the constantly increasing demand in resources and energy of people and business leads to more and...

World of Vacuum Technology

J. Schmalz GmbHAacher Strasse 29D-72293 GlattenTel. +49 (0)7443 2403 0 Fax +49 (0)7443 2403 259 [email protected]

Innovative Vacuum for Automation

Vacuum ComponentsCatalog 2012 / 2013

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CanadaSchmalz Vacuum Technology [email protected]

ChinaSchmalz (Shanghai) Co. [email protected]

FinlandOy Schmalz [email protected]

FranceSchmalz S.A.S.Champs sur [email protected]

GermanyJ. Schmalz [email protected]

IndiaSchmalz India Pvt. [email protected]

ItalySchmalz S.r.l. a Socio [email protected]

JapanSchmalz [email protected]

The NetherlandsSchmalz [email protected]

PolandSchmalz Sp. z [email protected]

RussiaSchmalz [email protected]

South KoreaSchmalz Co. [email protected]

Schmalz Worldwide

Find your local sales partner by visitingwww.schmalz.com/salesnetwork

SpainSchmalz S.A.Erandio (Biscay)[email protected]

SwitzerlandSchmalz [email protected]

TurkeySchmalz Vakum San. ve Tic. Ltd. [email protected]

United StatesSchmalz [email protected]

Scan code to access the digital catalog

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Tel. +49 (0)7443 2403 102 Tel. +49 (0)7443 2403 107 Tel. +49 (0)7443 2403 108 Tel. +49 (0)7443 2403 109

Vacuum Handling Systems Vacuum Clamping SystemsVacuum Gripping Systems

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World of Vacuum Technology

J. Schmalz GmbHAacher Strasse 29D-72293 GlattenTel. +49 (0)7443 2403 0 Fax +49 (0)7443 2403 259 [email protected]

Innovative Vacuum for Automation

Vacuum ComponentsCatalog 2012 / 2013

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CanadaSchmalz Vacuum Technology [email protected]

ChinaSchmalz (Shanghai) Co. [email protected]

FinlandOy Schmalz [email protected]

FranceSchmalz S.A.S.Champs sur [email protected]

GermanyJ. Schmalz [email protected]

IndiaSchmalz India Pvt. [email protected]

ItalySchmalz S.r.l. a Socio [email protected]

JapanSchmalz [email protected]

The NetherlandsSchmalz [email protected]

PolandSchmalz Sp. z [email protected]

RussiaSchmalz [email protected]

South KoreaSchmalz Co. [email protected]

Schmalz Worldwide

Find your local sales partner by visitingwww.schmalz.com/salesnetwork

SpainSchmalz S.A.Erandio (Biscay)[email protected]

SwitzerlandSchmalz [email protected]

TurkeySchmalz Vakum San. ve Tic. Ltd. [email protected]

United StatesSchmalz [email protected]

Scan code to access the digital catalog

S

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Vacuum Components

Tel. +49 (0)7443 2403 102 Tel. +49 (0)7443 2403 107 Tel. +49 (0)7443 2403 108 Tel. +49 (0)7443 2403 109

Vacuum Handling Systems Vacuum Clamping SystemsVacuum Gripping Systems

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Schmalz Online Shopwww.schmalz.com

Complete product range Easy and secure orderingComprehensive services

Your personal online shop account Quick checking of prices and availability Order history all orders visible at a glance,

complete with status Simple and fast follow-up and spare-part ordering Tracking see where your order is at any time

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Schm

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Contents

Page

Company Profile | Efficiency and Sustainability |Business Areas | Industry Solutions

Vacuum System and its Components | System Design |Units and Conversion Tables | Vacuum Glossary

Universal Suction Pads (Flat, Bellows) | Suction Pads for Special Applications (Metal, Wood, Packaging etc.)

Floating Suction Pads | Magnetic Grippers |Needle Grippers | Wafer Grippers | Composite Grippers

End Effectors | Jointed Mountings | Spring Plungers | Holders | Sections and Connectors

Ejectors | Vacuum Units |Pumps | Blowers

Solenoid Valves | Check Valves | Sensing Valves | Non-Return Valves | Manual Valves

Vacuum Switches | Pressure Switches |Measurings and Control Devices | Warning Devices

Vacuum Filters | Distributors |Hoses and Connectors | Accessories

Large-Area Gripping Systems | Layer Gripping Systems |Suction Spiders

Services | Test Center |Set of Test | Schmalz Academy

Schmalz Worldwide |Imprint

Products Sorted Alphabetically |Products Sorted by Industry

Schmalz - The Company

Vacuum Knowledge

Special Grippers

Mounting Elements

Vacuum Generators

Valve Technology

Switches and System Monitoring

Filters and Connections

Vacuum Gripping Systems

Services

Contact

Index of Products

Vacuum Suction Pads

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Consistent customer orientation and groundbreaking innovations,excellent quality and comprehensive consulting competence makeSchmalz the world's leading partner for vacuum technology inautomation, handling and clamping applications.

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We are committed to maintaining a fair partnership with our customers and suppliers: one that is beneficial for all parties.

Schmalz is a family-run company, and we focus on long-term objectives. Our companyphilosophy is based on the principle of sustainability: economic success combined withecological and social engagement. This ensures that we remain self-sufficient andaffords us the necessary creative freedom.

Our sustainability principle as well as our lean and efficient processes keep us perma nently competitive and reassure our customers that we are the right choice fora long-term partnership. Our customers associate Schmalz with innovative productsand services, advanced technology that is available worldwide, as well as unsurpassedapplication knowledge.

