Vacuum Handling Systems Solutions for the chemical and pharmaceutical sector

Transcription

1 Ergonomic Handling Solutions Vacuum Handling Systems Solutions for the chemical and pharmaceutical sector

2 Schmalz World of Vacuum Technology Strict customer-orientation and trend-setting innovations, excellent quality and comprehensive advisory skills make Schmalz the world's leading partner for vacuum technology in automation, handling and clamping technology. As a worldwide active company with excellent products and services, we offer our customers in trade and industry trend-setting solutions. We have many enthusiastic customers in all sectors where production processes are made more efficient with the aid of vacuum technology. In order to meet the specific requirements in various sectors of industry, we offer vacuum handling systems intended primarily for use in the following areas: Chemicals/pharmaceuticals Logistics/packaging Metal/sheet-metal Wood/plastics Aerospace industry Renewable energy (wind and solar energy) Thanks to our worldwide sales network with wholly-owned companies and sales partners in more than 50 countries, we have highly-qualified sales personnel and consultants available in your vicinity. Many prestigious awards document our company's ecological and social responsibility Send a request for our catalogue "Vacuum Handling Systems" today: Tel. +49 (0) or at link "Service" This contains our complete product range and many application examples. More detailed information about Schmalz vacuum technology can be found in our current catalogue "Vacuum Handling Systems Applications & Products". We will gladly send you a free printed copy of this catalogue.

3 Ergonomic and efficient workpiece handling Product innovations for the chemical industry Special suction pads for the chemical sector Damage-free handling of plastic and paper sacks (with inlayer) Safe handling of barrels up to 200 Iitres, even with bung holes Mechanical grippers for handling of buckets and canisters Simultaneous handling of several workpieces Flexible lifting devices with quick-change adapters for rapid changing of the suction pads Adaptable vacuum generators with long operating life Directly driven for low wear and minimum maintenance Quiet operation due to low speed Low blower temperature even when running at full load Vacuum-generator output can be adjusted to match the properties of the workpieces to be handled Optional: frequency regulation for handling workpieces of varying weights Special solutions for explosion-proof areas JumboHandy Ex for loads weighing up to 30 kg, with pneumatically powered multi-stage ejector JumboSprint Ex for loads weighing 45 to 300 kg Wide range of stainless-steel suction pads All mechanical parts with antistatic properties and grounding connections Suitable crane systems in stainless steel or painted, with grounding connections Comprehensive range of accessories suitable for explosion-proof areas (including quick-change system for rapid changing of the suction pads) Selection aid Selection criterion Workpiece Weight Vacuum tube lifters Jumbo (Page 6) Airtight and porous workpieces, such as barrels with bung holes, buckets, plastic and paper sacks, canisters, etc. Workpieces up to 300 kg Vacuum lifting devices VacuMaster (Page 8) Barrels of varying sizes and weights Workpieces up to 2000 kg Lifting speed Type of handling Frequent, fast lifting and movement with a single medium horizontal, 90 tilting The device grips the workpiece with vacuum and is lifted and lowered with a chain hoist horizontal, 90 tilting, 180 turning 1

4 Handling of sacks Damage-free handling of various materials and containing various substances Special industry requirements Productivity increases of up to 30% Damage-free gripping and palletizing of sacks, such as plastic and paper sacks Easy and fast emptying of sacks into mixers, silos, etc. Resistance to chemicals, salts, vapours, etc. Safe operation in explosion-proof zones 1/21 and 2/22 Our industry solutions Vacuum tube lifter Jumbo with sack gripper for fatigue-free work JumboSprint control unit for precise handling in an ergonomically optional posture Jumbo control-unit Flex for energysaving handling of sacks up to 25 kg Made from high-quality materials, also available in stainless steel Aluminium slewing cranes and crane systems for a perfectly matched system solution Jumbo Sprint, maximum load 45 kg, with sack gripper, for handling plastic and paper sacks JumboSprint, maximum load 65 kg, with sack gripper, for handling sacks in explosion-proof areas to ATEX 2 JumboSprint, maximum load 65 kg, with sack gripper, for commissioning of plastic and paper sacks JumboFlex, maximum load 35 kg, with sack gripper, for handling plastic sacks weighing up to 25 kg

5 Handling of canisters and buckets Dynamic and effortless for all shapes and sizes Special industry requirements Easy handling of workpieces which have to be gripped at difficult positions (handles, wire handles, lids) Simultaneous handling of several workpieces with a single gripper Safe and damage-free handling Resistance to chemicals, salts, vapours, etc. Our industry solutions Vacuum tube lifter Jumbo with single suction pad or mechanical grippers for independent unpacking and packing of the workpieces JumboErgo, maximum load 45 kg, for commissioning of canisters JumboFlex, maximum load 35 kg, with round suction pad, for handling of buckets JumboErgo, maximum load 65 kg, for unstacking five canisters on a roller conveyor JumboErgo, maximum load 45 kg, with dual suction pad, for simultaneous handling of two buckets 3

6 Handling of barrels Safe and ergonomic for a wide range of dimensions Special industry requirements Increased productivity Damage-free gripping and transport of barrels, including kegs Easy handling of barrels with varying types and shapes of lids, including barrels with bung holes and lids secured with clamping rings Gripping from the side and emptying of barrels weighing up to 85 kg Resistance to oils, chemicals, salts, etc. Safe operation in explosion-proof zoned 1/21 and 2/22 Our industry solutions Vacuum lifting devices VacuMaster with single suction pads Vacuum tube lifters Jumbo with round suction pads for fatigue-free operations Made from high-quality materials, optionally available in stainless steel Customer-specific gripper for gripping barrels from the side and tilting them Aluminium slewing cranes and crane systems for a perfectly matched system solution JumboErgo, maximum load 140 kg, with customer-specific gripper solution, for simultaneous handling of four barrels VacuMaster Eco, maximum load 250 kg, for barrel handling JumboErgo, maximum load 85 kg, with side gripper, for handling and emptying barrels JumboErgo, maximum load 300 kg, with round suction pad, for handling barrels 4

