Custom Grid Vacuum Table Vacuum Chuck Systems For Workpiece Processing

Custom Grid Vacuum Table Vacuum Chuck Systems for Workpiece Processing

In the intricate landscape of workpiece processing, the quest for efficient and reliable workholding solutions is unending. Custom grid vacuum table vacuum chuck systems have emerged as a game - changing technology, offering a unique blend of flexibility, precision, and adaptability. These systems are designed to meet the diverse needs of various industries, from manufacturing to prototyping, by securely holding workpieces during a wide range of processing operations.​

1. Design and Construction

Base Structure​

The base of a custom grid vacuum table is typically crafted from high - strength materials such as alloy steel or high - grade aluminum. Alloy steel provides exceptional rigidity and durability, making it suitable for heavy - duty workpiece processing applications. It can withstand the significant forces generated during machining, grinding, or other operations without deforming. High - grade aluminum, on the other hand, offers a lightweight alternative with good corrosion resistance, which can be beneficial in applications where weight reduction is crucial, such as in portable or high - speed processing setups.​

The base is precision - machined to ensure a flat and smooth surface. This flatness is essential for the proper functioning of the vacuum chuck system as it enables uniform vacuum distribution across the table surface. Reinforcements are often added to critical areas of the base, such as the edges and the mounting points, to enhance its structural integrity and load - bearing capacity.​

Grid Pattern Configuration​

The defining feature of these systems is the grid - pattern layout of the vacuum channels and ports. A network of precisely drilled holes and channels is arranged in a grid pattern across the surface of the table. The number, size, and spacing of the holes are carefully customized based on the specific requirements of the workpiece processing operations.​

For example, when processing small and intricate components, a higher density of smaller holes may be incorporated. This allows for a more targeted and precise vacuum hold, ensuring that delicate parts are securely fastened without causing damage. In contrast, for larger workpieces or those with irregular shapes, larger holes may be spaced farther apart, providing a strong and evenly distributed vacuum force over a larger surface area.​

The grid pattern also enables the use of modular fixtures and adapters. These can be easily attached to the grid, allowing for quick and easy customization of the workholding setup to accommodate different workpiece geometries.​

Vacuum Channel Integration​

Beneath the surface of the table, a network of vacuum channels is integrated. These channels connect the holes in the grid to a central vacuum source, such as a high - performance vacuum pump. The vacuum channels are designed to efficiently distribute the vacuum pressure to each of the holes in the grid.​

The layout of the channels is optimized to minimize pressure drops and ensure that the vacuum force is evenly dispersed across the entire table. In some advanced designs, the vacuum channels may be equipped with valves or regulators. These components allow for independent control of the vacuum pressure in different areas of the table. For example, if a workpiece has varying thicknesses or requires different levels of holding force in specific regions, the vacuum pressure in those areas can be adjusted accordingly.

Specifications

Specification	Magnetic attraction	Width (mm)	Length (mm)	Height (mm)	Weight (kg)
150*150	≥40KG	150	150	80	13.5
150*300	≥40KG	150	300	80	27
150*350	≥40KG	150	350	80	31.5
150*400	≥40KG	150	400	80	36
200*200	≥40KG	200	200	80	24
200*300	≥40KG	200	300	80	36
200*400	≥40KG	200	400	80	48
200*500	≥40KG	200	500	80	60
250*500	≥40KG	250	500	80	75
300*300	≥40KG	300	300	80	54
300*400	≥40KG	300	400	80	72
300*500	≥40KG	300	500	80	90
300*600	≥40KG	300	600	80	108
300*800	≥40KG	300	800	80	144
400*400	≥40KG	400	400	80	96
400*500	≥40KG	400	500	80	120
400*600	≥40KG	400	600	80	144
400*800	≥40KG	400	800	80	192
500*500	≥40KG	500	500	80	150
500*600	≥40KG	500	600	80	180
500*800	≥40KG	500	800	80	240
600*800	≥40KG	600	800	80	288
600*1000	≥40KG	600	1000	80	360

2. Working Principle​

Vacuum Generation and Holding Force​

When the vacuum source is activated, air is rapidly drawn out through the holes in the grid on the table surface. This creates a region of low pressure beneath the workpiece, while the atmospheric pressure above the workpiece remains constant. The resulting pressure differential exerts a downward force on the workpiece, pressing it firmly against the table surface.​

