UNILOCK Modular Workholding System Vol 5

UNILOCK multi-axis workholding products are designed to provide flexibility and functionality. These CNC workholding fixtures locate and stabilize the workpieces without obstructing access to the top and sides of the part. They also allow a clamped workpiece to be flipped into new orientations for subsequent machining operations without unclamping it from the workholding.

MODULAR WORKHOLDING SYSTEM

VOL. 5

OVERVIEW AND APPLICATION EXAMPLES

4-9

A.1 10-27

ROUND CHUCKS

A.2 28-39 A.3 40-45 A.4 46-59 A.5 60-89 A.6 90-97 A.7 98-105 A.8 106-114

PREASSEMBLED CHUCKS

AUTOMATION SYSTEMS

KNOBS, BALLS AND PALLETS

MULTI-AXIS SYSTEMS

CHAIN CLAMPING

STABILIZER SYSTEM

ACCESSORIES AND MAINTENANCE

OVERVIEW

How it Works UNILOCK uses spring pressure to drive clamping pins against a tapered knob for quick, repeatable clamping. Air pressure retracts the pins, and releasing the air re-engages the clamp. The knob mounts to a base plate, fixture or workpiece. A manual version is also available. Features • Powerful clamping: Heavy-duty die springs deliver reliable holding force • Quick release: Air pressure easily opens chuck by compressing springs • Stable and compact: Low-profile design with taper wedges ensures rock-solid stability • Precise positioning: Conforms to the workpiece for consistent accuracy

• Efficient operation: Unlocks with just 75 PSI of air pressure • Turbo Assist: Boosts clamping force for demanding applications

Single Chuck Applications The UNILOCK clamping knob engages with the chuck’s central taper to establish the XY reference in a Cartesian coordinate system. A timing pin or key fits into a notch or bushing to orient the fixture and prevent rotation. The Z reference is determined by contact between the bottom of the fixture or workpiece and the top ground surfaces of the chuck, ensuring axial alignment. When external locating features are utilized, the clamping knob can secure the workpiece without affecting its position.

OVERVIEW

Multiple Chuck Applications UNILOCK supports multiple clamping knobs and chucks for larger or heavier fixtures, ensuring stability beyond the range of a single chuck. Undersized knobs offer clearance for oversized parts or off-center locations.

SBC Knob Diametral Clearances Type Metric

Inch

SBA SBB SBC

.005mm .005mm

.0002 .0002

.1mm

.004

SBA = Establishes centerline SBB = Orients about centerline SBC = Clamp only, no positioning • See pg. 48 for more details on knob functions

Designed for Manufacturing UNILOCK chucks are easy to maintain with compressed air. Chips won’t be forced inside due to the tight fit between clamping rams and the chuck body. Any debris in the clamping pocket can be quickly cleared with an air gun. The fully retracting wedges and 1:1 length-to-diameter ratio make cleaning simple with no vacuum needed. The robust 40 mm × 40 mm clamping knob adds stability and acts as a foot for safe handling and storage. No protective sleeves or special shelving are required. Multiple male and female thread sizes are available.

Self-Guiding Design uiding n

23º

4.8mm

UNILOCK is built to accommodate warped workpieces and fixtures. Its shallow clamping pocket allows knob entry at angles up to 23°, making it ideal for uneven setups. Undersized, standard and special clamping knobs are available to support out-of-position datums with ease.

The radius on the clamping knob’s smaller bottom diameter helps guide it into the chuck during out-of-position loading. This is especially useful for large workpieces that may warp, expand or contract, ensuring smooth and accurate engagement.

OVERVIEW

Process Your Way to Savings Fixtures and workpieces easily adapt to UNILOCK clamping knobs, unlocking significant savings. By reorienting or transferring parts while still mounted, you can machine additional features without reclamping. On horizontal machines, fixtures can rotate 90° or shift to the top of the column. Minimizing clamping steps reduces setup time, scrap, and improves feature-to-feature accuracy, all while eliminating the need for multiple fixtures.

Transfer Workpieces Between Processes • Vertical machining cells • Horizontal machining cells • High-speed drilling and tapping centers

• Surface and cylindrical grinding cells • Horizontal and vertical lathes • Coordinate measuring cells

Once the part is fixtured, use UNILOCK to carry it through as many operations as possible without removal. UNILOCK clamps and locates from a single face, keeping other sides fully accessible for machining. With rotary tables, angle or sine plates, and multi-sided tombstones, parts can be easily reoriented for additional operations, maximizing efficiency and precision.

Expand the operational envelope of any UNILOCK chuck by adding external timing features and support for areas of the workpiece or pallet that extend beyond the chuck’s top surface.

OVERVIEW

Working Solutions in Minutes Table chucks come pre-mounted on base plates, ready to clamp directly to your workstation for fast setup. Supported by preassembled pallets, the Mono, Duo, and Quad table chucks offer versatile options for any application. Pneumatic kits are also available; install a complete solution in minutes.

Build Your Own Custom Solutions UNILOCK components are available individually, giving you the flexibility to integrate them seamlessly into your own custom designs.

APPLICATION EXAMPLES

Scheduling Flexibility and Setup Versatility A Clamping System Flexible Enough to Change the Entire Table or Workpieces and Fixtures UNILOCK creates predefined datums across all machines for fast, repeatable setups. Load, lock, and hit cycle start with no wasted time. Use multiple chucks to quickly switch between small parts or larger setups, converting from headstock and tailstock to table-mounted fixtures with ease.

Use in Any Configuration and Process Endless Applications — Limited Only by Your Imagination Quickly align all your rotary table fixtures with UNILOCK. As you move away from the spindle nose, UNILOCK’s heavy-duty chucks absorb the additional leverage and torque. These chucks ensure stability even during demanding cuts. Sold individually, the components allow you to create custom solutions in-house or with your tooling partner. Whether you need six chucks for heavy machining or a single chuck with a timing feature for inspection, UNILOCK adapts to nearly any setup or process.