7 Further solutions Simple handling, even for special applications Special industry requirements Handling of heavy and unwieldy workpieces by a single person, without risk of injury Customer-specific solutions Frequent and fast lifting and moving of workpieces Simultaneous handling of several workpieces Our industry solutions Vacuum tube lifters Jumbo with special suction-pad solutions Jumbo Flex, Ergo and Sprint, operator controls as desired, for precise handling in an ergonomical posture Vacuum lifting devices VacuMaster with customer-specific and application-specific modifications Mechanical grippers suspended on chain hoists Simultaneous handling of several workpieces JumboErgo, maximum load 65 kg, with mechanical crate gripper, for handling metal boxes JumboSprint, maximum load 65 kg, with vacuum sack gripper, for handling bales of raw rubber JumboSprint, maximum load 45 kg, with dual suction pad, for handling cardboard boxes VacuMaster, maximum load 140 kg, for moving barrels from a vehicle discharge point to a conveyor belt 5

8 Vacuum tube lifters Jumbo Versatile lifting and movement with a single medium Functionality The loads are gripped and lifted only by the vacuum Simple adaptation of the lifter to meet individual requirements, thanks to the modular system of variable basic components which can be combined in many ways Safety Quick-acting non-return valve and large suction-pad area prevent dropping of the load, even if the power fails Designed in accordance with the German accident-prevention regulations laid down in BGR/BGV 500 Ergonomy Compliance with the latest ergonomic best practices reduces the risk of injuries to the operator Reliability For all vacuum tube lifters, we offer a two-year warranty in single-shift operation Efficiency Efficiency is improved by up to 30% JumboFlex One-hand operation JumboSprint Precise handling of heavy and unwieldy loads JumboErgo Twist grip fast handling (similar to that on a motorcycle) Quick-change adapter SWA All suction pads can be changed in a matter of seconds with the aid of the quickchange adapter SWA 6 Ergonomic operator controls for almost every application Maximum loads from 20 kg to 300 kg Precise handling of light and heavy loads Safe operation and an ergonomic posture at any working height

9 Solutions for explosion-proof areas Simple handling, even for special applications Special industry requirements Handling of sacks, paint containers and explosive materials Our industry solutions Wide range of stainless-steel suction pads All mechanical components with antistatic coatings and, if necessary, with grounding connection Suitable crane systems made from stainless steel or painted, with grounding connection Comprehensive range of accessories suitable for use in explosion-proof areas (including a quick-change system for rapid changing of the suction pads) Antistatic lifting tubes and feed hoses Available in stainless steel or in specially coated aluminium Safety Meticulous testing of the components and assemblies by analysis of the ignition risk All documentation archived by the testing company JumboSprint, maximum load 65 kg, with sack gripper, for handling sacks in an explosion-proof area in accordance with ATEX JumboSprint, maximum load 45 kg, with single suction pad, for handling cardboard boxes in an explosion-proof area in accordance with ATEX JumboHandy Ex bow handle Maximum load 30 kg Pneumatically powered multi-stage ejector (SEM 100 Ex) JumboSprint Ex Pneumatically powered multi-stage ejector (SEM 300 Ex) - Maximum load 45 to 85 kg - Classification II 2 GD c II B 85 C(T6) 0 C Ta +40 C Vacuum blower SB-L Ex maximum load 250 kg - Classification II 3G / 3GD c II B 125 C(T4) 0 C Ta +40 C 7

10 Vacuum lifting devices VacuMaster The trendsetting generation of vacuum lifting devices VacuMaster Basic/Comfort For handling of barrels, sheets, etc. Extremely versatile vacuum lifting device Components matched individually to the specific application Main beam with integrated vacuum reservoir and distributor Ergonomic operator handle (on the Comfort version) with integrated push-button controls Electronic warning device, non-return valve Optional: 90 tilting or 180 turning of the workpiece Maximum load 125 to 750 kg 3-year warranty in single-shift operation VacuMaster Basic, maximum load 250 kg, horizontal, for handling of barrels Operator handle Basic Operator handle Comfort VacuMaster Eco For horizontal handling of smooth and airtight workpieces without an external power supply Safe operation thanks to battery-powered warning device with battery-test function Very flexible, since it needs no external power Construction similar to the VacuMaster Basic/Vario Maximum load 250 to 1000 kg 3-year warranty in single-shift operation VacuMaster Eco, maximum load 250 kg, horizontal, for handling of barrels VacuMaster Light For handling of airtight workpieces such as barrels Fatigue-free operation thanks to ergonomic controls and low intrinsic weight Suction pads can be adjusted quickly and easily for handling of workpieces with varying dimensions Fast commissioning thanks to simple installation (compressed air required) Safe handling thanks to an intelligent warning device Maximum load 100 kg 3-year warranty in single-shift operation 8 VacuMaster Light, maximum load 100 kg, horizontal, for handling of barrels

11 Crane systems and chain hoists Safety and mobility for vacuum handling systems Cranes Very ergonomical thanks to low moving masses Minimum overall height also suitable for use in rooms with low ceilings Optimal routing of power supplies (electricity, compressed air, vacuum) Designed especially for use with the Jumbo and VacuMaster Also available in stainless steel for use in explosion-proof areas (zones 1/21 and 2/22) 2-year warranty in single-shift operation Stainless-steel articulated-jib crane with Jumbo Column mounted jib crane with Jumbo Aluminium crane system with chain hoist Chain hoists High level of safety thanks to low voltages on the control unit Long operating life thanks to limit switches on the lifting system Precise, damage-free positioning with two lifting speeds Fast operation thanks to high lifting speeds Also available with frequency regulation for extremely precise positioning, particularly suitable for fragile workpieces or for assembly work 2-year warranty Wall mounted jib crane with chain hoist 9

