Vektek Metric Hydraulic Clamping Catalog

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THE LATEST TECHNOLOGY IN WORKHOLDING

METRIC CLAMPING HYDRAULIC PRECISION

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NEW

Universal Grippers The Latest Technology In End Of Arm Tooling

Zero-Point Quick Change Systems

Ultrasonic Position Sensing Clamps

NEW

Wireless Pressure Monitoring

Precise Location of the Piston in Each Cylinder

Automated Workholding

JULY

July 2024

GUARDIAN

•Continuous monitoring throughout the machining cycle. •Simple integration into your automation control system using industry standard connections. •Easy to install and powered by the Machine Tool’s 24 VDC power supply. •Extended transmitting range designed for large machines, linear pallet pool systems, and even small applications such as vertical machining centers and lathes. •Pallet Identification system that simplifies integration and can be used for unlimited pallet management. •Status monitoring outputs that include pressure, battery level, connection status, and M-code acknowledgement via internal isolated relay contacts.

Guardian 2.0 Transmitters work in all orientations

Pallet ID system allows for easy integration to your system

NEW UNIVERSAL GRIPPERS

The Latest Technology In End Of Arm Tooling

VGP: 2-Finger Parallel Gripper

VSO: 2-Finger Parallel Gripper

VEP: 2-Finger Parallel Gripper

ROBUST 10 SIZES (40 TO 300)

PROTECTED 7 SIZES (40 TO 160)

SMALL / COMPACT 8 SIZES (10 TO 70)

IP rating 40 ... 65

IP rating 67

IP rating 40

VZP: 3-Finger Self Centering Gripper

VZO: 3-Finger Self Centering Gripper

VLE: 2-Finger Parallel Gripper PROTECTED LARGE STROKE 5 SIZES (16 TO 40)

ROBUST 10 SIZES (40 TO 300)

PROTECTED 4 SIZES (50 TO 100)

IP rating 67

IP rating 40 ... 64

IP rating 67

Additional Products Available

VPR

VAO VRPEP VFB

2-Finger Angular/ Radial Gripper

Pneumatic/Hydraulic Swivel Actuator

2-Finger Parallel Swivel Gripper

Clamping Force Block Self Centering Vise

AND MORE!

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OPTIMIZE YOUR FIXTURE AND MACHINE MORE PARTS!!

REDUCE YOUR SET UP TIME BY 90% WITH ZERO POINT QUICK CHANGE SYSTEMS.

Hydraulic Modules / Pneumatic Modules Application: Zero-Point clamping systems optimize fixture and work piece changeover with auto blow-off.

Hydraulic Modules / Pneumatic Modules, Automation Application:

Zero-Point clamping systems for automation solutions offer direct monitoring of module piston location as well as auto blow-off.

Hydraulic Modules / Pneumatic Modules, Center Lock Application:

Zero-Point clamping systems for automation solutions including Central Lock with Pneumatic cleaning function of support surfaces.

FIXTURE & MODULE SUB PLATES AVAILABLE FOR COMPLETE SOLUTIONS

PRECISE LOCATION OF THE PISTON IN EACH CYLINDER

ULTRASONIC Position Sensing Clamps • Ultrasonic position sensing clamps provide accurate and repeatable clamp position measurements. • Sensing available for TuffCam Swing Clamps, VersaCam Swing Clamps, TuffLink Link Clamps, and Block Body Cylinders. • Repeat accuracy of +/-.002. • Works with up to 5000 psi of hydraulic pressure. • Accuracy unaffected by heat up to 185° F. • Simple to use with IO-Link. • All components rated to at least IP67. • All in one Vektek ultrasonic position sensing packages for easy integration. • Easy trouble shooting for identifying failed clamp or unclamp states.

How Does it Work?

The ultrasonic sensor sends an ultrasonic pulse from the bottom of the clamp and the signal is reflected back to the sensor off the bottom of the plunger. The sensor measures the return time and gives an accurate position reading for the clamp. Set up the desired clamping and unclamping ranges using the master control system included in the two sensing packages. During operation the master control will send a go or no-go signal to the machine depending on the data received from the sensors. No-go signal will prevent damage to the part or machine due to a failed or damaged clamp.

Contents

PLANNING

D-14 TuffLink™ 360° Link Clamp Frequently Asked Questions D-15 TuffLink™ 360° Link Clamp Dimensions D-16 TuffLink™ 360° Clamping Force Tables and Graphs

A-1 Planning A-2 Steps 1-13

A-3 Calculate Clamping Time A-4 Frequently Asked Questions A-7 Fixture Documentation Worksheet A-8 Fixture Building Tips B-1 Frequently Asked Questions B-2 Work Support Features B-3 High Capacity, Fluid Advance B-7 Part Present Sensing B-11 Spring Advance B-15 Air Advance B-19 Legacy Fluid Advance B-23 Work Support Accessories C-1 TuffCam™ Frequently Asked Questions C-2 TuffCam™ Clocking C-2 TuffCam™ Features C-2 TuffCam™ Clamp Time and Flow Rate C-3 TuffCam™ Top Flange C-5 TuffCam™ Top Flange Long Stroke C-7 TuffCam™ Bottom Flange C-9 TuffCam™ Bottom Flange Long Stroke

D-18 Link Clamp Lever Dimensions D-19 Link Clamp Lever Output Curves

SPECIAL USE CLAMPS E-1 Centering Clamps

WORK SUPPORTS

E-2 Small Bore Centering Clamp - 3 Point Contact E-3 Small Bore Centering Clamp - 2 Point Contact E-4 Large Bore Centering Clamp - 3 Point Contact E-5 Large Bore Centering Clamp - 2 Point Contact E-6 Centering Clamp Installation Dimensions E-7 Edge Clamps E-8 Pull-Down Clamp Eccentric E-9 Pull-Down Concentric Clamps E-11 Pull-Down Clamps, Manifold Mounted S/A E-12 Pull-Down Clamps, Double Acting E-13 Pull-Down Jaws

