Handling & Systems Leading magnetic solutions Eclipse Magnetics Ltd HANDLING / WORKHOLDING DIVISION
PICK CLAMP HOLD MANIPULATE Contents All of the following products are based around permanent magnets to provide an ultimate fail-safe hold in the event of a power or air failure. Pneumatic Range Optimag P Page 1 A high performance pneumatically actuated magnetic gripper. Comprehensive standard range of sizes. Off the shelf availability. Pneumatically Switchable Permanent Magnets Page 2 A semi standard range of pneumatically actuated magnetic grippers. Can be manufactured to meet customers exact requirements. Magnetic performance to suit the application. HPC 600 Page 3 Manufactured in a pneumatically or manually actuated format. Exceptionally high clamping forces generated on clamping thick plate. Off the shelf availability. Depalletiser Heads Page 4 A high performance pneumatically actuated magnetic gripper. Manufactured to suit all size applications, including "Euro Pallets". Integrated layer pad removal and pallet removal can be included if specified. Gantry Storage Beams Page 5 Supplied as a fully compliant handling beam for integration onto Gantry or Robotic Systems for Bakery Storage areas. Pneumatically switchable magnets include crash detection sensing, part position sensing, and actuation feed back, part compliance. High Volume Sheet Separation Page 6 Pneumatically actuated sheet floaters permit the loading and unloading of sheet stacks with advantages of remote & automated switching not possible with a non switchable magnetic floater.
Electronic Range Optimag E Page 7 A high performance electronically actuated magnetic gripper. Comprises of a comprehensive standard range. Off the shelf availability. Electronically Switchable Permanent Magnets Page 8 A semi standard range of electrically actuated magnetic grippers. Manufactured specifically to customers requirements. Magnetic performance to suit the application. Non specific Sheet Separation Page 9 To complement our pneumatic range of sheet separators producing a full range of permanent magnet sheet floaters in two formats. All are manufactured in a 100mm wide x 50mm thick format to your required length. Supplying ceramic magnet material for light duty separation, Rare Earth (neodymium) magnet material provides separation on heavily oiled components. Off the shelf availability. Specials Page 10 Eclipse Magnetics design expertise and magnetic knowledge means we can manufacture bespoke equipment to any size and format. Working with the customer we provide solutions meeting unique requirements. Conveying Page 11 Providing specialist conveyors to a wide range users, from laser welding lines through to simple scrap conveyors, within large rolling mills down to screw assembly lines. Systems Page 12 Eclipse Magnetics produce complete bespoke systems for a wide variety of industries. If your products are ferrous and you need a solution please give Eclipse Magnetics a call. One of our engineers will be pleased to discuss what we can offer you.
Optimag P Optimag provides a new concept in magnetic handling, clamping and manipulation. These magnets are offered in either Electronically or Pneumatically operated versions to suit your application perfectly. Optimag Pneumatic Magnets are permanent magnets which are switched using compressed air, this gives the benefit of providing a totally fail safe operation, The "Lose the Air, Maintain the Hold" principal of these magnets is essential for today s complex handling systems. The Optimag Pneumatic gripper is supplied as a modular system, in 5 standard sizes, each size having the option of a fine and a coarse pole configuration.this ensures maximum clamping power on minimum thickness materials. Fine Pole Clamping or lifting of thin or perforated ferrous pressings and sheet components. Single parts can be picked from a stack without the risk of the attraction of a second component. Coarse Pole Used for the clamping or lifting of rough, uneven surfaces, also provides greater clamping forces on thicker materials than the fine pole option. ELECTRONIC PNEUMATIC Typical Profile of Users General clamping or transporting of product where switching is required: Robotics Pick and place Transfer machinery End of arm grippers for manipulators Jigs and fixtures General lifting Turnover applications Benefits Fail-safe operation compressed air required for On / Off switching only. Specifically designed for thin or uneven surfaces. Designed to hold through large air gap (packaged parts). No damage to the product or packaging due to the inclusion of the high friction