12 World of Vacuum Technology Vacuum Components Innovative vacuum components from Schmalz offer many users in various sectors of industry reliable support in the solution of automation and handling tasks. The wide range of components extends from suction pads and vacuum generators to mounting elements and system monitoring devices. Tel. +49 (0) Fax +49 (0) Vacuum Gripping Systems Complex vacuum gripping systems from Schmalz permit decisive productivity improvements to be achieved. The range extends from layer and large-area gripping systems to complete vacuum spiders, delivered ready for connection, for use in all areas of automation. Tel. +49 (0) Fax +49 (0) Vacuum Handling Systems Ergonomical vacuum lifting devices Jumbo and VacuMaster for effortless, damage-free handling of workpieces. Crane systems to supplement these to form complete system solutions which are precisely matched to the planned application. Workshop equipment as practical aids in trade and industry. Tel. +49 (0) Fax +49 (0) Vacuum Clamping Systems Future-oriented vacuum clamping technology from Schmalz is the intelligent response to the continually increasing demands for more productivity and economic operation of CNC machine tools. Schmalz, 09/08 I Article No I Subject to technical changes without notice I Schmalz is a registered trademark in Europe Tel. +49 (0) Fax +49 (0) J. Schmalz GmbH Aacher Straße 29 D Glatten Tel. +49 (0) Fax +49 (0) schmalz@schmalz.de

13 Ergonomic handling solutions Vacuum Handling Systems Branch Solutions Metal

14 Schmalz World of Vacuum Technology Strict customer orientation and path-breaking innovations, excellent quality and comprehensive competence in customer advice make Schmalz the world's leading partner for vacuum technology in the areas of automation, handling and clamping. As a worldwide active company with excellent products and services, we offer our customers in trade and industry path-breaking solutions. We have enthusiastic customers wherever production processes need to be made more efficient with the aid of vacuum technology. In order to meet the specific requirements of the various sectors of industry, we offer vacuum handling systems with the main emphasis on the following branches: Metal/sheet metal Wood/plastics Logistics/packaging Chemicals/pharma Aerospace industry Renewable energy (wind, solar) With our international marketing network with our own companies and marketing partners in more than 50 countries, highly qualified consultants and engineers are at your service throughout the world. The company's excellent ecological and social responsibility is proved by the many awards it has won in these areas. Get your copy of our catalogue "Vacuum Handling Systems" now: Tel. +49 (0) or at Link Service Complete product range many application examples You can find detailed information about Schmalz vacuum technology in our current catalogue "Vacuum Handling Systems Applications & Products". We will be happy to send you a free printed copy of this catalogue.

15 Ergonomical and efficient workpiece handling Schmalz product innovations for the metal branch Special suction pads for handling sheet metal Oil-resistant suction pads ensure slip-free handling of oily sheets of metal Supports on the lower surfaces of the suction pads permit handling of thin steel sheets and aluminum sheets without deformation Suction pads FM (available only for the Jumbo) ensure safe handling of workpieces with apertures, holes and special contours Sprung/flexible suction pad mounting elements ensure optimal adaptation to sloping workpiece surfaces Adaptable vacuum generators with long operating lifetimes More safety with variable-length operator handle Vacuum blower (Jumbo) The directly driven blower ensures a long operating lifetime of the lifting device The low blower speed ensures quiet operation The optional frequency regulation ensures optimal adaptation of the lifting device to heavy and light workpieces Electrical vacuum pump (VacuMaster) Pump size can be selected to match workpiece properties Hard-wearing carbon vanes ensure a long lifetime Ensures that the operator remains at a safe distance from the workpiece Selection aid Selection criterion Workpieces Weight Speed Handling type Vacuum tube lifter Jumbo (Page 6ff) Airtight and porous parts such as metal sheets (even with apertures), sections and assemblies, etc. Workpieces weighing up to 300 kg Frequent and fast lifting and lowering with a single medium horizontal, 90 swiveling Vacuum lifting device VacuMaster (Page 7ff) Metal sheets (including checker plate), coils, bodies, sections, etc. Workpieces weighing up to 2000 kg, normally large, flat objects The device grips the workpiece, which is then lifted and lowered with a chain hoist horizontal, 90 swiveling, 180 turning 1

16 Handling of sheet metal Safe and ergonomical for many different tasks Special branch requirements Damage-free gripping and movement of laser-cut sheet metal (also checker plates and stud plates), particularly those made from stainless steel; even with apertures and coated with oil Injury-free handling of heavy and unwieldy workpieces by a single person Gripping of parts made of non-magnetic steel and non-ferrous metals Reduced machine-loading times Energy-independent handling with the aid of existing overhead cranes Handling types: horizontal, swiveling by 90 and turning by 180 Our branch solutions Vacuum lifting device VacuMaster Basic/Comfort for handling sheet metal, optionally for checker and stud plates with special suction plates Vacuum lifting device VacuMaster Eco for self-powered handling tasks (without external power supply) Vacuum tube lifter Jumbo with suction pad FM for laser-cut parts Jib cranes and aluminum overhead crane systems for a perfectly matched system solution VacuMaster Basic, maximum load 250 kg, horizontal, for loading and unloading sheetmetal storage rack systems (more on Page 7) JumboErgo, maximum load 35 kg, with double suction pad FM, for safe movement of raw sheets and machined circular-saw blades (more on Page 6) 2 JumboErgo, maximum load 45 kg, with double suction pad FM, for loading gluing systems (more on Page 6) VacuMaster Eco, maximum load 500 kg, with parking stand, for loading laser-cutting machines (more on Page 7)

