1、1液壓夾具設(shè)計手冊思誠機(jī)電2Good Fixture DesignGood fixtures position, clamp and support workpieces in the most effective way possible3Fixture design, workpiece Example 14Fixture design, process5DatumFixture design, workpiece datums6Fixture design, supporting7Fixture design, positioning8Fixture design, clamping9F

2、ixture design, additional support and clamping10Fixture, positioning, supporting and clamping11Fixture design, workpiece, Example 212Fixture design, process13Fixture design, supporting14Fixture design, clampingXX15Fixture design, clampingDatum16Fixture design, positioning and clamping17Fixture desig

3、n, positioning, supporting & clamping18Friction clampingIf clamping using friction only it must be remembered that the coefficient of friction () is normally calculated at 0.1Clamping force FReaction forceTotal clamping force= F x Clamping force FReaction forceTotal clamping force= FClamping force F

4、 2-30 from horizontalPreferable19Friction clampingIf clamping using friction only it must be remembered that the coefficient 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 workpiece20Fixture designD

5、EFINITION OF A CLAMPING FORCEThe 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 forces21Fixture designCLAMPING FORCESnMechanicalnlow cost, relatively low forcesnPneumaticn

6、higher cost, relatively low forces, large componentsnHydraulicnhigher initial cost, high forces, reliable, small components 22Mechanical ForcesMaximum clamping forceusing standard wrenchClamping force (kN)Clamping force with extension piecesas shown, 500N torque, = 0.123Standard clamping strapM20 th

7、readMax. recommended torque 223NmMax. clamping force 28kN Hydraulic swing clamp 6951F-11-21(page 63, metric catalogue)22 rod, 76mm long armMax. oil pressure 23 MPaClamping force 7.3kN Force comparison24Force comparisonStandard clamping strapM20 threadMax. recommended torque 223NmMax. clamping force

8、28kN Hydraulic swing clamp 6951F-11-21(page 63, metric catalogue)22 rod, clamping strapMax. oil pressure 35 MPaClamping force 13.7kN 25Standard clamping strapM24 threadMax. recommended torque 383NmMax. clamping force 40kN Hydraulic swing clamp 6951FN-33-21(page 71, metric catalogue) 38 rod, clamping

9、 strapMax. oil pressure 35 MPaClamping force 35kN Force comparison26Standard 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 comparison27Mechanic

10、al or Hydraulic ?28Mechanical 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 MPa29Force diagram30 MPa50 MPaSequence valve opensWorkpiecesMovement of cylin

11、derOil pressure30Component & Fixture designSENSIBLE USE OF FORCESensible introduction of positioning, clamping and supporting forces will enhance the quality of a workpiece31Oil supply to fixturesn2 basic methodsnthrough pipesnthrough gun drilled channelsnMethod depends onncost targetncomplexity of

12、fixturenproducts being used32Oil 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 clamps33Oil supply to fixtures, c

13、ost comparisonA: Through pipes usingflange type clampsnRelatively easy to manufacturenFittings weakest part of systemnChip trapsControl fixtureCOST 100%34Oil supply to fixtures, cost comparisonB: Through pipes usingthreaded type clampsnLess swarf traps nReduces machining areanFittings weakest part o

14、f systemCOST ?%against control fixture35Oil supply to fixtures, cost comparisonC: Through gun drilled channels & manifold mounted type clampsnMaximum component density nMinimum swarf trapsCOST ?%against control fixture36Oil supply to fixtures, cost comparisonD: Through gun drilled channels & threade

15、d body type clampsnMaximum component density nMinimum swarf trapsCOST ?%against control fixture37Oil supply to fixtures, cost comparisonC: Through gun drilled channels & manifold mounted type clamps98%B:130%D:104%A:100%38Hydraulic circuit design39Circuit design40Cam Cover fixture example41Circuit de

16、sign1432681079ILMOR ENGINEERING LTDQ3/22153DIA 10 POLYURETHANEDIA 10 POLYURETHANE1/4 BOREHOSE531524101010101010101010101010101012111313190355AIR PREPARATION SET1290079PUSH/PULL VALVE1396324PRESSURE SWITCH14GD63G040-600BARGAUGE1596054QUICK COUPLING1690041QUICK EXHAUST VALVE17U-3/8SILENCER18A82208BOOS

17、TER19A96212BLEED UNIT1101458-001THREADED BODY CYLINDER15112954-420SEQUENCE VALVE11270009TEE MANIFOLD1131913-010WORK SUPPORT2ITEMPART NUMBERDESCRIPTIONQTYDIA 8x1.5 STEELALL DIMENSIONS IN MILLIMETRES THIS DOCUMENT IS CONFIDENTIAL AND IS THE PROPERTY OF AC HYDRAULICS LTD. THE DOCUMENT AND ANY INFORMATI

18、ON 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 LTDACHOADBY, LEICESTER. LE2 5LGTELEPHONE 0116 2710561DRAWNCHECKEDTITLEISSUEDRG No.SHEETOFNONE - ORIGINAL1MAC29:5:2000

19、111OCAQUOTECIRCUIT 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 fittings must be thoroughly flushed out and free of swarf before fitting to the system.3. All equipment must be subje

20、cted 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 manufacturers Technical Spe

21、cification.421432681079ILMOR ENGINEERING LTDQ3/22153DIA 10 POLYURETHANEDIA 10 POLYURETHANE1/4 BOREHOSE531524101010101010101010101010101012111313190355AIR PREPARATION SET1290079PUSH/PULL VALVE1396324PRESSURE SWITCH14GD63G040-600BARGAUGE1596054QUICK COUPLING1690041QUICK EXHAUST VALVE17U-3/8SILENCER18A