APPLICATION EXAMPLES

Large Parts Save Money on Your Next Job

UNILOCK offers undersized clamping knobs so you don’t need to hold ultra-tight fixture tolerances, ideal when production specs are more forgiving. These knobs are perfect for warped or loosely toleranced workpieces. When tight tolerances aren’t required or possible, simply choose the right undersized knob for the job. For heavier setups, UNILOCK’s heavy-duty 40 mm knobs, with a 1:1 length-to-diameter ratio, provide the strength and stability needed for hoist loading and can stay on fixtures during handling, storage, and transport without risk of damage.

SBC Knob Diametral Clearances Type Metric

Inch

SBA SBB SBC

.005mm .005mm

.0002 .0002

.1mm

.004

SBA = Establishes centerline SBB = Orients about centerline SBC = Clamp only, no positioning • See pg. 48 for more details on knob functions

Small Parts Remove Process Time – Save More Than Just Setup Time With UNILOCK, parts that once required clamping and unclamping for each machining step now stay fixtured through multiple operations. This reduces labor, minimizes the chance for error, and increases spindle uptime. By keeping the part in the same fixture, you eliminate unnecessary setups, reduce scrap, and avoid the cost of additional fixtures for later operations, saving both time and money.

Before UNILOCK After UNILOCK Set Up Production Set Up Production Savings

Operation

2 hours 9 hours 6 hours 18 hours

Op-10 Lathe 3 hours

4 hours

1 hour

4 hours 2 hours 8 hours

Op-20 Lathe 2 hours 10 hours 1 hour

Op-30 Mill

4 hours 11 hours 1 hour

Total

10 hours 25 hours 3 hours 14 hours

A.1

ROUND CHUCKS INDEX

ESM 138A

12-13

ERGO 138

14-15

EFM 138A

16-17

ASM 90A

18-19

ASM 99

20-21

ISM 160

22-23

ESM 176A

24-25

ESM 168

26-27

ROUND CHUCKS

ESM 138A Air-Assisted Clamping Turbo Chuck Features air-assisted turbo clamping for enhanced holding power. A sealed cover plate over the piston enables a new slide wedge actuation system, delivering increased retention force and improved performance.

Features • Mid-sized diameter fits most applications • Top side mounting for ease of integration • Choose from air connections at bottom or side • Optional timing notch in face of chuck

• Same body and locating diameters • Same mounting bolt hole pattern • Same flange air port location • Same timing notch

Available with Notches

Recommended Bolt Sizes

Clamping Force (lbs)

Air Connection

Catalog Number

Notch (Width x Qty)

Weight (lbs)

Description

M10 M12 M16 M20† M24† Spring Only Turbo Assist Port Size Flange

15.270.140A 15.270.147A

—

ESM 138A

1,686

5,620

G1/8"

9.9

3 3 3 3 3

14 H7 x 1

ACCESSORIES S

†Optional • Screws, screw covers and O-ring included

DUST COVERS PG. 112

REPAIR PG. 113

KNOBS PG. 47

AIR FITTINGS PG. 108

ROUND CHUCKS

ESM 138A

+.018 0

14 H7

+.01 -.01

60.50

ø9 H7 +.015 0

Through All

G1/8" “Open” (Unclamp)

ø121 B.C.

G1/8" “Turbo” (Clamp)

M8 SHCS (6x) (Included)

0 -.01

ø138

9 f7

ø109.90

0 -.01

ø110

ø8x2 O-Ring Port “Confirmation” (Unclamp Confirmation)

ø8x2 O-Ring Port “Turbo” (Clamp)

ø8x2 O-Ring Port “Open” (Unclamp)

• All dimensions are in millimeters • Dimensions marked are for notch option

ROUND CHUCKS

ERGO 138 Space-Saving, Low-Profile Chuck With a compact height of just 28mm, the ERGO 138 saves 11mm compared to the ESM 138, making it ideal for applications where every millimeter counts.

Features • Mid-sized diameter fits most applications • Top side mounting for ease of integration • Choose from air connections at bottom or side

• Same mounting bolt hole pattern • Same flange air port location • Increased inner support ring diameter • Knee locking mechanism

• Optional timing notch in face of chuck • Same body and location diameters

Unclamped

Clamped

Available with Notches

Recommended Bolt Sizes

Clamping Force (lbs)

Air Connection

Catalog Number

Notch (Width x Qty)

Weight (lbs)

Description

M10 M12 M16 M20† M24† Spring Only Turbo Assist

Port Size Flange

15.270.110A 15.270.117A

—

ERGO 138

990-1,320 3,300-3,520

G1/8"

9.9

3 3 3 3 3

14 H7 x 1

ACCESSORIES S

†Optional • Screws, screw covers and O-ring included

KNOBS PG. 47

AIR FITTINGS PG. 108

DUST COVERS PG. 112

REPAIR PG. 113

ROUND CHUCKS

ERGO 138

14 H7 (9x)

ø10 H7 Through All

G1/8" BSP Open Port (Ships Plugged)

M8 SHCS (6x)

G1/8" BSP Open Port (Ships Plugged)

0 -.001

ø138

ø110 0 -.01 ø109.05

Detail A Scale 2:3 ø8x2 O-Ring (Ships Plugged)

Detail C Scale 2:3 Air Cleaning (Ships Plugged)

Detail B Scale 2:3 ø8x2 O-Ring (Ships Plugged)

ø12 M7

Open Port

M5 Port for Drain or Cleaning (Ships Plugged)

Turbo Port

• All dimensions are in millimeters • Dimensions marked are for notch option

ROUND CHUCKS

EFM 138A Ideal for Thin-Walled Tombstones This flange-mount chuck features a reduced projection height, making it easy to integrate into custom fixtures, perfect for use on thinner-walled tombstones.