Convincing customers requires enthusiastic employees, who develop excellent inno -vative products and market these in accordance with customers requirements and profitability. The Schmalz employees derive their motivation for their above-averageefforts and loyalty from a modern corporate culture and share in the economic successof our company.

Our companys readiness and capacity for change is important to us personally. We have,for example, already positioned ourselves successfully for the future by founding ourown subsidiary companies in the most important international growth markets.

You will profit from a partnership which ensures long-term and real advantages overyour competitors rely on Schmalzs world of vacuum technology.

Dr. Dipl.-Ing. Kurt SchmalzManaging Director

Dipl.-Ing. Wolfgang SchmalzManaging Director

Our Purpose

Dipl.-Ing. Wolfgang SchmalzDr. Dipl.-Ing. Kurt Schmalz


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Dynamic Growth is our Passion

Founded: 1910 by Johannes Schmalz

Market importance: Leading global supplier of vacuum technology in the areas of automation, handling and clamping technology

Business areas: Vacuum components Vacuum gripping systems Vacuum handling systems Vacuum clamping systems

Employees: More than 650 worldwide, 13% trainees (DE)

Innovation indicators: About 350 industrial rights chartered and granted 7% of turnover spent on research and development

Subsidiaries abroad: In 15 countries worldwide

Sales partners: In over 40 countries worldwide

Turnover quota: Around 50% Germany Around 50% International

Certifications: DIN ISO 9001 (quality management) since 1994 DIN ISO 14001 (environmental management) since 1997


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CanadaSchmalz Vacuum Technology Ltd.17-3190 Ridgeway DriveON L5L 5S8 Mississauga Ontario

Tel +1 905 569 9520Fax +1 905 569 [email protected]

ChinaSchmalz (Shanghai) Co. Ltd.1F Building No.1Jinhai Rd 1000 Jinlin Industrial Park 201206 Pudong, Shanghai

Tel +86 (0)21 510999 33Fax +86 (0)21 503988 [email protected]

FinlandOy Schmalz AbHakkilankaari 201380 VANTAA


FranceSchmalz S.A.S.Le Promthe65 Avenue du Gnral de Gaulle77420 Champs sur Marne


GermanyJ. Schmalz GmbHAacher Strae 2972293 Glatten


IndiaSchmalz India Pvt. Ltd.EL 38 J Block MIDCBhosari411026 Pune


ItalySchmalz S.r.l. a Socio UnicoVia delle Americhe 128100 Novara


JapanSchmalz K.K.3595 Ikonobe-choTsuzuki-ku224-0053 Yokohama

Tel +81 (0)45 308-9940Fax +81 (0)45 [email protected]

NetherlandsSchmalz B.V.Lansinkesweg 47553 AE Hengelo


PolandSchmalz Sp. z o.o.Al. Jerozolimskie 20202-486 Warszawa

Tel +48 (0)22 4604970Fax +48 (0)22 [email protected]

RussiaSchmalz Reprsentanzul. 26 Bakinskikh Komissarov, 9Office 109119571, Moscow


South Korea Schmalz Co. Ltd.Room 728, 775-1 Janghang 2-dong IlsandongGu GoyangCity KyungkiDo


SpainSchmalz S.A.Avda. Ribera de Axpe. 49P.A.E. UDONDO-Edificio B-Nave 248950 Erandio (Vizcaya)


SwitzerlandSchmalz GmbHEigentalstrae 18309 Nrensdorf


TurkeySchmalz VakumSan. ve Tic. Ltd. ti.Yeni Yol Sokak Cecanlar merkezi No: 20/2-334718 Acbadem Kadky STANBUL

Tel +90 (0)216 34001 21Fax +90 (0)216 34001 24 [email protected]

United StatesSchmalz Inc. 5200 Atlantic Avenue Raleigh, NC 27616


Schmalz Subsidiaries

Together with customers, the Schmalz system consultants design an appropriate vacuum system for the individualapplication. Whether you are looking for a vacuum solution for automation technology, handling technology orclamping technology, Schmalz is the right partner.

The sales network, with local field representatives, international subsidiaries and trade partners, ensures quickand competent information and advice.

International Sales NetworkExpertise in 50 countries


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The constantly increasing demand in resources and energy of people and business leads to more and more bottle -necks and increasing costs in material procurement. For this reason, it is necessary to deal with materials andresources in an efficient manner for reasons of economy and sustainability.

Process-OptimizedThese points are very important to Schmalz. Therefore the company has organized its processes to gain added value.The added-value system pursues aims such as lowest production and process costs, shortest processing times, lowstocks and at the same time highest quality. The added-value system, together with the companys modern workplaces, is the basis for efficient production and its ability to compete over the long term.

At Schmalz state-of-the-art production and logistic concepts determine most of the everyday tasks in manufactu-ring. For example, Schmalz uses the one-piece flow concept whenever it is possible and makes sense to do so.With this concept, the vacuum specialist can avoid large lot sizes, thus saving material and warehouse space. The manufacturing processes were changed over to piece-by-piece assembly. A second product is not manufactureduntil the first product is completely assembled and tested.

The milk run concept in conjunction with kanban warehousing makes material available to the employees asrequired and at the right time. Both of these systems ensure that material is refilled only in the quantity in whichit was consumed.

These innovative process optimizations provide lean processes and economical materials handling.

Quality ManagementAt Schmalz, the customer stands at the center. The goal is to meet the customers demands and deliver products in a quality, that it is expected by the customer.