The multiple holes in the grid increase the surface area over which the vacuum force acts. With more holes, there are more individual suction points, leading to a stronger and more uniform holding force. The holding force is directly proportional to the pressure differential and the surface area of the workpiece in contact with the table. The grid - pattern design enables a more efficient transfer of the vacuum force, ensuring that the workpiece remains securely in place even during high - speed or high - force processing operations.​

Adaptability to Different Workpiece Materials​

The custom grid vacuum table vacuum chuck systems are highly adaptable to various workpiece materials. For smooth - surfaced materials like metals, the vacuum creates a strong seal, providing a secure hold. The even distribution of the vacuum force across the grid compensates for any minor surface irregularities. When working with porous materials such as certain types of plastics or wood, the vacuum can penetrate through the pores, creating a more intimate connection between the workpiece and the table.​

For example, in a machining operation where a metal part with a slightly rough surface is being processed, the grid vacuum table can still hold the part securely due to the multiple suction points. In a grinding process with a porous plastic workpiece, the vacuum can seep into the pores, increasing the holding force and preventing the workpiece from moving during grinding.​

3. Advantages in Workpiece Processing​

Precision Processing​

In workpiece processing, precision is often a top priority. The custom grid vacuum table vacuum chuck systems offer a stable and secure workholding solution, minimizing any movement or vibration of the workpiece during processing. The uniform vacuum distribution across the grid ensures that the processing tools can operate with high precision.​

For example, when milling complex shapes or drilling precise holes in a workpiece, the stable hold provided by the chuck system allows the processing equipment to execute the programmed operations accurately. The ability to hold the workpiece firmly in place reduces the risk of tool deflection and ensures that the processing tolerances are met. This precision is crucial in industries such as aerospace, medical device manufacturing, and electronics, where even the slightest deviation from the desired specifications can have significant consequences.​

Versatility in Workpiece Sizes and Shapes​

The custom design of the grid vacuum table allows for great versatility in handling different workpiece sizes and shapes. Whether it's a small, intricate component or a large, irregularly shaped part, the chuck system can be customized to provide a secure hold. The modular nature of the grid pattern enables the use of custom fixtures and adapters, which can be easily attached to the grid to accommodate specific workpiece geometries.​

For example, when processing a large and uneven - shaped workpiece, a custom - made fixture can be attached to the grid to hold the workpiece in the correct position. The ability to adapt to different workpiece sizes and shapes makes the grid vacuum table suitable for a wide range of applications, from prototype development to mass production.​

Quick Setup and Changeover​

In a production environment, time is of the essence. The grid vacuum table vacuum chuck systems enable quick setup and changeover between different workpieces. Operators can easily place the workpiece on the table and use the modular fixtures or adapters to secure it in place. The vacuum system can then be activated to hold the workpiece firmly.​

When changing workpieces, the process is equally fast. The vacuum can be released, the fixtures or adapters can be removed or repositioned, and the new workpiece can be placed and secured in a short time. This efficiency reduces the overall production cycle time and increases productivity.​

4. Customization Options​

Grid Pattern Design​

The grid pattern design of the vacuum table can be customized to meet the specific needs of different workpiece processing applications. The number, size, and layout of the holes in the grid can be tailored based on the size, shape, and material of the workpieces.​

For example, in a processing operation where a large number of small, irregularly shaped components need to be processed, the grid can be designed with a high - density pattern of small holes to ensure a secure hold on each component. In contrast, for processing large and flat workpieces, the grid may have a fewer number of larger holes, spaced farther apart, to provide a strong hold over the large surface area.​

Vacuum System Tuning​

The vacuum system of the grid vacuum table can be tuned to optimize its performance for different materials and processing operations. The vacuum pressure can be adjusted using regulators to provide a more or less powerful hold, depending on the material and size of the workpiece. The system can also be equipped with sensors to monitor the vacuum pressure and ensure its stability.​

In some cases, the vacuum system can be integrated with the processing equipment's control system, allowing for automated control of the vacuum hold based on the processing process. For example, the vacuum pressure can be increased during high - speed or high - force processing operations to provide a stronger hold, and then decreased during more delicate finishing operations to avoid damaging the workpiece.​

5. Installation and Maintenance​

Installation Process​

Installing a custom grid vacuum table vacuum chuck system on a workpiece processing machine involves several steps. First, the table needs to be securely mounted on the machine's worktable or base. This may require the use of appropriate mounting brackets and fasteners to ensure stability. The vacuum source, such as a vacuum pump, is then connected to the table's vacuum ports, and the connections are checked for leaks.​

