Clamping devices are characterised first and foremost by the requirements of a

3 given work or clamping operation. The wide range of applications is reflected in

Types of clamping the large number of clamping devices of more or less specialised design. The
devices current trend is away from custom-built clamping devices and towards modular
clamping systems. Modular workpiece clamps are generally based on a small
number of basic components and product-specific clamp jaws. The basic compo-
nents can be used in all cases.

Clamping using a lever principle can be regarded as a technical variant of hold-

3.1 ing workpieces with the hand or fingers. Levers, in both straight and angle
Lever clamps form, can also be used to intensify force on the basis of the lever relationship
rule:
3.1.1
Simple lever clamps Force x force arm = Load x load arm

The levers in question are generally driven by pneumatic power cylinders, which
are widely used in clamping technology, due to the numerous mounting options
which they offer. Examples of these are shown in Fig. 3-1. The cylinders shown
here have integrated clevis foot mountings on their bearing caps. This allows
easy connection and any desired mounting position. The cylinders can also be
equipped with an integrated flow control system, which saves space and money.

Fig. 3-1:
Use of clamping cylinders
in lever clamps of the type
frequently installed on
vehicle bodywork welding
production lines

a) Mounting via integrated

clevis foot
b) Fixed foot mounting
c) Installation above actual
clamping point a b
d) Adaptation to meet local
requirements
1 3
1 Claw clamp 4
2 Workpiece
3 Compressed air connection
4 Pneumatic cylinder

2
c d

3 Types of clamping devices 43

 This type of clamp is very widely used and very effective. It is distinguished by
3.1.2 its force-intensifying action close to the fully-stretched position of the toggle
Toggle-lever clamps lever. Certain types of toggle-lever clamps require a relatively large amount of
installation space at the clamping point. Fig. 3-2 shows the design principles of
two toggle-lever clamps.

Fig. 3-2:
Toggle-lever clamps
with concealed pneumatic
cylinders

a) Horizontal clamping,
pulling clamping action
b) Vertical clamping,
pushing clamping action
a b

These are “half ” toggle-lever clamps, so called because their lever arms have
one fixed pivot point. Fig. 3-3, on the other hand, shows a “full” toggle-lever
system. The theoretically usable clamping force Fclamp of the device can be
calculated as follows:

Fclamp = p · A · Ë [( 1/tan · + ‚) – tan Ú]

In the above, ‚ is defined as follows:

‚ = arc sin (2 · R · Ì/L )

The coefficient of friction Ì is also defined as Ì = tan Ú. The tangent of the

frictional angle is the equal to the coefficient of friction.

Fig. 3-3:
Forces operative within a
“full” toggle-lever system,
shown by the example
of an internal clamp
A
A Piston cross section
F Piston force p
FS Clamping force
L Arm length
R Pivot pin radius R
p Operating pressure
Ë Efficiency
Ì Coefficient of friction
L

FS FS
α
F

44 3 Types of clamping devices

 The example assumes that the two lever arms have the same length L. If this
were not the case, it would be necessary to incorporate the ratio of the two lever
lengths into the equation.

For practical applications, it should be noted that approximately identical

clamping forces for each workpiece are obtained only within a narrow clamping
range. The examples in Figs. 3-4 and 3-5 show that the use of the toggle levers
and pneumatic cylinders in combination opens up a wealth of possible applica-
tions. The choice of variant for a particular application depends on a number of
factors. One of these is freedom of access to the clamping point and the ques-
tion of whether workpieces need to be inserted from the side or can also be
inserted from above, by automated means if necessary.

Fig. 3-4:
Push-rod clamp with toggle-
lever mechanism

Fig. 3-5:
Vertical clamping with a
toggle-lever system.
The piston rod is supported
by the base plate via a roller

Toggle-lever clamps are frequently used in automobile factories to clamp sheet-

metal workpieces, particularly on bodywork production lines. Chapter 3.10 will
deal with this type of clamp in detail. For present purposes, we will confine
ourselves to the clamp shown in Fig. 3-6. We see that the numerous connection
points allow a wide choice of mounting options. If the fishplate pin is extended
(Fig. 3-6b), it is even possible to arrange for the entire clamp housing to swivel
away as the clamp opens. This creates a large space in which a gripper can
operate.

3 Types of clamping devices 45

Fig. 3-6:
Examples of mounting
toggle-lever clamps

a) Use of a connection
surface to attach
a workpiece support
b) Use of a guide linkage
to swivel away the
complete clamp
c) Connection
to a clamping station

a b c

These clamps can centre workpieces to a constant clamp jaw mid-point. In order
3.1.3 to achieve this, the clamp arms are linked together via toothed segments.
Toothed-segment An example is shown in Fig. 3-7. Clamps of this kind can be used to good effect
clamps in a multiple parallel configuration to clamp long semi-finished products such
as rails, bars, system profiles and piping. The material to be clamped can be
inserted axially or horizontally. It is also possible to make the clamp jaws inter-
changeable. The motion sequence can be monitored via electrical inductive
sensors on the power cylinder or on the clamp arms.

