A product digest

QUICK MOLD CHANGE SYSTEMS

Hydraulic G series

Hydraulic Unit

Pneumatic H series

Pneumatic Q series

MEK2000-8S
Max. Clamping Force 176kN
200-220V50/60Hz7kVA

Magnetic Clamp

Quick Ejector Rod

Advantages of Automatic Clamping Systems

Shorter Mold Changing Time
1. With a manual clamping system, workers must loosen
and tighten bolts one by one. However, with an
automatic clamping system, a single operator
can release the clamps holding the mold on both sides
at once, reducing changing time.

Manual tightening

Automatic mold clamping

Confusion due to
searching,loosening,
tightening and so on makes
the work unstable,
jeopardizes safety and
decreases productivity.

Stable work anyone can

do improves the work
environment.
A better morale
increases productivity !

2. Reduction of mold changing time results in less time

the crane spends waiting to put the mold in place, an
important factor at plants where multiple molding
machines are in operation.
3. When there is an urgent need to repair a mold, the
automatic clamping system can reduce down time by
allowing faster dismounting and remounting of the
mold.
4. Reduction of mold changing time leads to an overall
improvement in productivity.

Comparison of Mold Setting Times

Conventional System
(Manual Tightening)

Automatic
Clamping System

Lower Mold in With Crane

Lower Mold in With Crane

Align With the Locator Ring

Rest Mold on the Support Block

Adjust Position and Close the Mold

Adjust Position and Close the Mold

Tighten the Operation Side
Open the Safety Door

Attach the Bolts/Fittings

Tighten the Bolts

4 Bolts

Close the Safety Door

Turn on the Lock Switch for the Stationary Side

Turn on the Lock Switch for the Moveable Side

Mold Setting Time

1 Minute and 59 Seconds!1

Go to the Non-Operation Side

Tighten the Non-Operation Side
Open the Safety Door

Attach the Bolts/Fittings

Tighten the Bolts

4 Bolts

Close the Safety Door

Setting Time is cut in half.

Time saved during
both setting and removal.

Move to operation side

Mold Setting Time

4 Minutes and 1 Second1

Remarks
1. Actual recorded times for mold settings performed on
a 180 ton Injection Molding Machine.
The Automatic Mold Clamping System used was
a KOSMEK Magnetic Clamp.

QMCS
Improvement of Work Environment and Work Efficiency
1. The mold change using bolts may be one of hard,
dangerous, dirty works.
Application of the automatic mold clamp allows everyone
to change molds by button operation, to prevent backache
and sweat-caused slip and to improve work environment.

Unsafe work
hurts your back.

Safe work
Stable work

2. Productivity can be improved because the work without

any tool results in saving time for searching tool.
3. Stationary type clamp and auto slide type clamp eliminate
the work at the non-operation side to reduce the work
time and improve productivity.
In addition, mold change by one person is also possible.
4. The application of the automatic mold clamp allows
everyone to mount molds by the same clamping force
which leads to work standardization.

Quality Improvement
1. It is difficult to tighten bolts equally because the workspace is
sometimes too narrow to handle the tool depending on the position
of the bolt.
And it is not efficient to tighten the operation and non-operation
sides bolts temporarily and then finally.
Therefore the bolts are tightened one by one without temporary
fastening.
Since tightening condition of bolts cannot be visually recognized,
sometimes final tightening may be forgotten.
This means the mold cannot be installed equally by manual
tightening.
Therefore burrs may be produced on molded products due to mold
deformation during molding, and product deformation may occur.
Application of the automatic mold clamp enables to mount a mold
in a condition close to molding action, leading to defective product
decrease.

I know equal and sequential fastening is needed.

But it is difficult to fasten the bolts at some
places while easy at other places.

Axial force of bolt is

not constant even
if torque is adjusted.

2. Some users say that they control the clamping force using the
torque wrench .
In that case, however, what they do is actually torque control but
not clamping force control. The application of the automatic mold
clamp allows the same mounting result without relating to
individual workers.

Advantages of Automatic Clamping Systems

Improvement of Safety
1. The automatic mold clamp system is designed to
assure safety by applying a non-leak valve, a back-up
pump unit, and the built-in mechanical locking system
to prevent mold dropping accidents.
2. Although loose bolts are hard to find visually, the
automatic mold clamp system is provided with various
types of interlocking between the clamp and molding
machine to provide safety measures such as shutting
down the molding machine, thus assuring safety even
if a trouble such as pressure drop occurs.
3. O p e r a t i o n a n d c o n t r o l p a n e l m a n u f a c t u r e d b y
KOSMEK is designed considering prevention of wrong
operation by workers as well as the interlocking with
the molding machine.