Features • Mid-sized diameter fits most applications • Top side mounting for ease of integration

• Reduced projection height by mounting in fixtures • Optional timing notch in face of chuck

Available with Notches

Recommended Bolt Sizes

Clamping Force (lbs)

Air Connection

Catalog Number

Notch (Width x Qty)

Weight (lbs)

Description

M10 M12 M16 M20† M24† Spring Only Turbo Assist

Port Size Flange

15.263.100A 15.263.107A

—

EFM 138A

1,348

4,496

—

8.0

3 3 3 3 3

14 H7 x 1

ACCESSORIES S

†Optional • Screws, screw covers and O-rings included

KNOBS PG. 47

AIR FITTINGS PG. 108

DUST COVERS PG. 112

REPAIR PG. 113

ROUND CHUCKS

EFM 138A

ø121

M8 Low Head SHCS (6x)

5 ø10 H7 Through All 14 H7

0 -.01

ø138

ø109.7

0 -.01

ø110

ø7x1.5 O-Ring Port “Open” (Unclamp)

ø7x1.5 O-Ring Port “Turbo” (Clamp)

• All dimensions are in millimeters • Dimensions marked are for notch option

ROUND CHUCKS

ASM 90A Compact Chuck for Small Applications One of the smallest in the UNILOCK lineup, the ASM 90A is designed for tight spaces and small jobs, providing secure clamping without obstructing the area.

Features • Reduced diameter for small work or tight spaces • Integrated toe clamp lip • Turbo option for increasing holding power

• Air supply from bottom or side of chuck • Optional reference notch in face of chuck

Available with Notches

Recommended Bolt Sizes

Clamping Force (lbs)

Air Connection

Catalog Number

Notch (Width x Qty)

Weight (lbs)

Description

M10 M12 M16 M20† M24† Spring Only Turbo Assist

Port Size Flange

15.240.090A 15.240.091A

—

ASM 90A

— — — 562

2,472

G1/8"

5.1

3 3

12 H7 x 1

ACCESSORIES S

†Optional • O-rings included

KNOBS PG. 47

AIR FITTINGS PG. 108

DUST COVERS PG. 112

REPAIR PG. 113

ROUND CHUCKS

ASM 90A

32.5 39

M5x.8 5.5

G1/8 "Open" (Unclamp) Shipped Plugged

G1/8 "Turbo" (Unclamp) Shipped Plugged

81 ø84.8

0 -.01

ø90

Detail A Scale 1:1 ø4x1.5 O-Ring (Ships Unplugged)

Detail B Scale 1:1 ø4x1.5 O-Ring (Ships Unplugged)

ø0

M5x0.8 - 6H

10 (8x)

+.012 0

ø5 H7

10 (2x)

• All dimensions are in millimeters • Dimensions marked are for notch option

ROUND CHUCKS

ASM 99 Semi-Compact Body Size The ASM 99 chuck helps to bridge the gap between the ASM 90 and ESM 138 chuck bodies.

NEW

Features • Medium diameter size • Mounting from top • Air supply from bottom or M5 side ports

• Unclamp conformation port • Multiple timing options

Available with Notches

Recommended Bolt Sizes

Clamping Force (lbs)

Air Connection

Weight (lbs)

Catalog Number

Notch (Width x Qty)

Description

M10 M12 M16 M20† M24† Spring Only Turbo Assist

Port Size Flange

15.240.099

—

ASM99

— — —

M5x0.8

5.5

3 3

12 H7 x 1 ø8 F7 x 1

15.240.097

ACCESSORIES S

†Optional • O-rings included

KNOBS PG. 47

AIR FITTINGS PG. 108

DUST COVERS PG. 112

REPAIR PG. 113

ROUND CHUCKS

ASM 99

(Unclamp Confirmation)

ø8 F7 10

"Turbo" (Clamp)

B.C. 87

"Open" (Unclamp)

ø7 F7

ø99 (2x) 0 -.01

ø4x1.5 O-Ring "Open" (Unclamp)

R43.5 (3x)

ø4x1.5 O-Ring "Turbo" (Clamp)

ø4x1.5 O-Ring (Unclamp Confirmation)

• All dimensions are in millimeters • Dimensions marked are for notch option

ROUND CHUCKS

ISM 160 Single-Chuck Solution for 4th and 5th Axis Rotary Tables

Engineered for the face of 4th and 5th axis rotary tables, the ISM 160 provides a compact, dependable clamping solution. Exterior timing features align with UNILOCK MCM 150 and MSM 170 chucks, while the adjustable timing pin slot supports non-standard pallet sizes, offering greater flexibility in setup. Features • Simple surface mount design • Now available with A2-6 mounting • Dowel pins into location • Supports 60º and 90º t-slots • Air-assisted clamping option • Low profile 46mm (1.811") • Through-hole eases cleaning • Multiple indexing options

Slot Allows for Variations in Radial Pin Location

Recommended Bolt Sizes

Clamping Force (lbs)

Air Connection

Catalog Number

Notch (Width x Qty)

Weight (lbs)

Description

M10 M12 M16 M20† M24† Spring Only Turbo Assist

Port Size Flange

ø14 H7 x 1 ø12 H7 x 4 ø12 H7 x 2

15.260.160

ISM 160

— — 1,100-1,540 3,300-3,740

G1/8"

12.1

3 3 3

15.300.008

ISM 160 (A2-6)

ACCESSORIES S

†Optional • No hardware included

KNOBS PG. 47

AIR FITTINGS PG. 108

DUST COVERS PG. 112

REPAIR PG. 113

Adapter Plate For ISM 160 to HAAS 160/210 Size Indexers and Trunnions

Features •Replaces t-slot platter •Allows for both open and turbo •Low 20mm height

Catalog Number

Indexer Model

Description

15.260.164 15.260.166

HAAS 160 HAAS 210

ISM 160

• Other sizes available upon request • Please contact the BIG DAISHOWA Engineering Dept. for additional information

ROUND CHUCKS

ISM 160

60º

13 TYP

M5 Turbo Port ø8x2 O-Ring (Ships Plugged)

M5 Open Port ø8x2 O-Ring (Ships Plugged)

52.5

0 -.01

ø162

0 -.005

14 H7

G1/8" BSP Open Port (Ships Unplugged)

ø12 H7 (4x)

12 H7 Through All (2x)

G1/8" BSP Turbo Port (Ships Unplugged)

• All dimensions are in millimeters

ROUND CHUCKS

ESM 176A Built for Heavyweight Fixtures The ESM 176A offers enhanced size and retention force, making it ideal for securely handling heavyweight fixtures with confidence.