The processes and procedures at Schmalz are based on the extensive know-how, many years of experience, mostmodern concepts and international standards. Since 1994 the quality management system of the vacuum specialisthas regularly been certified to DIN ISO 9001.

Computer Aided Quality (CAQ) software informs the employees of the company constantly on the current qualitylevel, so that Schmalz can react quickly to changes. Modern manufacturing concepts provide for early fault detectionand troubleshooting. "Continuous improvement" is part in everyday life and develops employees, companies andproducts continuously. This reduces the company's level of error in longterm.

Efficiency and Sustainability

Schmalz value creation


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Suppliers are also an important part of the overall system. Schmalz demands the same quality standard from suppliersas it demands of itself. Continuous supplier development contributes to the overall success of the company.

Efficient ProductsIn the development and manufacturing of its products, Schmalz puts great emphasis on efficiency in terms of energyconsumption and recyclability. Apart from the functionality, aspects such as a long service life, high efficiency andgood recyclability are taken into consideration. Therefore Schmalz has developed vacuum generators with an integrated air-saving function, lifting devices with a wireless remote control and suction pads with separable elastomer part and nipple, just to name a few.

Sustainability in PracticeSchmalz has made the principle of sustainable development one of its corporate objectives. Only sustainablegrowth allows Schmalz to protect its corporate interests. Since Schmalz is thinking in the long-term, the companyaligns its corporate strategy in such a way that economics, ecology and social commitment complete each other.This means Schmalz is able to finance its own growth in order to ensure secure jobs and actively realize our socialand ecological responsibility.

The special importance of sustainability is reflected in the corporate principles. The company management andemployees are required to think and practice business with environmental awareness. As a positive energy com -pany, Schmalz generates more energy from renewable sources then the company consumes itself. It is the firm opinion of the vacuum specialist that economic success goes hand-in-hand with the awareness of ecological andsocial responsibility.

Schmalz exceptional dedication has gained wide recognition and has been rewarded with numerous awards.


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Vacuum Components and Gripping Systems

Vacuum components and vacuum gripping systems from Schmalz permit decisive productivity improvements in automated processes. Be it in mechanical engineeringor in the robot industry Schmalz customers in all areas of automation technologyprofit from our qualified system consultancy services and our groundbreaking, innovative solutions. The range of workpieces which can be handled with vacuumextends from easily damaged, small parts such as electronic chips or CDs to furnitureelements or heavy sheets of steel.

Our specialists expertise guarantees efficient and economical solutions for theautomation of a process; from the individual components, to the complex grippingsystem, all the way through to the particular customer-specific application.

Vacuum Components Vacuum suction pads Special grippers Mounting elements Vacuum generators Valve technology Switches and system monitoring Filters and connections

Vacuum Gripping Systems Fully configured systems for industrial robots and portals, delivered ready for connection

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Vacuum Handling Systems

Business Areas

Vacuum handling systems from Schmalz rationalize and simplify production processes by facilitating easy and efficient workpiece handling. They feature functionality, safety and ergonomic operation in processes such as the loading and unloading of machines.

Vacuum Tube Lifter Jumbo Vacuum tube lifters Jumbo are ideal for the frequentand rapid lifting and moving of cardboard boxes, sacks,barrels, and numerous other applications weighing upto 300 kg.

Vacuum Lifting Devices VacuMaster Vacuum lifting devices VacuMaster are the ideal toolfor the ergonomic and safe handling of loads weighingup to several tons.

Cranes and Crane SystemsVarious working ranges, load classes and aluminum or steel crane rails facilitate their use in a variety of applications.

Workshop EquipmentWorkshop equipment provides invaluable support intrade and industrial production processes; in the woodand solar energy industries, for example.


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Vacuum Clamping Systems

Schmalz vacuum clamping technology enhances the efficiency in production processes for CNC machine tools.Innovative ideas, numerous national and international trade mark rights, system diversity and customer focushave made Schmalz to the world market leader in the area of vacuum clamping technology.

We are the system supplier to the internationally leading manufacturers, who equip their CNC machining centresas standard with Schmalz clamping systems, thus ensuring maximum productivity for their customers.

Clamping Solutions for the Wood Industry Profitability through shorten set-up times

Clamping Solutions for the Metal Industry Precise and secure

Modernising Retrofitting for consisting machines Set-up reduced by up to 80 percent

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Industry Solutions

In all areas of automation technology, Schmalz customers benefit from expert systems consulting and ground-breaking, innovative solutions. Schmalz vacuum components include everything they need to develop a fully operational vacuum system.

The wide product range of vacuum components corresponds to the specific requirements of a wide variety ofindustry sectors. The focus is on the industries described below. In the catalog, the industry-specific suitability of each product is indicated using symbols. The index at the end of the catalog can assist in finding appropriateitems for your industry sector.

Wood Handling of workpieces with a variety of surfaces underdifficult operating conditions Suction pads for handling and separating workpieces

the suck-through effect Comprehensive range of filters for protecting vacuum

systems from contamination Large area vacuum gripping systems for moving wooden

sheets, furniture parts, pallets or entire layers of boards

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Metal sheets /automotive Fast cycle times and high operational reliability Special suction pads for highly dynamic metal sheet

handling, even with oiled metal sheets or fragilecomponents

Vacuum generator with integrated system monitoring,condition monitoring and IO-Link technology forincreasing process reliability and improving energyefficiency

Optimized mounting elements for the requirementsof the automotive industry

Worldwide at home in many industries


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Packaging Packaging of goods and handling of packaged products with minimal cycle times Complete suction pad offering with a large variety of materials and geometries for a wide range of packaging

and products Large range of vacuum generators for various process requirements Modular system VEE for quick and cost-efficient assembly of vacuum end effectors Vacuum layer gripping systems for palletizing and order picking of packaged products

