 (8x)
10 (2x)
• 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. 40
DUST COVERS PG. 109
REPAIR PG. 110
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
G1/8"
12.1
P P P
P
15.300.008
ISM 160 (A2-6)
Ø12 H7 x 2
ACCESSORIES
†Optional • No hardware included
KNOBS PG. 40
AIR FITTINGS PG. 104
DUST COVERS PG. 109
REPAIR PG. 110
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 DAISHOWA 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
G1/8" BSP Open Port (Ships Unplugged)
Ø12 H7 (4x)
12 H7 Through All (2x)
22
G1/8" BSP Turbo Port (Ships Unplugged)
• All dimensions are in millimeters
23
ROUND CHUCKS
ESM 176A 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
15.272.170A 15.272.171A
—
ESM 176A
1,540-1,760 4,180-4,840
G1/8"
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. 40
AIR FITTINGS PG. 104
DUST COVERS PG. 109
REPAIR PG. 110
24
ROUND CHUCKS
M8 SHCS (6x)
C
Detail C
0 -.01
Ø176
B
A
0 -.01
Ø138
G1/8" BSP Turbo Port (Ships Plugged)
G1/8" 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
26
PREASSMBLEDCHUCKS PROVIDES EASY MOUNTING OF THE CHUCKS ERGO138 PREASSEMBLED BASES 28-29 E100A 30 E200A 31 E300A 32 E400A 33-34 E600A 35 E800A 36 E1000A 37
27
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 7.717 7.677 15.551 15.551 15.591 15.591
Height
15.270.370A 15.270.371A 15.270.372A 15.270.373A 15.270.374A 15.270.375A 15.270.376A
6 9
196 396 595 395 596 796 996
149 196 195 395 395 396 396
7.717
1 2 3 4 6 8
15.591 23.425 15.551 23.465 31.339 39.213
10 11 13 14 15
50
1.969
60
2.362
10
ACCESSORIES
• No hardware included • See pg. 14 for ERGO 138 chuck specifics
KNOBS PG. 40
AIR FITTINGS PG. 104
DUST COVERS PG. 109
REPAIR PG. 110
28
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 DAISHOWA Engineering Dept.
29
PREASSEMBLED CHUCKS
E100A
160 199
Ø6mm Tube Fittings (Inlcuded)
70
Ø138
G1/4 "Turbo" (Clamp)
G1/4 "Open" (Unclamp)
Ø12 H7 10 (2x)
Ø12 H7 6 (1x)
Catalog Number 15.270.370A
• All dimensions are in millimeters • For detailed information on additional mounting hole locations, please consult the BIG DAISHOWA Engineering Dept.
30
PREASSEMBLED CHUCKS
E200A
395
Ø14 H7 (5x) Through All
6mm Tube Fittings (Inlcuded)
33
Ø138
Ø138
G1/4 "Open" (Unclamp)
G1/4 "Turbo" (Clamp)
• All dimensions are in millimeters • For detailed information on additional mounting hole locations, please consult the BIG DAISHOWA Engineering Dept.
31
PREASSEMBLED CHUCKS
E300A
596
16
Ø14 H7 (4x) Through All
6mm Tube Fittings (Included)
Catalog Number 15.270.372A
G1/4 "Open" (Unclamp)
G1/4 "Turbo" (Clamp)
• All dimensions are in millimeters • For detailed information on additional mounting hole locations, please consult the BIG DAISHOWA Engineering Dept.
32
PREASSEMBLED CHUCKS
E400A
395
G1/4 Plugs (Inlcuded)
Ø14 H7 (5x) Through All
30
6mm Tube Fittings (Inlcuded)
Ø138
Ø138
G1/4 "Open" (Unclamp)
G1/4 "Turbo" (Clamp)
Catalog Number 15.270.373A
• All dimensions are in millimeters • For detailed information on additional mounting hole locations, please consult the BIG DAISHOWA Engineering Dept.
33
PREASSEMBLED CHUCKS
E400A 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.
34
PREASSEMBLED CHUCKS
E600A
595
Ø6mm Tube Fittings (Inlucded)
50
172.5
Ø138
G1/4 "Open" (Unclamp)
G1/4 "Turbo" (Clamp)
Catalog Number 15.270.374A
• All dimensions are in millimeters • For detailed information on additional mounting hole locations, please consult the BIG DAISHOWA Engineering Dept.
35
PREASSEMBLED CHUCKS
E800A
796
Catalog Number 15.270.375A
+.01 -.01
200 +.01 -.01
+.01 -.01
200
200
Ø138
G1/4 "Open" (Unclamp)
G1/4 "Turbo" (Clamp)
The ERGO E800A 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 DAISHOWA Engineering Dept.
