Electric Clamping

efficient and ready for serial production

Ratingen, den 27.08.2014
Electric clamps – no witchcraft involved

- Electric clamps are no longer innovations

- TÜNKERS has been supplying e-clamps for more than 20 years!
 2 disadvantages prevented industrial breakthrough

1. Efficiency
The technically complex concept including motor (servo), reduction
gear unit and toggle-joint mechanism, lead to prices of factor 3-5 in
comparison with pneumatic clamps.

2. Lack of acceptance of 240/ 400 V – drives by production

The blanket application of 240/ 400 V clamps is rejected by most
plants for safety reasons.

2
New TÜNKERS electric compact clamp
24 V DC (low voltage)

Driven via special spindle /

toggle-joint mechanism

Self-locking trapezoid spindle

Aluminium housing compatible
with the pneumatic series = same
arm and housing connection
Standard sensing cartridge
T12

24 V DC high-volume motor
Protective aluminium housing
with robust 5-pole Harting
standardised plug

3
Principle of electric clamp with
DC motor (24 V)

Emergency release in power-

free condition

Standard toggle-joint mechanism

Housing compatible with the

pneumatic series

Trapezoid spindle for power

transmission

Standard DC motor
(24 V DC) originating from high- Return signals Open/ Closed
volume automotive production via T12 sensing system

Central plug for power supply

and thermal protection

4
Serial Vario concept

• The desired opening angle can be set

freely via the bottom end switch of the
sensing system.
• The self-locking function of the spindle
also ensures safe positioning in opened
position.

5
Product range: EK series

EK 25.1 EK 40/40.5 EK 50 EK 63 EK 80

Spannmoment/
25 Nm 120 Nm 160 Nm 380 Nm 800Nm
Clamping moment
Haltemoment/
75 Nm 200 Nm 800 Nm 1500 Nm 2500 Nm
Holding moment
Spannung/
24V 24V 24V 24V 24V
Supply voltage
Gewicht/
1,5 kg 3,15 kg 4,3 kg 7,3 kg 15 kg
Weight
Länge/ 212
296 mm 367 mm 377 mm 485 mm
Length mm

Tiefe/
70 mm 140 mm 150 mm 150 mm 185 mm
Depth
Breite/
52 mm 54 mm 68 mm 78 mm 110 mm
Width EK 63

EK 50

EK 25.1
EK 40
10.05.2016 Product range: EK series 6
Features:
E-clamp with 24 V DC drive

 24 V DC voltage is already used by automotive plants for control and

sensing technology
 Low voltage – Safe operator protection!


 Broad and cost-effective range of very compact motors of different
manufacturers on the market
 Only the energy that is actually needed is consumed. Maintanance of
voltage is not required during standstill.
 Energy consumption is subject to loads. More energy can be saved by
optimising the weight of the clamping point


 Additional 24 V net required (transformers and decentralised supply)
 High currents  limited cable lengths, large cross-sections and central
power supply

7
 Control concepts

10.05.2016 Kapitel 8
Conventional control concept
Electric clamps

Sensor / Feedback 24 V

PLC Power via contactor 42/400 V

9
Concept for decentralised control unit

Bus system

“Motor terminal“ instead

24 VDC of valve terminal
PLC
= Decentralised
- Motor control
- Input/ Output signal
control unit management
≈ - “Cycle cascading”

Up to 8 clamps per control unit

400
230 VAC
110

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Concept 1
motorisland instead of valve island

400V or 220V…
1x TVM

24V 24V

2x TMI8
information
SPS

16x EK
Clamps
max.

