液压夹具设计手册培训讲学

1、液压夹具(jij)设计手册思诚机电(jdin)第一页，共81页。2Good Fixture DesignGood fixtures position, clamp and support workpieces in the most effective way possible第二页，共81页。3Fixture design, workpiece Example 1第三页，共81页。4Fixture design, process第四页，共81页。5DatumFixture design, workpiece datums第五页，共81页。6Fixture design, supporting

2、第六页，共81页。7Fixture design, positioning第七页，共81页。8Fixture design, clamping第八页，共81页。9Fixture design, additional support and clamping第九页，共81页。10Fixture, positioning, supporting and clamping第十页，共81页。11Fixture design, workpiece, Example 2第十一页，共81页。12Fixture design, process第十二页，共81页。13Fixture design, suppor

3、ting第十三页，共81页。14Fixture design, clampingXX第十四页，共81页。15Fixture design, clampingDatum第十五页，共81页。16Fixture design, positioning and clamping第十六页，共81页。17Fixture design, positioning, supporting & clamping第十七页，共81页。18Friction clampingIf clamping using friction only it must be remembered that the coefficient

4、 of friction () is normally calculated at 0.1Clamping force FReaction forceTotal clamping force= F x Clamping force FReaction forceTotal clamping force= FClamping force F 2-30 from horizontalPreferable第十八页，共81页。19Friction clampingIf clamping using friction only it must be remembered that the coeffic

5、ient of friction () is normally calculated at 0.1This can be improved on soft materials (eg. Al) if the clamping piston has enough force to penetrate the workpiece第十九页，共81页。20Fixture designDEFINITION OF A CLAMPING FORCEThe force acting on a workpiece to be clamped, is large enough to hold the workpi

6、ece firmly in its given position relative to the cutting tool, against the action of the machining forces第二十页，共81页。21Fixture designCLAMPING FORCESnMechanicalnlow cost, relatively low forcesnPneumaticnhigher cost, relatively low forces, large componentsnHydraulicnhigher initial cost, high forces, rel

7、iable, small components 第二十一页，共81页。22Mechanical ForcesMaximum clamping forceusing standard wrenchClamping force (kN)Clamping force with extension piecesas shown, 500N torque, = 0.1第二十二页，共81页。23Standard clamping strapM20 threadMax. recommended torque 223NmMax. clamping force 28kN Hydraulic swing clam

8、p 6951F-11-21(page 63, metric catalogue)22 rod, 76mm long armMax. oil pressure 23 MPaClamping force 7.3kN Force comparison第二十三页，共81页。24Force comparisonStandard clamping strapM20 threadMax. recommended torque 223NmMax. clamping force 28kN Hydraulic swing clamp 6951F-11-21(page 63, metric catalogue)22

9、 rod, clamping strapMax. oil pressure 35 MPaClamping force 13.7kN 第二十四页，共81页。25Standard clamping strapM24 threadMax. recommended torque 383NmMax. clamping force 40kN Hydraulic swing clamp 6951FN-33-21(page 71, metric catalogue) 38 rod, clamping strapMax. oil pressure 35 MPaClamping force 35kN Force

10、comparison第二十五页，共81页。26Standard clamping strapM24 threadMax. recommended torque 383NmMax. clamping force 40kN Hollow piston cylinder 6921-100 x10(page 26, metric catalogue) M24 threadMax. oil pressure 400 barClamping force 101kN Force comparison第二十六页，共81页。27Mechanical or Hydraulic ?第二十七页，共81页。28Mech

11、anical or Hydraulic ?50 MPaSequence Valve 47-0440-02 (J-3)Set at 30 MPaCartridge Mount Cylinder (x8)42-1010-04 (page F-12)2.5 kN each 50MPaThreaded Cylinder42-0010-06 (page F-4)3.4 kN 30 MPa5.7 kN 50 MPa第二十八页，共81页。29Force diagram30 MPa50 MPaSequence valve opensWorkpiecesMovement of cylinderOil press

12、ure第二十九页，共81页。30Component & Fixture designSENSIBLE USE OF FORCESensible introduction of positioning, clamping and supporting forces will enhance the quality of a workpiece第三十页，共81页。31Oil supply to fixturesn2 basic methodsnthrough pipesnthrough gun drilled channelsnMethod depends onncost targetncompl

13、exity of fixturenproducts being used第三十一页，共81页。32Oil supply to fixtures, cost comparisonnA:Through pipes using flange type clampsnB:Through pipes using threaded type clampsnC:Through gun drilled channels & manifold mounted type clampsnD:Through gun drilled channels & threaded body type clamps第三十二页，共

14、81页。33Oil supply to fixtures, cost comparisonA: Through pipes usingflange type clampsnRelatively easy to manufacturenFittings weakest part of systemnChip trapsControl fixtureCOST 100%第三十三页，共81页。34Oil supply to fixtures, cost comparisonB: Through pipes usingthreaded type clampsnLess swarf traps nRedu

