液压夹具设计手册

1、液压夹具设计手册液压夹具设计手册 思诚机电 2 Good Fixture Design Good fixtures position, clamp and support workpieces in the most effective way possible 3 Fixture design, workpiece Example 1 4 Fixture design, process 5 Datum Fixture design, workpiece datums 6 Fixture design, supporting 7 Fixture design, positioning 8 Fi

2、xture design, clamping 9 Fixture design, additional support and clamping 10 Fixture, positioning, supporting and clamping 11 Fixture design, workpiece, Example 2 12 Fixture design, process 13 Fixture design, supporting 14 Fixture design, clamping X X 15 Fixture design, clamping Datum 16 Fixture desi

3、gn, positioning and clamping 17 Fixture design, positioning, supporting & clamping 18 Friction clamping If clamping using friction only it must be remembered that the coefficient of friction () is normally calculated at 0.1 Clamping force F Reaction force Total clamping force = F x Clamping force F

4、Reaction force Total clamping force = F Clamping force F 2-30 from horizontal Preferable 19 Friction clamping If clamping using friction only it must be remembered that the coefficient of friction () is normally calculated at 0.1 This can be improved on soft materials (eg. Al) if the clamping piston

5、 has enough force to penetrate the workpiece 20 Fixture design DEFINITION OF A CLAMPING FORCE The force acting on a workpiece to be clamped, is large enough to hold the workpiece firmly in its given position relative to the cutting tool, against the action of the machining forces 21 Fixture design C

6、LAMPING FORCES Mechanical low cost, relatively low forces Pneumatic higher cost, relatively low forces, large components Hydraulic higher initial cost, high forces, reliable, small components 22 Mechanical Forces Maximum clamping force using standard wrench Clamping force (kN) Clamping force with ex

7、tension pieces as shown, 500N torque, = 0.1 23 Standard clamping strap M20 thread Max. recommended torque 223Nm Max. clamping force 28kN Hydraulic swing clamp 6951F-11-21 (page 63, metric catalogue) 22 rod, 76mm long arm Max. oil pressure 23 MPa Clamping force 7.3kN Force comparison 24 Force compari

8、son Standard clamping strap M20 thread Max. recommended torque 223Nm Max. clamping force 28kN Hydraulic swing clamp 6951F-11-21 (page 63, metric catalogue) 22 rod, clamping strap Max. oil pressure 35 MPa Clamping force 13.7kN 25 Standard clamping strap M24 thread Max. recommended torque 383Nm Max. c

9、lamping force 40kN Hydraulic swing clamp 6951FN-33-21 (page 71, metric catalogue) 38 rod, clamping strap Max. oil pressure 35 MPa Clamping force 35kN Force comparison 26 Standard clamping strap M24 thread Max. recommended torque 383Nm Max. clamping force 40kN Hollow piston cylinder 6921-100 x10 (pag

10、e 26, metric catalogue) M24 thread Max. oil pressure 400 bar Clamping force 101kN Force comparison 27 Mechanical or Hydraulic ? 28 Mechanical or Hydraulic ? 50 MPa Sequence Valve 47-0440-02 (J-3) Set at 30 MPa Cartridge Mount Cylinder (x8) 42-1010-04 (page F-12) 2.5 kN each 50MPa Threaded Cylinder 4

11、2-0010-06 (page F-4) 3.4 kN 30 MPa 5.7 kN 50 MPa 29 Force diagram 30 MPa 50 MPa Sequence valve opens Workpieces Movement of cylinder Oil pressure 30 Component & Fixture design SENSIBLE USE OF FORCE Sensible introduction of positioning, clamping and supporting forces will enhance the quality of a wor

12、kpiece 31 Oil supply to fixtures 2 basic methods through pipes through gun drilled channels Method depends on cost target complexity of fixture products being used 32 Oil supply to fixtures, cost comparison A:Through pipes using flange type clamps B:Through pipes using threaded type clamps C:Through

13、 gun drilled channels & manifold mounted type clamps D:Through gun drilled channels & threaded body type clamps 33 Oil supply to fixtures, cost comparison A: Through pipes using flange type clamps Relatively easy to manufacture Fittings weakest part of system Chip traps Control fixture COST 100% 34

14、Oil supply to fixtures, cost comparison B: Through pipes using threaded type clamps Less swarf traps Reduces machining area Fittings weakest part of system COST ?% against control fixture 35 Oil supply to fixtures, cost comparison C: Through gun drilled channels & manifold mounted type clamps Maximu

