Kosmek Diecast Clamping Systems

KDCS

Kosmek
Mold Change Systems

Point

for Die Casting Machines

Reduces Mold Change Time

Operation Side

Clamps the Mold with the Touch of a Button

Manual Bolts

Automatic Clamps

Open the Safety Door

Stationary Side: Lock SwitchON

Attach the Bolts/Fittings

x 4 Places
Tighten the Bolts
Close the Safety Door

Movable Side: Lock Switch ON

Mold Clampin g Completed

Non-Operation Side

Go to the Non-Operation Side

Open the Safety Door

Attach the Bolts/Fittings
x 4 Places
Tighten the Bolts
Close the Safety Door

Go to the Operation Side

M o l d C lam ping Com plet ed

Automatic clamps simplify

the mold change processes!

Time is saved during

both setting and removal!

This is only when using automatic slide clamps (Model GKE/GKF).

Point

Mold Changing Becomes Safer!

No tools are required. Clamping the mold with the touch of a button prevents injuries and accidents.

Slippery due to mold lubricant

Push-button operation!
Can cause back injuries

Tools are required

No tools are required!

Can forget to tighten bolts

No space on the Non-Operation side

Safe interlock function!

Manual Bolts

Automatic Clamps

Unsafe/Unstable Work

Safe/Stable Work

User Error

Safety functions prevent

the mold from falling.
The Kosmek operation control panel has interlocks with
the machine and is designed to prevent an operator error.

Point

Interlock

Automatic Clamps

Improve Quality!

Anyone can attach the mold with the same clamping force allowing for standardization.

Equal and sequential tightening of the bolts is

essential to maintain proper clamping force, but
some bolts are easier to tighten than others

Less Mold Deformation

Automatic clamps allow for equal tightening,
reducing mold deformation and burrs.

No Skilled Labor Required

No skilled labor is required with automatic
clamps and equal tightening force is ensured.
2

Kosmek Diecast Clamping Systems

KDCS

Kosmek Automatic Clamp

Point

Stable Performance
Special Coating Enables
a Longer Operational Life Span!

Protective Cover
Keeps out mold lubricant and
dust inltration that can cause
malfunctions.

Special Coating
Special coating on the lever and body
prevents rust caused by mold lubricant.

Anaerobically-Sealed Cylinder
The piston is anaerobically sealed in order to prevent
the entry of mold lubricant or dust which leads to
damage to the internal packing and piston.

Powerful Lever Return Spring

The powerful lever return spring reduces

Point

the release time.

Exclusive Sealing Enables

a Longer Operational Life Span!
Reduces release errors caused by corrosion of the fulcrum shaft.

Special Seal
L ow F r i ct i on and S m o o th Op e r ati o n
Special wear resistant sealing is used on the
sliding surface.
Hig h D u r a b i l i ty and Lo nge r Op e r ati ng Li f e
Maintains high-quality sealing due to the resilience
of the Viton seal that presses the special seal to the
sliding surface of the body.

Scraper
Keeps out foreign substances in
conjunction with the protective

Special Sealing

cover.
Body
Lever

Viton Packing

Packing for the Fulcrum Shaft

This packing, which is set on the fulcrum shaft,
keeps out mold lubricant and dust.

Point

Improved Maintenance
No Special Tools are Required to Assemble/Disassemble!
The structure has been redesigned. It's simple and easy to maintain.

No special tools are required.

N o skilled labor is required.

Small clamps can be assembled

Simple structure

and disassembled on the platens.

with high durability.

For larger models, it is recommended to remove them from the platen during assembly/disassembly for safety.

Kosmek Diecast Clamping Systems

KDCS

Additional Standard Models

Point

L ong er Str o k e M odel

The World's Best Long Stroke Clamp!

0100 0400 Size: St. 8 12mm, 0630 5000 Size: St. 15 16.5mm

For model 0630, the full stroke is 15 mm!