17 VacuMaster Basic, maximum load 250 kg, horizontal, for handling checker plates (more on Page 7) JumboErgo, maximum load 140 kg, for commissioning of small and medium-sized sheets of aluminum (more on Page 6) VacuMaster Comfort, maximum load 125 kg, with 180 turning unit, for handling sheet metal (more on Page 7) VacuMaster Vario, maximum load 2000 kg, horizontal, for loading mechanical saws with large sheets of aluminum (more on Page 8) VacuMaster Comfort, maximum load 250 kg, horizontal, for loading and unloading laser-cutting machines (more on Page 7) VacuMaster Basic, maximum load 250 kg, horizontal, for handling small metal sheets or sheets with apertures by individual activation of the suction pads (more on Page 7) 3

18 Handling of metal sections and coils Damage-free gripping without mechanical clamps Special branch requirements Damage-free gripping and movement of coils made of (very) thin metal sheets, metal foils, steel, tinplate, aluminum, etc. Gripping of long, narrow sections Injury-free handling of heavy and unwieldy workpieces by a single person Reduced machine-loading times Gripping of workpieces made of non-magnetic steel and non-ferrous metals Swiveling of coils by 90 Our branch solutions Vacuum tube lifter Jumbo with customer-specific vacuum-grippers Vacuum lifting device VacuMaster Light for fatigue-free work thanks to compact construction and low weight Vacuum lifting device VacuMaster Coil for lifting workpieces from a pallet in the horizontal position and placing them in the vertical position on a spindle Jib cranes and aluminum overhead crane systems for a perfectly matched system solution JumboErgo, maximum load 110 kg, horizontal, for handling of aluminum sections (more on Page 6) VacuMaster Light, maximum load 100 kg, horizontal, for loading and unloading CNC machining centers (more on Page 8) 4 VacuMaster Coil, maximum load 750 kg, horizontal, for handling stainless-steel coils (more on Page 8) VacuMaster Basic, maximum load 100 kg, horizontal, for handling aluminum sections (more on Page 7)

19 Further solutions Simple handling, even in special applications Special branch requirements Damage-free gripping and movement, even of finished products Injury-free handling of heavy and unwieldy workpieces by a single person Assistance of personnel in assembly tasks Customer-specific solutions Our branch solutions Vacuum lifting devices VacuMaster with customer- and application-specific modifications Vacuum tube lifters Jumbo with special vacuum-gripper solutions Vacuum stands PVS and vacuum benches PVT for clamping workpieces during machining VacuMaster Basic, maximum load 250 kg, horizontal, for handling chests of drawers (more on Page 7) VacuMaster Comfort, maximum load 250 kg, with 90 swiveling, for assembly of sheet-metal cabinets (more on Page 7) JumboErgo, maximum load 140 kg, with customer-specific vacuum-gripper solution for simultaneous handling of four barrels (more on Page 6) Vacuum stand PVS, maximum load 100 kg, with 90 swiveling, for assembly of switchgear cabinets 5

20 Vacuum tube lifters Jumbo Versatile lifting and movement with a single medium Functions The load is gripped and lifted with a single medium vacuum Simple adaptation of the device to individual requirements thanks to modular design with variable components which can be combined as desired Safety A quick-acting non-return valve and the large suctionpad area prevent dropping of the load, even if the electric power or the compressed-air supply fails The design complies with the German accident-prevention regulations Ergonomy Injury-free work thanks to consideration of the latest ergonomical principles Our two-year warranty demonstrates our confidence in this product. JumboHandy pistol grip JumboHandy bow handle JumboSprint JumboErgo Ergonomical controls for almost every application Maximum loads from 20 kg to 300 kg Precise positioning of light and heavy loads Safety and ergonomical posture at every working height 6

21 Vacuum lifting devices VacuMaster The path-breaking generation of vacuum lifting devices VacuMaster Basic Comprehensive basic configuration Operator-handle and crossbeam lengths matched to the customer-specific workpiece size Safety thanks to the electronic warning device and non-return valve Handling of workpieces of varying sizes by easy sliding of the suction pads and optional deactivation of individual suction pads 3-year warranty Optionally with 90 swiveling or 180 turning Maximum load 125 kg to 750 kg VacuMaster Basic, maximum load 250 kg, horizontal, for handling sheets of stainless steel VacuMaster Comfort, maximum load 750 kg, horizontal, for handling metal sheets VacuMaster Comfort With "high-end" configuration Basic configuration as for the VacuMaster Basic, with the following additional features: Ergonomically integrated controls for "chain hoist up/down", "vacuum on/off" and "swivel vertical/horizontal" (optional) Solenoid valve with two-hand actuation for vacuum off Regulated vacuum generator, pump with automatic air-saving function Delivery complete with chain hoist 3-year warranty Optional: chain hoist with frequency regulation Maximum load 125 kg to 750 kg VacuMaster Eco Horizontal handling of smooth and airtight workpieces without an external power supply Basic design as for the VacuMaster Basic Principle of operation: self-powered Can be used anywhere, since it requires no external power Safe operation thanks to battery-powered warning device 3-year warranty Maximum load 250 kg to 1000 kg VacuMaster Eco, maximum load 250 kg, horizontal, for handling metal sheets without an external power supply The piston is pulled out of the cylinder by the crane, acting against the weight of the workpiece. The cylinder volume is thus increased, generating a vacuum which is dependent on the weight of the workpiece and is sufficient to grip the workpiece safely. 7