Features • Flange design for top side mounting • Large diameter with turbo clamping for more rigidity

• Air supply from bottom or side of chuck • Optional reference notch in face of chuck

Available with Notches

Recommended Bolt Sizes

Clamping Force (lbs)

Air Connection

Catalog Number

Notch (Width x Qty)

Weight (lbs)

Description

M10 M12 M16 M20 † M24† Spring Only Turbo Assist

Port Size Flange

15.272.170A 15.272.171A

—

ESM 176A

2,023

8,992

G1/8"

17.5

3 3 3 3 3

25 H6 x 1

ACCESSORIES S

†Optional • Screws, screw covers and O-rings included • Notched version comes with timing bushing and all hardware listed above

KNOBS PG. 47

AIR FITTINGS PG. 108

DUST COVERS PG. 112

REPAIR PG. 113

ROUND CHUCKS

ESM 176A

M8 SHCS (6x)

G1/8" “Turbo” (Clamp)

ø152 B.C.

G1/8" “Open” (Unclamp)

0 -.01

ø176

+.01 -.01

6.2

ø12 n6

ø137.9

0 -.01

ø138

ø8x2 O-Ring Port “Open” (Unclamp)

ø8x2 O-Ring Port “Turbo” (Clamp)

ø8x2 O-Ring Port “Confirmation” (Unclamp Confirmation)

• All dimensions are in millimeters • Dimensions marked are for notch option

ROUND CHUCKS

ESM 168 Through-Hole Access for Versatile Machining Ideal for 4th and 5th axis rotary tables, lathes or mills, the ESM 168 allows workpieces to pass through the center of the chuck.

Features • Removable center cover

• Offers clamp/unclamp confirmation • Bolts into place from top side

• Work can pass through chuck • Air-assisted clamping option

Recommended Bolt Sizes

Clamping Forces (lbs)

Air Connection

Catalog Number

Notch (Width x Qty)

Weight (lbs)

Description

M10 M12 M16 M20 † M24† Spring Only Turbo Assist

Port Size Flange

15.500.168

2,248

8,992

G1/8”

14.3

ESM168

—

— — — —

ACCESSORIES S

†Optional • Screws, screw covers and O-rings included • See pg. 52 for M74 option

KNOBS PG. 47

AIR FITTINGS PG. 108

DUST COVERS PG. 112

REPAIR PG. 113

ROUND CHUCKS

ESM 168

M8 SHCS (6x) (Included)

G1/8 "Turbo" (Clamp)

B.C. ø152

G1/8 "Open" (Unclamp)

0 -.01

ø168

ø137.8

0 -.01

ø138

9x1.5 O-Ring Port "Confimration 2" (Clamp Confirmation)

9x1.5 O-Ring Port "Open" (Unclamp)

9x1.5 O-Ring Port "Turbo" (Clamp)

9x1.5 O-Ring Port "Confimration 1" (Unclamp Confirmation)

• All dimensions are in millimeters • Dimensions marked are for notch option

A.2

PREASSEMBLED CHUCKS INDEX

ERGO 138

30-31

E100B

E200B

E300B

E400B

35-36

E600B

E800B

E1000B

PREASSEMBLED CHUCKS

ERGO 138 PREASSEMBLED BASES Compact Double Table Chuck Solutions Preassembled base stations featuring the ERGO 138 chuck offer a low-profile design, saving 11mm in height compared to the ESM 138. Available with turbo clamping right out of the box.

Features •Mid-sized diameter chuck fits most operations •Finish ground steel baseplate

•Predesigned solutions for up to 10 chucks •Optional timing notch in face of ERGO 138 chucks

Metric (mm)

Imperial (in)

Catalog Number

Number of Chucks

Page

Length

Width

Height

Length

Width 5.866 7.717 7.677 15.551 15.551 15.591 15.591

Height

15.270.370B 15.270.371B 15.270.372B 15.270.373B 15.270.374B 15.270.375A 15.270.376A

32 33 34 35 37 38 39

196 396 595 395 596 796 996

149 196 195 395 395 396 396

7.717

1 2 3 4 6 8

15.591 23.425 15.551 23.465 31.339 39.213

1.929

2.362

ACCESSORIES S

• No hardware included • See pg. 14 for ERGO 138 chuck specifics

KNOBS PG. 47

AIR FITTINGS PG. 108

DUST COVERS PG. 112

REPAIR PG. 113

PREASSEMBLED CHUCKS

Application Examples ERGO 138 PREASSEMBLED BASES

ERGO 138 — Welding Four ERGO E600 bases are used to hold welding fixtures, allowing for the quick changeover of fixtures when the production changes from one series of parts to another. There is no need to retouch points between changes as the system repeatability of .005 μm (.0002") is greater then needed in most welding applications.

ERGO 138 — Timing Block The ERGO E100 base can be modified by the end user to accept a timing block allowing for the timing of smaller fixtures at 45° or 135°. In all cases the block ( 15.270.331 ) is sold separately.

ERGO E300 — Round, Special Item Special versions of round bases can be built to customer specifications. For assistance, please consult the BIG DAISHOWA Engineering Dept.

PREASSEMBLED CHUCKS

ERGO E100B

NEW

25 (2x)

15.351.004 (2x) (Included)

ø198

ø138

Catalog Number 15.270.370B

• All dimensions are in millimeters • For detailed information on additional mounting hole locations, please consult the BIG DAISHOWA Engineering Dept.

PREASSEMBLED CHUCKS

ERGO E200B

NEW

399

200

25 (4x)

ø25 H7 5.5

G1/8" Open Port (2x) (Unclamp)

G1/8" Turbo Port (2x) (Clamp)

15.351.004 (2x) (Included)

ø138

Catalog Number 15.270.371B

• All dimensions are in millimeters • Dimensions marked are for notch option • For detailed information on additional mounting hole locations, please consult the BIG DAISHOWA Engineering Dept.