SWING CLAMPS

CYLINDERS

F-1 Frequently Asked Questions F-2 Threaded Mini F-4 Threaded F-6 Block F-8 Block, Manifold F-10 Block, Combination F-12 Hollow Rod F-14 Cartridge Mount Mini F-16 Slip-In Cartridge Mount Pull Cylinder F-18 Easy Mount Cylinder

C-11 TuffCam™ Low Profile Features C-12 TuffCam™ Low Profile Clocking C-13 TuffCam™ Low Profile Top Flange C-15 TuffCam™ Low Profile Bottom Flange C-17 TuffCam™ Low Profile Rod Position Sensing C-18 TuffCam™ Low Profile Magnetic Position Sensing C-19 VersaCam™ Frequently Asked Questions C-20 VersaCam™ Clamp Time and Flow Rates C-20 VersaCam™ Features C-21 VersaCam™ Threaded Body C-23 VersaCam™ Threaded Long Stroke C-25 VersaCam™ Top Flange Mount C-27 VersaCam™ Bottom Flange Mount C-29 VersaCam™ Clocking C-29 Swing Restrictors C-30 Swing Clamp Arms Frequently Asked Questions C-31 Standard Arm C-31 Upreach Arm C-32 Extended Arm and Length/Pressure Limitations C-33 Double Ended C-33 Self-Produced Standard Arm C-34 Double Ended Rocker C-35 Double Ended Rocker Dimensions and Application

PUSH/PULL

G-1 Frequently Asked Questions G-2 Block Pull FITTINGS/ HOSES AND MANIFOLDS

H-1 6 mm Tube H-2 8 mm Tube H-3 Adapters, Extenders, Plugs and Seals

H-3 Quick Connector H-4 Hoses and Tubing H-4 Manifolds ROTARY UNIONS I-1 Rotating Unions I-2

Two Path Rotating Union Four Path Rotating Union Six Path Rotating Union One Path Angle Rotary Union One Path Axial Rotary Union

I-3 I-4 I-5 I-6

POWER SUPPLIES

C-36 Low Profile Extended Arm C-36 Low Profile Standard Arm C-37 Low Profile Double Ended Arm C-38 Low Profile Upreach Arm C-39 Self-Produced Low Profile Arm D-1 Frequently Asked Questions D-2 TuffLink™ 360° Twin Lever D-6 TuffLink™ 360° Single Lever D-8 TuffLink™ 360° Single Acting D-10 TuffLink™ 360° Double Acting D-12 Standard Link Clamp

J-1 Frequently Asked Questions and Hydraulic Oil J-2 Booster, Compact Air/Hydraulic J-3 Booster, with Control Packages J-4 Compact Air/Hydraulic Pump J-5 .75kW Advanced Workholding Pump J-6 .75kW Advanced Workholding Pump Options J-7 .75kW Advanced Workholding Pump Convenience Packages J-9 1.5kW Low Pressure Advanced Workholding Pump J-10 1.5kW Low Pressure Advanced Workholding Pump Packages J-12 Power Boss J-13 Portable/Electric Hydraulic Pump J-14 Threaded Body and Block Body Screw Pump

LINK CLAMPS

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Contents

Quick Reference

PALLET FIXTURE ACCESSORIES K-1 Frequently Asked Questions K-2 Manual Shutoff Valve Decoupler K-3 Automatic Shutoff Valve Decouplers K-4 One-Handed Operating Handle K-5 Two-Handed Operating Handle K-6 Two-Handed Operating Handle with Air K-7 Accumulators K-9 Thread-In Coupling Elements K-11 Guardian K-13 Handle Docking Module

PLANNING

WORK SUPPORTS

SWING CLAMPS AND ARMS

LINK CLAMPS AND LEVERS

HARDWARE

L-1 Mounting Hardware L-1 Spherical Contact Points ACCESSORY VALVES

SPECIAL USE CLAMPS

M-1 Frequently Asked Questions M-2 Flow Control and Check Valves M-3 In The Port Sequence Valves M-4 Air Sensing Control Kit M-4 Filter Plates M-5 In The Port Flow Control M-6 Unclamp Delay Valve M-7 Pilot Operated Check Valve M-9 Sequence Valve M-11 Sequence Valve Cavity M-13 Sequence/PRV Combination M-14 Pressure Reducing Valve

CYLINDERS

PUSH/PULL CYLINDERS

FITTINGS/ HOSES AND MANIFOLDS

ROTARY UNIONS

M-16 Low-High Valve Sequence/PRV Block M-17 Alternating Pressure Solenoid Valve M-18 Gauges, Filters, Relief M-20 Mechanical Waterproof Pressure Switch M-20 Electronic Pressure Switch M-21 Pneumatic Confirmation Valve DIRECTIONAL CONTROL VALVES N-1 Frequently Asked Questions N-2 CETOP 3 Valves 2-Position 3-Port N-2 CETOP Sub-plate N-3 Seat Valve, 2-Position 3-Port N-4 Manual Seat Valve, 2-Position 2-Port & 2-Position 3-Port

POWER SUPPLIES

PALLET FIXTURE ACCESSORIES

HARDWARE

ACCESSORY VALVES

N-5 Manual Seat Valve, 2-Position 3-Port N-6 Manual Seat Valve, 3-Position 4-Port

DIRECTIONAL CONTROL VALVES

N-7 Solenoid, 2-Position 3-Port N-7 Solenoid, 3-Position 4-Port N-8 Solenoid, 3-Port 4-Position N-9 Solenoid, 4-Port 3-Position

DRAWING VIEW - CONVERSION

O-1 CONCEPTS, FIXTURE LAYOUTS O-3 CONVERSION AND DRAWING INFORMATION MODEL INDEX SAFETY

SAFETY

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Why use VektorFlo ® Metric?