22 Vacuum lifting devices VacuMaster The path-breaking generation of vacuum lifting devices! VacuMaster Vario For horizontal handling of heavy and mainly airtight workpieces Operator-handle and crossbeam length matched to the customer-specific workpiece size Safe operation thanks to the electronic warning device, large vacuum reservoir and non-return valve Handling of workpieces of varying sizes by easy sliding of the suction pads and optional deactivation of individual suction pads 3-year warranty Maximum load 1000 kg to 2000 kg VacuMaster Vario, maximum load 1000 kg, horizontal, for loading and unloading plasma-cutting machines VacuMaster Light, maximum load 100 kg, horizontal, for handling painted furniture elements VacuMaster Light For horizontal handling of airtight and slightly porous workpieces such as furniture elements or sections Suitable for use in applications such as assembly, packaging, loading of machines, etc. Fatigue-free work thanks to the ergonomical controls and low weight Handling of workpieces of varying sizes and shapes by flexible and fast adjustment of the suction pads Quick commissioning thanks to simple installation (a compressed-air supply is needed) Safe operation thanks to the electronic warning device 3-year warranty Maximum load 100 kg VacuMaster Coil, maximum load 750 kg, with 90 swiveling, for handling of coils VacuMaster Coil For handling coils and split coils Suitable for (very) thin sheets of metal, metal foils, steel, tinplate, aluminum, etc. Damage-free gripping without mechanical clamps Handling of coils of varying diameters with the aid of separately activated annular chambers Precise and continuous swiveling of the load by 90 with the aid of an electromechanical linear drive Simple positioning thanks to transparent suction plate Safe operation thanks to electronic warning device, vacuum reservoir and non-return valve 3-year warranty Maximum load 500 kg to 1000 kg 8

23 Crane systems and chain hoists Safety and mobility for vacuum handling systems Crane Designed specifically for use with Jumbo and VacuMaster High mobility thanks to low moving mass Optimized overall height, can also be used in head-rooms Perfect power connections (electricity, compressed air, vacuum) Suitable for heavy loads, optionally available with electrically driven movement of the trolley and crane and electric swiveling Wall-mounted jib crane with chain hoist Jib crane with Jumbo Aluminum ceiling mounted bridge crane with chain hoist Chain hoists High safety level thanks to low voltage on the controls Long operating lifetime thanks to limit switches Precise and careful positioning thanks to two-speed control Fast working thanks to high lifting speeds Optionally with frequency regulation for very precise positioning, particularly suitable for handling fragile parts or for assembly operations 2-year warranty Chain hoist 9

24 World of Vacuum Technology Vacuum components and gripping systems For a large range of users in many different branches of trade and industry from the automotive to the pharmaceutical industries Schmalz offers reliable support and assistance in the solution of automation and handling tasks either as individual components or complex vacuum gripping systems. Our teams are at your service! Vacuum components Vacuum gripping systems Tel. +49 (0) Tel. +49 (0) Fax +49 (0) Fax +49 (0) Vacuum handling systems Ergonomical solutions for many types of applications. Vacuum lifting devices VacuMaster and vacuum tube lifters Jumbo for easy handling of workpieces without damage to their surfaces. Crane systems from Schmalz complement the system solutions designed for specific tasks. Workshop equipment as practical aids in trade and industry. Our "Vacuum Handling Systems" team is at your service! Tel. +49 (0) Fax +49 (0) Vacuum clamping systems Future-oriented vacuum clamping technology from Schmalz is the intelligent answer to the continually increasing demand for more productivity and the economic use of CNC machine tools. Our "Vacuum Clamping Systems" team is at your service!! Tel. +49 (0) Fax +49 (0) Schmalz, 12/07 I Article-No.: I Subject to technical changes without notice I Schmalz is a registered trademark in Europe J. Schmalz GmbH Aacher Straße 29 D Glatten Tel. +49 (0) Fax +49 (0) schmalz@schmalz.de

25 Branch-Oriented Solutions from SCHMALZ Vacuum Handling Systems Wood y Vacuum lifting units VACUMASTER y Vacuum tube lifters JUMBO y Vacuum clamping systems y For chipboard, wood-core plywood and plywood boards y For planks, beams and sheets y For windows, doors and glass sheets Branch-oriented solutions from SCHMALZ are perfect for daily handling tasks in industry and trade. Handling with vacuum. y Various load ranges up to 2000 kg y Swivelling and turning versions y Safe gripping without damage to the workpiece y Optimisation of feeding rates y All units comply with CE, accident prevention rules, ISO 9001 & 14001, EC environmental audit... y Warranty for VACUMASTERS vacuum lifting devices: 3 years y Warranty for all JUMBO vacuum tube lifters: 2 years

26 VACUM ASTER M ULTI For porous and airtight boards The VACUMASTER MULTI product line is suitable for handling porous and airtight workpieces such as raw and coated chipboards, MDF and OSB boards, gypsum fibre and gypsum plaster boards and plastic boards. Even very large loads can be moved horizontally with the VACUMASTER MULTI series. The units of the VACUMASTER MULTI-90 series can also swivel the loads by 90 to the vertical position with the aid of an electric motor. * VACUMASTER MULTI 400/ G B C A * VACUMASTER MULTI and cannot be swivelled by 90 * VACUMASTER MULTI VACUMASTER MULTI 400/ F D The all-round device VACUMASTER MULTI 400/ can additionally be used to remove boards from cantilever-arm racks. B C Technical Data Type VACUMASTER MULTI VACUMASTER MULTI VACUMASTER MULTI VACUMASTER MULTI VACUMASTER MULTI 400-1* 400-2* 400/ / / Max. lifting capacity at 400 kg 400 kg 400 kg horizontal 400 kg horizontal 400 kg horizontal 125 mbar vacuum 150 kg vertical 300 kg vertical 300 kg vertical A Max. board size 4100 x 2100 mm 5600 x 2100 mm 4100 x 2100 mm 5600 x 2100 mm 5600 x 2100 mm Max. board thickness unlimited unlimited 40 mm 40 mm 40 mm D VACUMASTER MULTI E Handling horizontal horizontal horizontal lifting horizontal lifting horizontal lifting + 90 swivelling + 90 swivelling + 90 swivelling Height A 520 mm 600 mm 535 mm 620 mm 625 mm Length of handlebar B 1050 mm 1050 mm 1050 mm 1050 mm 1050 mm B Suspension eye Ø C Ø 56 mm Ø 56 mm Ø 56 mm Ø 56 mm Ø 56 mm Number of pads 1 suction box 2 suction boxes 1 suction box 2 suction boxes 8 suction pads C Size of pads D x E 1000 x 675 mm 675 x 1000 mm 1000 x 675 mm 675 x 1000 mm Ø 400 mm Suction pad spacing F mm mm mm F D E A Suction pad spacing G mm Electric (vacuum blower) 50 Hz: 3~ 230/400 V; 0,95 kw, optional 60 Hz: 3~230 or 460 V; 1,6 kw (additional charge) 50 Hz: 3~ / V; 0,25 kw Electric (swivelling motor) 60 Hz: 3~ / V; 0,25 kw Weight approx.75 kg approx. 105 kg approx. 118 kg approx. 148 kg approx. 195 kg Article-No VACUMASTER MULTI 400/