U
OP NDER
ERA
TIO
N

Miss
Operation

Interlock

Cost Reduction
1. Improvement in operational ease and productivity by
reducing the mold change time leads to total cost
reduction.
2. Reliable mold mounting will reduce wear rate of a mold
guide bush, failure of an ejector pin and so on,
contributing to the mold repair cost reduction.
3. R e d u c t i o n o f t h e m o l d c h a n g e t i m e a n d t h e
improvement of productivity give the workers time to
do value added work, leading to reduction of total labor
cost.
4. Standardized work leads to a stable molding process
which by turn helps to reduce defective products, thus
resulting in the total cost reduction.

Defectiveness
Rate

Repair Expense

Cost Reduct
ion
Rate

QMCS
Enhancement of Total Business Power
Achievement of the above items enables to correspond to multi-item small lot production and short delivery
time, and to create stable quality products at a low price.
And the improvement of work environment contributes to attracting able employees and keeping them
committed and to the improvement of their work level, leading to enhancement of total power of the
enterprise.

Quick Mold Change Systems

In the technique that put improvement on the experience that the quick mold change system of KOSMEK
cultivated with many results from that in response to the many kinds and small quantity, stock reply production
of the visitor the die exchange of the injection molding airplane "is fast security realize, "single making
arrangements" surely".

VERTICAL LOADING
What is Vertical Loading?
Vertical loading is the system where by the mold is set from the top of the molding machine by crane.
The mold will be secured in the I.M.M. by hydraulic clamp.
Kosmek s molding change system enables to select the most suitable system structure by
the condition of molds and I.M.M.

Mold

Stationary
Platen

Movable
Platen

Clamp
MH Mold Support Block
(MJ Safety Block)

Clamp Variation
Hydraulic Clamping Systems

Pneumatic Clamping Systems

Magnetic Clamping Systems

GB

HB / QB

MEK
MEK2000-8S

Max. Clamping Force 176kN

200-220V50/60Hz7kVA

GE / GLA

HE / QE

GM

QM

GWA

HC

QMCS
Vertical Mold Loading Systems
Please refer to the chart below and select a clamping system for the most suitable manufacturing system
from a variety of Kosmek product.
Not every product is shown here. Please contact us for detailed specifications.

The thickness
of mold back-plate is
standardized.
NO

YES

The dimension
of mold width is not
standardized.

YES

YES

NO

MEK

YES

The operator can

go around and operate on
non-operator side.

NO

NO

GWA

GM

GE / GLA

GB

HC

QM

HE / QE

HB / QB

Magnetic Clamping SystemsMEK

Free Method

Hydraulic Clamping SystemsGWA

Hydraulic Clamping SystemsGM

Pneumatic Clamping SystemsHC

Pneumatic Clamping SystemsQM

Stationary Method
MEK Clamp

Power Unit

YES

Injection mold
machine has
T slots.

Remote Operation Unit

Electricity

Operation Control Panel

Manual Sliding Method

GWA Clamp
HC Clamp

GM Clamp
QM Clamp

MH Support Block
or
MJ Safety Block

MH Support Block
or
MJ Safety Block

MG Guide Block

MG Guide Block

Valve Unit
GWA Using I.M.M. hydraulic source

Air Valve Unit

For HC Clamp
Electricity

Hydraulic Unit
For GM Clamp

Air Valve Unit

For QM Clamp
Pneumatic

Hydraulic Clamping SystemsGE/GLA

Hydraulic Clamping SystemsGB

Pneumatic Clamping SystemsHE/QE

Pneumatic Clamping SystemsHB/QB

Automatic Sliding Method

Operation Control Panel

Electricity

Pneumatic

Manual Sliding Method

GE/GLA Clamp
HE/QE Clamp

GB Clamp
HB/QB Clamp

MH Support Block
or
MJ Safety Block

MH Support Block
or
MJ Safety Block

Model Code
Supporting Block
Safety Deviceetc.
Apparatus for Control
Device
Power Source

Operation Control Panel

Air Valve Unit
For HE/QE Clamp
Electricity

Hydraulic Unit
GE / GLA only
Air Valve Unit for Slider
For GE / GLA Clamp
Pneumatic

Operation Control Panel

Hydraulic Unit
For GB Clamp

Air Valve Unit

For HB/QB Clamp
Electricity

Pneumatic

HORIZONTAL LOADING
What is Horizontal Loading?
Horizontal Loading is the system where by the mold is set from either operation side or non-operation side using cart or table.
You may choose the most suitable arrangement according to the frequency of change of mold and layout of the factory.

