The fact that hydraulics is generally equated with “endless power” is nothing new. What is more surprising is that hydraulic clamping technology is also very flexible and sensitive. With reproducible and monitorable force, hydraulic clamping elements make processes reliable and ensure the process capability that is increasingly required in part machining – right up to full automation. An important aspect in times of skills shortages.
Hydraulic clamping elements push and pull with precisely metered and defined forces always in the same way and in the correct sequence at defined points and handle and fix workpieces reliably. The fact that they relieve the operating personnel of a lot of strenuous work and ensure ergonomic and safe working conditions during machining, assembly and welding operations also makes them popular at grassroots level. However, the hydraulic support elements must not be forgotten under any circumstances.
Providers with an all-round view think in a technology-independent and solution-oriented way
Andreas Maier GmbH & Co KG (AMF) has proven to be a provider with an all-round view. The Fellbach-based company is known as a full-range supplier of clamping technology and is one of the market leaders worldwide. This results in expertise and consulting skills that are characterized by solutions that are independent of clamping technology. The fact that the family-run company can do this is also due to its large product portfolio, which includes all clamping technologies. So let’s get down to the nitty-gritty of hydraulic clamping technology! First of all: it is by no means rigid, only suitable for one component and in the largest possible quantities. If a supplier masters the supreme discipline of clamping technology, it develops flexible clamping solutions – often embedded in intelligent fixtures – that can be used for different component variants and small quantities. This is also reflected in a flexible media feed, for example with tubing instead of piping, and with various combination options that provide a basis for greater modularity.
Hydraulic solutions are the supreme discipline in clamping technology
If you want to make the most of these options, you should consult the provider of your choice as early as possible – ideally when it comes to designing the components. If they refuse, they may not be the right partner for the optimum clamping technology solution. After all, it has to be process-capable and reliable and meet the customer’s requirements and standards. It is also designed to reduce the workload on employees and increase productivity. So let’s summarize: Hydraulic clamping technology can do it all. First and foremost, of course, is power. Depending on the component and available pressure, even 150 KN is no problem for the power packs when 350 bar is applied. For example, up to 70 KN are available at a factory-available continuous 250 bar. For example, a world-renowned manufacturer spans large axle housings and high-tech transmissions for tractors as well as construction and agricultural machinery. A diesel engine manufacturer relies on hydraulics in production just as much as a Bavarian forge. All large, heavy parts.
Hydraulic clamping technology makes processes possible and safe
First of all, it is important that the pressure generator safely and reliably builds up and maintains the required pressure. In addition to power units, a wide range of suppliers also offer push and pull cylinders, swing, lever, vertical, centering and toggle clamps as well as valves, pressure switches and rotary feedthroughs. If bore and pull-down clamps are also available, he can develop solutions for many situations. And not forgetting support elements. If their supporting force is not powerful without being voluminous, the performance of the clamping elements is wasted. AMF can provide elements with a high support force in relation to their size – unique on the market. To ensure process capability and reliability, hydraulic elements always clamp in the correct sequence, with the same force and at the correct contact points. Incidentally, a thoughtful partner can recommend these correctly at an early stage when designing the components so that they are accessible later on. If he recommends extra clamping lugs for complex geometries of demanding components that can be removed later, he demonstrates his in-depth understanding of the process.
Unique: Hydraulics can be adjusted
The hydraulics can also make incomparable adjustments if components become loose due to weight, vibrations or other reasons. This provides additional process reliability and guarantees that the required tolerances can be met. If the clamping elements are also as compact as possible, the component remains free of interfering contours and ideally allows 5-axis machining. Process capability and process reliability, together with adherence to ever tighter tolerances, become all the more important the fewer skilled workers are available at the machines. It is precisely this personnel situation that is also leading to ever stricter standards for customer requirements. This allows quality assurance to check component accuracy in defined processes independently of the technical and intellectual knowledge of employees. It is important that the clamping hydraulics adapt to the components and not vice versa. For example, AMF has manufactured flexible clamping fixtures for four variants of components for a customer, which are clamped and machined in pairs. A combination of hydraulic pull-down clamps and floating support elements ensures that large castings are held in place. This ensures that the parts are perfectly flat. Turned through 180°, zero-point clamping modules hold screwed-in clamping bolts and fix the components directly, without distortion and accessible from all sides for five-sided machining.
Complexity remains manageable and elements available
The highlight, however, is the flexibility of the clamping fixtures. Two movable superstructure plates are mounted on a base plate. Hydraulic support elements are inserted and bolted in a grid and can therefore be easily moved. This means that the fixtures not only accommodate two related side parts, which can be processed on five sides after turning. All four variants of the components can also be clamped in the respective processing states. In order for the workers to maintain an overview of this unimaginable complexity, the appropriate positions for the respective component are numbered in color. This creates safety and ensures speed when pre-equipping in parallel with the main time. For each component, there is both a clamping plan and a setup plan available on the machine. And what happens if the component changes, is discontinued or relocated to another supplier? – An often-heard objection. Is the costly hydraulic clamping technology then lost? Not at all – if you have chosen the right provider and solution partner. Hydraulic clamping fixtures can usually be adapted to changes in the component. And if the component is actually dropped from the program, the hydraulic clamping technology is by no means lost. Finally, the hydraulic components of a device can be used for other projects or devices. As they are designed for very high cycle stability, they promise great sustainability. A solution-oriented partner with a correspondingly wide range of products will certainly be available again.
A positive conclusion cites the advantages of hydraulic clamping technology
Hydraulic clamping technology is not only strong, but also sensitive and flexible. Solution-oriented providers with a wide range of products and extensive application experience provide advice independent of technology and product. The result then ensures process capability through to automation, process reliability and compliance with tight tolerances and standards. Those who make use of this can convince their customers with quality and reliability, even in times of a shortage of skilled workers. Web: www.amf.de