22、82208BOOSTER19A96212BLEED UNIT1101458-001THREADED BODY CYLINDER15112954-420SEQUENCE VALVE11270009TEE MANIFOLD1131913-010WORK SUPPORT2ITEMPART NUMBERDESCRIPTIONQTYDIA 8x1.5 STEELALL DIMENSIONS IN MILLIMETRES THIS DOCUMENT IS CONFIDENTIAL AND IS THE PROPERTY OF AC HYDRAULICS LTD. THE DOCUMENT AND ANY

23、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 LTDACHOADBY, LEICESTER. LE2 5LGTELEPHONE 0116 2710561DRAWNCHECKEDTITLEISSUEDRG No.SHEETOFNONE - ORIGINAL1MAC

24、29:5:2000111OCAQUOTECIRCUIT 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 fittings must be thoroughly flushed out and free of swarf before fitting to the system.3. All equipment must

25、 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 manufacturers Tech

26、nical Specification.43http:/www.ec- fixture example44Circuit 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,

27、 LEICESTER. LE2 5LGTELEPHONE 0116 2710561A C HYDRAULICS LTD48 KENILWORTH DRIVE, OADBY INDUSTRIAL ESTATE,ALL DIMENSIONS IN MILLIMETRESDRG No.TITLECHECKEDDRAWNSHEETISSUEOF1NONE - ORIGINAL1234222111ILMOR EHGINEERING LTDQ1/MAC 12:12:20011OCAQUOTE11PNEUMATIC CIRCUIT FOR DOUBLE ACTING CLAMPING FIXTURE1371

28、4011SOLENOIDS24VDC12410BZAB6A895141490355AIR PREPARATION SET113W2N-43GN-6AB-24VDCHYDRAULIC VALVE112A111050170BOLT4110811 324 100FLOW CONTROL110DFBH/HC-30Z-10-BM1.XPRESSURE FILTER19A96351PRESSURE SWITCH18A70191A LINE SLICE17KR40-BPV-R5M3PUMP WITH MANIFOLD16GD63G040-350BARGAUGE15A96170PO CHECK VALVE14

29、2954-429SEQUENCE VALVE13BKHU-DN6-1-1-1-32 WAY MANIFOLD BALL VALVE121460-101THREADED BODY 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

30、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. Where the

31、 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 DISCLOSED TO ANY THIRD PARTY WITHOUT P

32、RIOR 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.TITLECHECKEDDRAWNSHEETISSUEOF1NONE - ORIGINAL1234222111ILMOR EHGINEERING LTDQ1/MAC 12:12:20011OCAQUOTE11PN

33、EUMATIC CIRCUIT FOR DOUBLE ACTING CLAMPING FIXTURE13714011SOLENOIDS24VDC12410BZAB6A895141490355AIR PREPARATION SET113W2N-43GN-6AB-24VDCHYDRAULIC VALVE112A111050170BOLT4110811 324 100FLOW CONTROL110DFBH/HC-30Z-10-BM1.XPRESSURE FILTER19A96351PRESSURE SWITCH18A70191A LINE SLICE17KR40-BPV-R5M3PUMP WITH

34、MANIFOLD16GD63G040-350BARGAUGE15A96170PO CHECK VALVE142954-429SEQUENCE VALVE13BKHU-DN6-1-1-1-32 WAY MANIFOLD BALL VALVE121460-101THREADED BODY CYLINDER411893-628SWING CLAMP4ITEMPART NUMBERDESCRIPTIONQTY IMPORTANT NOTICE1. The air supply to this system must be clean and free of water and lubricated w

35、here 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 about the safe use of our equipment, consult BS 5304 (1988)

36、 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.46Getting the oil to the fixture47Rotary & Rotary Valve Couplings48Rotary CouplingsnUsed when free passage of oil is required t

37、o be distributed on rotary table arrangementsnStandard versions of single, twin, four and six passages with/without leakage portnMaximum operating pressure 250/500 barnWhen specifying include data on rotation speed, pressure, temperature, media and cycle timenSpecial designs available on request49Tw

38、in passage rotary couplingnUse on rotary table with two single acting cylinders50Four passage rotary couplingnUse on rotary table with 4 single acting or 2 double acting cylinders51Six 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

39、cylinders52Rotary Coupling circuitSingle acting circuitDouble acting circuit53Application example54Rotary 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 station

40、s.nApplications requiring 2, 3 or 4 stations use 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 unit55Rotary valve coupling functionLoad station

41、Unload stationRotary couplingWork stationClamping cylinder56Rotary Valve Coupling circuitSingleactingDoubleacting57Application example58Coupling unitsnQuick disconnect couplingsnOne-hand operation quick disconnectnCoupling unitsnAutomatic coupling systemsnThreaded coupling elements 59Quick Disconnec

42、tCouplingsnMax operating pressure 500 barnOne hand operationnAlways use dustcapsCoupling units60Coupling UnitsnSingle or double actingnIntegral accumulator and pressure gaugenMulti-coupler units availableCoupling units & accumulators61Coupling SystemsnAlways use accumulators on static systemsn10 tem

43、perature difference relates to 10 bar pressure differenceCoupling units & accumulators62Threaded coupling elements63Breathing64What is breathing?Breathing is the action of single acting cylinders during the spring return part of the component cycle65Why breathing has to be madenExcess pressure or va

44、cuum 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 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 impaired66What