27 VACUM ASTER M ULTI For porous and airtight boards The VACUMASTER MULTI permits rational and simple handling of boards with weights of up to 400 kg without absolutely no damage to the workpiece surfaces. Since even chipboards with a thickness of 38 mm are porous from the vacuum viewpoint, these units are equipped with SCHMALZ blowers with a high suction volume to ensure safe and easy handling of such porous materials. The specially developed blower unit with very long after-running period ensures that the load is not dropped suddenly in the event of a power failure. A reversing valve fitted as standard on the blower permits reversal of the air flow for simple and precise release of the load. Further advantages: y Electronic warning device with load detection: Maximum safety even in the case of a fault or incorrect operation. y Geared electric motor for swivelling with the VACUMASTER MULTI-90 units. VACUMASTER MULTI This prevents sinking of the load, which occurs when pneumatic tilting cylinders are used. y Swivelling control handle provided as standard. The user does not need to continually squat down or reach upwards. y Optional suction boxes with a width of less than 600 mm for lifting narrow kitchen worktops. Small suction pads (illustration 1) with a correspondingly high vacuum often cause two or more boards to be lifted simultaneously (which may result in accidents). This can be prevented effectively by using large area suction boxes and a lower vacuum (illustration 2). Illustration 1 Illustration 2 T RANSPORT T ROLLEYS The optimum solution for each application Transport Trolley HW 680 R2-A The new SCHMALZ STORAGE, ASSEMBLY AND TRANSPORT SYSTEMS are characterized by excellent handling and quality. TRANSPORT TROLLEYS from SCHMALZ offer solutions for a wide range of applications, such as drying painted furniture components, doors, windows, wood strips, profiles, boards, bodies,... y Extreme flexibility y Optimum functionality y Solvent-proof finish y Steel construction in rugged design y Powder-coated, colour RAL 7035, light grey y Two castors with parking brakes BOARD TRANSPORT TROLLEY PTS 250 The optimum trolley for the transport of boards from a vertical storage rack to a horizontal or vertical saw (and vice versa). y The rack can be raised and lowered to any desired height y Integrated, mechanical tilting device y Easy and safe handling of boards up to 250 kg y Lift, tilt and transport boards with a SINGLE trolley Board Transport Trolley PTS 250 Board Transport Trolley PTS 250 3

28 VACUM ASTER RE For cantilever-arm racks Technical Data Type VACUMASTER RE Max. lifting capacity at -250 mbar vacuum 250 kg Max. board size 5200 x 2400 mm Max. board thickness unlimited Height A 360 mm Length of handlebar B 1200 mm Suspension eye Ø C Ø 35 mm Number of pads 4 pieces Size of pads Ø D Ø 300 mm Suction pad spacing E mm Suction pad spacing F mm Required space in horizontal shelf 100 mm Operational air pressure 5 bar Air consumption at working pressure 4 bar 370 l/min Weight 80 kg Article-No F C B A D VACUMASTER RE The VACUMASTER RE can be used wherever raw or laminated wooden and plastic boards have to be manipulated horizontally. A typical application is to take a board from a pallet pile to move it into a horizontal saw. This device is particularly suitable for removing boards from space-saving cantilever-arm racks. The VacuMaster RE uses dual-circuit pneumatic vacuum generators. The front and rear suction pads are supplied separately with the vacuum. This means that a workpiece can be pulled out of the rack with two suction pads to a position where the lifting device can be repositioned to pick it up with all four suction pads. y Lifting capacity up to 250 kg y Perfect for unloading boards from pallets and cantilever-arm racks y Simple loading of boards into a horizontal saw y Pneumatic vacuum generators (maintenance- and wear-free ejectors) y Vacuum gauge y Acoustical warning device (with whistle) y Safety vacuum reservoir with non-return valve E VACUMASTER RE A standard unit from the VACUMASTER series can be used for airtight materials such as kitchen worktops. VACUMASTER RE 250-4

29 VACUM ASTER HHVM For standing racks VACUMASTER HHVM The board lifter VACUMASTER HHVM 90 from SCHMALZ makes handling of raw or laminated wooden and plastic boards much easier. It is used especially for removing boards from standing racks and for loading them onto vertical and horizontal saws. y Simple loading of boards onto a vertical or horizontal saw y Pneumatic vacuum generators (maintenance- and wear-free ejectors) y Vacuum gauge y Acoustical warning device (with whistle) VACUMASTER HHVM, G y Lifting capacity up to 200 kg y Can be swivelled vertically up to 90 in two directions y Perfect for unloading boards from standing racks F B C D A y Safety vacuum reservoir with non-return valve E Technical Data Type VACUMASTER VACUMASTER HHVM HHVM Max. lifting capacity -200 mbar vacuum 100 kg 200 kg Max. board side 3500 x 3050 mm 4100 x 3050 mm Max. board thickness 40 mm 40 mm Swivelling angle 2x 90 swivelling 2x 90 swivelling Height A 305 mm 305 mm Entire length B 2785 mm 3300 mm Suspension eye Ø C Ø 35 mm Ø 35 mm Number of pads 4 pieces 4 pieces Size of pads D x E 315 x 245 mm 600 x 220 mm Suction pad spacing F 2065 mm 2400 mm Suction pad spacing G 525 mm 500 mm Required space in vertical shelf 20 cm 20 cm Operational air pressure 5 bar 5 bar Air consumption at working pressure 370 l/min 370 l/min Weight 70 kg 75 kg Article-No VACUMASTER HHVM or VACUUM B ENCHES AND VACUUM STANDS The VACUUM CLAMPING DEVICES from SCHMALZ are indispensable aids for the safe and careful clamping of all types of workpieces. Whether they are used as planing benches or as assembly aids, there are no limits to their flexibility. All sides of a workpiece can be worked in no time at all without having to release the workpiece and clamp it in another position. This makes child s play of heavy work like the turning of doors during assembly. y Fast y No damage to workpiece surfaces y Universal application y Ergonomic design y Flexible VACUUM WORKSTAND PVS n WORKBENCH PVT WITH ELONGATION 5