Most expensive CNC metalworking machines are purchased without fixtures to hold the workpiece(s). Today’s sophisticated machines make tool changes in fractions of a second and cut at speeds and accuracies we once thought nearly impossible. The speed and quality of part clamping is the next important opportunity for time saving and productivity improvement. VektorFlo ® power clamps provide the "helping hands" to present more parts to the machine spindle with less effort, more consistency, and greater productivity at a cost only modestly more than manual fixtures. Use VektorFlo ® because it can increase your productivity. The selection of any single brand of hydraulic clamp, as any other important decision, must be made from an informed, intelligent point of view. Your choice should be based on many factors influenced by your specific application. Other factors can be used for general comparison and are strong indicators of the overall quality of the brand selected. Before making any decision, we ask that you take time to accurately compare product quality, product and information availability, technical support and service both before and after the sale. When you do, you’ll find VektorFlo ® "head and shoulders" above the rest! This is why Vektek is the world's leading manufacturer of power workholding products. Quality Product When we, at Vektek, made the decision to enter the Hydraulic Clamping market we knew that another "me too" product would not succeed. Professional users expect top quality products backed by knowledgeable technical support. They also expect ready availability of parts when needed. Armed with this knowledge, our team of engineers began an extensive product development process. Exhaustive research, design, development and testing yielded a unified product line all of which incorporate the following appropriate features: n BHC™, a special black hard coating, makes VektorFlo ® bodies extra durable. This high tech surface hardening process virtually eliminates the bore scoring and scratching that is the most common reason for seal failures and leakage in some brands.  Hardened and Chromed bearing surfaces are incorporated to provide improved load bearing areas where it is critical to device life.

A typical customer finds that it goes like this:

 Every device is ported using standard G1/4 or G1/8 L-Series porting. O-Ring porting normally installs without leaking the first and every time.  Special seals and wipers help keep leaks from starting by sealing fluid in and contaminants out. Loaded lip and crown seals virtually eliminate external (visible) and internal (invisible) leaks. Most devices incorporate a wiper to keep chips from entering the cylinder and damaging the seal. VektorFlo ® seals have been tested in most common coolants and found to be stable in all those tested.  Warranty is an indication of a manufacturer’s confidence in the ability of the product to run "trouble free" for a specified time. Our hydraulic products are warranted for one year from date of shipment. For details see our printed warranty statement. Compare the durability and long life of our devices with that of competitors. Prove it to yourself. We welcome any head-to-head run-off. Availability of Product & Information We customarily maintain inventory of all items in this catalog. This enables us to respond quickly to help you in a difficult situation. Many VektorFlo ® devices are interchangeable with competitive devices to help you out of a tight spot. Please plan adequate lead times into your production schedule when ordering large quantities. We have attempted to create a catalog that is easy to read, understand and use. You will find the catalog organized so that you can find specifications, dimensions and product specific features without a lot of useless rhetoric. Should you need information not contained in this catalog, our Application Engineering Staff would be happy to answer your questions. Service Before The Sale Our unique blend of telemarketing, catalog, web, and technical support is there for you when you need us. Pick up the phone and call us toll free. We’ll do our best to answer your questions, solve your problems or just discuss your application at your convenience. There is no charge for this service.

 After several conversations with a Vektek sales representative, you may uncover an application where hydraulic clamping will pay for itself in a very short time.  Call us at your convenience and discuss the application with one of our Application Engineers. They may ask you to send information about your current fixture, part, machine and/or processes for them to study and propose a clamping concept.  At your request, we will develop a custom hydraulic clamping concept based on your part and send drawings to help you in the finalization of your fixture design. We can even include a Bill of Materials, if you request one.  To aid in your fixture design, CAD files for each product are available to you online at www.vektek.com or by requesting a USB drive from your sales representative.  After your design is complete, call us to place your order. Again, call on your schedule, when you need the components. It’s our job to deliver promptly.  One more thing to keep in mind . . . You can have all this service at no charge! Call us and see for yourself. Service After The Sale Unlike some sales people, we don’t and won’t disappear after the sale. We want your fixture to work right the first time and keep on working. If it doesn’t work CALL US, you’ll find us ready to help.

Remember when you dial 913-365-1045 you talk to us, we can’t and won’t hide! We want your business today, tomorrow

and next year. We will continue to do what it takes to earn your business and respect. We want to help make your business more profitable.

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Planning

Introduction

Planning Your Power Workholding System . . . Successful powered workholding does not just happen. Like any other manufacturing process, it must be carefully planned. But that does not mean that you need to be a hydraulics engineer to implement a powered workholding system. Designing a system involves nothing more than the common-sense application of a few basic workholding concepts. the forces. Don’t risk damaging a machine bed because you tried to tie a 30 kN clamp into a T-slot that would only withstand 15 kN of force. Using power workholding does not in any way invalidate the principles of sound fixture design. The 3-2-1 concept as it relates to the location of the workpiece in three planes is just as applicable when using power workholding devices as when using manual methods.