Plastics Removal of hot plastic partsleaving very few marks Special materials of the

suction pads with tempe-rature resistance require-ments, requirements relating to the ability topaint or varnish the work-piece and requirementsthat very few marks beleft on the workpiece

Vacuum generator mini -mized in size for highlydynamic handling

SolarExtremely fast, accurate and gentle handling Wafer grippers for careful, fast and accurate

handling of photovoltaic components Suction pads in various materials and geometries Special grippers for low-contact and gentle handling


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CompositeHandling of porous composite materials Special grippers with integrated vacuum generation

and high volume flow for secure gripping even incase of porous materials such as carbon composites

Various suction pad geometries and materials providefor adjustment to a variety of applications

Needle grippers for handling of bending and unstablematerials, as well materials to which it is difficult toapply suction

BatteryHandling of electrodes, separators and battery cells without causing any damage Special grippers for lithium ion batteries Ideal marking behavior confirmed in contamination

tests of the FRAUNHOFER IPA Careful, fast and accurate handling of battery

components and cells

CD/DVDClean and flexible vacuum handling Complete suction pad range in a wide variety of materials for all processing steps

in CD/DVD production Vacuum generator with integrated system monitoring for increasing process reliability Small vacuum components minimized in size for highly dynamic handling

GlassMark-free and secure gripping Suction pads especially for handling flat, smooth

and thin workpieces Special suction plates made from special materials

for use in areas with high UV and ozone levels


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Overview of Section 2

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The Vacuum System and its Components

Basic Vacuum Knowledge and Vacuum Terminology

Page

Overview of a Vacuum System

Vacuum Suction Pads

Special Grippers

Mounting Elements

Vacuum Generators

Valve Technology

Switches and System Monitoring

Filters and Connectors

44

System Design Calculation Example 47

Symbols in Vacuum Technology 56

Units and Conversion Tables 57

Vacuum Glossary 59

Seminars and training

19

20

27

30

32

37

39

42

Schmalz offers customized training, seminars and courses at the Schmalz Academy. Customers benefit from our comprehensive expertise and all our years of experience as vacuum specialists.You will find more details in the chapter Services.


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Overview of a Vacuum System

Vacuum systems are used as grippers in automated applications. Customers benefit from the comprehensive component program ofSchmalz, the vacuum specialist, when designing a vacuum system.

Filters and connectors

Filters protect the vacuum generator;hoses and connectors connect the components

Switches and system monitoring

Measuring and control componentsensure safe operation of the vacuumsystem

Vacuum generators

Centralized or decentralized vacuum generation by means ofejectors, pumps or blowers

Mounting elements

Fast and flexible connection ofvacuum components to toolingsystems Vacuum suction pads or special grippers

Interface between vacuum system and workpieceValve technology

Valves are used to control the vacuumas well as the compressed air (decentralized or centralized)

Vacuum gripping systemsComplete solutions, such as large-area grippingsystems, layer grippers or vacuum spiders, arecustomized to meet customer needs

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Vacuum suction pads are the link between the workpiece andthe handling system. They consist of the suction pad (elastomer

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Suction pads from Schmalz can be divided into universal suction pads and suction pads for special applications. Universal suction pads cover a wide range of requirements. Suction pads for special applications were developed to meet the requirements of individualindustries. They may be characterized by special properties, such as the handling of thin-walled and greasy body panels in the sheetmetal industry or of porous and structured workpieces in the wood industry.

Suction Pad Shapes

Vacuum Suction Pads

part) and a connecting element.

Suction pads are used to gripand move workpieces in a plantor on a robot. A suction paddoes not attach itself to the surface of a workpiece. Instead,the ambient air pressure (atmos -pheric pressure) presses thesuction pad against the work-piece as soon as the ambientpressure is greater than thepressure between the suctionpad and the workpiece.

This pressure difference is achieved by connecting the suction padto a vacuum generator, which evacuates the air from the spacebetween the pad and the workpiece. If the suction pad is in con-tact with the surface of the workpiece, no air can enter it from the sides and a vacuum is generated.

The holding force of the suction pads increases proportionally with the difference between the ambient pressure and the pressure inside the pad.

The holding force of a suction pad is calculated with the formula:

F = p x A

F = Holding forcep = Difference between ambient pressure and pressure of the systemA = Effective suction area (the effective area of a suction pad under vacuum)

This means the holding force is proportional to the pressure difference and the suction area. The greater the difference between ambient pressure and pressure in the suction pad or thelarger the effective suction area, the greater the holding force. The force can vary depending on a change of the pressure difference and area parameters.


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Advantages of flat suction pads Large variety of different suction pad materials and shapes

(round, oval, steep or flat leveling sealing lip) Flat shape and low inner volume result in minimum evacuation

times Good stability of the suction pad allows for high shear forces

and positioning accuracy while workpieces are picked up

Typical areas of application Handling of smooth to lightly rough workpieces, such as sheet

metal plates, cardboard, glass plates, plastic parts and woodenboards

In automated processes with short cycle times

Bellows Suction PadsBellows suction pads are used when it is necessary to compensate for varying workpiece heights, to handle parts with uneven surfacesor fragile parts. The bellows make this suction pad especially flexible and adaptable.

