The extremely high performance of modern machine tools can be fully utilised only if the environment in which they are used can support them. Such high-performance machining centres do not automatically guarantee economical production: the running time of the machines is productive time only if the workpieces can be changed quickly and the non-productive times can be reduced.

However, too many users of such machines still shy away from additional investments in the rational handling of the parts to be machined and still load their expensive machines by hand, in spite of the fact that economical handling solutions with which the investment in a complex machine is worth its money already exist. A good example of a successful system solution is the vacuum-aided loading and unloading of a CNC machining centre at Metalldecor in D-72291 Betzweiler-Wälde, a company which produces large aluminium heat sinks.

The aluminium workpieces weigh 60 kg each and were previously placed on the machine by hand. After machining, the parts had to be lifted off the machine and stacked on pallets. The production managers soon noticed the discrepancy between the modern machining technology and the conventional handling of the workpieces, and started to look for a more efficient handling solution which would not cost too much money. They finally found this solution in the form of a complete vacuum handling system, consisting of a slewing column crane with a 3 m jib and a vacuum lifting device of the type VacuMaster Light made by the vacuum specialist J. Schmalz GmbH in D-72293 Glatten.

The slewing column crane, with the vacuum lifting device suspended from it, is mounted on a steel base plate, which means that the complete handling system can be used flexibly at various locations within the factory.

The universal "heart" of the handling system is, however, the vacuum lifting device VacuMaster Light 100/4, since this makes the loading and unloading of the machining centre far easier, safer and faster. This VacuMaster model is the smallest vacuum lifting device for crane suspension and is designed to lift loads weighing up to 100 kg. Furthermore, it can be suspended from almost any type of indoor crane. It is designed for the horizontal handling of workpieces and makes this very easy because all operator controls are mounted close to the ergonomical operator handle. The device is compact and light and can lift, move and position loads quickly, safely and precisely. In this example, the above-mentioned aluminium heats sinks are placed on the clamping system of the machine table, where they are clamped and then milled and drilled.

After machining, the parts are lifted from the table and placed carefully on a pallet. The machine operator no longer needs to do any physically strenuous work and no second person is needed to help him. The loading and unloading of the machine is very much faster and causes less damage to the parts, and the running times of the machine are now actual production times.

As already mentioned. The complete handling system can be moved easily to other locations, permitting it to be used in other parts of the factory. This flexible use is facilitated by the fact that the four suction pads of the VacuMaster Light 100/4, complete with the integrated vacuum supply, can be adjusted very quickly and easily, without the need for tools, to grip other workpieces. With one and the same vacuum handling system, it is thus possible to handle square parts as small as 250 x 250 mm or long, narrow parts with the dimension 190 x 710 mm or larger.

Due to its low overall height of only 310 mm and its low weight of 15 kg, the VacuMaster Light 100/4 can also be used in restricted spaces. The system is also easy to install and put into service. Suspend it from a crane, connect the compressed-air supply, adjust the suction pads to the dimensions of the workpiece and you are ready to go.