rubber facing ring. One module suits many applications. Modular design simple to extend existing systems. Multiple parts can be picked in a single operation. Initial part positioning not critical. Excellent weight to performance ratio. Extremely low maintenance. Single point fixing. Clamps 0.2mm thick material and above. Dia D Height H Magnetic Material Fine pole Coarse pole Finish Air Requirements Air Connection Max Operating Temp Neodymium Iron Boron (Rare Earth) Shallow field depth, used for thin materials Deep field depth, used for rough components, castings forgings, thin walled assemblies Blue Anodise Intermittent use (during switching only), 1.5 bar min 2 bar max. 1/8 BSP. 50ºC. Standard rear face fixing holes are provided for ease of mounting 1
Pneumatically switchable permanent magnets The Pneumatically Switchable Permanent Magnets (PSPM) are designed specifically for applications where product or part handling in the past has been extremely difficult. Imagine, picking up a thin, cast, limited contact and packaged range of products without changing grippers or handling devices. This and more can now be achieved with the Eclipse Magnetics PSPM range of magnets. Benefits Fail safe operation, compressed air required for On / Off switching only. Specifically designed for thin or uneven surface applications. Designed to hold through large air gap, (packaged parts). One module suits many applications. No damage to the product or packaging. Multiple parts can be picked in a single operation. Initial part positioning not critical. Special size ranges from 16mm diameter to 1400mm x 1200mm. Excellent weight to performance ratio. Replaceable wear plates or rubber facing available. Virtually maintenance free. Standard body sizes used, Interchangeable magnetic packs. Clamps 0.2mm thick material. Round modules Standard sizes 100mm Diameter 150mm Diameter 200mm Diameter 300mm Diameter Rectangular modules Standard sizes 76mm x 76mm 100mm x 200mm 150mm x 200mm 150mm x 300mm 200mm x 300mm 200mm x 400mm 300mm x 400mm 300mm x 500mm 1000mm x 1000mm 1000mm x 1200mm Reference No PSPM10R PSPM15R PSPM20R PSPM30R Reference No PSPM88 PSPM1020 PSPM1520 PSPM1530 PSPM2030 PSPM2040 PSPM3040 PSPM3050 PSPM100100 PSPM100120 2
HPC600 The HPC600 is unique within the Pneumatically operated range of permanent magnets, this magnet offers an extremely high clamping force this is due to ensuring all of the available magnetic force is being concentrated into the working face of this magnet. This magnet is predominantly used for similar applications to that associated with the performance generated by the Electronically Switchable Permanent Magnets, yet the HPC600, allows operation by either Pneumatics or Hand Ratchet options, dependant upon your preference. Typical Profile of Users Robotics Manipulator integration Transfer Machinery General Lifting Jigs and Fixtures Clamping of all Ferrous materials of 10mm thick or greater Benefits Fail Safe operation, compressed air required for On / Off switching only. Specifically designed for intimate contact. One module suits many applications. No damage to the product. Initial part positioning not critical. Replaceable wear plates available. Virtually maintenance free. Standard body sizes used, Interchangeable pole shoes can be profiled to suit your product. Performance The magnets are tested on 20mm thick ground mild steel (ideal conditions) and generate 650kg pull. In all lifting or manipulation applications we would recommend that the magnet would be used for a maximum of 200kgs SWL. Reference No Size Weight Actuation Length Width Height Kgs HPC600/P Pneumatic 216 74 90 7 6 to 10 Bar HPC600/R Ratchet 225 74 90 8.5 Manual Ratchet 3
De-palletiser/heads Applications These High Specification Pneumatically Switchable Permanent Magnets are extensively used for both Palletising and De-palletising of products in full layers, to and from production lines. When these units are used in transfer systems incorporating numerous product changes high benefits are realised. Reduced downtime is saved as no gripper changes are required. Typical Profile of Users Machine Manufactures / Integrators Robot Manufactures Aerosol fillers / Manufactures Tin Packaged Product Manufactures Tin Capped Glass Jar Fillers Manufactures Requiring to Load or Unload Ferrous Product in Bulk. Product Virtually any tin or capped glass container of product, can be lifted whether full or empty. Layer Pads can also be removed within the lifting operation. Finished product, shrink wrapped or boxed can also be transported without fear of damage to product or packaging. The