(Ex.) This model works with
three mold thicknesses: 40, 45 and 50mm!

40

45

mm

50

mm

mm

NEW

Poi nt!

PRODUCT

GKC Clamp

Your system will be capable of handling

more variations in backplate thickness
Current Model
GB-Y Clamp

by using the new longer stroke clamps.

Point

T-Slot Automatic Slide Model

Push Button Operation Completes

the Clamp Positioning and Lock Operation

There is no need to go to the non-operation side. Clamp movement is automated.

Point

Clamp Operation Time Reduction

Newly Developed Large Flow Air-Hydraulic Combination Pump
1

Reduces 50% of O.T.

(In comparison with

other Kosmek products.)

1. O.T. = Operation Time

Reduced time varies
depending on piping, etc.

(Ex.) For an 850 ton machine with eight 2500 clamps,

c l a m p op e r a t i on t im e is 1 6 s e co nds ! !
35

Time [Sec.]

30
25

Time required to reach

22.6

4.0

2. Cylinder CapacityAbout 700 m

full pressure is less than half!

26.1

20
15

5.5

10

10.2

9.9

Pressurization Completed
(22.5 MPa)

Pressure Switch
ON
(INC 17.6 MPa)

Pump

AB7000 Pump

2 Qty.

Discharge
Oil

1.3 [/min]

2 Qty.

Motor Pump 3
+
AB7000 Pump
14 [/min]
+
1.3 [/min]

AE7300
Large Flow Rate
Combination Pump

NEW
PRODUCT

3. When using a motor pump,

12.5 [/min]

to the 22.5MPa set pressure after

the pressure switch turns "ON".

Pump Pressurization Time Comparison

Compact and Space-Saving!

815

The protective cover is a standard option

to protect against mold lubricant/dust.
389

420

Point

it takes a long time to pressurize

Pressure relief valve allows for

temperature change in hydraulic circuit.

545

Current Model CT Unit

NEW
PRODUCT

Compact, High Pressure

CT E Un i t

and Large Discharge

6

Kosmek Diecast Clamping Systems

KDCS

Additional Smaller and Larger Sizes

S t a n d a r d Sy s t e m
Die Casting
Machine
Capacity

350

500

750

Clamp
Size

Stationary / Movable
Clamping Force [kN]

Clamp
Qty.

NEW

0100

40

0160

64

0250

100

1500

0400

160

2500

0630

252

5000

1000

NEW

8
Stationary: 4

400

Movable: 4

1600

640

2500

1000

4000

1600

5000

2000

NEW

11000

NEW

16500

NEW

22500

NEW

25000

2400

12

4000

Stationary: 6

NEW

30000

Pump Model

Unit Model

Clamp
Operation Speed

Mold
Fall Prevention
Block

Air Valve
Unit
(Only GKE/GKF)

MJ0010

NEW

6500

Hydraulic Unit

Movable: 6

5000

CTBN00
CTDN00
CTCN00
CTEN00

AB7000-
AD7300-
AC7001-
AE7300-

MJ0020
MV3012-25

CTDN00
CTCN00
CTEN00

AD7300-
AC7001-
AE7300-

CTCN00
CTEN00

AC7001-
AE7300-

CUEN00

MJ0030
MJ0040

MJ0050

AE7300-

Faster

MV3022-25

Please
contact
us.

3000

Notes
1. T-Slot Manual Slide (Model GKB/GKC): sizes 0100 5000, T-Slot Automatic Slide (Model GKE/GKF): sizes 0400 5000.
Please contact us for T-slot automatic slide clamp sizes smaller than 0400.
1. The standard system above is just a reference. Please contact us for exact specifications for your machine.