A-1

You should select "realistic" cycle times . . . the shorter the cycle time, the larger the power source you will require. For example, a pump with a 1/3-hp electric motor may be satisfactory to reach clamping pressure on a given system in three seconds. However, to accomplish the same task in one second may require a pump with a 1-hp electric motor — at a considerable increase in both initial expense and operating costs. So before you specify "instantaneous" cycling, be sure the increased clamping speed is really worth the higher costs for your particular installation. Ask yourself if you can productively utilize the seconds saved. With this in mind, let’s proceed step by step through a plan of attack for designing your system.

Applications for power workholding fall into two categories: retrofits to replace and upgrade clamping on existing fixtures and new fixtures designed from the outset with power workholding. In both cases it is imperative that you keep in mind the forces that can be generated by power workholding devices. A single device, small enough to hold in your hand, can generate five tons of clamping force. If you are replacing existing manual bolt and nut clamping or toggle clamps, make sure that the fixture or machine tool base will withstand For information on workholding products used in inch applications, contact your Vektek Customer Support Specialists and request our Inch Hydraulic catalog.

Workholding devices should be positioned in such a way as to ensure firm contact between the workpiece and locating buttons, pins, or surfaces. Begin the planning process by asking yourself the following: What do you want your system to accomplish? What sort of operation is going to use this system? What clamping "speed" is appropriate for the speed at which your production line runs?

In order to support our process of ongoing product improvements, specifications are subject to change without notice. Due to these improvements, products may not be exactly as illustrated. Visit our website PDF catalog for the most current catalog illustrations... www.vektek.com You will also find a CAD library on the website to assist in designing Vektek product into your machine fixture projects.

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Planning

Steps 1-13

Step 1: First, determine the nature of the operation to be performed, the number of parts to be processed per cycle, and whether operations will be performed on more than one surface of each part. Also determine the time that should be allowed for part loading, unloading, and clamping the part. Consult your machine tool file to determine the available work space on the machine table, bed, chuck or other surface, as applicable. Be sure that the space available will accommodate the part or quantity of parts to be processed according to your manufacturing work-flow. If not, revise your plan. In the initial phases of system planning, include adequate measures and devices to ensure the safety of workers and equipment. For more information, see the safety section on the back inside cover. Step 2: Prepare an outline of the sequence of events that will take place during the manufacturing cycle. This will assist you in determining the types of special sequencing valves that you might need, as well as any external control (such as a tie-in with machine controls) that your application may require. Step 3: Calculate the cutting forces generated in the machining process and note the direction that these forces tend to act on the workpiece. If you are planning a retrofit of a manual clamping system, you may use the torques presently being used. However, it is recommended that cutter forces be calculated as a precaution in such a case to ensure that workholding devices are sized to provide an adequate margin of safety. The operation manuals of many machine tools contain tables that list machining forces or simple formulas for calculating these forces. But if you can’t find the information, give us a call. We’ll be glad to get you started. Step 4 Plan your fixture(s) with positive fixed stops to resist the majority of cutting forces and to ensure correct location of the workpiece using the primary part locating features.

Step 5: (Optional) Normally you need to calculate the forces required to overcome workpiece weight and friction and to move the part into position against fixture stops. However, with our systems, this is an optional step, thanks to the two-stage design of VektorFlo ® hydraulic power sources. The low-pressure high-flow first stage will move clamping devices into position around the workpiece and generate sufficient force to settle the workpiece against fixture stops before high-pressure clamping forces are generated. Additionally, in many applications, the nature of the fixture itself will ensure that the part is located closely enough to eliminate the need for positioning devices as a separate fixture element. Step 6: After you have determined the machine cutting forces, it is easy to calculate the clamping force required to hold the workpiece on the fixture or machine table. Again, a simple formula is all you need to arrive at an answer for the materials you’ll be working. Give us a call if you need help. Step 7: Determine where clamps should contact the part to hold or support it securely and to avoid interference with machine operations. If clamps cannot be located so as to avoid interference with manufacturing operations, it will be necessary to use an external control device to move the clamps out of the way as the need arises during the manufacturing sequence. This will require that electrically actuated valves be used to control the offending devices separately. D etermine the type and number of workholding devices you need based on the total clamping force required and clamping positions you’ve selected. Choose by the size, strength and shape of the part, and on the machine operation. Step 9: To help determine the capacity of the power source you’ll need the total oil displacement requirements for the devices you have selected. Then choose a power source with equal or greater capacity and determine if it operates the system within your clamping time constraints by completing the “Calculate the Approximate Clamping Time of a Fixture” worksheet in Section A. Step 8:

Step 10: Select valves and other control components to accomplish the sequence of operations you outlined in Step 2. See the valve section of this catalog for guidance. Step 11: Select appropriate safety control mechanisms. All VektorFlo ® electrical power modules have a hydraulic pressure switch as standard equipment to ensure that consistent forces are maintained at all times. However, when a power source is used to power several separate individual systems, each system should also have its own pressure monitor. Step 12: Finally, select the plumbing components required to connect the power source to the valves and devices. Review your system specifications and layout to determine what you need in terms of ratings, sizes, and lengths. Step 13: Call us for help. Our application engineers do not design fixtures. Their job is to help you use hydraulic clamps successfully. Whether you are retrofitting existing fixtures, need a concept for clamping a new part or want a quick review of your design we stand ready to help Metric VektorFlo ® customers. Call +1-913-365-1045 for everything you need in power clamping. Discover how easy, economical, and efficient power clamping can be — with one call. We’ll be glad to answer your questions, provide concepts or advice, and give you a quote. Please visit us at www.vektek.com to download our most current CAD files.