Advantages of bellows suction pads Good adaptation to uneven surfaces Lift effect while picking up Compensation of differences in height Fragile workpieces are picked up gently

Typical areas of application Handling of curved or uneven workpieces, such as body panels,

tubes, cardboard, etc. Handling of fragile workpieces, such as electronic components,

injection molded plastic parts, etc. Handling of non-rigid or flexible workpieces, such as packaged

or shrink wrapped products

Both types of suction pads are available in a wide range of shapes and sizes. You will find more information on basic data and applications for the individual series in the chapter Vacuum Suction Pads.

Application and ambient conditions are important for the selection of the right suction pad and the appropriate material. Abrasion resistance, oil resistance and food safety are often required of a suction pad. These requirements can be met by selecting theappropriate material.

Schmalz develops its suction pad materials in-house with new materials being developed, tested and optimized in our own PlasticsCompetence Center.

Suction Pad Materials

The following shapes are generally distinguished: Flat suction pads Bellows suction pads

Each suction pad shape offers advantages that are reinforced and optimized by the combination with a suitable material. The availablesuction pad materials are described in detail in the section Suction pad materials.

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Flat Suction PadsFlat suction pads are particularly suited for handling workpieces with flat or slightly curved surface. Flat suction pads can be evacuatedquickly due to their flat shape and low inner volume, therefore they can grip the workpiece in a very short time and can withstand theforces which result from fast movement of the object during handling.


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Material Overview

* Approximate value: depends on ambient temperature, application force, recovery time and wall thickness of suction pad** After-bake of silicone 4 h/200 C = ~+5 Shore A*** With slight oil wetting**** Varies, for technical reasons, for foam rubber

Exellent Very good Good Poor to satisfactory

Chem

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Abbreviation

Chemical designation /trade name

Color / coding

General weathering resistance

Ozone resistance

Oil resistance

Fuel resistance

Alcohol resistance, ethanol 96%

Solvents resistance

General resistance to acids

Steam resistance

Wear resistance

Resistance to permanent deformation

Tensile strength

Specific resistance in [ x cm]

Shore hardness to DIN ISO 7619

Short-term in C (< 30 sec.)

Longer-term in C

Target industry

Food grade according to CFR 21 177.2600 FDA

Leaving few marks

Absence of PWIS (paint-wettingimpairment substances)

NBR NBR-AS SI SI-AS NK HT1

Nitrile caoutchuc Silicone caoutchuc Natural High temper-(AS = antistatic) (AS = antistatic) rubber ature

material

black, gray, black with white (trans- black with gray, light blueblue, light blue blue dot lucid), green red dot brown, black

107 107

40 to 90 5 55 5 30 to 85 5** 55 5 30 to 90 5 60 5

-30 to +120 -30 to +120 -50 to +220 -35 to +220 -35 to +120 -25 to +170

-10 to +70 -10 to +70 -30 to +180 -20 to +180 -25 to +80 -10 to +140

Universal Universal Packaging, Packaging, Wood, Plastics,CD/DVD CD/DVD, Packaging Glass

Electronics

NBR-60, NBR-45


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Material Overview

ED PU VU1 PVC FPM CR EPDM EPDM-MOS ECO

Elastodur Polyurethane Vulkollan Polyvinyl Fluor- Chloroprene Ethylene- Foam rubber Epichlorchloride caoutchuc propylene- made of Ethy-

caoutchuc lene-propy-lene-caoutchuc

green, blue blue, dark green blue black with black, gray black, gray black, gray blackdark green (translucid) white dot

*** ***

( )

( )

60 to 85 5 55 5 72 5 50 5 65 5 20 60 55 5 ~15**** 60 5

-40 to +100 -40 to +130 -40 to +100 -30 to +65 -10 to +250 -40 to +100 -35 to +130 -35 to +100 -25 to +160

-25 to +80 -30 to +100 -40 to +80 -15 to +50 -10 to +200 -20 to +70 -25 to +100 -25 to +70 -25 to +130

Packaging, Packaging Metal, Packaging, Glass, Metal, Glass Metal, MetalMetal Packaging, CD/DVD Solar, Wood Wood

Glass, Wood Met al

ED-85, ED-60


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Observe the following information regarding storage and cleaning for the sensitive elastomer part of the suction pad:Store suction pads in a cool place (between 0 C and 15 C, max. 25 C) that is dark, dry, low in dust and offers protection from theweather, ozone and drafts, as well as stress. The effects of ozone, light (especially UV), heat, oxygen, humidity, as well as mechanicalinfluences, can reduce the service life of the suction pad.

Clean suction pads with soap and warm water, and dry them at room temperature.

Storage and Cleaning of Suction Pads

Certain calculations are required for the selection of individual components when designing a vacuum system. The specified values are based on a vacuum level of -0.6 bar as well as a dry or lubricated workpiece surface. They are given without a safety factor.Depending on the operating conditions, one should keep in mind reductions that may occur due to friction or if a vacuum level is not reached (e.g. due to porous workpieces).

The most important technical data of the suction pads are explained below.

Technical Data of Suction Pads

Theoretical suction force Shear force

The shear force is the force acting tangen-tially to the surface. The specifications inthe catalog are measured values innewtons.

Inner volume

The inner volume indicates the volume ofa body that has to be evacuated to pickup a workpiece. It is used to determinethe total volume of the gripper systemand is included when calculating evacuation times.

The theoretical suction force is the forceacting perpendicular to the surface. The specifications in the catalog are calculated values in newtons.

FGFG

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The design of the suction pad always depends on the actual application For this reason, various physical values must be calculatedand determined before the correct suction pad can be selected.

Later in this chapter the design of a vacuum system is described in more detail based on a calculation example.