P um p Pe r f o r man c e Cu r v e

Discharge Pressure PH [MPa]

25
20
15
10
5
0
0

1
1.32/min
B : AB7000-

2
2.70/min
C : AC7001-

3.74/min
D : AD7300-

Discharge Oil [/min]

10

11

12

13
12.5/min
E : AE7300-

S yst e m S t r uc t u r e
Hyd r a u l i c C l a m p

T-Slot Manual Slide Model

Stationary
Platen

Control Unit

Hydraulic Clamp

T-Slot Manual Slide Model

Operation Panel

Electric Circuit

To Die Casting Machine

Hydraulic Unit

Movable
Platen

Air Circuit

Air

Stationary Side Hydraulic Circuit

Mold Safety Block

Movable Side Hydraulic Circuit

Movable Side Hydraulic Circuit

Hyd r a u l i c C l a m p

T-Slot Automatic Slide Model

Hydraulic Clamp

T-Slot Automatic Slide Model

Air Valve Unit

Stationary
Platen
Control Unit

Operation Panel

Electric Circuit

To Die Casting Machine

Relay
Box

Movable
Platen

Hydraulic Unit
Air Circuit

Air

Stationary Side Hydraulic Circuit

Mold Safety Block

Movable Side Hydraulic Circuit

Movable Side Hydraulic Circuit

Robotic Hand Changer

SWR

Zero Backlash

The One and Only Robotic Hand Changer

Master Cylinder

Tool Adapter

S p e ci ca t io n s Model SWR
Allowable Weight (Air at 0.5MPa)3 kg/ 7 kg/ 12 kg/ 25 kg/ 50 kg/ 75 kg/ 120 kgMaximum Operating Air Pressure1.0 MPa
Locating Repeatability3mOperating Temperature0 70
Please refer to the catalog or Kosmek website for further information.

Transfer Robot

For Molded Item

Point

Transfer Robot Hand Exchange

Minimum Fluctuation on the Tip
even with Longer Arm

B e f o re

After

General Robotic Hand Changer

Robotic Hand Changer

Molded Item Transfer Robot Hand

Kosmek Robotic Hand Changer

No Clearance
(No Backlash)

Clearance
(Backlash)

Suction Pad

Minimum
Fluctuation

Fluctuation

Clearance
(Backlash)

Dual contact with the movable

taper sleeve enables zero clearance
(No backlash on the connected part)

Robotic Hand Changer

Exchange of

DeburringChamfering Tool

Point

Deburring Tool

Molded
Item

Zero Backlash!
Suitable for Heavy Load Work

B e f o re

Deburring Process

After

General Robotic Hand Changer

Clearance
(Backlash)

Kosmek Robotic Hand Changer

Zero Clearance
(Zero Backlash)

Deterioration of

High rigidity
withstands the load.

Machining Quality

No Fluctuation

Fluctuation

Locating Repeatability during Tool Exchange

For Locating the Pallet in the

Next Process after Casting
Pallet

Step

Setup
Station

Step
Step 1
Image

Robotic Hand Changer

Tr ans f e r Ro bot

Pallet L oc atin g

10

Robotic Hand Changer

SWR

6 Reasons to Choose KOSMEK

Built-in Spring
Clearance

Backlash

No Clearance

General Robotic Hand Changer

No Backlash

Kosmek Robotic Hand Changer

No Backlash on Connected Part

Prevents the Tool from Falling

No clearance or backlash with dual contact by the

Even without pressure, the built-in spring

taper sleeve. It prevents core deflection and chattering

maintains the connection, which prevents

due to the work load and enhances productivity.

the tool from falling.

Air

Electric
Error
Prevention

Supply to the Tool

Connect Air/Electricity to the Tool Side

Better Work Efficiency with Electrode

Air and electricity can be connected to

No backlash on connected part. Highly reliable

the tool through air port and electrodes.

electrodes prevent momentary stop caused by

Solder terminals, D-sub connectors and

communication error.

power transmission connectors are available.

Locating
Repeatability

11

115g

0.003mm

Light and Compact

Prevents Fluctuation

Suitable for robotic hands which have critical

Locating repeatability of tool change is 0.003mm.

weight limits. Light weight but highly portable.