A-2

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Planning

Calculate the Approximate Clamping Time of a Fixture 1. Anticipated system operating pressure =__________________________________________________ (Bar) 2. For each non sequenced branch of a system: A. [Effective area per device __________ (cm 2 )] x [stroke used _________________ (cm)] =_ __________ (cm 3 ) B. Total number of devices = _______________________________________________________ C. Multiply line (2-A) x (2-B) = _____________________________________ ________________ (cm 3 ) D. Repeat steps (2-A) thru (2-C) for each different device and / or stroke length:____________________________ (cm 3 ) E. Total non-sequenced volume = lines (2-C) + (2-D) = _ _____________________________________ (cm 3 ) 3. First stage pump flow rate (faster - cm 3 /min, lower pressure) from the corresponding pump specifications page or Vektek catalog =_ _____________________________________________ (cm 3 /min) 4. Approximate time to achieve low pressure function = [line (2-E) ÷ line (3)] x (60) = _______________________ (seconds) 5. For each circuit branch with a sequence valve [if no sequence valves are used, skip to line (5-J) and enter -0-]: F. [Effective area per device__________ (cm 2 )] x [stroke used ________________ (cm)] = _ ___________ (cm 3 ) G. Total number of devices =_______________________________________________________ H. Multiply line (5-F) x (5-G) = _ ____________________________________________________ (cm 3 ) I. Repeat steps (5-F) thru (5-H) for each different device and / or stroke length: = _ ________________________ (cm 3 ) J. Total sequenced volume = line (5-H) + (5-I) =_ _________________________________________ (cm 3 ) 6. Estimate the approximate accumulator volume (if no accumulator is used, enter -0-): K. 49-0116-XX ≈ .155 x ____________ (system pres. - Bar) _ ________________________________ (cm 3 ) L. 49-0114-XX ≈ .045 x ____________ (system pres. - Bar) _ ________________________________ (cm 3 ) 7. Estimate the approximate flex hose expansion volume (*): M. Flex hose expansion volume (cm 3 / m) = _______________________________________________ (cm 3 / m) N. Total length of hose used (m) = ____________________________________________________ (m) O. Multiply line (7-M) x (7-N) =_ ____________________________________________________ (cm 3 ) P. Repeat steps (7-M) thru (7-N) for each different sized hose _ ____________________________________ (cm 3 ) Q. Total expansion volume for flex hoses = line (7-O) + (7-P) = __________________________________ (cm 3 ) 8. Low flow volume of devices in the system = line (5-J) + line (6K or 6L) + line (7-Q) = _____________________ (cm 3 ) 9. Estimate the anticipated volume of oil in the plumbing lines of the system: R. Steel tubing: 6 mm O.D. (x 4 mm I.D.) = (12.57 cm 3 / m) x (______ m) =_ ________________________ (cm 3 ) S. Steel tubing: 8 mm O.D. (x 5 mm I.D.) = (19.36 cm 3 / m) x (______ m) =_ ________________________ (cm 3 ) T. Flexible Hose: 4.8 mm I.D. = (18.10 cm 3 / m) x (______ m) = ________________________________ (cm 3 ) U. Flexible Hose: 9.53 mm I.D. = (71.25 cm 3 / m) x (______ m) =_ ______________________________ (cm 3 ) V. Total of lines (9-R) thru (9-U) =____________________________________________________ (cm 3 ) 10. Estimated total fluid in system = lines (2-E) + (5-J) + (6K or 6L) + (7-Q) + (9-V) = ____________________ (cm 3 ) 11. Approximate fluid compression factor = [line (10)] x [line (1) ÷ 17575] =_ ___________________________ (cm 3 ) 12. Second stage pump flow rate (slower - cm 3 /min, higher pressure) from the corresponding pump specifications page or Vektek catalog: _______________________________________________ (cm 3 /min) 13. Approximate time to achieve high pressure function = [line (8) + line (11)] ÷ line 12 x 60 =_________________ (seconds) 14. Estimated position and clamp time {** below} = line (4) + line (13) + 1.25 (motor control performance factor) = _ _________________________________________________________ (seconds) Note: * Not all hose manufacturers provide this information however, some logical value must be added to accommodate the hose“swell” volume when pressurized. See the hose chart in the “inch” section of the Vektek web site for examples. ** Flow rates will be additionally influenced by the style and number of fittings, control valves, specialty valves, manifolds, hose connectors and quick connects. Final positioning and clamping time can vary slightly from the above calculated times due to actual physical plumbing installation.

A-3

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Planning

Frequently Asked Questions

Frequently Asked Questions This list of questions was developed by

A-4

Is my plumbing free of obstructions and contaminants?

When I use a dial indicator on my part, it bends when it is clamped. Why? Clamps should be positioned directly opposite a fixed locator, hydraulic support, or other supporting element. This element may be a part of the fixture, a solid portion of a rigid part or a properly sized floating locator such as a hydraulic work support. If your clamp is putting force into your part which is not transmitted directly into a solid stop, it may distort the part. Clamping on draft angles or "mushrooming" the part with excessive force can also cause part distortion. Send us a print of your fixture design, we will be pleased to evaluate it and make suggestions. I hold all four corners of my part on solid locators. When unclamped, it seems to "spring" back into a different shape. Why? First, holding all four locating points in exactly the same plane on your fixture is virtually impossible. (See your favorite text on fixture design for an explanation of 3-2-1 fixturing principles.) Second, because your part can’t have all four of these points in the same plane, your part is distorting when clamped. Other factors such as stress relief may cause the part to change its "free" shape after machining. My pump turns on and off approximately every 3-5 seconds. Why? There could be several causes: A "spool" valve when used with a demand pump will cause it to turn on and off as its internal leakage bleeds off pressure. Use of spool valves voids warranties on VektorFlo ® pumps. We suggest the use of "zero leak" poppet or shear seal type valves.