15、m component density Minimum swarf traps COST ?% against control fixture 36 Oil supply to fixtures, cost comparison D: Through gun drilled channels & threaded body type clamps Maximum component density Minimum swarf traps COST ?% against control fixture 37 Oil supply to fixtures, cost comparison C: T

16、hrough gun drilled channels & manifold mounted type clamps 98% B:130% D:104% A:100% Hydraulic circuit design 39 Circuit design 40 Cam Cover fixture example 41 Circuit design 1 4 3 2 6 8 10 7 9 ILMOR ENGINEERING LTD Q3/22153 DIA 10 POLYURETHANE DIA 10 POLYURETHANE 1/4 BORE HOSE 5 315 24 1010 10101010

17、 1010 1010 10 10 1010 12 11 13 13 190355AIR PREPARATION SET1290079PUSH/PULL VALVE1396324PRESSURE SWITCH14GD63G040-600BARGAUGE1596054QUICK COUPLING1690041QUICK EXHAUST VALVE17U-3/8SILENCER18A82208BOOSTER19A96212BLEED UNIT1101458-001THREADED BODY CYLINDER15112954-420SEQUENCE VALVE11270009TEE MANIFOLD1

18、131913-010WORK SUPPORT2ITEMPART NUMBERDESCRIPTIONQTY DIA 8x1.5 STEEL ALL DIMENSIONS IN MILLIMETRES THIS DOCUMENT IS CONFIDENTIAL AND IS THE PROPERTY OF AC HYDRAULICS LTD. THE DOCUMENT AND ANY INFORMATION THEREIN MAY NOT BE USED, COPIED OR DISCLOSED TO ANY THIRD PARTY WITHOUT PRIOR WRITTEN AUTORISATI

19、ON OF AC HYDRAULICS LTD. 48 KENILWORTH DRIVE, OADBY INDUSTRIAL ESTATE, A C HYDRAULICS LTD ACH OADBY, LEICESTER. LE2 5LG TELEPHONE 0116 2710561 DRAWN CHECKED TITLE ISSUEDRG No. SHEETOF NONE - ORIGINAL1 MAC29:5:20001 11OCAQUOTE CIRCUIT FOR CAM COVER FIXTURE IMPORTANT NOTICE 1. The air supply to this s

20、ystem must be clean and free of water and lubricated where necessary. 2. All hydraulic pipework and fittings must be thoroughly flushed out and free of swarf before fitting to the system. 3. All equipment must be subjected to periodic inspection to ensure safe operation. Where there is any doubt abo

21、ut the safe use of our equipment, consult BS 5304 (1988) Code of Practice For Safety of Machinery. 4. Where the setting of pressure control valves is not specified on the drawing, consult the manufacturers Technical Specification. 42 1 4 3 2 6 8 10 7 9 ILMOR ENGINEERING LTD Q3/22153 DIA 10 POLYURETH

22、ANE DIA 10 POLYURETHANE 1/4 BORE HOSE 5 315 24 1010 10101010 1010 1010 10 10 1010 12 11 13 13 190355AIR PREPARATION SET1290079PUSH/PULL VALVE1396324PRESSURE SWITCH14GD63G040-600BARGAUGE1596054QUICK COUPLING1690041QUICK EXHAUST VALVE17U-3/8SILENCER18A82208BOOSTER19A96212BLEED UNIT1101458-001THREADED

23、BODY CYLINDER15112954-420SEQUENCE VALVE11270009TEE MANIFOLD1131913-010WORK SUPPORT2ITEMPART NUMBERDESCRIPTIONQTY DIA 8x1.5 STEEL ALL DIMENSIONS IN MILLIMETRES THIS DOCUMENT IS CONFIDENTIAL AND IS THE PROPERTY OF AC HYDRAULICS LTD. THE DOCUMENT AND ANY INFORMATION THEREIN MAY NOT BE USED, COPIED OR D

24、ISCLOSED TO ANY THIRD PARTY WITHOUT PRIOR WRITTEN AUTORISATION OF AC HYDRAULICS LTD. 48 KENILWORTH DRIVE, OADBY INDUSTRIAL ESTATE, A C HYDRAULICS LTD ACH OADBY, LEICESTER. LE2 5LG TELEPHONE 0116 2710561 DRAWN CHECKED TITLE ISSUEDRG No. SHEETOF NONE - ORIGINAL1 MAC29:5:20001 11OCAQUOTE CIRCUIT FOR CA

