Overcoming Challenges in Manufacturing Automation.

When finding solutions to workholding challenges in manufacturing automation, manufacturers should be aware of the advantages of powered workholding devices.

One of the more obvious advantages is increased clamping speed. Rather than taking several minutes to manually tighten and loosen the clamps on a workholding device, a machine operator can activate the complete clamping system from a single point in a matter of seconds. Increased clamping speed reduces the non-productive time during loading and unloading cycles and allows much faster machining cycles.

Other less-obvious reasons are even more important. Powered workholding systems allow much-faster machining cycles and offer added security. Instead of relying on an operator to properly tighten the clamps, power-operated clamping systems provide consistent clamping forces. Holding forces can be adjusted to suit the specific requirements of the workpiece. This permits clamping forces to be increased, holding workpieces more rigidly, preventing workpiece movement and allowing higher cutting speeds and faster feeds.

Improved part quality is perhaps the greatest benefit of powered workholding systems. These systems improve the overall quality and reduce rejected or scrapped parts by providing consistent, controllable clamping forces and self-adjusting work supports.

Less obvious, but equally important advantages of powered workholding are:

 

Consistent and Repeatable Operation

A major feature of power workholding systems is consistent and repeatable clamping forces. Manually operated clamps rely solely on the strength and diligence of the operator. Power clamps, however, are controlled by a power source, so the strength and fatigue level of the operator does not affect the clamping force.

 

Controlled Clamping Force

Power workholding systems are adjustable to provide exactly the right amount of clamping force. When either light or heavy clamping forces are required for a workpiece, the clamping force can be adjusted for those specific conditions. A controlled clamping force is important for parts with varying thicknesses, brittle materials, odd shapes, or similar characteristics. Reduced clamping forces can be applied if the workpiece is delicate or has thin cross-sections, as with some cast parts. Conversely, if the workpiece requires greater holding forces, power clamps can also be adjusted for additional pressure.

 

Automatically Adjusting Work Supports

Many workpieces require additional support to prevent deflection or vibration during the machining cycle. In these cases, self-adjusting work supports are useful. Supports are placed under the workpiece and either advance to meet the workpiece or are depressed by loading the part in the fixture. Once the required height is achieved, work supports are locked in position by hydraulic pressure and act as additional fixed locators throughout the machining cycle. When unloading, the work supports return to the free position and are repositioned with the loading and clamping of a new part. So, any differences in the supported surface, such as steps or irregular features, are easily accommodated.

Power workholding systems offer several other advantages over manual clamping and typically include:

• Remote clamp operation
• Reduced operator fatigue
• Automatic sequencing
• Fixture compactness
• Higher machining rates
• Increased machine-tool capacity

Manufacturers today understand good workholding devices and fixturing are the most fundamental physical devices that facilitate manufacturing automation and workholding is the key to manufacturing automation.

Powered workholding is the most common solution employed when designing workholding systems and fixtures to overcome challenges in manufacturing automation.

Powered workholding solutions offer significant advantages over manual workholding. In practice the advantages of power workholding are interdependent. Each benefit typically leads to several other production advantages.