listening to customers just like you when they asked, "Why didn’t I know that?" Before you order devices, build your fixture or even consider your design complete, we suggest that you run through this checklist to identify some common problems you might encounter. Double acting cylinders will assure full cylinder retraction on a timely basis even in systems where restrictions such as small orifices or long tubing runs have been introduced. The use of double acting cylinders is especially important if "plunger return" time is critical (as in Should I use or at least consider using double acting cylinders? some CNC systems). We also recommend use of double acting cylinders in systems operating below 60 bar (6 MPa). If single acting cylinders must be used ask yourself these questions. Have I reduced the number of fittings (orifices), length of tubing and restrictions as much as possible? Are all of these properly sized? Some fittings and hoses which are locally available (not from Vektek) have extremely small orifices which restrict flow. The use of G1/8 or similar size fittings can have this effect on a system. This restriction is even more pronounced when introduced at a main feed line. This can happen with some fittings and many hoses. Excessive tubing length can create a column of oil which is very long. Friction created by moving oil through tubing and hose will slow response times because of the inertia of the column of oil and increased back pressure of returning oil. If single acting springs are all that is pushing this oil, it is possible that this back pressure can become sufficient to stall the cylinder. Proper sizing of fittings for main feed lines and device supply lines will normally be accomplished by using the appropriate VektorFlo ® fluid distribution manifold. Device fittings are G1/4 or G1/8. Main feed lines should be at least 8 mm to avoid restrictions.

Tubing must always be flushed after cutting it. Even if not cut in your shop, it was cut before it came to you. Chips, burrs, dirt and other contaminants have collected inside your tubing and drilled passages. These contaminants can cut device seals, damage valve sealing surfaces, cause erratic operation and reduce service life if not cleaned prior to fixture start up. The use of improper fittings can also cause obstructions and restrictions. Be sure you haven’t created obstructions by using non-standard parts. Is my pump of appropriate size? It is rated for____l/min, or _____cm 3 per minute. My devices require a total of _____cc. of oil to actuate. For most normal size fixtures, a pump rated over 8 l/min (Liters per minute) is not recommended. If your pump is rated much more than 4 l/min, call us. It is better to give you sound advice now than have you damage clamps. Be sure that you do not exceed the recommended flow rates for your system. If you aren’t sure, ask us. My pump runs continuously. Is it the right type of pump? Call us. It can often be made to work. Some modifications will probably be necessary. If you have a VektorFlo ® pump which runs continuously, call us immediately (they are not designed to run continuously). I’ve been using a dump pump (builds to pressure, shuts off and releases pressure automatically). Is this pump suitable for workholding? It can be. It will work if the circuitry is properly designed. It may require special circuit modifications or a special pallet decoupler to work properly. I want to make a cut directly against (into) a clamp. Is this possible? Yes, it is but it will require special design considerations. We encourage that cutter forces always be directed toward a fixed stop. A fixed stop is designed to prevent part movement. A clamp is designed to position and force a part against a fixed stop. In order to machine "into" a clamp, the clamp must be sufficiently sized to resist all cutter and machine forces or the part will tend to shift.

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Frequently Asked Questions

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Industrial type double acting cylinders are not designed for clamping. These cylinders, even high quality ones, have significant leakage across their internal seals. This leakage will not normally be externally visible. Internal leaks from one side of the piston to the other will cause pumps to cycle excessively.

I need to disconnect my fixture from the pump. I also need double acting clamps. How can I do this? Vektek has designed several configurations in Automatic and Manual Shutoff Valve Decouplers to fit your application. VektorFlo ® automatic valve decouplers work with either single or double acting devices. Manual decouplers, originally designed for single acting systems, include an auxiliary port that can be used for double acting systems. By adding a second quick disconnect to the auxiliary port of the manual decoupler (we suggest female), connecting a second line and employing appropriate valves you can decouple your fixture from the power supply for machining. (Top plates or manual decouplers with self- closing valves are not designed for use with double acting circuits.) We run a fixture for 3 months, store it for 6 months, then bring it back on line. How can we keep everything working? Preventive maintenance . Before you store your fixtures, be sure that they are free of coolants, coolant buildup, clean and dry. A light coating of corrosion protection may help. Be sure to store in a cool, dry, clean environment. We encourage the use of double acting clamps on fixtures which will be stored for extended periods. Our clamps are used for cast iron grinding. Our coolants also seem to be corrosive (our fixture plates rust). Will your clamps stand up to this? Nothing is going to be 100% foolproof. Our extensive use of hard chrome plating, stainless steel and our corrosion resistant BHC™ will give you the best possible resistance to corrosion. Our processes will allow our clamps to run longer with fewer problems even in this destructive environment. Preventive maintenance is essential to keep hydraulic systems and components running at peak performance through millions of cycles. Be sure to flush your entire system at least once a year and more frequently in high contamination environments.