15、ces machining areanFittings weakest part of systemCOST ?%against control fixture第三十四页，共81页。35Oil supply to fixtures, cost comparisonC: Through gun drilled channels & manifold mounted type clampsnMaximum component density nMinimum swarf trapsCOST ?%against control fixture第三十五页，共81页。36Oil supply to fi

16、xtures, cost comparisonD: Through gun drilled channels & threaded body type clampsnMaximum component density nMinimum swarf trapsCOST ?%against control fixture第三十六页，共81页。37Oil supply to fixtures, cost comparisonC: Through gun drilled channels & manifold mounted type clamps98%B:130%D:104%A:100%第三十七页，

17、共81页。Hydraulic circuit design第三十八页，共81页。39Circuit design第三十九页，共81页。40Cam Cover fixture example第四十页，共81页。41Circuit design1432681079ILMOR ENGINEERING LTDQ3/22153DIA 10 POLYURETHANEDIA 10 POLYURETHANE1/4 BOREHOSE531524101010101010101010101010101012111313190355AIR PREPARATION SET1290079PUSH/PULL VALVE13

18、96324PRESSURE SWITCH14GD63G040-600BARGAUGE1596054QUICK COUPLING1690041QUICK EXHAUST VALVE17U-3/8SILENCER18A82208BOOSTER19A96212BLEED UNIT1101458-001THREADED BODY CYLINDER15112954-420SEQUENCE VALVE11270009TEE MANIFOLD1131913-010WORK SUPPORT2ITEMPART NUMBERDESCRIPTIONQTYDIA 8x1.5 STEELALL DIMENSIONS I

19、N 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 AUTORISATION OF AC HYDRAULICS LTD.48 KENILWORTH DRIVE, OADBY INDUSTRIAL ESTATE,A C HYDRAULICS L

20、TDACHOADBY, LEICESTER. LE2 5LGTELEPHONE 0116 2710561DRAWNCHECKEDTITLEISSUEDRG No.SHEETOFNONE - ORIGINAL1MAC29:5:2000111OCAQUOTECIRCUIT FOR CAM COVER FIXTURE IMPORTANT NOTICE1. The air supply to this system must be clean and free of water and lubricated where necessary.2. All hydraulic pipework and f

21、ittings 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 Safety of Machinery.4. W

22、here the setting of pressure control valves is not specified on the drawing, consult the manufacturers Technical Specification.第四十一页，共81页。421432681079ILMOR ENGINEERING LTDQ3/22153DIA 10 POLYURETHANEDIA 10 POLYURETHANE1/4 BOREHOSE531524101010101010101010101010101012111313190355AIR PREPARATION SET1290

23、079PUSH/PULL VALVE1396324PRESSURE SWITCH14GD63G040-600BARGAUGE1596054QUICK COUPLING1690041QUICK EXHAUST VALVE17U-3/8SILENCER18A82208BOOSTER19A96212BLEED UNIT1101458-001THREADED BODY CYLINDER15112954-420SEQUENCE VALVE11270009TEE MANIFOLD1131913-010WORK SUPPORT2ITEMPART NUMBERDESCRIPTIONQTYDIA 8x1.5 S

24、TEELALL 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 AUTORISATION OF AC HYDRAULICS LTD.48 KENILWORTH DRIVE, OADBY INDUSTRIAL EST

25、ATE,A C HYDRAULICS LTDACHOADBY, LEICESTER. LE2 5LGTELEPHONE 0116 2710561DRAWNCHECKEDTITLEISSUEDRG No.SHEETOFNONE - ORIGINAL1MAC29:5:2000111OCAQUOTECIRCUIT FOR CAM COVER FIXTURE IMPORTANT NOTICE1. The air supply to this system must be clean and free of water and lubricated where necessary.2. All hydr

26、aulic 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

27、ty of Machinery.4. Where the setting of pressure control valves is not specified on the drawing, consult the manufacturers Technical Specification.第四十二页，共81页。http:/www.ec- fixture example第四十三页，共81页。44Circuit design THIS DOCUMENT IS CONFIDENTIAL AND IS THE PROPERTY OF AC HYDRAULICS LTD. THE DOCUMENT

28、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 5LGTELEPHONE 0116 2710561A C HYDRAULICS LTD48 KENILWORTH DRIVE, OADBY INDUSTRIAL ESTATE,ALL DIMENSIONS IN MILLIMETRESDRG No.TITLECHECKEDD

29、RAWNSHEETISSUEOF1NONE - ORIGINAL1234222111ILMOR EHGINEERING LTDQ1/MAC 12:12:20011OCAQUOTE11PNEUMATIC CIRCUIT FOR DOUBLE ACTING CLAMPING FIXTURE13714011SOLENOIDS24VDC12410BZAB6A895141490355AIR PREPARATION SET113W2N-43GN-6AB-24VDCHYDRAULIC VALVE112A111050170BOLT4110811 324 100FLOW CONTROL110DFBH/HC-30