25、M COVER FIXTURE IMPORTANT NOTICE 1. The air supply to this system must be clean and free of water and lubricated where necessary. 2. All hydraulic pipework and fittings must be thoroughly flushed out and free of swarf before fitting to the system. 3. All equipment must be subjected to periodic inspe

26、ction to ensure safe operation. Where there is any doubt about the safe use of our equipment, consult BS 5304 (1988) Code of Practice For Safety of Machinery. 4. Where the setting of pressure control valves is not specified on the drawing, consult the manufacturers Technical Specification. http:/www

27、.ec- 43 Barrel fixture example 44 Circuit design THIS DOCUMENT IS CONFIDENTIAL AND IS THE PROPERTY OF AC HYDRAULICS LTD. THE DOCUMENT AND ANY INFORMATION THEREIN MAY NOT BE USED, COPIED OR DISCLOSED TO ANY THIRD PARTY WITHOUT PRIOR WRITTEN AUTHORISATION OF AC HYDRAULICS LTD. OADBY, LEICESTER. LE2 5L

28、G TELEPHONE 0116 2710561 A C HYDRAULICS LTD 48 KENILWORTH DRIVE, OADBY INDUSTRIAL ESTATE, ALL DIMENSIONS IN MILLIMETRES DRG No. TITLE CHECKED DRAWN SHEET ISSUE OF 1NONE - ORIGINAL 1 2 3 4 222 111 ILMOR EHGINEERING LTD Q1/ MAC 12:12:20011 OCAQUOTE11 PNEUMATIC CIRCUIT FOR DOUBLE ACTING CLAMPING FIXTUR

29、E 13 7 140 11 SOLENOIDS 24VDC 12 4 10 B Z A B 6 A 8 9 5 14 1490355AIR PREPARATION SET113W2N-43GN-6AB-24VDCHYDRAULIC VALVE112A111050170BOLT4110811 324 100FLOW CONTROL110DFBH/HC-30Z-10-BM1.XPRESSURE FILTER19A96351PRESSURE SWITCH18A70191A LINE SLICE17KR40-BPV-R5M3PUMP WITH MANIFOLD16GD63G040-350BARGAUG

30、E15A96170PO CHECK VALVE142954-429SEQUENCE VALVE13BKHU-DN6-1-1-1-32 WAY MANIFOLD BALL VALVE121460-101THREADED BODY CYLINDER411893-628SWING CLAMP4ITEMPART NUMBERDESCRIPTIONQTY IMPORTANT NOTICE 1. The air supply to this system must be clean and free of water and lubricated where necessary. 2. All hydra

31、ulic pipework and fittings must be thoroughly flushed out and free of swarf before fitting to the system. 3. All equipment must be subjected to periodic inspection to ensure safe operation. Where there is any doubt about the safe use of our equipment, consult BS 5304 (1988) Code of Practice For Safe

32、ty of Machinery. 4. Where the setting of pressure control valves is not specified on the drawing, consult the manufacturers Technical Specification. 45 THIS DOCUMENT IS CONFIDENTIAL AND IS THE PROPERTY OF AC HYDRAULICS LTD. THE DOCUMENT AND ANY INFORMATION THEREIN MAY NOT BE USED, COPIED OR DISCLOSE

33、D TO ANY THIRD PARTY WITHOUT PRIOR WRITTEN AUTHORISATION OF AC HYDRAULICS LTD. OADBY, LEICESTER. LE2 5LG TELEPHONE 0116 2710561 A C HYDRAULICS LTD 48 KENILWORTH DRIVE, OADBY INDUSTRIAL ESTATE, ALL DIMENSIONS IN MILLIMETRES DRG No. TITLE CHECKED DRAWN SHEET ISSUE OF 1NONE - ORIGINAL 1 2 3 4 222 111 I

34、LMOR EHGINEERING LTD Q1/ MAC 12:12:20011 OCAQUOTE11 PNEUMATIC CIRCUIT FOR DOUBLE ACTING CLAMPING FIXTURE 13 7 140 11 SOLENOIDS 24VDC 12 4 10 B Z A B 6 A 8 9 5 14 1490355AIR PREPARATION SET113W2N-43GN-6AB-24VDCHYDRAULIC VALVE112A111050170BOLT4110811 324 100FLOW CONTROL110DFBH/HC-30Z-10-BM1.XPRESSURE