Reduces the fluctuation of the hand tool and

Shows the weight of SWR0030 without the electrode option.

conducts a high accurate operation.

This catalog (KDCS: Kosmek Diecast Clamping System Complete Catalog) does not include the details about SWR.
Please contact us or visit our website (http://www.kosmek.co.jp/english/) for further information.

Port Options
A : Wit h A ir B l o w P o r t
Air Supply
(For Blowing)

When connecting, there is moderate clearance between the taper reference surface and seating surface that enables
high accuracy. This allows for effective cleaning with air blow, foreign substance prevention and longer operating life.

F : Wit h S e a t Ch e c k P o r t
Air Supply
(For Seat Check)

Close contact check detects secure connection of the master cylinder and tool adapter.
This prevents connection error of the robotic hand changer.
A close contact check is conducted with the air catch sensor. (The air catch sensor must be installed separately.)

Point

Wat erproof Electrodes

Waterproof Electrodes
Prevent Mold Lubricant and Dust Inltration!

Waterproof Electrode (Non-contact Waterproof Option)

Waterproof Electrode (Simple Waterproof Option)

IP67

Only When Connected / Equivalent to IP54

12

Company Profile

K OS ME K LTD. H ea d O f f i ce

Company Name

KOS ME K L T D .

Established

Ma y 1 9 8 6

Capital

99,000,000

Sales

5 5 b i l l i o n y e n ( p er io d en d ed Mar ch 2014)

Chairman

Ke i t a r o Y o n e z a w a

President

T s u t o m u S h i r a ka w a

Employee Count

220

Group Company

KOS ME K L T D .
KOS ME K E N G I N E ERING L TD.
KOS ME K ( U S A ) L TD.
KOS ME K ( C HI N A ) L TD.

Business Fields

Design, production and sales of precision products, and hydraulic and pneumatic equipment

Customers

Manufacturers of automobiles, industrial machinery, semiconductors and electric appliances

Banks

R e s o n a b a n k, T o k y o -Mit s ubis h i ban k, Iked a ban k

Major Machine Tool Devices (As of March 2014)

Lathe machine devices etc.

Composite CNC lathe etc. (57units)

Machining center devices etc. Horizontal Machining center etc. (18 units)
Grinding machine

Internal and external cylindrical NC grinding machine etc. (6 units)

Other machine tools

Honing machine etc. (24 units)

Measuring instruments

Precision 3D CMM etc. (9 units)

Heat treatment etc.

Nitriding furnace etc. (5 units)

Major Industrial Property Rights

(Including patent right and patent pending as of March 2014)
Domestic

110

International 250 (USA, EU, Taiwan, South Korea, China, India, Brazil, Mexico, Thailand, Indonesia)
57

Hydraulic Clamp

Product Line-Up
Hydraulic Unit

DI E CAST CLAMPI NG SYSTE MS

For Diecast Machines
Kosmek Diecast Clamping Systems (KDCS) enable stable die

Operational
Control Unit

Cautions
Company Profile

clamping for die casting and magnesium molding machines

that are subjected to severe conditions caused by
exposure to mold release agents and high temperature.

Hydraulic Clamp
GKB
GKC
GKE
GKF

Hydraulic Unit
CTB
CTD
CTC
CTE

QUI CK MOLD CHANG E SYSTE MS

For Injection Molding Machines

Automatic clamping systems have reduced mold change times

and increased production eciency for plastics manufacturers

C UC
C UE

Air Valve Unit

MV

in a multitude of industries.
We oer a variety of dierent clamping options, including
hydraulically powered clamps, pneumatic clamps with a force
multiplying mechanism, and magnetic clamping systems.

Operational
Control Unit
Y MB0 8 0

Cautions
Notes on Design
Installation Notes
Hydraulic Fluid List
Notes on Hydraulic Cylinder
Speed Control Circuit
Notes on Handling

QUIC K DIE C H AN GE SY ST EM S
For Press Machines
Kosmek Quick Die Change Systems are a cost eective way to

Maintenance/
Inspection
Warranty

Our Products

improve the working environment, allow diversied and

QMC S

small-lot production, and reduce press down time.