Magnet The magnet is manufactured to suit the customer s requirements, the magnet is comparatively light, its weight, plus the product weight, must be taken into account when integration is being made with either a gantry system or robot. Eclipse Magnetics produce a full range of de-palletising magnets. This ranges from units designed to pick individual components, through to the units to suit the full range of pallet sizes including the Euro Pallet. Magnet Operation The magnetic heads are a High Specification Pneumatically Switchable Permanent Magnet arrangement. The magnet weight to performance ratio makes it ideal for robot and gantry integration. The high-energy magnets retain their magnetism indefinitely never needing to be re-energised. The magnet arrangement is determined during the design stages; this takes account of all product types that require moving. The magnetic face is supplied with a stainless steel contact / wear plate. To give the unit rigidity and long life. High quality precision bearings and pneumatic cylinders are used. Compressed air is used to switch the magnet On / Off, the magnet remains on in the event of total air failure. This failsafe feature is extremely beneficial in the environments where these magnets operate. The magnetic head movement is enclosed reducing the risk of contamination with your products in pre filling applications. The magnet head will pick up product through normal packaging materials or even boxed products if required. Air pressure required: 5 bar minimum 7 bar maximum. Additional Options Available Magnetic State Sensors Compliance Assemblies Over travel Sensors Part Present Sensors Layer Pad Removal Pallet Removal 4
Gantry storage beams Typical applications These magnetic beams provide a solution for baking tray storage systems, in automated bakeries. The system picks multiple trays from storage and deposits them onto the production line. Once the production of a particular bread type has finished, the trays are returned into storage and the next tray type is brought out with no changes to the magnetic picking head. Coverage / length of beam: 8 metres. Product Case Study Products to be moved are baking trays, the sizes of which vary dependent upon bread type and size, but range from 100mm x 150mm through to any size. The trays can be handled as individual trays, single strap and double strap. The contact area is limited to the roll edge at the top opening of each individual tray. Every tray type has a different pick up profile. Solution Eclipse Magnetics designed and manufactured single span, lightweight beams, supplied with the optimum number of pneumatically operated permanent magnetic heads to suit the required length of beam. The beams require compressed air for operation and electrical connections for sensing, and are supplied complete with all safety and positional feed back sensors for integration into any transfer gantry. The Beam Manufactured from a 100mm x 100mm x 6mm mild steel box section. All service pipe work is fully enclosed along one side of the beam. An identical enclosure along the other side houses the signal wiring, both services terminate in their own central connection point. Magnetic Heads High-energy magnets retain their magnetism indefinitely, the magnet arrangement is determined taking into account, all tray types to be moved. The magnetic face is supplied with a stainless steel contact / wear plate. Rigidity and long life is guaranteed by the use of high quality components. Air pressure required: 5 bar min 10 bar max. Compliance Assemblies Vertical compliance assemblies integrated into the beam to ensure that the magnets are correctly seated on the trays and provide up to 100mm of vertical movement. Over Travel Sensors Crash protection is provided on each vertical compliance assembly. Part Present Sensors Each magnet has part-present sensing. 5
high volume sheet separation Two types of magnet material are used in the magnetic sheet separators Ceramic dry to lightly oiled sheet applications Rare Earth lightly to heavily oiled sheet application Typical Profile of Users Automation houses and system integrators Automotive manufacturers Steel Blank Pressings manufacturers Punch Press manufacturers All high speed sheet steel processing lines have one common need; to handle only one sheet steel blank at a time. Accidently handling two sheets can cause expensive damage and down time. Eclipse Sheet Separation Modules efficiently separate stacked sheet steel. This model of sheet floater is designed to be energised and de-energised to aid with the loading / unloading