10.05.2016 Concept 1 11
Motor terminal TMI8
the new valve island

• Power supply for 8 clamps (engine performance and sensor)

• Integrated bus interface (Profi-Bus, Profi-Net, Ethernet, IP, etc.)
• Moving single electric clamps or groups,
• Motor island provides the tact cascading to prevent voltage peaks of
the engines independently of the PLC
• Control and feedback of e-clamp position to higher-level PLC
• The CPU is relieved and the positioning is done in a timely manner
without influence of the CPU cycle time.
• Display for status of the e-clamp
• Preselection and control (open / close) of the clamp with arrow keys
• 4 additional M12 connectors for up to 8 additional initiators or
photocells

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TVM8
converting 400V/220V in 24V

• The power supply of

each motor terminal is
safeguarded by a
power supply unit.
• The input voltage is
adjusted to the
customer‘s grid.
• As an encapsulated
version needs to be
offered as well,
electrochemical
double layer
capacitors are used
• because
currents of 8 x 6 A are
to be realised.

10.05.2016 TVM8 13
Motor terminal TMI8
Control unit for up to 8 clamps

View of the new motor terminal TMI8

Power connection Bus connection Menu keys Supply 24 VDC for

E-clamp IN / OUT sensing unit + motor
Sensing Info display additional
E-clamp digital inlets 14
Power consumption of an electric clamp
(here EK 50.1)

Power
consumption
max. 13A
• High momentary power
consumption during
start-up

• High power consumption

during closing / clamping
Averaged ≈ 6A

t
Start-up peak Clamping operation

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“Motor terminal“ ─ Manager of power
consumption

A. Theoretical overlap of power B. Cycle cascading through

consumption, e.g. when 5 intelligent clamp control via
clamps are purely operated in “motor terminal“
parallel

500 % 5

2 150 %

100 % 1
100 %

 High net/ transformer output  Low net/ transformer output

 5-fold power consumption in total!  1.5-fold power consumption in
total
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Concept 2
decentralized Cartridge concept

1x TSM1 for
1x EK Clamp

10.05.2016 Kapitel 17
Additional control variants (1/2)
Control cabinet module TSM1

• Control cabinet module for Opening and Closing an

Electrical Clamp
• Integrated H-bridge to gear the motor in both
directions
• Housing compatible for control cabinet
TSM1 the movement speed in 4
• DIP switch to approach
steps
• Front LEDs Spannermodul Produktbeschreibung

Power supply available

LED grün +24V Versorgung vorh. Das Modul TSM1 dient zum Öffnen und
LED rot °C/F Overheated
Übertemp. motor Schliessen eines Elektrospanners. Es ist mit
Motor
LED rot Motor Störung Ausgang
Error outlet einer H-Brücke ausgestattet, die es erlaubt,
LED gelb öffnen den Gleichstrommotor in beiden Richtungen
Opening
LED gelb schließen anzutreiben und zu bremsen.
Closing Aufbau im 22,5mm-Modulgehäuse.
LED gelb geöffnet
Opened Die Geschw indigkeit des Spanners kann in
LED gelb geschlossen 4 Stufen von je 25% über DIP-Schalter an
Closed
der Front eingestellt w erden
2 Eingänge 24V Schließen / Öffnen
2 Eingänge 24V Endlagenmelder
1 Eingang Thermokontakt 18
Die Ansteuerung ist von der Versorgung
Concept 3
Hand-held control

Status LEDs • Driving an electric clamp on

handheld with integrated
24V battery for direct power
supply of the clamp
Hold-to-run control
OPEN/CLOSE • Tip operation and reduced
speed for easy setup
process

Connection for the

power supply of an
electrical clamp

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Energy and cost comparison
Example: Fixture with 10 size-50 clamps
50er Baureihe; 135° Öffnungswinkel Vario-Serie Electric Clamp

Einzelspanner Vorrichtung Einzelspanner Vorrichtung

Energieverbrauch (bei 6 bar) [l] [l] [kWh] [kWh]

Energieverbrauch (l bzw. kWh) (Zyklus) / Energy Consumption (l or kWh) (cycle) 1,71 17,10 0,00003 0,0003

Energieverbrauch (Zyklus) Spannerstelle inkl.