30 VACUM ASTER VHB For beams, planks and boards VACUMASTER VHB With the aid of the VACUMASTER VHB, a single person can handle boards, planks and beams up to 6 m long. While the two versions VHB 250 and VHB 500 are intended for handling wood which is free of cracks, the VACUMASTER VHB 350/500 is also suitable for wood with cracks (such as that from deciduous trees). This is achieved by means of automatic check valves operating together with the suction pads which automatically detect when the necessary vacuum cannot be established. Each suction pad is divided into two independent sections. If one of these sections is not covered by the workpiece, or if there is too much air leaking into it as the result of damage or cracks, the related check valve closes to prevent the vacuum in the system from breaking down. y Safe handling by one person with absolutely no damage to the workpiece surfaces y Lifting capacity up to 500 kg (VHB) y Electric vacuum generator (lowmaintenance oil-free pump) y Water separator and filter integrated y Electronic warning device Technical Data VHB y Safety vacuum reservoir with non-return valve Type VACUMASTER VACUMASTER VACUMASTER VHB VHB VHB 350/500-2 Max. lifting capacity at -600 mbar vacuum 250 kg 500 kg 350/500 kg Max. length of wooden plank 6000 mm 6000 mm 6000 mm Min. width of wooden plank 120 mm 220 mm 220 mm Height A 490 mm 490 mm 490 mm Length of handlebar B 3010 mm 3010 mm 3010 mm Suspension eye Ø C Ø 80 mm Ø 80 mm Ø 80 mm Number of pads 2 pieces 2 pieces 2 pieces Size of pads D x E 550 x 100 mm 550 x 200 mm 550 x 200 mm Suction pad spacing F mm mm mm Max. insertion length G 1460 mm 1460 mm 1460 mm Max. insertion height H approx. 600 mm approx. 600 mm approx. 600 mm 50 Hz: 3~ / V; 0,90 kw Electric supply 60 Hz: 3~ / V; 0,90 kw Weight 133 kg 135 kg 135 kg Article-No. (with hand slide valve) Article-No. (with solenoid valve) B E A C D D G F H VACUMASTER VHB VACUMASTER VHB

31 VACUM ASTER W INDOW For glass sheets and windows The VACUMASTER WINDOW lifting devices are designed for handling sheets of glass and complete windows in a vertical position. The workpiece can be rotated left and right by up to 90 each (around its horizontal axis). The special arrangement of the suction pads even permits the handling of multi-wing windows whose posts and frame project by up to 45 mm. y Lifting capacity up to 300 kg y Ergonomically mounted handle y Electric vacuum generator (low-maintenance, oil-free pump) y Vacuum gauge y Electronic warning device y Safety vacuum reservoir with non-return valve y Optionals: Electrical driven rotation unit Pneumatic vacuum generator ØC A VACUMASTER WINDOW B D Technical Data E Type VACUMASTER VACUMASTER VACUMASTER WINDOW WINDOW WINDOW VACUMASTER WINDOW Max. lifting capacity at -600 mbar vacuum 170 kg 225 kg 300 kg Bear out frame: max. thickness 45 mm 45 mm 45 mm Swivelling angle 2 x 90 swivelling 2 x 90 swivelling 2 x 90 swivelling Height A 760 mm 760 mm 760 mm Length of handlebar B 390 mm 390 mm 390 mm Suspension eye Ø C Ø 52 mm Ø 52 mm Ø 52 mm Number of pads 2 pieces 4 pieces 4 pieces Size of pads Ø D Ø 300 mm Ø 250 mm Ø 300 mm Suction pad spacing E mm mm mm Suction pad spacing F 600 mm 710 mm Electric supply 50 Hz: 3~ / V; 0,18 kw 60 Hz: 3~ / V; 0,216 kw Weight 34 kg 37 kg 41 kg Article-No B ØC E A D F VACUMASTER WINDOW and

32 VACUUM TUBE LIFTER JUMBO Loading wood CNC-machines The vacuum tube lifters JUMBO from SCHMALZ are the alternative to the VACUMASTER in cases where very short cycle times are required. Lifting speeds of up to 70 m/min can be achieved. The JUMBO needs only one medium air for gripping and lifting the loads. Applications: With the application package vacuum tube lifter and crane system, a single operator can effortlessly load a machining center with cumbersome wooden and plastic boards. y For furniture components, door leafs, wall elements, and many other loads. y For all kinds of wooden and plastic boards. Your savings: y Reduced handling cycle time. y Typical pay back period: just 6 to 10 months! y Gripping without damage to the workpiece. y Rapid work with reduced risk to the operator s health mm 3000 mm Features: y Ergonomic motorcycle throttle control (one control element for all functions). y Complete system ready-to-install on location. y Special crane to pass vertical obstructions such as CNC-suction hoses. y The JUMBO is a modular kit for up to 300 kg lifting capacity. Machine configuration with telescopic crane: top view (example) y Extensive variety of standard and special suction pads, for example door vacuum head. y Frequently-controlled vacuum generator SB-V for often changing workpiece weights. y Many accessories and options available (on request). y Detailed, easy-to-understand operation instructions. Safety: y Designed to prevent operator from exceeding the systems capacity. y Check valve for safely lowering the load during a power outage. y Robust multi-layer lifting tube, extended service life. y On-site demonstration of a vacuum tube lifter possible. y After-Sales-Service. v JUMBO with quadruple vacuum head for door frames 8