Fig. 3-7:
Toothed-segment clamps

1 Clamp jaw 1
2 Rod clevis
3 Piston rod 2
4 Mounting bracket
5 Pneumatic cylinder
3
6 Stop to limit opening angle
7 Basic plate
8 Clamping jaw

4 5 6 7 8

Toothed-segment clamps are also a good way of clamping panel material.

A clamp of this kind is shown in Fig. 3-8. A major advantage is that the clamp
claw swings fully away, thus ensuring that the insertion of panels from above is
not impeded. This principle is also used in various underclamping systems

46 3 Types of clamping devices

Fig. 3-8:
Clamping panels 1
1 Workpiece
2 Clamp segment
3 Gear rack
4 Pneumatic cylinder

3
4

These are generally standard clamping devices which execute a lifting/rotary

3.1.4 motion. After the clamp claw opens, it swivels to the side, allowing unimpeded
Swivel clamps removal of the workpiece from above. This is an important factor if the clamping
device is to be fed by program-controlled handling devices. As Fig. 3-9 shows,
the 90° swivel motion is achieved by means of a spiral-slot guide in the piston
rod.

Fig. 3-9:
Design of a pneumatic
swivel clamp
1
1 Clamp claw
2
2 Workpiece
3 Spiral slot
4 Piston

3 Types of clamping devices 47

 There are various types of swivel clamps (Fig. 3-10), generally designed to
provide higher clamping forces than hydraulic cylinders. Pneumatic swivel
clamps generate clamping forces from 0.2 to 1.6 kN, which is usually sufficient,
for example, to clamp workpieces for welding. The advantages of swivel clamps
are their smooth outer surfaces and favourable deflection angles, which ensure
that swarf and drilling emulsion slide off easily and do not accumulate in trap
points. The swivel area of the clamps must at all times be kept free of collision
hazards. Clamping forces must be used only during the vertical lifting phase.
Versions are available which swivel to the right or to the left. In the case of
twin-arm types, the clamping force available for each workpiece is half the
total.

Fig. 3-10:
Common types of com-
mercially-available swivel
clamps

a) Table-mounting type
b) Screw-in swivel clamp
c) Double-arm swivel clamp

a b c

Workpieces to be welded must be held by hand or by means of a robot in a

suitable position for tack and finish welding. The clamping devices used must
3.1.5 be robust and unaffected by the stress resulting from the application of heat. In
Welding clamps view of the fact that work with welding torches or spot-welding tongs requires a
great deal of space, the interference contours created by the clamping compo-
nents should be kept as small as possible. Consideration must also be given to
those components of the clamping device which are susceptible to dirt. Power
cylinders are equipped with a special wiper ring which prevents welding spatter
from damaging the piston rod. Another way of achieving this would be to fit
gaiters, but these are costly. It is always advantageous to position the drive
units slightly away from the working area (Fig. 3-11) or install these under cover
if possible (Fig. 3-12).

48 3 Types of clamping devices

 In conclusion, let us look at a type of clamp for very high clamping forces
(Fig. 3-13). The top-fitted clamping plate is driven via an angle-arm device
which forms a toggle-lever linkage. The end position is limited by an adjustable
stop bolt.

Fig. 3-11:
Wide-opening lever clamp
for workpieces to be welded

1 Workpiece to be welded
2 Clamp arm
3 Frame

Fig. 3-12:
Welding workstation with
pipe clamping device 1

1 Workpiece 2
2 Pull-down stop 3
3 Clamp lever
4 Pneumatic cylinder
with rod eye

3 Types of clamping devices 49

Fig. 3-13:
Clamping station with
toggle-lever clamp system

1 Pressure plate
2 Workpiece support
1
3 Stop bolt
4 Fishplate
5 Bracket 2
6 Device body 6 7
7 Power cylinder

The requirements of production technology often mean that workpieces must

3.1.6 be clamped with centring action, which ensures that, despite dimensional
Clamps tolerances, workpieces are always centre-aligned. This is necessary in cases
with a centring action where machine-tool operating program are based on this centre point
(symmetrical axes, reference point). From the point of view of the clamping
device, this means that there can be no fixed clamping block and that the clamp-
ing components must move towards each other equally. To achieve this, the
clamp jaws must be coupled together in one way or another. In the solution
shown in Fig. 3-14, this is achieved by means of a lever mechanism. It would
also be possible to introduce force at another point within the system. This
principle of synchronous mechanical clamping allows high clamping forces to
be achieved. The clamp jaw inserts are interchangeable, permitting adaptation
to different shapes of workpieces or semi-finished products.

50 3 Types of clamping devices