Friction coefficientThe friction coefficient describes the relationship betweenfriction force and normal force. It is not possible to specify generally valid values of the friction coefficient between the suction pad and the workpiece. It has to be determined correctlythrough trials with the condition of the workpiece surface(rough/dry/moist/oily) or the properties of the suction pad(shape/sealing lip/sealing edge/suction pad material/Shore hardness) having a major influence.

Calculation of the holding forcesThe calculation of holding forces can only be about theoretical values. In practical applications, many factors, such as the size and shape of the suction pad, the surface finish and the rigidity of the workpiece (deformation) play a decisive role. That is the reason whywe recommend a safety factor (S) of at least 2. The German accident prevention regulation, UVV, prescribes a binding safety factor of1.5. When swiveling workpieces during the handling task, a safety factor of 2.5 or higher has to be used, in order to cope with theresulting turning forces.

The holding force of a suction pad is the product of:

F = p x A

F = Holding force (without safety factor, purely static)p = Difference between ambient pressure and pressure of the systemkA = Effective suction area (the effective area of a suction pad under vacuum)


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Design of the Suction Pad

Minimum radius of curvatureof the workpiece

Suction pad stroke

Refers to the suction pads stroke (z) thatoccurs during evacuation of the suctionpad.

Indicates the radius up to which theworkpiece can be gripped securely withthe respective suction pad.

Friction coefficient approx. approx. 0.51.10.1 0.4

Table of typical valuesWorkpiece surfaceGlass, stone, plastic (dry)Sandpaper (dry)Moist or oily surface

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Suction rate or required volume flow [ ]The volume flow that generates the vacuum is important for thesuction force. The workpiece material is the principal factor for therequired volume flow. The table shows typical values for the volume flow or suction ratedepending on the diameter of the suction pad with smooth andair-tight surface.

Important:Conduct suction trials for porous parts.

Typical value (with smooth, air-tight surfaces)Suction pad Suction area A Volume flow

[cm2] [m3/h] [l/min]up to 60 mm 28 0.5 8.3up to 120 mm 113 1.0 16.6up to 215 mm 363 2.0 33.3up to 450 mm 1,540 4.0 66.6

Plastic sheet: m = 50 kgVacuum: PU = 0.4 barNumber of suction pads: n = 4Measured friction coefficient: = 0.5Safety factor: S = 2

Plastic sheet: m = 50 kgVacuum: PU = 0.4 barNumber of suction pads: n = 4Measured friction coefficient: = 0.5Safety factor: S = 2

A sensible selection is the suction pad PFYN 150 with a nominal diameter of 150 mm.

Calculation example for vertical pick-up:

d = 1.12 x

d = 12.5 cm

50 kg x 20.4 bar x 4 x 0.5

d

For horizontal pick-up:

d = 1.12 x

For vertical pick-up:

d = 1.12 xm x SPU x n

m x SPU x n x

d = Suction pad diameter in cm (with double lip internal diameter, with bellows suction pad = inner diameter of sealing lip)

m = Weight of the workpiece in kgPU = Vacuum in barn = Number of suction pads = Friction coefficient S = Safety factor

Diameter of the suction padThe holding force of a suction pad depends on its effective diameter. The condition of the workpiece and the number of suction padsare also crucial for the holding force that a vacuum system can generate.

The required diameter can be determined with the aid of the following formula:

A sensible selection is the suction pad PFYN 95 with a nominal diameter of 95 mm.

50 kg x 20.4 bar x 4

Calculation example for horizontal pick-up:

d = 1.12 x

d = 8.85 cm


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Special grippers are used in applications in which regular suction pads cannot be used. Special grippers are used to handle wafers,films, paper, fragile workpieces or textile fiber composites. They serve as a connection element between the workpiece and the handling system just like the suction pad.

Schmalz separates special grippers into the following series: Floating suction pads Wafer grippers Magnetic grippers Composite grippers Needle grippers


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Special Grippers

Floating suction pads are pneumatically operated special grippers with integrated vacuum generation. They operate on the Bernoulliprinciple and work as a low-contact system. The workpiece floats on an air cushion at the gripper surface. This makes the floatingsuction pad ideally suited for the handling of very sensitive products. The high volume flow can compensate for leakage, when handling porous workpieces.

Advantages of floating suction pads: Low-contact handling High volume flow Safe separation of thin, porous workpieces Integrated vacuum generation

Typical areas of application: Handling of fiber composites, paper, film, wood veneer, printed

circuit boards, wafers and solar cells Separation of thin, porous workpieces

Floating Suction Pads

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Magnetic grippers provide safe gripping of ferromagnetic workpieces by using the magnetic field of an integrated permanent magnet.The magnet is moved with compressed air to activate and deactivate gripping. Magnetic grippers are operated with pneumatic valves.The gripper does not require a voltage source for this purpose.

Advantages of magnetic grippers: Safe gripping with a permanent magnet is possible without

voltage source Control of permanent magnet with compressed air and vacuum

Typical areas of application: Handling of ferromagnetic workpieces Handling of blanks and perforated plates as well as sheet metal

parts with drilled holes/breakouts or complex shapes Support of vacuum gripping system in highly dynamic handling

of sheet metal parts

Magnetic Grippers

The needles are pressed into the workpiece and herewith the gripping process is realized. The needles are ejected pneumatically. The needles are extended at an angle to ensure reliable gripping of the workpieces. Once the gripping process is complete, the needles are retracted either through spring force or pneumatically.