MP Mold Positioning Equipment

Clamp
MF Mold Holding Equipment
MM Mold Stop

Stationary
Platen

Movable
Platen

Mold

ML Pre-Roller

MR Plate-Roller

Clamp Variation
Hydraulic Clamping Systems

Pneumatic Clamping Systems

Magnetic Clamping Systems

GWA

HC

MEK
MEK2000-8S

Max. Clamping Force 176kN

200-220V50/60Hz7kVA

QMCS
Horizontal Mold Loading Systems
Please refer to the chart below and select a clamping system for the most suitable manufacturing system
from a variety of Kosmek product.
Not every product is shown here. Please contact us for detailed specifications.

The thickness
of mold back-plate is
standardized.
NO

YES

YES

GWA

MEK

HC

Magnetic Clamping SystemsMEK

Hydraulic Clamping SystemsGWA

Pneumatic Clamping SystemsHC

Free Method

Stationary Method
MEK Clamp

GWA Clamp
HC Clamp

ML Pre-Roller

MP Positioning Equipment

MR Platen Roller

ML Pre-Roller

MM Mold Stop

MR Platen-Roller
MF Holding Equipment
MM Mold Stop
Power Unit
Electricity

Remote Operation Unit

Operation Control Panel

Air Valve Unit
For HC/MP Clamp
Electricity

Model Code
Supporting Block
Safety Deviceetc.
Apparatus for Control
Device
Power Source

Valve Unit
For GWA Clamp
Air Valve Unit
For MP when using GWA
Pneumatic

Q MC S

HYDRAULIC CLAMP

GB

T-Slot Manual-Slide Clamp (Single-Action)

Please refer to a catalog for the detail of each product.

Hydraulic 24.5MPa
GB Clamp is a common type of clamp with T-Slots,
which can be used with molds of various widths.
[Specification]
Clamping Force kN

(at 24.5MPa) 9.8 15.7 24.5 39.2 61.7 98 157 245

Operating Pressure

MPa 24.5

[Option]
With Handle

Reinforced Body

Wide Lever

NPT Port

Low Lever

With Proximity Switch for Mold Detection

High Temperature Rear Port

GE

T-Slot Automatic-Slide Clamp (Single-Action)

Long Stroke

With Check Valve

Hydraulic 24.5MPa
GE Clamp has the ability to slide and lock molds of
different sizes by remote control.
[Specification]
Clamping Force kN

(at 24.5MPa) 24.5 39.2 61.7 98 157 245

Operating Pressure

MPa 24.5

Driving Pneumatic Pressure for Air Cylinder

MPa 0.39 0.49

[Option]

GWA

Stationary Clamp (Double-Action)

Reinforced Body

Low Lever

Rear Port

Wide Lever

NPT Port

Double Cylinder

Special Spacer

High Temperature

Hydraulic 13.7MPa
GWA Clamp adopting a mechanical locking system, is a
highly reliable clamp which maintains its clamping power
when the hydraulic pressure for locking drops to 0.
[Specification]
Clamping Force kN

(at 13.7MPa) 9.8 15.7 24.5 39.2 61.7 98 157 245 392 490

Operating Pressure

MPa 13.7

[Option]
High Temperature

GLA

T-Slot Automatic-Slide Clamp (Double-Action)

Hydraulic 13.7MPa
GLA Clamp developed from the GWA Clamp, is capable of
sliding and locking variable width molds by remote control.
[Specification]
Clamping Force kN
Operating Pressure

(at 13.7MPa) 157 245 392 490

MPa 13.7

Driving Pneumatic Pressure for Air Cylinder MPa 0.39 0.49

[Option]
Double Cylinder

High Temperature

Please refer to a catalog for the detail of each product.