36
PREASSEMBLED CHUCKS
E1000A
996
200 +.01 -.01
200 +.01 -.01
+.01 -.01
+.01 -.01
200
200
Catalog Number 15.270.376A
Ø138
G1/4 "Turbo" (Clamp)
G1/4 "Open" (Unclamp)
The ERGO E1000A 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. 49. • All dimensions are in millimeters • For detailed information on additional mounting hole locations, please consult the BIG DAISHOWA Engineering Dept.
37
38
CLAMPINGKNOBS PROVIDES HIGH ACCURACY LOCATION
OVERVIEW
40
SYSTEM 40 KNOBS
41-43
SYSTEM 25 KNOBS
44-45
SYSTEM 68 KNOBS
46
CLAMPINGBALLS PROVIDES HIGH DEGREE OF FLEXIBILITY
5-AXIS STABILIZER BALLS
47-48
PALLETS PROVIDED FULLY ASSEMBLED
SYSTEM 40 PALLETS
49-51
39
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.
40
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 DAISHOWA 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
41
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 DAISHOWA 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
42
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
43
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. 88 for compatible chucks
44
SYSTEM 25 SHOULDER SCREWS
Hex 8
35 Min.
L 1
L 2
L 3
Catalog Number
Shoulder Diameter
Weight (lbs)
Thread
L 1
L 2
L 3
15.255.425 15.255.426 15.255.427 15.255.428
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
• All dimensions are in millimeters • Other sizes available upon request; please consult BIG DAISHOWA Engineering Dept.
45
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
46
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. 48 for Ø50 balls
47
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
48
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
Pallet Name
Catalog Number
Thickness (mm)
Length (mm)
Width (mm)
Length w/Handles (mm)
#12 H7 of Pin Holes
Weight (lbs)
Material
15.260.540A 15.260.540B 15.260.640A 15.260.640B 15.250.645A 15.260.645A 15.270.546A 15.250.646A 15.270.544A 15.250.644A
0° (1x)
MONO*
SPA200
STEEL
20
199
199
279
9.3
0° & 45° (2x)
0° (1x)
MONO*
APA200
ALUM
25
199
199
279
4.9
0° & 45° (2x)
SAP400 APA400 SPQ300 APQ300 SPQ400 APQ400
STEEL ALUM STEEL ALUM STEEL ALUM
20 25 20 25 20 25
— — — — — —
23.4 11.2 34.4 16.3 61.7 26.5
DUO
399
159
481
TRIO
599
159
681
QUAD
399
399
481
*MONO pallets include Ø12mm pin (1x) and Ø25mm pin (1x); customer to install as needed **For pallet compatibility to older base stations please contact the BIG DAISHOWA Engineering Dept. for assistance
49
KNOBS, BALLS AND PALLETS
SYSTEM 40 MONO PALLET
25 (AL) 20 (ST) 5 (AL) 20 (ST)
199 197 199 197
81 81
10x45º 10x45º
R10 (3x) R10 (3x)
Pallet A Fig. 1 Pallet A Fig. 1
Pallet B Fig. 1.2 Pallet B Fig. 1.2
(279) (279)
SBA40 Knob SBA40 Knob
• Ø12mm pin (1x) and Ø25mm pin (1x); customer to install as needed • For pallet compatibility please contact the BIG DAISHOWA Engineering Dept. for assistance
SYSTEM 40 DUO PALLET
25 (AL) 20 (ST) 5 (AL) 20 (ST)
399 399
10x45º 10x45º
R10 (3x) R10 (3x)
(481) (481)
SBA Knob SBA Knob
SBB Knob SBB Knob
200 +.015 -.015 200 +.015 -.015
Fig. 2 Fig. 2
• All dimensions are in millimeters
50
KNOBS, BALLS AND PALLETS
SYSTEM 40 TRIO PALLET
25 (AL) 20 (ST) 25 (AL) 20 (ST)
599
599
10x45º
R10 (3x) R10 (3x)
10x45º
(681)
(681)
SBA Knob SBA Knob
SBB Knob SBB Knob
SBC Knob SBC Knob
200 +.015 -.015 200 +.015 -.015
+.015 -.015
200
+.015 -.015
200
Fig. 3
Fig. 3
SYSTEM 40 QUAD PALLET
25 (AL) 20 (ST) 25 (AL) 20 (ST)
399
399
SBC Knob (2x) SBC Knob (2x)
38x45º
R35 (3x) R35 (3x)
38x45º
(481)
(481)
SBA Knob SBA Knob
SBB Knob SBB Knob
200 +.015 -.015 200 +.015 -.015
Fig. 4
Fig. 4
• All dimensions are in millimeters
51
52
AUTOMATIONCHUCKS CONFIRM CLAMPING RING/FIXTURE VIA AIR PRESSURE MONITORING ESA 120/70
54-55
ESA 110
56-57
NSA 125
58-59
AUTOMATION PALLET ASSEMBLIES
60
Pallet
Clamping Wedge
Clamping Ring UNILOCK
Piston
Automation Chuck
Confirmation Port (x2)
Base Plate Turbo Port Open Port
L H
L H
Fig. 2
Fig. 1
The clamping chuck has a ground cone projecting out of its base that is used to establish centerline. Elevation is controlled with small raised pads surrounding the cone. They reduce the surface area on which debris and chips can contaminate the positioning and clamping process. The clamping ring resides on the bottom of the pallet, a location that is not prone to collecting contamination when it is being stored in the robot or locked in a UNILOCK chuck. When the chuck is in an open position (Fig. 1), an upward air blast is activated. These air passages project onto the bottom of the clamping ring to assist in the cleaning process. As the pallet nears its final position, the restriction of the upward air flow is redirected onto the contact surface (Fig. 2). The air passages are restricted once the pallet is clamped. This restriction can be measured and used to verify pallet presence.