of the sheet stacks. Technical information Pneumatically Actuated TOP PROTECTOR PLATE 100 TO SUIT APPLICATION AIR PORTS 100 120 BASEPLATE 100 FIXING HOLES Std Permanent Floaters (see page 9) Max Temperature: Ceramic 250ºC Rare Earth 100ºC Solutions Eclipse Magnetics supply a full range of sheet separators ranging from the Mini Separator for small component feeders within the automotive industry, through the standard range of Steel Sheet Separators found in all sheet steel works. Pneumatically operated magnets suit the high production, large installations providing a "No Hassle" insertion of the steel blank stack. Because steel sheet products are supplied oiled, this does vary the type of resistance that the magnet will need to overcome, depending upon the viscosity and vacuum caused by the oil, the magnet type offered will vary for the different applications There are two basic types of magnet material used for the different applications, if the sheets you process are dry or lightly oiled, Ceramic (Ferrite) magnet material is used when there will be little resistance to the separation process. Rare Earth (Neodymium Iron Boron) Magnet Material is used for the heavily oiled sheet separation, this material provides the high energy that is required to separate these types of sheets in order to overcome the adhesion / suction caused by the oils. Separator sizing is dependant upon the component size, however through experience we have found that the Eclipse Standard 100mm x 50mm section separator is extremely efficient at separating parts over a full spectrum of shapes, sizes and thickness. By standardising the basic section and offering variations in length and material we are able to make a product with extremely good quality, performance and price. 6
Optimag e Optimag provides a new concept in magnetic handling, clamping and manipulation. These magnets are offered in either Electronically or Pneumatically operated versions to suit your application perfectly. Optimag Electronic Magnets are permanent magnets which are electrically switched, this gives the benefit of providing a totally fail safe operation. The "Lose the power Maintain the Hold" principal of these magnets is essential in today s complex handling systems. The Optimag Electronic gripper is supplied as a modular system, in standard sizes and performances. Several magnets can be operated from a single controller in order to produce the required performance for your system, in addition if you require an up grade at any point, additional magnets can be added to your system until the maximum current rating of the controller is reached. Standard rear face fixing holes are provided for ease of mounting ELECTRONIC PNEUMATIC Typical Profile of Users Automation houses and system integrators. Automotive manufacturers. Manipulator manufacturers / distributors. Jig and fixture manufacturers. Crane manufacturers and lifting distributors. Benefits Once energised, the magnets retain their hold indefinitely and are not affected by failure or interruption of the power supply making them fail-safe. Power is only required for the On / Off switching operation. On / Off switching takes less than 0.2 seconds. Can be controlled by push buttons or via a signal from a PLC or robot / computer interface. No moving parts therefore virtually maintenance free. Pole extensions can be profiled to the shape of the component to be clamped. Standard Controller Features Illuminated Push Buttons to indicate the magnetic state of the system. Remote Switching Facility the controller can be interfaced to a PLC or operated by remote switches. Output Interlocks confirm the magnetic state of the system to an automated cell. These can be used to prevent machine operation until the magnets have been switched on. Current Sensing / Safety Circuit the lights / interlocks will not operate if the magnet has not been fully magnetised. Operating Voltage 110 Vac, 240 Vac and 415Vac versions are available. IP Rating IP55. Height Diameter Fixing holes M37058 4.6amp 100v 7