When I unclamp my single acting clamps, a small amount of coolant comes out of the vent port. I am running flood coolant and the clamps are covered during the entire machine cycle. Can I eliminate this problem? Maybe. We suggest you run a vent line to fresh air from each breather port. This can be done in copper or plastic tubing. If you can’t get to fresh air, a trap in the tubing or protected vent inlet area will reduce the amount of coolant entering the cylinders. Keeping the coolant out will reduce the chance of corrosion in the cylinders. It will also keep the cylinders from having to expel the coolant as they return causing sluggish return. Our swing clamps are now available with bottom venting to allow them to breathe dry air from protected areas under the fixture. When I look at my clamps, there are threaded holes in them. What do the labels "P" "ADVANCE" "RETRACT" mean? These threaded holes are called ports. The label "P" or "ADVANCE" ports are normally used to clamp the part, "RETRACT" indicates the port normally used to unclamp or retract the clamp. My local chemical representative has recommended the use of "water-glycol" hydraulic fluid. What are the benefits of this fluid and should I use it? Water-glycol is a nontraditional hydraulic fluid. This fluid was developed for use where petroleum based fluids are not allowed. They are commonly used in areas requiring "flameproof" fluid. They often cause problems with device seals, valves and pumps. We do not recommend water-glycol fluids. We may in some cases be able to provide devices with seal compounds acceptable for use in this environment. We cannot recommend or warrant their use in any Vektek pump or directional control valve.

NOTE: These cylinders should be avoided in all palletized

applications as they may cause pressure loss or back pressure quick disconnects.

All leaks at fittings, seals, or other typical leak points will eventually cause a pump to cycle. If your VektorFlo ® pump cycles more often than you feel appropriate (more than once per minute without a valve being shifted) call us. We will gladly offer advice. I want to limit the pressure into a sequenced hydraulic circuit. Which valve would I install first? We recommend that you avoid putting one special function valve behind another if possible. If you must, put the pressure limiting valve after the sequence valve. This avoids the limiting valve being shut off before the sequenced circuit is fully actuated. I want several sequenced operations to happen on my fixture. Can I put three or four sequence valves in series? We do not recommend it. Our sequence valves operate better if run directly from the main hydraulic supply line and set at different pressures. We recommend at least a 35 bar (3.5 MPa) differential. My company uses a lot of brass fittings on our product. Can I use these to connect my hydraulic clamps? No, brass fittings and some aluminum or steel fittings are for low pressures. Be sure that locally sourced fittings are rated for 350 bar (35 MPa) operation. We do not recommend the use of lower pressure fittings. Ask your local source for high pressure BSPP S-Series fittings.

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Frequently Asked Questions

I need some type of retractable locator. After my part is loaded, I want it to "disappear." Do you have anything to do this? Block pull cylinders or any double acting cylinder may be used in this way. If a highly precise location is required, please be sure to use a guide bushing to provide more precise location. How do I read my gauge and what does it mean? First, release all pressure on the system. Check the gauge for proper operation. Check to be sure that the gauge is returning to "zero." Pressurize the system and read the gauge. The current reading from the gauge indicates the pressure your clamping system operates at when clamped unless there is a pressure limited circuit branch. (The entire system equalizes at this pressure and ∆ P is negligible when under static clamping conditions.) I need a clamp just like your 41-5011-11 except it needs a 150 mm long rod. Can you help me? Maybe. We do entertain specials from time to time. Please ask us. We often find that "special" requests coincide with our ongoing new product development. If you have a special need, it is worth asking. We may decide to do your special as a development project. We may not be able to produce it (actually you may not want it) because of cost. It may be something we have done before and will be relatively easy. The danger involved in using "specials" is that we do not stock replacements on custom parts. When your machine crashes (when, not if) and you need a rush spare, custom parts have to be made from scratch. You will need to order spares at the time of the original order. The cost of a single replacement on a complicated special can often be 5-10 times the cost paid in the beginning. A little foresight will be very beneficial if you must have a special.

What about using seals made of Viton ® ? Seals made of fluorocarbon, such as Viton ® , can be a good answer for high heat applications, up to 178°C; however, fluid type is also important. It may be acceptable in most fluids at lower pressures, but fluorocarbon is not a universal remedy for all fluid problems. There are other acceptable seal compounds for use in water-glycol and other unusual fluids. Our staff can help direct you to a seal that is best suited to perform in your application. Because seals made of fluorocarbon may work in your application, we offer this as an option on many of our cylinders; call for details. How hot is too hot to run hydraulic fluid? Anything above 177°C is considered too hot for most hydraulic fluids and seals. Our standard seals are rated to operate at temperatures from 4°C to 71°C. Even seals made of Viton ® (fluorocarbon) are not recommended above 177°C. For advice on high heat applications, I have my cylinder hooked up to a pump. It extended but won’t retract. What have I done wrong? Is there a directional control valve in the circuit? If not, one is required. Is the cylinder single or double acting? Can you provide a schematic or simple hand sketch for us to troubleshoot? We are glad to help. I want to run my clamps on air. I really don’t need much force. Since these cylinders are being used to position workpieces, is it OK to use air? Some of our cylinders (but not work supports) can be run on air, others may be adapted. If air will provide adequate force and you are happy, so are we. In some cases straight line cylinders and work supports have been run successfully using high pressure gas. Swing clamps may not be used on high pressure gas. Please call our factory for information on our pneumatic clamping line, specifically designed for workholding with shop air (available in inch measures only). please contact Vektek’s Engineering Department who stand ready to help.

