Approach to System Design
The implementation from theory to practice is shown with a system design based on an example. The Schmalz Calculator in the "Services" section provides helpful support for system design.
Flowchart for system design
- Calculation of forces
- Suction cups
- Mounting elements
- Vacuum hoses
- Distributors
- Vacuum generators
- Solenoid valves
- Vacuum switches
The following calculations are based on this application:
Workpiece
Material: Steel sheets, stacked on a pallet
Surface: Smooth, level, dry
Dimensions:
Length: max. 2,500 mm
Width: max. 1,250 mm
Thickness: max. 2.5 mm
Weight: approx. 60 kg
Handling system
Used system: Gantry handling system
Existing compressed air: 8 bar
Control voltage: 24 V DC
Working sequence: Horizontal Pick & Place
A steel sheet is picked up from a pallet, lifted, transported horizontally and deposited in a machining center.
Max. acceleration:
X, Y axis: 5 m/s2
Z axis: 5 m/s2
Cycle time: 30 s
Scheduled time:
for pick-up: < 1s
for releasing: < 1s
Schmalz Calculator
Precisely calculate the holding force, suction rate, and compressed air consumption of your vacuum system.
Weight Calculation of a Workpiece
It is important to determine the weight (m) of the workpiece to continue with additional calculations. It is calculated based on the following formula.
Theoretical Holding Force of a Suction Cup
To calculate the theoretical holding force, we show and describe the three most important and most frequently occurring load cases (handling sequences).
Suction Cup Selection
In order to select the right suction cup, you must take the ambient conditions into consideration.
Mounting Elements Selection
The mounting of the suction cups is usually selected according to customer requirements. But there may be compelling reasons for a particular type of mounting.
Vacuum Hose Selection
Schmalz selects the vacuum hoses to match the size of the flow rates as well as the size of the suction cups.
Distributor Selection
The distributor has to match the used hose diameter and the number of suction cups.
Vacuum Generator Selection
The selection of the matching vacuum generator (ejector, pump or blower) is determined by several factors.
Valve Technology Selection
The selection of the right valve technology depends on the suction rate of the generator and the control voltage.
Vacuum Switch Selection
Vacuum switches and manometers are usually selected based on the existing requirements regarding functionality and switching frequency.
Calculation of Evacuation Times
Calculate evacuation times and judge the cost-efficiency of your complete system from Schmalz.
Test with Original Parts
In addition to calculations, tests and original parts demonstrate the efficiency of Schmalz vacuum systems.