PREASSEMBLED CHUCKS

ERGO E300B

NEW

146 196

170

ø14 H7 (4x) Through All

G1/8 "Open" (Unclamp)

G1/8 "Turbo" (Clamp)

15.351.004 (2x) (Included)

Catalog Number 15.270.372B

ø138 (3x)

• All dimensions are in millimeters • For detailed information on additional mounting hole locations, please consult the BIG DAISHOWA Engineering Dept.

PREASSEMBLED CHUCKS

ERGO E400B

NEW

399

200

ø25 H7 5.5

25 (2x)

G1/8 "Open" (Unclamp)

G1/8 "Turbo" (Clamp)

15.351.004 (2x) (Included)

ø138

Catalog Number 15.270.373B

• All dimensions are in millimeters • For detailed information on additional mounting hole locations, please consult the BIG DAISHOWA Engineering Dept.

PREASSEMBLED CHUCKS

Application Examples ERGO E400B

The ERGO E400 base stations shown above are mounted together for a master reference system on the table of the machine. They are also pneumatically linked to operate in unison. The vise plate (left bottom) and the grid plate (right bottom) are easily swapped or removed entirely. Then, when needed, replaced within .0002" (.005mm) of their original location.

PREASSEMBLED CHUCKS

ERGO E600B

NEW

200

ø25 H7 5.5

M8 (4x) (Lifting)

ø11 (4x) Through All

20 H6 (2x)

G1/8 “Turbo” Port (Clamp)

G1/8 “Open” Port (Unclamp)

Catalog Number 15.270.374B

• All dimensions are in millimeters • For detailed information on additional mounting hole locations, please consult the BIG DAISHOWA Engineering Dept.

PREASSEMBLED CHUCKS

ERGO E800A

796

Catalog Number 15.270.375A

+.01 -.01

200

ø138

G1/4 "Open" (Unclamp)

G1/4 "Turbo" (Clamp)

The ERGO E800A preassembled bases shown with custom mounting holes designed to match the T-slot pattern of the customer’s machine for fast, precise installation. • All dimensions are in millimeters • For detailed information on additional mounting hole locations or base modifications,, please consult the BIG DAISHOWA Engineering Dept.

PREASSEMBLED CHUCKS

ERGO E1000A

996

+.01 -.01

200

Catalog Number 15.270.376A

ø138

G1/4 "Turbo" (Clamp)

G1/4 "Open" (Unclamp)

Shown with four custom-designed fixtures. Standard fixture pallets are available in aluminum or steel, and come in a variety of sizes and thicknesses. See pg. 30 for details. • All dimensions are in millimeters • For detailed information on additional mounting hole locations, please consult the BIG DAISHOWA Engineering Dept.

A.3

AUTOMATION SYSTEMS INDEX

AUTOMATION SYSTEMS OVERVIEW

ESA 138

EGM 110-75

PKL 110

AUTOMATION SYSTEMS

AUTOMATION SYSTEMS Supporting End-User or Integrator Applications for Robotic Loading of Palletized Fixtures

NEW

ESA 138 Chuck – Enables automatic loading and unloading, with clamp/unclamp confirmation and pallet presence detection. An optional through-center air blast is available for knob cleaning. PKL 110 Pallet Adaptor – Allows end users or integrators to modify pallets or fixtures for robotic pick-and-place operations. EGM 110-75 Chuck – Used with an adapter on the end of arm to grip the pallet for pick-and-place applications. Clamp/unclamp confirmation is built into the chuck, and an air-blast option is available.

PKL 110 Adaptor

EOA Adaptor Per Robot Specifications

Standard or Custom Pallets Per Application Specifications

EGM 110-75 Chuck

ESA 138 Chucks

Basestations Per Customer Specifications

Robot and control not supplied by BIG DAISHOWA. Pallet storage rack not supplied by BIG DAISHOWA. Direct part picking not available.

AUTOMATION SYSTEMS

ESA 138

ø1.5

NEW

G1/8 "Open" (Unclamp)

Detail A Scale 2:3 Pallet Presence Pads (4x)

30º

B.C. ø121

G1/8 "Turbo" (Clamp)

M8 SHCS (6x) (Included)

ø138 ø144

ø109.9

0 -.01

ø110

"Pallet Presence" Ports (4x)

"Unclamp Confirmation" Port

"Turbo" Port (Clamp)

"Open" Port (Unclamp)

R62 (8x) (ø8x2 O-Ring)

"Clamp Confirmation" Port

Clamping Force (lbs)

Air Connection

Catalog Number

Weight (lbs)

Description

Notch

Spring Only

Turbo Assist

Port Size

Flange

15.279.300

ESA 138

—

1,686

5,620

G1/8

9.9

• All dimensions are in millimeters

AUTOMATION SYSTEMS

EGM 110-75

NEW

80 110

45 (2x)

M8 (4x)

G1/8" “Turbo” Port (Clamp)

G1/8" “Open” Port (Unclamp)

49.8

"Turbo" (Clamp)

"Open" (Unclamp)

M7x1.0 Air Blow

"Unclamp Confiramtion"

"Clamp Confiramtion"

Clamping Force (lbs)

Air Connection

Catalog Number

Weight (lbs)

Description

Notch

Spring Only

Turbo Assist

Port Size

Flange

15.279.320

EGM110-75

2x 12

899

3,147

G1/8

5.9

• All dimensions are in millimeters

AUTOMATION SYSTEMS

PKL 110

NEW

135

Pallet (Not Included)

Catalog Number

Weight (lbs)

15.279.330

3.5

Pallet Modifications

45 (4x) ø12.2 85.3 (4x) ø10.2 80 (4x) M12x1.75-6H

55 110

(80) (85.3)

(45)

ø10 H7 +.015 0

(2x)

• All dimensions are in millimeters

A.4

KNOBS, BALLS AND PALLETS INDEX

CLAMPING KNOBS CLAMPING KNOB OVERVIEW

SYSTEM 40 KNOBS

49-51

SYSTEM 25 KNOBS

52-53

SYSTEM 68 KNOBS

CLAMPING BALLS 5-AXIS STABILIZER BALLS

55-56

PALLETS

SYSTEM 40 PALLETS

57-59

KNOBS, BALLS AND PALLETS

CLAMPING KNOBS Can be attached to fixtures or directly to workpieces. Our standard knobs can be mounted in a blind hole from the bottom or pulled up from the top. Standard clamping knobs accept the following: OPTION 1: PASS-THROUGH BOLT – The bolt is inserted past the clamping knob and threads into the workpiece or fixture. OPTION 2: RETAIN FROM TOP – The bolt passes through the workpiece or fixture and pulls the knob into position.