Advantages of needle grippers: Safe handling of non-rigid materials or materials with an

unstable shape Different shapes for unique operating conditions Selectable needle diameters and adjustable strokes

Typical areas of application: Handling of porous and/or non-rigid workpieces, such as textiles,

insulating and foam materials, fiber composites such as carbonand glass fiber, fleece or felts, carpets, filters, fabric, styrofoamas well as metal foams

Needle Grippers


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Wafer grippers are ideally suited for the handling of sensitive parts, especially photovoltaic components such as wafers and cells. The wafer gripper is equipped with an integrated vacuum generator. The high volume flow and the moderate vacuum level allowgentle handling of workpieces.

Advantages of wafer grippers: Extremely fast and accurate handling; implements cycle times of

less than one second High volume flow with low air consumption Integrated vacuum generation, including blow-off function Many accessories for perfect matching to different process

steps in photovoltaics industry

Typical areas of application: Handling of photovoltaics components also under cleanroom

conditions Handling of fragile workpieces Handling of porous, permeable workpieces

Wafer Grippers

Composite grippers are mainly used for handling fragile workpieces. They are operated pneumatically and have an integrated vacuumgenerator.

Due to their high volume flow and the moderate vacuum level, composite grippers are ideally suited for handling fragile components.

Advantages of composite grippers Secure gripping, even with porous materials or partial coverage Short cycle times and accurate positioning Integrated vacuum generation, including blow-off function High volume flow

Typical areas of application Handling of fiber composites, such as carbon fiber reinforced

composites Handling of electrodes, separators and battery cells Handling of extremely thin, sensitive components Handling of porous, permeable workpieces Handling of blank circuit boards

Composite Grippers

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Mounting Elements

Schmalz offers a broad product range of mounting elements to integrate grippers (suction pads or special grippers) into gripping systems.

The following mounting elements can basically be distinguished: Vacuum end effectors Spring plunger Sections, crossbeams and connectors Jointed mountings Holders and adapters

Products from Schmalz are listed in the chapter Mounting Elements.

Vacuum End EffectorsThe Schmalz modular system for vacuum end effectors (VEE)allows fast, flexible configuration of end effectors for differentprocesses.

A wide selection of combinations of vacuum feed and zones, connection elements and suction pad connections is available tocreate the matching end effector.

Vacuum end effectors can be combined with many suction padsfrom the Schmalz product range (see chapter Vacuum SuctionPads)

Vacuum suction pads(can be selected fromthe Schmalz productrange)

Flange plates

Basic modules

Connectorupper part

Connectornode

Connectorlower part

(incl. sealing element)

Stabilization element(available as suctionpad accessory)

Connectingtubes

Flange modules

G1/8-IG

G3/8-IG

G3/8-IG

G1/4-IG

Plugs


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Sections, crossbeams and connectorsThese elements are used to build the basic structure of a vacuumgripping system. To reduce the number of hoses, you can build thesections as vacuum distributors with end covers and sealing frames.

Jointed mountingsJointed mountings provide a better adaption of the suction padto the workpiece due to the design of Flexolink FLK and balljoint KGL that can be swiveled in all directions.

Suction pads (chapter Vacuum Suction Pads or Special Grippers)

Holders and adaptersThe suction pads are attached to the basic structure or the traverse with holders and adapters. Different types of aluminumsections or square and round tubes are available.

Spring plungersSpring plungers are used to compensate height differences ofworkpieces. They also cushion the impact of the suction pad andallow handling of fragile workpieces.


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Vacuum Generators

Vacuum generators provide the vacuum level that is required for the handling task. The vacuum is created either pneumatically orelectrically.

Pneumatic vacuum generators implement short cycle times and can be integrated directly into the system due to their compact andlightweight design.

Electrical vacuum generators are used in applications when compressed air is not available or when very high suction capacities arerequired.

Pneumatic vacuum generators Ejectors

Electrical vacuum generators Pumps Vacuum Blowers

Important: The nominal suction rate of all vacuum generators is given inl/min or m3/h. The values are based on an ambient pressure of1,013 mbar (sea level) and an ambient temperature of 20 C.

The maximum suction rate therefore indicates the volume flowthat the vacuum generator evacuates from the environment (free flow).

Free pick flow Additional suction while workpiece ispicked up


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Principle of operation of a multi-stage ejector

In addition to the single-stage Venturi principle, there are ejectorsin which the vacuum is created by several Venturi nozzles arrangedin a row. Compressed air is supplied to the ejector through con-nection (A). It passes through several Venturi nozzles (B) arrangedin a row. A vacuum is created and the air is drawn in through thevacuum connection (D). The suction volumes of the individualnozzles add up to form a total suction rate D. The air that wasdrawn in and the compressed air escape through the silencer (C).

Compared to single-stage ejectors, multi-stage ejectors create amuch higher suction rate in the lower vacuum range using thesame amount of compressed air.

The Schmalz multi-stage ejectors are based on the multi-stageVenturi principle.

Advantages of ejectors Compact shape Low weight Fast vacuum generation No flexible parts, resulting in low maintenance and low wear Choose an installation position No heat generation

Typical areas of application Industrial robot applications in all industries, such as feeder

applications in the automotive industry

Ejectors work on the Venturi principle. They are divided into single-stage and multi-stage ejectors depending on the number of nozzlepairs.

The compressed air is supplied through the connection (A) to thesingle-stage ejectors. It flows through the Venturi nozzle (B). The air is accelerated and compressed during this process. After passing through the nozzle, the accelerated air expandsonce again and a vacuum is created. Air is drawn in this waythrough the vacuum connection (D). The air that was drawn inand the compressed air escape through the silencer (C).