electronically switchable permanent magnets Each magnet has two outer steel poles (North and South) and two sets of permanent magnets are sandwiched between them. One set of magnets are constantly polarised in one direction. The other set have an electrical coil around them and, by passing a short current through this coil, the polarity of the magnet can be changed. When both sets have the same polarity they compliment each other and full magnetic power is achieved. When both sets have opposite polarity they cancel / balance each other and the magnet is effectively switched off. Typical Profile of Users Automation houses and system integrators. Automotive manufacturers. Manipulator manufacturers / distributors. Jig and fixture manufacturers. Crane manufacturers and lifting distributors. Benefits Once energised, the magnets retain their hold indefinitely and are not affected by failure or interruption of the power supply making them failsafe. Power is only required for the on / off switching operation. On / off switching takes less than 0.2 seconds. Can be controlled by push buttons or via a signal from a PLC or robot / computer interface. No moving parts therefore virtually maintenance free. Pole extensions can be profiled to the shape of the component to be clamped. Standard Controllers Features Illuminated Push Buttons to indicate the magnetic state of the system. Remote Switching Facility the controller can be interfaced to a PLC or operated by remote switches. Output Interlocks confirm the magnetic state of the system to an automated cell. These can be used to prevent machine operation until the magnets have been switched on. Current Sensing / Safety Circuit the lights / interlocks will not operate if the magnet has not been fully magnetised. Operating Voltage 110 Vac and 240 Vac versions are available. IP Rating IP55. Can be supplied with a plug / socket or hardwired. The magnets have a series of tapped holes in the rear to allow them to be mounted onto a structure. If the structure is steel then the aluminium isolator plate provided is to be used between the magnet and structure to prevent the magnet flux from being short-circuited. 8
Sheet separation Applications The separation of top layers of stacked steel sheets, in order to either allow automated or manual removal of single sheets only. This applies not only to single sheet but also to pressed products requiring lifting from stacks onto assembly lines. Typical Profiles of Users Automation Houses and System Integrators Automotive Manufactures Robotic Suppliers Steel Blank Pressing Manufactures. Punch Press Manufactures Product Steel sheet / pressings from material 0.2mm thick up to 3mm thick, for vertically separated sheet applications. Almost any shape and size can be catered for within the range of sizes that Eclipse Magnetics manufacture. Operating Parameters Oiled sheets are easily separated with these magnets, however on either old stacks with dried out oil or excessively oiled sheets, separation can be reduced. Contrary to rumours, size is important, as using too large a magnet, on too small a component will simply cause the component to flip and stick directly onto the face of the magnet. Ask for the correct size for your application. Small Components Where the width of the separator is twice the width of the component, the top component can flip onto the face of the separator instead of separating. This has been overcome by the introduction of the Mini Separator, with the size being only 30mm x 30mm, the magnet can be easily placed to best effect within the working areas. Dimensions: L B A C Permanent Magnetic Sheet Separator Part No Length Width Depth Fixing holes L (mm) B (mm) C (mm) A SF100 100 100 50 2 @ 50mm CTRS SF200 200 100 50 2 @ 150mm CTRS SF300 300 100 50 2 @ 200mm CTRS SF400 400 100 50 2 @ 200mm CTRS SF500 500 100 50 3 @ 200mm CTRS Rare earth attach suffix /R to part no. e.g. SF200/R Ceramic attach suffix /C to part no. e.g. SF200/C See page 10 for technical spec. 9
specials Special Applications Applied Magnetic Systems have earned an excellent reputation for designing and manufacturing special applications, represented and fully supported by a time served Engineering team. This team has accumulated over 200 years of experience in the field of Magnetic applications. This experience allows Eclipse Magnetics to work with you the customer, to meet the exact needs and requirements of your application, all within the physical confines of Magnetic principals. This expertise allows, special bespoke products to be manufactured as the norm and surprisingly the cost of them are little more than the cost of a standard product, many being designed and manufactured in 4 6 weeks from placement of order. Our customer base for specials is extensive, manufacturing products for a wide spectrum of industries, the following illustrations show this versatility Cannon Rubber Quick-change system to hold quick change wooden formers for vacuum forming rubber products. Vacuum / Magnetic bed with 4 independently switchable zones including a central vacuum area. Nukem Ultimate lifting device for picking and moving radioactive waste containers, ranging