Option 1: Pass-Through Bolt

Option 2: Retain From Top

Standard clamping knobs have a metric positioning boss which is ø25mm and ground to a fit of h6. This boss is 5mm tall. The overall measurements of the clamping knob is ø40mm by 40mm tall.

The SBA Knob is ground to fit with the center ground taper of the chuck. This fit establishes centerline location. This location will repeat to better than +/-.0002" (.005mm).

The SBB Knob is ground like a diamond pin and orients your work relative to the centerline of the SBA Knob.

The SBC Knob is ground undersize. It will bring the bottom of the workpiece or fixture down on the top of the UNILOCK chuck.

KNOBS, BALLS AND PALLETS

SYSTEM 40

ø25 H7 +.021 0

Knobs

Contact Pads (B Type Only)

Hex

Section A-A

Knob Type

Catalog Number

Repeatability (in)

Internal Thread

Pass-Through Bolt Size

Description

Hex

15.260.300 15.260.301 15.260.302 15.260.400 15.260.401 15.260.402

A B C A B C

SBA—Absolute Position

.0002 .0002 .0040 .0002 .0002 .0040

M12 M12 M12 M16 M16 M16

M10 M10 M10 M12 M12 M12

10mm 10mm 10mm 17mm 17mm 17mm

SBB—Orientation

SBC—Undersized .1mm—Downward Clamping Only

SBA—Absolute Position

SBB—Orientation

SBC—Undersize .1mm

• For inch options please consult the BIG DAISHOWA Engineering Dept. • All dimensions are in millimeters

T-Slot Knobs

Thread

T-Slot

Knob Type

Catalog Number

Repeatability (in)

Description

Thread

T-Slot

15.250.360 15.250.361 15.250.366 15.250.367 15.250.362 15.250.363 15.250.364 15.250.365

A C A C A C A C

SBA—Absolute Position SBC—Undersized .3mm SBA—Absolute Position SBC—Undersized .3mm SBA—Absolute Position SBC—Undersized .3mm SBA—Absolute Position SBC—Undersized .3mm

.0002 .0040 .0002 .0004 .0002 .0040 .0002 .0040

M10xP1.5 M10xP1.5 M12xP1.75 M12xP1.75 M12xP1.75 M12xP1.75 M12xP1.75 M12xP1.75

14mm 14mm 16mm 16mm 18mm 18mm 22mm 20mm

• T-nuts and fasteners are included • Inch t-slot versions available upon request • All dimensions are in millimeters

KNOBS, BALLS AND PALLETS

SYSTEM 40 PASS-THROUGH Knobs and Screws (ø12mm)

ø12 H6 +.011 0

Thread G

SYSTEM 40 Pass-Through ø12mm Knob

ø18.5

Knob Type SBA SBB

Knob Catalog Number

15.250.317 15.250.318 15.250.319

Screw

SBA

Knob

L 1

L 2

Hex 10

SYSTEM 40 Pass-Through ø12mm Screw

Screw Catalog Number

øD 1

Thread (G)

L 1

L 2

L 3

L 4

15.250.505 15.250.501

12 12

M12xP1.75 M12xP1.75

50.0 55.0

22.0 22.0

30.0 35.0

8.0

13.0

• All dimensions are in millimeters • Other sizes available upon request; please consult the BIG DAISHOWA Engineering Dept.

KNOBS, BALLS AND PALLETS

SYSTEM 40 PASS-THROUGH Knobs and Screws (ø16mm)

ø16 H6 +.011 0

Thread G

SYSTEM 40 Pass-Through ø16mm Knob

ø21

Knob Type SBA SBB

Knob Catalog Number

15.250.307 15.250.308 15.250.309

Screw

SBC

Knob

12.5

L 1

L 2

Hex 14

SYSTEM 40 Pass-Through ø16mm Screw

Screw Catalog Number

øD 1

Thread (G)

L 1

L 2

L 3

L 4

15.250.535 15.250.504 15.250.537 15.250.523 15.250.528

16 16 16 16 16

M16xP2 M16xP2

55.0 43.5 37.5 28.0 28.0

25.0 24.0 18.0

35.0 23.5 17.5

10.0

— — — —

M12xP1.75 M12xP1.75 M10xP1.5

— —

8.0 8.0

• All dimensions are in millimeters

KNOBS, BALLS AND PALLETS

SYSTEM 25 Knobs

M10 SHCS

19.5

Contact Pads (B Type Only)

Section A-A Scale 1:1

Fig. 1

M8 C-Sink Cap Screw

Thread

ø10.5

+.017 +.006

ø12 G6

ø16

Fig. 3

Fig. 2

Knob Type

Catalog Number

Location Diameter

Internal Thread

Pass-Through Thread

Weight (lbs)

Description

Hex

Fig.

15.255.400 15.255.401 15.255.402 15.255.410 15.255.411 15.255.412 15.255.420 15.255.421 15.255.542

A B C A B C A B C

SPA25—Absolute Position

SPB25—Orientation

ø18 h6

M10

.11

SPC25—Undersized .1mm SPA25—Absolute Position

SPB25—Orientation

ø18 h6

—

— 2

.11

SPC25—Undersized .1mm

SPA25—Absolute Position (Thru Bore)

SPB25—Orientation (Thru Bore)

ø12 G6

—

M8/M10/M12

— 3

.11

SPC25—Undersized .1mm (Thru Bore)

• All dimensions are in millimeters • See pg. 82 for compatible chucks

KNOBS, BALLS AND PALLETS

SYSTEM 25 Shoulder Screws

Hex 8

L 1

L 2

L 3

Catalog Number

Shoulder Diameter

Weight (lbs)

Thread

L 1

L 2

L 3

15.255.425 15.255.426 15.255.427 15.255.428

28.0 17.5 14.5 11.5

45.7 35.7 32.7 29.7

M12xP1.75

ø12 h5

14.4

.04

M10xP1.5 M8xP1.25

• All dimensions are in millimeters • Other sizes available upon request; please consult BIG DAISHOWA Engineering Dept.