The Schmalz basic ejectors, inline ejectors and compact ejectorsare based on the single-stage Venturi principle.

Vacuum Ejectors

Principle of operation of a single-stage ejector


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Basic- and inline ejectors Multi-stage ejectors

Vacuum generators with several nozzlechambers arranged in a row with a veryhigh suction rate.

Used mainly for handling porous work-pieces, such as cardboard, chipboards,OSB or MDF sheets

Compact ejectors

Vacuum generators with integrated valvetechnology and system monitoring,SCPi/SMPi and SXPi/SXMPi series areequipped with IO-Link technology

Control of pick-up and blow-off feasiblewithout external valves

Optional with integrated air-saving regulation

Used in fully automatic handling systems(e.g. sheet metal processing, automotiveindustry, robot applications)

Vacuum generators without valve con-trol and system monitoring with highmaximum vacuum level (85% vacuum)

Used mainly to handle air-tight workpieces

We distinguish between three basic types of ejectors:

Vacuum Pumps

Vacuum pumps include an eccentrically mounted impeller withlamellas (A) which are pressed against the walls of the housingby centrifugal force and thus provide a seal. As the impeller rotates,the size of each chamber (B) varies. As the chamber becomes larger, the air in it expands and the pressure drops, resulting in a partial vacuum. The air is drawn in through the inlet (C), compressed, and ejected through the outlet (D).

Due to their high compression factor, pumps generate a very highvacuum and, according to the type, have a very high suction capacity.

Advantages of vacuum pumps High vacuum with high evacuation volume Central vacuum generation

Typical areas of application As central vacuum generation in gantry handling systems In manual vacuum handling systems In packaging machines

Functional principle vacuum pump


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Vacuum Blowers

The blades (A) transport, accelerate and compress the air on themomentum principle. The air is dragged by the blades in this case.A vacuum is created at the suction end (B) this way. The compressedair (exhaust air) escapes through the outlet opening (C).

Blowers provide a very high suction rate due to the large airchannel volume and specially shaped blades.

Advantages of vacuum blowers Enormous suction rate High leakage compensation Evacuation of large volumes in a short time

Typical areas of application Handling of porous workpieces, such as cardboard, insulation

material, chipboards or bags Functional principle vacuum blower

Dry-running pumps Oil-lubricated pumps

Vacuum pump with extremely highvacuum level (up to 95% vacuum)

Used in handling systems with anemphasis on low noise and low main-tenance as well as high vacuum, forhandling air-tight workpieces

Water-ring pumps

Vacuum pump requiring little mainten-ance with internal water cooling forhandling air-tight workpieces

Used especially in areas with highdemands on ambient air (e.g. packagingin the food industry)

Universal vacuum pumps requiring little maintenance

Used mainly as central vacuum gene-rator in large gripping systems for handling air-tight workpieces

We distinguish between three basic types of vacuum pumps:


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Vacuum blowers Vacuum blowers with reversing

Vacuum blowers are either directly drivenor frequency-regulated.

Used especially for handling porousworkpieces (chipboards, bags, etc.).

Frequency-controlled blowers can be customized by controlling the motorspeed and respectively the suction rate.

Vacuum blower with electro-pneumaticreversing for control of suction, blowingand neutral position.

Used for handling air-tight workpiecesthat are picked up and deposited quickly.

Vacuum Units

Vacuum units are complete solutions with ejector, monitoring andcontrol. The vacuum unit is used as a purely pneumatic vacuumsupply with internal control. The vacuum unit turns off automati-cally due to the pneumatic control when the set vacuum value isreached while picking up a workpiece.

Advantages of vacuum units Universal applications High suction rate Minimum compressed air consumption

Typical areas of application Stand-alone solution, for example, for clamping

and handling tasks

We distinguish between two basic types of vacuum blowers:


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Valve Technology

Valves are used to control vacuum as well as compressed air. They can increase process safety in vacuum gripping systems.

The following functional principles can be distinguished: Solenoid valves for vacuum and compressed air Check valves and flow resistors; sensing valves Manual valves for vacuum and compressed air

Solenoid Valves

Solenoid valves are used to control the flow of vacuum and com-pressed air. The valves themselves are controlled with the aid ofelectrical signals. Solenoid valves are available in various nominalsizes, permitting selection of a valve which precisely matches thecustomer-specific requirements. They are available with direct control as well as with pneumatic pilot operation.


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Check Valves, Flow Resistors and Sensing Valves

Check valves and flow resistors, as well as sensing valves, increasethe process safety and efficiency in a vacuum system.

Check valves interrupt the flow as soon as a certain volume flow has been reached. This will turn off any suction pads in the gripper system that may not be covered completely. The systemvacuum will remain intact.

Flow resistors reduce the flow cross-section in the vacuum system and are mainly used in gripper systems for handlingporous workpieces. By reducing the flow cross-section, the systemvacuum remains intact even if the suction pads are not covered.

Sensing valves open the suction channel with a spring-mountedplunger when a workpiece is present at the suction pad. Whenthe suction pad is occupied (= workpiece present), the line for thevacuum is opened. Sensing valves do not protect the system frompartially occupied suction pads.

Non-Return Valves

Non-return valves seal the vacuum system against leakage, forexample, in the event of a vacuum failure caused by a poweroutage. Thus, gripped workpieces are prevented from falling offthe gripping system.

Manual Valves

Manual valves are used for manual activation or deactivation of vacuum or compressed air circuits or of individual suctionpads in lifting equipment. The valves are available as 2/2-way or 3/2-way valves.


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Vacuum Switches

Vacuum s

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