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Wedge clamps

Hydraulic block cylinders that operate a clamping bolt in a guide housing.

For straight or tapered clamping edge, double acting.

Wedge clamps are hydraulic clamping elements, which are installed in a fixed position, e.g. on press beds or machine table. Here you will find compact, sturdy and proven clamping elements with highest clamping forces in many different versions.

max. clamping force: 25 ... 630 kN
adm. retaining force: 25 ... 820 kN
cylinder diameter: 25 ... 125 mm
clamping stroke: 1 ... 36 mm

on request
clamping forces up to 1250 kN
Temperature range up to 300 °C

Series Data sheet Technical data
2.2401
2.2401
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WZ 2.2401 Wedge Clamps for Tapered Clamping Edge

 

double acting

max. clamping force 25 to 630 kN

without and with position monitoring at the side

without and with position monitoring at the side
max. clamping force: 25 .. 630 kN
adm. retaining force: 35 .. 820 kN
cylinder diameter: 25 .. 125 mm
clamping stroke: 20 .. 40 mm
max. temperature: 160/100 °C
(300 °C on request)

2.2402
2.2402
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WZ 2.2402 Wedge Clamps for Tapered Clamping Edge

 

double acting

max. clamping force 25 to 630 kN

with adjustable position monitoring at the back

with adjustable position monitoring at the back
max. clamping force: 25 .. 630 kN
adm. retaining force: 35 .. 820 kN
cylinder diameter: 25 .. 125 mm
clamping stroke: 20 .. 40 mm
max. temperature: 80/120 °C

2.2403
2.2403
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WZ 2.2403 Wedge Clamps for Tapered Clamping Edge

 

double acting

max. clamping force 25 to 630 kN

with safety step

without and with position monitoring

with safety step
without and with position monitoring

max. clamping force: 25 .. 630 kN
adm. retaining force: 35 .. 820 kN
cylinder diameter: 25 .. 125 mm
clamping stroke: 20 .. 40 mm
max. temperature: 160/100 °C
(300 °C on request)

2.2404
2.2404
 
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WZ 2.2404 Wedge Clamps for Tapered Clamping Edge

 

double acting

max. clamping force 50 to 400 kN

with form-fit safety step and position monitoring

with form-fit safety step and position monitoring
max. clamping force: 50 .. 400 kN
adm. retaining force: 65 .. 520 kN
cylinder diameter: 40 .. 100 mm
clamping stroke: 40 .. 70 mm
max. temperature: 100 °C

2.2405
2.2405
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WZ 2.2405 Wedge Clamps for Tapered Clamping Edge

 

double acting

max. clamping force 25 to 630 kN

with locking bolt

without and with position monitoring at the side

with locking bolt
without and with position monitoring at the side

max. clamping force: 25 .. 630 kN
adm. retaining force: 35 .. 820 kN
cylinder diameter: 25 .. 125 mm
clamping stroke: 20 .. 40 mm
max. temperature: 160/100 °C
(300 °C on request)

2.2407
2.2407
show
WZ 2.2407 Wedge Clamps for Tapered Clamping Edge

 

double acting

max. clamping force 25 to 630 kN

with sequence valve control for high temperature ranges

with sequence valve control
with hydraulic position monitoring

max. clamping force: 25 .. 630 kN
adm. retaining force: 35 .. 820 kN
cylinder diameter: 25 .. 125 mm
clamping stroke: 20 .. 40 mm
max. temperature: 160/100 °C
(300 °C on request)

2.2409
2.2409
show
WZ 2.2409 Wedge Clamps for Tapered Clamping Edge

 

double acting

max. clamping force 100 to 630 kN

with single valve control for individual control

with single valve control for individual control
max. clamping force: 100 .. 630 kN
operating pressure: 200 .. 350 bar
valve voltage: 24 VDC
max. temperature: 100 °C

2.2410
2.2410
 
show
WZ 2.2410 Wedge Clamps for Tapered Clamping Edge

 

double acting

max. clamping force 100 to 630 kN

with cooling circuit for temperatures up to 250 °C

with cooling circuit
without and with position monitoring

max. clamping force: 100 .. 630 kN
max. operating pressure: 350 bar
max. temperature: 250 °C

2.2450
2.2450
 
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WZ 2.2450 Wedge Clamps for Straight Clamping Edge

 

single acting

operating force 25 up to 120 kN

clamping with spring force and hydraulic unclamping

without and with Position Monitoring

 

adm. retaining force: 25 .. 120 kN
cylinder diameter: 35 .. 85 mm
clamping stroke: 14 .. 19 mm
temperature resistance: up to 80°C
(on request: up to 250 °C)

2.2451
2.2451
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WZ 2.2451 Wedge Clamps for Straight Clamping Edge