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If you have questions you’d like answered, call, write, fax or e-mail us. We would be glad to help you use VektorFlo ® products more effectively. +1- 913-365-1045 1334 East 6th Avenue Emporia, KS 66801 USA Fax: 1-816-364-0471 internationalsales@vektek.com

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Fixture Documentation Worksheet

VektorFlo ® Hydraulic Fixture Setup Documentation and Troubleshooting Worksheet

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Fixture Designed By: __________________________________ Fixture Built By: ______________________________________ Built For: __________________________________________ Fixture Serial # ______________________________________

1. All pressure gauge readings checked and verified at "0" operating pressure. ______ Yes ______ No 2. Main system operating pressure read from the gauge mounted on the clamping system pump ______ bar (MPa) or inlet air pressure from air gauge

on boosters ______ bar (MPa), booster ratio ______:______. 3. Pump restart pressure checked. Pump restarts at ______ bar (MPa). 4. Fixture operating pressure read at fixture gauge ______bar (MPa), side A and ______bar (MPa), side B 5. Pressure limit circuits pressure checked: Side A ______ bar (MPa) Components & location: ______________________________________ Side A ______ bar (MPa) Components & location: ______________________________________ Side A ______ bar (MPa) Components & location: ______________________________________ Side B ______ bar (MPa) Components & location: ______________________________________ Side B ______ bar (MPa) Components & location: ______________________________________ Side B ______ bar (MPa) Components & location: ______________________________________ 6. Sequence operations set to: Side A ______ bar (MPa) Components & location: ______________________________________ Side A ______ bar (MPa) Components & location: ______________________________________ Side A ______ bar (MPa) Components & location: ______________________________________ Side B ______ bar (MPa) Components & location: ______________________________________ Side B ______ bar (MPa) Components & location: ______________________________________ Side B ______ bar (MPa) Components & location: ______________________________________ 7. Fittings checked, secure, no leaks, proper type, not restrictive. ______ Yes ______ No 8. Schematic diagram attached. 9. Bill of materials (hydraulic components) attached.

For troubleshooting assistance contact your Designer/Builder or complete steps 1-9 above and fax this sheet with all additional pages to 1-816-364-0471. We are pleased to be of service.

© 1996-2019 Vektek, This documentation sheet may be used to document fixtures built using VektorFlo ® brand hydraulic clamps. This sheet is copyrighted material and remains the sole property of Vektek. The use of this documentation sheet in its original form or altered state to document fixtures with non-Vektek product is a violation of your assigned rights .

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Fixture Building Tips

General Tips n When Manifold mounting VektorFlo ® components the mating surface must be flat within 0.08 mm, with a maximum surface roughness of 1.6 µm R a for proper sealing (unless otherwise noted in the catalog). n Fluorocarbon seals are available for most components (except power supplies) that do not include them in the device design. These items may be ordered online or on fax orders by adding an “F” as the last digit of the model number. When ordering with one of our order entry specialists, please mention that you would like fluorocarbon seals. n Unless otherwise noted in our catalog, VektorFlo ® devices require a minimum pressure of 34.5 bar (3.4 MPa) for double acting components and 51.7 (5.2 MPa) bar for single acting components. n Maximum system flow rate is 5.7 l/m for all VektorFlo ® special function valves. Excess flow voids warranty. n Deburring of pockets or cavities is extremely important to avoid leaks from damaged seals. n Fluid filtration to catch chips will prevent leaks and extend the life of your components. n Preventive maintenance is essential to keep hydraulic systems and components running at peak performance through millions of cycles. Be sure to flush your entire system at least once a year Work Support Tips n Length of thread engagement on Fluid Advance work support contact bolt determines the spring contact force. n Tighten with a six point socket only. Other types of wrenches may damage the work support. Swing Clamp Tips n Never allow swing clamp arm to contact the workpiece during arm rotation. n Use of optional bottom porting on all single acting swing clamp models may significantly reduce contamination potential. Contact your Vektek Customer Service representative for details on the bottom porting option. n Swing restrictors are available in 30°, 45° and 60° angles. Order from your Vektek Sales Representative or Order Entry Specialist. Other swing restricting angles are available upon request as a special. and more frequently in high contamination environments.

Plumbing Tips n Use of standard rubber hoses and end fittings can hamper the action of many devices due to excessive end fitting restrictions. If you choose to purchase hoses from another supplier, be sure that hose diameters and end fittings are not causing excessive restrictions. Power Supplies n To extend the life of your hydraulic pumps: * Hydraulic fluid should be changed and the reservoir cleaned out annually * If you operate a full production schedule (one shift daily): change fluid twice annually * Two shifts daily: change fluid three times annually * Three shifts: four times annually * In very dirty conditions (foundries): change hydraulic fluid monthly 1. Flow Rate : Time Requirement? SYSTEM VOLUME ÷ FLOW RATE = TIME 2. Power Supply: MANUAL, PNEUMATIC, or ELECTRIC 3. System Requirements: SINGLE ACTING, DOUBLE ACTING, n Pump Selection: Accessory Valves n The “CETOP” valve interface used on our surface mounted (manifold) valves was designed to allow mounting in only one direction. This interface has (4) fluid passages, P, T, A and B, as well as four mounting holes. The distance between the mounting holes on one end (31 mm) is not equal to the distance between the holes on the opposite end (32.5 mm). The narrower hole pattern is 21.5 mm from centerline of mounting hole to centerline of the “P” passage, while the wider hole pattern is only 19mm center to center. This non-equal mounting spacing is intended to prevent the valve from being installed incorrectly. CONTINUOUSLY COUPLED, DECOUPLED or PALLETIZED

Speed Control n Flow controls are often required to make swing clamps and work supports function at appropriate speeds. Swing clamps may be damaged by swinging large mass arms at a greater distance from the clamp centerline than recommended on the catalog pages. Work supports may advance with speed faster than expected, bounce off of the intended part surface and become locked before the spring can mechanically re-extend them. n In cases where speed control is necessary, all workholding devices should be flow controlled with “meter-in” devices like our in-line or in-port flow controls with free-flow return. Needle valves or “meter-out” flow controls, as are often used in pneumatics, should not be used to prevent a pressure intensification which may occur on “meter-out” hydraulic applications.

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Arms/Levers n When installing a swing clamp arm,

restrict the arm to prevent rotational torque to the plunger and potential internal cam damage. You may then tighten the cap screw to specification without damage to your clamp.

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