KNOBS, BALLS AND PALLETS

SYSTEM 68

Knobs

øD H7 Thread

ød

Knob Type

Fig. 1

Bolt Size

Thread øD H7

M24xP3

ø d h6

øD H7

Knob Type

ø35

Fig. 2

Knob Type

Catalog Number

Bolt Thread

Hex 10mm

Fig.

Description

øD/ød

15.500.593 15.500.594 15.500.595 15.500.596 15.500.597 15.500.598 15.500.603 15.500.604 15.500.605 15.500.606 15.500.607 15.500.608

A B C A B C A B C A B C

1 1 1 1 1 1 1 1 1 2 2 2

SBA—Absolute Position

M24 M24 M24 M30 M30 M30 M24 M24 M24 M24 M24 M24

57H7/57h6 57H7/57h6 57H7/57h6 57H7/57h6 57H7/57h6 57H7/57h6 25H7/25h6 25H7/25h6 25H7/25h6 25H7/25h6 25H7/25h6 25H7/25h6

SBB—Orientation

SBC—Retention Only SBA—Absolute Position

SBB—Orientation

SBC—Retention Only SBA—Absolute Position

SBB—Orientation

SBC—Retention Only SBA—Absolute Position

SBB—Orientation

SBC—Retention Only

• All dimensions are in millimeters

KNOBS, BALLS AND PALLETS

5-AXIS STABILIZER Ball to Knob Adaptor

Ball Size

Catalog Number

Ball Size

Length (mm)

Weight (lbs)

Description

15.252.060 15.252.061

SBA40 SBA40

ø25.4

35 24

1.5 2.4

ø50

SYSTEM 40

ø78

Ball Mounting Screw

Catalog Number

Ball Size

Length (mm)

Weight (lbs)

Length

Thread

Ball Size

15.252.080 15.252.082 15.252.084 15.252.085 15.252.086 15.252.087 15.252.089

M12xP1.75

.4 .4 .4 .9

Hex Nut

M16xP2

ø25.4

M20xP2.5

M24xP3 M24xP3

50 60 70

1.2 1.3 1.5

M30xP3.5

ø50

M36xP4

• Hex nut included; T-nut not included • Inch sizes available upon request

Ball and Collar

ø18 H6 +.011 0

M10

ø18 -.05 -.01

Fig. 1

Fig. 2

Catalog Number

Ball Size

Height (mm)

Weight (lbs.)

Fig.

Description

15.252.382 15.252.383 15.252.385*

1 2

5-Axis Stabilizer Ball and Collar with Location 5-Axis Stabilizer Ball and Collar without Location

ø25.4

1&2

5-Axis Stabilizer Ball and Collar Set

*Set includes 1 ball and 3 collars • See pg. 56 for ø50 balls

KNOBS, BALLS AND PALLETS

5-AXIS STABILIZER Ball Location Type

ø25 h6 ø22 (ø32.50)

ø24.50 ø17

Catalog Number

Weight (lbs)

15.252.100

• All dimensions are in millimeters • M16 x L50 SHCS not included

Ball Grip Type

øD ød

Catalog Number

Screw Size

Weight (lbs)

ød

øD

15.252.101 15.252.102

M16 M12

17 13

24.5 18.5

16.5

.9 .9

• All dimensions are in millimeters • Mounting screw not included • This will mar surfaces and should be used with rough surfaces

KNOBS, BALLS AND PALLETS

Pallets Preassembled with Knobs and Handles Pallets are provided fully assembled with their required quantity of UNILOCK knobs and lifting handles, and are available in either steel or aluminum. SYSTEM 40 Mono Pallet The UNILOCK ESM 138 chuck accepts a 14mm key or pin. The UNILOCK ESM 176 chuck accepts a 25mm key or pin.

Can be Configured for the Following Chucks • ESM/EFM/ERGO 138 • MLM/MCM 150 • ISM 160

• MSM 170 • ESM 176 TURBO • DC 200

Duo & Quad Pallet Duo and Quad pallets will load on the UNILOCK QC 400 or any set of chucks on 200mm spacing. Can be configured for the UNILOCK ERGO base stations. While loading and unloading work into the fixture, the holes in the bottom of the pallet mate to setup plates that stabilize the pallet for safe operation outside of a UNILOCK chuck.

Pallet Type

Pwallet Name

Catalog Number

Thickness (mm)

Length (mm)

Width (mm)

Length w/Handles (mm)

#12 H7 of Pin Holes

Weight (lbs)

Page

Material

15.260.540A 15.260.540B 15.260.640A 15.260.640B 15.260.545A 15.260.645A 15.270.546A 15.270.646A 15.270.544A 15.270.644A

0° (1x)

MONO*

SPA200

STEEL

199

279

9.3

0° & 45° (2x)

0° (1x)

MONO*

APA200

ALUM

199

279

4.9

0° & 45° (2x)

SAP400 APA400 SPQ300 APQ300 SPQ400 APQ400

STEEL ALUM STEEL ALUM STEEL ALUM

20 25 20 25 20 25

— — — — — —

23.4 11.2 34.4 16.3 61.7 26.5

DUO

399

159

481

TRIO

599

159

681

QUAD

399

481

*MONO pallets include ø12mm pin (1x) and ø25mm pin (1x); customer to install as needed • For pallet compatibility to older base stations please contact the BIG DAISHOWA Engineering Dept. for assistance

KNOBS, BALLS AND PALLETS

SYSTEM 40 Mono Pallet

25 (AL) 20 (ST)