53
AUTOMATION CHUCKS
ESA 120/70 For Automatic Pallet Loading
Open and turbo functions from the original system and all of the properties from the automation series allow it to be monitored by a control. With the original SYSTEM 40 knobs, it is a more economical option for automatic pallet loading of pre-existing fixtures.
FEATURES • Uses standard knobs • Integrated coolant output
• Reduced ring support with sealing air • Turbo assist for increased holding power
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
15.277.200
ESA 120/70
—
— — — 660-880 1,980-2,200
—
6.3
P P
P
ACCESSORIES
†Optional
KNOBS PG. 40
AIR FITTINGS PG. 104
Detail A Scale 4:1
A
Chip Slot
54
AUTOMATION CHUCKS
M8 SHCS (4x)
Ø118
28
Open
Cleaning
Signal In
Ø10 H7 (4x)
Signal Out
Turbo
25.456 +.01 -.01
+.01 -.01
25.456
• All dimensions are in millimeters • Please consult the BIG DAISHOWA Engineering Dept. for detailed mounting instructions
55
AUTOMATION CHUCKS
ESA 110 For the Verification of a Pallet Can be used as a single or multiple chuck solution. Pallets seal off air passages allowing for the verification of a pallet through back pressure monitoring.
FEATURES • Tapered chuck eases cleaning • Turbo assist clamping option • Air blast cleaning passages
• Air verification of pallet presence • Four elevated support pads
ACCESSORIES
KNOBS PG. 40
AIR FITTINGS PG. 104
Clamping Force (lbs)
Air Connection
Catalog Number
Chuck Model
Weight (lbs)
Spring Only
Turbo Assist* 3,080-3,300
Port Size
Flange
15.277.300
ESA 110
660-880
—
4.8
P
*Sealed pocket required for turbo assist • Screws, screw covers and O-rings included
M6 SHCS (4x) (Optional)
M6 SHCS (4x) (Optional)
CLAMPING RING
A
Ring Type
Catalog Number
A
15.277.030 15.277.031 15.277.032
SRA 110 SRB 110 SRC 110
• Screws included
M6 SHCS
Contact Pads (SRB Only)
+ . 0 1 0
16
M6 SHCS (8x)
0 -.006
Contact Pads (SRB Only)
Section A-A 16 + . 0 1 0
25
• All dimensions are in millimeters
A
0 -.006
25
Section A-A
A
56
AUTOMATION CHUCKS
M6 SHCS (8x)
A
Opening Port (1x) Ø4.2x1.5 O-Ring (1x)
A
Section A-A
39
Side Ports Plugged (5x) Do Not Remove Plugs
15
Confirmation Port (4x) Ø4.2x1.5 O-Ring (4x)
22
25
• All dimensions are in millimeters • Please consult the BIG DAISHOWA Engineering Dept. for detailed mounting instructions
57
AUTOMATION CHUCKS
NSA 125 Air Verification of Pallet Presence Can be used as a single or multiple chuck solution. Pallets seal off air passages allowing for the verification of a pallet through back pressure monitoring.
FEATURES • Tapered chuck eases cleaning • Turbo assist clamping option • Air blast cleaning passages
• Air verification of pallet presence • Two elevated support pads
ACCESSORIES
REPAIR PG. 110
AIR FITTINGS PG. 104
Clamping Force (lbs)
Air Connection
Catalog Number
Weight (lbs)
Description
Spring Only 1,100-1,350
Turbo Assist* 3,300-3,740
Description
Flange
15.277.125
NSA 125
—
7.9
P
*Sealed pocket required for Turbo Assist • Screws, screw covers and O-rings included
CLAMPING RING
Centering Disc
Centering Disc
M8 SHC
Ring Type
Catalog Number
M8 SHCS (4x)
A
A
15.277.001 15.277.002 15.277.003
SRA 125 SRB 125 SRC 125
M6 SHCS (2x)
M6 SHCS (2x)
• Screws included
M8 SHCS (12x)
M8 SHCS (12x)
• All dimensions are in millimeters
+.01 0
+.01 0
11
11
Contact Pads (SRB Only)
Contact Pads (SRB Only)
0 -.008
0 -.008
38
Section A-A 38
Section A-A
58
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