35、FILTER19A96351PRESSURE SWITCH18A70191A LINE SLICE17KR40-BPV-R5M3PUMP WITH MANIFOLD16GD63G040-350BARGAUGE15A96170PO CHECK VALVE142954-429SEQUENCE VALVE13BKHU-DN6-1-1-1-32 WAY MANIFOLD BALL VALVE121460-101THREADED BODY CYLINDER411893-628SWING CLAMP4ITEMPART NUMBERDESCRIPTIONQTY IMPORTANT NOTICE 1. The

36、 air supply to this system must be clean and free of water and lubricated where necessary. 2. All hydraulic pipework and fittings must be thoroughly flushed out and free of swarf before fitting to the system. 3. All equipment must be subjected to periodic inspection to ensure safe operation. Where t

37、here is any doubt about the safe use of our equipment, consult BS 5304 (1988) Code of Practice For Safety of Machinery. 4. Where the setting of pressure control valves is not specified on the drawing, consult the manufacturers Technical Specification. Getting the oil to the fixture 47 Rotary & Rotar

38、y Valve Couplings 48 Rotary Couplings nUsed when free passage of oil is required to be distributed on rotary table arrangements nStandard versions of single, twin, four and six passages with/without leakage port nMaximum operating pressure 250/500 bar nWhen specifying include data on rotation speed,

39、 pressure, temperature, media and cycle time nSpecial designs available on request 49 Twin passage rotary coupling Use on rotary table with two single acting cylinders 50 Four passage rotary coupling Use on rotary table with 4 single acting or 2 double acting cylinders 51 Six passage rotary coupling

40、 Use on rotary tables with combination of up to 6 oil feeds ie. 6 s/a, 3 d/a, 2 d/a & 2 s/a cylinders 52 Rotary Coupling circuit Single acting circuitDouble acting circuit 53 Application example 54 Rotary Valve Couplings Used on rotary table arrangements when loading/unloading of stations is require

41、d whilst maintaining clamping pressure on remaining stations Versions include 5,6,7,8,9 &10 stations. Applications requiring 2, 3 or 4 stations use 6 & 8 stations with unused ports plugged. Special designs available Up to 200 bar an accumulator is recommended, above 200 bar it is essential due to in

42、ternal leakage within the oil return cavity of the unit 55 Rotary valve coupling function Load station Unload station Rotary coupling Work station Clamping cylinder 56 Rotary Valve Coupling circuit Single acting Double acting 57 Application example 58 Coupling units nQuick disconnect couplings nOne-

43、hand operation quick disconnect nCoupling units nAutomatic coupling systems nThreaded coupling elements 59 Quick Disconnect Couplings Max operating pressure 500 bar One hand operation Always use dustcaps Coupling units 60 Coupling Units Single or double acting Integral accumulator and pressure gauge

44、 Multi-coupler units available Coupling units & accumulators 61 Coupling Systems Always use accumulators on static systems 10 temperature difference relates to 10 bar pressure difference Coupling units & accumulators 62 Threaded coupling elements Breathing 64 What is breathing? Breathing is the acti

45、on of single acting cylinders during the spring return part of the component cycle 65 Why breathing has to be made Excess pressure or vacuum in the spring area changes the spring forces which leads to malfunction Formation of condensation water promotes rust formation and can lead to a complete fail

46、ure of the elements Leakage of hydraulic seals must drain off to exterior without pressure otherwise there will be malfunctions Dust and chips are retained by sintered metal air filters Liquids can be drawn through the sintered metal filter, thus the breathing spring area is reduced, a higher excess

47、 pressure or vacuum is caused and the function is impaired 66 What is breathing? What happens during breathing 67 Precautions Cover Clamping elements without breather ports can be covered. Due to high coolant pressure and flow this is not always successful Consider using double acting elements where

48、ver possible 68 Precautions Breather hose Connection of a breather hose is approved if the outlet is sited at a point where no liquid can penetrate Ensure no fluid traps in hose 69 Precautions Closed breather system Spring area is increased by connection of additional closed area. Electrical die cas

49、t boxes are ideal Volume of additional area should be 10 times the stroke volume of all connected components 70 System bleeding The system must always be free from air 71 Component Design Components can be of fixed design 72 Component Design Clamping points can be incorporated into design of component 73 Designed for Clamping 74 Designed for Clamping 75 Inaccessible clamping posi