GM

Block Type Manual-Slide Clamp (Single-Action)

Q M CS

HYDRAULIC CLAMP

Hydraulic 24.5MPa
GM Clamp is suitable for I.M.M. without T-slot.
It can be used with molds of various widths and allows for
the variation of h dimension up to 5mm.
[Specification]
Clamping Force kN

(at 24.5MPa) 24.5 39.2 61.7 98

MPa 24.5

Operating Pressure
[Option]
NPT Port

High Temperature With Proximity Switch for Mold Detection

With Slider

CP / CR / CS
Hydraulic Unit

Hydraulic 13.7MPa/24.5MPa
There are compact hydraulic unit consisting of pump, valves,
pressure relief valve and pressure switch.
Corresponds to wide range of I.M.M. size.
[Correspondence Clamping Force (Aim)]

MV00

Hydraulic Valve Unit

CP Unit

kN 9.8

15.7

CR Unit

kN 61.7

98

CS Unit

kN 98

157

24.5

39.2

Hydraulic 13.7MPa
MV00 unit is used when the hydraulic source is the I.M.M.
The lock circuit of the GWA Clamp, GLA Clamp is equipped
with a pressure relief valve.
[Specification]
Operating Pressure MPa 13.7
Control Voltage

AC100V / AC110V / AC200V / AC220V / DC24V

[Option]
NPT Port

MV30

Pneumatic Valve Unit

Pneumatic 0.39 0.49MPa

MV30 Pneumatic Valve Unit controls the movement of
clamps.
[Specification]
Operating Pressure MPa 0.39 0.49
Control Voltage

AC100V / AC200V / DC24V

[Option]
NPT Port

10

Q MC S

PNEUMATIC CLAMP

HB

T-Slot Manual-Slide Clamp (Double-Action)

Please refer to a catalog for the detail of each product.

Pneumatic 0.49MPa
H series clamp is the compact clamp which has strong power
with output powered only by pneumatic pressure.
Holding / clamping force remain even when pressure falls to zero.
[Specification]
Clamping Force(at 0.49MPa)

kN :

9.8 15.7 24.5 39.2 61.7 98 157

Operating Air Pressure

MPa :

0.49

Min. Operating Air Pressure

MPa :

0.39

[Option]
With Handle

High Type

Low Type

High Temperature With Proximity Switch for Mold Detection

HE

T-Slot Automatic-Slide Clamp (Double-Action)

Pneumatic 0.49MPa
HE clamp has the ability to slide and lock molds of different
sizes by remote control.
[Specification]
Clamping Force(at 0.49MPa)

kN :

9.8 15.7 24.5 39.2 61.7 98 157

Operating Air Pressure

MPa :

0.49

Min. Operating Air Pressure

MPa :

0.39

Driveing Pneumatic Pressure for Air Cylinder MPa :

0.39 0.49

[Option]

HC

Stationary Clamp (Double-Action)

High Type

Low Type

Special Spacer

High Temperature

Double Cylinder

Pneumatic 0.49MPa
It is suitable for various usages of vertical / horizontal
mold change system of vertical mold loading and
horizontal mold loading.
The lock / release confirmation switch is standard equipment.
[Specification]
Clamping Force(at 0.49MPa)

kN :

9.8 15.7 24.5 39.2 61.7 98 157 245

Operating Air Pressure

MPa :

0.49

Min. Operating Air Pressure

MPa :

0.39

[Option]
Extremely Small Load Switch Type

MV7000
Pneumatic Valve Unit

High Temperature

Pneumatic 0.49MPa
The pneumatic valve unit controls lock / release of clamp and
it is able to confirm pressure rising of clamp circuit by pressure
switch.
[Specification]
Operating Air Pressure
Control Voltage
[Option]
NPT Port

11

MPa :
:

0.39 / 0.49
AC100V / DC24V

Please refer to a catalog for the detail of each product.

QB

T-Slot Manual-Slide Clamp (Double-Action)

Q M CS

PNEUMATIC CLAMP

Pneumatic 0.4MPa
The power cylinder with powered output enables
compact and high power at the same time.
[Specification]
Clamping Force(at 0.4MPa)

kN :

10

MPa :

1.0

Min. Operating Air Pressure(Release) MPa :

0.3

Max. Operating Air Pressure

16

25

40

63

[Option]
High Type

Low Type

With Proximity Switch for Mold Detection

High Temperature

QE

T-Slot Automatic-Slide Clamp (Double-Action)

Pneumatic 0.4MPa
QE clamp has the ability to slide and lock molds of different
sizes by remote control.
[Specification]
Clamping Force(at 0.4MPa)

kN :

10

16

Operating Air Pressure

MPa :

0.4 0.8

Min. Operating Air Pressure

MPa :

0.39

Driving Pneumatic Pressure for Air Cylinder

MPa :

0.39 0.49

25

40

63

[Option]

QM

Block Type Manual-Slide Clamp (Double-Action)

