How to Choose an Automation Magnetic Holder
The choice of the correct automation magnetic holder is done with respect to the workpiece, machine, operating environment, and required magnetic force.
1. Identify the Material of the Workpiece
It is necessary to find out whether the component is ferromagnetic. As a rule, steel and iron are magnetic materials, but aluminum, copper, plastic, and many stainless steels are not.
2. Determine the Required Holding Force
Find out how much load the holder has to sustain during the lifting, acceleration, vibrations, and movement. The static weight of the part is not sufficient. Take into account the safety margin.
3. Surface condition check
Smooth and clean surfaces always provide better magnetic coupling. Any presence of paint, rust, oil, gaps, curvatures, and roughness reduces holding performance.
4. Electromagnetic or Permanent Operation
Use a permanent magnetic holdtor to reduce power consumption. Electromagnetic holders are useful when automatic electrical control of holder engagement and release is desired.
5. Consider the Speed of Automation
Accelerations, decelerations, vibrations, and abrupt direction changes in robots and other automation equipment cause additional stresses on the workpiece. The magnetic holder must ensure that it holds the workpiece throughout the entire process.
6. Verify mounting requirements
Prior to choosing the holder, consider the mounting holes, bolt pattern, dimensions, cable routing, actuator interface, and the available mounting space.
7. Assess Operating Environment
Take into account temperature, dust, moisture, oil, vibrations, welding sparks, and other environmental factors. Choose a construction suitable for the environment.
8. Consider Duty Cycle
For electromagnetic systems, calculate the operating voltage, current, energizing time, release time, and duty cycle to avoid overheating.
9. Safety Requirements Review
Choose the right safety factor and estimate the workpiece holding conditions in the event of power failure, emergency stop, and equipment malfunction.
10. OEM Customization
Automation equipment may require a custom magnetic circuit, mounting structure, dimensions, interface with sensors, or switching mechanism, which will perform better than the standard product.
Magnetic Holder Design Mistakes in Automation: Tips for Avoidance
Holding force is not calculated based only on workpiece weight.
Robotic movement causes accelerations and vibrations; don’t forget about them.
Not all stainless steel grades are supermagnetic.
Air gaps should be minimized between the magnetic pole and the workpiece.
Imagine paint, rust, oil, scale, and surface roughness.
Don’t save on the installation space using a small magnet.
Provide a safety factor for dynamic applications.
Check the heating of the electromagnetic coil when continuously working.
Check whether the power supply corresponds to the holder’s voltage.
Design proper mounting hardware and load paths.
Think of the emergency stop and power failure situations.
Don’t use the magnetic system under high temperatures if it is not designed for it.
Test the holder with the real production workpiece.
Check the holding performance under actual acceleration and vibration.
Think of sensors when automated workpiece holding confirmation is required.
Leave enough room for the robot to move and release the workpiece.
Protect cables and connectors from the industrial damage.
Make sure the magnetic holder won’t interfere with any nearby sensors or electronic devices.
Test the prototype prior to mass production.
Define mechanical, electrical, and performance specifications for OEM projects prior to design.