 

double acting

operating force 35 up to 120 kN

hydraulic clamping and unclamping

without and with position monitoring

adm. retaining force: 35 .. 120 kN
cylinder diameter: 25 .. 50 mm
max. clamping pressure: 50 bar
temperature resistance: up to 100/160°C
(on request: up to 300 °C)

2.2460
2.2460
show
WZ 2.2460 Wedge Clamps for Straight Clamping Edge

 

double acting

clamping force 25 up to 100 kN

hydraulic clamping and unclamping

without and with position monitoring

 

max. clamping force: 25 .. 100 kN
adm. retaining force: 45 .. 145 kN
cylinder diameter: 25 .. 50 mm
clamping stroke: 1 mm
temperature resistance: up to 100/160°C
(on request: up to 300 °C)

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figure 1: Clamping principle
Wedge clamps for tapered clamping edge



















 
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figure 2: Wedge clamp 2.2401
without and with position monitoring at the side

 
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figure 3: Wedge clamp 2.2402
with adjustable position monitoring at the back


 
show
figure 4: Wedge clamp 2.2403
with safety step, without and with position Monitoring
 
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figure 5: Wedge clamp 2.2404
with form-fit safety step and position monitoring
 
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figure 6: Wedge clamp 2.2405
with locking bolt, without and with position monitoring at the side
 
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figure 7: Wedge clamp 2.2407
with sequence valve control
 
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figure 8: 2.2407 Double sequence valve control
 
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figure 9: Wedge Clamp 2.2409
with single valve control
 
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figure 10: 2.2409 Single valve control
 
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figure 11: Wedge Clamp 2.2410
with cooling circuit
 
show
figure 12: Cooling ports C and D
 
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figure 13: Clamping principles
Wedge clamps for straight clamping edge
 
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figure 14: Wedge Clamps 2.2450
with and without position monitoring
 
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fugure 15: Wedge Clamp 2.2450














 
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figure 16: Wedge clamp 2.2451




















 
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figure 17: Wedge clamp 2.2460
 

Wedge clamps for tapered clamping edge
Double-acting wedge clamp for clamping dies on a press bed or ram or for clamping dies in injection moulding machines. The wedge clamp consists of a hydraulic block cylinder and a piston guided in a housing. The clamping bolt is provided with 20° bevel to clamp on the tapered clamping surface of the die. Based on the internal design of the wedge clamp and the 20° bevel of the clamping bolt, the system is providing internal friction. For safety reasons and in the sense of the machine tool guide lines 89/37/EC the hydraulic pressure must be maintained. When upper dies are clamped by wedge clamps, they must be secured mechanically when maintenance work is carried out.

Applications

  • safe clamping of dies with tapered clamping edge
  • for clamping of dies on press bed and ram
  • for clamping of dies in injection moulding machines

Special features

  • sizes from 25 kN to 1250 kN clamping force
  • high operational safety by position monitoring and automatic motion sequence
  • very sturdy and proven clamping element with a high standard of safety and a long service life

Safety steps (figure 1)

  • 1. without safety step
  • 2. with safety step
  • 3. with form-fit safety step

2.2401 Wedge clamps (figure 2)
without and with position monitoring at the side
The proximity switches are installed in the guide housing. They are activated by means of the wedge bolt. The positions bolt in off position or in clamping position are displayed.
Temperature resistance: up to 100 °C (with position monitoring)
cable length: 250 mm
connector: 4 pole

2.2402 Wedge clamps (figure 3)
with adjustable position monitoring at the back
The position monitoring will be screwed on at the cylinder bottom and can also be mounted in a position rotated by 180°. Different versions are available according to the application conditions.
A control cam is provided at the extended piston rod causing the activation of the proximity switches. Adjustment of the switching position is effected by displacement of the proximity switches in the lateral groove.
The proximity switches are switched on in a stroke range of approx. 6 mm by means of the control cam. The minimum distance to the positions to be monitored depends on the switch type.

2.2403 Wedge clamps (figure 4)
with safety step, without and with position monitoring
The clamping bolt of this version has an additional support surface parallel to the clamping edge. In the case of pressure drop (machine failure or down time) the upper die can be lowered to the safety step and safely held.

2.2404 Wedge clamps (figure 5)
with form-fit safety step and position monitoring
This patented design has a form-fit safety step in the form of a lug at the clamping bolt, which has the same shape as the adapter on the mould/die clamping edge. In the case of pressure drop (machine failure or down time) the upper mould/die lowers to the safety step onto the safety lug and is safely held by form fit. The clamping bolt can not be returned to the unclamping position and the upper mould/die is safely held.

2.2405 Wedge clamps (figure 6)
with locking bolt, without and with position monitoring at the side
The clamping bolt of the wedge clamp is secured against retraction with an additional locking cylinder. Leaving the clamping position is only possible by unlocking the locking bolt.