33 VACUUM TUBE LIFTER JUMBO Loading wood CNC-machines Options: y Silencer box SBB for reduction of the noise level of the blower to 65 db(a) y Pneumatic swivelling unit PSE for loading of vertical saws y Large-area gripper FM for moving complete layers of cut wood 9

34 VACUUM TURNING BENCH VWT 180 Turning workpieces through 180 With the vacuum turning bench VWT 180 from SCHMALZ, unwieldy panels (e.g. of wood, plastics, glass, etc.) can be turned over easily. Fast safe ergonomical. Your application: y Machining both sides of wood or plastic panels y Assembly work on both sides y Quality inspection of both sides of workpieces y Machining of edges Loading Turning Unloading The vacuum turning bench VWT 180 is the simple solution for turning y kitchen worktops y table tops y cupboard doors y wall elements y with weights up to 150 kg through any angle up to 180! Your benefits: y Reduced loading times y Rapid, stress-free work y All handling can be carried out by a single person y Machining and quality inspection at a single position y Complete After-Sales-Service 10 The advantages of the VWT 180 : y Solenoid valve: The workpiece can be released only at the end position of the bench. y Electronic warning device (audible): Remains functional even in the case of a power failure. y Operator stand: The operator is kept well away from the danger area Simple maintenance because all electrical and pneumatic components are integrated y Geared motor mounted directly on the shaft: Increased speed of motion Vibration-free turning, gentle starting and stopping Less wear and tear y Many options: Foot switch Larger vacuum pump Various vacuum gripper plates etc. User package: Vacuum tube lifter JUMBOERGO and vacuum turning bench VWT 180. With the tube lifter JUMBOERGO from SCHMALZ, a single operator can load and unload a CNC machining centre quickly and safely. The workpiece is then placed with the JUMBO on the turning bench, where it can be turned to any desired angle for further processing. After this, the panel can be moved again with the JUMBO to the machining centre. Simple operation with clearly designed control panel Easy adjustment of the suction pads

35 VACUUM TURNING BENCH VWT 180 Turning workpieces through 180 machining centre crane system turning bench JUMBO exhaust system JUMBO turning bench pallet pile H1 L H2 machining centre Machine arrangement, top view (example) Machining centre, tube lifter and turning bench VWT 180 Technical data of vacuum turning bench VWT 180 Type VWT 100/ Maximum load with non-porous surface 100 kg 150 kg Maximum workpiece width 2000 mm 1500 mm Maximum workpiece length 3000 mm 2500 mm Maximum workpiece thickness 50 mm Number of suction pads 4 (type SPU 210) Suction-pad diameter 210 mm Crossbeam-length of the gripper L 1650 mm Overall height H H1 = 1510 mm; H2 = 1015 mm Overall width B 2670 mm Turning angle 180 Turning time 10 sec/180 (50 Hz) Suction capacity of the pump 10 m 3 /h Electrical data at 50 Hz 0,55 kw 3~400 VY (other voltages/frequencies available to order) Paintwork RAL 7035 light-grey and RAL 7004 signal-grey Weight approx kg Article-No MATERIAL FLOW SOLUTIONS We deliver and install entire handling systems comprising: y Vacuum lifting device y Hoist y Crane systems Column-mounted slewing crane n SKL and SKV with chain hoist, can be mounted at most hall locations Includes y Manometer y Vacuum filter y Non-return valve y Audible warning device (electronic) y Solenoid valve y Controls integrated into stand Options Type Foot switch (turn left/right)) Foot switch (vacuum on/off) Pump (suction capacity 16 m 3 /h) Other suction pads Article No Ask for details Ask for details Further options or special dimensions available to order m Double-beam crane system ZTK with chain hoist, y electric trolley and crane travel y high-lying hoist for low ceilings y also for lift masts m Single-beam crane system ETK with chain hoist, reaches every point of rectangular area (great area utilization) v Single-rail craneway ESB with chain hoist, great cost-performance ratio m Wall-mounted slewing crane WKL and WKV with chain hoist, can be mounted at a building wall or column (saves crane column) 11

36 VACUUM CLAMPING SYSTEMS For comprehensive information see the complete overview in our brochure Vacuum clamping technology for CNC machine tools. Please order it free of charge. SCHMALZ presents innovative vacuum clamping technology for the wood and plastics industries. The extensive programme of vacuum clamping systems offers decisive advantages with respect to: y Reduced set-up times (up to 90%!) y Flexibility y Reduced machine downtimes y Ergonomic operation Vacuum clamping system VC-G with hose connections Due to enormous savings which result from the reduced setting-up times, these systems pay for themselves very quickly. Maximum potential for savings are in the production of one-off jobs and small batches. INNOSPANN Adapter-Plate Vacuum clamping systems VC-K1 and VC-K2 for consoles with single-circuit resp. two-circuit system Vacuum clamping systems INNOSPANN The power range from SCHMALZ. Ask for your catalogues now! SCHMALZ 10/06 Art. No Subject to technical alterations without notice SCHMALZ is a registered trademark in Europe Vacuum Handling Systems- Applications & Products Vacuum clamping technology for CNC machine tools Product line vacuum components S E N D E R : Company/Name: Address: Function/Dept.: Phone: Fax: Handling with vacuum. J. Schmalz GmbH Förder- und Handhabungstechnik Aacher Straße 29 D Glatten Phone: / Fax: / schmalz@schmalz.de