Task: Eliminate non-productive time

The combination of swivel table, zero point clamping system and clamping pyramid enables efficient production of the smallest batch sizes on 5-axis machines. The basic principle is simple: One or ideally even several workpieces can be clamped per side, which are then machined directly one after the other. With the aid of modern CAD/CAM systems, it is possible in this way to manufacture even the smallest batch sizes down to individual parts in a highly efficient automated manner. Setup is carried out on the basis of workpiece-specific setup plans, ideally outside the machine room at the machine’s own or external setup stations.

The machine is then loaded with the clamping pyramid using the machine’s own transfer systems, or alternatively by crane or robot. Unproductive non-productive times, such as reclamping, aligning or determining the zero point, are therefore consistently eliminated from the machine with the help of the pyramids. Where the operation is particularly flexible or the number of pyramids is insufficient, the gredoc NRS zero point clamping system shortens the workpiece, clamping device or pallet change.

In this animation we would like to show you the accessibility in case of multiple clamping on our pyramids.

Here you can see a 3-fold variant equipped with our C2 125 L-160 center clamps. Taking into account the maximum swivel ranges of your machine, we can ideally design the clamping surfaces of the pyramid. The result can be seen very well here. Ideally, optimum accessibility from all sides is achieved. This significantly increases the spindle running time on your 5-axis machine.

And here are a few practical examples of pyramids. Here we have already made many variants and versions in recent years and can therefore fall back on a large pyramid library including the matching 3D data. Please contact us for more information.

FAQ about pyramids on 5-axis machines:

When is a pyramid used?

• Multi-clapming in the 5A range
• Increase in machine running time
• A pyramid solution is not only suitable for small series, also quantity 1 / order is interesting with a corresponding runtime.

What types of pyramid are available at GRESSEL?

• 2-, 3- or 4-fold clamping pyramids are most frequently requested by customers
• The clamping angle of the clamping surface depends on the component, the swiveling movements of the machine, the interference circle Ø of the machine and the machining.

=> The steeper the angle the better the accessibility for 5A machining

How to build the pyramid on the machine table?

• Mounting hole pattern for direct mounting with mounting screws directly through the pyramid body
• Zero point interface gredoc + VERO-S from SCHUNK (= gauge block 200x200mm)
• Customer interface on request

How are the GRESSEL clamping devices attached to the pyramid?

• Mounting hole pattern for direct mounting of the clamping devices on the pyramid
• Zero point interface gredoc + VERO-S from SCHUNK
• Customer mounting hole pattern possible at extra cost

Which GRESSEL clamping devices can I use on the pyramid?

• All C2 and C3 centric clamps as well as our single clamps solinos, SC2
• Customer fixtures or direct workpiece clamping