QDC S

Available for a wide range of machines; from large size

KWCS

transfer-presses to smaller high speed presses.

FAIndustrial Robot
Related Products

Company Profile
Company Profile
After-Sales Service
History
Sales Offices

KOSME K WORK CLAMPI NG SYSTE MS

Machine Tool Related Products
Our clamping system enables boltless automation making
loading and unloading workpieces easier.
The non-leak valve enables the use of hydraulic source and
xtures in a disconnected condition after locking
(clamping action).

58

Company Profile

Sales Offices
Sales Offices across the World
FAX. +81-78-991-8787

Japan

TEL. +81-78-991-5162

Overseas Sales

KOSMEK LTD. 1-5, 2-chome, Murotani, Nishi-ku, Kobe-city, Hyogo, Japan 651-2241

USA

TEL. +1-630-241-3465

KOSMEKUSALTD.

1441 Branding Avenue, Suite 110, Downers Grove, IL 60515 USA

China

TEL.+86-21-54253000

KOSMEKCHINALTD.
()

651-2241

215

FAX. +1-630-241-3834

FAX.+86-21-54253709

21/F, Orient International Technology Building, No.58, Xiangchen Rd, Pudong Shanghai 200122., P.R.China
5821F 200122

FAX. +66-2-715-3453

Thailand

TEL. +66-2-715-3450

Thailand Representative Office

67 Soi 58, RAMA 9 Rd., Suanluang, Suanluang, Bangkok 10250, Thailand

Taiwan

TEL. +886-2-82261860

Full Life Trading Co., Ltd.

16F-4, No.2, Jian Ba Rd., Zhonghe District, New Taipei City Taiwan 23511

(Taiwan Exclusive Distributor)

FAX. +886-2-82261890

2 16F- 4

Philippines

(Philippines Exclusive Distributor)

TEL.+63-2-310-7286

G.E.T. Inc, Phil.

Victoria Wave Special Economic Zone Mt. Apo Building, Brgy. 186, North Caloocan City, Metro Manila, Philippines 1427

Europe

(Europe Exclusive Distributor)

TEL. +43-463-287587-10 FAX. +43-463-287587-20

KOS-MECH GmbH

Schleppeplatz 2 9020 Klagenfurt Austria

Indonesia

TEL. +62-21-5818632

(Indonesia Exclusive Distributor)

FAX. +63-2-310-7286

FAX. +62-21-5814857

P.T PANDU HYDRO PNEUMATICS Ruko Green Garden Blok Z- No.51 Rt.005 Rw.008 Kedoya Utara-Kebon Jeruk Jakarta Barat 11520 Indonesia

Sales Offices in Japan

Head Office
Osaka Sales Office
Overseas Sales

Tokyo Sales Office

Nagoya Sales Office

Fukuoka Sales Office

61

TEL.078-991-5115
651-2241

215

TEL.048-652-8839
331-0815

FAX.0566-74-8808

2101

TEL.092-433-0424
812-0006

FAX.048-652-8828

481

TEL.0566-74-8778
446-0076

FAX.078-991-8787

FAX.092-433-0426

18-10-101

Global Network
Overseas Aliates and Sales Oces
Distributors

Europe
U.S.A.
Asia

Mexico

Brazil
Australia

Asia Detailed Map

Korea
Japan

China
Taiwan

India
Thailand

Philippines

Malaysia
Singapore

Indonesia

FOR FURTHER INFORMATION ON UNLISTED SPECIFICATIONS AND SIZES, PLEASE CALL US.
SPECIFICATIONS IN THIS CATALOG ARE SUBJECT TO CHANGE WITHOUT NOTICE.

JQA-QMA10823

KOSMEK HEAD OFFICE

62