 

 

2.2407 Wedge clamps (figure 7)
with sequence valve control for high temperature ranges
An additional valve block on the standard wedge clamp enables hydraulic control of the clamping position. Only after the last wedge clamp has been clamped, the machine control is released by a pressure switch on the pressure generator.

 

2.2407 Wedge clamps with double sequence valve control (figure 8)
to monitor the clamping and unclamping position
The wedge clamp enables the hydraulic control of the clamping and unclamping position. Only after the last wedge clamp has been clamped, the machine control is released by a pressure switch on the pressure generator. 

 

2.2409 Wedge clamps (figure 9/10)
with single valve control for individual control
with manifold-mounted directional control valves as control valves for the separate control of all clamping elements
Special advantages:

  • each element can be individually controlled
  • single dies can be clamped
  • little installation work as a result of a plug-type closed hydraulic circuit
  • suitable for BUS systems
  • high degree of operational safety thanks to integrated position monitoring and check valves

with safety step on request

  • very sturdy clamping element with a high standard of safety and a long service life

2.2410 Wedge clamps (figure 11/12)
with cooling circuit for temperatures up to 250 °C
In addition, there is a cooling circuit for oil cooling in the block cylinder. This cooling circuit guarantees a steady temperature at the sealing surfaces of the hydraulic supply.
When dimensioning the cooling circuit, the occurring temperatures and the admissible temperature at the clamping element must be considered.

 

 

 

 

Wedge clamps for straight clamping edge

Applications

  • safe clamping of dies with straight clamping edge
  • for clamping of dies in injection moulding machines
  • for clamping of dies on press bed and ram

Clamping principles
see figure 13


2.2450 Wedge Clamps (figure 14-15)
single acting, clamping with spring force and hydraulic unclamping,
retention force 25 up to 120 kN, with and without position monitoring

The wedge clamping elements consist of a guide housing with one-piece clamping bolt.
Clamping cycle: the clamping bolt which is inclined by 6° performs an idle stroke and simultaneously a clamping stroke. The clamping bolt is lowered axially onto the clamping edge. The 6° angle, the spring force in the clamping bolt and the frictional engagement at the clamping point create a self-locking connection. The wedge clamping element should preferably be used with position monitoring.

Advantages

  • safe clamping of dies with straight clamping edge
  • high operating safety due to clamping by spring force, inductive and visual position monitoring
  • position monitoring on the left or right side
  • clamping element with self-locking
    dimensions in accordance with Euromap guidelines
  • no clamping edge bevels are required
  • variable clamping edge heights (spacer plates)
  • tolerance of clamping edge height ± 0.5 mm
  • the pressure of the machine hydraulics of 160 bar is sufficient for unclamping
  • very sturdy and compact design
  • housing with stainless coating
  • flexible connecting possibilities by 4 hydraulic Connections

 

 

2.2451 Wedge clamps (figure 16)
double acting, operating force 35 up to 120 kN, hydraulic clamping and
unclamping, without and with position monitoring at the side

Double-acting wedge clamp for clamping dies on a press bed or ram or for clamping dies in injection moulding machines with Euromap mounting grid.
The wedge clamp consists of a hydraulic block cylinder connected with a clamping bolt in a floating manner. Clamping cycle: the clamping bolt which is inclined by 5° performs an idle stroke and simultaneously a clamping stroke.
The clamping bolt is lowered axially onto the clamping edge. The 5° angle of the housing has been determined so as to ensure that despite frictional engagement on the clamping edge the hydraulic pressure required for unclamping is sufficient. Since the clamping force is vertically transmitted to the clamping point, only low side loads occur. The wedge clamp is available with or without position monitoring.

Special features

  • side loads are compensated by drill bushings
  • high operational safety by position monitoring and automatic motion sequence
  • very sturdy and compact design clamping element with a high standard of safety and a long service life
  • retracting clamping bolt ensures unimpeded die and tool change
  • clamping and unclamping pressures are different

temperature resistance up to 250°C
available on request

2.2460 Wedge clamps (figure 17)
double acting, operating force 35 up to 120 kN, hydraulic clamping and
unclamping, without and with position monitoring at the side

Double-acting wedge clamps are particularly suitable for safe clamping of dies with flat clamping edge on a press bed or ram or for clamping dies in injection moulding machines.
The wedge clamp consists of a hydraulic block cylinder and a two-piece mechanical clamping bolt.
Clamping cycle: the clamping bolt with thrust pad first performs an idle stroke. When the inner stop is reached, the clamping bolt is lowered onto the clamping edge. The 5° angle of the thrust pad has been determined so as to ensure that despite self-locking the hydraulic pressure required for clamping is not higher than that required for clamping.
Since the clamping force is vertically transmitted to the clamping point, no side loads occur.
The wedge clamp is available with or without position monitoring.