30、Z-10-BM1.XPRESSURE 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 IMPO

31、RTANT NOTICE1. 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 inspection to ensure safe op

32、eration. 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.第四十四页，共81页。45 THIS DOCUMENT IS CON

33、FIDENTIAL 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 5LGTELEPHONE 0116 2710561A C HYDRAULICS LTD48 KENILWORTH DRIVE, OADBY IN

34、DUSTRIAL ESTATE,ALL DIMENSIONS IN MILLIMETRESDRG No.TITLECHECKEDDRAWNSHEETISSUEOF1NONE - ORIGINAL1234222111ILMOR EHGINEERING LTDQ1/MAC 12:12:20011OCAQUOTE11PNEUMATIC CIRCUIT FOR DOUBLE ACTING CLAMPING FIXTURE13714011SOLENOIDS24VDC12410BZAB6A895141490355AIR PREPARATION SET113W2N-43GN-6AB-24VDCHYDRAUL

35、IC VALVE112A111050170BOLT4110811 324 100FLOW CONTROL110DFBH/HC-30Z-10-BM1.XPRESSURE FILTER19A96351PRESSURE SWITCH18A70191A LINE SLICE17KR40-BPV-R5M3PUMP WITH MANIFOLD16GD63G040-350BARGAUGE15A96170PO CHECK VALVE142954-429SEQUENCE VALVE13BKHU-DN6-1-1-1-32 WAY MANIFOLD BALL VALVE121460-101THREADED BODY

36、 CYLINDER411893-628SWING CLAMP4ITEMPART NUMBERDESCRIPTIONQTY IMPORTANT NOTICE1. 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 equ

37、ipment 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 Safety of Machinery.4. Where the setting of pressure control valves is not specified on the drawing, consult the manufac

38、turers Technical Specification.第四十五页，共81页。Getting the oil to the fixture第四十六页，共81页。47Rotary & Rotary Valve Couplings第四十七页，共81页。48Rotary CouplingsnUsed when free passage of oil is required to be distributed on rotary table arrangementsnStandard versions of single, twin, four and six passages with/wit

39、hout leakage portnMaximum operating pressure 250/500 barnWhen specifying include data on rotation speed, pressure, temperature, media and cycle timenSpecial designs available on request第四十八页，共81页。49Twin passage rotary couplingnUse on rotary table with two single acting cylinders第四十九页，共81页。50Four pas

40、sage rotary couplingnUse on rotary table with 4 single acting or 2 double acting cylinders第五十页，共81页。51Six passage rotary couplingnUse 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第五十一页，共81页。52Rotary Coupling circuitSingle acting circuitDouble acting

41、 circuit第五十二页，共81页。53Application example第五十三页，共81页。54Rotary Valve CouplingsnUsed on rotary table arrangements when loading/unloading of stations is required whilst maintaining clamping pressure on remaining stationsnVersions include 5,6,7,8,9 &10 stations.nApplications requiring 2, 3 or 4 stations u

42、se 6 & 8 stations with unused ports plugged.nSpecial designs availablenUp to 200 bar an accumulator is recommended, above 200 bar it is essential due to internal leakage within the oil return cavity of the unit第五十四页，共81页。55Rotary valve coupling functionLoad stationUnload stationRotary couplingWork s

43、tationClamping cylinder第五十五页，共81页。56Rotary Valve Coupling circuitSingleactingDoubleacting第五十六页，共81页。57Application example第五十七页，共81页。58Coupling unitsnQuick disconnect couplingsnOne-hand operation quick disconnectnCoupling unitsnAutomatic coupling systemsnThreaded coupling elements 第五十八页，共81页。59Quick

44、DisconnectCouplingsnMax operating pressure 500 barnOne hand operationnAlways use dustcapsCoupling units第五十九页，共81页。60Coupling UnitsnSingle or double actingnIntegral accumulator and pressure gaugenMulti-coupler units availableCoupling units & accumulators第六十页，共81页。61Coupling SystemsnAlways use accumul

45、ators on static systemsn10 temperature difference relates to 10 bar pressure differenceCoupling units & accumulators第六十一页，共81页。62Threaded coupling elements第六十二页，共81页。Breathing第六十三页，共81页。64What is breathing?Breathing is the action of single acting cylinders during the spring return part of the compon

46、ent cycle第六十四页，共81页。65Why breathing has to be madenExcess pressure or vacuum in the spring area changes the spring forces which leads to malfunctionnFormation of condensation water promotes rust formation and can lead to a complete failure of the elementsnLeakage of hydraulic seals must drain off to

47、 exterior without pressure otherwise there will be malfunctionsnDust and chips are retained by sintered metal air filtersnLiquids can be drawn through the sintered metal filter, thus the breathing spring area is reduced, a higher excess pressure or vacuum is caused and the function is impaired第六十五页，共81页。66What is breathing?What happens during breathing第六十六页，共81页。67PrecautionsCovernClamping element