High Type

Low Type

Special Spacer

High Temperature

Double Cylinder

Pneumatic 0.4MPa
It is suitable for I.M.M. without T-slot,
and also for molds of different sizes.
[Specification]
Clamping Force(at 0.4MPa)

kN :

10

MPa :

1.0

Min. Operating Air Pressure(Release) MPa :

0.3

Max. Operating Air Pressure

16

25

40

63

[Option]
High Temperature

MV9011
Pneumatic Valve Unit

Pneumatic 0.4MPa
The pneumatic valve unit controls lock / release of clamp and
it is able to confirm pressure rising of clamp circuit by pressure
switch. It also solves an insufficiency of supply pneumatic
pressure by a boosting valve.
[Specification]
Incoming supply pneumatic pressure MPa :

0.4 or more

Control Voltage

AC100V / DC24V

[Option]
NPT Port

12

QMCS

MEK

MAGNETIC CLAMP
New

Please refer to a catalog for the detail of each product.

Power Supply

Magnetic Clamp

We have developed the new magnetic clamp

which combines safety, quickness and ecology.
MEK2000-8S

Max. Clamping Force 176kN

200-220V50/60Hz7kVA

[Specification]
Control Voltage

MEC

New

MEC

New

Power Unit

The compact power source unit

which does not take the setting space.

Remote-Control Unit

MES

200V / 230V / 400V / 460 480V50 / 60Hz

Supporting Metal Fittings

The palm-sized remote-control unit is highly operable

which enables to check the adsorption force at hand.

Preparing for mold falling by any chance,

the mold support fitting improves safety.
[Specification]
Operating Load(Dead Load)
Chain Length

13

kN 12.5 20
per 100mm

32

50

80

125

Please refer to a catalog for the detail of each product.

YMB

Q M CS

ACCESORIES

New

Operational PanelControl Unit

The operational panel and control unit are separated

which allows control methods more free. Only a little space
needed for mounting due to the compact design.
[Specification]
PS Voltage

: AC100V AC240V (50 / 60Hz)

PS Capacity

: 30W / 100W

Operating Voltage of YMB080

: DC24V

[Option]
Available to the proximity switch for mold detection
Control Unit

PME

Operational Panel

Available to the proximity switch for mold detection (When using 6 to 8 on one side)

New

Manual Operation

Quick Ejector Rod

Kosmek s original quick connect ejector rod

enables to exchange ejector pins in a single operation.

JL

Hydraulic

Auto Joint

Pneumatic

Water

Warm Water

The joint for mold temperature control

which enables automation of mold change systems.
[Specification]
Body Size

1/4

3/8

1/2

3/4 1

[Option]
NPT port
Plug

Socket

Support Block/Safety Device

MH Support Block

MG Guide Block

ML Extension Roller

MJ Fall Prevention Block

MR Platen Roller

MM Safety Stop

MF Mold Safety Retainer

MP Mold Positioning Equipment

MS Mold Thickness Detection

In addition, we offer various products.

14

 Pr o d u c t l ineu p
We manufacture a wide range of clamping systems and components. Feel free to contact us.

Q U I C K D I E C H A N G E SYST EMS
This clamp system enables single minute die change.
Used on all sizes and types of stamping presses.

D I EC A ST C L A MPI N G SYST EMS

Safe and stable clamp system for diecast machines
under severe conditions such as high temperature
and sticky release agent etc.

http://www.kosmek.co.jp
HEAD OFFICE

1-5, 2-Chome, Murotani, Nishi-ku, Kobe 651-2241

TEL.81-78-991-5162
FAX.81-78-991-8787

BRANCH OFFICE

KOSMEK (U.S.A.) LTD.

1441 Branding Avenue, Suite 110, Dowbers Grove, IL 60515 USA
TEL.21-5425-3000
FAX.21-5425-3709

THAILAND REPRESENTATIVE OFFICE 67 Soi 58, RAMA 9 Rd., Suanluang, Suanluang, Bangkok 10250
TEL.66-2-715-3450
FAX.66-2-715-3453
FOR FURTHUR INFOMATION ON UNLISTED
SPECIFICATIONS AND SIZES, PLEASE CALL US.
SPECIFICATIONS ON THIS LEAFLET ARE
SUBJECT TO CHANGE WITHOUT NOTICE.

JQA-QMA10823
KOSMEK HEAD OFFICE

CAT.NO.QMC001-01-GB
Printed in Japan

2014. 03 First 1Ry