Once the physical installation is complete, the vacuum system needs to be calibrated to ensure proper vacuum generation and distribution. This may involve adjusting the vacuum pressure, testing the sealing performance of the table, and verifying the functionality of any integrated sensors or controls. In some cases, the processing equipment's control system may need to be configured to work in tandem with the vacuum table system.​

Maintenance Requirements​

Maintenance of the grid vacuum table vacuum chuck systems is relatively straightforward. Regular inspection of the table surface for any signs of wear, damage, or contamination is important. The holes in the grid should be cleaned periodically to remove any debris or particles that could block the vacuum flow. The vacuum channels and associated components should be checked for any blockages or leaks.​

The vacuum pump and its components should be maintained according to the manufacturer's instructions, including regular oil changes, filter replacements, and performance checks. The seals and gaskets in the vacuum system should be inspected regularly and replaced if there are any signs of leakage. By following these maintenance procedures, the grid vacuum table vacuum chuck systems can maintain their performance and reliability over an extended period.​

6. Conclusion​

Custom grid vacuum table vacuum chuck systems are an essential workholding solution for workpiece processing. Their unique design, working principle, and numerous advantages make them suitable for a wide range of applications in different industries. Whether it's achieving precision in high - tech manufacturing or enhancing productivity in general production, these systems offer a reliable and efficient solution. If you are involved in workpiece processing and are looking to improve the performance of your workholding system, consider investing in a custom grid vacuum table vacuum chuck system. Reach out to our team of experts to explore how this innovative system can be customized to meet your specific needs and take your workpiece processing capabilities to the next level.

Dongguan Hie Hardware Co., Ltd is a metal products enterprise with a profound history of twenty years. We are an integrated entity that combines research and development, manufacturing, sales, and service. We are not only an OEM processing manufacturer for many domestic and foreign mold accessories counterparts but also a pioneer in the field of minimally invasive surgical instruments.

In the design and manufacture of minimally invasive surgical instrument structural components and fine metal combination pipe fittings, we focus on the design and manufacture of minimally invasive surgical structure space components, covering surgical components such as endoscopic structures, ablation structures, puncture analysis, sampling biopsy analysis, endoscopic intervention, suture cutting, heart stents, and vascular stents. Our technical team with twenty years of manufacturing experience has broken through various technical barriers in minimally invasive structure manufacturing, effectively addressing the high complexity of the process of minimally invasive instrument structural components. With advanced manufacturing processes such as multi-pole expansion and contraction, non-standard surface marking, arbitrary latitude bending, step forming, multiple side holes, multi-axis welding, six-axis component forming, pipe body expansion and contraction, micro-tube cutting, multi-level surface perforation, surface partial insulation, surface partial roughness, clean slender inner tubes, and non-sticking liquid in liquid-conducting tubes, we can meet the design needs of various high-difficulty special-shaped parts for customers and have received unanimous recognition and long-term cooperation from domestic and foreign customers. 

In the field of mold accessories manufacturing, our technical backbones have decades of processing experience in mold parts from Japan and Taiwan. The company regularly conducts various skill trainings and grade evaluations to lay a solid foundation for continuous development in the mold parts manufacturing industry and gradually move towards industry standardization and modernization. We always strictly follow the technical standards of manufacturers such as "MISUMI", "Punch", "DME", and "HASCO" for production and inspection. We can also design and provide various standard and non-standard mold accessories according to different customer requirements. We specialize in manufacturing precision photoelectric tooth shafts, screw thread electrodes, pen mold cores, cosmetic parts, precision inserts, cores, bushings, and SKH51/SKD61 series cartridge ejector pin mold accessories, etc. Our products are widely used in fields such as photoelectric, digital electronics, medical packaging instruments, pen making, cosmetic packaging, electrical appliances, automobiles, and mechanical motor shaft manufacturing. In particular, we have significant advantages in non-standard mold accessories processing, various wear-resistant block processing, guide pillar and bushing processing, non-standard insert processing, precision plastic mold accessories processing, etc., providing customers with a full range of solutions for precision mold accessories processing.

The company holds multiple independent product structure manufacturing patents and has passed ISO9001:2015 and ISO13485 quality system certifications. With excellent quality, exquisite craftsmanship, innovative design, and high-quality service, we are committed to creating greater value for customers.