Special features

  • the clamping piston does not retract in the case of pressure drop
  • sizes of 25 kN, 50 kN and 100 kN
  • high operational safety by position monitoring and automatic motion sequence
  • very sturdy and compact design
  • special versions on request
  • well-proven clamping element with high degree of safety and long service life
  • retracting clamping bolt ensures unimpeded die and tool change
 

Safety steps for the installation
of wedge clamps

see data sheet 2.2460 – Seite 4

show
figure 1: Hardenend V-shaped inserts and drill bushings
 
show
figure 2: Multiple-circuit hydraulic supply
 

Definition: Clamping force
This is the force the clamping element applies to the workpiece at maximum operating pressure. The die or the tool is clamped on the fixture plate by means of this force. The external forces acting on die or tool (e.g. ejecting force or die cushion force) shall not exceed the totality of the elements’ clamping force.

Definition: Retaining force
This is the holding force of clamping element and fastener (screw quality 8.8). The data given in the above table are based on the condition that the appropriate tightening torque has been applied, and that material and geometry of the fixtures are suitable for the purpose. It must be ensured that in cases of emergency, e.g. workpiece jammed in die or tool, the sum total of the elements’ operating forces is not exceeded.

 

Important notes on wedge clamps

Wedge clamping of existing dies is possible by retrofitting V-shaped inserts as shown. Max. hardness 50 HRC (figure 1).

The occurring side loads must be absorbed by drill bushings (accessory) to be inserted into the fixture plate (figure 1).

Please observe: in case of incorrect operation of the wedge clamping element, the clamping bolt may fully retract into the guide housing and thus cause the upper die falling off the ram.

The greasing intervals (high temperature grease) should be adapted to the existing operating conditions. Please note that greasing of the wedge bolts should only be made with the elements being retracted.

Clamping elements with wedge clamping bolt must be protected against dirt, scale, swarf, coolant, etc. by means of a suitable covering.

Dies or tools clamped by means of wedge clamping elements are subject to side loads that may be strong enough to displace them. Thus, positioning is required to compensate the side loads. Therefore, location pins or suitable limit stops should be provided, in order to keep the dies in their correct position.

When using wedge clamping elements on the press ram, it is recommended that multiple-circuit hydraulic supply of the clamping elements and pilot-controlled check valves are used for securing hydraulic clamping (figure2).

 

Drill bushings ( figure 1 )
for wedge clamps
=> see PDF data sheets of the wedge clamps

Connection cable with screw coupling or plug
for wedge clamps with position monitoring
=> see PDF data sheets of the wedge clamps

  • high-pressure hoses
  • quick-disconnect couplings
  • connecting block
  • plug-in connectors

data sheet 11.3800

  • directional control valve
  • pressure switch
  • pressure relief valve
  • pressure control valve
  • pressure gauge
  • check valve
  • hydraulic oil

data sheet 11.9200

Hydraulic power units for die clamping systems
Hydraulic power units

show
figure 1a: 5-stage drop forge, equipped with wedge clamps
 
show
figure 1b: 5-stage drop forge, equipped with wedge clamps
 
show
figure 2: Wedge clamps with sequence valve control on a forging press
 
show
figure 3: Wedge clamps with directly manifold-mounted directional control valves
 
show
figure 4: Wedge clamps on a Demag Ergotech 250/630 injection moulding machine
 
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figure 5: Wedge clamps on a Demag Ergotech 250/630 injection moulding machine
 
show
figure 6: Wedge clamps in a forging die
 
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figure 7: Wedge clamps with check valve on a Krauss Maffai injection moulding machine
 
show
figure 8: Wedge clamp with cooling circuit
 
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Figure 9: Wedge clamp with cooling circuit
 
show
figure 10: Wedge clamp with cooling circuit on the press ram
 

Application example 1 (figure 1a/1b)
5-stage drop forge, equipped with wedge clamps, with directional control valves for the control of the different stages.

 

 

Application example 2 (figure 2)
Wedge clamps with sequence valve control on a forging press

 

 

Application example 3 (figure 3)
Wedge clamps with directly manifold-mounted directional control valves. Clamping and unclamping position electrically monitored. Easy to install with plug-in connections between the clamping elements.

 

 

 

Application example 4 (figure 4)
Wedge clamps 160 kN clamping force on a Windsor W 550.

 

 

 

Application example 5 (figure 5)
Wedge clamps on a Demag Ergotech 250/630 injection moulding machine.

 

 

 

 

Application example 6 (figure 6)
Wedge clamps in a forging die. Temperatures up to 250C. Possible versions for forging applications.

 

 

Application example 7 (figure 7)
Wedge clamps with check valve on a Krauss Maffai injection moulding machine.

 

 

 

Application example 8 (figure 8, 9, 10)
Wedge clamp with hydraulic ports A + B at the right and an additional
cooling circuit C + D at the opposite, left side.