Druckluftzuleitung (3m) » 1,8 l /
Energy consumption (cycle) clamping point incl. 3,52 35,20
Compressed-air supply line (3m) » 1,8

Energieverbrauch (0,13 kWh/m³) / Energy consumption (0,13 kWh/m³) [kWh] [kWh] [kWh] [kWh]

pro Tag (1.000 Zykl / Tag) / per day (1,000 cycles / day): 0,46 4,58 0,03 0,30 In terms of
pro Jahr (250 Tage) / per year (250 days): 114 1.144 7,50 75 operating costs the
Im Projekt (8 Jahre) / during the project term (8 years): 915 9.151 60 600
electric clamp beats
CO2-Emission (600 g/kWh) / CO2-emission (600 g/kWh) [kg] [kg] [kg] [kg]
its pneumatic
counterpart by the
pro Tag (1.000 Zykl / Tag) / per day (1,000 cycles / day): 0,27 2,75 0,02 0,18
factor 15
pro Jahr (250 Tage) / per year (250 days): 69 686 4,5 45

Im Projekt (8 Jahre) / during the project term (8 years): 549 5.491 36 360

Betriebskosten (1,43 ct/m³ ─ 11 ct/kWh) [€] [€] [€] [€]

pro Tag (1.000 Zykl / Tag) / per day (1,000 cycles / day): 0,050 € 0,50 € 0,003 € 0,03 €

pro Jahr (250 Tage) / per year (250 days): 12,58 € 125,82 € 0,83 € 8,25 €

Im Projekt (8 Jahre) / during the project term (8 years): 100,66 € 1.006,59 € 6,60 € 66,00 €

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Additional 24V DC electric components
Electric pin units

• Electric unit for pin unit functions or as a feed unit for NC-blocks /
contour pieces
• Dual push rod as a precise, robust and protected against twisting
guide element
• Gear by a conventional DC motor 24 V
• Locked end position up / down even when the voltage drops by self-
locking of the drive spindle

Typ/Type Hub / Stat. Entspr Zugkraft / Druckkraft / Gewicht /

Stroke Querkraft Kolben ø tensile force compressive weight
max (N) /side (mm) / comp. force
force Piston ø

ESZK 40 40 150 40 400 200 3,0

ESVD 50 40 400 50 640 700 7
ESZK 63 40 200 63 1400 1400 3,8
ESZK 80 80 800 80 1150 1300 24

eSZK 80

eSZVD 50

eSZK 40

10.05.2016 Weitere 24V DC Elektro-Komponenten 22

Mini-Elektro linear guide – EMS 40.5

Features:

EK 40.1 Compact electric carriage in width as electric clamp

Linear movement of the clamp e. g. at robot gripper in

two defined working positions

Max. Stroke 50 mm

Bolted end position by self-locking of the drive spindle

Adapter compatible with the clamp size 40 fit? To

Eurogreifer- and tubular gripper system

EMS 40.5

10.05.2016 Produktportfolio Spanntechnik 23

Electric linear unit

Pneumatic units and swiveling units have the equal conditions to consider. Small loads and long
cylce times are unproblematic, but heavy loads and short cycle times are with compressed-air
difficult to handle. The Tünkers electric power systems and Tünkers automatic traversing units
provide not only performance-enhancing and more dynamic traversing axes, but also an integrated
servo trigger with a freely programmable linear axle as optimized solution.

1 Robust rail guide

2 Recirculating ballscrew
5
1 3 Servodrive with brake

2
4 Protective plate for mechanism

3 4 5 Housing in stable steel plate design

Typ Max. load stroke

LE 60 30 kg 0-200
LE 100 100 kg 0-500
LE 200 200 kg 0-500
LE 500 500 kg 0-500
10.05.2016 Produktportfolio Spanntechnik 24
Thank you for your attention.
Contact:
Tünkers Maschinenbau GmbH
Am Rosenkothen 4-12
40880 Ratingen
E-mail: info@tuenkers.de
Mr Stefan Bröxkes
Mr Christian Kleinschmidt
Telephone +49 (0) 2102-45 17-0
Telefax +49 (0) 2102-45 17-9999
Internet: www.tuenkers.de
Telephone +49 (0) 2102-45 17-167
E-mail: stefan.broexkes@tuenkers.de
Telephone +49 (0) 2102-45 17-595
E-mail: christian.kleinschmidt@tuenkers.de
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