199 197

10x45º

R10 (3x)

Pallet A Fig. 1

Pallet B Fig. 1.2

(279)

SBA40 Knob

• ø12mm pin (1x) and ø25mm pin (1x); customer to install as needed • For pallet compatibility please contact the BIG DAISHOWA Engineering Dept. for assistance

Duo Pallet

25 (AL) 20 (ST)

399

10x45º

R10 (3x)

(481)

SBA Knob

SBB Knob

+.015 -.015

200

Fig. 2

• All dimensions are in millimeters

KNOBS, BALLS AND PALLETS

SYSTEM 40

Trio Pallet

25 (AL) 20 (ST)

599

10x45º

R10 (3x)

(681)

SBA Knob

SBB Knob

SBC Knob

+.015 -.015

200

Fig. 3

Quad Pallet

25 (AL) 20 (ST)

399

SBC Knob (2x)

38x45º

R35 (3x)

(481)

SBA Knob

SBB Knob

+.015 -.015

200

Fig. 4

• All dimensions are in millimeters

A.5

MULTI-AXIS SYSTEMS INDEX

5-AXIS SYSTEM OVERVIEW

62-63

5-AXIS BASE

64-65

5-AXIS B-STYLE BASE

66-67

5-AXIS C-STYLE BASE

68-69

5-AXIS DOUBLE-ENDED CLAMPING BASE

70-71

5-AXIS TABLE ADAPTER

72-73

5-AXIS EXTENSIONS

74-75

DOUBLE-ENDED BASE

5-AXIS REDUCTIONS

ESA125/85 FLAT CHUCK

78-79

5-AXIS ER COLLET CHUCK

SERRATED ADAPTER

5-AXIS SYSTEM 25

82-84

SYSTEM 68

86-89

MULTI-AXIS SYSTEMS

5-AXIS SYSTEMS Precision Where You Need It Most

When your optimal work zone is centered on the machine table, our low-profile grid plates with integrated UNILOCK zero-point clamping offer out-of-the-box, turnkey solutions. These plates combine cap screw and dowel pin technology with UNILOCK chucks, enabling fast setup of virtually any workholding product, including 5-axis vises and dovetail clamps. Need to elevate the workpiece? UNILOCK allows you to raise the workholding or the workpiece, or enables clamping knobs to be mounted directly to the bottom of the part—within 25mm of the machining edge. UNILOCK chucks like the ASM 146 and ISM 160 (46mm height) can also be surface-mounted for fast, flexible changeover. Pair with Univice Synchro, Uniclamp or First Grip for a fully integrated 5-axis solution.

Assembly Examples

Reductions

UNILOCK Knobs

Extensions

UNILOCK Knobs

Bases

Grid Plate

UNILOCK Basestation

Machine Table

MULTI-AXIS SYSTEMS

5-AXIS SYSTEM 40 UNILOCK Riser Chucks, Extensions & Reductions

UNILOCK riser chucks feature an 80mm working diameter and are available as base-mounted units or stackable modules in 75mm and 100mm heights. Base plate chucks include ø12mm dowel pin holes for locating on 40mm and 50mm grid patterns. They can also accept clamping knobs for use in other UNILOCK chucks. Stackable versions provide added elevation and clearance. All versions open and close quickly with a single hex key. These chucks are compatible with all UNILOCK System 40 (40mm) clamping knobs. Using riser assemblies, parts can be clamped just 40mm from their edge. Extensions reduce the working diameter to 50mm and add 25mm or 50mm of additional height, enabling clamping as close as 25mm from the edge.

SBA Clamping Knob (Not Included with 5-Axis Base)

Clamping Saddle

Clamping Jaw

Base

Differential Screw (6mm Hex Wrench Not Included)

MULTI-AXIS SYSTEMS

5-AXIS Base Integral Mounting Flange

Offered with a timing key for single base applications. Table adapters are also offered. These chucks can be mounted on 40mm, 50mm and M12 grids, as well as on UNILOCK clamping systems using UNILOCK clamping knobs.

Features • Elevate your workpiece for clearance • Use UNILOCK clamping knobs

• Stackable chucks available • Quickly open and close with a single hex key

Catalog Number

Notch (Width x Qty)

Clamping Force (lbs) (at 11 ft/lbs)

Weight (lbs)

Height

15.250.101 15.250.103* 15.250.102 15.250.104*

—

8.1

10 H7 x 1

2,200-2,500

—

100

9.8

10 H7 x 1 *Timing key option is a non-stock standard • All dimensions are in millimeters • Manual actuation, 6mm hex wrench not included

ACCESSORIES

KNOBS PG. 47

MULTI-AXIS SYSTEMS

5-AXIS Base

ø144

+.01 -.01 +.01 -.01

100 120

ø12 G6 (6x)

10 h7

35.5

Hex 6 (15 Nm) (11 ft-lbs.)

ø25 H7

15.250.101 & 15.250.103

SYSTEM 40 Knob (Not Included) 15.260.400

35.5

10 h7

15.250.102 & 15.250.104

• All dimensions are in millimeters • Dimensions marked are for notch option

MULTI-AXIS SYSTEMS

5-AXIS B-Style Base For Flexibility of Position

Chucks allow for flexibility of the position of the base via the use of a slotted flange directly over t-slots. These chucks can be mounted on 40mm, 50mm and M12 grids as well as on t-nut machine tables.

Features • Elevate your workpiece for clearance • Use UNILOCK clamping knobs

• Stackable chucks available • Quickly open and close with a single hex key

Catalog Number

Notch (Width x Qty)

Clamping Force (lbs) (at 11 ft/lbs)

Weight (lbs)

Height

15.250.111 15.250.113* 15.250.112 15.250.114* 15.250.115 15.250.116*

—

125

14.7

10 H7 x 1

—

150

2,200-2,500

16.8

10 H7 x 1

—

175

18.6

10 H7 x 1 *Timing key option is a non-stock standard • All dimensions are in millimeters • Manual actuation, 6mm hex wrench not included

ACCESSORIES

KNOBS PG. 47

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