from 3 mm thick files filled with waste, through to sealed drums. Supply was a fully remotely actuated, hydraulically operated system, incorporating fully flexible magnet pads, capable of holding flat or radiused containers, all pads are self-adjusting. Clancy Ltd Multiple fixtures for cylindrically grinding engine components. Designed to have repeatability on 1,000,000s of components ground to tight tolerances. Supply was rotary magnets affectionately named the "Hedgehog" because of its looks. These units switch in two halves, the fixtures have multiple accurate locations that are hardened and ground. Initially ordering a single unit, the fixture proved to be so successful that many are now in use, mass-producing auto components. 10
conveying Conveyors Eclipse Magnetics produces a range of conveyors and conveyor systems to suit the full spectrum of applications and industries. We specialise in producing the correct specification to suit your application Applications on our conveyors have been within the following industries: Food manufacture / processing Container transportation Product Transportation Laser Welding Conveyors Scrap Conveyors Rolling Mill Transfer Conveyors Conveyors can be supplied as freestanding units or indeed as part of an integrated system that you are building; we will meet your specific requirements. Features Conveyors manufactured in stainless steel or mild steel construction and powder coated to suit the application. Option of Permanent Magnet, Electro Permanent Magnet or Electro Magnet conveyors to suit. High quality build. Supplied with or without controls. All are supplied and tested to meet with the agreed specifction and are complete with their respective certification. 11
systems Until recently, Eclipse Magnetics manufactured lifting magnets for the handling of ferrous sheets and vacuum lifting systems for the handling of non-magnetic materials such as aluminium and stainless steel but never a combination of the two systems. The challenge set to the design team was to develop a system which can lift both ferrous and non-ferrous sheets. The result was The Eclipse MagVac a dual purpose Magnetic and Vacuum system which is set to take the handling industry by storm. The MagVac system uses high powered Electronically Switchable Permanent Magnets each with a safe working load of 800kg combined with a vacuum Lifting Beam which has a safe working load of 750kg. Both systems have been tested and rated with a 3:1 safety factor. Eclipse Magnetics are aware that safety is paramount in such a system. The magnets are designed to require power for the On / Off switching only. Once energised, the magnets retain their hold indefinitely and are not affected by failure or interruption of the power supply therefore making the magnet part of the system fail safe. The vacuum system has a vacuum safety reserve which is automatically connected to the vacuum pad in the event of a power failure, allowing the beam to hold the load for approximately 30 minutes. Low vacuum in the lift condition triggers an audible alarm and visible red flashing light. The Eclipse Aerosol De-palletising System was designed to de-palletise empty aerosol cans one layer at a time to provide a constant feed of cans to a filling line operating at speeds of up to 500 cans / min. The system also automatically removes layer pads from between the can layers and handles empty pallets. The system automatically accommodates different sizes of cans, for maximum flexibility. These magnets are extensively used for: Robotic Palletising / de-palletising Automated transfer machinery for cans and metal capped jars Features Incredibly light weight and yet extremely powerful in operation. High energy Magnets, give a massive holding force providing a safe reliable lift on all tinned products and most metal capped jars. These high energy Magnets retain their Magnetism indefinitely thus never never have to be re-energised. The Magnetic face is supplied with a stainless steel contact / wear plate. This ensures that your customer s products are not marked or damaged. 12
Handling & Systems The Eclipse Magnetics Handling / Workholding Division are responsible for providing magnetic solutions to a wide ranging customer base with an overall focus on reducing our clients manufacturing costs by means of bespoke magnetic solutions. Eclipse Magnetics Ltd HANDLING / WORKHOLDING DIVISION Eclipse Magnetics Ltd. Units 1-4 Vulcan Road,Sheffield S9 1EW, England T: +44(0)114 225 0600 F: +44(0)114 225 0610 E:sales@eclipse-magnetics.co.uk Website: www.eclipse-magnetics.co.uk EM HB UK/1